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  Aerodynamically enhanced cooling fanRelated Patent Categories: Heat Exchange, Intermediate Fluent Heat Exchange Material Receiving And Discharging Heat, Liquid Fluent Heat Exchange Material, Cooling Electrical DeviceThe Patent Description & Claims data below is from USPTO Patent Application 20060237169. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND [0001] Computer systems include numerous electrical components that draw electrical current to perform their intended functions. For example, a computer's microprocessor or central processing unit ("CPU") requires electrical current to perform many functions such as controlling the overall operations of the computer system and performing various numerical calculations. Generally, any electrical device through which electrical current flows produces heat. The amount of heat any one device generates generally is a function of the amount of current flowing through the device. [0002] Typically, an electrical device is designed to operate correctly within a predetermined temperature range. If the temperature exceeds the predetermined range (i.e., the device becomes too hot or too cold), the device may not function correctly, thereby potentially degrading the overall performance of the computer system. Thus, many computer systems include cooling systems to regulate the temperature of their electrical components. One type of cooling system is a forced air system that relies on one or more cooling fans to blow air over the electronic components in order to cool the components. [0003] The cubic feet per minute ("CFM") of air that can be moved across an electric device is an important factor in how much heat can be removed from the device. Thus, the capacity of a cooling fan is a critical factor in selecting an air mover for use in a cooling application. The CFM that a cooling fan can produce is governed a number of factors including: the total area of the blades generating the airflow, the free area provided for airflow through the fan, the design of the blades, and the power generated by the electric motor. [0004] Axial flow fans generally comprise a plurality of radial blades rotating within a housing. Increasing performance demands on axial flow fans have required that fans provide increased volumes of air while, at the same time, reducing the size of the fan. One solution to increasing fan performance is simply to increase the speed at which the fan rotates. Increasing fan speed can also be accompanied by increased acoustic emissions, increased vibration, and decreased component life. Therefore, as can be appreciated, there remains a need in the art for cooling fans that provide high volumes of airflow by designs and improvements that increase performance without necessitating an increase in the speed at which fan operates. BRIEF SUMMARY [0005] The problems noted above are solved in large part by a cooling fan comprising a fan housing that connects to a chassis supporting an electronic device. A motor is disposed within the fan housing. A blade assembly is rotatably coupled to the motor. The fan housing has a length at least 10 mm longer than a distance between a leading edge and a trailing edge of the blade assembly. BRIEF DESCRIPTION OF THE DRAWINGS [0006] For a detailed description of exemplary embodiments of the invention, reference will now be made to the accompanying drawings in which: [0007] FIG. 1 shows a computer system including cooling fans constructed in accordance with embodiments of the invention; [0008] FIG. 2 shows a cross-sectional view of a cooling fan having a conical hub constructed in accordance with embodiments of the invention; [0009] FIG. 3 shows a cross-sectional view of cooling fan having an extended intake as constructed in accordance with embodiments of the invention; [0010] FIG. 4 shows a cross-sectional view of cooling fan having an extended length motor constructed in accordance with embodiments of the invention; [0011] FIG. 5 shows a cross-sectional view of cooling fan having aerodynamically optimized stator blades constructed in accordance with embodiments of the invention; [0012] FIG. 6 shows a cross-sectional view of cooling fan having forward swept blades as constructed in accordance with embodiments of the invention; [0013] FIG. 7 shows a cross-sectional view of cooling fan having an asymmetric trailing edge constructed in accordance with embodiments of the invention; [0014] FIG. 8 shows a cross-sectional view of cooling fan having a variable chord length constructed in accordance with embodiments of the invention; [0015] FIG. 9 shows a cross-sectional view of cooling fan having an extended housing constructed in accordance with embodiments of the invention; and [0016] FIG. 10 shows a cooling fan having a rippled housing constructed in accordance with embodiments of the invention. NOTATION AND NOMENCLATURE [0017] Certain terms are used throughout the following description and claims to refer to particular system components. As one skilled in the art will appreciate, computer companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to . . . ." Also, the term "couple" or "couples" is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections. DETAILED DESCRIPTION [0018] The following discussion is directed to various embodiments of the invention. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure, including the claims, is limited to that embodiment. [0019] Many computer cooling applications utilize cooling fans that have been designed to minimize the size of the fan. This design methodology results in small fans that face performance limitations, have inherent aerodynamic inefficiencies, and unwanted acoustic emissions. The embodiments described herein illustrate aerodynamic enhancements that can be made to a cooling fan in order to improve performance, efficiency, and/or acoustic emissions. Many of the embodiments described herein will utilize more space than a conventional fan design but the increase in size can be offset by an increase in efficiency of the fan. As it is used herein, an aerodynamically enhanced cooling fan is a cooling fan used in an electronics cooling application that has been designed for aerodynamic performance as opposed to compactness. Aerodynamically enhanced cooling fans are characterized by features that improve aerodynamic performance but also increase the length of the fan including, but not limited to, a conical hub, a recessed blade assembly, an elongated motor, stator and impeller blades, shaped blades, tapered inlet, tapered outlet, and other features that reduce pressure disturbances. Continue reading... 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