Cooling Fan Impeller Ultrathin Blade Integration

Solution Overview

Problem

Conventional cooling fan impellers with plastic blades face challenges in reducing blade thickness while maintaining strength and securely connecting ultrathin blades to the hub, as direct welding or engagement often results in breakage.

Innovation Solution

The fan impeller structure incorporates an annular cover body integrally connected to the blades via injection molding or laser fusion, which is connected to the hub through a flange section with perforations and assembling sections, enhancing the fixing strength and preventing blade detachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If blade thickness is reduced to achieve ultrathin blades, then the cooling fan achieves more compact design and lower weight, but the blade strength decreases and becomes prone to breakage

Engineering Contradiction:

Improveblade thicknessVSAvoidblade strength

Core Design Contradiction:

Length of moving objectVSStrength

Solution Approach 1:

The patent employs composite material construction by integrating the blade with the hub through injection molding to form a unified structure. This composite approach allows the blade to achieve both ultrathin profile and sufficient strength, as the integrated design distributes mechanical loads more effectively across the blade-hub assembly compared to separate components.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The blade and hub are merged into a single integrated component through injection molding. This merging eliminates the need for separate connection elements and creates a unified structure that maintains structural integrity while allowing the blade to remain ultrathin. The integrated design ensures that the blade roots are properly supported without requiring additional reinforcement that would increase thickness.

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If blades are directly welded or engaged with the hub, then the connection process is simple, but the connected parts are apt to break due to stress concentration

Engineering Contradiction:

Improveconnection structure complexityVSAvoidconnection reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The blade and hub are merged into a single integrated component through injection molding. This merging eliminates the need for separate connection elements and creates a unified structure that maintains structural integrity while allowing the blade to remain ultrathin. The integrated design ensures that the blade roots are properly supported without requiring additional reinforcement that would increase thickness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection molding process acts as an intermediary that creates a gradual, stress-distributing transition between the blade and hub. Unlike direct welding or mechanical engagement that creates stress concentration points, the injection molded connection provides a smooth gradient that distributes mechanical stresses evenly, preventing crack initiation and propagation at the connection interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If blade thickness is increased to enhance strength, then the blade can better bear wind resistance, but the cooling fan size and weight increase

Engineering Contradiction:

Improveblade strengthVSAvoidblade thickness

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The patent employs composite material construction by integrating the blade with the hub through injection molding to form a unified structure. This composite approach allows the blade to achieve both ultrathin profile and sufficient strength, as the integrated design distributes mechanical loads more effectively across the blade-hub assembly compared to separate components.

Inventive Principle:

Principle #40Composite materials

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 allows for the production of ultrathin blades with increased strength and secure attachment to the hub, preventing breakage and improving the overall structural integrity of the cooling fan impeller.

Implementation Method 1

The annular cover body is integrally formed on the rear ends of the blades by injection molding to enclose and connect with the rear ends of the blades

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

Multiple fusion sections are formed between the rear ends of the blades and contact sections of one side of the annular cover body in adjacency to the insertion slits

Methodology Applied

Scientific EffectLaser fusion: Laser Beam Welding

Data Source

PatentUS10273971B2Fan impeller structure of cooling fan

Publication Date: 2019.04.30 ASIA VITAL COMPONENTS CO LTD

AI summary

A fan impeller structure of cooling fan includes a blade assembly and a hub. The blade assembly has multiple blades and an annular cover body. The annular cover body is integrally formed on the rear ends of the blades by injection molding to enclose and connect with the rear ends of the blades. Alternatively, the annular cover body is fused and integrally connected with the rear ends of the blades by means of laser welding. The blade assembly and the hub are integrally connected with each other to form the fan impeller structure.