Circular Fan Blade Structure for Low-Noise, Burr-Free Molding
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Solution Overview
Problem
Existing fan blades with circular designs face high production complexity and cost due to complex mold structures, leading to burrs and degraded aerodynamic performance.
Innovation Solution
The fan blade design features a first segment part with non-overlapping first inner and outer annular surfaces, allowing for molding with two molds, reducing complexity and cost while minimizing burrs, and incorporating additional segment parts for airflow guidance and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a circular blade design is used to lower noise, then noise reduction is achieved, but the mold structure becomes complex and production cost increases
Solution Approach 1:
The blade is divided into multiple segments (first segment part, second segment part, third segment part) with distinct functions. The first segment part handles noise reduction through its hollow structure, while the second and third segment parts handle airflow guidance. This segmentation allows each part to be optimized independently, simplifying the overall mold structure while maintaining noise reduction performance.
Solution Approach 2:
The hollow area enclosed by the first segment part acts as an intermediary structure that reduces noise without requiring complex external mold components. The hollow structure absorbs and dampens noise internally, eliminating the need for complex noise-canceling mold features.
2Object-affected harmful factors
If a circular blade design is used to lower noise, then noise reduction is achieved, but production cost increases due to complex molds
Solution Approach 1:
By segmenting the blade into functional sections, each with simple geometric features, the mold design becomes straightforward. The first segment part with its hollow structure can be molded using standard techniques, and the second and third segment parts can be added through simpler secondary processes, significantly reducing overall production cost.
Solution Approach 2:
Different segments of the blade are given different local qualities and functions. The first segment part has a hollow structure for noise reduction, while the second and third segment parts have streamlined shapes for airflow guidance. This localized optimization allows each part to be manufactured efficiently with appropriate mold complexity only where needed.
3Object-affected harmful factors
If complex mold structures are used to produce circular blades, then noise reduction is achieved, but burrs are formed and aerodynamic performance degrades
Solution Approach 1:
The blade is segmented into parts that can be molded separately with simpler molds, eliminating the need for complex multi-component molds that create burrs. The first segment part with the hollow structure and the second and third segment parts can each be molded with straightforward mold designs, ensuring clean surfaces without burr formation.
Solution Approach 2:
Instead of using a complex single-piece mold to create the entire circular blade, the invention inverts the approach by using multiple simpler molds to create segmented parts that are then assembled. This inversion of the molding strategy eliminates burrs while maintaining the noise-reducing circular blade functionality.
Data Source
AI summary
A fan blade includes a hub and a blade connected to a circumferential side face of the hub. The blade presents a circular shape, the inner annular surface of the blade encloses a hollow area. In the radial direction of the hub, an end of the blade connected to the hub is the root part of the blade. In a direction from the end part to the root part, at least a portion of the area of the blade is a first segment part that includes a first inner annular surface and a first outer annular surface. In the axial direction of the hub, the first inner annular surface and the first outer annular surface turn direction at the end part, and the first inner annular surface and the first outer annular surface on both sides of the end part do not overlap.