Fan and manufacturing method thereof

Abstract

The invention provides a fan and a manufacturing method thereof. The fan comprises a hub, a plurality of first fan blades, a mute ring and a plurality of second fan blades. The hub has a periphery. Each first fan blade comprises a first end connected with the periphery of the hub and a second end opposite to the first end. The mute rings are arranged at the second ends of the first fan blades. The second fan blades are arranged at the second ends of the first fan blades and connected with the mute ring, and the second fan blades and the first fan blades are alternately arranged.

Description

Technical Field

[0001] The present invention relates to a fan and a manufacturing method thereof, and more particularly to a fan with improved structure and performance and a manufacturing method thereof. Background Art

[0002] Current laptop fan blades are primarily categorized as plastic or metal. Plastic blades have limitations on thickness and height due to factors like the injection molding process and molds. Metal blades, on the other hand, have limitations on the number of blades they can support due to the production process. Therefore, regardless of whether the fan is made of plastic or metal, the number of blades they can support is limited, impacting fan performance.

[0003] Current laptop fans also feature a silent ring. These are typically made of plastic, which, due to manufacturing processes and mold requirements, has thickness limitations. For example, the minimum thickness must be 0.5mm. This can reduce the fan blade's workable area, which in turn affects fan performance.

[0004] Therefore, it is necessary to develop a fan and a manufacturing method thereof to improve the above-mentioned deficiencies of the prior art. Summary of the Invention

[0005] An object of the present invention is to provide a fan which effectively improves fan performance through material or structure improvement.

[0006] Another object of the present invention is to provide a fan that uses a metal material to make a silent ring, thereby effectively reducing the thickness of the silent ring and improving the fan performance.

[0007] Another object of the present invention is to provide a fan and a manufacturing method thereof, which improves fan performance by adding blades to the existing fan blade structure without changing the existing process, is easy to implement and has significant benefits.

[0008] To achieve the above-mentioned object, the present invention provides a fan comprising a hub, a plurality of first blades, a silent ring, and a plurality of second blades. The hub has a periphery. Each first blade comprises a first end connected to the periphery of the hub, and a second end opposite the first end. The silent ring is disposed at the plurality of second ends of the plurality of first blades. The plurality of second blades are disposed at the plurality of second ends of the plurality of first blades and connected to the silent ring, and the plurality of second blades and the plurality of first blades are arranged alternately.

[0009] In one embodiment, each second blade has a third end and a fourth end opposite to the third end, and the third end faces the hub, and the distance between the third end and the fourth end of each second blade is smaller than the vertical distance between the second end and the periphery of each first blade.

[0010] In one embodiment, the plurality of first blades are made of metal material, and the plurality of second blades are made of plastic material.

[0011] In one embodiment, the silent ring is made of plastic and is integrally formed with the plurality of second blades.

[0012] In one embodiment, the silent ring includes a metal base portion and a plastic covering portion, and the plastic covering portion and the plurality of second blades are integrally formed.

[0013] In one embodiment, the silent ring is fixed to the second ends of the first blades through the plastic covering portion.

[0014] In one embodiment, the silent ring is fixed by connecting the metal base portion to the plurality of second ends of the plurality of first blades.

[0015] To achieve the above-mentioned purpose, the present invention provides a fan manufacturing method, comprising the following steps: (a) providing a hub having a periphery; (b) providing a plurality of first blades, each first blade having a first end and a second end opposite to the first end, and connecting the plurality of first ends of the plurality of first blades to the periphery of the hub; and (c) forming a silent ring and a plurality of second blades at the plurality of second ends of the plurality of first blades through an injection molding process, and the plurality of second blades and the plurality of first blades are arranged alternately with each other.

[0016] In one embodiment, each second blade has a third end facing the hub and a fourth end opposite to the third end, and the distance between the third end and the fourth end of each second blade is smaller than the vertical distance between the second end of each first blade and the periphery.

[0017] In one embodiment, the plurality of first blades are made of metal material, and the plurality of second blades are made of plastic material.

[0018] In one embodiment, the silent ring is made of plastic and is integrally formed with the plurality of second blades.

[0019] In one embodiment, the silent ring includes a metal base portion and a plastic covering portion.

[0020] In one embodiment, step (c) further includes the following steps: (c1) disposing a metal substrate portion at a plurality of second ends of a plurality of first blades; and (c2) forming a plastic covering portion and a plurality of second blades by an injection molding process.

[0021] In one embodiment, step (c1) further includes: positioning the metal substrate portion at the plurality of second ends of the plurality of first blades by a clamp.

[0022] In one embodiment, step (c1) further includes: bonding the metal substrate to the plurality of second ends of the plurality of first blades.

[0023] To achieve the above objectives, the present invention provides a fan comprising a hub, a plurality of first blades, and a silent ring. The hub has a peripheral edge. The plurality of first blades are made of a metal material, each having a first end and a second end opposite the first end, and the plurality of first ends are connected to the peripheral edge of the hub. The silent ring is made of a metal material and is disposed at the plurality of second ends of the plurality of first blades.

[0024] In one embodiment, the second end of each first blade is further bent to form a welding surface, and the silent ring has multiple openings corresponding to the multiple welding surfaces, and the silent ring is fixed by welding the multiple welding surfaces and the multiple openings.

[0025] In one embodiment, the second end of each first fan blade has a first locking structure, and the silent ring has multiple second locking structures corresponding to the multiple first locking structures, and the silent ring is fixed by mutual locking between the multiple first locking structures and the multiple second locking structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 A schematic diagram showing a fan according to a first embodiment of the present invention is shown.

[0027] Figure 2 A table showing data comparison between fans using the metal silent ring of the present invention and fans in a control group that do not use the metal silent ring.

[0028] Figure 3A A schematic diagram showing a fan according to a second embodiment of the present invention.

[0029] Figure 3B A schematic diagram showing another angle of view of a fan according to a second embodiment of the present invention.

[0030] Figure 4A show Figure 3A Enlarged schematic diagram of box A.

[0031] Figure 4B show Figure 3B Enlarged schematic diagram of box B.

[0032] Figure 5 A top view of a fan according to a second embodiment of the present invention is shown.

[0033] Figure 6 A diagram showing a performance comparison between a fan using a metal first blade combined with a plastic second blade and a fan using only metal blades according to the present invention.

[0034] Figure 7 A flow chart of a fan manufacturing method according to an embodiment of the present invention is shown.

[0035] Figure 8 A flow chart of a fan manufacturing method according to another embodiment of the present invention is shown.

[0036] Figure 9 A flow chart of a fan manufacturing method according to yet another embodiment of the present invention is shown.

[0037] Description of Reference Numerals

[0038] 10: Fan,

[0039] 11: Wheel hub,

[0040] 12: fan blades,

[0041] 13: Silent ring,

[0042] 121: First end,

[0043] 122: Second end,

[0044] 20: Fan,

[0045] 21: Wheel hub,

[0046] 22: First blade,

[0047] 221: First end,

[0048] 222: Second end,

[0049] 23: Silent Ring,

[0050] 24: Second blade,

[0051] 241: The third end,

[0052] 242: The fourth end,

[0053] A, B: box,

[0054] D1, D2: distance,

[0055] S100, S102, S104, S200, S202, S204, S300, S302, S304: steps. DETAILED DESCRIPTION

[0056] Some typical embodiments embodying the features and advantages of the present invention will be described in detail in the following description. It should be understood that the present invention is capable of various modifications in different forms without departing from the scope of the present invention, and that the descriptions and illustrations herein are intended to be illustrative in nature and not to limit the present invention.

[0057] See also Figure 1, which shows a schematic diagram of a fan according to a first embodiment of the present invention. The fan 10 includes a hub 11, a plurality of blades 12, and a silent ring 13. Each blade 12 has a first end 121 and a second end 122, the first end 121 is arranged around the periphery of the hub 11, and the silent ring 13 is arranged at the second end 122 of the blade 12. In this embodiment, the blades 12 and the silent ring 13 are made of metal materials, such as stainless steel, titanium, aluminum alloy, etc., but are not limited thereto, and other suitable metal materials can be used according to different actual implementation circumstances. In other words, by adopting metal materials, the thickness of the silent ring 13 is greatly reduced, thereby achieving the purpose of improving the fan performance.

[0058] Here, the combination of the blade 12 and the silent ring 13 can be achieved by, for example, welding, but is not limited thereto and can vary according to the actual implementation situation. When a welding process is adopted, the silent ring 13 and the blade 12, in addition to being directly close to each other for welding, can also cooperate with each other in structure to make the welding process easier to perform. For example, the second end 122 of the blade 12 can be bent laterally to form a welding surface (not shown), that is, the blade 12 can be bent at the position of the second end 122 corresponding to the silent ring 13 to form a welding surface perpendicular to the surface of the blade 12, and the silent ring 13 can form an opening (not shown) at the welding surface corresponding to each blade 12. In this way, when the two are configured together, the welding process can be completed by filling solder in the opening, or the silent ring 13 and the blade 12 can be combined by directly performing a welding process in the opening.

[0059] In other embodiments, the fan blades 12 and the silent ring 13 can be further implemented as having a first engaging structure (not shown) and a second engaging structure (not shown) that engage with each other, respectively. In addition to being beneficial to the welding process, it also helps to stabilize the combination between the fan blades 12 and the silent ring 13. For example, the silent ring 13 can be provided with a groove to engage the fan blades 12; or the fan blades 12 can be provided with a notch to engage the silent ring 13; or the fan blades 12 can be provided with a coupling and the silent ring 13 can be provided with a corresponding receiving portion, so as to increase the fixing effect by passing the coupling through the receiving portion. Therefore, various suitable engaging structure designs can be adopted without limitation.

[0060] Figure 2 A table comparing the performance of fans using the metal silent ring of the present invention and a control group of fans without the metal silent ring is shown. The data in the table shows that compared to the airflow of approximately 3.65 CFM of a fan using the thicker silent ring (0.5 mm), the airflow of a fan using the thinner metal silent ring (0.2 mm) of the present invention is approximately 4.03 CFM, effectively improving performance by at least 10%. This confirms that reducing the thickness of the silent ring by changing its material can achieve the desired effect of increasing fan performance.

[0061] Next, please refer to Figures 3A to 3B 、 Figures 4A to 4B ,and Figure 5 . Figure 3A A schematic diagram showing a fan according to a second embodiment of the present invention, Figure 3B A schematic diagram showing another angle of view of a fan according to a second embodiment of the present invention is shown. Figure 4A show Figure 3A The enlarged schematic diagram of box A in the middle, Figure 4B show Figure 3B An enlarged schematic diagram of box B, and Figure 5 The fan 20 includes a hub 21, a plurality of first blades 22, a silent ring 23, and a plurality of second blades 24. Figure 1 , the fan 20 further includes a plurality of second blades 24 disposed on the silent ring 23. More specifically, in this embodiment, the first blade 22 is disposed on the periphery of the hub 21 with a first end 221, and the second blade 24 is disposed at the second end 222 of the first blade 22 away from the hub 21 through the silent ring 23, and the plurality of first blades 22 and the plurality of second blades 24 are arranged alternately with each other, that is, a second blade 24 is provided between every two first blades 22, and therefore, the number of first blades 22 and second blades 24 is equal. Under this configuration, compared to only providing the first blades 22, the provision of the second blades 24 doubles the total number of blades, and the fan efficiency can be improved.

[0062] In particular, the second blades 24 are only located between the second ends 222 of the first blades 22, and no blades are added between the first ends 221 of the first blades 22. In other words, the length of the second blades 24 is less than the length of the first blades 22. Figure 5 As shown in the figure, the distance D2 between the third end 241 of the second blade 24 facing the hub 21 and the fourth end 242 relative to the third end 241 is less than the vertical distance D1 between the second end 222 of the first blade 22 and the periphery of the hub 21. Through such a design, the second blade 24 can be fixed by the silent ring 23 as a medium, and the effect of increasing the blades and thus improving the fan efficiency can be achieved without changing the structure of the hub 21 and the first blade 22. It should be noted that the length of the second blade 24, that is, the distance D2 between the third end 241 and the fourth end 242, can be determined according to the needs of actual implementation and is not limited to the contents shown in the figure.

[0063] More specifically, the present invention is based on the premise that the number of first blades 22 that can be set on the periphery of the hub 21 is limited. Based on the fact that the second end 222 of the first blade 22 has a longer circumference than the first end 221 and can provide more installation space, combined with the structure in which the silent ring 23 is set at the second end 222 of the first blade 22, a fan with a novel structure and effectively improved performance is developed to achieve the purpose of adding additional blades without changing the existing fan structure.

[0064] In one embodiment, the first blades 22 are made of a metal material, such as stainless steel, titanium, aluminum alloy, etc., but are not limited thereto, and other suitable metal materials may be used depending on the actual implementation. On the other hand, the second blades 24 are made of a plastic material, such as LCP, PPE, PBT, etc., but are not limited thereto, and other suitable plastic materials may be used depending on the actual implementation. By using the first blades 22 made of a metal material in combination with the second blades 24 made of a plastic material, the advantages of both can be provided simultaneously, so the performance of the fan 20 of the present invention can be greatly improved compared to conventional fans.

[0065] In another embodiment, the first blades 22 can be made of plastic material, and combined with the silent ring 23 and the second blades 24 made of plastic material, this configuration can double the number of blades of the fan, thereby effectively increasing the fan efficiency.

[0066] Figure 6 A graph comparing the performance of a fan using the present invention's metal first blades combined with plastic second blades versus a fan using only metal blades shows that by adding plastic second blades between the metal first blades, fan performance can be increased by at least 15-20%, confirming that increasing the number of blades in this manner can achieve the desired effect of increasing fan performance.

[0067] The dissimilar materials bonding between the metal first blade 22 and the plastic second blade 24 can be achieved by the following method. However, it should be noted that the following method is for example only and the present invention is not limited thereto.

[0068] The manufacturing method according to an embodiment of the present invention is shown in Figure 7 . In this embodiment, the silent ring 23 is implemented to be made of plastic material. In step S100, the hub 21 and the metal first blades 22 are first combined with each other to form a fan body. In step S102, the fan body is positioned in a fixture. Finally, in step S104, a plastic injection molding process is performed to form a plastic silent ring 23 on the second end 222 of the metal first blades 22 and to form plastic second blades 24 on the plastic silent ring 23 that fall between each metal first blade 22, thereby forming a structure in which the metal first blades 22 and the plastic second blades 24 are alternately arranged.

[0069] More specifically, in this method, the hub 21 and the metal first blades 22 are first combined to form the fan body. Then, through secondary processing, in addition to forming the plastic silent ring 23 and the plastic second blades 24, the plastic silent ring 23 is also combined with the metal first blades 22. Thus, the silent ring 23 and the second blades 24, both made of plastic, are formed at the second end 222 of the metal first blades 22. In a preferred embodiment, the silent ring 23 and the second blades 24 are formed in an integral manner.

[0070] A fan manufacturing method according to another embodiment of the present invention is shown in FIG. Figure 8 . In this embodiment, the silent ring 23 is implemented to include a metal base material portion and a plastic covering portion. In step S200, the hub 21 and the metal first blade 22 are first combined with each other to form a fan body. In step S202, the fan body and the metal base material portion of the silent ring 23 are respectively positioned in a fixture, and the metal base material portion of the silent ring 23 is positioned at the second end 222 of the metal first blade 22. Finally, in step S204, a plastic injection molding process is performed to form the plastic covering portion of the silent ring 23 and to form plastic second blades 24 on the silent ring 23 that fall between each metal first blade 22, thereby forming a structure in which the metal first blades 22 and the plastic second blades 24 are alternately arranged.

[0071] More specifically, in this method, the hub 21 and the metal first blades 22 are first combined to form the fan body. Then, through secondary processing, in addition to covering the metal base portion with plastic to form the silent ring 23, the plastic second blades 24 are simultaneously formed and the plastic is used to bond the metal base portion and the metal first blades 22. Thus, the silent ring 23 and the plastic second blades 24 are formed at the second end 222 of the metal first blades 22. In a preferred embodiment, the plastic covering portion of the silent ring 23 and the second blades 24 are integrally formed.

[0072] A fan manufacturing method according to another embodiment of the present invention is shown in Figure 9 . In this embodiment, the silent ring is implemented to include a metal base material portion and a plastic covering portion. In step S300, the hub 21 and the metal first blade 22 are first combined with each other to form a fan body. In step S302, the metal base material portion of the silent ring 23 is bonded to the second end 222 of the metal first blade 22, for example, by the welding process as described above. Finally, in step S304, a plastic injection molding process is performed to form the plastic covering portion of the silent ring 23 and to form plastic second blades 24 on the silent ring 23 that fall between each metal first blade 22, thereby forming a structure in which the metal first blades 22 and the plastic second blades 24 are alternately arranged.

[0073] More specifically, in this method, the hub 21 and the metal first blades 22 are first combined to form the fan body. Then, through further processing, the metal base portion is first combined, and then the plastic coating portion is formed outside the metal base portion and the plastic second blades 24 are formed. Finally, the silent ring 23 and the plastic second blades 24 are formed at the second end 222 of the metal first blades 22. In a preferred embodiment, the plastic coating portion of the silent ring 23 and the second blades 24 are formed in an integral manner, and the plastic coating portion is implemented to at least partially cover the metal base portion to ensure the stable placement of the plastic second blades 24.

[0074] In the above embodiments, the plastic material used in the injection molding process may be, for example, LCP, PPE, PBT, etc. In other embodiments, other suitable plastic materials may be used according to different actual implementation situations without limitation.

[0075] In addition, in the present invention, the combination between the first blade and the hub can also vary according to the actual implementation situation. For example, a hub made of plastic can be molded and combined with the metal first blade by injection molding; a hub made of metal can be combined with the metal first blade by welding; or other suitable processes can be used, so there is no limitation. In addition, the position of the silent ring can fall at the end position of the second end of the first blade (as shown in Figures 2A to 2B), or it can fall at a position close to the end (as shown in Figures 2A to 2B). Figure 1 As shown), it can vary according to the actual implementation situation and is not limited.

[0076] In summary, the present invention utilizes a metal, reduced-thickness silent ring in conjunction with metal blades to enhance fan performance. Furthermore, the present invention utilizes the silent ring as a medium for adding blades, effectively increasing the number of blades without changing the existing fan hub and blade structure, significantly improving fan performance.

[0077] It should be noted that the above-described preferred embodiments are merely illustrative of the present invention and are not limited to the embodiments described. The scope of the present invention is determined by the appended patent application. Furthermore, the present invention is subject to various modifications conceived by those skilled in the art, without departing from the intended scope of protection of the appended patent application.

Claims

1. A fan, wherein: Include a hub having a circumferential rim; a plurality of first blades, each of the plurality of first blades comprising a first end connected to the periphery of the hub, and a second end opposite to the first end; a mute ring disposed at the second ends of the first blades; and A plurality of second blades are arranged at the second ends of the plurality of first blades and connected to the mute ring, and the plurality of second blades and the plurality of first blades are arranged alternately.

2. The fan according to claim 1, wherein Each of the plurality of second blades has a third end facing the hub and a fourth end opposite to the third end, and the distance between the third end and the fourth end of each of the plurality of second blades is smaller than the vertical distance between the second end of each of the plurality of first blades and the periphery.

3. The fan according to claim 1, wherein The plurality of first blades are made of metal material, and the plurality of second blades are made of plastic material.

4. The fan according to claim 3, wherein The silent ring is made of plastic material and is integrally formed with the plurality of second fan blades.

5. The fan according to claim 3, wherein The silent ring includes a metal base material portion and a plastic covering portion, and the plastic covering portion and the plurality of second blades are integrally formed. The fan according to claim 5 , wherein: The silent ring is fixed to the second ends of the first blades through the plastic covering portion.

7. The fan according to claim 5, wherein The silent ring is fixed by connecting the metal base portion to the second ends of the first blades.

8. A method for manufacturing a fan, wherein: The following steps are involved: (a) providing a hub having a peripheral rim; (b) providing a plurality of first blades, each of the plurality of first blades having a first end and a second end opposite to the first end, and connecting the plurality of first ends of the plurality of first blades to the periphery of the hub; and (c) A silent ring and a plurality of second blades are formed at the second ends of the plurality of first blades through an injection molding process, and the plurality of second blades and the plurality of first blades are alternately arranged.

9. The method according to claim 8, wherein Each of the plurality of second blades has a third end facing the hub and a fourth end opposite to the third end, and the distance between the third end and the fourth end of each of the plurality of second blades is smaller than the vertical distance between the second end of each of the plurality of first blades and the periphery.

10. The method according to claim 8, wherein The plurality of first blades are made of metal material, and the plurality of second blades are made of plastic material.

11. The method according to claim 10, wherein: The silent ring is made of plastic material and is integrally formed with the plurality of second fan blades.

12. The method according to claim 10, wherein: The silent ring comprises a metal base material portion and a plastic covering portion.

13. The method according to claim 12, wherein: Step (c) further comprises the following steps: (c1) disposing the metal substrate portion at the second ends of the first blades; and (c2) The plastic covering portion and the plurality of second blades are formed by the injection molding process.

14. The method according to claim 13, wherein: Step (c1) further includes: positioning the metal substrate portion at the plurality of second ends of the plurality of first blades by a clamp.

15. The method according to claim 13, wherein Step (c1) further includes: bonding the metal substrate to the plurality of second ends of the plurality of first blades.

16. A fan, wherein: Include: a hub having a circumferential rim; a plurality of first blades made of a metal material, wherein each of the plurality of first blades comprises a first end connected to the periphery of the hub, and a second end opposite to the first end; and A silent ring is made of a metal material and is disposed on the second ends of the first blades.

17. The fan according to claim 16, wherein The second end of each of the plurality of first blades is further bent to form a welding surface, and the silent ring has a plurality of openings corresponding to the plurality of welding surfaces, and the silent ring is fixed by welding the plurality of welding surfaces to the plurality of openings.

18. The fan according to claim 16, wherein The second end of each of the multiple first fan blades has a first locking structure, and the silent ring has multiple second locking structures corresponding to the multiple first locking structures, and the silent ring is fixed by mutual locking between the multiple first locking structures and the multiple second locking structures.

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