3D Injection-Molded Impeller for Efficient Low-Noise Ventilators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing impellers for diagonal or radial fans with 2D geometry have low efficiency, low air flow rates, and high noise levels, while 3D-printed wheels with multiple parts are not economical to manufacture.
Innovation Solution
Designing an impeller with a three-dimensional geometry that can be manufactured as a single-piece injection-molded part, featuring a base plate, cover plate, and blades with angled trailing and leading edges, and a cover plate diameter that increases from the air inlet to the outlet, allowing for high efficiency, low noise, and easy demolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If 2D geometry impellers are used, then manufacturing is simple, but efficiency and air flow rate are low and noise levels are high
Solution Approach 1:
The patent transitions from 2D impeller geometry to 3D geometry by giving the impeller blades curved surfaces and angled trailing/leading edges that extend in the axial direction. This dimensional change enables complex aerodynamic profiles that improve efficiency and reduce noise while still being manufacturable through injection molding.
Solution Approach 2:
The impeller blades are designed with curved surfaces rather than flat planes. The trailing edges and leading edges are angled relative to the rotation axis, creating three-dimensional curved geometries that optimize airflow patterns and reduce turbulence, thereby improving efficiency and reducing noise.
2Loss of energy
If 3D-printed wheels with multiple parts are used, then aerodynamic performance improves, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple components (base plate, cover plate, and all blades) into a single integrated impeller structure that is manufactured as one piece through injection molding. This eliminates the need for separate manufacturing and assembly of multiple parts, reducing manufacturing cost while maintaining the aerodynamic benefits of 3D geometry.
Solution Approach 2:
The injection molding process is used to create a single component that performs multiple functions: the base plate provides structural support, the cover plate encloses the blades, and the blades themselves are integrated directly into the plates. This multi-functional design reduces part count and manufacturing complexity.
3Quantity of substance
If thin walls are used in injection molded impeller, then material usage decreases, but structural strength may be compromised
Solution Approach 1:
The patent specifies the use of fiber-reinforced thermoplastics for the injection molded impeller. The embedded fibers (such as glass, carbon, or aramid) provide structural reinforcement within the thin-walled plastic structure, enabling the impeller to maintain high strength while using minimal material. This composite approach allows thin walls without compromising structural integrity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The impeller has a base plate (7) and a cover plate (1) connected to each other by vanes (6). The cover plate (1), the base plate (7), and the vanes (6) are three-dimensionally shaped so that they can be manufactured together in one piece by injection molding. When projected onto a cylinder coaxial with the axis of rotation (13) and having a mean diameter of the trailing and leading edges (15, 17), respectively, the extensions of the trailing and/or leading edges (15, 17) of the vanes (6) form an angle with a line parallel to the axis of rotation (13), at least one of which is not equal to 0°. The injection mold has at least one mold insert located between two slides for manufacturing the base plate (7) with an interface.