US3601876A - Method of manufacturing a one-piece fan - Google Patents

Method of manufacturing a one-piece fan Download PDF

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US3601876A
US3601876A US807686A US3601876DA US3601876A US 3601876 A US3601876 A US 3601876A US 807686 A US807686 A US 807686A US 3601876D A US3601876D A US 3601876DA US 3601876 A US3601876 A US 3601876A
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fan blades
fan
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Norman B Vogt
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Motors Liquidation Co
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General Motors Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/78—Making other particular articles propeller blades; turbine blades
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49327—Axial blower or fan

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  • Heiter and John P. Moran ABSTRACT A method of manufacturing a one-piece axial flow fan including the following steps: (1) forming one end of a cylindrical tube into a partially closed. flat end surface having an opening therein of a predetermined diameter; (2) separating the wall of the cylinder into a predetermined number of arcuate sections; (3) bending the sections to extend radially outwardly from the partially closed end; (4) trimming off the edges of the radial extensions and portions of the bottom flat surface to form fan blades and a hub; and (5) twisting the blades to the desired final curvature, the final product being a 0ne-piece axial flow fan having blades, each with one edge thereofon the same plane as the hub and a trailing edge bending away from the leading edge.
  • This invention relates to fluid propulsion devices, such as fans, propellers and the like, and, more particularly to a novel method of manufacturing a one-piece axial flow fan.
  • Present methods of manufacturing metal axial flow fans include such methods as forming a hub or spider, forming blades and then assembling the blades to the spider and balancing the assembly; or assembling blades to form a hub as part of the blade material; or blanking the fan as one piece from sheet metal stock and shaping the blades thereof.
  • the latter method results in considerable waste of material, thereby greatly increasing material cost.
  • a primary object of the invention is to provide a novel method of manufacturing a one-piece axial flow fan from a strip of sheet metal which is formed into welded cylindrical tubing, or seamless cylindrical tubing, with very little offal or waste material.
  • Another object of the invention is to provide a manufacturing method which is simple and economical and which results in the production ofa durable and efficient finished product.
  • a further object of the invention is to provide a novel method of manufacturing a one-piece fan whose blades are variably spaced about an integral hub and have trailing edges which terminate variable blade curvatures, the variable spacing and curvatures serving to produce a minimal operative noise level.
  • FIG. l is a top view of a sheet of metal material which may be employed in the invention.
  • FIG. an illustrate the results of the various manufacturing steps used in the invention
  • FIG. '7 illustrates a typical finished product resulting from the invention
  • FIG. d is an end view taken along the plane ofthe line 8-4; of FIG, 7, and looking in the direction of the arrows.
  • FIG. 1 illustrates a flat strip iii) of sheet metal which may be used in the novel method embodied in the invention.
  • the metal strip it) is first formed into an open-ended cylinder l2 (FIG. 2), the mating longitudinal edges of which are then fixedly attached to one another by any suitable method, such as welding, resulting in a welded seam M.
  • the seam M is thereupon smoothed by any suitable method, for example, along its outer surface by scarfing or planishing, and along its inner surface by being drawn over a mandrel. It is apparent that the cylinder 112 could consist of seamless tubing of suitable diameter and thickness in lieu ofa welded cylinder.
  • the cylinder 112 may then be annealed, if necessary, after which one end of the cylinder i2 is formed in a forming die to include a radial end to (FIG. 3), resulting in an opening 17 remaining in the formed end 116 which is substantially smaller then the inside diameter d of the cylinder 112.
  • the forming die would normally include a die set comprising an upper shoe and a lower shoe, and suitable tooling inserts.
  • the radial end it) of the cylinder 112 is further formed in a suitable forming die to produce a flat end surface 18 (FIG. d), which is substantially perpendicular to the wall of the cylinder 12,
  • the opening in the formed end l8 becomes a substantially smaller opening Ml during this operation.
  • the latter opening Bill may be sized by being formed around a pilot on the die set. As the openings l7 and 2b are made progressively smaller, the adjacent end portion ill would become thicker by virtue ofthe displacement of metal. This is desirable from the standpoint of having a finished fan whose hub is thicker than its blades.
  • the wall of the cylinder i2. is next separated (FIG. along predetermined equally spaced lines 22a, 22b, 22c, 22d and 22e by any suitable shearing operation, such as lancing.
  • the designated lines are all lanced simultaneously by utilizing a plurality of shearing tools, cams and cam drivers, the number thereof corresponding to the number of separations 22 required.
  • Each separation 22 extends longitudinally along the cylindrical wall from the edge 24 of the open end to the inner face 26 of the end 18, or to some predetermined distance there along, as illustraled in FIG, 5.
  • the separations 22 result in a number ofarcuate wall segments 28, the total number thereof being determined by the number offon blades desired.
  • Holes 29a, 29b, Mic, 29d and 2% may be pierced at the bottom end of each of the lanced edges of the separations Lilla, 22b, 22c, 22d and 22a, respectively, to prevent tearing in this area during subsequent operations.
  • Each of the arcuate wall sections 28 is next bent outwardly from the axis of the cylinder l2, and flattened along the plane of the bottom surface 18 so as to form flat extensions 30 (FIG. 6) extending radially outwardly from the central opening Elli.
  • This may be accomplished be using a flared or tapered punch to start spreading the individual wall segments 23 at their free ends E l.
  • a downwardly descending, flat upper die will complete the flattening process, the original arcuate shape of each wall segment 2b being caused to assume a flat condition.
  • variable included angles may be attained between segments during the flattening operation, the arced segments 28a, 23b, 28c, 28d and 28.? having been formed into flat radial extensions Ella, Elllb, Ellie, 30d and 3011, respectively.
  • each of the radial extensions Ill includes sufficient area to form a fan blade 32 with very little waste area, the latter being represented by 34.
  • the hub I.D. Ml may be trimmed in the same operation as just described: however, as discussed above, the ll). 2b would have been formed around a pilot on the die set during the operation described relative to Fifi. i.
  • the resultant flat, one'piece structure would next be placed in another forming die wherein the mating upper and lower shoes and/or tooling inserts would have curved mating surfaces formed in pockets or openings, there being one pocket for each blade 32.
  • the flattened fan structure would be placed therein such that: each of the blades 32 would be seated in some one of the pockets and pressed therein to conform to the curvature of its respective pocket.
  • the curvature need not be the same for all the blades 32.
  • the result of this operation is illustrated in FIG. 8, wherein it may be noted that the leading edge 36 of a blade 32 remains on the same plane as the flat hub, while thetrailing edge 38 thereof terminates the blades arcuate or curved shape.
  • the finished fan 40 is similar in appearance to that illustrated in FIG. 7, with each of the variably spaced blades 32 having its own predetermined twist and/or curvature relative to the central hub portion thereof.
  • the number of blades could vary from that illustrated.
  • the fan resulting from the above-described novel method includes desirable high-speed noise abatement characteristics.
  • a method of producing a one-piece metal fan comprising forming one end of a cylindrical tube to include a flat end surface having an opening therein of a predetermined diameter, longitudinally cutting said formed cylindrical tube to produce a plurality of adjacent arcuate segments, said arcuate segments being unequally spaced and separated by lanced edges extending the full length of the remaining wall of said cylindrical tube after said flat end has been formed thereon, bending said arcuate segments outwardly so as to cause said segments to'become flattened, and to extend substantially radially from said flat end surface, trimming said segments and said flat end surface to form a hub with integral flat fan blades extending therefrom, said flat fan blades being variably spaced with respect to one another, and forming predetermined blade curvatures on said fan blades.
  • a method of manufacturing a one-piece metal fan comprising the following steps:
  • a method of manufacturing a one-piece metal fan comprising the following steps:
  • a method of producing a one-piece metal fan from a cupshaped member having a base portion and a circular sidewall portion comprising longitudinally cutting said sidewall portion of said cup-shaped member into a plurality of adjacent arcuate segments of said circular sidewall portion, bending said circular sidewall portion and said arcuate segments outwardly substantially into the plane of said base portion to form a substantially flat blank, trimming said blank to form said base portion into a hub and said arcuate segments into integral flat fan blades integrally extending substantially radially from said base portion and being variably spaced with respect to one another, and forming predetermined blade pitch curvatures on said fan blades.
  • a method of producing a one-piece metal fan comprising forming a cup-shaped member having a substantially flat bottom portion and a circular wall portion extending therefrom, longitudinally cutting said circular wall portion of said cup-shaped member to form a plurality of adjacent arcuate segments, said arcuate segments being unequally spaced and separated by adjacent edges extending the full length of said wall portion of said cup-shaped member, bending said arcuate segments outwardly so as to cause said segments to become flattened and to extend substantially radially from said bottom portion, trimming said segments and said bottom portion of said cup-shaped member to form a hub with integral planar fan blades extending therefrom and being variably spaced with respect to one another, and forming predetermined blade curvatures on said fan blades.
  • a method of manufacturing a one-piece metal fan comprising the following steps:

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Abstract

A method of manufacturing a one-piece axial flow fan including the following steps: (1) forming one end of a cylindrical tube into a partially closed flat end surface having an opening therein of a predetermined diameter; (2) separating the wall of the cylinder into a predetermined number of arcuate sections; (3) bending the sections to extend radially outwardly from the partially closed end; (4) trimming off the edges of the radial extensions and portions of the bottom flat surface to form fan blades and a hub; and (5) twisting the blades to the desired final curvature, the final product being a one-piece axial flow fan having blades, each with one edge thereof on the same plane as the hub and a trailing edge bending away from the leading edge.

Description

[72] Inventor Norman B. Vogt Utica, Mich. [21] Appl. No. 807,686 [22] Filed Mar. 17, 1969 [45] Patented Aug. 31, 1971 [73] Assignee General Motors Corporation Detroit, Mich.
[54] METHOD OF MANUFACTURING A ONE-PIECE FAN 9 Claims, 8 Drawing Figs.
[52] U.S. Cl 29/1568 18, 1 13/1 16 D [51] l1nt.Cl 1132114 3/1141, B23p 15/02,B23p 15/04 [50] Field of Search 29/1568 CF, 156.8 T, 156.8 B, 156.8 P, 156.8 H, 159.01; 113/116D, 116 BB [56] References Cited UNITED STATES PATENTS 629,121 7/1899 Bicalky 113/116D 749,638 l/1904 Steiner 113/116 D 2,235,461 3/1941 Miller 113/116D Primary Examiner-John F. Campbell Assistant ExaminerD0nald P. Rooney Attorneys-J5. W. Christen, A. M. Heiter and John P. Moran ABSTRACT: A method of manufacturing a one-piece axial flow fan including the following steps: (1) forming one end of a cylindrical tube into a partially closed. flat end surface having an opening therein of a predetermined diameter; (2) separating the wall of the cylinder into a predetermined number of arcuate sections; (3) bending the sections to extend radially outwardly from the partially closed end; (4) trimming off the edges of the radial extensions and portions of the bottom flat surface to form fan blades and a hub; and (5) twisting the blades to the desired final curvature, the final product being a 0ne-piece axial flow fan having blades, each with one edge thereofon the same plane as the hub and a trailing edge bending away from the leading edge.
PATENTEBAusm-mn 3501.876
44 mm? 15. fly; zhmzau ATTORNEY METHOD OF MANUFACTUIMNG A ONE-NECK; FAN
This invention relates to fluid propulsion devices, such as fans, propellers and the like, and, more particularly to a novel method of manufacturing a one-piece axial flow fan.
Present methods of manufacturing metal axial flow fans include such methods as forming a hub or spider, forming blades and then assembling the blades to the spider and balancing the assembly; or assembling blades to form a hub as part of the blade material; or blanking the fan as one piece from sheet metal stock and shaping the blades thereof. The latter method results in considerable waste of material, thereby greatly increasing material cost.
Accordingly, a primary object of the invention is to provide a novel method of manufacturing a one-piece axial flow fan from a strip of sheet metal which is formed into welded cylindrical tubing, or seamless cylindrical tubing, with very little offal or waste material.
Another object of the invention is to provide a manufacturing method which is simple and economical and which results in the production ofa durable and efficient finished product.
A further object of the invention is to provide a novel method of manufacturing a one-piece fan whose blades are variably spaced about an integral hub and have trailing edges which terminate variable blade curvatures, the variable spacing and curvatures serving to produce a minimal operative noise level.
Other objects and advantages of the invention will become apparent when reference is made to the following specification and accompanying drawings wherein:
FIG. l is a top view of a sheet of metal material which may be employed in the invention;
FIG. an illustrate the results of the various manufacturing steps used in the invention;
FIG. '7 illustrates a typical finished product resulting from the invention; and
FIG. d is an end view taken along the plane ofthe line 8-4; of FIG, 7, and looking in the direction of the arrows.
Referring now to the drawings in greater detail, FIG. 1 illustrates a flat strip iii) of sheet metal which may be used in the novel method embodied in the invention.
The metal strip it) is first formed into an open-ended cylinder l2 (FIG. 2), the mating longitudinal edges of which are then fixedly attached to one another by any suitable method, such as welding, resulting in a welded seam M. The seam M is thereupon smoothed by any suitable method, for example, along its outer surface by scarfing or planishing, and along its inner surface by being drawn over a mandrel. It is apparent that the cylinder 112 could consist of seamless tubing of suitable diameter and thickness in lieu ofa welded cylinder.
The cylinder 112 may then be annealed, if necessary, after which one end of the cylinder i2 is formed in a forming die to include a radial end to (FIG. 3), resulting in an opening 17 remaining in the formed end 116 which is substantially smaller then the inside diameter d of the cylinder 112. The forming die would normally include a die set comprising an upper shoe and a lower shoe, and suitable tooling inserts.
The radial end it) of the cylinder 112 is further formed in a suitable forming die to produce a flat end surface 18 (FIG. d), which is substantially perpendicular to the wall of the cylinder 12, The opening in the formed end l8 becomes a substantially smaller opening Ml during this operation. The latter opening Bill may be sized by being formed around a pilot on the die set. As the openings l7 and 2b are made progressively smaller, the adjacent end portion ill would become thicker by virtue ofthe displacement of metal. This is desirable from the standpoint of having a finished fan whose hub is thicker than its blades.
The wall of the cylinder i2. is next separated (FIG. along predetermined equally spaced lines 22a, 22b, 22c, 22d and 22e by any suitable shearing operation, such as lancing. Preferably, the designated lines are all lanced simultaneously by utilizing a plurality of shearing tools, cams and cam drivers, the number thereof corresponding to the number of separations 22 required. Each separation 22 extends longitudinally along the cylindrical wall from the edge 24 of the open end to the inner face 26 of the end 18, or to some predetermined distance there along, as illustraled in FIG, 5. The separations 22 result in a number ofarcuate wall segments 28, the total number thereof being determined by the number offon blades desired. Holes 29a, 29b, Mic, 29d and 2% may be pierced at the bottom end of each of the lanced edges of the separations Lilla, 22b, 22c, 22d and 22a, respectively, to prevent tearing in this area during subsequent operations.
Each of the arcuate wall sections 28 is next bent outwardly from the axis of the cylinder l2, and flattened along the plane of the bottom surface 18 so as to form flat extensions 30 (FIG. 6) extending radially outwardly from the central opening Elli. This may be accomplished be using a flared or tapered punch to start spreading the individual wall segments 23 at their free ends E l. After some predetermined angle is reached between the outer surface of the wall segments and the plane of the bottom surface llll, a downwardly descending, flat upper die will complete the flattening process, the original arcuate shape of each wall segment 2b being caused to assume a flat condition.
It may be noted by referring to FIGS. 5 and ti that, where some one line has not been lanced the full length of the segments 28, such as line 22b in FIG. 5, when the segments 28d and 2&2 are flattened, they will tend to pull toward one another, the solid wall portion x" below the pierced hole 2% preventing a full spread therebetween. The result will be a reduced included angle, such as angle *A" of FIG. t5, between adjacent segments. It may be visualized that, when the wall of the cylinder l2. is lanced full length, such as represented at line 22a in HQ. 5, the flattening process will spread the segments 28a and 28b farther apart, as represented by angle in Fit]. 6. Thus it can be seen that by controlling the lengths of the lanced cuts, variable included angles may be attained between segments during the flattening operation, the arced segments 28a, 23b, 28c, 28d and 28.? having been formed into flat radial extensions Ella, Elllb, Ellie, 30d and 3011, respectively.
After flattening, the extensions Ellla, 341th, 3531c, 36th! and Ellie, as well as portions of the flat end iii, are trimmed by any convenient means, such as with a trim die, producing the individual blades represented by 32 in FIG. 6. it may be noted that each of the radial extensions Ill) includes sufficient area to form a fan blade 32 with very little waste area, the latter being represented by 34. If desired, the hub I.D. Ml may be trimmed in the same operation as just described: however, as discussed above, the ll). 2b would have been formed around a pilot on the die set during the operation described relative to Fifi. i.
As a result of the above lancing, flattening and trimming operations, a fan structure is produced with a minimal amount of scrap material involved, since the size of the cylinder l2 is selected such that each segment and 3% will include an area which is suitable for a particular blade 32. width plus sufficient stoclt for trimming, but without an excessive amount of the latter.
It may be realized that if the segments Elba, 238b, Elle, 28d and were lanced to include different are lengths, and each lancing operation were performed along the full length of the cylinder l2, rather than variable lengths therealong, the fan blades 3?; could be individually located on their respective variable-width flat segments Elli such that variation in the angles "A," D, and .E." would result. However, such a technique would require a slightly larger cylinder for a given fan size than in the steps described above.
After trimming, the resultant flat, one'piece structure would next be placed in another forming die wherein the mating upper and lower shoes and/or tooling inserts would have curved mating surfaces formed in pockets or openings, there being one pocket for each blade 32. The flattened fan structure would be placed therein such that: each of the blades 32 would be seated in some one of the pockets and pressed therein to conform to the curvature of its respective pocket.
Obviously, the curvature need not be the same for all the blades 32. The result of this operation is illustrated in FIG. 8, wherein it may be noted that the leading edge 36 of a blade 32 remains on the same plane as the flat hub, while thetrailing edge 38 thereof terminates the blades arcuate or curved shape.
The finished fan 40 is similar in appearance to that illustrated in FIG. 7, with each of the variably spaced blades 32 having its own predetermined twist and/or curvature relative to the central hub portion thereof. The number of blades, however, could vary from that illustrated. Hence, it is apparent that the fan resulting from the above-described novel method includes desirable high-speed noise abatement characteristics.
It should also be apparent that, in the method described above, a one-piece axial flow fan is produced with a negligible amount of scrap material, representing substantial savings in material costs.
While but one general product has been illustrated and described as being manufactured by the above-described method, it should be apparent that variations in the structure of the product could be attained by the method described.
lclaim:
1. A method of producing a one-piece metal fan, said method comprising forming one end of a cylindrical tube to include a flat end surface having an opening therein of a predetermined diameter, longitudinally cutting said formed cylindrical tube to produce a plurality of adjacent arcuate segments, said arcuate segments being unequally spaced and separated by lanced edges extending the full length of the remaining wall of said cylindrical tube after said flat end has been formed thereon, bending said arcuate segments outwardly so as to cause said segments to'become flattened, and to extend substantially radially from said flat end surface, trimming said segments and said flat end surface to form a hub with integral flat fan blades extending therefrom, said flat fan blades being variably spaced with respect to one another, and forming predetermined blade curvatures on said fan blades.
2. A method of manufacturing a one-piece metal fan, said method comprising the following steps:
a. forming a rectangular piece'of sheet metal material of predetermined dimensions into a cylindrical shape;
b. joining the longitudinal mating edges thereof as a seam to produce a cylindrical tube;
c. smoothing said seam;
d. forming one end of said cylindrical tube to produce a flat end surface having an opening therein of a predetermined diameter;
c. cutting the wall of said cylindrical tube into a predetermined number of adjacent longitudinal arcuate sections;
f. bending said sections outwardly so as to cause said sections to become flattened and to lie on the plane of said flat end surface; g. trimming of the edges of said sections and a portion of said flat end surface to form a hub with integral fan blades extending therefrom; and forming the individual blades to include predetermined blade curvatures thereon.
3. A method of manufacturing a one-piece metal fan, said method comprising the following steps:
a. forming one end of a cylindrical tube to produce a flat end surface having an opening therein ofa predetermined diameter;
b. separating the wall of said cylindrical tube into a predetermined number of adjacent longitudinal arcuate sections by cutting said wall of said cylindrical tube such that the resultant cut edges between adjacent sections are variable in length;
c. bending said sections outwardly so as to cause said sections to become flattened and to lie on the plane of said flat end surface;
d. trimming off the edges of said sections and a portion of said flat end surface to form a hub with integral fan blades extending therefrom; and e. forming the individual blades to include predetermined blade curvatures thereon.
4. The method described in claim 3, wherein a hole is pierced at the bottom of each lanced separation.
5. The method described in claim 3, wherein said arcuate sections are equally spaced prior to said bending operation.
6. The method described in claim 5, wherein said fan blades are variably spaced from one another after said trimming operation.
7. A method of producing a one-piece metal fan from a cupshaped member having a base portion and a circular sidewall portion, said method comprising longitudinally cutting said sidewall portion of said cup-shaped member into a plurality of adjacent arcuate segments of said circular sidewall portion, bending said circular sidewall portion and said arcuate segments outwardly substantially into the plane of said base portion to form a substantially flat blank, trimming said blank to form said base portion into a hub and said arcuate segments into integral flat fan blades integrally extending substantially radially from said base portion and being variably spaced with respect to one another, and forming predetermined blade pitch curvatures on said fan blades.
8. A method of producing a one-piece metal fan, said method comprising forming a cup-shaped member having a substantially flat bottom portion and a circular wall portion extending therefrom, longitudinally cutting said circular wall portion of said cup-shaped member to form a plurality of adjacent arcuate segments, said arcuate segments being unequally spaced and separated by adjacent edges extending the full length of said wall portion of said cup-shaped member, bending said arcuate segments outwardly so as to cause said segments to become flattened and to extend substantially radially from said bottom portion, trimming said segments and said bottom portion of said cup-shaped member to form a hub with integral planar fan blades extending therefrom and being variably spaced with respect to one another, and forming predetermined blade curvatures on said fan blades.
9. A method of manufacturing a one-piece metal fan, said method comprising the following steps:
a. forming a cup-shaped member having a substantially flat bottom portion and a circular wall portion extending therefrom;
. cutting said wall portion of said cup-shaped member into a predetermined number of adjacent longitudinal arcuate sections such that the resultant edges therebetween are variable in length;
. bending said arcuate sections outwardly so as to cause said arcuate sections to become flattened and to lie substantially on the plane of said flat bottom portion;
trimming off said edges of said flattened sections and a portion of said bottom portion to form a hub with integral fan blades extending substantially radially therefrom; and
. forming the individual fan blades to include predetermined blade curvatures thereon.

Claims (9)

1. A method of producing a one-piece metal fan, said method comprising forming one end of a cylindrical tube to include a flat end surface having an opening therein of a predetermined diameter, longitudinally cutting said formed cylindrical tube to produce a plurality of adjacent arcuate segments, said arcuate segments being unequally spaced and separated by lanced edges extending the full length of the remaining wall of said cylindrical tube after said flat end has been formed thereon, Bending said arcuate segments outwardly so as to cause said segments to become flattened, and to extend substantially radially from said flat end surface, trimming said segments and said flat end surface to form a hub with integral flat fan blades extending therefrom, said flat fan blades being variably spaced with respect to one another, and forming predetermined blade curvatures on said fan blades.
2. A method of manufacturing a one-piece metal fan, said method comprising the following steps: a. forming a rectangular piece of sheet metal material of predetermined dimensions into a cylindrical shape; b. joining the longitudinal mating edges thereof as a seam to produce a cylindrical tube; c. smoothing said seam; d. forming one end of said cylindrical tube to produce a flat end surface having an opening therein of a predetermined diameter; e. cutting the wall of said cylindrical tube into a predetermined number of adjacent longitudinal arcuate sections; f. bending said sections outwardly so as to cause said sections to become flattened and to lie on the plane of said flat end surface; g. trimming of the edges of said sections and a portion of said flat end surface to form a hub with integral fan blades extending therefrom; and h. forming the individual blades to include predetermined blade curvatures thereon.
3. A method of manufacturing a one-piece metal fan, said method comprising the following steps: a. forming one end of a cylindrical tube to produce a flat end surface having an opening therein of a predetermined diameter; b. separating the wall of said cylindrical tube into a predetermined number of adjacent longitudinal arcuate sections by cutting said wall of said cylindrical tube such that the resultant cut edges between adjacent sections are variable in length; c. bending said sections outwardly so as to cause said sections to become flattened and to lie on the plane of said flat end surface; d. trimming off the edges of said sections and a portion of said flat end surface to form a hub with integral fan blades extending therefrom; and e. forming the individual blades to include predetermined blade curvatures thereon.
4. The method described in claim 3, wherein a hole is pierced at the bottom of each lanced separation.
5. The method described in claim 3, wherein said arcuate sections are equally spaced prior to said bending operation.
6. The method described in claim 5, wherein said fan blades are variably spaced from one another after said trimming operation.
7. A method of producing a one-piece metal fan from a cup-shaped member having a base portion and a circular sidewall portion, said method comprising longitudinally cutting said sidewall portion of said cup-shaped member into a plurality of adjacent arcuate segments of said circular sidewall portion, bending said circular sidewall portion and said arcuate segments outwardly substantially into the plane of said base portion to form a substantially flat blank, trimming said blank to form said base portion into a hub and said arcuate segments into integral flat fan blades integrally extending substantially radially from said base portion and being variably spaced with respect to one another, and forming predetermined blade pitch curvatures on said fan blades.
8. A method of producing a one-piece metal fan, said method comprising forming a cup-shaped member having a substantially flat bottom portion and a circular wall portion extending therefrom, longitudinally cutting said circular wall portion of said cup-shaped member to form a plurality of adjacent arcuate segments, said arcuate segments being unequally spaced and separated by adjacent edges extending the full length of said wall portion of said cup-shaped member, bending said arcuate segments outwardly so as to cause said segments to become flattened and to extend substantially radially from said bottom portion, trimming said segments and said bottom portion of said cuP-shaped member to form a hub with integral planar fan blades extending therefrom and being variably spaced with respect to one another, and forming predetermined blade curvatures on said fan blades.
9. A method of manufacturing a one-piece metal fan, said method comprising the following steps: a. forming a cup-shaped member having a substantially flat bottom portion and a circular wall portion extending therefrom; b. cutting said wall portion of said cup-shaped member into a predetermined number of adjacent longitudinal arcuate sections such that the resultant edges therebetween are variable in length; c. bending said arcuate sections outwardly so as to cause said arcuate sections to become flattened and to lie substantially on the plane of said flat bottom portion; d. trimming off said edges of said flattened sections and a portion of said bottom portion to form a hub with integral fan blades extending substantially radially therefrom; and e. forming the individual fan blades to include predetermined blade curvatures thereon.
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4117793A (en) * 1976-04-07 1978-10-03 Lucas Industries Limited Pole claw member for a dynamo electric machine rotor
US6514036B2 (en) 2001-04-27 2003-02-04 Black & Decker Inc. Radial flow fan with impeller having blade configuration for noise reduction
US6789998B2 (en) 2002-09-06 2004-09-14 Honeywell International Inc. Aperiodic struts for enhanced blade responses

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US2235461A (en) * 1939-04-19 1941-03-18 James M Miller Heat scatterer
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US3129496A (en) * 1959-12-08 1964-04-21 Darwin S Cox Method of producing improved vehicle wheels
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US4117793A (en) * 1976-04-07 1978-10-03 Lucas Industries Limited Pole claw member for a dynamo electric machine rotor
US6514036B2 (en) 2001-04-27 2003-02-04 Black & Decker Inc. Radial flow fan with impeller having blade configuration for noise reduction
US6789998B2 (en) 2002-09-06 2004-09-14 Honeywell International Inc. Aperiodic struts for enhanced blade responses

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