Rotor, manufacturing method and ceiling fan

Abstract

The present invention addresses the problem of achieving weight reduction. A rotor (10) is used in a ceiling fan. At least three vanes are attached to the rotor (10). The rotor (10) comprises a body portion (11), at least three sets of a pair of a first flange (12) and a second flange (13), and a plurality of spokes (14). The body portion (11) is formed in a disc shape centered around a rotational axis around which the at least three vanes rotate. The first flanges (12) of the pairs of the at least three sets respectively correspond to the at least three vanes, and protrude away from the rotational axis of the body portion (11) along radial directions of the body portion (11). The plurality of spokes (14) extend from the body portion (11) toward the rotational axis. Each of the first flanges (12) includes a first opening portion (121) that is open along the rotational axis. Each of the second flanges (13) includes a second opening portion (131) that is open along the rotational axis.

Description

[Technical Field]

[0001] The present disclosure relates generally to rotors, manufacturing methods, and ceiling fans, and more particularly to a rotor having three blades attached thereto, a manufacturing method for the rotor, and a ceiling fan including the rotor. [Background technology]

[0002] Conventionally, ceiling fans that are suspended from a ceiling have been known (see Patent Document 1). The ceiling fan of Patent Document 1 comprises a suspension part that is fixed to the ceiling and a main body part that is engaged with and supported by the suspension part. The main body part comprises a rotary drive part and a plurality of blades. The rotary drive part comprises a rotor that rotates when electricity is applied to the rotary drive part. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2016 / 051665 Summary of the Invention

[0004] There is a demand for lighter components in ceiling fans.

[0005] The present disclosure has been made in consideration of the above-mentioned problems, and aims to provide a rotor, a manufacturing method, and a ceiling fan that can be made lighter.

[0006] A rotor according to one embodiment of the present disclosure is used in a ceiling fan and has at least three blades attached thereto. The rotor includes a body portion, at least three pairs of first and second flanges, and a plurality of spokes. The body portion is formed in a circular shape centered on a rotation axis about which the at least three blades rotate. The at least three pairs of first and second flanges correspond to the at least three blades, respectively, and protrude radially from the body portion away from the rotation axis. The plurality of spokes extend from the body portion toward the rotation axis. Each of the first flanges has a first opening that opens along the rotation axis. Each of the second flanges has a second opening that opens along the rotation axis. Each of the first flanges has a first mounting portion at the radial tip of the body portion, for mounting a corresponding one of the at least three blades, and a second mounting portion located circumferentially from the first mounting portion to the body portion, for mounting a cover that holds the at least three blades. Each of the first flanges has a first beam portion extending from the first mounting portion to the body portion, a second beam portion extending from the second mounting portion to the body portion, a first member extending from the first mounting portion to the body portion and disposed between the first beam portion and the second beam portion, and a second member extending from the second mounting portion to the body portion and disposed between the first beam portion and the first member. The first opening includes a third opening and a fourth opening. The third opening is formed by the first beam portion, the first member, and a first wall portion that is a part of the body portion. The fourth opening is formed by the second beam portion, the second member, and a second wall portion that is a part of the body portion and is different from the first wall portion.

[0007] A manufacturing method according to one aspect of the present disclosure is a method for manufacturing the rotor. The manufacturing method includes attaching gates to a mold for the rotor at locations corresponding to two of the at least three first flanges corresponding to the at least three blades, and forming the rotor by pouring molten aluminum alloy into the mold through each of the gates. A manufacturing method according to one embodiment of the present disclosure includes: Manufacture rotors for ceiling fans with at least three blades It is a method. The rotor includes a body portion, at least three pairs of first and second flanges, and a plurality of spokes. The body portion is formed in a circular shape centered on a rotation axis about which the at least three blades rotate. The at least three pairs of first and second flanges correspond to the at least three blades, respectively, and protrude radially from the body portion so as to move away from the rotation axis. The plurality of spokes extend from the body portion toward the rotation axis. Each of the first flanges has a first opening that opens along the rotation axis. Each of the second flanges has a second opening that opens along the rotation axis. In the manufacturing method, gates are attached to the rotor mold at locations corresponding to two of the at least three first flanges corresponding to the at least three blades, and molten aluminum alloy is poured into the mold through each of the gates to form the rotor.

[0008] A ceiling fan according to one embodiment of the present disclosure includes the rotor and the at least three blades. [Brief explanation of the drawings]

[0009] [Figure 1]FIG. 1 is a perspective view showing a ceiling fan according to one embodiment. [Figure 2] FIG. 2 is an exploded perspective view of the ceiling fan. [Figure 3] FIG. 3 is a perspective view showing a rotor provided in the ceiling fan. [Figure 4] FIG. 4 is a plan view of the rotor of the same. [Figure 5] 5 is a cross-sectional view taken along line X1-X1 shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0010] The embodiments and modifications described below are merely examples of the present disclosure, and the present disclosure is not limited to the following embodiments and modifications. Various modifications other than the following embodiments and modifications are possible depending on the design, etc., as long as they do not deviate from the technical concept of the present disclosure.

[0011] (Embodiment) The rotor 10 according to this embodiment and the ceiling fan 1 including the rotor 10 will be described below with reference to FIGS.

[0012] (1) Overview The ceiling fan 1 according to this embodiment is a fan (ceiling fan) that is installed on the ceiling of a building. As shown in Figures 1 and 2, the ceiling fan 1 includes a rotor 10. In other words, the rotor 10 is used in the ceiling fan 1. Three blades 20 are attached to the rotor 10.

[0013] As shown in FIG. 3, the rotor 10 includes a body portion 11, three pairs of first and second flanges 12 and 13, and three spokes 14. The body portion 11 is formed in a circular shape centered on a rotation axis A1 (see FIG. 3) about which the three blades 20 rotate. The three pairs of first and second flanges 12 and 13 correspond to the three blades 20, respectively. The three pairs of first and second flanges 12 and 13 protrude radially from the body portion 11 away from the rotation axis A1. The three spokes 14 extend from the body portion 11 toward the rotation axis A1. Each of the first flanges 12 has a first opening 121 that opens along the rotation axis A1. Each of the second flanges 13 has a second opening 131 that opens along the rotation axis A1.

[0014] According to this configuration, first opening 121 and second opening 131 are provided in first flange 12 and second flange 13 of rotor 10, respectively, so that weight reduction can be achieved.

[0015] In the following description, unless otherwise specified, the up-down direction of rotor 10 is defined by the arrows shown in Fig. 3. However, this direction is not intended to define the direction in which rotor 10 is used. Furthermore, the arrows shown in Fig. 3 and elsewhere are merely provided to assist in the description and do not have any substance.

[0016] (2) Composition The configuration of rotor 10 and ceiling fan 1 equipped with rotor 10 will now be described in detail.

[0017] 1 and 2, ceiling fan 1 includes rotor 10 and three blades 20. Ceiling fan 1 also includes cover 30 and a rotation control unit that includes a motor that rotates three blades 20. The rotation control unit is not shown in the figures.

[0018] The blades 20 are fixed to the rotor 10 via the cover 30 with screws or the like (not shown). The blades 20 are formed, for example, as metal plates. As shown in FIG. 2, the blades 20 have a connection portion 21 and a blowing portion 22. The connection portion 21 is attached to the rotor 10 and the cover 30. Specifically, the connection portion 21 is placed on the cover 30 and fastened with screws. The blowing portion 22 is located radially outward of the body portion 11 from the connection portion 21. The blowing portion 22 of the blades 20 blows air as the blades 20 rotate around the rotation axis A1 under rotation control by the rotation control unit. The blowing portion 22 of the blades 20 is inclined at an angle suitable for blowing air relative to the connection portion 21 of the blades 20.

[0019] The cover 30 holds the three blades 20. The cover 30 is disposed between the three blades 20 and the rotor 10. The connection portions 21 of the blades 20 are placed on the cover 30, and are fixed to the cover 30 and the first flange 12 of the rotor using screws (not shown). For example, the screws are inserted into through holes provided in the cover 30 and into the first flange 12 of the rotor 10, and the cover 30 is screwed in place. Furthermore, the cover 30 accommodates at least a portion of the rotation control unit between the cover 30 and the rotor 10.

[0020] 3 and 4, the rotor 10 includes a body portion 11, three pairs of first flanges 12 and second flanges 13, and a plurality of (here, three) spokes 14. When it is necessary to distinguish between the three first flanges 12, they will be referred to as first flanges 12a, 12b, and 12c.

[0021] The rotor 10 is formed by die-casting. That is, the body 11, three pairs of first flanges 12 and second flanges 13, and three spokes 14 are formed by die-casting. The rotor 10 is formed from, for example, an aluminum alloy.

[0022] The body 11 is formed in a circular shape centered on a rotation axis A1 (see FIG. 3) about which the three blades 20 rotate. The rotation axis A1 is an imaginary axis. The body 11 has a first body part 11a, a second body part 11b, and a third body part 11c. The first body part 11a, the second body part 11b, and the third body part 11c are formed in a circular shape centered on the rotation axis A1. The second body part 11b and the third body part 11c are arranged along the rotation axis A1. The first body part 11a is arranged to surround the outer peripheries of the second body part 11b and the third body part 11c, and is connected to the second body part 11b and the third body part 11c.

[0023] The three pairs of first flanges 12 and second flanges 13 respectively correspond to the three blades 20. The pairs of first flanges 12 and second flanges 13 protrude in the radial direction of the body portion 11 so as to move away from the rotation axis A1. The three pairs of first flanges 12 and second flanges 13 support the cover 30 from below.

[0024] Each of the first flanges 12 and each of the second flanges 13 is provided in a first body portion 11a of the body portion 11. That is, each of the first flanges 12 and each of the second flanges 13 protrudes in the radial direction of the body portion 11 in the first body portion 11a so as to move away from the rotation axis A1.

[0025] Each of the first flanges 12 has a first opening 121 that opens along the rotation axis A1. Each of the second flanges 13 has a second opening 131 that opens along the rotation axis A1.

[0026] 4, each of the first flanges 12 has a first mounting portion 122, a second mounting portion 123, a first beam portion 124, and a second beam portion 125. Each of the first flanges 12 further has a first member 126 and a second member 127.

[0027] The first mounting portion 122 is the radial tip of the body portion 11, and is a portion for mounting a corresponding one of the three blades 20. The first mounting portion 122 has a first through-hole that penetrates along the rotation axis A1. Screws are inserted sequentially through the through-holes provided in the blades 20, the through-holes provided in the cover 30, and the first through-holes provided in the first mounting portion 122, and fastened.

[0028] The second mounting portion 123 is located at a position along the circumferential direction of the body portion 11 from the first mounting portion 122, and is a portion for mounting the cover 30 that holds the three blades 20. The second mounting portion 123 has a through hole that passes through along the rotation axis A1. Screws are inserted sequentially into the through hole of the cover 30 and the second through hole provided in the second mounting portion 123, and fastened.

[0029] The first beam portion 124 extends from the first mounting portion 122 to the body portion 11. That is, the first beam portion 124 extends from the first mounting portion 122 to the first body part 11a of the body portion 11. Specifically, the first beam portion 124 extends from the first mounting portion 122 to the first body part 11a so as to intersect with a straight line extending from the first mounting portion 122 in the radial direction of the body portion 11, and is connected to the first body part 11a. The second beam portion 125 extends from the second mounting portion 123 to the body portion 11. That is, the second beam portion 125 extends from the second mounting portion 123 to the first body part 11a of the body portion 11. Specifically, the second beam portion 125 extends from the second mounting portion 123 to the first body portion 11a and connects to the first body portion 11a so as to intersect with a straight line extending from the second mounting portion 123 along the radial direction of the body portion 11. Here, the first beam portion 124 and the second beam portion 125 extend away from each other as they approach the first body portion 11a.

[0030] The first member 126 extends from the first mounting portion 122 to the body portion 11 and is provided between the first beam portion 124 and the second beam portion 125. Specifically, the first member 126 extends from the first mounting portion 122 to the first body portion 11a so as to intersect a straight line extending from the first mounting portion 122 along the radial direction of the body portion 11, and is connected to the first body portion 11a. The second member 127 extends from the second mounting portion 123 to the body portion 11 and is provided between the first beam portion 124 and the second beam portion 125. Specifically, the second member 127 extends from the second mounting portion 123 to the first body portion 11a so as to intersect a straight line extending from the second mounting portion 123 along the radial direction of the body portion 11, and is connected to the first body portion 11a. Here, the first member 126 and the second member 127 extend closer to each other as they approach the first body portion 11a.

[0031] The first opening 121 includes a third opening 121a and a fourth opening 121b. The third opening 121a and the fourth opening 121b are generally triangular. The third opening 121a is formed by a first beam 124, a first member 126, and a first wall 111 that is a part of the body 11. The first wall 111 is a portion of the first body part 11a between the connection position of the first beam 124 and the connection position of the first member 126. In other words, when the first flange 12 is viewed from the radial direction of the body 11, the first wall 111 is a portion of the first body part 11a between the first beam 124 and the first member 126. The fourth opening 121b is formed by a second beam 125, a second member 127, and a second wall 112 that is a part of the body 11 and different from the first wall 111. The second wall portion 112 is a portion of the first body portion 11a between the connection position of the second beam portion 125 and the connection position of the second member 127. In other words, the second wall portion 112 is a portion of the first body portion 11a between the second beam portion 125 and the second member 127 when the first flange 12 is viewed from the radial direction of the body portion 11.

[0032] Of the three first flanges 12, the first opening 121 in the first flange 12c further includes a fifth opening 121c. The fifth opening 121c is substantially trapezoidal in shape. The fifth opening 121c is formed by the first member 126, the second member 127, the third member 128 connecting the first mounting portion 122 and the second mounting portion 123, and the third wall portion 113 that is part of the body portion 11 and is located between the first wall portion 111 and the second wall portion 112. Of the three first flanges 12, the first flanges 12a and 12b further include a surface portion 129. The surface portion 129 closes the space formed by the first member 126, the second member 127, the third member 128, and the third wall portion 113.

[0033] As shown in FIG. 4, each of the second flanges 13 has a third mounting portion 132, a third beam portion 133, a fourth beam portion 134, and a fifth beam portion 135.

[0034] The third mounting portion 132 is a radial tip of the body portion 11, and is a portion for mounting a corresponding one of the three blades 20. Each of the three blades 20 is held by the first mounting portion 122 of the corresponding one of the three first flanges 12 and the adjacent second flange 13 counterclockwise from the first mounting portion 122 when the rotor 10 is viewed from above. For example, the blade 20 corresponding to the first flange 12a is held by the first mounting portion 122 of the first flange 12a and the adjacent second flange 13 counterclockwise.

[0035] The third beam portion 133 extends from the second mounting portion 123 to the body portion 11. That is, the third beam portion 133 extends from the second mounting portion 123 to the first body portion 11a of the body portion 11. Specifically, the third beam portion 133 extends from the second mounting portion 123 to the first body portion 11a so as to intersect with a straight line extending from the second mounting portion 123 along the radial direction of the body portion 11, and is connected to the first body portion 11a. The fourth beam portion 134 extends from the second mounting portion 123 to the body portion 11. That is, the fourth beam portion 134 extends from the second mounting portion 123 to the first body portion 11a of the body portion 11. Specifically, the fourth beam portion 134 extends from the second mounting portion 123 to the first body portion 11a and connects to the first body portion 11a so as to intersect with a straight line extending from the second mounting portion 123 along the radial direction of the body portion 11. Here, the third beam portion 133 and the fourth beam portion 134 extend away from each other as they approach the first body portion 11a.

[0036] The fifth beam portion 135 extends from the second mounting portion 123 to the first body portion 11a along the radial direction of the body portion 11 extending from the second mounting portion 123 between the third beam portion 133 and the fourth beam portion 134, and connects to the first body portion 11a.

[0037] The second opening 131 includes a sixth opening 131a and a seventh opening 131b. The sixth opening 131a and the seventh opening 131b are generally triangular. The sixth opening 131a is formed by a third beam portion 133, a fifth beam portion 135, and a fourth wall portion 114 that is a part of the body portion. The fourth wall portion 114 is a portion of the first body portion 11a between the connection position of the third beam portion 133 and the connection position of the fifth beam portion 135. In other words, the fourth wall portion 114 is a portion of the first body portion 11a between the third beam portion 133 and the fifth beam portion 135 when the second flange 13 is viewed from the radial direction of the body portion 11. The seventh opening 131b is formed by the fourth beam portion 134, the fifth beam portion 135, and a fifth wall portion 115 that is a part of the body portion 11 and different from the fourth wall portion 114. The fifth wall portion 115 is a portion of the first body portion 11a between the connection position of the fourth beam portion 134 and the connection position of the fifth beam portion 135. In other words, the fifth wall portion 115 is a portion of the first body portion 11a between the fourth beam portion 134 and the fifth beam portion 135 when the second flange 13 is viewed from the radial direction of the body portion 11.

[0038] A plurality of (here, three) spokes 14 extend from the body portion 11 toward the rotation axis A1. In this embodiment, the plurality of spokes 14 correspond one-to-one to the three first flanges 12. When viewed from the radial direction of the body portion 11, each of the plurality of spokes 14 is provided on the body portion 11 so as to overlap with a corresponding one of the three first flanges 12. Specifically, when viewed from the radial direction of the body portion 11, each of the plurality of spokes 14 is provided on the second body part 11b so as to overlap with a corresponding one of the three first flanges 12.

[0039] Each spoke 14 has a first spoke element 141 and a second spoke element 142. The first spoke element 141 extends downward from the second body element 11b. The second spoke element 142 is formed in a plate shape. The second spoke element 142 extends from the downwardly extending tip of the first spoke element 141 in the radial direction of the body portion 11 toward the rotation axis A1.

[0040] Three ribs 143, 144, and 145 are provided in the second spoke region 142 of each spoke 14 along the radial direction of the body portion 11 so as to protrude upward from the second spoke region 142. The ribs 144 and 145 are provided at both ends in the width direction of the second spoke region 142. The rib 143 is provided between the rib 144 and the rib 145.

[0041] At least one of the width W1 (see FIG. 5) and thickness H1 (see FIG. 5) of the second spoke portion 142 of each spoke 14 is reduced compared to the second spoke portion of the comparative example. In this case, the width W1 and thickness H1 of the second spoke portion 142 of the spoke 14 are set on the assumption that the motor rotation speed can be maintained without changing the motor drive conditions.

[0042] For example, the width W1 and thickness H1 of the second spoke portion 142 of the comparative example are 20 mm and 2.6 mm, respectively. In this embodiment, both the width W1 and thickness H1 of the second spoke portion 142 of the spoke 14 are smaller than those of the second spoke portion of the comparative example. That is, the width W1 of the second spoke portion 142 of the present embodiment is less than 20 mm, and the thickness H1 is less than 2.6 mm. For example, in this embodiment, the width W1 of the second spoke portion 142 of the spoke 14 is 15 mm, and the thickness H1 is 1.5 mm. Note that the width W1 of the second spoke portion 142 of the spoke 14 may be 16 mm or 17 mm. That is, the width W1 of the second spoke portion 142 of the spoke 14 is preferably 15 mm or more and less than 20 mm. Furthermore, the thickness H1 of the second spoke portion 142 of the spoke 14 is preferably 1.5 mm or more and less than 2.6 mm.

[0043] If only the thickness H1 of the second spoke portion 142 of the spokes 14 is reduced compared to the second spoke portion of the comparative example, the width W1 of the second spoke portion 142 of the spokes 14 may be 20 mm. If only the width W1 of the second spoke portion 142 of the spokes 14 is reduced compared to the second spoke portion of the comparative example, the thickness H1 of the second spoke portion 142 of the spokes 14 may be 2.6 mm.

[0044] As shown in FIG. 3 , the rotor 10 further includes a tubular portion 15. The tubular portion 15 is formed in a cylindrical shape centered on the rotation axis A1. That is, the tubular portion 15 has a through-hole 151 that penetrates along the rotation axis A1. The diameter of the tubular portion 15 is smaller than the diameter of the body portion 11. The tip of a second spoke portion 142 that extends radially from the first spoke portion 141 of each spoke 14 to the body portion 11 is connected to the lower end of the tubular portion 15.

[0045] (3) Manufacturing method Here, a method for manufacturing the rotor 10 will be described.

[0046] The rotor 10 is formed by aluminum die casting.

[0047] In the mold for the rotor 10, gates are attached to positions corresponding to two of the three first flanges 12, 12a and 12b, which correspond to the three blades 20. For example, in the mold, gates are attached to positions corresponding to the third members 128 of the first flanges 12a and 12b.

[0048] The molten aluminum alloy is poured (filled) into the mold through each of the gates. After the molten aluminum alloy is filled into the mold, the aluminum alloy inside the mold is solidified. Once the aluminum alloy inside the mold has solidified, the solidified aluminum alloy is separated from each gate, and the solidified aluminum alloy mold, i.e., rotor 10, is removed from the mold using a removal device or the like.

[0049] Furthermore, the rotor 10 is polished. In particular, the portions of the rotor 10 separated from the gates, and the third members 128 of the first flanges 12a and 12b are polished.

[0050] When filling the mold with molten aluminum alloy, the pressure at the outlet of the gate is higher than the pressure at other locations. In this embodiment, the first flanges 12a, 12b to which the gates are attached are provided with surface portions 129. This reduces the possibility of deformation of the mold of the first flanges 12a, 12b due to the pressure at the outlet of the gate when filling the mold with molten aluminum alloy.

[0051] Furthermore, by providing the first opening 121 and the second opening 131, the flow path for the molten aluminum alloy can be reduced compared to when the first opening 121 and the second opening 131 are not provided. This makes it easier for the molten aluminum alloy to flow when forming the rotor 10. Therefore, the pressure applied to the entire rotor when filling the molten aluminum alloy when forming the rotor 10 is approximately uniform. As a result, fewer bubbles are generated when forming the rotor 10 compared to when the first opening 121 and the second opening 131 are not provided. Furthermore, because fewer bubbles are generated, the occurrence of shrinkage cavities after solidification of the rotor 10 is also reduced compared to when the first opening 121 and the second opening 131 are not provided.

[0052] (4) Effects As described above, the rotor 10 according to this embodiment is used in a ceiling fan 1 and has three blades 20 attached thereto. The rotor 10 includes a body 11, three pairs of first and second flanges 12 and 13, and a plurality of spokes 14. The body 11 is formed in a circular shape centered on the rotation axis A1 around which the three blades 20 rotate. The three pairs of first flanges 12 correspond to the three blades 20, respectively, and protrude radially from the body 11 away from the rotation axis A1. The plurality of spokes 14 extend from the body 11 toward the rotation axis A1. Each of the first flanges 12 has a first opening 121 that opens along the rotation axis A1. Each of the second flanges 13 has a second opening 131 that opens along the rotation axis A1.

[0053] According to this configuration, first opening 121 and second opening 131 are provided in first flange 12 and second flange 13 of rotor 10, respectively, so that weight reduction can be achieved.

[0054] Moreover, the ceiling fan 1 of the embodiment includes the rotor 10 described above and three blades 20.

[0055] According to this configuration, first opening 121 and second opening 131 are provided in first flange 12 and second flange 13 of rotor 10, respectively, so that ceiling fan 1 can be made lighter in weight.

[0056] (5) Variations The following are examples of modifications. The modifications described below can be applied in appropriate combination with the above-described embodiment.

[0057] (5.1) Variation 1 In the embodiment, the plurality of spokes 14 are configured to be provided on the body portion 11 so that each of the plurality of spokes 14 overlaps a corresponding one of the three first flanges 12 when viewed from the radial direction of the body portion 11. However, the present invention is not limited to this configuration.

[0058] The multiple spokes 14 may be provided on the body portion 11 so that when each of the multiple spokes 14 is viewed from the radial direction of the body portion 11, it does not overlap with a corresponding one of the three first flanges 12.

[0059] (5.2) Variation 2 In the embodiment, the number of spokes 14 is three, but the number is not limited to this. The number of spokes may be two, or may be four or more.

[0060] (5.3) Variation 3 In the embodiment, the first flange 12 is configured such that the first mounting portion 122 and the second mounting portion 123 are connected by the third member 128, but the present invention is not limited to this configuration.

[0061] The first flange 12 does not need to connect the first mounting portion 122 and the second mounting portion 123 with the third member 128. That is, the first flange 12 may include a protruding portion made up of the first mounting portion 122, the first beam portion 124, and the first member 126, and a protruding portion made up of the second mounting portion 123, the second beam portion 125, and the second member 127. In other words, the first flange 12 may include two protruding portions.

[0062] (5.4) Variation 4 The rotor 10 is configured to have three blades, but is not limited to this configuration and may have four or five blades.

[0063] When the rotor 10 has four blades, the rotor 10 has four pairs of first flanges 12 and second flanges 13. Two adjacent first flanges 12 of the four first flanges 12 further have a surface portion 129. That is, these two first flanges 12 are gated first flanges to which gates are attached when produced by die-casting. In the remaining two first flanges 12 of the four first flanges 12, the first openings 121 include fifth openings 121c. That is, these remaining two first flanges 12 are ungated first flanges to which no gates are attached when produced by die-casting.

[0064] When the rotor 10 has five blades, the rotor 10 has five pairs of first flanges 12 and second flanges 13. Two adjacent first flanges 12 of the five first flanges 12 further have a surface portion 129. That is, these two first flanges 12 are gated first flanges to which gates are attached when produced by die-casting. In the remaining three first flanges 12 of the five first flanges 12, the first openings 121 include fifth openings 121c. That is, these remaining three first flanges 12 are ungated first flanges to which no gates are attached when produced by die-casting.

[0065] That is, the number of blades only needs to be at least three. In this case, the rotor 10 has at least three pairs of first flanges 12 and second flanges 13. Two adjacent first flanges 12 of the at least three first flanges 12 further have a surface portion 129. That is, these two first flanges 12 are gated first flanges to which gates are attached when produced by die-casting. In the remaining first flanges 12 of the at least three first flanges 12, the first openings 121 include the fifth openings 121c. That is, these remaining first flanges 12 are ungated first flanges to which no gates are attached when produced by die-casting.

[0066] (6) Summary As described above, the rotor (10) of the first embodiment is used in a ceiling fan (1) and has at least three blades (20) attached thereto. The rotor (10) includes a body portion (11), at least three pairs of first flanges (12) and second flanges (13), and a plurality of spokes (14). The body portion (11) is formed in a circular shape centered on a rotation axis (A1) about which the at least three blades (20) rotate. The at least three pairs of first flanges (12) correspond to the at least three blades (20), respectively, and protrude radially from the body portion (11) away from the rotation axis (A1). The plurality of spokes (14) extend from the body portion (11) toward the rotation axis (A1). Each of the first flanges (12) has a first opening (121) that opens along the rotation axis (A1). Each of the second flanges (13) has a second opening (131) that opens along the rotation axis (A1).

[0067] According to this configuration, the first flange (12) and the second flange (13) of the rotor (10) are provided with the first opening (121) and the second opening (131), respectively, thereby achieving weight reduction.

[0068] In the rotor (10) of the second embodiment, in the first embodiment, each of the first flanges (12) has a first mounting portion (122), a second mounting portion (123), a first beam portion (124), a second beam portion (125), a first member (126), and a second member (127). The first mounting portion (122) is a radial tip of the body portion (11) and is a portion for mounting a corresponding one of the at least three blades (20). The second mounting portion (123) is located from the first mounting portion (122) along the circumferential direction of the body portion (11) and is a portion for mounting a cover (30) that holds the at least three blades (20). The first beam portion (124) extends from the first mounting portion (122) to the body portion (11). The second beam portion (125) extends from the second mounting portion (123) to the body portion (11). The first member (126) extends from the first mounting portion (122) to the body portion (11) and is provided between the first beam portion (124) and the second beam portion (125). The second member (127) extends from the second mounting portion (123) to the body portion (11) and is provided between the first beam portion (124) and the first member (126). The first opening (121) includes a third opening (121a) and a fourth opening (121b). The third opening (121a) is formed by the first beam portion (124), the first member (126), and a first wall portion (111) that is part of the body portion (11). The fourth opening (121b) is formed by a second beam portion (125), a second member (127), and a second wall portion (112) that is part of the body portion (11) and is different from the first wall portion (111).

[0069] According to this configuration, the third opening (121a) and the fourth opening (121b) are provided in the first flange (12) of the rotor (10), thereby achieving weight reduction.

[0070] In the rotor (10) of the third embodiment, in the second embodiment, the body portion (11), each of the first flanges (12), each of the second flanges (13), and each of the spokes (14) are formed by die-casting. When produced by die-casting, each of the first flanges (12) is either a gated first flange (e.g., first flanges 12a, 12b) to which a gate is attached or an ungated first flange (e.g., first flange 12c) to which no gate is attached. In the ungated first flange, the first opening (121) further includes a fifth opening (121c). The fifth opening (121c) is formed by the first member (126), the second member (127), a third member (128) connecting the first mounting portion (122) and the second mounting portion (123), and the third wall portion (113) which is part of the body portion (11) and is located between the first wall portion (111) and the second wall portion (112). The gated first flange has a surface portion (129) which closes the space formed by the first member (126), the second member (127), the third member (128), and the third wall portion (113).

[0071] According to this configuration, the first flanges with gates (first flanges 12a, 12b) are provided with surface portions (129). This reduces the possibility of deformation of the mold of the first flange with gates due to pressure at the outlets of the gates when the molten aluminum alloy is filled. In addition, the first flange without gates (first flange 12c) is provided with the fifth opening (121c), which contributes to weight reduction.

[0072] In a rotor (10) of a fourth aspect, in the third aspect, each of the second flanges (13) has a third mounting portion (132) and a third beam portion (133), a fourth beam portion (134), and a fifth beam portion (135). The third mounting portion (132) is a radial tip portion of the body portion (11) and is a portion for mounting a corresponding blade (20) among the at least three blades (20). The third beam portion (133), the fourth beam portion (134), and the fifth beam portion (135) extend from the third mounting portion (132) to the body portion (11). The second opening (131) includes a sixth opening (131a) and a seventh opening (131b). The sixth opening (131a) is formed by a third beam (133), a fifth beam (135), and a fourth wall (114) that is part of the body (11). The seventh opening (131b) is formed by a fourth beam (134), a fifth beam (135), and a fifth wall (115) that is part of the body (11) and different from the fourth wall (114).

[0073] According to this configuration, the sixth opening (131a) and the seventh opening (131b) are provided in the second flange (13) of the rotor (10), thereby achieving weight reduction.

[0074] In the rotor (10) of the fifth aspect, in the third or fourth aspect, the plurality of spokes (14) correspond one-to-one to the at least three first flanges (12). When viewed in the radial direction of the body portion (11), each of the plurality of spokes (14) is provided on the body portion (11) so as to overlap with a corresponding one of the at least three first flanges (12).

[0075] This configuration can reduce deformation of the body portion (11) due to the force applied to the first flange (12).

[0076] The manufacturing method of the sixth aspect is a method for manufacturing the rotor 10 of any one of the first to fifth aspects. In the manufacturing method, gates are attached to a mold for the rotor 10 at locations corresponding to two of the at least three first flanges 12 corresponding to each of the at least three blades 20. In the manufacturing method, molten aluminum alloy is poured into the mold through each of the gates to form the rotor 10.

[0077] This manufacturing method allows the rotor (10) to be made lighter.

[0078] A ceiling fan (1) of the seventh aspect includes the rotor (10) of any one of the first to fifth aspects and at least three blades (20).

[0079] According to this configuration, the rotor (10) has the first opening (121) and the second opening (131) in the first flange (12) and the second flange (13), respectively, so that the ceiling fan (1) can be made lighter. [Explanation of symbols]

[0080] 1 ceiling fan 10 rotor 11 Body 12, 12a, 12b, 12c First flange 13 Second flange 14 spokes 20 Feathers 30 Cover 111 1st wall 112 2nd wall section 113 Third wall section 114 4th wall 115 Fifth wall 121 First Opening 121a 3rd opening 121b 4th opening 121c 5th opening 122 First mounting part 123 Second mounting part 124 1st beam section 125 2nd beam section 126 First member 127 Second member 128 Third member 129 Menu 131 Second Opening 131a 6th opening 131b 7th opening 132 Third mounting part 133 Third beam section 134 4th beam section 135 5th beam section A1 rotation axis

Claims

1. A rotor for use in a ceiling fan, having at least three blades attached thereto, a circular body portion having a center on a rotation axis when the at least three blades rotate; at least three pairs of first and second flanges corresponding to the at least three blades, respectively, and protruding from the body portion along a radial direction of the body portion so as to move away from the rotation shaft; a plurality of spokes extending from the body portion toward the rotation axis, Each of the first flanges has a first opening that opens along the rotation axis, Each of the second flanges has a second opening that opens along the rotation axis, Each of the first flanges comprises: a first attachment portion that is a distal end portion of the body portion in the radial direction and that is adapted to attach a corresponding one of the at least three blades; a second mounting portion located at a position along the circumferential direction of the body portion from the first mounting portion, for mounting a cover that holds the at least three blades; a first beam portion extending from the first mounting portion to the body portion; a second beam portion extending from the second mounting portion to the body portion; a first member extending from the first mounting portion to the body portion and provided between the first beam portion and the second beam portion; a second member extending from the second mounting portion to the body portion and provided between the first beam portion and the first member, the first opening includes a third opening and a fourth opening, the third opening is formed by the first beam portion, the first member, and a first wall portion that is a part of the body portion, the fourth opening is formed by the second beam portion, the second member, and a second wall portion that is a part of the body portion and is different from the first wall portion. Rotor.

2. The body portion, each of the first flanges, each of the second flanges, and each of the plurality of spokes are formed by die-casting, each of the first flanges is either a gated first flange having a gate attached thereto or a non-gated first flange having no gate attached thereto when produced by the die casting; In the gateless first flange, the first opening further includes a fifth opening formed by the first member, the second member, a third member connecting the first mounting portion and the second mounting portion, and a third wall portion that is a part of the body portion and is a region between the first wall portion and the second wall portion, the first flange with a gate has a surface portion that closes a space formed by the first member, the second member, the third member, and the third wall portion; The rotor according to claim 1 .

3. Each of the second flanges is a third attachment portion that is a distal end portion of the body portion in the radial direction and that is used to attach a corresponding one of the at least three blades; a third beam portion, a fourth beam portion, and a fifth beam portion extending from the third mounting portion to the body portion, the second opening includes a sixth opening and a seventh opening, the sixth opening is formed by the third beam portion, the fifth beam portion, and a fourth wall portion that is a part of the body portion, the seventh opening is formed by the fourth beam portion, the fifth beam portion, and a fifth wall portion that is a part of the body portion and is different from the fourth wall portion; The rotor according to claim 2 .

4. The plurality of spokes correspond one-to-one to at least three of the first flanges, When viewed from the radial direction of the body portion, each of the plurality of spokes is provided on the body portion so as to overlap a corresponding one of the at least three first flanges. A rotor according to claim 2 or 3.

5. A manufacturing method for manufacturing a rotor according to any one of claims 1 to 3, comprising: In the rotor mold, gates are attached to locations corresponding to two of the at least three first flanges corresponding to the at least three blades, respectively; The molten aluminum alloy is poured into the mold through each of the gates to form the rotor. Manufacturing method.

6. A manufacturing method for manufacturing a rotor for use in a ceiling fan, to which at least three blades are attached, comprising: The rotor is a circular body portion having a center on a rotation axis when the at least three blades rotate; at least three pairs of first and second flanges corresponding to the at least three blades, respectively, and protruding from the body portion along a radial direction of the body portion so as to move away from the rotation shaft; a plurality of spokes extending from the body portion toward the rotation axis, Each of the first flanges has a first opening that opens along the rotation axis, Each of the second flanges has a second opening that opens along the rotation axis, The manufacturing method includes: In the rotor mold, gates are attached to locations corresponding to two of the at least three first flanges corresponding to the at least three blades, respectively; The molten aluminum alloy is poured into the mold through each of the gates to form the rotor. Manufacturing method.

7. A rotor according to any one of claims 1 to 3, and the at least three blades. Ceiling fan.

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