Fan Impeller with Modular Plastic Blades and Metal Base
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Solution Overview
Problem
Conventional fan impeller manufacturing methods limit blade design variability and universality, and are costly due to complex and expensive mold designs for plastic injection molding, and restricted shape options in metal connection methods.
Innovation Solution
A fan impeller structure comprising a metal base seat, plastic blades, and a metal ring member connected via metal fixing members, allowing for diversified blade designs and reduced manufacturing costs through plastic injection molding and sheet metal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If plastic injection molding is used to manufacture blades, then manufacturing precision and blade shape diversity are improved, but mold design complexity and cost increase
Solution Approach 1:
The blade assembly is segmented into modular components: a standardized metal base seat, interchangeable plastic blade bodies, and metal fixing members. This segmentation allows the blade body to be manufactured separately via plastic injection molding with high precision, while the standardized base seat and fixing members maintain simplicity. The modular design enables different blade bodies to be attached to the same base seat, reducing mold complexity by reusing the same base seat and fixing member components across multiple blade variations.
2Adaptability or versatility
If metal connection method is used to manufacture blades, then blade universality and ease of assembly are improved, but blade shape diversity is limited
Solution Approach 1:
The blade assembly employs composite construction by combining metal components (base seat and fixing members) with plastic blade bodies. The metal base seat provides structural strength, universality, and ease of assembly through standardized connection interfaces. The plastic blade bodies enable diverse aerodynamic shapes and configurations. This composite approach allows different shaped plastic blade bodies to be mounted on the same universal metal base seat, achieving both blade shape diversity and assembly universality simultaneously.
3Ease of manufacture
If conventional manufacturing methods are used, then manufacturing process simplicity is maintained, but manufacturing cost increases
Solution Approach 1:
The design implements universality through standardized components: the metal base seat serves as a universal mounting platform for different blade configurations, and the fixing members provide standardized attachment mechanisms. This universality allows a single base seat and fixing member set to support multiple blade body variations, reducing the need for multiple specialized molds and tooling sets. Consequently, manufacturing cost decreases while maintaining process simplicity, as the same base components can be produced in large quantities and reused across different blade designs.
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
Enables diverse blade designs and increased universality while significantly lowering manufacturing costs by using metal and plastic materials in conjunction with sheet metal processing and plastic injection molding.
Implementation Method 1
molding multiple blades by means of plastic injection molding
Implementation Method 2
at least one fixing member made of metal material
Data Source
AI summary
A fan impeller structure and a manufacturing method thereof. The fan impeller structure includes a base seat, multiple blades and a ring member. Each blade has a main body made of plastic material and at least one fixing member made of metal material. The base seat and the ring member are made of metal material. The base seat and the ring member are respectively disposed on two sides of the blades. By means of the manufacturing method, the blades can be diversified and the universality of the blades is greatly increased to lower the manufacturing cost.