Composite Fan Blade and Fan Device

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. application claims the benefits of priority to Taiwan application No. 113143936, filed on November 15, 2024, titled “Composite fan blade and fan device” of which is incorporated herein by reference in its entirety.

BACKGROUND

As processors processing power continues to increase, it generates substantial amounts of heat. To prevent damage from excessive heat, fans are used in electronic devices to dissipate the heat and maintain the processor operate within an appreciate temperature range.

However, the rotation of fan blades induces vibrations during operation, potentially resulting in noise. At certain speeds, the noise becomes significant and adversely impacts the fan’s functionality.

SUMMARY

In general terms, this disclosure relates to a composite fan blade and fan device, and more particularly to a composite fan blade and fan device having a hub structure formed of composite materials.

Aspects of the present disclosure provide a composite fan blade. The composite fan blade includes a metal member including a binding portion and a plurality of blade portions, the plurality of blade portions being circumferentially arranged around the binding portion, and a plastic member at least partially secured to the binding portion to form a hub structure, the binding portion includes a substrate and a plurality of connecting plates, the connecting plates are circumferentially arranged around the substrate, each of the connecting plates has an inner surface and an opposite outer surface, and the blade portions protrude from the outer surfaces of the corresponding connecting plates, and a notch is disposed between any two adjacent connecting plates.

In some embodiments, the substrate includes a relief recess corresponding to each notch.

In some embodiments, the metal member is fabricated using at least one of a forging process or a computer numerical control machining process.

In some embodiments, the binding between the metal member and the plastic member is achieved by an injection molding process, an adhesive bonding process, a riveting process, or a combination of the above.

In some embodiments, the metal member further includes an outer ring portion that radially encompasses the blade portions, the outer ring portion being secured to the outermost periphery of the blade portions opposite the binding portion.

In some embodiments, each connecting plate includes a coupling member that mechanically couples the plastic member with the metal member.

In some embodiments, the coupling member includes a groove disposed on the inner surface.

Another aspect of the present disclosure provides a fan device including a bracket, a composite fan blade rotatably disposed on the bracket, the composite fan blade including a metal member including a binding portion and a plurality of blade portions, the plurality of blade portions being circumferentially arranged around the binding portion, and a plastic member at least partially secured to the binding portion to form a hub structure, a driving element, disposed on the bracket and used to rotate the composite fan blade relative to the bracket; and the binding portion includes a substrate and a plurality of connecting plates, the connecting plates are circumferentially arranged about the substrate, each of the connecting plates has an inner surface and an opposite outer surface, and the blade portions protrude from the outer surfaces of the corresponding connecting plates, and a notch is disposed between any two adjacent connecting plates.

In some embodiments, the substrate of the fan device includes a relief recess corresponding to each notch.

In some embodiments, the binding between the metal member and the plastic member in the fan device is achieved by an injection molding process, an adhesive bonding process, a riveting process, or a combination of the above.

In some embodiments, the metal member of the fan device includes an outer ring portion that radially encompasses the blade portions and is secured to the outermost periphery of the blade portions opposite the binding portion.

In some embodiments, each connecting plate of the fan device includes a coupling member that mechanically couples the plastic member with the metal member.

In some embodiments, the coupling member includes a groove disposed on the inner surface.

Another aspect of the present disclosure provides a method for forming a composite fan blade comprising forming a metal member including a binding portion and a plurality of blade portions, the plurality of blade portions being circumferentially arranged around the binding portion, and forming a plastic member at least partially secured to the binding portion, the binding portion includes a substrate and a plurality of connecting plates, the connecting plates are disposed on the periphery of the substrate, each of the connecting plates has an inner surface and an opposite outer surface, and the blade portions protrude from the outer surfaces of the corresponding connecting plates, and a notch is disposed between any two adjacent connecting plates.

In some embodiments, the substrate includes a relief recess that corresponds to each notch.

In some embodiments, the fabrication of the metal member includes at least one of a forging process and a computer numerical control machining process.

In some embodiments, the binding of the metal member and the plastic member includes an injection molding process, an adhesive bonding process, a riveting process, or a combination of the above.

In some embodiments, the metal member includes an outer ring portion that radially encompasses the blade portions, and the outer ring portion is secured to the outermost periphery of the blade portions, opposite the binding portion.

In some embodiments, each connecting plate includes a coupling member for mechanically coupling the plastic member with the metal member.

In some embodiments, the coupling member includes a groove disposed on the inner surface.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective schematic view of the fan device according to the first embodiment of the present disclosure.

FIG. 2 is an exploded schematic view of the fan device shown in FIG. 1.

FIG. 3 is a perspective schematic view of the fan device according to the second embodiment of the present disclosure.

FIG. 4 is an exploded schematic view of the fan device shown in FIG. 3.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.

Refer to FIGS. 1 and 2. FIG. 1 is a perspective schematic view of the fan device according to the first embodiment of the present disclosure. FIG. 2 is an exploded schematic view of the fan device shown in FIG. 1.

The fan device 10 of this embodiment includes a bracket 20, a composite fan blade 30, and a driving element 40. The composite fan blade 30 is rotatably disposed on the bracket 20. The driving element 40 is also disposed on the bracket 20 and utilized to rotate the composite fan blade 30 relative to the bracket 20. Specifically, the driving element 40 may be a motor, which includes a stator (not shown) and a rotor (not shown). The stator and the rotor may be matched magnets or coils. The stator is securely disposed on the bracket 20. The rotor could rotate relative to the stator via electromagnetic effects, allowing the composite fan blade 30 to rotate relative to the bracket 20.

The composite fan blade 30 includes a metal member 31 and a plastic member 32. The metal member 31 is formed, for example, by forging and computer numerical control (CNC) machining processes, and includes a binding portion 311 and multiple blade portions 312. These blade portions 312 are connected around the binding portion 311. The metal member 31 may be made of aluminum, and the plastic member 32 may be made of ABS resin.

Specifically, the binding portion 311 includes a substrate 3111 and multiple connecting plates 3112. These connecting plates 3112 are connected to the periphery of the substrate 3111 and are spaced apart to form a notch N between any two adjacent connecting plates 3112; given the top surface of the substrate 3111 a gear-like shape, it facilitates the processing of the metal member 31 and prevents interference between the binding portion 311 and the tool of the processing machine. In addition, by incorporating these notches N, magnetic conduction between the metal member 31 and the driving element 40 could be avoided, thereby reducing noise generation during the operation of the composite fan blade 30.

Each connecting plate 3112 has an inner surface 31121, an outer surface 31122, and a groove 31123. The outer surfaces 31122 face away from the inner surfaces 31121. The blade portions 312 respectively protrude from the outer surfaces 31122 of the connecting plates 3112. The grooves 31123 are located on the inner surfaces 31121.

The plastic member 32 is, for example, cylindrical and at least partially combined with the binding portion 311 of the metal member 31. More specifically, the plastic member 32 is at least partially combined with the grooves 31123, such that the binding portion 311 of the metal member 31 and the plastic member 32 together form a hub structure. The combination method between the metal member 31 and the plastic member 32 may be, for example, an injection molding process, an adhesive bonding process, or a riveting process. Taking the injection molding process as an example, the plastic member 32 is integrally formed onto the grooves 31123 through overmolding, such that the binding portion 311 and the plastic member 32 together form a hub structure. The grooves 31123 increase the bonding strength between the metal member 31 and the plastic member 32.

In this embodiment, since the composite fan blade 30 is composed of the metal member 31 and the plastic member 32, compared with fan blades made of general plastic materials or other single materials, the composite fan blade 30 in this embodiment is capable of sound absorption or vibration reduction to reduce the noise generated during operation. Moreover, the notches N could prevent magnetic conduction between the metal member 31 and the driving element 40, thereby reducing the noise generated during the operation of the composite fan blade 30.

The metal member 31 of the composite fan blade 30 is made of metal material, which not only enhances the appearance of the composite fan blade 30 but also provides the metal member 31 with good durability, corrosion resistance, and structural strength, extending the service life of the fan device 10. On the other hand, besides being formed using forging and CNC machining processes, the metal member 31 may also be formed via welding, casting, or machining to meet various design requirements.

In this embodiment, the substrate 3111 of the binding portion 311 may further have multiple relief recesses 31111, which correspond to the notches N. The relief recesses 31111 enable the metal member 31, through forging and CNC processing to allow cutting tools to cut in these recesses 31111, facilitating fine trimming of the entire fan device 10 and preventing interference between the cutting tool and the binding portion 311 of the fan device 10, thereby increasing machining convenience.

In this embodiment, the plastic member 32 may further have an annular groove 321. The annular groove 321 facilitates the combination of the metal member 31 and the plastic member 32 in the manufacturing of the composite fan blade 30. For example, the metal member 31 and the plastic member 32 may be bonded via the annular groove 321.

In this embodiment, the substrate 3111 of the metal member 31 may also have multiple openings (not shown) arranged along a circular line. These openings allow the plastic member 32, after being injection molded, to be more firmly bonded to the binding portion 311 of the metal member 31.

Refer to FIGS. 3 and 4. FIG. 3 is a perspective schematic view of the fan device according to the second embodiment of the present disclosure. FIG. 4 is an exploded schematic view of the fan device shown in FIG. 3.

Referring to the fan device 10 of one embodiment described above, the fan device 10A of the present embodiment incorporates similar features unless otherwise specified. In this embodiment, the metal member 31A further includes an outer ring portion 313A for sound dampening. The outer ring portion 313A is connected to the side of the blade portions 312 away from the binding portion 311A and encloses the blade portions. The outer ring portion 313A may mitigate noise generated during the operation of the composite fan blade 30A and enhance the structural strength.

In this embodiment, the plastic member 32A does not have an annular groove as shown in another previous embodiment, but the substrate 3111A of the metal member 31A includes two annular grooves 3111A1. These annular grooves 3111A1 facilitate the bonding of the metal member 31A and the plastic member 32A during the manufacturing of the composite fan blade 30A.

In embodiments described above, the side and top surfaces of the plastic members 32, 32A are connected via an inclined surface, but are not limited thereto. In other embodiments, the side and top surfaces of the plastic members 32, 32A may also be connected via a step-shaped structure according to processing requirements.

The aforementioned embodiments of the composite fan blade and fan device indicate that the composite fan blade, made of a combination of a metal member and a plastic member, is capable of sound absorption and vibration reduction, thereby diminishing operational noise compared with fan blades made of general plastic materials or other single materials. Additionally, the presence of gaps formed between any two adjacent double connection plates prevent magnetic conduction between the metal components and the driving elements, thereby further reducing noise generated during the operation of the composite fan blades. As a result, users could enjoy a more comfortable experience when using the electronic device.

Moreover, the metal member of the composite fan blade is made of metal material, which not only enhances the appearance of the composite fan blade but also provides superior durability, corrosion resistance, and structural strength, increasing the service life of the fan device. The metal member could be made by forging, CNC processing, welding, or casting, making it flexible to a variety of design needs .

Embodiments of the present disclosure also discloses a method of manufacturing a composite fan blade. The method includes forming a metal member 31 having a binding portion 311 and a plurality of blade portions 312, which are circumferentially arranged around the binding portion 311. The method further includes forming a cylindrical plastic member 32 that is at least partially secured to the binding portion 311 to form a hub structure. The binding portion 311 includes a substrate 3111 and a plurality of connecting plates 3112. The connecting plates 3112 are circumferentially arranged around the substrate 3111. Each connecting plate 3112 has an inner surface 31121 and an outer surface 31122 opposite to the inner surface. The blade portions 312 protrude from the outer surfaces 31122 of the corresponding connecting plates 3112. In certain implementations, a notch N is disposed between any two adjacent connecting plates 3112 to enhance flexibility and potentially reduce magnetic or structural interference.

In some embodiments, the substrate 3111 includes a relief recess 31111 corresponding to each notch N. These relief recesses 31111 may alleviate stress concentrations or enhance molding alignment during manufacture.

In certain implementations, the fabrication of the metal member 31 may involve one or more of a forging process or a CNC machining process, depending on the material properties and dimensional requirements.

In certain implementations, the binding of the metal member 31 and the plastic member 32 may involve at least one of the following processes: an injection molding process, adhesive bonding process, or riveting process, ensuring strong mechanical integration between the two materials.

In certain implementations, the metal member 31 further includes an outer ring portion 313A that radially encompasses the blade portions 312 and is secured to the outermost periphery of the blade portions, opposite the binding portion 311A, thereby enhancing the overall structural support of the fan blade.

In certain implementations, each connecting plate 3112 may further include a coupling member configured to mechanically engage the plastic member 32. In some cases, the coupling member includes a groove formed on the inner surface 31121 of the connecting plate 3112, allowing molded plastic to fill and interlock with the groove, therefore enhancing bonding strength.

The embodiments illustratively disclosed herein suitably may be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods could also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some number. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces.