Box fan grill with integral motor support

Abstract

A box fan with a motor and impeller that is supported by a polymer grill is provided. The device may include a metal body and at least one polymer grill, a motor and an axial air impeller. The motor being structurally supported by the polymer grill.

1 . A box fan comprising:
 a fan body formed of metal comprising:
 at least one wall forming a substantially polygonal shape having a rear body opening and a front body opening substantially parallel to said rear body opening and located on the opposite side of said fan body from said rear body opening; 
   a unitary rear grill formed of polymer disposed proximate and substantially covering said rear body opening, said unitary rear grill comprising;
 a perimeter rail defining extents of said unitary rear grill; 
 a plurality of grill elements defining flow through openings, said flow through openings allowing air to pass through said unitary rear grill; 
 an integrated motor interface structure substantially centered with reference to said extents of said unitary rear grill; 
   a front grill disposed proximate and substantially covering said front body opening;   an interior space defined by said at least one wall of said fan body, said unitary rear grill, and said front grill;   a motor having a shaft extension disposed within said interior space, said motor being connected to and structurally supported by said integrated motor interface structure of said unitary rear grill; and   an axial air impeller disposed within said interior space, said air impeller comprising;
 a hub connected to said shaft extension of said motor; 
 a plurality of blades extending radially outward from said hub. 
   
   
   
       2 . The box fan of  claim 1 , wherein said unitary rear grill further comprises support channels extending from said motor interface structure to said perimeter rail of said unitary rear grill, said support channels structurally support said motor and said axial air impeller. 
   
   
       3 . The box fan of  claim 2 , wherein said support channel further defines a conduit and electric conducting wires of said box fan are located in said conduit. 
   
   
       4 . The box fan of  claim 2 , wherein perimeter rail, grill elements, motor interface, and support channels are a single molded polymer part. 
   
   
       5 . The box fan of  claim 4 , wherein said single molded polymer part electrically isolates said motor from all external surfaces of said box fan. 
   
   
       6 . The box fan of  claim 2 , wherein said support channel further comprises at least one wall defining a recess. 
   
   
       7 . The box fan of  claim 1 , wherein at least a portion of said plurality of grill elements extend from said motor interface structure to said perimeter rail of said unitary rear grill and said portion of said plurality of grill elements structurally support said motor and said axial air impeller. 
   
   
       8 . The box fan of  claim 1 , wherein said unitary rear grill comprises a spherical form as defined by a surface of the rear grill, wherein said surface comprises a spherical radius. 
   
   
       9 . The box fan of  claim 1 , wherein said motor further comprises a rear end bell including ventilation openings and said integrated motor interface further comprises:
 a motor mounting surface; and   a cooling opening substantially centered in said motor mounting surface;   wherein said ventilation openings of said rear end bell and said cooling opening in said integrated motor interface are substantially aligned.   
   
   
       10 . The box fan of  claim 9 , wherein said hub of said axial air impeller further comprises a first circumferential periphery and said motor mounting surface is defined by a second circumferential periphery and said first and said second circumferential peripheries are substantially aligned. 
   
   
       11 . The box fan of  claim 1 , wherein said integrated motor interface structure further comprises a plurality of motor mounting holes. 
   
   
       12 . The box fan of  claim 1 , wherein said unitary rear grill further comprises a unitary handle. 
   
   
       13 . The box fan of  claim 1 , further comprising a controller wherein said motor and controller is accessible through said unitary rear grill. 
   
   
       14 . The box fan of  claim 13 , wherein said unitary rear grill further comprises a handle as an integral part of said unitary rear grill. 
   
   
       15 . The box fan of  claim 1 , wherein said perimeter rail further comprises:
 a first wall substantially parallel to said grill elements;   a second wall extend substantially orthogonal and outward from said first wall; and   a third wall extending substantially orthogonal from said second wall.   
   
   
       16 . The box fan of  claim 1 , wherein said rear grill perimeter rail further comprises:
 a first wall substantially parallel to said grill elements;   a second wall extending outward from said first wall;   a recess formed in said second wall;   a third wall extending from said second wall, said third wall oriented substantially orthogonal to said first wall; and   angular ribs extending between said first wall and said third wall, said angular ribs connecting said first wall, said second wall, and said third wall.   
   
   
       17 . The box fan of  claim 1 , wherein said rear grill further comprises:
 horizontal structural supports extending from said integrated motor interface to sides of said perimeter rail; and   vertical structural supports extending from said integrated motor interface to a top and a bottom of said perimeter rail.   
   
   
       18 . The box fan of  claim 17 , wherein said horizontal structural supports and said vertical structural supports are constructed dimensionally thicker than said grill elements. 
   
   
       19 . The box fan of  claim 1 , wherein said rear grill further comprises:
 a plurality of substantially concentric arcuate grill elements; and   radial structural supports extending radially from said integrated motor interface to said perimeter rail, said radial structural supports connected to said concentric arcuate grill elements.   
   
   
       20 . A box fan comprising:
 a fan body formed of metal comprising:   at least one wall forming a substantially polygonal shape having a rear body opening and a front body opening substantially parallel to said rear body opening and located on the opposite side of said fan body from said rear body opening;   a unitary rear grill formed of polymer disposed proximate and substantially covering said rear body opening, said unitary rear grill comprising;
 a perimeter rail defining extents of said unitary rear grill; 
 a plurality of grill elements defining flow through openings, said flow through openings allowing air to pass through said unitary rear grill; 
 a substantially circular-shaped integrated motor interface structure substantially centered with reference to said extents of said unitary rear grill; 
 support channels extending between and connecting said motor interface structure to said perimeter rail of said unitary rear grill; 
   a front grill disposed proximate and substantially covering said front body opening;   an interior space defined by said at least one wall of said fan body, said unitary rear grill, and said front grill;   a motor disposed within said interior space, said motor being connected to and structurally supported by said integrated motor interface structure of said unitary rear grill, said motor having a shaft extension;   an axial air impeller disposed within said interior space, said air impeller comprising;
 a hub connected to said shaft extension of said motor; 
 a plurality of blades extending radially outward from said hub. 
   
   
   
       21 . A box fan comprising:
 at least one wall formed of metal forming a substantially polygonal shape;   a rear opening formed by said at least one wall;   a front opening formed by said at least one wall, said front opening oriented substantially parallel to said rear body opening and located on the opposite side of said at least one wall;   a front grill disposed proximate and substantially covering said front opening;   a plurality of front grill elements defining front flow through openings, said front flow through openings allowing air to pass through said front grill   a rear grill disposed proximate and substantially covering said rear opening;   a perimeter rail defining extents of said rear grill;   a plurality of rear grill elements defining rear flow through openings, said rear flow through openings allowing air to pass through said rear grill;   a substantially circular shaped integrated motor interface structure substantially centered with reference to said extents of said rear grill;   motor cooling openings in a center region of said integrated motor interface structure;   support channels extending outward from said motor interface structure and connect to said perimeter rail;   wherein said rear grill, said perimeter rail, said rear grill elements, said motor interface, and said support channels are a single molded polymer part;   an interior space defined by said at least one wall of said fan body, said front grill, and said rear grill;   a motor disposed within said interior space, said motor being connected to and structurally supported by said integrated motor interface structure of said rear grill;   a shaft extending from said motor;   a rear end bell of said motor;   ventilation openings in said rear end bell, wherein said ventilation openings of said motor rear end bell substantially align with said motor cooling openings in said integrated motor interface structure;   an axial air impeller disposed within said interior space;   a substantially circular shaped hub of said air impeller connected to said motor shaft, wherein a circumference of said substantially circular shaped hub is substantially equal to said substantially circular shaped integrated motor interface structure; and   a plurality of blades of said air impeller extending radially outward from said hub.