US20120107100A1

US20120107100A1 - Radiator fan assembly structure and method of forming

Info

Publication number: US20120107100A1
Application number: US13/208,830
Authority: US
Inventors: Liang-Sheng Chang; Tien-Chin Wu; Sheng-Chi Lei
Original assignee: Forcecon Technology Co Ltd
Current assignee: Forcecon Technology Co Ltd
Priority date: 2010-10-29
Filing date: 2011-08-12
Publication date: 2012-05-03
Also published as: TWI424662B; TW201218587A

Abstract

A radiator fan assembly structure has a base board with a seating surface and a stator installing surface; a stator inserting and positioning part, configured in the center of the stator installing surface of the base board; a stator set, has a silicon-steel plate, a coil and an insulate frame; and a plastic assembly seat formed integrally on the stator set, which is formed through a projection from the center of the insulate frame of the stator set. The shape of the plastic assembly seat enables it to be inserted into the stator inserting and positioning part. An axis is combined with the plastic assembly seat, with its root part fixed on the center of the plastic assembly seat. A rotor blade assembly has a wheel hub, blades, a bush, a bearing assembly and a magnet ring. The radiator fan runs smoothly and quietly.

Description

CROSS-REFERENCE TO RELATED U.S. APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT Not applicable.

REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates generally to a radiator fan, and more particularly to an innovative assembly structure of the rotor and stator of the radiator fan and its forming method.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
In a prior-art radiator fan with its axis configured on the side of the rotor wheel hub, there are many places with mismatch errors, for example, mismatch between the axis and the rotor wheel hub, mismatch between the rotor magnet ring and the stator coil, mismatch between the axis and the stator bearing, and mismatch between the stator bearing and the axle seat. There are always problems and shortcomings of excessive noise in actual manufacturing of such radiator fans due to the difficulty in accurate positioning.
To overcome this problem, the industry has developed a new kind of radiator fan with reversed axis positioning. In the structural configuration of such a radiator fan, as the root part of the rotor axis is inversely combined to the stator seat, vertical accuracy between the axis and the stator seat can be easily realized. However, because the coil assembly of the stator is attached to the projecting barrel preformed in the stator seat as a singular module, after the assembly, there may be an excessive mismatch error between the coil assembly and the axis, and as a result, after assembly of the rotor and stator, it is hard to realize accurate positioning between the coil of the stator and the magnet ring of the rotor, and the problem of unsmooth and noisy running will still exist.
Thus, to overcome the aforementioned problems of the prior art, it would be an advancement if the art to provide an improved structure that can significantly improve the efficacy.
Therefore, the inventor has provided the present invention of practicability after deliberate design and evaluation based on years of experience in the production, development and design of related products.

BRIEF SUMMARY OF THE INVENTION

The main feature of the innovative “radiator fan assembly structure and its forming method” disclosed in the present invention is that the axis of the radiator fan is integrated onto the plastic construction of the stator set, and the stator set can be fitted into the base board, so that the axis, the silicon-steel plate of the stator set, and the coil assembly can be accurately aligned through planning and designing of the projection mould. In this way, when the rotor blade assembly, the stator set, and the axis are assembled, the mismatch error between these three components can be minimized, and the assembly error between the stator set and the base board will not affect the accurate alignment between the stator set, the axis, and the rotor blade assembly. In this way, the assembly accuracy of the radiator fan can be dramatically improved, the running will be smoother, and noise will be effectively reduced. These constitute the advantages and practical advancement of the present invention.
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an exploded sectional view of a preferred embodiment of the present invention.

FIG. 2 is an assembled sectional view of a preferred embodiment of the present invention.

FIG. 3 depicts an example implementation with the plastic assembly seat configured with a positioning column.

FIG. 4 depicts an example implementation as shown in FIG. 3 with the end of the positioning column formed with a hot melt expanded tip.

FIG. 5 depicts an example implementation with the stator set insulate frame formed with a positioning projector column.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 shows a preferred embodiment of the radiator fan assembly structure and its forming method disclosed in the present invention. However, such an embodiment is presented for illustrative purpose only, and it is noted that the invention is not limited to the specific embodiment described herein.
Said radiator fan assembly structure comprises the following components.
A base board 10, which can be a metal board, comprises a seating surface 11 and a stator installing surface 12. The stator installing surface 12 is configured with a circuit board 13.
A stator inserting and positioning part 14 is configured in center of the stator installing surface 12 of the base board 10.
A stator set 20 which comprises a multiple silicon-steel plate 21, a coil 22 and an insulate frame 23. The insulate frame 23 is to cover and set the silicon-steel plate 21.
A plastic assembly seat 30 is formed integrally on the stator set 20. The plastic assembly seat 30 is formed through a projection from the center of the insulate frame 23 of the stator set 20. The shape of the plastic assembly seat 30 enables it to be inserted into the stator inserting and positioning part 14 configured in the center of stator installing surface 12 of the base board 10.
An axis 40 is combined with the plastic assembly seat 30. The root part 41 of the axis 40 is vertically fixed on the center of the plastic assembly seat 30.
A rotor blade assembly 50 which comprises a wheel hub 51, multiple blades 52, a bush 53, a bearing assembly 54 and a magnet ring 55. The blades 52 are configured at intervals outside the peripheral wall of the wheel hub 51. The bush 53 is configured in the internal center of the wheel hub 51. The bearing assembly 54 is configured inside the bush 53 to fit the axis 40. The magnet ring 55 is configured around the inner peripheral wall of the wheel hub 51.
The stator inserting and positioning part 14 can be implemented in the shape of a through hole (as depicted in FIGS. 1 and 2) or an inside recessing groove, so that the plastic assembly seat 30 can be tightly inserted into the stator inserting and positioning part 14 (as depicted in FIG. 2).
As depicted in FIGS. 3 and 4, the plastic assembly seat 30 can also integrally form a positioning column 31 projecting to the direction of the base board 10, and a through hole 16 is configured on the corresponding position of the base board 10 for the positioning column 31 to go through. Moreover, a hot-melt expanded tip 32 is formed through heat pressing (as marked by Arrow L1 in FIG. 4) at the end of the positioning column 31 to resist against the seating surface 11 of the base board 10.
As depicted in FIG. 5, the insulate frame 23 of the stator set 20 can be made of plastic material, and the insulate frame 23 integrally forms a positioning projector column 24 projecting to the direction of the base board 10, and a through hole 15 is configured on the corresponding position of the base board 10 for the positioning projector column 24 to go through. Moreover, a hot-melt expanded tip 25 is formed at the end of the positioning projector column 24 to resist against the seating surface 11 of the base board 10.
In reference to the structure set forth above, the forming method of the radiator fan structure disclosed in the present invention is described as follow:
Said radiator fan mainly comprises a base board 10, a stator set 20, an axis 40, and a rotor blade assembly 50; wherein the base board 10 comprises a seating surface 11 and a stator installing surface 12, with the stator installing surface 12 configured with a circuit board 13. The stator set 20 comprises multiple silicon-steel plates 21, a coil 22 and an insulate frame 23, with the insulate frame 23 configured to cover and set the silicon-steel plate 21. The rotor blade assembly 50 comprises a wheel hub 51, multiple blades 52, a bush 53, a bearing assembly 54 and a magnet ring 55. Said blades 52 are configured at intervals outside the peripheral wall of the wheel hub 51. The bush 53 is configured in the internal center of the wheel hub 51. The bearing assembly 54 is configured inside the bush 53 to fit the axis 40. The magnet ring 55 is configured around the inner peripheral wall of the wheel hub 51.
Said forming method has the following features:
A stator inserting and positioning part 14 is configured in the center of the stator installing surface 12 of the base board 10.
When manufacturing the stator set 20, the silicon-steel plate 21 and the axis 40 are fixed at the same time in a projection forming mould by means of intramodal projection forming, and then the insulate frame 23 and plastic assembly seat 30 are formed through projection molding. In this way, the axis 40 is accurately fixed and integrated in the right center of the stator set 20.
As the plastic assembly seat 30 and stator inserting and positioning part 14 are configured for insertion, the stator set 20 can be fixed on the base board 10.
As the bearing assembly 54 can allow the axis 40 to insert into, the rotor blade assembly 50 can be joined with the stator set 20, and until now, the whole radiator fan is completely assembled.
In the above forming method, the plastic assembly seat 30 and the stator inserting and positioning part 14 are joined and fixed through tight fitting between the projector part and the groove (as depicted in FIGS. 1 and 2).
In the above forming method, the tight fixing between the plastic assembly seat 30 and the base board 10, or between the insulate frame 23 of the stator set 20 and the base board 10 are realized by letting the projector positioning column 31 to go through the base board 10, and by forming an expanded tip 32 at the end of the positioning column 31 through hot melting (the style depicted in FIGS. 3 and 4, or the style depicted in FIG. 5).
In the above forming method, the insulate frame 23 of the stator set 20, the plastic assembly seat 30 and the axis 40 are formed integrally as a whole through projection forming.

Claims

1. A radiator fan assembly structure comprising:

a base board, comprising a seating surface and a stator installing surface; the stator installing surface is configured with a circuit board;

a stator inserting and positioning part, configured in the center of the stator installing surface of the base board;

a stator set, comprising a silicon-steel plate, a coil and an insulate frame;

a plastic assembly seat formed integrally on the stator set; the plastic assembly seat is formed through a projection from the center of the insulate frame of the stator set; the shape of the plastic assembly seat enables it to be inserted into the stator inserting and positioning surface of the base board;

an axis combined with the plastic assembly seat; the root part of the axis is vertically fixed on the center of the plastic assembly seat; and

a rotor blade assembly, which comprises a wheel hub, multiple blades, a bush, a bearing assembly and a magnet ring; the blades are configured at intervals outside the peripheral wall of the wheel hub; the bush is configured in the internal center of the wheel hub; the bearing assembly is configured inside the bush to fit the axis; the magnet ring is configured around the inner peripheral wall of the wheel hub.

2. The structure defined in claim 1, wherein the stator inserting and positioning part of the base board is implemented in the shape of a through hole or an inside recessing groove, so that the plastic assembly seat can be tightly inserted into the stator inserting and positioning part.

3. The structure defined in claim 1, wherein the plastic assembly seat integrally forms a positioning column projecting to the direction of the base board, and a through hole is configured on the corresponding position of the base board for the positioning column to go through; a hot-melt expanded tip is formed at the end of the positioning column to resist against the seating surface of the base board.

4. The structure defined in claim 1, wherein the insulate frame of the stator set is made of plastic material, and the insulate frame integrally forms a positioning projector column projecting to the direction of the base board, and a through hole is configured on the corresponding position of the base board for the positioning projector column to go through; a hot-melt expanded tip is formed at the end of the positioning projector column to resist against the seating surface of the base board.

5. A radiator fan assembly structure forming method, wherein said radiator fan mainly comprises a base board, a stator set, an axis, and a rotor blade assembly; wherein the base board comprises a seating surface and a stator installing surface, with the stator installing surface configured with a circuit board; the stator set comprises a silicon-steel plate, a coil and an insulate frame; the insulate frame covers and sets the silicon-steel plate; the rotor blade assembly comprises a wheel hub, multiple blades, a bush, a bearing assembly and a magnet ring; said blades are configured at intervals outside the peripheral wall of the wheel hub; the bush is configured in the internal center of the wheel hub; the bearing assembly is configured inside the bush to fix the axis; the magnet ring is configured around the inner peripheral wall of the wheel hub; said forming method has the following features:

a stator inserting and positioning part is configured in the center of the stator installing surface of the base board; when manufacturing the stator set, the silicon-steel plate and the axis are fixed at the same time in a projection forming mould by means of intramodal projection forming, and then the insulate frame and plastic assembly seat are formed through projection molding; in this way, the axis is accurately fixed and integrated in the right center of the stator set;

as the plastic assembly seat and stator inserting and positioning part are configured for insertion, the stator set can be fixed on the base board;

as the bearing assembly can allow the axis to insert into, the rotor blade assembly can be joined with the stator set.

6. The method defined in claim 5, wherein the plastic assembly seat and stator inserting and positioning part are joined and fixed through tight fitting between the projector part and the groove.

7. The method defined in claim 5, wherein the tight fixing between the plastic assembly seat and the base board, or between the insulate frame of the stator set and the base board are realized by letting the projector positioning column to go through the base board, and by forming an expanded tip at the end of the positioning column through hot melting.

8. The method defined in claim 5, wherein the insulate frame of the stator set, the plastic assembly seat and the axis are formed integrally as a whole through projection forming.