Cooling Fan Circuit Board Positioning via Metal Seat Engagement
Solution Overview
Problem
Existing cooling fan designs face challenges in miniaturization, assembly complexity, structural strength, and insulation between the metal seat and circuit board, making it difficult to reduce height and ensure reliable assembly and insulation.
Innovation Solution
The cooling fan design incorporates a metal seat with an engaging portion and a circuit board featuring a positioning hole and insulation layer, allowing the stator-coil unit to be mounted after the circuit board is adhered to the metal seat, simplifying assembly and ensuring effective insulation through a film-based insulation layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the circuit board is coupled to the stator unit before mounting on the seat, then the assembly structure is stable, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent divides the assembly process into two independent stages: first mounting the circuit board to the seat, then mounting the stator unit to the circuit board. This segmentation allows each component to be assembled separately without requiring complex integration steps, thereby simplifying the overall assembly process while maintaining structural stability.
Solution Approach 2:
The circuit board is pre-mounted on the seat before the stator unit is assembled. This preliminary action establishes a stable base structure that simplifies subsequent assembly operations, as the stator unit only needs to be mounted on the already-positioned circuit board rather than coordinating multiple components simultaneously.
2Strength
If the first engaging portions and second engaging portions are used to connect the seat and stator unit, then the structural strength is improved, but the height of the cooling fan cannot be reduced
Solution Approach 1:
The patent transitions from a vertical stacking arrangement (where engaging portions extend in the height direction) to a horizontal arrangement (where engaging portions extend in the radial direction). This dimensional change allows the engaging portions to provide structural connection without increasing the height of the cooling fan, while still maintaining adequate structural strength through the engaging portion design.
3Weight of moving object
If the housing is made of plastic to reduce weight, then the weight is reduced, but the structural strength and quality deteriorate
Solution Approach 1:
The patent employs a composite structure where the seat is made of metal (providing strength) and the housing is made of plastic (providing weight reduction). This composite material approach allows different parts of the housing to have different material properties optimized for their specific functions: the seat requires high strength for structural support, while the housing can use lighter plastic material for weight reduction and insulation.
4Device complexity
If the circuit board is mounted on the metal seat directly, then the assembly process is simplified, but insulation between the circuit board and metal seat cannot be ensured
Solution Approach 1:
The patent introduces an insulation layer as an intermediary component between the metal seat and the circuit board. This insulation layer serves as a mediator that provides both mechanical support for mounting the circuit board and electrical insulation to prevent short circuits. The insulation layer is integrated into the assembly process, allowing the circuit board to be mounted on the metal seat while maintaining reliable insulation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the assembly process, enhances insulation between the metal seat and circuit board, reduces the cooling fan's height, and improves structural strength, resulting in a more convenient and efficient assembly method while maintaining performance.
Implementation Method 1
insulation between the circuit board and the metal seat is ensured
Implementation Method 2
the circuit board can be easily mounted on the metal seat
Data Source
AI summary
A cooling fan includes a fan frame, a circuit board, a stator-coil unit and an impeller. The fan frame includes a metal seat and a lateral wall. The metal seat includes an engaging face and an engaging portion arranged on the engaging face. The lateral wall is arranged on a periphery of the metal seat and includes an air inlet and an air outlet. The circuit board includes a positioning hole. The circuit board is press fit around the engaging portion of the metal seat via the positioning hole and adhered to the engaging face of the metal seat. The circuit board includes an insulation layer facing the metal seat. The stator-coil unit is mounted on the metal seat of the fan frame and electrically connected to the circuit board. The impeller is rotatably coupled with the stator-coil unit.