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  Box fan grill with integral motor supportUSPTO Application #: 20080089798Title: 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. (end of abstract)
Agent: Woodcock Washburn LLP - Philadelphia, PA, US Inventor: Charles D. Litvin USPTO Applicaton #: 20080089798 - Class: 41742315 (USPTO) The Patent Description & Claims data below is from USPTO Patent Application 20080089798. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE APPLICATIONS [0001]This application claims priority to provisional patent application 60/829,766 filed Oct. 17, 2006. TECHNOLOGY FIELD [0002]The present invention relates to an air moving apparatus. More specifically, the present invention relates to the motor mounting structure utilized on a conventional box fan. BACKGROUND [0003]The box fan has been in existence for many years. The box fan has proven itself to be one of the most versatile air moving devices, selling numerous millions of units every year. Because of its popularity there has been constant pressure on the manufacturer to produce the box fan less expensively without compromising the safety or the quality of the final product. [0004]One manner to effectively achieve this goal is to reduce the material usage and by default the raw material cost needed to produce the device. The use of motor production technology, plastic materials, size reduction etc. have all yielded cost reductions for the box fan over the years. [0005]What is needed are further innovations in the box fan structure that will maintain or improve the quality and safety of the device while at the same time allow the manufacturer the ability to produce the device at a lower cost. The lower cost will enhance the appeal of the item to a greater number of users. SUMMARY [0006]The present invention is directed to embodiments of a box fan that utilizes a motor mounting structure incorporated into a polymer rear grill of the device. The utilization of the polymer grill in this manner eliminates the need for metal brackets and the additional labor needed to assemble the metal brackets in the construction of a conventional box fan. This reduces the cost of the box fan to the consumer and allows the product to be more affordable to a wider range of users and more profitable to the manufacturer. Another advantage of the described device is the ability of the polymer rear grill to electrically isolate the motor of the device from external metal components such as the body of the box fan. [0007]In accordance with one embodiment, a box fan includes 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. The front and rear openings are substantially parallel to one another and are located on the opposite side of the fan body. A unitary rear grill formed of polymer may be disposed proximate and substantially covering the rear body opening. The unitary rear grill includes a perimeter rail defining extents of the unitary rear grill, a plurality of grill elements defining flow through openings that allow air to pass through the unitary rear grill, and an integrated motor interface structure substantially centered with reference to the extents of the unitary rear grill. The box fan includes a front grill disposed proximate and substantially covering the front body opening. An interior space is defined by the at least one wall of the fan body, the unitary rear grill, and the front grill. A motor having a shaft extension is disposed within the interior space. The motor is connected to and structurally supported by the integrated motor interface structure of the unitary rear grill. An axial air impeller is disposed within the interior space. The air impeller includes a hub connected to the shaft extension of the motor, and a plurality of blades extending radially outward from the hub. [0008]According to one aspect of the invention, the unitary rear grill includes support channels extending from the motor interface structure to the perimeter rail of the unitary rear grill. The support channels structurally support the motor and the axial air impeller. The support channel may define a conduit and control wires of the box fan may be located in the conduit. The support channel may include at least one wall defining a recess. [0009]According to another aspect of the invention, the at least a portion of the plurality of grill elements extend from the motor interface structure to the perimeter rail of the unitary rear grill. This portion of the plurality of grill elements functions, in part, to structurally support the motor and the axial air impeller. [0010]According to another aspect of the invention, the unitary rear grill comprises a spherical form as defined by a surface of the rear grill, wherein the surface comprises a spherical radius. [0011]According to another aspect of the invention, the motor includes a rear end bell having ventilation openings. The integrated motor interface includes a motor mounting surface, and a cooling opening substantially centered in the motor mounting surface. The ventilation openings of the rear end bell and the cooling opening in the integrated motor interface may be substantially aligned. [0012]According to another aspect of the invention, the hub of the axial air impeller further comprises a first circumferential periphery and the motor mounting surface is defined by a second circumferential periphery. The first and the second circumferential peripheries may be substantially aligned. [0013]According to another aspect of the invention, the integrated motor interface structure further comprises a plurality of motor mounting holes for receiving fasteners to secure the motor to the integrated motor interface structure. [0014]According to another aspect of the invention, the perimeter rail, grill elements, motor interface, and support channels are a single molded polymer part. The single molded polymer part electrically isolates the motor from all external surfaces of the box fan. [0015]According to another aspect of the invention, the perimeter rail includes: a first wall substantially parallel to the grill elements; a second wall extend substantially orthogonal and outward from the first wall; and a third wall extending substantially orthogonal from the second wall. [0016]According to another aspect of the invention, the rear grill perimeter rail includes: a first wall substantially parallel to the grill elements; a second wall extending outward from the first wall; a recess formed in the second wall; a third wall extending from the second wall, the third wall oriented substantially orthogonal to the first wall; and angular ribs extending between the first wall and the third wall, the angular ribs connecting the first wall, the second wall, and the third wall. [0017]According to yet another aspect of the invention, the rear grill further includes: horizontal structural supports extending from the integrated motor interface to sides of the perimeter rail; and vertical structural supports extending from the integrated motor interface to a top and a bottom of the perimeter rail. The horizontal structural supports and the vertical structural supports may be constructed dimensionally thicker than the grill elements. [0018]According to another aspect of the invention, the rear grill includes: a plurality of substantially concentric arcuate grill elements; and radial structural supports extending radially from the integrated motor interface to the perimeter rail. The radial structural supports may be connected to the concentric arcuate grill elements. [0019]According to another embodiment of the invention, a box fan includes a fan body formed of metal. The fan body includes at least one wall forming a substantially polygonal shape having a rear body opening and a front body opening. The rear and front openings are substantially parallel to one another and located on the opposite sides of the fan body. A unitary rear grill may be formed of polymer and may be disposed proximate and substantially covering the rear body opening. The unitary rear grill includes a perimeter rail defining extents of the unitary rear grill. The unitary rear grill also includes a plurality of grill elements defining flow through openings, the flow through openings allowing air to pass through the unitary rear grill. The unitary rear grill further includes a substantially circular-shaped integrated motor interface structure substantially centered with reference to the extents of the unitary rear grill. Moreover, the unitary rear grill includes support channels extending between and connecting the motor interface structure to the perimeter rail of the unitary rear grill. The box fan also includes a front grill disposed proximate and substantially covering the front body opening. An interior space is defined by the at least one wall of the fan body, the unitary rear grill, and the front grill. A motor is disposed within the interior space, the motor being connected to and structurally supported by the integrated motor interface structure of the unitary rear grill. The motor also has a shaft extension. An axial air impeller is disposed within the interior space. The air impeller includes a hub connected to the shaft extension of the motor and a plurality of blades extending radially outward from the hub. [0020]According to yet another embodiment of the invention, a box fan includes at least one wall formed of metal forming a substantially polygonal shape. Rear and front openings are formed by the at least one wall. The rear and front openings are oriented substantially parallel to one another and are located on the opposite sides of the at least one wall. A front grill is disposed proximate and substantially covering the front opening. The front grill includes a plurality of front grill elements defining front flow through openings that allow air to pass through the front grill. A rear grill is disposed proximate and substantially covering the rear opening. A perimeter rail defines extents of the rear grill. The rear grill includes a plurality of rear grill elements defining rear flow through openings that allow air to pass through the rear grill. The rear grill also includes a substantially circular shaped integrated motor interface structure substantially centered with reference to the extents of the rear grill. Motor cooling openings may be provided in a center region of the integrated motor interface structure. Support channels may extend outward from the motor interface structure and connect to the perimeter rail. The rear grill, the perimeter rail, the rear grill elements, the motor interface, and the support channels are preferably formed as a single molded polymer part. An interior space is defined by the at least one wall of the fan body, the front grill, and the rear grill. A motor is disposed within the interior space and may be connected to and structurally supported by the integrated motor interface structure of the rear grill. The motor includes a shaft and a rear end bell. Ventilation openings may be provided in the rear end bell. Preferably, the ventilation openings of the motor rear end bell substantially align with the motor cooling openings in the integrated motor interface structure. An axial air impeller is disposed within the interior space. A substantially circular shaped hub of the air impeller connects to the motor shaft. A circumference of the substantially circular shaped hub may be substantially equal to the substantially circular shaped integrated motor interface structure. A plurality of blades of the air impeller extend radially outward from the hub. Continue reading... Full patent description for Box fan grill with integral motor support Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Box fan grill with integral motor support patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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