Iron-Containing Fan Bushing Structure for Injection Molding
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Solution Overview
Problem
Conventional fan bushing structures with metal bushings made of brass have high material and manufacturing costs, limited design flexibility, and are prone to deformation during injection molding, leading to tolerance issues in assembly.
Innovation Solution
A bushing structure made of an iron-containing material with a cylindrical body and extension portion, integrated as a single piece, using pressing and deep drawing processes, which provides enhanced bonding with a plastic fan frame and reduces costs while maintaining rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal bushing made of brass is used to improve rigidity, then the rigidity of the bushing structure is improved, but the material cost and manufacturing cost increase
Solution Approach 1:
The invention changes the material parameter from brass to iron-containing material, which maintains the required rigidity while significantly reducing material cost and manufacturing complexity. The iron-containing material can be formed through simpler pressing and deep drawing processes compared to brass turning.
Solution Approach 2:
The invention uses a composite structure where an iron-containing material bushing is integrated with a plastic fan frame through injection molding. This composite approach combines the rigidity benefits of metal with the cost advantages of plastic, achieving a balance between performance and manufacturing cost.
2Strength
If a metal bushing made of brass is used to improve rigidity, then the rigidity of the bushing structure is improved, but the manufacturing time increases
Solution Approach 1:
The invention merges the bushing and fan frame into a single integrated component through injection molding. The iron-containing material bushing is formed and integrated with the plastic fan frame in one manufacturing process, eliminating separate assembly steps and reducing total manufacturing time.
Solution Approach 2:
The invention changes the manufacturing process parameter from brass turning to pressing and deep drawing for iron-containing material, which are faster processes that reduce manufacturing time while maintaining the required rigidity.
3Ease of manufacture
If a simple design of metal bushing is used to control cost, then the manufacturing cost is reduced, but the design flexibility is limited
Solution Approach 1:
The composite structure of iron-containing material bushing integrated with plastic fan frame provides design flexibility. The bushing can be designed with various features such as positioning protrusions, recesses, and mounting structures that would be difficult or expensive to achieve with simple brass turning processes.
Solution Approach 2:
Changing to iron-containing material allows for more complex geometries and design features to be achieved through pressing and deep drawing processes, providing greater design flexibility while controlling manufacturing cost.
4Strength
If a brass metal bushing is used to improve rigidity, then the rigidity is improved, but deformation occurs during injection molding causing tolerance issues
Solution Approach 1:
The iron-containing material bushing is integrated with the plastic fan frame through injection molding in a way that the bushing serves as a mold insert. This integration method provides better dimensional stability and control during the injection molding process, reducing deformation and ensuring tighter assembly tolerances.
Solution Approach 2:
The change to iron-containing material provides better dimensional stability during injection molding compared to brass, reducing deformation and ensuring tighter assembly tolerances in the final product.
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 iron-containing bushing structure offers lower costs, increased rigidity, and improved assembly accuracy, minimizing deformation and waste, while allowing for more complex designs and environmental sustainability.
Implementation Method 1
The bushing structure is disposed on the fan frame, and the fan frame is connected to the bushing structure by injection molding
Data Source
AI summary
A bushing structure cooperating with a shaft is disclosed. The bushing structure includes a cylindrical body and an extension portion. The cylindrical body has a shaft hole and the shaft is disposed in the shaft hole. The extension portion is disposed at one end of the cylindrical body and surrounds the cylindrical body. The cylindrical body and the extension portion are made of an iron-contained material.