Welded Modular Fan Assembly for Variable Shapes and Lower-Cost Molding
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Solution Overview
Problem
The manufacturing of fan devices for climate control and air conditioning systems is complex and expensive due to the use of multiple molds designed for each specific fan shape, increasing the overall cost of the cooling unit.
Innovation Solution
A modular fan structure comprising a first module with a central hub and first plate-shaped portions, and second modules with variable second plate-shaped portions connected by welds or joints, allowing the use of a single common mold for the first module and lower-cost molds for the second modules, enabling flexibility in fan diameter and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single one-piece fan is manufactured using injection molding with specifically prearranged molds for each fan shape, then the fan structure is integrated and simple, but the manufacturing cost increases significantly and the production complexity increases
Solution Approach 1:
The fan is divided into multiple separate components (blades and hub) that can be manufactured independently using standard molds, then assembled together. This segmentation allows the use of common mold inventory for different fan configurations while maintaining integrated fan performance through proper assembly.
Solution Approach 2:
Standardized hub and blade components are designed to be universally applicable across different fan models and configurations. The same hub can accommodate different blade sets, and the same blade design can be used in various fan diameters, reducing the need for custom molds for each specific fan shape.
2Manufacturing precision
If multiple specific molds are used for manufacturing one-piece fans with different shapes and dimensions, then each fan type can be precisely manufactured, but the overall manufacturing cost increases
Solution Approach 1:
By separating the fan into modular components (blades and hub), the need for completely different molds for each fan configuration is eliminated. The same blade molds can produce blades for different fan sizes, and the hub molds remain constant, maintaining manufacturing precision while reducing mold inventory requirements.
Solution Approach 2:
The design allows for parameter variations (fan diameter, blade count, blade geometry) to be achieved through component selection and assembly configuration rather than through completely different mold designs. This enables precise manufacturing of different fan types using a standardized set of molds.
3Device complexity
If a one-piece fan structure is used, then the fan has simple structure, but the manufacturing process becomes complex and expensive
Solution Approach 1:
The fan structure is segmented into separate manufacturable components (blades and hub) that are then assembled. This approach maintains the simplicity of the final fan structure while enabling cost-effective manufacturing through the use of standard molds and modular assembly processes.
Solution Approach 2:
Separately manufactured blade and hub components are merged through assembly to create the complete fan. This combining process allows each component to be optimized for its specific manufacturing requirements while achieving the overall simple fan structure needed for aerodynamic performance.
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 modular design reduces manufacturing costs and allows production of fans with different dimensions and shapes efficiently, while maintaining aeraulic performance, and simplifies the manufacturing process.
Implementation Method 1
connected by welds or joints
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A fan device (1) is described comprising an electric motor (3) provided with a drive shaft (3a) coupled to a fan (4), which comprises a first module (5) consisting of a one-piece of molded thermoplastic material that is formed by a central hub (5a) and a plurality of first plate-shaped portions (5b) extending cantilevered from the central hub (5a) along longitudinal axes (B), and second modules (6) consisting of respective second plate-shaped portions (6a) molded in thermoplastic material, which have the axial ends stably connected by means of a weld or thermal joint to the axial ends of respective first plate-shaped portions (5a) in order to form the blades (7) of the fan (4).