Dual flow fan heat sink application

Abstract

A cooling system includes a fan assembly that is rotated to move air in a primary path through a housing. The fan assembly includes a hub and a plurality of spaced reinforcing ribs that establish channels between a motor casing and the interior of the hub. A heat sink assembly is axially spaced from a hub bottom to define an air cavity that is in communication with a gap. The hub includes a tube that defines an air passage to establish communication with the cavity. A plurality of air vanes extend in a spiral path from the hub bottom and into the air cavity to move air through the air passage and create turbulence over the heat sink assembly. The air vanes move the air over the heat sink assembly and through the air passage to establish communication between the channels and the air cavity.

1 . A cooling system for producing an airflow across a heat sink assembly comprising;
 a housing disposed about an axis,   a fan assembly extending radially from said axis for moving air in a primary path axially through said housing,   said fan assembly including a hub and a plurality of fan blades extending radially outwardly from said hub for moving air in the primary path axially through said housing,   a motor assembly supported by said housing for rotating said fan assembly, and   said hub defining an air passage extending axially through the center of said hub and surrounding said axis for moving air axially through said hub.   
   
   
       2 . A cooling system as set forth in  claim 1  wherein said hub includes a hub bottom and a tube extending axially from said hub bottom for further defining said air passage. 
   
   
       3 . A cooling system as set forth in  claim 2  including a plurality of air vanes extending axially from said hub bottom and having the same continued geometry as said fan blades for moving air through said air passage of said hub. 
   
   
       4 . A cooling system as set forth in  claim 2  including a plurality of air vanes extending axially from said hub bottom to a vane edge each extending in a spiral path and radially away from said tube for moving air through said air passage of said hub. 
   
   
       5 . A cooling system as set forth in  claim 4  wherein said housing includes a top plate having a motor support, a bottom plate spaced axially from said top plate, and a cylinder extending axially between said top and bottom plates. 
   
   
       6 . A cooling system as set forth in  claim 5  including a heat sink assembly aligned with said housing for transferring heat away from an electronic device disposed on a base and wherein said heat sink assembly includes a core having a top core portion, a bottom core portion, and a cylindrical side core portion. 
   
   
       7 . A cooling system as set forth in  claim 6  wherein said motor assembly is rotatably supported by said motor support on said axis and includes an electric motor rotatably supported by said motor support and extending axially from said motor support into said cylinder and towards said bottom plate, wherein said motor assembly includes a motor casing surrounding said electric motor and is rotatable therewith. 
   
   
       8 . A cooling system as set forth in  claim 7  wherein said fan assembly is rotatably secured to said motor assembly and wherein said hub is a cup shape defining said hub bottom extending radially to a hub periphery and a hub side wall extends axially from said hub periphery of said hub bottom to a rim, and wherein said hub includes a plurality of reinforcing ribs each being L-shaped and circumferentially spaced about the interior of said cup-shaped hub and wherein each of said reinforcing ribs begin at said rim of said hub and extend axially along said hub side wall and thereafter inward radially along said hub bottom to an inner end disposed on a circle about said axis, said reinforcing ribs being press-fit against said motor casing in spaced relationship to the interior of said cup-shaped hub for securing said fan assembly to said motor casing and establishing channels between said motor casing and the interior of said cup-shaped hub. 
   
   
       9 . A cooling system as set forth in  claim 8  wherein said heat sink assembly includes a plurality of cooling fins extending radially from said side core portion of said heat sink assembly into axial alignment with said fan blades for guiding air moved by said fan blades from an upstream region to a downstream region. 
   
   
       10 . A cooling system as set forth in  claim 9  including a mounting plate for interconnecting said bottom plate and said cooling fins, said mounting plate including an annular mounting rib having a rib diameter to define an annular gap between said cooling fins and said bottom plate. 
   
   
       11 . A cooling system as set forth in  claim 10  wherein said top core portion of said heat sink assembly is axially spaced from said hub bottom to define an air cavity in communication with both said gap and said air passage. 
   
   
       12 . A cooling system as set forth in  claim 11  wherein each of said vanes extend axially from said hub bottom a greater distance adjacent said tube than adjacent said gap for moving the air over said top core portion and through said air passage to establish communication between the channels and said air cavity. 
   
   
       13 . A cooling system as set forth in  claim 11  wherein each of said vanes extend axially from said hub bottom a shorter distance adjacent said tube than adjacent said gap for moving the air over said top core portion and through said air passage to establish communication between the channels and said air cavity. 
   
   
       14 . A cooling system as set forth in  claim 11  including a shaft being hollow and extending along said axis and through said motor assembly to said tube for the movement of air therethrough and for establishing communication between said shaft and said air cavity. 
   
   
       15 . A cooling system as set forth in  claim 11  wherein said top plate includes four top edges defining a rectangular top periphery about said axis and interconnected by rounded top corners, and wherein said bottom plate includes four bottom edges defining a rectangular bottom periphery about said axis and interconnected by rounded bottom corners. 
   
   
       16 . A cooling system as set forth in  claim 15  wherein said top plate includes a first funnel section converging radially inward and axially downward across each of said top corners to define a first air opening having a first diameter and said top plate includes an axially extending top depending section tangent to and between adjacent first funnel sections. 
   
   
       17 . A cooling system as set forth in  claim 16  wherein said bottom plate includes a second funnel section converging radially inward and axially upward across each of said bottom corners to define a second air opening having a second diameter equal to said first diameter and said bottom plate including an axially extending bottom depending section tangent to and between adjacent second funnel sections. 
   
   
       18 . A cooling system as set forth in  claim 17  wherein said top and bottom plates include a through hole having a through hole diameter disposed in each of said top and bottom corners, and wherein said peripheries of said top and bottom plates are axially aligned. 
   
   
       19 . A cooling system as set forth in  claim 18  wherein said motor support is disposed on said axis and said housing includes a plurality of spokes each being tubular and extending radially outward of said motor support with one of said spokes extending to each of said first funnel sections adjacent said top depending sections. 
   
   
       20 . A cooling system as set forth in  claim 19  including a wire port extending radially through one of said top edges adjacent one of said spokes for extending electrical lead wires from said electric motor and through one of said spokes and said wire port to connect said electric motor to a power source. 
   
   
       21 . A cooling system as set forth in  claim 20  wherein said heat sink assembly includes diametrically opposite groups of said cooling fins defining attachment notches each being U-shaped and extending radially inward. 
   
   
       22 . A cooling system as set forth in  claim 21  wherein said mounting plate is generally rectangular with four rounded plate corners, said mounting rib defining a third air opening and extending axially from said mounting plate for defining said annular gap between said cooling fins and said bottom plate, and said mounting plate having a plurality of mounting holes disposed adjacent each of said plate corners and having a mounting hole diameter equal to said through hole diameter and aligned with said through holes in said bottom plate of said housing for securing said mounting plate to said bottom plate of said housing. 
   
   
       23 . A cooling system as set forth in  claim 22  including a plurality of locking arms extending axially from said mounting plate at said plate corners and including a hook extending radially inward for engaging said attachment notches in said cooling fins to attach said mounting plate to said cooling fins of said heat sink assembly, and including a plurality of alignment pins extending axially from said mounting rib between adjacent cooling fins to prevent said mounting plate from rotating about said axis. 
   
   
       24 . A cooling system as set forth in  claim 23  including a fastening mechanism having a pin being T-shaped and an expandable body of rubber disposed in each of said through holes of said bottom plate and each of said mounting holes for securing said housing to said mounting plate. 
   
   
       25 . A cooling system as set forth in  claim 24  wherein said cylinder has an internal diameter equal to said first and second diameters and extends axially between said first and second funnel sections of said top and bottom plates. 
   
   
       26 . A cooling system as set forth in  claim 25  wherein said housing includes a web at each of said top and bottom corners extending axially along said cylinder between said first funnel sections and said second funnel sections and radially outwardly from said cylinder. 
   
   
       27 . A cooling system as set forth in  claim 26  wherein side core portion defines a core diameter disposed radially inwardly of said hub side wall. 
   
   
       28 . A cooling system as set forth in  claim 27  wherein said core defines a chamber and includes a fill neck being tubular and extending radially from said side core portion of said core for adding a liquid to said chamber of said core. 
   
   
       29 . A cooling system as set forth in  claim 28  including an attachment mechanism attached to said base for engaging said heat sink assembly with the electronic device and wherein said attachment mechanism includes an anchor plate defining a core aperture receiving said core diameter and having four legs each extending radially outward through an axial offset away from said bottom core portion to a distal end and each of said legs having an attachment hole disposed adjacent to said distal end and wherein said attachment mechanism includes four fasteners spaced about said axis and secured to selected cooling fins and extending through said attachment holes in said legs and for engaging the base. 
   
   
       30 . A cooling system for cooling a blower motor comprising;
 a housing of plastic being generally rectangular about an axis,   said housing including a top plate having four top edges defining a rectangular top periphery about said axis and interconnected by rounded top corners,   said top plate including a first funnel section converging radially inward and axially downward across each of said top corners to define a first air opening having a first diameter,   said top plate including an axially extending top depending section tangent to and between adjacent first funnel sections,   said housing including a bottom plate spaced axially from said top plate and having four bottom edges defining a rectangular bottom periphery about said axis and interconnected by rounded bottom corners,   said peripheries of said top and bottom plates being axially aligned,   said bottom plate including a second funnel section converging radially inward and axially upward across each of said bottom corners to define a second air opening having a second diameter equal to said first diameter,   said bottom plate including an axially extending bottom depending section tangent to and between adjacent second funnel sections,   said top and bottom plates having a through hole with a through hole diameter disposed in each of said top and bottom corners,   said housing including a cylinder having an internal diameter equal to said first and second diameters and extending axially between said first and second funnel sections of said top and bottom plates,   said housing including a web at each of said top and bottom corners extending axially along said cylinder between said first funnel sections and said second funnel sections and radially outwardly from said cylinder,   said housing including a motor support on said axis and a plurality of spokes each being tubular and extending radially outward of said motor support with one of said spokes extending to each of said first funnel sections adjacent said top depending sections,   a motor assembly including an electric motor rotatably supported by said motor support and extending axially from said motor support into said cylinder and towards said bottom plate,   a wire port extending radially through one of said top edges adjacent one of said spokes for extending electrical lead wires from said electric motor and through one of said spokes and said wire port to connect said electric motor to a power source,   said motor assembly including a motor casing surrounding said electric motor and rotatable therewith,   a fan assembly of plastic secured to said motor casing for rotation by said electric motor and extending radially from said axis within said cylinder for moving air in a primary path axially through said cylinder,   said fan assembly including a hub having a cup shape defining a hub bottom extending radially to a hub periphery and a hub side wall extending axially from said hub periphery of said hub bottom to a rim,   said fan assembly including a plurality of fan blades extending radially outwardly from said hub side wall for moving air in the primary path axially through said cylinder from an upstream region to a downstream region,   said hub including a plurality of reinforcing ribs each being L-shaped and circumferentially spaced about the interior of said cup-shaped hub,   each of said reinforcing ribs beginning at said rim of said hub and extending axially along said hub side wall and thereafter inward radially along said hub bottom to an inner end disposed on a circle about said axis,   said reinforcing ribs being press-fit against said motor casing in spaced relationship to the interior of said cup-shaped hub for securing said fan assembly to said motor casing and establishing channels between said motor casing and the interior of said cup-shaped hub,   a base,   an electronic device disposed on said base,   a heat sink assembly aligned with said housing for transferring heat away from said electronic device,   said heat sink assembly including a core of copper having a top core portion and a bottom core portion and a cylindrical side core portion defining a core diameter disposed radially inwardly of said hub side wall,   said core defining a chamber and including a fill neck being tubular and extending radially from said side core portion of said core for adding a liquid to said chamber of said core,   said heat sink assembly including a plurality of cooling fins of aluminum extending radially from said side core portion of said heat sink assembly into axial alignment with said fan blades for guiding air moved by said fan blades from the upstream region to the downstream region,   diametrically opposite groups of said cooling fins defining attachment notches each being U-shaped and extending radially inward,   an attachment mechanism attached to said base for engaging said heat sink assembly with said electronic device,   said attachment mechanism including an anchor plate defining a core aperture receiving said core diameter and having four legs each extending radially outward through an axial offset away from said bottom core portion to a distal end,   each of said legs having an attachment hole disposed adjacent to said distal end,   said attachment mechanism including four fasteners spaced about said axis and secured to selected cooling fins and extending through said attachment holes in said legs and into engagement with said base,   a mounting plate of plastic being generally rectangular with four rounded plate corners for interconnecting said bottom plate and said cooling fins,   said mounting plate including an annular mounting rib having a rib diameter defining a third air opening and extending axially from said mounting plate to define an annular gap between said cooling fins and said bottom plate,   said mounting plate having a plurality of mounting holes disposed adjacent each of said plate corners and having a mounting hole diameter equal to said through hole diameter and aligned with said through holes in said bottom plate of said housing for securing said mounting plate to said bottom plate of said housing,   a plurality of locking arms extending axially from said mounting plate at said plate corners and including a hook extending radially inward for engaging said attachment notches in said cooling fins to attach said mounting plate to said cooling fins of said heat sink assembly,   a plurality of alignment pins extending axially from said mounting rib between adjacent cooling fins to prevent said mounting plate from rotating about said axis,   a fastening mechanism having a pin being T-shaped and an expandable body of rubber disposed in each of said through holes of said bottom plate and each of said mounting holes for securing said housing to said mounting plate,   said top core portion of said heat sink assembly being axially spaced from said hub bottom to define an air cavity in communication with said gap,   said hub including a tube extending axially from said hub bottom and defining an air passage extending axially through the center of said hub bottom for establishing communication with said cavity, and   a plurality of air vanes extending from said hub bottom and into said air cavity to a vane edge each extending in a spiral path and radially away from said tube for moving air through said air passage of said hub and creating turbulence over said top core portion.   
   
   
       31 . A cooling system as set forth in  claim 30  wherein each of said vanes extend axially from said hub bottom a greater distance adjacent said tube than adjacent said gap for moving the air over said top core portion and through said air passage to establish communication between the channels and said air cavity. 
   
   
       32 . A cooling system as set forth in  claim 30  wherein each of said vanes extend axially from said hub bottom a shorter distance adjacent said tube than adjacent said gap for moving the air over said top core portion and through said air passage to establish communication between the channels and said air cavity. 
   
   
       33 . A cooling system as set forth in  claim 30  including a shaft being hollow extending along said axis and through said motor assembly to said tube for the movement of air therethrough and for establishing communication between said shaft and said air cavity.