Fan Frame and Fans Including the Fan Frame

Abstract

A fan frame is provided to solve the problem that the metal plate of the conventional fan frame is easily squeezed and deformed. The fan frame includes a metal plate and a rim. The metal plate includes at least one notch located on an edge of the metal plate. The rim is formed on the edge of the metal plate by injection molding. The rim includes at least one gap located corresponding to the at least one notch of the metal plate. The at least one gap divides the rim into a plurality of side wall parts. A vertical extent of the at least one gap does not overlap with the metal plate. Fans including the fan frame are also disclosed.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] The application claims the benefit of Taiwan application serial No. 112143052, filed on Nov. 8, 2023, and the entire contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION1. Field of the Invention

[0002] The present invention relates to a frame member and, more particularly, to a fan frame which can distribute the stress of injection molding to avoid deformation of a base of the fan.2. Description of the Related Art

[0003] A conventional cooling fan generally includes a rim formed on a metal base by injection molding. An impeller may be disposed in a space surrounded by the rim, and an upper lid may be coupled to an upper edge of the rim to accommodate the impeller.

[0004] However, a fan for cooling a system used in a narrow space must be thinned and lightweight, such that when the base or the upper lid is formed on the rim by injection molding, the thinned base or the thinned upper lid will be squeezed by the stress of injection molding of the rim. Particularly, the stress is apt to concentrate on a bent section of the rim, such that the base or the upper lid tends to be squeezed and deformed under uneven stress concentration. Thus, the surface of the base or the upper lid is not flat. Furthermore, the thinned fan restricts the disposition space for the impeller, such that the gap between the impeller and the base and the gap between the impeller and the upper lid are reduced. The rotating impeller will collide with the base or the upper lid if the surface of the base or the upper lid is not flat, resulting in noises or unbalanced operation of the fan. As a result, the service life of the conventional cooling fan is shortened, and the operating efficacy of the fan is reduced.

[0005] Thus, it is necessary to improve the fan frame of the conventional cooling fan.SUMMARY OF THE INVENTION

[0006] To solve the above problems, it is an objective of the present invention to provide a fan frame which can avoid the metal board from being squeezed and deformed.

[0007] It is another objective of the present invention to provide a fan which can avoid collision and reduce noise during operation.

[0008] It is a further objective of the present invention to provide a fan with improved operating efficacy.

[0009] As used herein, the term “a”, “an” or “one” for describing the number of the elements and members of the present invention is used for convenience, provides the general meaning of the scope of the present invention, and should be interpreted to include one or at least one. Furthermore, unless explicitly indicated otherwise, the concept of a single component also includes the case of plural components.

[0010] As used herein, the term “coupling”, “assembly”, “disposition”, or similar terms is used to include separation of connected members without destroying the members after connection or inseparable connection of the members after connection. A person having ordinary skill in the art would be able to select according to desired demands in the material or assembly of the members to be connected.

[0011] A fan frame according to the present invention includes a metal plate and a rim. The metal plate includes at least one notch located on an edge of the metal plate. The rim is formed on the edge of the metal plate by injection molding. The rim includes at least one gap located corresponding to the at least one notch of the metal plate. The at least one gap divides the rim into a plurality of side wall parts. A vertical extent of the at least one gap does not overlap with the metal plate.

[0012] In an aspect, a fan according to the present invention includes the above-mentioned fan frame, an impeller, and an upper lid. The metal plate is a base of the fan. The impeller is disposed in the fan frame and is rotatable about a rotating axis perpendicular to a plane of the metal plate. The upper lid is coupled to an end of the rim opposite to the metal plate.

[0013] In another aspect, a fan according to the present invention includes the above-mentioned fan frame, a base, and an impeller. The metal plate is an upper lid of the fan. The base is coupled to an end of the rim opposite to the metal plate. The impeller is disposed between the fan frame and the base. The impeller is rotatable about a rotating axis perpendicular to a plane of the base.

[0014] Therefore, in the fan frame and the fans including the fan frame according to the present invention, by forming the gap in the rim, the stress generated during formation of the rim on the metal plate can be distributed to avoid the metal plate from being squeezed and becoming deformed during the manufacturing process of the metal plate. This can avoid the impeller from colliding with the metal plate and can assure rotating balance of the impeller.

[0015] Therefore, the present invention can reduce damage rate of the fan, increase the operating efficacy of the fan, and reduce the operating noise of the fan.

[0016] In an example, the at least one notch is located on an arcuate portion of the edge of the metal plate. The at least one notch equally divides an arc of the arcuate portion. Thus, each notch can evenly distribute the stress acting on the arcuate edge, thereby avoiding stress concentration that may squeeze the metal plate.

[0017] In an example, the at least one gap divides the rim into a plurality of side wall parts separate from each other. Thus, each side wall part can be separately formed on the metal plate by injection molding, thereby avoiding stress concentration.

[0018] In an example, two distal ends respectively of two adjacent side wall parts are connected by a connecting wall. The connecting wall is located in a respective gap between the two adjacent side wall parts. Thus, two adjacent side wall parts can be aligned and connected to avoid misalignment during formation of the rim.

[0019] In an example, the connecting wall extends to a respective notch corresponding to the respective gap. The connecting wall abuts an edge of the respective notch. The connecting wall has a height flush with a thickness of the metal plate or higher than the thickness of the metal plate by a difference smaller than or equal to 0.5 mm. Therefore, the rim can abut the notch via the connecting wall and, thus, can be securely formed on the metal plate, thereby enabling secure coupling of the fan frame.

[0020] In an example, two distal ends respectively of two adjacent side wall parts are staggered to form L-shaped structures complementary to each other. A respective gap between the two distal ends is substantially Z-shaped. Thus, two adjacent side wall parts may be discontinuous, and the gap does not directly extend through the rim, thereby avoiding leakage of air currents.

[0021] In an example, the at least one gap has a width greater than or equal to 0.4 mm and smaller than or equal to 0.5 times a thickness of the rim. Thus, the gap of the minimum width can be formed by injection molding of the rim, and the gap of the maximum width can distribute the stress caused by the rim, thereby permitting easy manufacture and distribution of the stress.

[0022] In an example, air currents driven by the impeller flow along an inner wall of the rim in an advancing direction and a passage from an inner side of the rim through the at least one gap to an outer side of the rim is in a direction reverse to the advancing direction. Thus, leakage of air currents to the outside of the fan via the gap can be reduced, thereby enhancing the operational efficiency of the fan.

[0023] In an example, the upper lid includes at least one bent extension protruding from an edge of the upper lid in a direction parallel to the rotating axis of the impeller. The at least one bent extension is located corresponding to the at least one gap of the rim. Thus, the bent extension can cover the gap to reduce leakage of air currents.

[0024] In an example, the base includes at least one bent extension protruding from an edge of the base in a direction parallel to the rotating axis of the impeller. The at least one bent extension is located corresponding to the at least one gap of the rim. Thus, the bent extension can cover the gap to reduce leakage of air currents.

[0025] In an example, two distal ends respectively of two adjacent side wall parts do not overlap with each other in a radial direction perpendicular to the rotating axis of the impeller. The at least one gap forms a radial opening in the rim. The at least one bent extension is inserted into a respective gap to cover the radial opening. Thus, two adjacent side wall parts can be formed easily and form the gap, and the bent extension can be easily installed in the gap, thereby permitting easy manufacture and convenient installation.

[0026] In an example, each of the two distal ends respectively of two adjacent side wall parts forms a recess on an outer wall of the rim, such that the vertical extent of the respective gap is substantially T-shaped. The at least one bent extension is inserted into the recesses on the outer wall of the rim. Thus, the bent extension can cover the gap from the outer side of the rim, thereby permitting convenient installation and reducing air leakage.

[0027] In an example, each of the two distal ends respectively of two adjacent side wall parts forms a recess on an inner wall of the rim, such that the vertical extent of the respective gap is substantially T-shaped. The at least one bent extension is inserted into the recesses on the inner wall of the rim. Thus, the bent extension can cover the gap from the inner side of the rim, thereby permitting convenient installation and reducing air leakage.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention will become more fully understood from the detailed description given hereinafter and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:

[0029] FIG. 1 is an exploded, perspective view of a fan of a first embodiment according to the present invention.

[0030] FIG. 2 is an exploded, perspective view of a portion of the first embodiment according to the present invention.

[0031] FIG. 3 is a top view of a portion of the first embodiment according to the present invention after assembly.

[0032] FIG. 4 is an enlarged view of a circled portion A of FIG. 3.

[0033] FIG. 5 is a cross sectional view taken along section line 5-5 of FIG. 4.

[0034] FIG. 6 is a partial, enlarged view of a fan of a second embodiment according to the present invention.

[0035] FIG. 7 is a cross sectional view taken along section line 7-7 of FIG. 6.

[0036] FIG. 8 is a partial, enlarged view of another example of the fan of FIG. 6.

[0037] FIG. 9 is a partial, enlarged view of a further example of the fan of FIG. 6.

[0038] FIG. 10 is an exploded, perspective view of a fan of a third embodiment according to the present invention.

[0039] FIG. 11 is a perspective view of the fan of the third embodiment according to the present invention after assembly.

[0040] FIG. 12 is a cross sectional view taken along section line 12-12 of FIG. 11.

[0041] FIG. 13 is a cross sectional view of a portion similar to that shown in FIG. 12 of another example of the fan of the third embodiment according to the present invention.

[0042] FIG. 14 is an exploded, perspective view of a fan of a fourth embodiment according to the present invention.

[0043] FIG. 15 is a top, cross sectional view taken along section line 15-15 of FIG. 14.

[0044] FIG. 16 is an exploded, perspective view of a fan of a variation to the third embodiment according to the present invention.

[0045] When the terms “front”, “rear”, “left”, “right”, “up”, “down”, “top”, “bottom”, “inner”, “outer”, “side”, and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawings as it would appear to a person viewing the drawings and are utilized only to facilitate describing the invention, rather than restricting the invention.DETAILED DESCRIPTION OF THE INVENTION

[0046] With reference to FIG. 1, a fan frame of a first embodiment according to the present invention includes a metal plate 1 and a rim 2 formed on an edge of the metal plate 1. In this embodiment, the metal plate 1 is a base of a fan F. An upper lid 3 is coupled to another edge of the rim 2 opposite to the metal plate 1. An impeller 4 may be disposed in a receiving space S delimited by the metal plate 1, the rim 2, and the upper lid 3. Furthermore, a rotating axis of the impeller 4 is preferably perpendicular to a plane of the metal plate 1. An axial direction of the fan frame is perpendicular to the plane of the metal plate 1 and parallel to the rotating axis. The direction extending radially outward from the center of the metal plate 1 or the rotating axis is in the radial direction. Alternatively, as shown in FIG. 16, the metal plate 1 may be the upper lid of the fan F, and a base 5 is coupled to another end of the rim 2 opposite to the metal plate 1. An impeller 4 is disposed between the metal plate 1 and the base. The rotating axis of the impeller 4 is perpendicular to the plane of the base.

[0047] With reference to FIGS. 1 and 2, the edge of the metal plate 1 may be divided into a rectilinear portion 11 and an arcuate portion 12. In this embodiment, the metal plate 1 includes three rectilinear portions 11 delimiting a square area and an arcuate portion 12 delimiting a semi-circular area. Nevertheless, the present invention is not limited to the shape of the metal plate 1. Furthermore, the metal plate 1 includes at least one notch 13 which may be located on the rectilinear portion 11 or the arcuate portion 12.

[0048] Preferably, the at least one notch 13 is located on the arcuate portion 12 and equally divides the arc of the arcuate portion 12. For example, in this embodiment, a notch 13 is provided on the arcuate portion 12. The notch 13 is located on a middle point of the arcuate portion 12 to divide the arc of the arcuate portion 12 into two equal sections.

[0049] With reference to FIGS. 2 and 3, the rim 2 is located on the rectilinear sections 11 and the arcuate portion 12 of the metal plate 1. The rim 2 may be formed on the edge of the metal plate 1 by injection molding. The rim 2 includes at least one gap 21 located corresponding to the at least one notch 13 of the metal plate 1. The at least one gap 21 renders the rim 2 discontinuous and divides the rim 2 into a plurality of side wall parts 22 separate from each other, which can distribute the stress while forming the side wall parts 22 on the metal plate 1 by injection molding.

[0050] With reference to FIGS. 3-5, in this embodiment, two distal ends 22a respectively of two adjacent side wall parts 22 are staggered to form L-shaped structures complementary to each other. Furthermore, as shown in FIG. 4, the two L-shaped structures (which are inverted relative to each other) are spaced from each other by a gap 21. Due to staggering of the two adjacent distal ends 22a, the vertical extent of the gap 21 between the two distal ends 22a is substantially Z-shaped, which can reduce leakage of air currents of the fan. More specifically, in this and the following embodiments, the vertical extent of the gap 21 refers to the vertical projection of the gap 21 on the plane of the metal plate 1. Still referring to FIG. 5 showing an axial cross section of the gap 21 and the two distal ends 22a, the gap 21 is located corresponding to the notch 13 of the metal plate 1, such that the vertical extent of the gap 21 does not overlap with the metal plate 1. The gap 21 has a width W preferably greater than or equal to 0.4 mm and smaller than or equal to 0.5 times a thickness D1 of the rim 2. Therefore, the gap 21 can distribute the stress caused by the rim 2 and permits easy injection molding of the rim 2.

[0051] Furthermore, the impeller 4 is rotatable in the receiving space S to drive air currents to flow along an inner wall of the rim 2 in an advancing direction T. Then, a passage from the receiving space S through the gap 21 to an outer side of the rim 2 is preferably in a direction reverse to the advancing direction T, which can reduce leakage of air currents to the outer side of the fan F via the gap 21.

[0052] Please refer to FIGS. 3, 6 and 7 showing a second embodiment of the fan frame according to the present invention. This embodiment is substantially the same as the above-mentioned first embodiment. In this embodiment, two distal ends 22a respectively of two adjacent side wall parts 22 are connected by a connecting wall 23, such that the gap 21 does not render the rim 2 completely discontinuous. This avoids dislocation during formation of the rim 2. Namely, the gap 21 is in the form of a groove structure 21a on the rim 2. The connecting wall 23 is located in a respective gap 21 between the two adjacent side wall parts 22 and extends to a respective notch 13 corresponding to the respective gap 21. The connecting wall 23 has a height H flush with a thickness D2 of the metal plate 1 or higher than the thickness D2 of the metal plate 1 by a difference which is preferably smaller than or equal to 0.5 mm. This enables the connecting wall 23 to abut an edge of the respective notch 13, thereby securely coupling the rim 2 and the metal plate 1. Furthermore, the vertical extent of the gap 21 merely overlaps with the connecting wall 23 and does not overlap with the metal plate 1.

[0053] With reference to FIGS. 8 and 9 showing other examples of the gap 21. The gap 21 may be V-shaped, slant lines, etc. The extending direction of the gap 21 from the inner side to the outer side of the fan F is also reverse to the advancing direction T of the air currents.

[0054] Please refer to FIGS. 10 and 11 showing a third embodiment of the fan frame according to the present invention. This embodiment is substantially the same as the above-mentioned first embodiment. In this embodiment, the at least one gap 21 of the rim 2 renders the rim 2 discontinuous in both the axial direction and the radial direction, such that the distal ends 22a of the two side wall parts 22 respectively on two sides of the respective gap 21 do not overlap with each other in the radial direction. Furthermore, the upper lid 3 includes at least one bent extension 31 located corresponding to the at least one gap 21 of the rim 2. The at least one bent extension 31 protrudes from an edge of the upper lid 3 in a direction parallel to the rotating axis of the impeller 4, as shown in FIG. 11. When the upper lid 3 is coupled with the rim 2, the at least one bent extension 31 can cover the radial opening of the at least one gap 21 in the rim 2, which can reduce leakage of air currents to the outer side of the fan F via the gap 21. Alternatively, in the variation that the metal plate 1 serves as the upper lid of the fan F, the base 5 includes at least one bent extension 51 located corresponding to the at least one gap 21 of the rim 2. The at least one bent extension 51 protrudes from an edge of the base 5 in a direction parallel to the rotating axis of the impeller 4, as shown in FIG. 16. When the base 5 is coupled with the rim 2, the at least one bent extension 51 can cover the radial opening of the at least one gap 21 in the rim 2, which can reduce leakage of air currents to the outer side of the fan F via the gap 21.

[0055] With reference to FIGS. 11-13, each bent extension 31 is located in a vertical extent of a respective gap 21, such that the bent extension 31 can be inserted into the respective gap 21, as shown in FIG. 12. Each of the two distal ends 22a respectively of two adjacent side wall parts 22 forms a step-like recess 22b on an outer wall of the rim 2, such that the vertical extent of the respective gap 21 is substantially T-shaped, and the bent extension 31 is inserted into the recesses 22b on the outer wall of the rim 2. Furthermore, as shown in FIG. 13, each of the two distal ends 22a respectively of two adjacent side wall parts 22 may form a recess 22b on an inner wall of the rim 2, such that the vertical extent of the respective gap 21 is substantially inverted T-shaped, and the bent extension 31 is inserted into the recesses 22b on the inner wall of the rim 2. With each bent extension 31 inserted into and covering the respective gap 21, the installation is convenient, and air leakage is reduced.

[0056] Please refer to FIGS. 14 and 15 showing a fourth embodiment of the fan frame according to the present invention. This embodiment is substantially the same as the above-mentioned third embodiment. In this embodiment, two distal ends 22a respectively of two adjacent side wall parts 22 are connected by a connecting wall 23, such that the gap 21 does not render the rim 2 completely discontinuous. Namely, the gap 21 forms a groove structure 21a on the rim 2. The connecting wall 23 is located in a respective gap 21 between the two adjacent side wall parts 22 and extends to a respective notch 13 corresponding to the respective gap 21, such that the connecting wall 23 abuts an edge of the respective notch 13. Furthermore, the vertical extent of the gap 21 merely overlaps with the connecting wall 23 and does not overlap with the metal plate 1. Furthermore, the height H of the connecting wall 23 is the same as that of the second embodiment.

[0057] In summary, in the fan frame and the fans including the fan frame

[0058] according to the present invention, by forming the gap in the rim, the stress generated during formation of the rim on the metal plate can be distributed to avoid the metal plate from being squeezed and becoming deformed during the manufacturing process of the metal plate. This can avoid the impeller from colliding with the metal plate and can assure rotating balance of the impeller. Therefore, the present invention can reduce damage rate of the fan, increase the operating efficacy of the fan, and reduce the operating noise of the fan.

[0059] Although the present invention has been described with respect to the above preferred embodiments, these embodiments are not intended to restrict the present invention. Various changes and modifications on the above embodiments made by any person skilled in the art without departing from the spirit and scope of the present invention are still within the technical category protected by the present invention. Accordingly, the scope of the present invention shall include the literal meaning set forth in the appended claims and all changes which come within the range of equivalency of the claims. Furthermore, in a case that several of the above embodiments can be combined, the present invention includes the implementation of any combination.

Claims

1. A fan frame comprising:a metal plate including at least one notch located on an edge of the metal plate; anda rim formed on the edge of the metal plate by injection molding, wherein the rim includes at least one gap located corresponding to the at least one notch of the metal plate, wherein the at least one gap divides the rim into a plurality of side wall parts, and wherein a vertical extent of the at least one gap does not overlap with the metal plate.

2. The fan frame as claimed in claim 1, wherein the at least one notch is located on an arcuate portion of the edge of the metal plate, and wherein the at least one notch equally divides an arc of the arcuate portion.

3. The fan frame as claimed in claim 1, wherein the at least one gap divides the rim into a plurality of side wall parts separate from each other.

4. The fan frame as claimed in claim 1, wherein two distal ends respectively of two adjacent side wall parts are connected by a connecting wall, and wherein the connecting wall is located in a respective gap between the two adjacent side wall parts.

5. The fan frame as claimed in claim 4, wherein the connecting wall extends to a respective notch corresponding to the respective gap, wherein the connecting wall abuts an edge of the respective notch, wherein the connecting wall has a height flush with a thickness of the metal plate.

6. The fan frame as claimed in claim 4, wherein the connecting wall extends to a respective notch corresponding to the respective gap, wherein the connecting wall abuts an edge of the respective notch, wherein the connecting wall has a height higher than the thickness of the metal plate by a difference smaller than or equal to 0.5 mm.

7. The fan frame as claimed in claim 1, wherein two distal ends respectively of two adjacent side wall parts are staggered to form L-shaped structures complementary to each other, and wherein a respective gap between the two distal ends is substantially Z-shaped.

8. The fan frame as claimed in claim 1, wherein the at least one gap has a width greater than or equal to 0.4 mm and smaller than or equal to 0.5 times a thickness of the rim.

9. A fan comprising:the fan frame as claimed in claim 1, wherein the metal plate is a base of the fan;an impeller disposed in the fan frame, wherein the impeller is rotatable about a rotating axis perpendicular to a plane of the metal plate; andan upper lid coupled to an end of the rim opposite to the metal plate.

10. The fan as claimed in claim 9, wherein air currents driven by the impeller flow along an inner wall of the rim in an advancing direction and a passage from an inner side of the rim through the at least one gap to an outer side of the rim is in a direction reverse to the advancing direction.

11. The fan as claimed in claim 9, wherein the upper lid includes at least one bent extension protruding from an edge of the upper lid in a direction parallel to the rotating axis of the impeller, and wherein the at least one bent extension is located corresponding to the at least one gap of the rim.

12. The fan as claimed in claim 11, wherein two distal ends respectively of two adjacent side wall parts do not overlap with each other in a radial direction perpendicular to the rotating axis of the impeller, wherein the at least one gap forms a radial opening in the rim, and wherein the at least one bent extension is inserted into a respective gap to cover the radial opening.

13. The fan as claimed in claim 12, wherein each of the two distal ends respectively of two adjacent side wall parts forms a recess on an outer wall of the rim, such that the vertical extent of the respective gap is substantially T-shaped, and wherein the at least one bent extension is inserted into the recesses on the outer wall of the rim.

14. The fan as claimed in claim 12, wherein each of the two distal ends respectively of two adjacent side wall parts forms a recess on an inner wall of the rim, such that the vertical extent of the respective gap is substantially T-shaped, and wherein the at least one bent extension is inserted into the recesses on the inner wall of the rim.

15. A fan comprising:the fan frame claimed in claim 1, wherein the metal plate is an upper lid of the fan;a base coupled to an end of the rim opposite to the metal plate; andan impeller disposed between the fan frame and the base, wherein the impeller is rotatable about a rotating axis perpendicular to a plane of the base.

16. The fan as claimed in claim 15, wherein air currents driven by the impeller flow along an inner wall of the rim in an advancing direction and a passage from an inner side of the rim through the at least one gap to an outer side of the rim is in a direction reverse to the advancing direction.

17. The fan as claimed in claim 15, wherein the base includes at least one bent extension protruding from an edge of the base in a direction parallel to the rotating axis of the impeller, and wherein the at least one bent extension is located corresponding to the at least one gap of the rim.

18. The fan as claimed in claim 17, wherein two distal ends respectively of two adjacent side wall parts do not overlap with each other in a radial direction perpendicular to the rotating axis of the impeller, wherein the at least one gap forms a radial opening in the rim, and wherein the at least one bent extension is inserted into a respective gap to cover the radial opening.

19. The fan as claimed in claim 18, wherein each of the two distal ends respectively of two adjacent side wall parts forms a recess on an outer wall of the rim, such that the vertical extent of the respective gap is substantially T-shaped, and wherein the at least one bent extension is inserted into the recesses on the outer wall of the rim.

20. The fan as claimed in claim 18, wherein each of the two distal ends respectively of two adjacent side wall parts forms a recess on an inner wall of the rim, such that the vertical extent of the respective gap is substantially T-shaped, and wherein the at least one bent extension is inserted into the recesses on the inner wall of the rim.

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