Integrated solar fountain and production and assembly method thereof

Abstract

The invention discloses an integrated solar fountain and a production and assembly method thereof, and belongs to the technical field of fountain equipment. The fountain comprises a shell integrally formed through injection molding, a containing cavity, a rotor cavity and a flow channel are integrated in the shell, a PCB and a winding stator iron core are installed in the containing cavity in a sealed mode, a rotor in the rotor cavity is connected with blades in a pump shell, the flow channel is communicated with the pump shell and a water outlet, a floating ring is arranged below the shell, and a filter screen is arranged below the pump shell. The production and assembly method comprises the steps of shell pretreatment, installation of the winding stator core, the PCB, the rotor and the blade assembly, sealing of the placing cavity, installation of the solar panel, coating of the protection glue layer, installation of the filter screen and the floating ring and the like. Through the integrated design, the waterproof performance and the stability are improved, the assembly process is simplified, the product quality is guaranteed through the production and assembly method, the production efficiency is improved, and the production cost is greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of fountain equipment technology, and in particular to an integrated solar fountain and its manufacturing and assembly method. Background Technology

[0002] Solar fountains utilize solar energy to drive water pumps and create water features, and their applications are widespread. Existing products mostly have a modular structure: the solar panel, controller (PCB board), water pump (including motor and pump body), and float are manufactured separately and then assembled. This design has a significant flaw:

[0003] Poor waterproofing: Numerous cable interfaces and physical connection gaps exist between multiple independent components (such as controller boxes, water pump seals, and component connection points), creating numerous seepage paths. Seals are prone to aging and failure, allowing moisture to easily penetrate and cause short circuits in PCB electronic components, corrosion of motor windings, high equipment failure rates, and difficult maintenance.

[0004] Assembly is complex and inefficient: It requires the separate procurement and assembly of multiple components, involving many manual processes such as fixing, wiring, connecting, and waterproofing. The process is cumbersome, labor costs are high, and assembly errors (such as loose wiring or poor sealing) are easily introduced, affecting product performance and consistency, and increasing the difficulty of material management.

[0005] Insufficient operational stability: The dispersed components result in an unbalanced center of gravity and a loose structure. When used on water, the fountain is prone to tilting, rotating, or drifting due to the backlash from its own spray and the influence of ambient water flow, affecting the fountain's performance and often requiring additional securing measures.

[0006] Limited water flow efficiency: The water pump outlet needs to be connected to the nozzle through an additional pipe, which increases water flow resistance and potential leakage points.

[0007] Existing improvements mostly involve strengthening the seal locally or increasing the size of the float, but they cannot fundamentally solve the problems of numerous gaps between components and loose structure, and may increase costs or weight.

[0008] Therefore, there is an urgent need for a highly integrated design and manufacturing method to fundamentally solve the problems of waterproofing, assembly efficiency, and stability of split-type solar fountains. Summary of the Invention

[0009] The purpose of this invention is to provide an integrated solar fountain and its production and assembly method to solve the problems of poor waterproofing, complex assembly, and insufficient stability of existing split-type solar fountains.

[0010] To achieve the above objectives, the present invention adopts the following technical solution:

[0011] An integrated solar fountain includes a shell, a solar panel, a PCB board, a wound stator core, a rotor, and blades. The shell is an integrally injection-molded structure, internally integrating a placement cavity, a rotor cavity, and a flow channel. The solar panel is fixed to the upper surface of the shell. The PCB board and the wound stator core are sealed and installed within the placement cavity, with the wound stator core surrounding the outside of the rotor cavity. A rotating shaft is provided within the rotor cavity, and the rotor is mounted on the rotating shaft. The bottom of the placement cavity is connected to a pump housing, and the blades are fixed to the rotor and located within the pump housing. The lower end of the flow channel connects to the pump housing, and the upper end extends to the top of the shell to form a water outlet. This technical solution integrates the placement cavity, rotor cavity, and flow channel into a single unit through an integrally injection-molded shell, combining the core components such as the solar panel, PCB board, wound stator core, rotor, and blades. Solar panels absorb sunlight and convert it into electricity. After being controlled by a PCB board, this electricity drives the wound stator core to generate a magnetic field, which in turn rotates the rotor and blades. The rotating blades create negative pressure within the pump casing, drawing water from the bottom and ejecting it from the outlet through a flow channel, thus achieving a coordinated "power generation-drive-pumping" workflow. The integrated structure reduces gaps between components, fundamentally improving overall waterproofing performance; it eliminates the step-by-step assembly process of traditional modular structures, reducing material and labor costs; and the higher degree of compatibility among components effectively improves equipment operating efficiency.

[0012] Furthermore, the housing is circular in shape, and the placement cavity is located below the housing and protrudes downward; a floating ring is provided below the housing and outside the placement cavity, and the floating ring is made of EVA material.

[0013] Furthermore, the top of the placement cavity is sealed with a cover plate, and the connection between the cover plate and the placement cavity is filled with waterproof adhesive. The cover plate at the top of the placement cavity forms the first sealing barrier through physical shielding, and the waterproof adhesive at the connection between the cover plate and the placement cavity fills the gap, forming a second sealing barrier, thus doubly blocking the path of moisture entering the placement cavity from the top. Through the sealing structure of "cover plate + adhesive," external moisture is effectively prevented from invading the interior of the placement cavity, avoiding short circuits in electronic components such as the PCB board and the wound stator core due to water ingress, significantly improving the waterproof reliability of the equipment and extending its service life. Moreover, it eliminates the need to inject waterproof adhesive into the PCB board and the wound stator core, effectively reducing production costs.

[0014] Furthermore, the surface of the solar panel is covered with a transparent protective adhesive layer, which simultaneously achieves the dual functions of "protecting the solar panel and sealing internal components"; compared with the solution of sealing the solar panel and the placement cavity separately, the waterproofing process is simplified and the risk of seal failure is reduced.

[0015] Furthermore, the PCB board integrates Hall effect sensors and an energy storage capacitor, which is either a supercapacitor or a rechargeable battery. The energy storage capacitor is electrically connected to the solar panel and the wound stator core via wires. The Hall effect sensors on the PCB board can detect the rotor position in real time and precisely control the current direction in the wound stator core to ensure stable rotor rotation. The energy storage capacitor (supercapacitor or rechargeable battery) can store excess electrical energy generated by the solar panel and release it to drive the equipment when sunlight is insufficient.

[0016] Furthermore, the water inlet of the pump casing is located directly above the filter screen, and the water outlet of the pump casing is connected to the lower end of the flow channel through a side inclined water channel. The angle between the side water channel and the flow channel is 30°-60°. This angle design conforms to the principles of fluid mechanics, which can reduce turbulence and resistance when the water flow turns, and make the water flow enter the flow channel more smoothly.

[0017] Furthermore, the rotor cavity is located in the central area of ​​the placement cavity, and the rotor cavity and the placement cavity are coaxially arranged. A wear-resistant bearing is provided between the rotating shaft and the inner wall of the rotor cavity. The rotor is rotatably connected to the rotating shaft through the bearing, which improves the efficiency of the rotor driving the blades to pump water and extends the mechanical life of the equipment.

[0018] Furthermore, the filter screen is located below the pump casing, and the filter screen and the pump casing are connected by a detachable snap-fit. The mesh size of the filter screen is 0.5-2mm, which avoids impurities from wearing the blades and shaft, prevents flow channel blockage, reduces the frequency of equipment downtime maintenance, reduces performance degradation caused by impurities, and ensures long-term stable operation of the water pump.

[0019] This invention also discloses a method for manufacturing and assembling an integrated solar fountain, comprising the following steps:

[0020] Step 1: Shell pretreatment. The one-piece injection molded shell is deburred and the inside of the flow channel is polished to make the surface roughness Ra≤1.6μm.

[0021] Step 2: Install the wound stator core. Press the wound stator core into the placement cavity, ensuring that the outer circle of the wound stator core fits the inner wall of the placement cavity with a clearance of 0.15mm ± 0.05mm.

[0022] Step 3: Install the PCB board. Fix the PCB board to the bottom of the placement cavity with screws. Protect the wires connecting the winding stator core and the PCB board with silicone tubing. Leave a 5mm slack for the wires.

[0023] Step 4: Assemble the rotor and blade assembly. After fixing the rotor and blades together, install them into the rotor cavity to ensure that the rotor rotates flexibly without jamming and that the axial movement is ≤0.5mm.

[0024] Step 5: Seal the placement cavity. The cover plate made of ABS material is bonded to the top of the placement cavity with waterproof adhesive. After applying the adhesive, apply a pressure of 5N and keep it for 24 hours to cure. The cured sealing layer can withstand a water pressure of 0.2MPa without leakage.

[0025] Step 6: Install the solar panel. Attach the solar panel to the upper surface of the casing using adhesive film, removing air bubbles during the process to ensure a fit of ≥95%.

[0026] Step 7: Apply a protective adhesive layer. A transparent protective adhesive layer is applied to the surface of the solar panel using a potting process. The potting thickness is 2.5mm ± 0.2mm. The layer is then cured in a 120℃ oven for 2 hours to form the protective adhesive layer. The edge of the protective adhesive layer extends to the upper surface of the cover plate.

[0027] Step 8: Install the filter screen and float ring. Install the filter screen to the bottom of the pump housing using clips. Attach the float ring to the lower surface of the housing using hot melt adhesive, ensuring the lower surface of the float ring is flush with the lower surface of the housing.

[0028] Furthermore, in step three, the wound stator core is made of Φ0.6mm high-strength enameled copper wire, which is connected in a star configuration in three groups, with 100 turns in each group and a DC resistance of 4Ω±0.2Ω. The three-phase windings are spatially 120° electrical angles apart.

[0029] Furthermore, in step four, the rotor uses N35 grade neodymium iron boron permanent magnets encapsulated in POM plastic through injection molding. The rotor surface is treated with a nickel-copper-nickel three-layer plating, with a total plating thickness of 8μm. The blades are made of POM plastic, with 4 blades in total, designed with a 35° sweep angle, and the blade edges are rounded with a radius of 0.8mm.

[0030] Furthermore, in step seven, the transparent protective adhesive layer is made of food-grade silicone rubber, which is vulcanized at 120°C for 2 hours and has a light transmittance of over 92% and a waterproof rating of IP68.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] Integrated design: The shell, placement cavity, rotor cavity, flow channel and other structures are injection molded as one piece, reducing the gaps between parts and improving the overall waterproof performance; at the same time, it eliminates the step assembly process and reduces labor and material costs.

[0033] Enhanced stability: A hollow floating ring is installed at the bottom of the shell, which, together with the circular structure, improves the floating stability of the fountain on the water surface and reduces the deviation caused by the impact of water flow.

[0034] High-efficiency water flow drive: The water channels and flow channels on the side of the pump casing are designed at an inclined angle to reduce water flow resistance and improve drainage efficiency; the removable filter screen prevents impurities from entering the pump body and extends the equipment life.

[0035] Optimized circuit protection: The silicone protective layer on the surface of the solar panel is sealed to the cover plate, providing double protection for the electronic components inside the cavity. At the same time, the energy storage capacitor can store electrical energy to ensure that the fountain continues to work when the light is unstable.

[0036] The scientific and rational production and assembly methods ensure product consistency and reliability, improve production efficiency, and reduce production costs.

[0037] This invention adopts an integrated assembly and installation method, thereby reducing the need for separate production, assembly, and installation of individual water pumps, controllers, and solar panels, effectively improving overall product performance and reducing material and labor costs. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 , 2 This is an overall schematic diagram provided for an embodiment of the present invention;

[0040] Figure 3 , 4 An exploded view diagram provided for an embodiment of the present invention;

[0041] Figure 5 , 6 This is a schematic diagram of the shell structure provided in an embodiment of the present invention;

[0042] Figure 7 This is a cross-sectional schematic diagram provided for an embodiment of the present invention;

[0043] Figure 8 A cross-sectional view illustrating the working principle of an embodiment of the present invention.

[0044] The following are the labeling elements in the figure:

[0045] 1. Shell; 11. Float ring; 12. Placement cavity; 13. Rotor cavity; 14. Flow channel; 141. Outlet; 15. Shaft; 2. Solar panel; 3. Cover plate; 4. PCB board; 5. Winded stator core; 6. Rotor; 7. Blades; 8. Pump casing; 9. Filter screen.

[0046] The accompanying drawings have illustrated specific embodiments of the invention, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0047] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0048] To make the technical solutions and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0049] Please see Figures 1-8 As shown, the integrated solar fountain disclosed in this invention aims to overcome the inherent defects of traditional split-type solar fountains in terms of waterproofing performance, assembly efficiency, and operational stability through a highly integrated structural design. The following will describe in detail the embodiments of this invention in conjunction with specific structural parameters, material properties, assembly processes, and working mechanisms to ensure that those skilled in the art can accurately understand and successfully implement it.

[0050] like Figure 5 , 6 As shown, the housing 1, serving as the core support of the entire device, is integrally molded from ABS engineering plastic using a precision injection molding process. This material selection is based on its excellent comprehensive performance: it maintains stable mechanical properties within a temperature range of -40℃ to 80℃, has a tensile strength of not less than 40MPa, a flexural strength of over 60MPa, and a water absorption rate of ≤0.2%, effectively resisting performance degradation caused by long-term immersion in water. The housing 1 is generally disc-shaped. The integrated structure of the housing 1 is the basis for realizing the integrated design. It integrates three functional areas: the placement cavity 12, the rotor cavity 13, and the flow channel 14. Each area is formed in one piece using an injection mold, avoiding the gaps caused by the splicing of components in a split structure.

[0051] The placement cavity 12 is located at the lower part of the housing 1 and protrudes downward. The rotor cavity 13 is coaxially set at the center of the placement cavity 12. The inner wall of the cavity is precision ground and the surface roughness Ra≤0.8μm to ensure the concentricity of the rotor 6 when it rotates. The flow channel 14 can adopt a spiral rising structure, starting from the side of the pump housing 8 and ending at the outlet 141 at the top of the housing 1. The cross-section of the flow channel 14 can be a cone shape that is narrow at the top and wide at the bottom.

[0052] Solar panel 2, serving as the energy input unit, employs a monocrystalline silicon solar panel whose dimensions match the upper surface of casing 1. Its effective power generation area is 90% of the upper surface area of ​​casing 1, with a stable conversion efficiency of 18%-20%. Even in low-light conditions such as cloudy days, it can maintain over 70% of its rated output power. The connection between solar panel 2 and the upper surface of casing 1 utilizes an adhesive film bonding process. The adhesive film is 0.25mm thick and hot-pressed at 130℃ and 0.1MPa for 30 minutes. After curing, the peel strength reaches 10N / cm, ensuring no detachment under long-term water flow impact and temperature changes. The surface of solar panel 2 is covered with a 2.5mm thick transparent silicone protective layer. This layer is made of food-grade silicone rubber, vulcanized at 120℃ for 2 hours, and has a light transmittance of over 92%, ensuring that the light-gathering efficiency of solar panel 2 is not affected. Simultaneously, this layer exhibits excellent weather resistance; accelerated aging tests show no yellowing or cracking after 5000 hours of continuous UV exposure, achieving a waterproof rating of IP68, completely preventing moisture intrusion. The edge of the protective layer extends to the upper surface of cover plate 3, further strengthening the waterproof barrier of placement cavity 12.

[0053] The core of the circuit control module is PCB board 4, which uses an FR-4 epoxy glass cloth substrate, possessing excellent insulation performance and mechanical strength. PCB board 4 integrates various key components, including a Hall effect sensor, model A3144, in an SOT-23 surface mount package. Its mounting position is 6mm ± 0.2mm from the outer diameter of rotor 6, enabling precise detection of magnetic field changes during rotor 6 rotation. The frequency of the output pulse signal is linearly correlated with the rotor 6 speed, with a response time ≤ 2μs, providing precise timing control for motor commutation.

[0054] In this embodiment, two energy storage options are provided: Using a 2.7V / 10F supercapacitor, the device can continue operating for approximately 4 minutes after a light outage, suitable for short periods of cloudy weather; using a 3.7V / 2000mAh lithium polymer battery, the device can operate for 10 hours in complete darkness when fully charged, meeting the needs of nighttime or cloudy days. Both options use energy storage components soldered to the copper foil on the PCB board 4 via nickel strips, with the solder joints covered with insulating varnish to prevent short circuits. The drive circuit uses a BTN7971 chip in a TO-263 package, which, together with an external N-channel MOSFET, forms an H-bridge drive structure to flexibly control the current direction of the wound stator core 5, ensuring stable rotation of the rotor 6. The protection circuit includes overcharge protection, over-discharge protection, and short-circuit protection. When an abnormal state is detected, the main circuit can be cut off within 100ms to prevent component damage.

[0055] The outer diameter of the wound stator core 5 is fitted with the inner wall of the placement cavity 12 with a clearance fit. The clearance is controlled within 0.15mm ± 0.05mm to ensure the core is securely installed while avoiding deformation of the housing 1 caused by interference fit. The winding uses Φ0.6mm high-strength enameled copper wire, which is connected in a star configuration in three groups, with 100 turns in each group. The DC resistance is 4Ω ± 0.2Ω. The three-phase windings are spatially aligned at 120° electrical angles. When a symmetrical alternating current is applied, a rotating magnetic field is generated with a magnetic field strength of 0.8T-1.0T, providing a stable driving torque for the rotor 6.

[0056] The power transmission system consists of a rotor 6, blades 7, a shaft 15, and a pump casing 8. The rotor 6 uses N35 grade neodymium iron boron permanent magnets, encapsulated in POM plastic using injection molding to form a cylindrical structure. The permanent magnets have a remanence ≥1.23T and a coercivity ≥860kA / m, ensuring sufficient magnetic power. The rotor 6 surface undergoes a nickel-copper-nickel three-layer plating treatment with a total plating thickness of 8μm. It passes a 48-hour salt spray test without corrosion, effectively resisting water corrosion. The rotor 6 has a Φ10mm shaft hole at its center, which mates with the shaft 15 via a sintered bronze bearing. The bearing has an oil content ≥20%, allowing for long-term operation without additional lubrication. The clearance between the bearing and the shaft 15 is controlled at 0.03mm ± 0.01mm, ensuring that the radial runout of the rotor 6 during rotation is ≤0.1mm, reducing mechanical losses.

[0057] Blade 7 is made of POM plastic, which has excellent wear resistance and self-lubrication. There are 4 blades in total, with a 35° sweep angle design. Optimized by fluid dynamics simulation, it can generate a head of 1.0m at a speed of 2000rpm and a flow rate of 10L / min. The edges of blade 7 are rounded with a radius of 0.8mm, which reduces water flow disturbance and keeps the operating noise below 50dB.

[0058] The pump casing 8 is made of modified PP, which has good impact resistance and chemical resistance. The internal flow channel of the pump casing 8 features a volute design, with a smooth transition between the outlet and the side water channel, ensuring smooth water flow. The connection angle between the side water channel and the flow channel 14 is designed to be 45°. This angle, verified by CFD simulation, reduces local resistance loss by 35% compared to the traditional 90° right-angle connection, significantly improving water transmission efficiency. The water inlet of the pump casing 8 is located directly above the filter screen 9, ensuring a stable water flow during intake and preventing cavitation caused by vortices.

[0059] Floating ring 11 uses a density of 0.12 g / cm³. 3 Made of EVA foam material, it is connected to the annular groove on the lower surface of the shell 1 by hot melt adhesive, with a bonding strength ≥2.5 N / cm. 2This ensures that the float ring 11 will not fall off during long-term use. The lower surface of the float ring 11 is flush with the lower surface of the housing 1 to ensure that the equipment remains horizontal in the water and to reduce uneven water flow caused by tilting.

[0060] The filter screen 9 is injection molded from nylon 66 material, possessing excellent weather resistance and mechanical strength, and can be used in environments ranging from -40℃ to 120℃. The filter screen 9 has a regular hexagonal mesh structure with a pore size of 1mm ± 0.2mm. This design ensures an interception efficiency of ≥98% while maintaining a water flow resistance of ≤4kPa, effectively balancing filtration performance and water intake efficiency. The filter screen 9 is connected to the pump housing 8 via a snap-fit ​​connection, with four evenly distributed elastic snaps around the circumference. The snaps can deform by ≥2mm and can be repeatedly disassembled and reassembled more than 500 times without failure, facilitating regular cleaning of the filter screen 9 and preventing clogging by impurities.

[0061] The production and assembly method of the present invention is carried out according to the following steps to ensure product performance:

[0062] Step 1: Pre-treatment of shell 1. The shell 1, which is integrally injection molded, is deburred. In particular, the inside of the flow channel 14 needs to be polished with special tools so that the surface roughness Ra of the flow channel 14 is ≤1.6μm.

[0063] Step 2: Install the wound stator core 5. Press the wound stator core 5 into the placement cavity 12, ensuring that the outer circle of the wound stator core 5 is in clearance fit with the inner wall of the placement cavity 12, with a clearance of 0.15mm ± 0.05mm. The wound stator core 5 uses Φ0.6mm high-strength enameled copper wire, which is divided into 3 groups for star connection, with 100 turns in each group and a DC resistance of 4Ω ± 0.2Ω. The three-phase windings are spatially 120° electrical angles apart.

[0064] Step 3: Install PCB board 4. Fix PCB board 4 to the bottom of placement cavity 12 with screws. The wires connecting the winding stator core 5 and PCB board 4 should be protected with silicone tubes. Leave a 5mm margin in the length of the wires to avoid pulling and causing wire breakage.

[0065] Step 4: Assemble the rotor 6 and blade 7 assembly. After fixing the rotor 6 and blade 7 together, install them into the rotor cavity 13, ensuring that the rotor 6 rotates flexibly without jamming and that the axial movement is ≤0.5mm. The rotor 6 uses N35 grade neodymium iron boron permanent magnets encapsulated in POM plastic through injection molding. The surface of the rotor 6 is treated with a nickel-copper-nickel three-layer plating, with a total plating thickness of 8μm. The blades 7 are made of POM plastic, with 4 blades in total, designed with a 35° sweep angle, and the edges of the blades 7 are rounded with a radius of 0.8mm.

[0066] Step 5: Seal the placement cavity 12. The cover plate 3, made of ABS material, is bonded to the top of the placement cavity 12 with waterproof adhesive. The adhesive used is silicone sealant. After applying the adhesive, apply a pressure of 5N and keep it for 24 hours to cure. The sealed layer formed after curing can withstand a water pressure of 0.2MPa without leakage.

[0067] Step 6: Install solar panel 2. Attach solar panel 2 to the upper surface of casing 1 using adhesive film. During the attachment process, air bubbles must be removed to ensure a fit of ≥95%.

[0068] Step 7: Apply a protective adhesive layer. A transparent protective adhesive layer is applied to the surface of the solar panel 2 using a potting process. The potting thickness is controlled at 2.5mm ± 0.2mm. The layer is then cured in a 120℃ oven for 2 hours. The transparent protective adhesive layer is made of food-grade silicone rubber with a light transmittance of over 92% and a waterproof rating of IP68. The edge of the protective adhesive layer extends to the upper surface of the cover plate 3 to further enhance the waterproof effect.

[0069] Step 8: Install the filter screen 9 and float ring 11. Install the filter screen 9 under the pump housing 8 using clips. Attach the float ring 11 to the lower surface of the housing 1 using hot melt adhesive. The lower surface of the float ring 11 should be flush with the lower surface of the housing 1. This completes the overall assembly.

[0070] like Figure 8 As shown, the working process of this invention is as follows: Under sunlight, the solar panel 2 absorbs light energy and converts it into electrical energy. Part of the electrical energy directly drives the wound stator core 5 to generate a rotating magnetic field through the PCB board 4, while the other part of the electrical energy can be stored in the energy storage element. The Hall effect device detects the position of the rotor 6 in real time and transmits the signal to the control circuit of the PCB board 4. The control circuit switches the current direction of the wound stator core 5 in a timely manner according to the position of the rotor 6, so that the rotating magnetic field continuously drives the rotor 6 to rotate. The rotor 6 drives the blades 7 to rotate at high speed in the pump casing 8. The centrifugal force generated by the rotation of the blades 7 creates a negative pressure in the pump casing 8. Water is sucked into the pump casing 8 through the filter screen 9, enters the flow channel 14 through the side water channel, and finally sprays out from the outlet 141 to form a fountain. When there is insufficient sunlight, the energy storage element releases the stored electrical energy to ensure continuous operation of the equipment. The filter screen 9 effectively intercepts impurities such as sand and weeds in the water, preventing them from entering the pump casing 8 and causing wear on the blades 7 or blockage of the flow channel 14. The float ring 11 provides stable buoyancy, keeping the equipment balanced on the water surface and reducing the offset caused by water flow impact.

[0071] This embodiment fully discloses the implementation details of an integrated solar fountain and its production and assembly method through detailed structural parameters, material selection, process parameters, and assembly steps. Those skilled in the art can accurately implement this invention based on the above description, achieving the technical effects of improved waterproof performance, increased assembly efficiency, and enhanced operational stability. Furthermore, in practical applications, parameters such as the size of the shell 1, the power of the solar panel 2, and the capacity of the energy storage element can be adjusted according to specific needs; all such adjustments fall within the protection scope of this invention.

[0072] Other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention. This application is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of the invention are indicated by the foregoing claims.

[0073] It should be understood that the present invention is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. An integrated solar-powered fountain, characterized in that: The system includes a housing, a solar panel, a PCB board, a wound stator core, a rotor, and blades. The housing is an integrated injection-molded structure, which integrates a placement cavity, a rotor cavity, and a flow channel. The solar panel is fixed to the upper surface of the housing. The PCB board and the wound stator core are sealed and installed inside the placement cavity, and the wound stator core is arranged around the outside of the rotor cavity. A rotating shaft is fixedly installed inside the rotor cavity, and the rotor is installed on the rotating shaft. The bottom of the placement cavity is fixedly connected to the pump casing, and the blades are fixed to the rotor and located inside the pump casing. The lower end of the flow channel is connected to the pump casing, and the upper end extends to the top of the housing to form a water outlet. The system also includes a removable filter screen located below the pump casing.

2. The integrated solar fountain according to claim 1, characterized in that: The housing is circular, and the placement cavity is located below the housing and protrudes downward. A floating ring is provided below the housing and outside the placement cavity. The rotor cavity is located in the central area of ​​the placement cavity and is coaxial with the placement cavity.

3. The integrated solar fountain according to claim 1, characterized in that: The top of the placement cavity is sealed by a cover plate, and the gap between the cover plate and the placement cavity is filled with glue to achieve waterproofing.

4. The integrated solar fountain according to claim 1, characterized in that: The surface of the solar panel is covered with a transparent protective adhesive layer, which simultaneously covers the cover plate to seal the electronic components inside the cavity.

5. The integrated solar fountain according to claim 1, characterized in that: The PCB board integrates Hall effect devices and energy storage components, wherein the energy storage components are supercapacitors or rechargeable batteries.

6. The integrated solar fountain according to claim 1, characterized in that: The water inlet of the pump casing is located directly above the filter screen, and the water outlet of the pump casing is connected to the lower end of the flow channel through a side water channel.

7. A method for producing and assembling an integrated solar fountain as described in any one of claims 1-6, characterized in that, Includes the following steps: Step 1: Shell pretreatment, deburring the one-piece injection molded shell and polishing the inside of the flow channel; Step 2: Install the wound stator core. Press the wound stator core into the placement cavity, ensuring that the outer circle of the wound stator core fits the inner wall of the placement cavity with a clearance of 0.15mm ± 0.05mm. Step 3: Install the PCB board. Fix the PCB board to the top of the winding stator core with screws, and use silicone tubing to protect the wires connecting the winding stator core and the PCB board. Step 4: Assemble the rotor and blade assembly. After fixing the rotor and blades together, install them into the rotor cavity to ensure that the rotor rotates flexibly without jamming and that the axial movement is ≤0.5mm. Step 5: Seal the placement cavity. The cover plate made of ABS material is bonded to the top of the placement cavity with waterproof adhesive. After applying the adhesive, apply 5N of pressure and keep it in place for 24 hours to cure. Step Six: Install the solar panel. Attach the solar panel to the upper surface of the casing using adhesive film, removing any air bubbles during the process. Step 7: Apply a protective adhesive layer. A transparent protective adhesive layer is applied to the surface of the solar panel using a potting process. The potting thickness is 2.5mm ± 0.2mm. The panel is then cured in a 120℃ oven for 2 hours to form the final product. Step 8: Install the filter screen and float ring. Install the filter screen to the bottom of the pump housing using clips. Attach the float ring to the lower surface of the housing using hot melt adhesive, ensuring the lower surface of the float ring is flush with the lower surface of the housing.

8. The production and assembly method of the integrated solar fountain according to claim 7, characterized in that, In step three, the wound stator core is made of Φ0.6mm high-strength enameled copper wire, which is connected in a star configuration in three groups. Each group has 100 turns and a DC resistance of 4Ω±0.2Ω. The three-phase windings are spaced 120° apart.

9. The production and assembly method of the integrated solar fountain according to claim 7, characterized in that, In step four, the rotor uses N35 grade neodymium iron boron permanent magnets encapsulated in POM plastic through injection molding. The rotor surface is treated with a three-layer nickel-copper-nickel plating with a total plating thickness of 8μm. The blades are made of POM plastic, with 4 blades in total, designed with a 35° sweep angle, and the blade edges are rounded with a radius of 0.8mm.

10. The production and assembly method of the integrated solar fountain according to claim 7, characterized in that, In step seven, the transparent protective adhesive layer is made of food-grade silicone rubber and is formed by vulcanization at 120°C for 2 hours.

Images