Thin Fan Housing Integrating Circuit Layout to Reduce Height
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fans face challenges in miniaturization due to the need for a circuit board and additional wiring, which limits their thin design and poses safety risks from rotating blades hitting wires, while maintaining effective heat dissipation.
Innovation Solution
A thin fan design utilizing a plastic housing with metal particles, where a layout area and extended circuit are formed on the housing, eliminating the need for internal wiring by exposing metal particles and using a metal layer for electrical connections, thereby reducing height and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional circuit board with electronic components is used, then the fan can be controlled, but the height and space of the fan increase
Solution Approach 1:
The control circuit is merged with the housing by integrating the circuit board directly into the housing structure. The housing serves dual functions as both the protective enclosure and the mounting platform for electronic components, eliminating the need for separate circuit board space and reducing overall fan height.
Solution Approach 2:
The housing is designed to perform multiple functions: it provides structural protection, serves as the mounting surface for the circuit board and electronic components, and acts as part of the control system integration platform. This multi-functionality reduces the need for additional components and space.
2Ease of operation
If additional wire is configured inside the housing for motor excitation control, then the motor control function is achieved, but safety risk increases due to rotating blades hitting the wire
Solution Approach 1:
The wire is extracted from the internal housing space and routed externally along the periphery of the housing. This removes the wire from the dangerous zone where rotating blades could strike it, eliminating the safety hazard while maintaining the motor control function.
Solution Approach 2:
The wire is positioned as an intermediary element that connects the external control source to the motor through the housing periphery, serving as a safe transmission path for electrical signals without being exposed to the rotating blade environment.
3Ease of manufacture
If electronic components are disposed on one surface of the circuit board, then the assembly is simplified, but the fan height increases to accommodate the circuit board and components
Solution Approach 1:
The circuit board is merged with the housing structure, where the housing surface serves as the mounting platform for electronic components. This integration eliminates the need for a separate, height-consuming circuit board assembly while maintaining manufacturing simplicity.
4Length of stationary object
If the fan is designed to be thinner, then the space utilization is improved, but the design is limited by the airflow channel and mechanism requirements
Solution Approach 1:
The design moves electronic components and control elements from the vertical dimension (height) to the horizontal dimension (housing surface area). By utilizing the housing perimeter and surface for circuit board placement and wire routing, the design achieves thinness in the height direction while maintaining functionality in the horizontal plane.
Data Source
AI summary
A manufacturing method of a structure of a thin fan includes providing a plastic material containing a plurality of metal particles and forming a housing from the plastic material. A part surface of the housing is removed, and a layout area and an extended circuit are formed on the housing. One terminal of the extended circuit connects to the layout area. A first signal connecting structure is disposed on the housing. The first signal connecting structure connects to the other terminal of the extended circuit. A metal layer is disposed on the layout area and the extended circuit.