Axial fan of air-cooled electric aircraft motor

Abstract

A fan assembly for an electric aircraft motor is described, the fan assembly having an axial fan having an inner hub and an outer hub, the inner hub having a first diameter and the outer hub having a second diameter. The outer hub may be concentrically aligned with the inner hub. A plurality of blades may extend between the inner hub and the outer hub. The fan assembly may also have a mounting plate connected to the inner hub. The mounting plate may be attached to a component of an electric aircraft motor.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims priority to U.S. Non - Provisional Patent Application No. 17 / 950,497, filed on September 22, 2022, entitled “AXIAL FAN FOR AIR COOLED ELECTRICAL AIRCRAFT MOTOR” (“the ‘497 application”). The entire content of the ‘497 application is hereby incorporated by reference. Field of the Invention

[0003] The field of the present invention relates to cooling aircraft motors. In particular, cooling electric aircraft motors. Background Art

[0004] Air - cooled aircraft motors can rely on air circulation through cooling fins fixed to the motor or air directly circulating over various parts of the motor itself. The air circulation can be met by ram air from flight movement or by propeller wake. Summary of the Invention

[0005] As used in this patent, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to broadly refer to all of the subject matter of this patent and the appended patent claims. Statements containing these terms should be understood not to limit the subject matter described by this invention or the meaning or scope of the appended patent claims. The embodiments of the invention covered by this patent are defined by the appended claims rather than the summary of the invention. The summary of the invention is a high - level generalization of various aspects of the invention and introduces some concepts that are further described in the detailed description section below. The summary of the invention is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0006] According to certain embodiments of the present invention, a fan assembly for an electric aircraft motor is described. The fan assembly may include an axial fan. The axial fan may be defined by an inner hub having a first diameter and an outer hub having a second diameter. The outer hub may be concentrically aligned with the inner hub. A plurality of blades may extend between the inner hub and the outer hub. A mounting plate may be connected to the inner hub. The mounting plate may be connected to the inner hub and arranged to mount the fan assembly to a component of the electric aircraft motor. The first diameter may correspond to a third diameter of the electric aircraft motor, and the second diameter may correspond to a fourth diameter of the electric aircraft motor.

[0007] According to certain embodiments of the present invention, a system is described that includes an electric aircraft motor having an annular body and a set of cooling fins extending from the annular body. The system may also include an axial fan connected to the electric aircraft motor. The axial fan may be defined by an inner hub having a first diameter that may correspond to the annular body. The axial fan may also be defined by an outer hub having a second diameter that may be concentrically aligned with the inner hub. The second diameter may correspond to the set of cooling fins. The axial fan may also include a plurality of blades extending between the inner hub and the outer hub.

[0008] According to certain embodiments of the present invention, a system including an electric aircraft motor is described. The electric aircraft motor may have a first annular housing that may include an electric motor, a second housing that may include electronics, and a motor shaft that may be connected to the electric motor. The system may also include an axial fan connected to the motor shaft. The axial fan may have an inner hub defined by a first diameter that may correspond to the first annular housing. The axial fan may also have an outer hub defined by a second diameter. The outer hub of the axial fan may be concentrically aligned with the inner hub, where the second diameter may be greater than the first diameter. The axial fan may have a plurality of blades extending between the inner hub and the outer hub. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is an isometric view of a fan-cooled motor system for cooling an electric aircraft motor according to at least one example.

[0010] Figure 2 is a cross-sectional view of a fan-cooled motor system for cooling an electric aircraft motor according to at least one example.

[0011] Figure 3 is a cross-sectional view of a fan-cooled motor system for cooling an electric aircraft motor according to at least one example.

[0012] Figure 4 is an isometric view of an axial fan and a mounting plate according to at least one example.

[0013] Figure 5 is an isometric view of an electric aircraft motor and a set of cooling fins according to at least one example.

[0014] Figure 6 is a top view of the blades of an axial fan according to at least one example. DETAILED DESCRIPTION

[0015] The subject matter of the embodiments of the present invention is described herein in detail to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be implemented in other ways, may include different elements or steps, and may be used in combination with other existing or future technologies. The description should not be construed as implying any particular order or arrangement among or between the various steps or elements, unless the order of the individual steps or the arrangement of the elements is explicitly described.

[0016] The embodiments of the present invention provide an axial fan for an electric aircraft motor. Although the axial fan for an electric aircraft motor is discussed as being used with an electric aircraft motor, they are in no way limited thereto. Instead, embodiments of the axial fan can be used in any other suitable application for guiding air flow, exhausting, etc.

[0017] An electric aircraft motor can be adequately cooled in some cases, but may require additional cooling in other cases. For example, when the aircraft is in flight or when the propeller wake provides sufficient air flow, the electric aircraft motor can be adequately cooled by ram air. Even so, the electric aircraft motor may lack sufficient cooling during ground operating conditions such as taxiing. During pre-takeoff taxiing, the lack of sufficient cooling can be particularly problematic, in which case the power output requirements for the aircraft motor may be highest. The lack of adequate cooling for the power electronics can also have a negative impact on the avionics.

[0018] The lack of sufficient cooling can be made more complex due to certain design decisions, such as mounting the power electronics close to the aircraft motor. For example, a phase change heat exchanger of a water-cooled system may increase undesirable weight, cost, or design complexity. In some such cases, an axial fan can compensate for the lack of air flow.

[0019] In a specific example, the axial fan described in the present invention can be driven by a motor shaft shared by the propeller and the aircraft motor. In another example, a gearbox between the propeller and the motor shaft can drive the axial fan. In such an example, the gearbox can allow the propeller, the motor shaft, or the axial fan to operate at different speeds. The axial fan can be directed at cooling fins that can be fixed to the aircraft motor and a housing including the power electronics. The cooling fins can be located within an annular flow region of the assembly that includes the aircraft motor, the housing including the power electronics, and the motor shaft. The axial fan can be formed to minimally increase weight and can not draw a corresponding amount of power from the motor shaft. The axial fan can be formed and positioned such that it does not adversely affect in-flight operating conditions such as takeoff, cruise, and landing. The axial fan can avoid such negative impacts by cooling the fins on the aircraft motor housing rather than directly cooling the motor cavity of the aircraft motor.

[0020] Turning now to the drawings, Figure 1 is an isometric view of a fan-cooled motor system 100 for cooling an electric aircraft motor 103 according to at least one example. The fan-cooled motor system 100 includes a fan assembly 101 and an electric aircraft motor 103. The fan assembly 101 includes a spinner cone 102 and an axial fan 104 with blades 106. The inner hub of the axial fan 104 may have a first diameter 112, and the outer hub of the axial fan 104 may have a second diameter 114. In some examples, the axial fan 104 may have 7 to 30 blades 106. In some examples, the axial fan 104 may have fewer than seven blades 106 or more than thirty blades 106. It should be understood that the number of blades 106 may depend on certain design considerations such as the flow rate required for cooling, the fan weight, the power required to rotate the axial fan 104, and other similar considerations. The axial fan 104 may be adapted to any suitable alternative geometry of the spinner cone 102. In some examples, the axial fan 104 may be integral with the spinner cone 102. The axial fan 104 may be formed from materials including but not limited to aluminum, stainless steel, fiberglass, graphite fiber, nickel-aluminum bronze alloy, manganese bronze alloy, other metallic materials, composite materials, or other suitable similar materials.

[0021] The electric aircraft motor 103 includes an aircraft motor 108 enclosed within a motor housing and power electronics 110 enclosed within an electronics housing. The airflow provided by the axial fan 104 can provide cooling by flowing through the fins of the electric aircraft motor 103. In particular, the electric aircraft motor 103 may include cooling fins 111 that are radially disposed around the housings of the aircraft motor 108 and the power electronics 110.

[0022] Figure 2A cross-sectional view of a fan-cooled motor system 100 for cooling an electric aircraft motor 103 according to at least one example. As shown, a hub cap cone 102 is aligned with a rotational axis 202 extending through the center of the fan-cooled motor system 100. The hub cap cone 102 can be integrally formed with an axial fan 104. The blades 106 of the axial fan 104 can direct an air flow 214 through an annular space 206 of the hub cap cone 102. The inner hub 226 of the axial fan 104 can have a first diameter 222 and the outer hub 228 of the axial fan 104 can have a second diameter 224. In some examples, the first diameter 222 can correspond to the minimum diameter of the inner hub 226 (e.g., the surface facing the interior portion of the fan-cooled motor system 100), or can correspond to the maximum diameter of the inner hub 226 (e.g., the surface facing away from the interior portion of the fan-cooled motor system 100). In some examples, the second diameter 224 can correspond to the minimum diameter of the outer hub 228 (e.g., the surface facing the interior portion of the fan-cooled motor system 100) or can correspond to the maximum diameter of the outer hub 228. Thus, in some examples, the width of the annular space 206 defined by the difference between the second diameter 224, measured as the minimum diameter of the outer hub 228, and the first diameter 222, measured as the maximum diameter of the inner hub 226, can be between 5 mm and 50 mm. The blades 106 can be axially or radially adjusted based on the width of the annular space 206. Depending on the size of the annular space 206, the number of blades 106 can vary between 7 and 30.

[0023] The first diameter 222 can correspond to a third diameter 223 of the aircraft motor 108, and the second diameter 224 can correspond to a fourth diameter 225 of the aircraft motor 108. The annular space 206 can also be defined by the difference between the fourth diameter 225 and the third diameter 223 of the aircraft motor 108. The cooling fins 111 of the aircraft motor 108 can be fitted within the space between the fourth diameter 225 and the third diameter 223. In some examples, the height of the cooling fins 111.

[0024] The airflow 214 can be in fluid communication with the cooling fins 111 of the aircraft motor 108 and the power electronics 110. The height of the cooling fins 111 can correspond to the dimensions of the annular space 206. The swirling airflow can be generated by the axial fan 104. In some examples, the height of the cooling fins 111 can be substantially the same as the width of the annular space 206. In some examples, the width of the annular space 206 can be greater than or less than the height of the cooling fins 111. In alternative examples, a flow straightening component such as an air straightener screen can be introduced between the axial fan 104 and the aircraft motor 108 to mitigate the swirling airflow within the annular space 206. The air straightener screen can include a pattern of hexagonal channels. In some examples, flow straightening components with other shape factors can be used.

[0025] The power electronics 110 can supply power to the aircraft motor 108. The aircraft motor 108 can rotate the motor shaft 204. The mounting plate 220 can connect the inner hub 226 of the axial fan 104 to the motor shaft 204 via suitable fasteners, which include but are not limited to screws, bolts, rivets, or other mechanical or chemical fasteners. The movement of the motor shaft 204 can cause the axial fan 104 to generate the airflow 214 through the annular space 206. In some examples, the inner hub 226 of the axial fan 104 can be integrally formed with the hub cap cone 102. Although not shown, the motor shaft 204 can also be used to rotate the propeller of the fan-cooled motor system 100.

[0026] Figure 3 is a cross-sectional view of a fan-cooled motor system 300 for cooling an electric aircraft motor according to at least one example. The fan-cooled motor system 300 is an alternative example of the fan-cooled motor system 100 described herein. The axial fan 307 is an alternative example of the axial fan 104 described herein. The motor shaft 304 is an alternative example of the motor shaft 204 described herein. This example can be different from Figure 2 the example shown because the axial fan 307 is not integrally formed with the propeller hub cap. As a result, the axial fan 307 can be directly mounted on the motor shaft 304, which can change the position of the axial fan 307 relative to the motor shaft 304 and can change the distance between the axial fan 307 and the aircraft motor 108. The inner hub 328 of the axial fan 307 can have a first diameter 322, and the outer hub 330 of the axial fan 307 can have a second diameter 324. Regarding Figure 2 the values of the diameters described can equally apply to Figure 3 the diameters shown.

[0027] The blades 308 of the axial fan 307 can direct the airflow 312 through the annular space 306 of the fan-cooled motor system 300. The annular space 306 is an alternative example of the annular space 206 described in the present invention. The airflow 312 can be in fluid communication with the cooling fins 111 and the power electronics 110 of the aircraft motor 108. The airflow 312 is an alternative example of the airflow 214 described in the present invention. The axial fan 307 can be formed from materials including but not limited to aluminum, stainless steel, fiberglass, graphite fiber, nickel-aluminum bronze alloy, manganese bronze alloy, other metallic materials, composite materials, or other similar materials. Figure 3 The dimensions of the inner hub, outer hub, annular space 306, and fins shown can be similar to Figure 2 the construction of those elements shown.

[0028] The mounting plate 326 can connect the inner hub 328 of the axial fan 307 to the motor shaft 304 through suitable fasteners, which include but are not limited to screws, bolts, rivets, or other mechanical or chemical fasteners. The mounting plate 326 can also connect the narrow area of the propeller hub cap cone to the motor shaft 304. The movement of the motor shaft 304 can cause the axial fan 307 to generate the airflow 312 through the annular space 306.

[0029] Figure 4 is an isometric view of the axial fan 104 and the mounting plate 220 according to at least one example. In Figure 1 and Figure 2 the axial fan 104 and the hub cap cone 102 integral with the axial fan 104 are depicted together. The inner hub 226 of the axial fan 104 can have a first diameter 222 and the outer hub 228 can have a second diameter 224. The outer hub 228 can be concentrically aligned with the inner hub 226. The blades 106 of the axial fan 104 can extend between the inner hub 226 and the outer hub 228. The outer hub 228 can reduce tip losses and can contribute to the structural integrity of the axial fan 104. The mounting plate 220 can be integrally formed with the inner hub 226 and can radially extend from the center of the axial fan 104 to the first diameter 222 of the inner hub 226. The outer hub 228 of the axial fan 104 can include a ring of uniform thickness, characterized in that the second diameter 224 serves as the inner ring and some thickness of the fifth diameter serves as the outer ring. The inner hub 226 of the axial fan 104 can be connected to the outer hub 228 of the axial fan 104 through a plurality of blades 106 between the inner hub 226 and the outer hub 228. The root of each blade 106 can be connected to the inner hub 226, and the tip of each blade can be connected to the outer hub 228.

[0030] The mounting plate 220 can be connected to the motor shaft, for example Figure 2The motor shaft 204. The mounting plate 220 can be connected by suitable fasteners, including but not limited to screws, bolts, rivets, or other mechanical or chemical fasteners. The motor shaft can be connected to the mounting plate 220 at the shaft opening 402. Depending on the attachment method, the insert 404 that connects the mounting plate 220 to the axial fan 104 can be threaded or smooth. In an alternative example, a mounting plate similar to Figure 3 The mounting plate of the mounting plate 326 can connect the axial fan 307 to the motor shaft without an integrally attached propeller hub cover. The mounting plate 220 can also be defined by weight reduction features 406 that can reduce the moment of inertia and thus reduce power loss.

[0031] The first diameter 222 can correspond to the third diameter of the aircraft motor 108, and the second diameter 224 can correspond to the fourth diameter of the aircraft motor 108. The radial distance between the first diameter 222 and the second diameter 224 can be approximately equal to the radial distance between the third diameter and the fourth diameter of the aircraft motor 108.

[0032] Figure 5 is an isometric view of an electric aircraft motor 103 and a set of cooling fins 504 according to at least one example. The set of cooling fins 504 is an example of the cooling fins 111. The electric aircraft motor 103 can be surrounded by the cooling fins 504. Power electronics (such as Figure 1 and Figure 2 The power electronics 110) can include similar cooling fins, such as the cooling fins 111. The cooling fins 504 can be surrounded by a shroud 502. A third diameter 522 that can be approximately equal to the first diameter 222 in some examples can correspond to the body of the electric aircraft motor 103. A fourth diameter 524 that can be approximately equal to the second diameter 224 in some examples can correspond to the diameter of the shroud 502. The radial distance between the third diameter 522 and the fourth diameter 524 can have a height approximately equal to that of the cooling fins 504 extending from the body of the electric aircraft motor 103 toward the shroud 502. Airflow can pass through an annular space 506 defined by the difference between the fourth diameter 524 and the third diameter 522.

[0033] Figure 6Top view of a blade 602 of an axial fan according to at least one example. The blade 602 can be formed from the following materials, including but not limited to aluminum, stainless steel, fiberglass, graphite fiber, nickel aluminum bronze alloy, manganese bronze alloy, other metallic materials, composite materials, or other suitable similar materials. The root 608 of the blade can be connected to the inner hub of the axial fan, and the tip 610 of the blade can be connected to the outer hub of the axial fan. The blade 602 can taper from the root 608 of the blade to the tip 610 of the blade. The blade 602 can be one of a plurality of blades (7 to 30 blades), and can be characterized in that the root angle 604 is between 25 degrees and 75 degrees. The blade 602 can also be characterized in that the tip angle 606 is between 25 degrees and 75 degrees. The difference between the root angle 604 and the tip angle 606 can define the twist of the blade 602. Other configurations are possible. The blade twist, blade thickness, and blade angle can vary according to the rotational speed of the application in order to maintain an aerodynamic flow with minimal flow separation, thereby maintaining low energy losses. The twist can be adjusted based on the engine to which they are paired to maintain an aerodynamic flow with minimal flow separation.

[0034] In the following, additional examples are described to assist in understanding the present invention:

[0035] Example A. A fan assembly for an electric aircraft motor, comprising: an axial fan including: an inner hub having a first diameter; an outer hub having a second diameter and concentrically aligned with the inner hub; and a plurality of blades extending between the inner hub and the outer hub; and a mounting plate connected to the inner hub and configured to mount the fan assembly to a component of the electric aircraft motor, wherein the first diameter corresponds to a third diameter of the electric aircraft motor, and the second diameter corresponds to a fourth diameter of the electric aircraft motor.

[0036] Example B. The fan assembly according to any one of the preceding or following examples, wherein a first radial distance measured between the first diameter and the second diameter is approximately equal to a second radial distance measured between the third diameter and the fourth diameter.

[0037] Example C. The fan assembly according to any one of the preceding or following examples, wherein the third diameter corresponds to the body of the electric aircraft motor, and the fourth diameter corresponds to the shroud of the electric aircraft motor.

[0038] Example D. The fan assembly according to any one of the preceding or following examples, wherein the radial distance between the third diameter and the fourth diameter is approximately equal to the height of a set of cooling fins that radially extend from the body of the electric aircraft motor towards the shroud.

[0039] Example E. The fan assembly according to any one of the preceding or following examples, wherein a radial distance between the third diameter and the fourth diameter is approximately equal to a height of a set of cooling fins that radially extend from a body of the electric aircraft motor.

[0040] Example F. The fan assembly according to any one of the preceding or following examples, wherein the component includes at least one of a motor shaft or a propeller of the electric aircraft motor.

[0041] Example G. The fan assembly according to any one of the preceding or following examples, wherein the inner hub is integrally formed with the propeller hub cap.

[0042] Example H. The fan assembly according to any one of the preceding or following examples, wherein the plurality of blades includes a number between seven and thirty.

[0043] Example I. The fan assembly according to any one of the preceding or following examples, wherein a root of each of the plurality of blades is connected to the inner hub, and a tip of each of the plurality of blades is connected to the outer hub.

[0044] Example J. The fan assembly according to any one of the preceding or following examples, wherein each of the plurality of blades is characterized in that a root angle and a tip angle are between 25 degrees and 75 degrees.

[0045] Example K. The fan assembly according to any one of the preceding or following examples, further comprising a cone that is concentrically aligned with and connected to the inner hub.

[0046] Example L. The fan assembly according to any one of the preceding or following examples, wherein a width of an annular region of the cone is between 5 mm and 50 mm.

[0047] Example M. The fan assembly according to any one of the preceding or following examples, wherein the mounting plate is integrally formed with the inner hub and radially extends from a center of the axial fan to a first diameter of the inner hub.

[0048] Example N. The fan assembly according to any one of the preceding or following examples, wherein the outer hub includes a ring of uniform thickness, characterized in that the second diameter is an inner ring diameter and a fifth diameter is an outer ring diameter.

[0049] Example O. The fan assembly according to any one of the preceding or following examples, wherein the inner hub is connected to the outer hub via the plurality of blades.

[0050] Example P. A system includes: an electric aircraft motor including an annular body and a set of cooling fins extending from the annular body; and an axial fan connected to the electric aircraft motor, the axial fan including: an inner hub having a first diameter corresponding to the annular body; an outer hub having a second diameter and being concentrically aligned with the inner hub, wherein the second diameter corresponds to the set of cooling fins; and a plurality of blades extending between the inner hub and the outer hub.

[0051] Example Q. The system according to any one of the preceding or following examples, wherein the electric aircraft motor further includes an annular shroud surrounding the set of cooling fins, and wherein a first radial distance between the first diameter and the second diameter is approximately equal to a second radial distance between the annular body and the annular shroud.

[0052] Example R. The system according to any one of the preceding or following examples, wherein the axial fan is connected to the electric aircraft motor via a motor shaft of the electric aircraft motor or via a propeller connected to the motor shaft.

[0053] Example S. A system includes: an electric aircraft motor housing including: a first annular housing containing an electric motor; a second housing including control electronics; and a motor shaft rotatably connected to the electric motor; and an axial fan connected to the motor shaft, the axial fan including: an inner hub having a first diameter corresponding to the first annular housing; an outer hub having a second diameter and being concentrically aligned with the inner hub, wherein the second diameter is greater than the first diameter; and a plurality of blades extending between the inner hub and the outer hub.

[0054] Example T. The system according to any one of the preceding or following examples, further including a propeller, and wherein the axial fan is connected to the motor shaft via the propeller.

[0055] Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described, are possible. Similarly, some features and sub - combinations are useful and can be used without reference to other features and sub - combinations. The embodiments of the present invention have been described for illustrative rather than restrictive purposes, and alternative embodiments will be apparent to the reader of this patent. Accordingly, the present disclosure is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the appended claims.

[0056] Accordingly, the specification and drawings are to be regarded as illustrative rather than restrictive. However, it will be apparent that various modifications and changes can be made to the invention without departing from the broader spirit and scope of the disclosure as set forth in the claims.

[0057] Other variations are within the spirit of the disclosure. Thus, while the disclosed techniques are susceptible to various modifications and alternative constructions, certain illustrative examples have been shown in the drawings and have been described in detail above. However, it is to be understood that the disclosure is not intended to be limited to the one or more specific forms disclosed, but on the contrary, is intended to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the disclosure as defined by the appended claims.

[0058] In the context of describing the disclosed examples (especially in the context of the appended claims), the use of the terms "a", "an", "the", and similar indicators should be construed to cover both the singular and the plural, unless the invention otherwise indicates or is clearly contradicted by the context. Unless otherwise specified, the terms "comprising", "having", "including", and "containing" should be construed as open-ended terms (e.g., meaning "including but not limited to"). The term "connected" should be construed to mean partly or wholly enclosed within, attached to, or joined together, even if there is some intervening element. Unless otherwise indicated in the invention, the recitation of numerical ranges in the invention is only intended as a shorthand method for separately referring to each individual value falling within the range, and each individual value is incorporated into the specification as if it were separately recited in the invention. All methods described in the invention can be performed in any suitable order, unless the invention otherwise indicates or is clearly contradicted by the context. The use of any and all examples or exemplary language (e.g., "such as") provided in the invention is only intended to better illustrate the examples of the disclosure and does not limit the scope of the disclosure, unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0059] Unless otherwise specifically stated, disjunctive language such as the phrase "at least one of X, Y, or Z" should be understood in context to generally mean that items, terms, etc. can be X, Y, or Z or any combination thereof (e.g., X, Y, and / or Z). Thus, such disjunctive language is generally not intended to and should not imply that certain examples require the presence of at least one of X, at least one of Y, or at least one of Z each.

[0060] The word "or" as used in the invention is intended to cover both inclusive and exclusive or conditions. In other words, A or B or C includes any one or all of the following alternative combinations suitable for a particular use: A alone; B alone; C alone; only A and B; only A and C; only B and C; and all three of A, B, and C.

[0061] The present disclosure describes preferred examples of the invention, including the best mode known to the inventors for practicing the present disclosure. Variations of these preferred examples will be apparent to those of ordinary skill in the art after reading the foregoing description. The inventors expect those skilled in the art to appropriately employ these variations, and the inventors intend the invention to be practiced otherwise than as specifically described herein. Accordingly, the invention includes all modifications and equivalents of the subject matter recited in the appended claims as permitted by applicable law. In addition, any combination of the above-described elements in all possible variations thereof is covered by the present invention unless the present invention is otherwise stated or is clearly inconsistent with the context.

[0062] All references cited in this invention, including publications, patent applications, and patents, are hereby incorporated by reference to the extent that each reference is individually and specifically indicated to be incorporated by reference and is set forth in its entirety herein.

Claims

1. A fan assembly for an electric aircraft motor, comprising: Axial fan, the axial fan comprising: An inner hub having a first diameter; An outer hub having a second diameter and being concentrically aligned with the inner hub; and A plurality of blades extending between the inner hub and the outer hub; and A mounting plate connected to the inner hub and configured to mount the fan assembly to a component of the electric aircraft motor, Wherein the first diameter corresponds to a third diameter of the electric aircraft motor, and the second diameter corresponds to a fourth diameter of the electric aircraft motor.

2. The fan assembly according to claim 1, wherein, A first radial distance measured between the first diameter and the second diameter is approximately equal to a second radial distance measured between the third diameter and the fourth diameter.

3. The fan assembly according to claim 1, wherein, The third diameter corresponds to the body of the electric aircraft motor, and the fourth diameter corresponds to the shroud of the electric aircraft motor.

4. The fan assembly according to claim 3, wherein, The radial distance between the third diameter and the fourth diameter is approximately equal to the height of a set of cooling fins that radially extend from the body of the electric aircraft motor towards the shroud.

5. The fan assembly according to claim 1, wherein, The radial distance between the third diameter and the fourth diameter is approximately equal to the height of a set of cooling fins that radially extend from the body of the electric aircraft motor.

6. The fan assembly according to claim 1, wherein, The component includes at least one of the motor shaft or the propeller of the electric aircraft motor.

7. The fan assembly according to claim 1, wherein, The inner hub is integrally formed with the propeller hub cover.

8. The fan assembly according to claim 1, wherein, The plurality of blades includes a number between 7 and 30.

9. The fan assembly according to claim 1, wherein, The root of each blade of the plurality of blades is connected to the inner hub, and the tip of each blade of the plurality of blades is connected to the outer hub.

10. The fan assembly according to claim 1, wherein, Each blade of the plurality of blades is characterized in that the root angle and the tip angle are between 25 degrees and 75 degrees.

11. The fan assembly according to claim 1, wherein, The fan assembly further includes a cone that is concentrically aligned with the inner hub and connected to the inner hub.

12. The fan assembly according to claim 11, wherein, The width of the annular region of the cone is between 5 mm and 50 mm.

13. The fan assembly according to claim 1, wherein, The mounting plate is integrally formed with the inner hub and radially extends from the center of the axial fan to the first diameter of the inner hub.

14. The fan assembly according to claim 1, wherein, The outer hub includes a ring with a uniform thickness, and the ring is characterized in that the second diameter is the inner ring diameter and the fifth diameter is the outer ring diameter.

15. The fan assembly according to claim 1, wherein, The inner hub is connected to the outer hub through the plurality of blades.

16. A system, comprising: An electric aircraft motor, the electric aircraft motor including an annular body and a set of cooling fins extending from the annular body; And An axial fan connected to the electric aircraft motor, the axial fan comprising: An inner hub having a first diameter corresponding to the annular body; An outer hub having a second diameter and being concentrically aligned with the inner hub, wherein the second diameter corresponds to the set of cooling fins; and A plurality of blades extending between the inner hub and the outer hub.

17. The system according to claim 16, wherein, The electric aircraft motor further includes an annular shroud surrounding the set of cooling fins, wherein a first radial distance between the first diameter and the second diameter is approximately equal to a second radial distance between the annular body and the annular shroud.

18. The system according to claim 16, wherein, The axial fan is connected to the electric aircraft motor via the motor shaft of the electric aircraft motor or via a propeller connected to the motor shaft.

19. A system comprising: An electric aircraft motor housing, the electric aircraft motor housing comprising: A first annular housing, the first annular housing including an electric motor; A second housing, the second housing including control electronics; and A motor shaft rotatably connected to the electric motor; and an axial fan connected to the motor shaft, the axial fan including: An inner hub having a first diameter corresponding to the first annular housing; An outer hub having a second diameter and concentrically aligned with the inner hub, wherein the second diameter is greater than the first diameter; and A plurality of blades extending between the inner hub and the outer hub.

20. The system according to claim 19, further comprising a propeller, and wherein the axial fan is connected to the motor shaft via the propeller.

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