Decoupled Fan Rotor Support for Low Z-Height Chassis
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Solution Overview
Problem
Current fan designs in electronic devices face challenges in reducing the Z-height while preventing chassis interference with the fan rotor, leading to increased air gap requirements that affect airflow and acoustics, and require thicker chassis for structural support, which increases weight and machining complexity.
Innovation Solution
A fan support system with a decoupled center shaft from the fan blade, using bearings for support and rotation, allowing for a thinner chassis and reduced air gap, and incorporating a rotor that acts as a center support extending from the top to the bottom cover with profiled tips for low friction and vibration dampening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the Z-height is reduced, then the overall system size is minimized, but the chassis may interfere with the fan rotor
Solution Approach 1:
A non-rotating center shaft is introduced as an intermediary component between the chassis and the rotating fan blades. The center shaft extends downward to support the rotating members while being decoupled from rotation, acting as a mediator that allows the chassis to be positioned closer to the fan without causing interference. This resolves the contradiction by enabling reduced Z-height while preventing chassis interference through the intermediary structure.
2Reliability
If a larger air gap is provided between the chassis and fan rotor, then chassis interference is prevented, but airflow performance deteriorates
Solution Approach 1:
The non-rotating center shaft serves as a mediator that allows the chassis to be positioned much closer to the fan rotor without causing interference. By supporting the rotating members through this decoupled shaft, the air gap can be minimized to less than 1mm, thereby maintaining optimal airflow performance while still preventing chassis interference through the protective intermediary structure.
3Strength
If the chassis is made thicker for structural support, then structural integrity is improved, but device weight and machining complexity increase
Solution Approach 1:
The center shaft acts as a structural intermediary that provides support for the fan assembly without requiring the chassis to be thickened. The shaft extends through the chassis and supports the rotating members, distributing mechanical loads through this dedicated support structure rather than relying on increased chassis thickness. This resolves the contradiction by maintaining structural integrity through the intermediary shaft while keeping the chassis thin, lightweight, and easy to machine.
4Reliability
If the center shaft is decoupled from fan blade rotation, then chassis interference is prevented, but the complexity of the fan support structure increases
Solution Approach 1:
The center shaft is designed as a simple non-rotating intermediary component that provides structural support while being decoupled from the rotating members through bearings. This straightforward mediator approach prevents chassis interference without introducing complex mechanisms, as the decoupling is achieved through standard bearing arrangements rather than complicated linkages or active control systems.
Solution Approach 2:
The rotational function is extracted from the center shaft and assigned to separate rotating members supported by bearings. The center shaft retains only the structural support function, while the rotation is handled by the bladeless rotating members. This separation of functions simplifies the overall design by allowing the center shaft to be a simple non-rotating support element rather than a complex rotating assembly.
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 design reduces the overall system Z-height and weight, minimizes air gap requirements, and maintains fan performance by preventing chassis interference with the fan rotor, enhancing thermal management and structural integrity.
Implementation Method 1
using bearings for support and rotation, allowing for a thinner chassis and reduced air gap, and incorporating a rotor that acts as a center support extending from the top to the bottom cover with profiled tips for low friction
Implementation Method 2
incorporating a rotor that acts as a center support extending from the top to the bottom cover with profiled tips for low friction and vibration dampening
Data Source
AI summary
Particular embodiments described herein provide for an electronic device that can be configured to include a fan where the fan blades are decoupled from the center shaft. The fan can include a center shaft, a motor coil support, motor coils coupled to the motor coil support, a rotator coupled to the center shaft, and fan blades coupled to the rotator, where rotation of the fan blades is decoupled from the center shaft by the rotator. A blade support can be coupled to the rotator, where the blade support couples the fan blades to the rotator and magnets can be coupled to the blade support. In an example, the rotator can include an inner, an outer race, and bearings.