Fan Frame Lead Pin Structure for Automated Low-Noise Connection

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Solution Overview

Problem

The conventional manual soldering process for connecting the circuit board of a fan to an external lead set is labor-intensive, costly, and prone to poor connections, leading to unstable power supply and signal transmission, while existing automated solutions cause wind resistance and noise due to the integration of lead pins in static blades, affecting fan performance.

Innovation Solution

The fan frame electrical connection structure integrates lead pins into an enclosure static blade via injection molding, allowing for automated assembly and connection without soldering, and modifies the static blade configuration to maintain fan performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual soldering is used to connect the external lead set to the circuit board, then reliable electrical connection can be achieved, but manufacturing time and labor cost increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the manual soldering process (thermal/mechanical system) with an automated pressing mechanism. The pressing mechanism applies mechanical force to create electrical connections between the lead pins and circuit board contact points, eliminating the need for manual soldering operations while maintaining connection reliability and enabling automated mass production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If the external lead set is overheated during soldering, then the insulation skin softens or burns out, but this causes poor contact or fake soldering

Engineering Contradiction:

Improvesoldering connection qualityVSAvoidinsulation skin damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates thermal damage to the insulation skin by replacing the soldering process with a mechanical pressing system. The pressing mechanism creates electrical connections through applied force rather than heat, thereby preventing the insulation skin from softening or burning out while still achieving reliable electrical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Extent of automation

If a support structure is added to enable automated connection, then automated assembly is achieved, but wind resistance and noise increase

Engineering Contradiction:

Improveassembly automationVSAvoidwind resistance and noise

Core Design Contradiction:

Extent of automationVSObject-generated harmful factors

Solution Approach 1:

The patent merges the electrical connection function with the existing static blade structure. The lead pins are integrated into the static blade, eliminating the need for separate support structures. This integration allows automated assembly while minimizing additional wind resistance and noise, as the connection components become part of the aerodynamic flow path rather than separate obstacles.

Inventive Principle:

Principle #5Merging (Combining)

4Extent of automation

If the static blade is thickened to enclose the lead pin set, then automated connection is enabled, but fan performance deteriorates

Engineering Contradiction:

Improveconnection automationVSAvoidfan performance

Core Design Contradiction:

Extent of automationVSPower

Solution Approach 1:

The patent applies local quality by making the static blade thickened only in specific regions where the lead pin sets are located, rather than uniformly thickening the entire blade. This localized thickening provides the necessary structural support for automated connection while minimizing the impact on the overall aerodynamic performance and air volume output of the fan.

Inventive Principle:

Principle #3Local quality

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 automates the assembly process, reduces costs, and maintains fan performance by eliminating soldering errors and wind resistance, while ensuring stable power and signal transmission.

Implementation Method 1

a lead pin set (1) is integrally enclosed in an enclosure static blade (24) by injection molding

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

when the fan impeller creates airflow

Methodology Applied

Scientific EffectAirflow generation:

Implementation Method 3

the static blade front edge (241) has a front edge arc (241A), and the static blade rear edge (242) has a rear edge arc (242A)

Methodology Applied

Scientific EffectFlow guidance:

Data Source

PatentUS12612919B2Fan frame electrical connection structure

Publication Date: 2026.04.28 ASIA VITAL COMPONENTS (CHINA) CO LTD

AI summary

A fan frame electrical connection structure includes a frame body. The frame body has a wind incoming side and a wind outgoing side. A bearing cup seat is disposed at the wind outgoing side. Multiple static blades and an enclosure static blade are integrally formed between the bearing cup seat and the frame body. A lead pin set is integrally enclosed in the enclosure static blade. The enclosure static blade has a static blade front edge and a static blade rear edge. The static blade front edge is directed to the wind incoming side and has a front edge arc. The static blade rear edge is directed to the wind outgoing side and having a rear edge arc. Accordingly, the assembling and manufacturing process of the fan can be automated and speeded and the fan can keep having its original property.