Integrated plastic-coated fan cowl assembly

Abstract

The invention discloses an integrated plastic-coated fan cowl assembly which comprises a cowl, a driving motor and a fan, the cowl comprises a cowl body and a motor mounting hub located in the cowl body, the motor mounting hub is connected with the cowl body through a plurality of rib plates, a stator assembly is integrally formed in the motor mounting hub in a plastic-coated mode, and the motor mounting hub is connected with the cowl body through a plurality of rib plates. A rotor mounting cavity is formed in the center of the stator assembly, a rotor assembly is rotatably mounted on the motor mounting hub and located in the rotor mounting cavity, the front end of a rotor shaft of the rotor assembly penetrates through the motor mounting hub and is used for fixing a fan impeller, and a heat dissipation end cover is fixed to the motor mounting hub. The heat dissipation cover is provided with an external wire harness which is electrically connected with a stator winding of the stator assembly. According to the fan cowl assembly, the stator assembly of the motor is wrapped in the motor mounting hub, so that the motor is directly assembled in the motor mounting hub, and the assembly process is reduced.

Description

Technical Field

[0001] This invention relates to a cooling fan assembly, and more particularly to an integrated plastic-coated fan shroud assembly. Background Technology

[0002] Cooling fan assemblies are mainly used in systems requiring thermal management, such as automobiles, energy storage, and data centers, to dissipate heat. The cooling fan assembly includes a shroud, a drive motor, and a fan. The shroud includes a housing and a motor mounting hub located within the housing. The motor mounting hub and the housing are connected by several stiffening plates. The drive motor is fixed to the motor mounting hub. The fan mainly includes a central hub and a set of fan blades. The inner ends of the set of fan blades are fixed to the central hub, and pressure-holding rings are fixed to the outer ends of the set of fan blades. The central hub is fixed to the rotor of the motor, and the high-speed rotation of the rotor drives the fan to rotate. The invention disclosed in patent application CN202420792649.0 discloses a brushless cooling fan specifically for hybrid electric vehicles. This fan assembly has the following disadvantages: 1. The motor assembly of this cooling fan needs to be assembled first and then fixed in the limiting part, making assembly complex; 2. Because the motor assembly includes its own metal housing and is then fixed to the cooling fan, the overall weight of the cooling fan is relatively heavy. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide an integrated plastic-coated fan shroud assembly, which covers the stator assembly of the motor inside the motor mounting hub, thereby allowing the motor to be assembled directly in the motor mounting hub and reducing the assembly process.

[0004] To solve the above-mentioned technical problems, the technical solution of the present invention is: an integrated plastic-coated fan guard assembly, the fan guard assembly including a cover body and a motor mounting hub inside the cover body, the motor mounting hub and the cover body being connected by a plurality of stiffening plates, a stator assembly integrally plastic-coated inside the motor mounting hub, a rotor mounting cavity being provided at the center of the stator assembly, a rotor assembly being rotatably mounted on the motor mounting hub within the rotor mounting cavity, the front end of the rotor shaft of the rotor assembly passing through the motor mounting hub and used to fix the fan impeller, a heat dissipation end cover being fixed on the motor mounting hub, and an external wiring harness electrically connected to the stator winding of the stator assembly being provided on the heat dissipation end cover.

[0005] As a preferred embodiment, the motor mounting hub includes a cylindrical plastic body with a diameter larger than its outer edge. The stator assembly is encased and embedded within the plastic body. A central cylindrical body with a diameter smaller than the plastic body is located on the front end face of the plastic body. A bearing for facilitating rotor shaft rotation is embedded within the central cylindrical body, and the rotor shaft extends through the central cylindrical body. A first mounting step for mounting a PCBA board is provided at the rear end of the plastic body. Several bolt support platforms for fixed connection to the PCBA board are provided on the first mounting step. The three-phase windings of the stator assembly are connected one-to-one with three phase connection pieces embedded in the plastic body. The PCBA board is fixed to the bolt support platforms by bolts, and the phase connection pieces are welded to the PCBA board. A second mounting step is also provided at the rear end of the plastic body. The heat dissipation end cap is bolted to the second mounting step. The rear end of the rotor shaft is rotatably mounted on the heat dissipation end cap via a bearing. A three-phase terminal block is also provided on the PCBA board. The three-phase terminal block is insulated through the heat dissipation end cap and is correspondingly connected to the external wiring harness.

[0006] As a preferred embodiment, the outer edge is also provided with several ventilation holes that run from front to back.

[0007] As a preferred embodiment, a baffle corresponding to the ventilation hole is also provided on the rear end face of the outer edge, and the baffle guides the airflow to the heat dissipation end cover.

[0008] As a preferred embodiment, reinforcing ribs are provided between the front end face of the plastic body and the side surface of the central cylinder.

[0009] As a preferred embodiment, the heat dissipation end cover is provided with a mounting ear, the mounting ear is provided with a bolt mounting hole, and the second mounting step is provided with a mounting groove to accommodate the bolt mounting hole. The mounting ear is fixed in the mounting groove by a bolt installed in the bolt mounting hole.

[0010] As a preferred embodiment, a metal heat dissipation plate is also embedded in the stiffener, and the inner end of the heat dissipation plate extends to the stator assembly and contacts the stator core.

[0011] As a preferred embodiment, the surface portion of the reinforced heat dissipation plate is embedded within the rib plate, while the other portion is exposed.

[0012] As a preferred embodiment, the inner end of the reinforced heat dissipation plate is provided with an extension section extending along the axial direction of the plastic body, and the extension section is partially exposed outside the plastic body.

[0013] After adopting the above technical solution, the effect of the present invention is as follows: An integrated plastic-coated fan shroud assembly includes a shroud body and a motor mounting hub located within the shroud body. The motor mounting hub and the shroud body are connected by several reinforcing ribs. A stator assembly is integrally plastic-coated within the motor mounting hub. A rotor mounting cavity is centrally located within the stator assembly. A rotor assembly is rotatably mounted on the motor mounting hub within the rotor mounting cavity. The front end of the rotor shaft of the rotor assembly passes through the motor mounting hub and is used to fix the fan impeller. A heat dissipation end is fixed on the motor mounting hub. The heat dissipation cover is equipped with an external wiring harness that is electrically connected to the stator windings of the stator assembly. Therefore, the motor mounting hub of the heat shield assembly directly covers the stator assembly during the molding process. Then, the rotor assembly can be directly assembled into the rotor mounting cavity of the motor mounting hub, using the motor mounting hub as the motor housing of a conventional motor. This allows for the direct assembly of the motor rotor assembly and the heat dissipation cover within the motor mounting hub, reducing assembly steps and processes, simplifying the overall structure, and eliminating the need for a metal motor housing by covering the stator assembly, thus reducing the overall weight.

[0014] Furthermore, since the motor mounting hub includes a cylindrical plastic body, the outer side of which has a diameter larger than the outer edge of the plastic body. The stator assembly is encased and embedded within the plastic body. A central cylinder with a diameter smaller than the plastic body is provided on the front end face of the plastic body. A bearing for facilitating rotor shaft rotation is embedded within the central cylinder. The rotor shaft extends through the central cylinder. The rear end of the plastic body has a first mounting step for mounting the PCBA board. Several bolt support platforms for fixed connection to the PCBA board are provided on the first mounting step. The three-phase windings of the stator assembly are connected one-to-one with three phase connection pieces embedded in the plastic body. The PCBA board is fixed to the bolt support platform by bolts, and the phase connecting piece is welded to the PCBA board. The rear end of the plastic body is also provided with a second mounting step. The heat dissipation end cover is bolted to the second mounting step. The rear end of the rotor shaft is rotatably mounted on the heat dissipation end cover through a bearing. The PCBA board is also provided with a three-phase terminal block. The three-phase terminal block is insulated through the heat dissipation end cover and is correspondingly connected to the external wiring harness. Therefore, with the above structure, the rotor assembly can be easily rotated and installed. The PCBA board and the heat dissipation end cover can be easily and quickly assembled and fixed using the first and second mounting steps.

[0015] Furthermore, since several ventilation holes are provided on the outer edge, when the fan impeller and the shroud are assembled, the fan impeller is mounted on the rotor shaft and rotates with it. The fan is driven to rotate, and the airflow generated will pass through the ventilation holes, thereby dissipating heat from the heat dissipation end cover and improving the heat dissipation effect of the PCBA board.

[0016] Furthermore, since a flow guide baffle corresponding to the ventilation hole is provided on the rear end face of the outer edge, the baffle guides the airflow to the heat dissipation end cover. Therefore, when the airflow passes through the ventilation hole from front to back, the airflow will be guided by the flow guide baffle, and more airflow will flow to the surface of the heat dissipation end cover, thereby further improving the heat dissipation effect.

[0017] Furthermore, reinforcing ribs are provided between the front end face of the plastic body and the side surface of the central cylinder. This increases the connection strength between the central cylinder and the plastic body.

[0018] Furthermore, since the heat dissipation end cover is provided with mounting ears, and the mounting ears are provided with bolt mounting holes, and the second mounting step is provided with a mounting groove to accommodate the bolt mounting holes, the mounting ears are fixed in the mounting groove by bolts installed in the bolt mounting holes. In this way, the mounting groove can be used to easily cooperate with the mounting ears, thereby facilitating the positioning of the heat dissipation end cover and making assembly simpler.

[0019] Furthermore, since a metal heat dissipation plate is also embedded in the stiffener, and the inner end of the heat dissipation plate extends to the stator assembly and contacts the stator core, the heat dissipation plate embedded in the stiffener can enhance the overall strength of the wind shield. At the same time, the metal heat dissipation plate can conduct heat from the stator core, thereby further improving the heat dissipation of the motor.

[0020] Furthermore, since part of the reinforced heat dissipation plate is embedded in the rib plate while the other part is exposed, the airflow from the fan will also carry away the heat from the exposed reinforced heat dissipation plate, thus accelerating heat dissipation.

[0021] Furthermore, since the inner end of the enhanced heat dissipation plate is provided with an extension section extending along the axial direction of the plastic body, and the extension section is partially exposed outside the plastic body, the length of the extension section can increase the contact length with the stator core inside the plastic body, increase the heat conduction area, and at the same time, the part exposed outside the plastic body can also enhance heat dissipation. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0023] Figure 1 This is a perspective view of the rear structure of an embodiment of the present invention;

[0024] Figure 2 This is a frontal perspective view of an embodiment of the present invention;

[0025] Figure 3 This is a perspective sectional view of an embodiment of the present invention;

[0026] Figure 4This is a schematic diagram of the heat dissipation end cap and external wiring harness;

[0027] Figure 5 It is a cross-sectional view of the heat dissipation end cap and the external wiring harness;

[0028] Figure 6 This is a magnified view of a portion of the PCBA board and heat sink cover that are hidden.

[0029] Figure 7 This is a partially enlarged schematic diagram showing the rotor assembly hidden.

[0030] Figure 8 This is a schematic diagram of the setup for an enhanced heat sink;

[0031] In the attached diagram: 1. Windshield assembly; 11. Cover body; 12. Rib plate; 13. Reinforced heat dissipation plate; 131. Extension section; 14. Motor mounting hub; 141. Plastic body; 142. Central cylinder; 143. Outer edge; 144. Reinforcing rib; 15. Bolt support platform; 16. Second mounting step; 17. Mounting groove; 18. Ventilation hole; 19. Guide baffle; 2. Heat dissipation end cover; 21. Mounting ear; 3. Sealing gasket; 31. Sealing boss; 32. Sealing neck; 4. External wiring harness; 41. Three-phase terminal; 42. Metal connection terminal; 5. PCBA board; 6. Rotor assembly; 61. Rotor shaft; 7. Stator assembly; 71. Stator winding; 72. Stator core; 8. Phase connection piece. Detailed Implementation

[0032] The present invention will be further described in detail below through specific embodiments.

[0033] like Figures 1 to 8 As shown, an integrated plastic-coated fan guard assembly 1 includes a guard body 11 and a motor mounting hub 14 located within the guard body 11. The motor mounting hub 14 and the guard body 11 are connected by several reinforcing ribs 12. Several concentric protective ribs of different diameters can also be provided on the reinforcing ribs 12. The attached figure only illustrates one ring of protective ribs; the number of protective ribs can be optimized according to actual needs. Multiple protective ribs can improve the overall protection level of the fan assembly.

[0034] The stator assembly 7 is integrally molded within the motor mounting hub 14. The motor mounting hub 14 includes a cylindrical plastic body 141. An outer edge 143 with a diameter larger than the outer edge of the plastic body 141 is provided on the outer side of the plastic body 141. The stator assembly 7 is encased and embedded within the plastic body 141. A central cylindrical body 142 with a diameter smaller than the outer edge of the plastic body 141 is provided on the front end face of the plastic body 141. During the molding process of the windshield assembly 1, the stator assembly 7 is placed into the molding die, thereby... After the motor mounting hub 14 is formed, it will directly enclose the stator assembly 7. The stator assembly 7 has a rotor mounting cavity at its center. The rotor assembly 6 is rotatably mounted on the motor mounting hub 14 within the rotor mounting cavity. The front end of the rotor shaft 61 of the rotor assembly 6 passes through the motor mounting hub 14 and is fixed with a transmission disk. The fan is fixed on the transmission disk. A heat dissipation end cover 2 is fixed on the motor mounting hub 14. An external wire harness 4 that is electrically connected to the stator winding of the stator assembly 7 is provided on the heat dissipation cover.

[0035] Among them, such as Figure 3 As shown, a bearing for facilitating the rotation of the rotor shaft 61 is embedded in the central cylinder 142. The rotor shaft 61 extends through the central cylinder 142. A first mounting step for mounting the PCBA board 5 is provided at the rear end of the plastic body 141. Several bolt support platforms 15 fixedly connected to the PCBA board 5 are provided on the first mounting step. The three-phase windings of the stator assembly 7 are connected one-to-one with three phase connecting pieces 9 embedded in the plastic body 141. The PCBA board 5 is fixed to the bolt support platform 15 by bolts, and the phase connecting pieces 9 are welded to the PCBA board 5. A second mounting step 16 is also provided at the rear end of the plastic body 141. The heat dissipation end cover 2 is bolted to the second mounting step 16. The rear end of the rotor shaft 61 is rotatably mounted on the heat dissipation end cover 2 through the bearing. A three-phase terminal block 41 is also provided on the PCBA board 5. The three-phase terminal block 41 is insulated through the heat dissipation end cover 2 and is correspondingly connected to the external wiring harness 4.

[0036] In this embodiment, the external wiring harness 4 and the three-phase terminal block 41 are sealed together.

[0037] In this embodiment, the heat dissipation end cover 2 is provided with a through hole for the three-phase terminal 41 to pass through. The front end face of the heat dissipation end cover 2 is provided with a sealing gasket 3. The sealing gasket 3 is provided with a sealing boss 31. The sealing boss 31 is provided with a sealing neck 32. The sealing boss 31 passes through the through hole and protrudes from the rear end face. The sealing neck 32 is inserted into the through hole. The sealing boss 31 is provided with a socket for the three-phase terminal 41 to be inserted. In this embodiment, the three-phase terminal 41 is a terminal with a circular cross-section. One end of the three-phase terminal is soldered and fixed to the corresponding pin on the PCBA board 5, and the other end passes through the sealing boss 32 and protrudes. The external wire harness 4 is provided with a metal connection terminal 42. The metal terminal 42 is sleeved on the three-phase terminal 41 and fixedly connected.

[0038] Since the sealing neck 32 is stuck in the through hole and the sealing gasket 3 is squeezed after being fixed, the sealing neck 32 and the through hole are better sealed. At the same time, the socket on the sealing boss 31 can also better seal with the three-phase terminal 41, thus improving the overall sealing performance.

[0039] The stator winding of the stator assembly 7 is connected to the circuit of the PCBA board 5 through the phase connection piece 9, and the external wiring harness 4 is also electrically connected to the PCBA board 5 through the three-phase terminal 41, thereby realizing the power supply and control of the motor.

[0040] The outer edge 143 is also provided with several through ventilation holes 18. In actual use, the central hub of the fan impeller wraps around the plastic body 141. Auxiliary blades are provided on the inner wall of the central hub. The fan impeller includes a pressure-holding ring, and several fan blades are provided between the pressure-holding ring and the central hub. During installation, the central hub is fitted onto the outside of the plastic body 141 and fixed to the rotor shaft 61 through a transmission disc. After fixing, the rotation of the rotor shaft 61 will drive the fan impeller to rotate. When the fan impeller rotates, the auxiliary blades will also rotate, thereby generating airflow in the central hub. This airflow will flow backward through the ventilation holes 18 to cool the heat dissipation end cover 2. At the same time, the airflow will also pass through the extension section 131 of the reinforced heat dissipation plate 13, which will also accelerate the heat dissipation of the reinforced heat dissipation plate.

[0041] Furthermore, a baffle plate 19 corresponding to the ventilation hole 18 is provided on the rear end face of the outer edge 143. The baffle plate guides the airflow to the heat dissipation end cover 2, so that the airflow passes better through the surface of the heat dissipation end cover 2 to improve the heat dissipation effect. In this embodiment, there are four ventilation holes 18 and two baffle plates 19. The two baffle plates 19 are provided to facilitate the installation of the heat dissipation end cover 2.

[0042] like Figure 6As shown, a reinforcing rib 144 is provided between the front end face of the plastic body 141 and the side surface of the central cylinder 142. The reinforcing rib 144 extends radially and is evenly distributed around the circumference.

[0043] The heat dissipation end cover 2 is provided with a mounting ear 21, and the mounting ear 21 is provided with a bolt mounting hole. The second mounting step 16 is provided with a mounting groove 17 to accommodate the bolt mounting hole. The mounting ear 21 is fixed in the mounting groove 17 by a bolt installed in the bolt mounting hole. The mounting groove 17 can more quickly determine the assembly direction of the heat dissipation end cover 2 during assembly, ensuring more convenient assembly.

[0044] like Figure 3 and Figure 8 As shown, a metal heat dissipation plate 13 is also embedded in the stiffener 12. The inner end of the heat dissipation plate 13 extends to the stator assembly 7 and contacts the stator core 72. Therefore, the heat dissipation plate 13 embedded in the stiffener 12 can improve the overall strength of the wind shield. At the same time, the metal heat dissipation plate 13 can conduct heat away from the stator core 72, thereby further improving the heat dissipation of the motor.

[0045] The reinforced heat dissipation plate 13 is partially embedded in the rib plate 12, while the other part is exposed. This allows the airflow from the fan to carry away heat from the exposed reinforced heat dissipation plate 13, thus accelerating heat dissipation. Figure 8 As shown, the inner end of the enhanced heat dissipation plate 13 is provided with an extension section 131 extending along the axial direction of the plastic body. The extension section 131 is partially exposed outside the plastic body 141. Therefore, the length of the extension section 131 can increase the contact length with the stator core 72 inside the plastic body 141, increase the heat conduction area, and at the same time, the part exposed outside the plastic body can also enhance heat dissipation.

[0046] Compared with existing structures, the fan assembly of the present invention has at least the following advantages: 1. The fan shield assembly eliminates the need for a motor housing. The stator assembly 7 is integrally molded within the motor mounting hub 14 of the fan shield assembly 1, thus eliminating the need to first mold the fan shield assembly 1, assemble the motor (which requires an additional housing), and then perform assembly, making the overall assembly simpler; 2. The fan shield assembly can better utilize the airflow generated during fan rotation to dissipate heat from the heat dissipation end cover 2, improving the heat dissipation effect; 3. The external wiring harness of the fan shield assembly has good sealing at the connection point with the three-phase terminal block 41; 4. The fan shield assembly utilizes a reinforced heat dissipation plate 13 to better transfer heat from the stator core 72, further improving the heat dissipation effect. This fan shield assembly can be applied to passenger cars, commercial vehicles, off-road vehicles, digital centers, and energy storage equipment.

[0047] The above-described embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Any modifications and alterations made to the technical solutions of the present invention without departing from the spirit of the present invention shall fall within the protection scope defined by the claims of the present invention.

Claims

1. A one-piece plastic-coated fan guard assembly, the fan guard assembly comprising a guard body and a motor mounting hub located within the guard body, the motor mounting hub and the guard body being connected by a plurality of stiffening plates, characterized in that: The stator assembly is integrally molded within the motor mounting hub, and a rotor mounting cavity is provided at the center of the stator assembly. The rotor assembly is rotatably mounted on the motor mounting hub within the rotor mounting cavity. The front end of the rotor shaft of the rotor assembly passes through the motor mounting hub and is used to fix the fan impeller. A heat dissipation end cover is fixed on the motor mounting hub, and an external wiring harness electrically connected to the stator winding of the stator assembly is provided on the heat dissipation end cover.

2. The integrated plastic-coated fan guard assembly as described in claim 1, characterized in that: The motor mounting hub includes a cylindrical plastic body with a diameter larger than the outer edge of the plastic body. The stator assembly is encased and embedded in the plastic body. A central cylinder with a diameter smaller than the plastic body is provided on the front end face of the plastic body. A bearing for facilitating the rotation of the rotor shaft is embedded in the central cylinder. The rotor shaft extends through the central cylinder. A first mounting step for mounting a PCBA board is provided at the rear end of the plastic body. Several bolt support platforms for fixing the PCBA board are provided on the first mounting step. The three-phase windings of the stator assembly are connected one-to-one with three phase connection pieces embedded in the plastic body. The PCBA board is fixed to the bolt support platforms by bolts, and the phase connection pieces are welded to the PCBA board. A second mounting step is also provided at the rear end of the plastic body. The heat dissipation end cover is bolted to the second mounting step. The rear end of the rotor shaft is rotatably mounted on the heat dissipation end cover by bearings. A three-phase terminal block is also provided on the PCBA board. The three-phase terminal block is insulated through the heat dissipation end cover and is correspondingly connected to the external wiring harness.

3. The integrated plastic-coated fan guard assembly as described in claim 2, characterized in that: Several ventilation holes that run through the front and back are also provided on the outer edge.

4. The integrated plastic-coated fan guard assembly as described in claim 3, characterized in that: The rear end face of the outer edge is also provided with a flow guide baffle corresponding to the ventilation hole, which guides the airflow to the heat dissipation end cover.

5. The integrated plastic-coated fan guard assembly as described in claim 4, characterized in that: A reinforcing rib is provided between the front end face of the plastic body and the side surface of the central cylinder.

6. The integrated plastic-coated fan guard assembly as described in claim 5, characterized in that: The heat dissipation end cover is provided with a mounting ear, and the mounting ear is provided with a bolt mounting hole. The second mounting step is provided with a mounting groove to accommodate the bolt mounting hole. The mounting ear is fixed in the mounting groove by a bolt installed in the bolt mounting hole.

7. The integrated plastic-coated fan guard assembly as described in claim 2, characterized in that: The stiffener plate also contains a metal heat dissipation plate, the inner end of which extends to the stator assembly and contacts the stator core.

8. The integrated plastic-coated fan guard assembly as described in claim 7, characterized in that: The surface of the reinforced heat dissipation plate is partially embedded in the rib plate, while the other part is exposed.

9. The integrated plastic-coated fan guard assembly as described in claim 8, characterized in that: The inner end of the reinforced heat dissipation plate is provided with an extension section extending along the axial direction of the plastic body, and the extension section is partially exposed outside the plastic body.

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