Fan Frame Rim Segmentation for Injection Molding Stress Relief
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Solution Overview
Problem
Conventional cooling fans face deformation and noise issues due to stress concentration during injection molding, leading to uneven surfaces and reduced service life.
Innovation Solution
A fan frame design featuring a metal plate with notches and a rim with gaps, which distributes stress during injection molding, preventing deformation and ensuring even surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the base or upper lid is thinned to reduce fan weight and size, then the fan becomes lightweight and compact, but the base or upper lid is squeezed and deformed by injection molding stress
Solution Approach 1:
The rim is divided into multiple side wall parts by introducing gaps, which segment the injection molding stress into separate zones. This prevents stress concentration at any single location, thereby avoiding deformation of the thinned base or upper lid while maintaining the lightweight design
2Weight of moving object
If the base or upper lid is thinned to reduce fan weight, then the fan becomes lightweight, but the gap between the impeller and base/lid is reduced causing collision and noise
Solution Approach 1:
By segmenting the rim into side wall parts with gaps, the base or upper lid maintains its thinned lightweight structure while the stress distribution prevents deformation. This ensures sufficient clearance between the impeller and base/lid, avoiding collision and noise during operation
3Ease of manufacture
If the rim is formed by injection molding on a thinned base, then the fan structure is integrated, but stress concentrates on bent sections causing deformation
Solution Approach 1:
The rim is segmented into multiple side wall parts separated by gaps, which distributes the injection molding stress across multiple locations rather than concentrating it. This allows the integrated structure to be manufactured while preventing stress-induced deformation of the thinned base
Solution Approach 2:
Gaps are strategically positioned at bent sections of the rim where stress concentration is most likely to occur. This local modification provides stress relief precisely where needed, maintaining surface flatness in critical areas while preserving the integrated structure
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 design reduces the risk of impeller collision, enhances rotating balance, decreases noise, and extends the service life of the fan while improving its operating efficacy.
Implementation Method 1
the stress generated during formation of the rim on the metal plate can be distributed to avoid the metal plate from being squeezed and becoming deformed
Data Source
AI summary
A fan frame is provided to solve the problem that the metal plate of the conventional fan frame is easily squeezed and deformed. The fan frame includes a metal plate and a rim. The metal plate includes at least one notch located on an edge of the metal plate. The rim is formed on the edge of the metal plate by injection molding. The rim includes at least one gap located corresponding to the at least one notch of the metal plate. The at least one gap divides the rim into a plurality of side wall parts. A vertical extent of the at least one gap does not overlap with the metal plate. Fans including the fan frame are also disclosed.