Monolithic Fan Assembly With 3D-Printed Stator Housing
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Solution Overview
Problem
Traditional in-line fan assemblies require specialized manufacturing equipment and materials, limiting design flexibility and increasing production costs due to the need for welding and the use of hot-rolled steel, making it difficult to use higher strength materials like stainless steel.
Innovation Solution
The fan assembly features an integrated internal housing with stator blades and a monolithic design produced through 3D printing, using materials such as galvanized steel and copolymers for the external and internal housings, respectively, to reduce welding and enhance spark resistance, along with a fan wheel produced as a single component without welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cylindrical fan housing is constructed using hot-rolled steel with welding, then structural strength is achieved, but manufacturing complexity and cost increase due to specialized equipment and multiple welding operations
Solution Approach 1:
The patent combines the internal housing, stator blades, and motor mounting structure into a single monolithic component produced by 3D printing. This merging eliminates the need for separate welding operations and specialized manufacturing equipment, reducing manufacturing complexity while maintaining structural integrity through the additive manufacturing process
Solution Approach 2:
The patent replaces traditional mechanical welding processes with additive manufacturing (3D printing) technology. This substitution eliminates the need for welders, seam welding equipment, and associated post-weld treatments, significantly reducing manufacturing complexity and equipment requirements while producing an integrated housing structure with equivalent or superior strength
2Strength
If traditional cylindrical fan housing is constructed using hot-rolled steel with welding, then structural strength is achieved, but production cost increases due to specialized equipment and significant welding amounts
Solution Approach 1:
The patent combines the internal housing, stator blades, and motor mounting structure into a single monolithic component produced by 3D printing. This merging eliminates the need for separate welding operations and specialized manufacturing equipment, reducing manufacturing complexity while maintaining structural integrity through the additive manufacturing process
Solution Approach 2:
The patent replaces traditional mechanical welding processes with additive manufacturing (3D printing) technology. This substitution eliminates the need for welders, seam welding equipment, and associated post-weld treatments, significantly reducing manufacturing complexity and equipment requirements while producing an integrated housing structure with equivalent or superior strength
3Strength
If traditional cylindrical fan housing is constructed using hot-rolled steel, then structural strength is achieved, but material versatility is limited requiring paint for corrosion protection
Solution Approach 1:
The patent utilizes composite or advanced material capabilities of 3D printing to produce the housing from materials that inherently resist corrosion without requiring paint coatings. The additive manufacturing process enables use of materials such as stainless steel alloys, aluminum alloys, or polymer composites that provide both structural strength and corrosion resistance, expanding material versatility beyond traditional hot-rolled steel
4Strength
If higher strength materials like stainless steel are used, then structural strength is improved, but manufacturing difficulty increases due to difficulty of forming tubes and curved shapes
Solution Approach 1:
The patent replaces traditional mechanical welding processes with additive manufacturing (3D printing) technology. This substitution eliminates the need for welders, seam welding equipment, and associated post-weld treatments, significantly reducing manufacturing complexity and equipment requirements while producing an integrated housing structure with equivalent or superior strength
Solution Approach 2:
The patent changes the manufacturing approach from subtractive or formative processes (which are difficult with high-strength materials) to additive manufacturing. This parameter change in the manufacturing process enables easy formation of complex curved shapes and tubular structures from high-strength materials like stainless steel, eliminating the traditional manufacturing difficulties
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 reduces manufacturing complexity, lowers costs, and improves airflow efficiency by up to 8%, while allowing the use of spark-resistant materials suitable for hazardous environments.
Implementation Method 1
stator blades having an air-foil shape
Implementation Method 2
a fan wheel including fan blades extending from the hub to an inner surface of a wheel cone
Data Source
AI summary
A fan assembly includes an internal housing having an outer internal housing, and an inner internal housing partially disposed within the outer internal housing. The inner internal housing defines an internal cavity, and has a curved exterior surface. Stator blades extend between the inner internal housing and the outer internal housing.