Adapter Device for Automotive Cooling Fan Motor Assembly
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Solution Overview
Problem
Existing cooling fan and motor assemblies in automotive systems face challenges in achieving a compact structure with reliability, low vibration, and noise while being cost-effective, as previous attachment methods like radial spring clips and molded-in-place metal hubs either fail due to fatigue or increase manufacturing complexity and cost.
Innovation Solution
A cooling fan module with an adapter device that includes a connection member for rotational fixation to the rotor and an attachment member for the fan hub, utilizing bearings to support the rotor for rotation, which reduces axial length and enhances stability, and can be manufactured from robust materials like metal or polymer plastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If radial spring clips are used to attach the fan to the motor shaft, then the assembly can be manufactured simply, but the spring clips fatigue and break over time causing fan separation
Solution Approach 1:
The patent replaces the reusable spring clip with a one-time use plastic deformed attachment member that is discarded after serving its purpose of securing the fan hub to the motor shaft during assembly and initial operation
Solution Approach 2:
The patent changes the material properties from metal spring clip (elastic) to plastic deformed attachment member (plastic deformation), altering the attachment mechanism from elastic recovery to permanent deformation for more reliable fixation
2Ease of manufacture
If radial spring clips are used to attach the fan, then assembly is simple, but the axial length of the assembly increases
Solution Approach 1:
The patent combines the attachment function and the structural support function into a single integrated plastic deformed attachment member that is formed as part of the fan hub, eliminating the need for separate spring clips and reducing axial length
3Ease of manufacture
If radial spring clips are used, then initial assembly is easy, but the fan rocks relative to the motor shaft during operation
Solution Approach 1:
The plastic deformed attachment member is designed as a disposable component that provides rigid fixation during its service life, preventing fan rocking by creating a permanent deformation lock rather than relying on flexible spring clips that can fatigue
Solution Approach 2:
The patent employs curved or rounded features in the plastic deformed attachment member that provide bearing surfaces to counteract rocking loads, distributing forces more effectively than the small diameter spring clips
4Reliability
If a molded-in-place metal hub with pin attachment is used, then fan connection is reliable, but manufacturing complexity and cost increase
Solution Approach 1:
The patent uses composite construction by molding a plastic deformed attachment member directly into the plastic fan hub, combining the advantages of plastic molding (cost-effective, complex shapes) with the strength requirements for reliable attachment, eliminating the need for separate metal hubs
Solution Approach 2:
The patent merges the attachment member and fan hub into a single molded plastic component, eliminating the need for separate metal hubs and pin insertion steps, thereby reducing manufacturing complexity while maintaining reliability through plastic deformation attachment
Data Source
AI summary
The present invention provides an adapter device for attaching a cooling fan to a motor in a cooling fan module for an automotive cooling system. The device includes a connection member for rotationally fixed connection with a rotor of the motor. The rotor is surrounded by a stator comprising windings or coils arranged annularly about the rotor. The connection member is separate from the rotor and is configured for insertion into a central aperture or opening of the rotor for connection thereto via an outer surface of the connection member. An attachment member is provided at an end region of the connection member for attachment of a cooling fan thereto. The adapter device is configured to accommodate at least one bearing which supports the rotor for rotation about a rotational axis.