High-performance molded fan

Claim 2

A cooler, comprising: a) a molded cooler housing supported on a base, having an exterior, an interior, and front and rear openings, the base being integrally formed with the housing; b) at least one brace integrally formed with the housing and capable of supporting at least one evaporative cooling pad positioned within the rear opening of the housing; c) a molded fan brace coupled to the cooler housing; d) a molded hub coupled to the fan brace and having a plurality of fan blade receivers; and e) a plurality of molded fan blades removably attachable to the fan blade receivers, the fan blades each having a blade portion attachable to the fan blade receivers on the hub.

Claim 3

The cooler of claim 1 , further comprising a first alignment indicia disposed on the fan blade receivers and a second alignment indicia disposed on the fan blades.

Claim 4

The cooler of claim 1 , wherein the fan blades comprise an airfoil cross section having a high pressure portion on one side and a low pressure portion of an opposite side.

Claim 5

The cooler of claim 1 , wherein the fan blades further comprise a longitudinal twist from the blade portion toward a tip end of the fan blades.

Claim 6

The cooler of claim 1 , wherein the cooler produces an airflow of at least about 15 cubic feet per minute (CFM) per watt at a static pressure of about 0.15 inches of water.

Claim 7

The cooler of claim 1 , further comprising a venturi wherein the fan blades are adapted to at least partially rotate within a cross sectional volume formed by the venturi.

Claim 8

A molded fan, comprising: a) a molded hub having a plurality of fan blade receivers; and b) a plurality of molded fan blades coupled to the hub, the fan blades comprising an airfoil cross section having a high pressure portion on one side and a low pressure portion of an opposite side.

Claim 9

A molded fan, comprising: a) a molded hub having a plurality of fan blade receivers; and b) a plurality of molded fan blades coupled to the hub, the fan blades comprising an airfoil cross section having a high pressure portion on one side and a low pressure portion of an opposite side.

Claim 10

The fan of claim 7 , wherein the molded fan produces an air flow of at least about 20 CFM per at a static pressure of about 0.00 inches of water.

Claim 11

The fan of claim 8 , wherein the hub and four fan blades weigh less than about five pounds for a 36-inch diameter sized fan.

Claim 12

The fan of claim 7 , wherein the fan blades comprise a root end disposed toward the hub and a tip end disposed away from the hub and wherein the fan blades further comprise a longitudinal twist from the root end to the tip end.

Claim 13

The fan of claim 7 , further comprising a venturi wherein the fan blades are adapted to at least partially rotate within a cross sectional volume formed by the venturi.

Claim 14

The fan of claim 7 , wherein the hub and fan blades are molded by a resin transfer molding (RTM) method.

Claim 15

The fan of claim 12 , wherein the molded hub comprises fiber reinforced polymeric material.

Claim 16

The fan of claim 12 , wherein the fan blades comprise fiber reinforced polymeric material.

Claim 17

The fan of claim 7 , further comprising one or more drive surfaces integrally formed on the molded hub.

Claim 18

The fan of claim 12 , further comprising alignment indicia formed on the hub and fan blades wherein the fan blades are rotationally indexable relative to the hub using the alignment indicia.

Claim 19

The fan of claim 7 , wherein the fan comprises an evaporative cooler.

Claim 20

A fan, comprising: a) a molded hub having a plurality of fan blade receivers; b) a plurality of molded fan blades coupled to the fan blade receivers; and c) a venturi wherein the fan blades are adapted to at least partially rotate within a cross sectional volume formed by the venturi, the fan producing an air flow of at least about 20 CFM of airflow per watt at a static pressure of about 0.00 inches of water.

Claim 21

A fan, comprising: a) a molded hub having a plurality of fan blade receivers; b) a plurality of molded fan blades coupled to the fan blade receivers; and c) a venturi wherein the fan blades are adapted to at least partially rotate within a cross sectional volume formed by the venturi, the fan producing an air flow of at least about 20 CFM of airflow per watt at a static pressure of about 0.00 inches of water.

Claim 22

The fan of claim 18 , wherein the fan blades comprise an airfoil cross section having a high pressure portion on one side and a low pressure portion of an opposite side.

Claim 23

The fan of claim 18 , wherein the fan blades comprise a root end disposed toward the hub and a tip end disposed away from the hub and wherein the fan blades further comprise a longitudinal twist from the root end to the tip end.

Claim 24

The fan of claim 18 , further comprising a first alignment indicia on the fan blade receivers and a second alignment indicia on the fan blades.

Claim 25

A cooler, comprising: a) a molded cooler housing supported on a base, having an exterior, an interior, and front and rear openings, the base being integrally formed with the housing; b) at least one brace integrally formed with the housing and capable of supporting at least one evaporative cooling pad positioned within the rear opening of the housing; c) a molded fan brace coupled to the cooler housing; d) a molded hub coupled to the fan brace and having a plurality of fan blade receivers; e) a plurality of molded fan blades removably attachable to the fan blade receivers, the fan blades each having a blade portion attachable to the fan blade receivers on the hub and formed with an airfoil cross section and a longitudinal twist from the blade portion toward a tip end of the fan blades; and f) a first alignment indicia disposed on the fan blade receivers and a second alignment indicia disposed on the fan blades, the cooler having an efficiency rating of at least about 20 CFM of airflow per watt at a static pressure of about 0.00 inches of water.

Claim 26

A cooler, comprising: a) a molded cooler housing supported on a base, having an exterior, an interior, and front and rear openings, the base being integrally formed with the housing; b) at least one brace integrally formed with the housing and capable of supporting at least one evaporative cooling pad positioned within the rear opening of the housing; c) a molded fan brace coupled to the cooler housing; d) a molded hub coupled to the fan brace and having a plurality of fan blade receivers; e) a plurality of molded fan blades removably attachable to the fan blade receivers, the fan blades each having a blade portion attachable to the fan blade receivers on the hub and formed with an airfoil cross section and a longitudinal twist from the blade portion toward a tip end of the fan blades; and f) a first alignment indicia disposed on the fan blade receivers and a second alignment indicia disposed on the fan blades, the cooler having an efficiency rating of at least about 20 CFM of airflow per watt at a static pressure of about 0.00 inches of water.