One-Piece 3D Impeller Molding for Low-Noise Ventilation
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Solution Overview
Problem
Impellers with 2D geometry have low efficiency, high noise levels, and are costly to manufacture due to multiple parts, while 3D impellers are inefficient and noisy when constructed from multiple parts.
Innovation Solution
Designing an impeller with a three-dimensional geometry that integrates the base plate, cover plate, and vanes as a single-piece injection-molded part, featuring angled trailing and leading edges, and a cover plate diameter that increases from the air inlet to outlet, with rounded transitions to ensure high efficiency, low noise, and easy demolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If impellers with 2D geometry are used, then manufacturing is simple, but efficiency is low, air flow is low, and noise levels are high
Solution Approach 1:
The patent transitions from 2D impeller geometry to 3D impeller geometry by giving the blades thickness and creating a three-dimensional structure. This dimensional change enables the impeller to achieve higher efficiency and air flow performance while maintaining manufacturability through integral construction that eliminates the need for multiple parts and connections.
2Productivity
If impellers with 3D geometry are constructed from multiple parts, then aerodynamic performance improves, but manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The patent merges the hub and blades into a single integral structure that can be manufactured as one piece. This combining of parts maintains the beneficial 3D geometry for aerodynamic performance while eliminating the complexity of assembling multiple components, reducing manufacturing cost, and improving reliability by removing connection points.
3Loss of substance
If blades are designed with thin walls to save material, then material usage decreases, but structural strength decreases
Solution Approach 1:
The patent applies curvature and three-dimensional shaping to the blade structure, creating optimized aerodynamic surfaces that maintain structural integrity. The 3D geometry provides inherent structural strength through its form, allowing thin-walled construction without compromising strength, as the curved surfaces distribute stresses more effectively than flat or 2D structures.
Data Source
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AI summary
The impeller has a base plate (7) and a cover plate (1) connected to each other by vanes (6). The cover plate (1), the base plate (7), and the vanes (6) are three-dimensionally shaped so that they can be manufactured together in one piece by injection molding. When projected onto a cylinder coaxial with the axis of rotation (13) and having a mean diameter of the trailing and leading edges (15, 17), respectively, the extensions of the trailing and/or leading edges (15, 17) of the vanes (6) form an angle with a line parallel to the axis of rotation (13), at least one of which is not equal to 0°. The injection mold has at least one mold insert located between two slides for manufacturing the base plate (7) with an interface.