Extruded Polystyrene Ceiling Fan Blades
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Solution Overview
Problem
Traditional ceiling fan blades made from wood and molded plastics like ABS and PVC face issues such as warping, instability under heat and UV exposure, high power consumption, moisture absorption, mold and mildew resistance, and increased costs due to material expenses and labor for color changes.
Innovation Solution
The development of polystyrene extruded ceiling fan blades that are lighter, more cost-effective, resistant to warping and moisture, and can be produced with dual colors without additional painting or staining, using a method involving two extruders to combine different colored polystyrene pellets and post-processing techniques to shape and finish the blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional solid wood or molded plastic (ABS/PVC) blades are used, then structural strength is improved, but weight increases leading to higher power consumption
Solution Approach 1:
The patent uses composite materials by combining polystyrene base material with wood flour or other fillers to create blades that have both reduced weight and maintained structural strength. This composite approach allows the blades to be lighter than solid wood or ABS while retaining necessary mechanical properties through the synergistic combination of materials.
2Ease of manufacture
If traditional wood or ABS/PVC materials are used, then initial manufacturing cost may be lower, but long-term cost increases due to warping, fading, and replacement needs
Solution Approach 1:
The patent changes the material parameters by using polystyrene with specific properties including UV stabilizers and moisture resistance. This material selection fundamentally alters how the blades respond to environmental factors, providing stability under heat and UV exposure while maintaining cost-effectiveness through the extrusion manufacturing process.
3Weight of moving object
If light weight materials like balsa wood or thin plastic are used, then power consumption is reduced, but structural integrity deteriorates causing wobbling and breaking
Solution Approach 1:
The composite formulation using polystyrene with wood flour or other reinforcing fillers creates a material that achieves the optimal balance between light weight and structural integrity. The composite structure provides the necessary strength to prevent wobbling and breaking while maintaining reduced weight for lower power consumption.
4Adaptability or versatility
If traditional wood blades are used, then natural aesthetic is achieved, but additional labor and materials are needed for staining and coating to prevent moisture absorption
Solution Approach 1:
The patent incorporates colorants and wood grain effects directly into the polystyrene material during the extrusion process. This allows the blades to achieve various aesthetic appearances including wood grain patterns and different colors without requiring separate staining or coating operations, thereby simplifying the manufacturing process while maintaining aesthetic versatility.
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
The polystyrene extruded blades offer improved stability, reduced power consumption, and cost savings by allowing the use of smaller motors, while maintaining durability and aesthetic versatility without the need for separate color coatings.
Implementation Method 1
combining a first part feeding out of the first extruder with a second part feeding out of the second extruder into a dye
Implementation Method 2
combining a first part feeding out of the first extruder with a second part feeding out of the second extruder into a dye
Data Source
AI summary
Novel extruded ceiling fan blades, compositions and methods of making the blades from plastic material such as polystyrene are disclosed. The blades can be formed from two extruders so that different colors and/or finishes, such as wood grain looks can be formed on the upper and lower surfaces of the blades.