IRON FOR DIAGONAL OR RADIAL FANS, INJECTION MOLDING TOOL FOR MANUFACTURING SUCH AN IRON, AND DEVICE WITH AT LEAST ONE SUCH IRON

Description

[0001] The invention relates to an impeller for diagonal or radial fans according to the preamble of claim 1 or 2, an injection molding tool for producing such an impeller according to the preamble of claim 14 and a device with at least one such impeller according to claim

[0002] A generic impeller is known from JP-A-2012193740 and US-A-2012 / 0315135.

[0003] Impellers for diagonal or radial fans are known which have a 2D geometry and are manufactured as one-piece injection-molded parts (GB-A-2 458 617).

[0004] However, impellers with 2D geometry have relatively low efficiencies, low air flow and high noise levels.

[0005] 3D wheels are also known, but they are constructed from multiple parts and must be connected together. Therefore, such wheels are not very economical to manufacture.

[0006] Impellers are also known (DE 20 2004 012 015 U1) in which the blades are arranged vertically on a cover plate and are attached to a central hub with their radially inner ends.

[0007] The invention is based on the object of designing the generic impeller, the generic injection molding tool and the device in such a way that a simple production of impellers with three-dimensional geometry and thus particularly high efficiencies, particularly high air performance and particularly low acoustics is possible using only a small amount of material.

[0008] This object is achieved in the generic impeller according to the invention with the characterizing features of claim 1 or 2, in the generic injection molding tool according to the invention with the characterizing features of claim 14 and in the device with the features of claim 16.

[0009] The impeller according to the invention is characterized in that its base plate, its cover plate, and its vanes are three-dimensionally shaped so that they can be manufactured integrally with one another using an injection molding process. When projected onto a coaxial cylinder with an average diameter of the trailing or leading edge, the extensions of the trailing and / or leading edge of the vanes each form an angle with a line parallel to the axis of rotation, at least one of which angles is not equal to 0°. The three-dimensional impeller geometry results in high efficiency with a low noise level. The impeller is designed to ensure demoldability in the injection mold. The three-dimensional design enables these parts to be designed with thin walls while still achieving a high impeller strength. Advantageously, at least one of the angles is greater than 0°.

[0010] According to the invention, the impeller is designed such that the two angles between the projections of the extensions of the trailing and / or leading edge of the blades with the parallel to the axis of rotation are significantly different, which can lead to a curved course of the trailing and / or leading edge.

[0011] The angle assigned to the cover plate is larger than the angle assigned to the base plate.

[0012] The cover plate is advantageously designed so that its diameter, viewed in axial section, increases from the air inlet toward the air outlet. This design facilitates demolding in the injection mold. Furthermore, this design of the cover plate contributes to high efficiency and low noise levels.

[0013] The generatrix of the cover plate is preferably curved such that the diameter of the cover plate increases continuously from the air inlet to the air outlet. The generatrix allows the three-dimensional shape of the cover plate to be very easily defined.

[0014] The fact that the generator runs straight at a distance from the air inlet also contributes to the easy demoulding of the impeller from the injection moulding tool.

[0015] In another advantageous design, the diameter of the base plate, viewed in axial section, increases from the end closest to the cover plate. A base plate designed in this way contributes significantly to high efficiency and low noise levels.

[0016] The generatrix of the bottom plate is curved from the side facing the shroud in such a way that the diameter of the bottom plate increases in axial section. This generatrix allows the three-dimensional shape of the bottom plate to be easily adapted to the required operating conditions of the impeller.

[0017] The fact that the generatrix runs straight at a distance from its end facing the cover plate further contributes to easy demoulding.

[0018] In a particularly advantageous embodiment in which high air performance, high efficiency and low noise emission are achieved, the angle α2 which the base plate encloses with a radial in axial section at its free edge facing away from the cover plate is at least 3° smaller than the angle α1 which the cover plate encloses with a radial in axial section at its end facing the air outlet.

[0019] To ensure high strength despite the thin-walled design of the blades, the transition area between the blades and the cover plate and / or the base plate is rounded. This allows the critical transition area to be designed in such a way that stress peaks are avoided during impeller use and the loads in this area can be safely absorbed.

[0020] In order to adapt the transition area to the loads during use, it is advantageous if the transition from the wings to the cover plate and / or the base plate extends to different widths on both sides of the wings.

[0021] For example, the rounding in the direction of the wing and in the direction of the deck / floor pane is of different widths.

[0022] In order to easily connect the impeller to the motor, the base plate is provided with a corresponding interface for connecting to a motor.

[0023] If the motor has only small dimensions, then the interface is advantageously an annular disc provided on the inner edge of the base disc.

[0024] To enable easy connection of the impeller to the motor, the interface is located within the area surrounded by the blades of the impeller, seen in the axial direction of the impeller.

[0025] If the impeller is intended for a larger motor, the interface is advantageously positioned at a distance from the inner edge of the base plate and formed by domes protruding from the outer side of the base plate. The fastening screws can be screwed directly into the domes or into metal sleeves inserted into the domes to connect the motor to the impeller.

[0026] In a preferred embodiment, the impeller is connected to the motor using self-tapping plastic screws that are screwed into the domes.

[0027] In order to improve the flow guidance in the area of ​​the interface, in an advantageous embodiment a flow cap can be attached to the inner edge of the base plate.

[0028] It is advantageously designed in such a way that its outer side forms at least approximately a continuous continuation of the inner side of the base plate.

[0029] The injection molding tool according to the invention is provided with at least one mold insert located between two slides for producing the cover plate and the interface. The mold insert is used to produce the base plate with the interface within the injection molding tool within the two molds. The shape of the mold insert depends on the desired shape of the interface. Thus, by simply changing the mold insert, it is possible to easily produce base plates with different interfaces in the injection molding tool.

[0030] Since the entire base plate including the interface is formed with the mold insert, tooling costs are not yet optimal. For this reason, an advantageous design provides for the mold insert to be an adapter insert into which smaller mold inserts can be inserted to form the interface. The adapter insert essentially serves to form the base plate, while the inserted small mold inserts are used to form the interface on the base plate. Using the adapter insert with the small mold inserts saves tooling costs, since only the small mold inserts are required to form the various interfaces.

[0031] The device according to the invention has at least one fan with an impeller according to the invention.

[0032] It's advantageous if the device has at least two fans arranged side by side. This allows for excellent cooling.

[0033] If the axial distance between the fans is at most approximately 1.75*D1, where D1 is the diameter of the cover plate in the area of ​​the air outlet, the device can be designed compactly despite having at least two fans.

[0034] A particularly compact unit with respect to air flow can be designed so that the unit's side panels extend radially very close to the fan impeller's air outlet without significant loss of efficiency, air flow, or low noise. A particularly compact unit has characteristic dimensions of the unit's side panels Dg (diameter in the case of a round shape, side panel distances in the case of a square shape) of Dg<=1.75 D1, where D1 is the diameter of the cover plate in the area of ​​the air outlet.

[0035] Further features of the invention emerge from the further claims, the description and the drawings.

[0036] The invention will be explained in more detail with reference to the embodiments shown in the drawings. Fig. 1 an impeller according to the invention, Fig. 2 an axial section through the impeller according to Fig. 1 , Fig. 3 a side view of the impeller according to the invention, Fig. 3a a two-dimensional representation of the blade trailing edges with characteristic angles, Fig. 4a to Fig. 4c different design options of the detail X in Fig. 2 in an enlarged view, Fig. 5 a front view of the impeller according to the invention, Fig. 6 an axial section through the impeller, which is provided with a motor connection for structurally large motors, Fig. 6a in a representation according to Fig. 2 characteristic angles for determining the profile section of the blades of the impeller, Fig. 6b a representation according to Fig. 2 the impeller with motor, Fig. 7 in schematic representation a section through an injection molding tool with which an impeller with a motor connection for structurally small motors is produced, Fig. 8 in a representation corresponding Fig. 7 the injection molding tool for producing an impeller with a motor connection for structurally large motors, Fig. 9 and Fig. 10 each in representations corresponding Fig. 7 further designs of injection moulding tools for the manufacture of the impeller, Fig. 11 in schematic representation and in section a flow cap of the impeller, Fig. 12 in enlarged representation a section along the line AA in Fig. 6a , Fig. 13 a device according to the invention with two fans arranged next to each other, Fig. 14 a further embodiment of a device according to the invention.

[0037] The impeller is designed for a fan, which can be a diagonal or radial fan. The impeller is characterized by a free three-dimensional geometric design. This means that there are no straight lines or flat or extruded surfaces on the fan blades. Extrusion here refers to the formation of the surface of the fan blades by parallel displacement of a generating curve in space. Fans with such impellers are very efficient and have a particularly low noise level. The impeller is a single-piece injection-molded part. Small wall thicknesses are used for the fan blades, the base plate, and the cover plate of the impeller, thus saving material in the manufacture of the impeller. Nevertheless, the impeller is characterized by its high strength.

[0038] The impeller is advantageously made of a fiber-reinforced thermoplastic. In possible embodiments, the thermoplastic can be polyamide (PA6, PA66, PA66 / 6, PAPA, PPA, PA 4.6, PA12), polyester (PBT, PET), polypropylene (PP), PPS, PES, PESU, PEEK, ABS, PC, or ASA, preferably a polyamide or polypropylene. The reinforcing fibers can be made of glass, carbon, aramid, a thermoplastic (PET, PA), or a natural fiber (e.g., flax, hemp, sisal, jute, coconut), preferably glass fiber.

[0039] The impeller has a cover plate 1, through which air is sucked in in the direction of the flow arrows 2. The cover plate 1 is designed as a rotating body and has a flow cross-section that continuously expands in the inflow direction. Advantageously, the cover plate 1 is designed so that it is in the area of ​​the outlet 4 ( Fig. 2 ) has a diameter approximately 30 to 70% larger than in the area of ​​inlet 5.

[0040] The cover disk 1 is connected to the base disk 7 by vanes 6. Like the base disk 1 in the exemplary embodiment, it is designed as a rotating body. The base disk 7 is essentially conical and has a casing 8 which, together with the opposite wall of the cover disk 1, forms a passage for the flowing air. The base disk 7 has its largest diameter at its free end, which is, for example, larger than the diameter of the inlet 5 of the cover disk 1. From the free end of the casing 8, the diameter of the base disk 7 advantageously decreases continuously towards the cover disk 1. A motor connection 9 is connected to the inner end of the casing 8 and forms an interface for connecting the drive motor. The motor connection 9 is designed as an annular disk. The motor connection 9 lies in a radial plane of the impeller. The motor connection has through openings 10 for fastening screws distributed around the circumference.

[0041] The casing 8 of the base plate 7 can be straight along its length in axial section. In the illustrated embodiment, the casing 8 is curved adjacent to the motor connection 9 and only becomes straight at a distance from it.

[0042] The cover plate 1 and the base plate 7 are preferably designed as rotating bodies. However, they can also have any other shape, depending on the application and the design of the fan to which the impeller is to be mounted.

[0043] The cover plate 1 and the base plate 7 are connected by the wings 6. As can be seen from the Fig. 1 bis 3 The blades 6 are arranged at a short distance from the inlet 5 of the cover plate 1 and a short distance from the free edge 11 of the base plate 7. The blades 6 are of the same design and ensure, when the fan is in use, that the air is sucked in via the inlet opening 5 of the cover plate 1 in the direction of the flow arrows 2 and flows diagonally outwards in the direction of the flow arrows 12 between the wall 3 of the cover plate 1 and the casing 8 of the base plate 7. In the axial section according to Fig. 2 the flow direction 12 projected onto the plane of the drawing, which corresponds to an axial plane, lies at the acute angle α to the corresponding radial of the impeller.

[0044] The angle α describes the angle between the imaginary mean flow direction 12 projected onto the axial plane at the air wheel outlet, which is estimated from the geometric properties of the impeller, and the perpendicular to the impeller's axis of rotation 13 contained in the axial plane. For diagonal fans, the angle α lies between approximately 20° and approximately 70°. The angle α is defined according to the relationship α=0.5*( α1 + α2). The angle α1 ≥ α2 is maintained if high efficiency with low noise levels is required. In a particularly advantageous embodiment, in which high air flow, high efficiency and low noise emissions are achieved, α2 is at least 3° smaller than α1. An advantageous angle range is between approximately 5° and 15°.

[0045] The angle α1 is determined between the perpendicular to the rotation axis 13 contained in the axial plane and the extension of the wall 3 of the base plate 1 contained in the axial plane. The perpendicular to the rotation axis 13 passes through the free end 14 of the base plate 1.

[0046] In the same way, the angle α2 between the perpendicular to the rotation axis 13 contained in the axial plane and the extension of the shell 8 of the base plate 7 contained in the axial plane is determined. The perpendicular passes through the free edge 11 of the base plate 7.

[0047] Based on Fig. 3 The three-dimensional design of the blades 6 is explained. The blades 6 have trailing edges 15 whose curve differs significantly from the corresponding straight chord 16. This connects the two ends of the trailing edge 15. The leading edge 17 of the blades 6 also has a curve that differs significantly from the corresponding straight chord. In an advantageous embodiment, the maximum distance of the chord 16 from the blade trailing edge is greater than 8% of the length of the chord 16. This also applies analogously to the blade leading edge and its chord. The blades 6 are designed such that the entire impeller can be manufactured easily and cost-effectively in an injection mold, despite the complex three-dimensional geometry.

[0048] The following describes how the two-dimensional representation of the trailing edges 15 in Figur 3a is received. In Figur 3a are the trailing edges 15, which in Figur 3 represented by narrow surfaces, simplified by the course of their center line. Figur 3a out of Figur 3 To derive this, the trailing edges, represented simply as a line, are projected onto a cylinder surface. The cylinder used for the projection has the rotation axis as its axis and the mean diameter of the two endpoints of the trailing edge 15 as its diameter. The projection method used is that of the smallest distance (the projected point is the point on the cylinder surface with the smallest distance to the original point). The image of the trailing edge 15 projected onto the cylinder surface is then unwrapped into the plane of the drawing, thus finally obtaining the representation of the trailing edges 15 in Figur 3a In a completely analogous manner, one can derive a two-dimensional representation of the course of the wing leading edge 17.

[0049] The angles β, β1 and β2 in Fig. 3a have positive values. Positive angles tend to cause the trailing edge to move in the direction of rotation 47 of the impeller when moving along the trailing edge toward the base plate.

[0050] Depending on the aerodynamic requirements of the impeller, negative angles β, β1 and β2 are also possible. Fig. 3a A negative angle β2- is shown schematically as an example. The negative angle β2- is determined in the same way as previously explained for positive values ​​of the angle β2.

[0051] To approximately determine the three-dimensionality of the blades 6 and thus of the impeller, the angles β, β1 and β2 ( Fig. 3a ) are used, which are significantly larger than 0°. These angles are in Fig. 3a the angles between the respective tangents (dotted line) to the blade trailing edge 15 and the dashed axis parallels. For example, the two angles β1 and β2 at the end points of the blade trailing edge 15 can be greater than approximately 10°. It is advantageous if the angles β1 and β2 have positive values. The two angles β1 and β2 ( Fig. 3a ) can be of equal size, but also significantly different from one another. In a particularly advantageous embodiment, the two angles β1 and β2 differ by more than 10°. β1 is greater than β2. The course of the angle β from the starting point of the trailing edge 15 on the cover disk 1, where it assumes the value β1, to the end point of the trailing edge 15 on the base disk 7, where it assumes the value β2, is monotonically decreasing in the exemplary embodiment. A non-monotonic course of the angle β is also conceivable.

[0052] The profiles of the angles β, β1, and β2 described for the blade trailing edge can also be applied analogously to the profile of the blade leading edge. The blade trailing edge profile or the blade leading edge profile, or both profiles, can have the described properties, thereby describing a three-dimensional impeller geometry. In an advantageous embodiment, the trailing edge 15 and the leading edge 17 of the blade 6 are tangent-continuous, i.e., they do not exhibit any kink.

[0053] Large angles β, β1, and β2 lead to aerodynamic and aeroacoustic advantages. For manufacturing reasons (elimination from the injection mold in one-piece production), it is advantageous to choose angles that are not too large. Thus, β1 and β2 should not exceed 50° in magnitude, and the largest angle β should not exceed 65° across the entire trailing edge 15.

[0054] In Figur 12 a cross-section of a wing 6 is shown. Such a cross-section is created by cutting a wing 6 with a cutting plane AA, as shown in Figur 6a The position of the section planes AA will now be described in more detail.

[0055] Each possible cutting plane AA intersects the centerline of the trailing edge 15 of the wing at a point P ( Fig. 6a ). At this point P, the section plane AA runs parallel to the imaginary flow exit direction 12 projected onto the local axial plane, which was described by the angle α. In addition, the section plane AA at point P runs parallel to the local direction of the rotational speed (circumferential direction). Only section planes that intersect both the blade trailing edge and the blade leading edge are considered. This condition creates a section plane that is the one closest to the cover disk 1, and a section plane that is the one closest to the base disk 7. These two extreme section planes represent the beginning (cover disk) and end (base disk) of the section planes.

[0056] A cross-section of a wing 6 obtained in the manner described ( Fig. 12 ) preferably resembles an airfoil as known from aircraft. This leads to low noise emissions during operation and high levels of efficiency. In order to save material and costs, thin profile cross-sections are preferably selected. The ratio of the maximum profile thickness dmax (largest inscribed circle diameter) to the profile chord length s is preferably d / s < 0.04. In order to further minimize noise emissions, the thickness of the wing 6 in the area of ​​the trailing edge 15 (downstream side) is further minimized. In order to be able to manufacture the smallest possible trailing edge thickness, the thickness in the area shk (the last 10% of the chord length s) is massively reduced. The thickness reduction factor from the beginning to the end of this area directly at the trailing edge 15 is greater than 30%, preferably 50%.

[0057] The angle γ in the section plane ( Fig. 12 ) denotes the angle of the chord s to the line l connecting the chord center with the rotation axis 13. This angle γ is advantageously between 20° and 70°. In a particularly advantageous embodiment, this angle γ changes by considerably more than 10° between the different sections (from the top plate to the bottom plate). The blade 6 is therefore twisted, which is particularly advantageous for efficiency and acoustics.

[0058] The twisting of the blades 6 can also be described using the angles γ1 and / or γ2. In particularly advantageous embodiments, the angles γ1 and / or γ2 change between the different sections (from the cover to the base plate) by significantly more than 10°.

[0059] γ1 denotes Fig. 12 the angle between the tangent to the skeleton line of the wing profile at the wing leading edge 17 to the line l1 connecting the leading edge 17 with the rotation axis 13. Analogously, γ2 denotes Fig. 12 the angle between the tangent to the skeleton line of the wing profile at the wing trailing edge 15 to the line l2 connecting the trailing edge 15 to the axis of rotation 13.

[0060] The three-dimensionality of a wing is also evident in the significant variation in chord length s between the different sections (from the top plate to the bottom plate). In a particularly advantageous embodiment, the chord length between the two outermost sections (on the top plate and bottom plate) changes by more than 5%.

[0061] In another particularly advantageous embodiment, the section with the longest chord length is located in a central region of the impeller between the cover and base plates. In this case, the maximum chord length is at least 3% greater than the chord length in the section associated with the cover plate and at least 3% greater than the chord length in the section associated with the base plate.

[0062] The wings 6 are formed in one piece with the cover plate 1 and the base plate 7 ( Fig. 2 ). The transitions between the wings 6 and the base or cover plate can be designed differently, which can be seen from the Fig. 4a bis 4c described in more detail. In particular, these transitions can be designed in such a way that, with minimal material usage, stress peaks in this transition area are avoided or reduced to such an extent that they are not problematic during use of the impeller.

[0063] During training according to Fig. 4a The two outer sides 18, 19 of the blade 6 each merge with the inner side 20 of the casing 8 of the base plate 7 at a sharp edge. Due to this sharp-edged transition, higher stress peaks occur during impeller use, which are associated with a notch effect. The blade 6 and the casing 8 therefore have a wall thickness such that fracture does not occur in this transition area.

[0064] In the embodiment according to Fig. 4b The outer sides 18, 19 of the blade 6 each merge with the inner side 20 of the casing 8 in a rounded manner. The rounding is designed so that it extends approximately equally far in the blade direction dy and in the deck / base plate direction dx. Due to the rounding, the cross-section increases steadily in the transition area from the blade 6 to the casing 8. Due to this design, only very small stress peaks occur in the transition area during use.

[0065] In the example according to Fig. 4c The rounding is designed differently on both sides of the blade 6. The extent of the rounded area in the transition zone is adapted to the loads occurring during operation. Thus, the transition extending in the blade direction dy is significantly larger than the area extending in the direction dx of the cover / base plate 1, 7. For example, the transition area dy is larger by approximately 1.5 dx. This uneven design of the transition area between the blade 6 and the cover / base plate 1, 7 allows the impeller to be optimally adapted to the loads expected during use.

[0066] The wheel according to the Fig. 1 , 2 and 5 is intended for motors with a small interface diameter. The motor can be screwed to the ring-shaped motor connection 9. How Fig. 5 As shown, the leading edges 17 of the vanes 6 are spaced radially from the motor connection 9, as seen in the axial direction of the impeller. This allows the motor to be easily screwed to the annular motor connection 9 using its corresponding interface.

[0067] In Figur 6b Such an impeller is shown with a screwed-on motor 39. The motor 39, in whose rotating flange 40 threaded holes are made, is fastened with screws 41, which are screwed in from the intake opening 5. It is also conceivable that no threaded holes are made in the motor flange 40, but rather the screws 41 are fastened to the motor 39 with a nut. The stationary part 39' of the (external rotor) motor 39 is mounted in a known manner.

[0068] In an advantageous embodiment, metal sleeves are also inserted into the passage opening 10 of the plastic impeller, which leads to increased strength of the screw connection.

[0069] However, if the impeller is to be used for motors 39 which have a larger interface diameter, then the motor connection 9 is provided in the area of ​​the casing 8 of the base plate 7 ( Fig. 6 ). The motor connection 9 is formed by domes 21 arranged one behind the other at a distance in the circumferential direction, which protrude from the outer side 22 of the casing 8 of the base plate 7. The domes 21 are each provided with a recess 23 for receiving fastening screws, with which the motor 39 can be screwed to its corresponding interface. The motor 39 can also be connected to the motor connection 9 via an additional adapter piece made of sheet metal or plastic. The base plate 7 according to Fig. 6 differs from the previous embodiment in that it does not have an annular disc at the tapered end. Otherwise, the base disc 7 can be designed the same as in the previous embodiment. Since the domes 21 are provided on the outer side 22 of the casing 8 facing away from the cover disc 1, the impeller can be conveniently connected to the motor 39.

[0070] In order to be able to easily manufacture the impeller with the different motor connections 9, only different inserts for injection molding tools are used, as shown in the Fig. 7 bis 10 will be explained. This makes it very easy to manufacture impellers for different sized engines using injection molding.

[0071] The described impellers have characteristic dimensions or dimensional ratios that allow for easy production of the impellers using the injection molding process.

[0072] The cover plate 1 has an inner diameter Ds in the area of ​​the inlet 5. The ends 24 of the vanes 6 adjacent to the inlet 5 lie on a circle with a diameter Di1. The ends 24a of the vanes 6 located on the base plate 7 lie on a circle with a diameter Di2, viewed in axial section. The cover plate 1 has a diameter D1 in the area of ​​the outlet 4. The base plate 7 has a diameter D2 at the free edge 11.

[0073] In Fig. 6 The diameters mentioned are not given, but the corresponding radii in the form of Ds / 2, Di1 / 2, Di2 / 2, D1 / 2 and D2 / 2.

[0074] The ends 24 of the wings 6 are shown in the illustration according to Fig. 6 not in the plane of the drawing, but offset rearward relative to the plane of the drawing. The wing tips 24 rest on the shroud 3 of the cover disk 1. Depending on the shape of the shroud 3, the diameter Di1 can therefore be equal to the diameter Ds, but also smaller or larger than this diameter Ds.

[0075] The diameters D1 and D2, as well as Di1 and Di2, differ in specific ratios. Furthermore, the impeller's Ds / D1 ratio is relatively large, ranging from approximately 0.6 to 0.85, for example. This diameter ratio results in the impeller generating only low noise during operation. The large Ds / D1 ratio allows the fan to deliver a large airflow rate.

[0076] The diameter D2 is less than or equal to D1. Preferably, D2 is in the range 0.8 to 0.95 * D1. This selection of D2 enables a high air flow rate, since the air flow is not deflected as far in the radial direction at the base plate 7.

[0077] This is also due to the fact that the diameters D1 and D2 are matched to each other in such a way that the air outlet (flow arrows 12) is optimally designed and contributes to the high level of quietness of the impeller.

[0078] The diameter Di2 is significantly smaller than Di1. In an advantageous embodiment, Di2 lies in the range of 0.2 to 0.5 * Di1. This results in high efficiencies and low acoustics. Furthermore, this ratio characterizes the three-dimensionality and complexity of the impeller geometry, which presents a challenge when removed from an injection mold as a single piece.

[0079] The blades 6 are also designed to produce little noise when the impeller is in use, while still optimally conveying the air.

[0080] The described impellers are characterized by high efficiency and particularly low noise levels. The impellers can be manufactured cost-effectively, in particular by being manufactured in one piece. The impellers are particularly advantageously manufactured from a fiber-reinforced plastic as an injection-molded part. This makes the impellers not only lightweight but also highly rigid. Due to the special design of the transition between the blades 6 and the casing 8 of the base plate 7 or the casing 3 of the cover plate 1, the blades 6 can be designed with very thin walls without compromising strength. The transition between the blades 6 and the cover plate 1 or the base plate 7 can, as shown in Fig. 4c As described above, the blades must be adapted to the loads that arise in this area during impeller use. The rounding at the transition from blade 6 to cover plate 1 or base plate 7 is selected so that the transition area can withstand the loads that arise during impeller use. The blades 6 themselves can therefore be designed with very thin walls, which not only contributes to the low weight of the impeller but also significantly reduces the amount of plastic used to manufacture the impeller.

[0081] The following describes the production of the different impellers in an injection mold. Fig. 7 shows schematically an injection moulding tool with which the impeller is produced according to the Fig. 1 , 2 and 5can be produced in which the motor connection 9 is formed by the annular disc on the inner edge of the base disc 7. The injection molding tool has two slides 26, 27, which are located on either side of a mold insert 28, with which the base disc 7 with the annular disc 9 is produced. The mold insert 28, together with other (not shown) injection molded parts, delimits the cavity into which the plastic is injected to produce the base disc 7. After the injection process has ended, the two slides 26, 27 located on either side of the mold insert 28 can be moved away from each other in the direction of the arrow.

[0082] Should a wheel be Fig. 6 are manufactured in which the motor connection 23 is not located on the inner edge of the base plate 7, a mold insert 29 ( Fig. 8 ) is used, which is designed so that the domes 21 can be manufactured on the outer side 22 of the casing 8 of the base plate 7. The slides 26, 27 remain the same.

[0083] In the manner described, by using different inserts, the base plate 7 can be manufactured in such a way that motors of different sizes can be connected to the impeller.

[0084] For motor connection 9 according to the Fig. 1 , 2 and 5 The fastening screws are screwed from the inlet side 5 through the openings 10 into the motor flange 40. The drive motor itself is located in the area enclosed by the base plate 7.

[0085] For a wheel according to Fig. 6 The screws are screwed from the side of the base plate 7 through the motor or adapter flange directly into the dome 21 of the base plate 7. Self-tapping and self-locking plastic screws are preferably screwed directly into the dome 21. However, threaded metal bushings can also be inserted into the dome 21, into which the fastening screws are screwed.

[0086] Fig. 9 shows a further embodiment of an injection molding tool with which the base plate 7 is produced according to the Fig. 1 , 2 and 5 In contrast to the embodiment according to Fig. 7 Two mold inserts 30, 31 are used, which are located between the slides 26, 27 of the injection molding tool. The mold insert 30 forms an adapter insert into which different mold inserts can be inserted to create different motor connections. The mold insert 30 is designed to essentially form the shell 8 of the base plate 7. The much smaller mold insert 31 is used to produce the remaining part of the shell 8 as well as the motor connection 9 of the base plate 7.

[0087] How Fig. 10 shows, a different shape of the motor connection 9 of the base plate 7 can be produced by exchanging the small mold insert 31. The mold insert 30 is the same as the mold insert of the injection mold according to Fig. 9 .

[0088] The two examples with the mold inserts 31 demonstrate that different motor connections 9 can be easily manufactured using very small mold inserts. The adapter insert 30 makes it possible to save tooling costs when different designs of the motor connections 9 are to be manufactured at the inner end of the base plate 7.

[0089] Fig. 11 shows the possibility of providing a flow cap 32 on the base plate 7, with which the flow guidance in the area of ​​the motor connection can be improved. The flow cap 32 can be retrofitted to the impeller. Its design can be tailored, for example, depending on the motor used, its external geometry, and also its thermal behavior. In the exemplary embodiment, the flow cap 32 is closed and thus closes the opening 33 in the center of the base plate 7. The flow cap 32 can also have a central opening, which leaves space for a part of the motor, for example a motor bell housing.

[0090] The illustrated flow cap 32 is approximately conical with a rounded conical tip 34 and has at least one fastening element 35 on its free edge, with which it can be attached to the base plate 7. The fastening element 35 is, for example, a circumferential ring with an external annular groove 36, into which a shaped piece 37 engages on the edge 25 of the base plate 7. The shaped piece 37 and the annular groove 36 engage in the manner of a dovetail groove, whereby the flow cap 32 is securely connected to the base plate 7.

[0091] The outer side 38 of the flow cap 32 forms an essentially continuous continuation of the inner side 20 of the base plate 7.

[0092] The flow cap 32 can be connected to the base plate 7 in any suitable manner, for example by snap hooks, by means of a screw connection and the like.

[0093] The impellers described are particularly suitable for use at operating points with relatively low flow resistance. The impellers are compactly designed, allowing them to be used even in tight installation situations. Due to their one-piece design, the impellers can be manufactured cost-effectively using appropriate injection molding tools.

[0094] Fig. 13 shows a device 42, which can be, for example, a split unit, a roof fan, or a heat pump, to which two fans 43 with impellers according to the invention are attached. These fans 43 suck air out of the device 42. The shape of the impeller enables a very close arrangement of several fans 43 next to one another without significant losses in efficiency or acoustics. The reason lies primarily in the choice of the discharge angle α, but also in the optimal three-dimensional blade geometry. It is now possible to arrange two or more fan impellers according to the invention in parallel with an axial distance Dax of 1.75*D1 or less (in particular 1.4..1.7*D1) in a very compact arrangement while remaining quiet and energy-efficient.

[0095] The fans 43 can be arranged side by side and / or one above the other. The number of fans 43 can be selected depending on the size of the device 42 to be cooled. The fans are each connected by their cover plate 1 to an inlet nozzle 44 of the device 42. Since the air streams from the fans exit diagonally outward in the direction of the flow arrows 12, the fans can be arranged relatively close to one another on the device 42 without the air streams 12 exiting the fans interfering with one another.

[0096] Figur 14shows a device 45, which can be, for example, an air conditioning unit or a duct fan, in which a fan 43 with an impeller according to the invention pushes air into the device 45 from the left. The shape of the device wall 46 can be round (duct) or square (air conditioning unit) in diameter. On the downstream side, the side walls 46 disrupt the air flow due to design or space constraints. Due to the special shape of the impeller according to the invention, the disruptive device walls 46 can be positioned very close to the fan 43 without significant degradation (acoustics, efficiency). This allows for a very compact design. The distance Dg between the device walls 46 can be selected to be < 1.75*D1, in particular 1.4... 1.7*D1.

[0097] The impellers described can be used in a wide variety of devices and fans. These impellers can be used advantageously in duct or tube fans, precision air conditioning units, heat pumps, compact or box air conditioning units, electronics cooling, generator cooling, ventilation boxes, or residential ventilation units.

Claims

1. Impeller for diagonal or radial ventilators, having a bottom disc (7) and a top disc (1), which are connected to one another by three-dimensionally shaped blades (6) which are formed in one piece with the bottom disc (7) and the top disc (1), characterized in that in the projection onto a cylinder with average diameter of the rear edge (15), which cylinder is coaxial with the axis of rotation (13), the extension of the rear edge (15) of the blades (6) encloses an angle (β1) with a line parallel to the axis of rotation (13) at a starting point of the rear edge (15) at the top disc (1) and encloses an angle (β2) with a line parallel to the axis of rotation at an end point of the rear edge (15) at the bottom disc (7), wherein the angle (β1) at the starting point of the rear edge (15) at the top disc (1) is larger than the angle (β2) at the end point of the rear edge (15) at the bottom disc (7), wherein the angle (β2) at the end point of the rear edge (15) at the bottom disc (7) is not equal to 0°.

2. Impeller for diagonal or radial ventilators, having a bottom disc (7) and a top disc (1), which are connected to one another by three-dimensionally shaped blades (6) which are formed in one piece with the bottom disc (7) and the top disc (1), characterized in that in the projection onto a cylinder with average diameter of the rear edge (15), which cylinder is coaxial with the axis of rotation (13), the extension of the rear edge (15) of the blades (6) encloses an angle (β1) with a line parallel to the axis of rotation (13) at a starting point of the rear edge (15) at the top disc (1) and encloses an angle (β2) with a line parallel to the axis of rotation at an end point of the rear edge (15) at the bottom disc (7), wherein at least one angle (β1, β2) is not equal to 0°, wherein in the projection onto a cylinder with average diameter of the front edge (17), which cylinder is coaxial with the axis of rotation (13), the extensions of the front edge (17) of the blades (6) encloses an angle (β1v) with the line parallel to the axis of rotation (13) at a starting point of the front edge (17) at the top disc (1) and encloses an angle (β2v) with a line parallel to the axis of rotation at an end point of the front edge (17) at the bottom disc (7), of which at least one angle (β1v, β2v) is not equal to 0°.

3. Impeller according to claim 1, characterized in that in the projection onto a cylinder with average diameter of the front edge (17), which is coaxial with the axis of rotation (13), the extensions of the front edge (17) of the blades (6) enclose an angle (β1v, β2v) with the line parallel to the axis of rotation (13), at least one of which angles (β1v, β2v) is not equal to 0°.

4. Impeller according to any one of claims 1 to 3, characterized in that the diameter of the top disc (1) increases in axial section from the air inlet (5) in the direction of the air outlet (4).

5. Impeller according to any one of claims 1 to 4, characterized in that the generatrix of the top disc (1) runs in a curved manner such that the diameter of the top disc (1) steadily increases from the air inlet (5) in the direction of the air outlet (4), wherein the generatrix advantageously runs straight at a distance from the air inlet (5).

6. Impeller according to any one of claims 1 to 5, characterized in that the diameter of the bottom disc (7) increases in axial section starting from the side facing the bottom disc (1), wherein the generatrix of the bottom disc (7) preferably runs in a curved manner starting from the side facing the top disc (1) such that the diameter of the bottom disc (7) increases, and advantageously runs straight at a distance from its end facing the top disc (1).

7. Impeller according to any one of claims 1 to 6, characterized in that the angle (α2), which the bottom disc (7) encloses with a radial line at its free edge (11) in axial section, is smaller than the angle (α1), which the top disc (1) encloses with a radial line at its end facing the air outlet (4) in axial section.

8. Impeller according to any one of claims 1 to 7, characterized in that the transition region of the blades (6) to the top disc (1) and / or to the bottom disc (7) is rounded, wherein the transition of the blades (6) to the top disc (1) and / or to the bottom disc (7) preferably extends to a different width on both sides of the blades (6).

9. Impeller, particularly according to claim 8, characterized in that the rounding has a different width in the blade direction (dy) and in the direction (dx) of the top / bottom disc (1, 7).

10. Impeller according to any one of claims 1 to 9, characterized in that the bottom disc (7) is provided with an interface (9, 21) for connection to a motor (39).

11. Impeller according to claim 10, characterized in that the interface (9) is a ring-shaped disc which is provided on the inner edge of the bottom disc (7) and is advantageously inside the region surrounded by the blades (6) as viewed in the axial direction of the impeller.

12. Impeller according to claim 10, characterized in that the interface (21) is provided at a distance from the inner edge of the bottom disc (7) and is formed by domes that protrude from the outside (22) of the bottom disc (7), and in that the connection of the impeller to the motor (39) is advantageously produced using self-cutting plastic screws which are screwed into the domes (21).

13. Impeller according to any one of claims 1 to 12, characterized in that a flow cap (32) can be fitted to the inner edge of the bottom disc (7), the outer side (38) of which flow cap advantageously at least approximately forms a steady continuation of the inner side (20) of the bottom disc (7).

14. Injection mould for producing the impeller according to any one of claims 1 to 13, having moulding tools, into which a plastic is injected for producing the impeller, characterized in that at least one mould insert (28 to 31), which is located between two sliders (26, 27), is provided for producing the bottom disc (7) with the interface (9, 21).

15. Injection mould according to claim 14, characterized in that the mould insert (30) is an adapter insert into which smaller mould inserts (31) can be inserted for forming the interface (9, 21).

16. Device having at least one ventilator (43) having an impeller according to any one of claims 1 to 13,17. Device according to claim 16, characterized in that the device (42) has at least two ventilators (43) arranged next to one another, the axial spacing (Dax) of which from one another is at most approximately 1.75*D1, wherein D1 is the diameter of the top disc (1) in the region of the air outlet (4).

18. Device according to claim 17, characterized in that the device interior which adjoins a ventilator (23) according to the invention on the pressure side has a diameter or radial side wall distance (Dg) of at most approximately 1.75*D1, wherein D1 is the diameter of the top disc (1) in the region of the air outlet (4).