Fan

The application claims priority to U.S. Provisional Patent Application No. 63/717,493, filed Nov. 7, 2024, and U.S. Provisional Patent Application No. 63/644,710, filed May 9, 2024, the entire contents of all of which are incorporated by reference herein.

The present disclosure relates to a fan.

Fans, such as jobsite fans, are used to induce airflow in an environment.

The present disclosure provides, in one aspect, a fan including a base having a base housing, a battery receptacle disposed on the base housing, the battery receptacle configured to receive a battery, a user interface disposed on the base housing, and a plurality of cleats extending from a bottom surface of the base housing. The plurality of cleats are configured to cooperate with corresponding recesses on a support structure. The fan includes a blower unit supported by the base. The blower unit includes a blower unit housing, a motor positioned within the blower unit housing and having a motor output shaft, and a blade coupled to the motor output shaft.

The present disclosure provides, in another aspect, a fan including a base and a blower unit supported by the base. The blower unit includes a housing, a motor positioned within the housing and having a motor output shaft, a blade coupled to the motor output shaft, and a grille coupled to the housing. The grille includes a plurality of vanes forming hexagonal shapes sized to prevent a probe having a diameter of 12 millimeters from being inserted through the grille.

The present disclosure provides, in another aspect, a fan including a base and a blower unit supported by the base. The blower unit includes a housing having a motor housing and a plurality of vanes extending radially outward from the motor housing, a motor positioned within the motor housing and having a motor output shaft, a blade coupled to the motor output shaft, and a boot located between the motor housing and the motor to at least partially isolate the motor housing from vibrations from the motor.

Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings.

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.

illustrates a fanincluding a base, a pair of armsfastened to the base, and a blower unitsupported by the base. Specifically, the blower unitis pivotably coupled to the pair of arms. The baseincludes a base housing, a user interface(e.g., dial), and an actuator. The user interfaceand the actuatorare disposed on a front portion of the housing. The baseincludes a battery receptacledisposed at a rear portion of the housing. The battery receptacleis configured to receive a batteryalong an insertion axis A. In some embodiments, the battery receptacleincludes a support structure (e.g., rails, etc.) configured to mechanically couple the batteryto the fanand contacts configured to electrically couple the batteryto the fan.

In some embodiments, the batterymay be an 18-volt rechargeable power tool battery pack. The batterymay include multiple battery cells having, for example, a lithium (Li), lithium-ion (Li-ion), or other lithium-based chemistry. For example, the battery cells may have a chemistry of lithium-cobalt (Li—Co), lithium-manganese (Li—Mn) spinel, or Li—Mn nickel. In such embodiments, each battery cell may have a nominal voltage of about, for example, 3.6V, 4.0V, or 4.2V. In other embodiments, the battery cells may have a nickel-cadmium, nickel-metal hydride, or lead acid battery chemistry. In further embodiments, the batterymay include fewer or more battery cells, and/or the battery cells may have a different nominal voltage. In yet another embodiment, the batterymay be a dedicated battery housed (partially or entirely) within the housingof the base. The batterymay also be configured for use with other cordless power tools, such as drills, screwdrivers, grinders, wrenches, and saws. When received in the battery receptacle, the illustrated batteryremains at least partially exposed. In other embodiments, the basemay include a cover or lid to enclose the battery.

With continued reference to, the pair of armsare fastened to sides of the housingthat extend between the front and the rear portion. The pair of armsextend upwardly from the base. The blower unitincludes a blower unit housingthat is pivotably coupled to the pair of arms. In the illustrated embodiment, the blower unit housingis generally cylindrical. The blower unit housingincludes a handle. The handleextends radially outward from an outer circumferential wall of the blower unit housing. In the illustrated embodiment, the handleis located on a side of the blower unit housingopposite from the base. In other embodiments, the handlemay be located elsewhere on the fan. The blower unitincludes a grillethat is coupled to the blower unit housing. The grilleis generally cylindrical and has a similar size (e.g., diameter) as the blower unit housing. The grilleincludes a plurality of outlet vanes. In the illustrated construction, the grilleis an outlet grille. The blower unit housingincludes a plurality of inlet vanes. In other words, the blower unit housingforms a grille. In the illustrated construction, the blower unit housingforms an inlet grille.

illustrates the baseincluding a plurality of cleatsextending from a bottom surface of the base. In the illustrated embodiment, the baseincludes four cleats. In other embodiments, the basemay include fewer or more cleats(e.g., a single cleat 148 or more than four cleats). The illustrated cleatsextend from a bottom surface of the housing. The cleatsare configured to cooperate with recesses on a support structure. For example, the cleatsmay be configured to cooperate or interface with a toolbox, a wall plate, or the like of the PACKOUT modular storage system sold by Milwaukee Electric Tool Corporation. The basealso includes a plurality of feetdisposed on the plurality of cleats. The feetare comprised of an elastomer (e.g., rubber, polyurethane, silicone). The feethelp resist movement of the fanrelative to the support structure and reduce marring of the support structure. Additionally, the feetattenuate vibration between the fanand the support structure. The actuator() includes a projectionextending downwardly from the bottom surface of the housing. The actuatorand the projectionare biased by a spring. In the resting position, the actuatorand projectionare biased by the spring such that the projectionprojects from the housing. A user may retract the projectioninto the housing by manipulating the actuator. The projectionis configured to selectively engage and disengage a corresponding recess on the support structure to releasably secure the fanto the support structure.

illustrates the blower unit housingincluding a pair of circumferential vanes. The circumferential vanesextend about a circumference of the blower unit housingand couple the inlet vanesto one another. The inlet vanesand the circumferential vanesare arranged such that openings formed between adjacent vanes of the vanes,satisfy dimensional requirements of International Electrotechnical Commission (IEC) 60335-1. Similarly, the outlet vanesare arranged to satisfy dimensional requirements of IEC 60335-1. Specifically, the outlet vanesand the vanes,are arranged to prevent the insertion of the probe according to the IEC 60335-1. The blower unit housingand the grilleenclose a blade. The bladeis configured to propel air out of the grille. In other words, the fanis configured to induce an airflow. In the illustrated embodiment, the bladeis comprised of a glass reinforced polymer (e.g., glass-reinforced polypropylene). In other embodiments, the bladeis comprised of a polymer (e.g., Acrylonitrile butadiene styrene). In other embodiments, the bladeis comprised of a metal. The bladeincludes a plurality of projectionsextending from a hub(). In the illustrated embodiment, the plurality of projectionsdefine a blade diameter D(). Specifically, the endsof the plurality of projectionsdefine the blade diameter D. In the illustrated embodiment, the diameter Dis between 150 millimeters and 200 millimeters. In the illustrated embodiment, the diameter Dis 180 millimeters.

The fanincludes a width Wthat is measured between the pair of armsalong a direction that is parallel to a pivot axis A(). The width Wis between 22 centimeters and 27 centimeters. In the illustrated embodiment, the width Wis approximately 24.50 centimeters. The fanincludes a length Li measured from the front portion to the rear portion of the housingof the base(). The length Li is between 21 centimeters and 25 centimeters. In the illustrated embodiment, the length Li is approximately 23 centimeters. The fanincludes a height Hthat is measured from the bottom of the cleatsto the handlein a direction that is perpendicular to the insertion axis Aand the pivot axis A(). The height His between 35 centimeters and 47 centimeters. In the illustrated embodiment, the height His approximately 41 centimeters.

With continued reference to, the baseincludes an alternative power source connection(e.g., an AC inlet or prongs). In other embodiments, the alternative power source includes an IEC AC input. In some instances, the fanis powered by the battery. In other instances, the fanis powered by an AC power source coupled to the AC prongs. In some embodiments, the fanmay include a charging circuit positioned within the base. In such embodiments, the AC power source may both power the fanand charge the battery. In other words, if AC and DC power sources are simultaneously available (e.g., AC power source coupled to the AC prongsand the batterycoupled to the fan), the power will be drawn from the AC power source to prevent discharge of the DC source (e.g., the battery).

illustrates the batteryfully inserted into the battery receptaclealong the insertion axis A. In the instance the batterypowers the fan, the batterysupplies energy to a printed circuit board(“PCB”) that is mounted within the housing. Alternatively, the PCBcan be supplied with energy from the AC power source coupled to the AC prongs. The PCBis mounted in the housingon a plane Pthat is perpendicular to the insertion axis A. The PCBis coupled to the user interfaceand includes a controller programmed with an algorithm configured to supply power to a motorthat powers the blade() based on user input from the user interface. The fanincludes wiresthat are routed from the PCB, through an arm of the pair of arms, and to the blower unit.

illustrates the pivotable connection between the pair of armsand the blower unit. The blower unit housingincludes cylindrical projections() that each receive a bushingto define a pivot axis A. The blower unit housingis pivotable about the pivot axis A. The bushingsinclude a pair of seals(e.g., O-rings) such that the cylindrical projectionscan pivot about the bushings. The sealshelp maintain the blower unitin any angular position relative to the arms. The bushingsare coupled to the pair of armsvia fasteners (not shown) that are received by protrusionsof the pair of arms. Each bushingincludes an outer lipsuch that the blower unit housingis disposed between the bushingand an arm of the pair of armswhen the bushingis coupled to the arm of the pair of arms.

illustrates the grilleincluding an inner walland an outer wall. The inner wallis proximal to the bladeand is coupled to the plurality of outlet vanes. The plurality of outlet vanesextend radially inward from the inner walland to a center hub. In other words, the center hubis coupled to the inner wallvia the outlet vanes. The outlet vanesextend radially outward from the center hubin a spiral manner. The outer wallincludes a projectionthat meshes with a grooveformed in in the blower unit housing. The meshing between the projectionand the grooveis configured to align the blower unit housingand the grille. The blower unit housingand the grilleare coupled together via plurality of fastenersthat extend through projectionson the blower unit housingand corresponding projectionson the grille(). The inner wallincludes an endthat abuts the blower unit housing.

illustrates the blower unit housingincluding a motor housingthat partially defines a motor cavitythat houses the motor. The motorused may vary depending on airspeed requirements. Similarly, the motor housingmay have a different diameter to accommodate different motors. The inlet vanesextend radially outward relative to an outer surface of the motor housing. The fanincludes a motor coverthat encloses the motor cavity. The motor coveris coupled to the motor housingvia a plurality of fastenersand partially defines the motor cavity. The motor coverincludes a plurality of openings. The openingsmay facilitate cooling the motorwithin the motor housing. The blower unit housingincludes a wire supportthat routes the wire from one arm of the pair to armsto the motor. The wire supporthas a side openingfacing the blade. In the illustrated embodiment, the wire supportis integrated with a vane of the plurality of inlet vanes. In other embodiments, the wire supportis separate from the plurality of inlet vanes. The motor housingincludes an openingfor the wiresto be routed into the motor cavityand connected to the motor. An optional wire covercan be coupled to wire supportvia a fastener passing through the wire coverand into a protrusionof the wire support. The wire covercovers the side openingof the wire support and the openingof the motor housing. In the illustrated embodiment, a surfacethe inlet vanesproximal to the bladeare disposed at a distance Xfrom the blade. In the illustrated embodiment, the distance Xis approximately 71 millimeters. The inlet vanesinclude a thickness Tof approximately 10 millimeters. As such, an external surface of the inlet vanesis disposed approximately 81 millimeters from the blade. In some embodiments, the external surface of the inlet vanesmay be disposed at least 80 millimeters from the blade. In such embodiments, the distance Xand/or the thickness Tmay be larger or smaller, as long as the combination of the distance Xand the thickness Tis at least 80 millimeters. For example, the distance Xmay be approximately 75 millimeters and the thickness Tmay be approximately 5 millimeters. Alternatively, the distance Xmay be approximately 60 millimeters and the thickness Tmay be approximately 20 millimeters.

illustrates the motorcoupled to the motor housing. Specifically, the motor housingincludes an aperturethat receives a screw bushing. A bootis located between the motor housingand the motor. The bootis comprised of an elastomer (e.g., rubber, polyurethane, silicone). The bootis configured to isolate the motor housingfrom vibrations from the motor. A shoulder screwextends through the screw bushingand the bootand is received by the motor. Although only a single screw bushingand screwis illustrated, a plurality of bushings and screws secure the motorto the motor housing. Specifically, in the illustrated construction, the apertureis a first aperture of a trio of apertures.

The motorincludes a stator (not shown) and a rotor. The motorincludes a motor output shaftcoupled for co-rotation with the rotorabout a motor axis A. The motor axis Ais perpendicular to the pivot axis A. When the blower unitis in an upright position (i.e., when the grilleis facing forward and perpendicular to the bottom surface of the base), the motor axis Ais parallel to the insertion axis A. As the blower unitpivots or rotates about the arms, the motor axis Abecomes angled relative to the insertion axis A. A sleeveis coupled to the motor output shaftvia an interference fit. In other embodiments, the motor output shaftis coupled to the sleevevia a fastener. The sleeveis coupled to the blade, such that the bladeco-rotates with the motor output shaftabout the motor axis A.

Specifically, the sleeveis received by an apertureof the blade. The sleeveincludes a shoulderon a first side of the bladethat is proximal to the motoralong the motor axis A. A seal(e.g., an O-ring) is disposed between the shoulderand the bladesuch that the bladeis axially preloaded by O-ring compression along the motor axis A. The axial preloading of the bladepromotes isolation from axial vibrations from the motor output shaft. In other words, the sealisolates the bladefrom vibrations from the motor output shaft. The sleeveincludes a channelon a second side of the bladethat is located further away from the motoron the motor axis Athan the first side of the blade. The channelis configured to receive a fastener(e.g., a clip) on the second side of the blade. The combination of the shoulderabutting the sealagainst the first side of the bladeand the clipon the second side of the bladeaxially secures the sleeveto the bladealong the motor axis A. In some embodiments, the sleeveis coupled to the bladevia an interference fit (e.g., a press fit). In some embodiments, the sleeveis coupled to the bladewith a combination of the shoulder, the seal, the clip, and the interference fit.

In the illustrated embodiment, the fanincludes continuous variable speed control. That is, the fancan operate at any speed within a range of speeds, rather than only at discrete speed settings. In some embodiments, motorof the fanis a variable speed motor that rotates the bladeat a speed set the user interface. As shown in, the illustrated user interfaceincludes a dial that is rotatable to set the speed of the motor. The dial is located on the front portion of the housing, opposite from the battery receptacle. The illustrated dial is also offset from a central plane of the fan(i.e., a vertical plane that includes the motor axis A). In other embodiments, the user interfacemay include other suitable actuators, such as a slidable switch, a touchscreen, and the like, to set the speed of the motorand/or the user interfacemay be located elsewhere on the housing. In some embodiments, the fanincludes the controller of the PCBprogrammed with an algorithm capable of varying the rotation of the motorby using a variable voltage.

To activate the blower unit, the user actuates the user interfacefrom an off position to an on position. In the illustrated embodiment, the off position is indicated when an off indicatoron the dial is aligned with an arrowon the housing(). The on position is indicated by various speed indicatorscircumferential located on the dial. In the on position, the controller of the PCBreceives the signal from the dial and controls the rotational speed of the motorand consequently the speed of the motor output shaftand the bladebased on the signal from the dial.

illustrates a blower unitcompatible with the fan. In other words, the blower unitis interchangeable with the blower unit. The blower unitis like the blower unitwith like features being denoted by the same reference numerals. Since the blower unitis like the blower unit, only differences will be discussed. The blower unitincludes a housinghaving projectionsthat extend from the housing. In some embodiments, the projectionsare coupled to the arms. In some embodiments, the housingincludes the cylindrical projectionssuch that the blower unitis pivotable relative to the armsof the fan. In some constructions, the projectionsare coupled to the base. The blower unitincludes a grille(e.g., an outlet grate) that is coupled to the housingand a blower unit housing(e.g., an inlet grate) that is coupled to the housing.

The grille, or outlet grille, includes a plurality of outlet vanesthat extend between a central portionand an outer portion. The outer portionis coupled to the housing. An inner surface of the outer portiondefines a diameter D. In the illustrated embodiment, each of the plurality of outlet vanesare linear in shape and couple the central portionand the outer portiontogether. The plurality of outlet vanesinclude between 5 vanes and 15 vanes. More specifically, in the illustrated embodiment, the plurality of outlet vanesincludes 10 vanes. In the illustrated embodiment, the grilleincludes a uniform construction (e.g., monolithic).

illustrates the blower unit housing, or inlet grille, including a plurality of vanescompatible with the fan. The plurality of vanesare arranged such that openings formed between adjacent vanes of the vanessatisfy dimensional requirements of IEC 60335-1. The vanesinclude walls extending in a direction parallel to the motor axis A. The vanesextend between a central portionand an outer portion. The outer portionis coupled to the housing. An inner surface of the outer portiondefines a diameter D. In the illustrated embodiment, the diameter Dis larger than the diameter D. The plurality of vanesincludes an alternating pattern of a first group of vanes, a second group of vanes, and a spacewithin the blower unit housing. Specifically, the first group of vanesand the second group of vanesalternate circumferentially relative to the central portionand the outer portion. The spaceextends between outer peripheriesof adjacent vanes of the first and second groups of vanes,. The first group of vanesform a collection of hexagons (e.g., honeycomb structure) organized in a stack extending between the central portionand the outer portion. The stack of the first group of vanesincludes a width equivalent to that of a single hexagon. The central portionincludes an outer surfaceand a central circle. The outer surfaceis disposed radially outward relative to the central circleand is coupled to the central circle. The outer surfaceincludes a plurality of partial hexagonal shapes. The first group of vanesis coupled to the outer surface. The second group of vanesform a collection of hexagons (e.g., honeycomb structure) formed as a triangle with a base of the triangle disposed on the outer portionand a tip of the triangle disposed proximal to the central portionrelative to the outer portion. In other words, the second group of vanesdiverges from the central portionto the outer portion. The tip of the triangle of the second group of vanesis defined by a single hexagon and is coupled to the central circleby a linear vane. The second group of vanesincludes some adjacent hexagons that share a common interior space. In other words, the second group of vanesinclude adjacent hexagons without a wall separating adjacent hexagons.

schematically illustrate vanes of the plurality of vanes(not drawn to scale). In the illustrated embodiment, the vanes have a length L, a length L, and length Lmeasured between opposite, parallel walls of the hexagon. In the illustrated embodiment, each of the lengths L-Lare the same value. In other words, the hexagons of the plurality of vanes are identical in dimensions. In other embodiments, the lengths L-Lare different from one another. The lengths L-Lare sized to prevent a probefrom contacting the blade. The probeis representative of the standards set by the IEC 60335-1. Although not illustrated, the probeis tapered from a first end to a second end. When moving along the first end of the probeto the second end of the probe, a diameter Dof the probe increases. The diameter Dat the first end is smaller than the diameter Dat the second end. In other words, the diameter Dis dependent on an axial location of the probe.

Since the probeis tapered, the lengths L-Lof the vanes depend on the distance Xto prevent axial overlap of the probeand the blade. In the illustrated embodiment, the distance Xis 71 millimeters and the length Lhas a length less than or equal to 12 millimeters, the length Lhas a length less than or equal to 12 millimeters, and the length Lhas a length less than or equal to 12 millimeters. Each length of the lengths L-Lof the vanesis less than or equal to 12 millimeters. Each of the lengths L-Lbeing 12 millimeters prevents a portion of the probehaving the diameter Dbeing 12 millimeters and greater from passing through the vanes. A portion of the probehaving a diameter Dbeing less than 12 millimeters can pass the plurality of vanesbut will not axially overlap with the blade.

In other embodiments with the distance Xbeing less than 71 millimeters, each of the lengths L-Ldecrease to accommodate the smaller diameter of the probeto prevent axial overlap of the probeand the blade. In other embodiments with the distance Xbeing greater than 71 millimeters, each of the lengths L-Lincrease to accommodate the greater diameter of the probe.

illustrates an arrangement of the vanes of the vanesforming three separate spaces.illustrates an arrangement of the vanes of the vanesforming a spaceand a space. In the illustrated embodiment, the spaceis formed by removing a shared wall between two adjacent hexagons (e.g., the first spaceis equivalent to two of the three spaces). In other words, the spaceis larger than the space. Despite the spacebeing larger than the space, the arrangement of the vanesstill prevents the probefrom being inserted. This can be attributed to maintaining at least two opposite walls that are disposed at a distance less than or equal to 12 millimeters. Larger spaces increase the available air for the blade. To create larger spaces and thereby increase the availability of air, walls of the vanesmay be removed. The removal of walls lowers a resistance experienced by the flow path induced by bladewhen moving across the vanes of the vanesand reduces the turbulence of the airflow when meeting the blade.

illustrates a blower unit housinghaving a plurality of vanesaccording to another embodiment that is compatible with the fan. Also, the blower unit housingis interchangeable with the blower unit housing. The plurality of vanesare arranged such that openings formed between adjacent vanes of the vanessatisfy dimensional requirements of IEC 60335-1. In the illustrated embodiment, the plurality of vanesincludes an alternating group of a first group of vanesand a second group of vanes. The first group of vanesextends from an outer portionto a central portion(e.g., radially inward from the outer portion). The first group of vanesalternates between two hexagons and three hexagons. The first group of vanesdefines hexagonal spaces. The second group of vanesextends between the first group of vanes(e.g., diagonally from adjacent first groups). In the illustrated embodiment, the second group of vanesdefines spaces. Like the space, the spacesare larger than individual hexagonal space because walls of adjacent hexagons are removed. In the illustrated embodiment, the second groups of vanesare parallel zigzag lines (e.g., two sides of each hexagon being removed). As such, the second group of vanesresults in greater air availability to the fan. In some constructions, the first group of vanesis optional and the plurality of vanesis only comprised of the second group of vanes.

Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described.