Multi-Layer Fan Base With PCB Core for Low-Weight Stiffness
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Solution Overview
Problem
Existing fan assemblies in electronic devices are heavy due to their all-metal construction, leading to potential deflection and unwanted rubbing noise, and require multiple flexible circuits for electrical connections, which increases complexity and weight.
Innovation Solution
A fan base with multiple layers, including metal layers for stiffness and a core layer for reduced weight, optionally a PCB for electrical routing, and separate formation of cover and sidewall to minimize rubbing noise and reduce overall weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an all-metal construction is used for the fan base, then structural strength and stiffness are improved, but weight increases and deflection occurs
Solution Approach 1:
The fan base is constructed as a composite structure with a metal layer (providing strength and stiffness) and a plastic core layer (providing weight reduction). This composite construction allows the fan base to maintain structural integrity while significantly reducing overall weight compared to traditional all-metal designs.
2Stability of the object's composition
If an all-metal construction is used for the fan base, then structural stiffness is improved, but deflection and rubbing noise increase
Solution Approach 1:
The composite structure with plastic core layer provides sufficient stiffness to prevent deflection while the material composition eliminates rubbing noise by preventing direct metal-to-metal contact.
3Reliability
If multiple flexible circuits are used for electrical connections, then electrical connectivity is improved, but device complexity and weight increase
Solution Approach 1:
The PCB is integrated directly into the fan base structure, merging the electrical connection function with the structural component. This eliminates the need for separate flexible circuits and reduces overall device complexity while maintaining reliable electrical connectivity.
Data Source
AI summary
A fan assembly includes a base with multiple layers with at least one layer formed from a relatively lightweight material to reduce the overall weight of the fan assembly. The base may include multiple metal layers and one or more core layers positioned between the metal layers. At least one of the core layers may include a PCB used to route electrical signals between components of the fan assembly and/or between components of an electronic device in which the fan assembly is positioned. Alternatively, at least one of the core layers may include a lightweight material (e.g., plastic) with a channel used to receive a flexible circuit. The base, having layers of different materials, may be lighter in weight as compared to a base consisting of a metal layer (or metal layers), while also substantially retaining flexural stiffness to counter against applied forces to the base.