Fan Blade Device With Segmented Hubs And Interlocking Protrusions
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Solution Overview
Problem
Conventional fan blade devices face challenges in miniaturization and noise reduction due to increased blade density, which leads to manufacturing difficulties and separation issues during rotation, causing turbulence and noise.
Innovation Solution
A fan blade device design featuring an upper and lower hub member with obliquely arranged main and extension fan blades, interconnected via protrusions and engaging grooves, ensuring stable positioning and reduced airflow turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of fan blades is increased to improve heat dissipation efficiency, then the volume of air that can be moved increases, but the central hub must be made larger which is not conducive to miniaturization
Solution Approach 1:
The patent transitions from a single-plane blade arrangement to a three-dimensional stacked configuration with upper and lower blade layers. This dimensional change allows increased blade density and air moving capacity without proportionally increasing the horizontal footprint of the central hub, thereby improving heat dissipation efficiency while maintaining compact device dimensions.
Solution Approach 2:
The fan blade device is segmented into multiple independent layers (upper hub member with upper fan blades, lower hub member with lower fan blades). Each layer can be manufactured separately and then assembled, allowing for optimized blade distribution across vertical space without requiring a larger central hub structure.
2Productivity
If fan blades are arranged with overlapping projections to increase blade density, then the number of fan blades increases, but demolding during manufacturing becomes difficult
Solution Approach 1:
The fan blade device is divided into separate upper and lower hub members that can be manufactured independently using conventional molding techniques. This segmentation avoids the demolding difficulties associated with overlapping blade projections in a single integrated structure, as each layer can be molded separately with standard techniques.
Solution Approach 2:
Instead of increasing blade density within a single plane (which causes demolding issues), the patent distributes blades across multiple vertical layers. This dimensional approach achieves high blade density while maintaining manufacturability, as each layer can be produced using conventional single-plane molding methods.
3Ease of manufacture
If the fan blade device is configured in two-halves with projection and engaging groove for positioning, then demolding becomes easier, but the upper and lower hubs may separate during rotation causing turbulence and noise
Solution Approach 1:
The patent combines multiple connection mechanisms: the projection-engaging groove interface between upper and lower hub members, plus additional connection structures between corresponding fan blades of adjacent layers. This merging of connection methods at both hub and blade levels prevents separation during rotation, eliminating turbulence and noise while maintaining manufacturing ease.
Solution Approach 2:
The fan blades themselves serve as intermediary connection elements between the upper and lower hub members. The connection structures on corresponding fan blades act as mediators that reinforce the hub-to-hub connection, ensuring that the two-halves configuration remains stable during rotation without causing separation.
4Productivity
If more fan blades are arranged to move larger volume of air, then heat dissipation improves, but turbulence impinging on the fan frame generates excessive noise
Solution Approach 1:
The patent distributes fan blades across multiple vertical layers instead of concentrating them in a single plane. This dimensional distribution allows the device to move larger volumes of air through increased blade count while reducing localized turbulence intensity. The staggered arrangement across layers creates more gradual airflow patterns that impinge less violently on the fan frame, thereby reducing noise generation.
Data Source
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AI summary
A fan blade device includes a plurality of main fan blades (5) and extension fan blades (6). Each main fan blade (5) extends from an upper hub member (3) and includes a main fan blade body (51) arranged obliquely, a plurality of first protrusions (52), and at least one engaging groove (53). Each extension fan blade (6) extends from a lower hub member (4), and includes an extension fan blade body (61) arranged obliquely and having a top surface that is contiguously flush with a top surface of the main fan blade body (51) of a respective main fan blade (5), a plurality of second protrusions (62) respectively abutting against the first protrusions (52) of the respective main fan blade (5), and at least one engaging piece (63) engaging the at least one engaging groove (53) of the respective main fan blade (5).