Fan structure and manufacturing method thereof

A fan structure includes a first fixing ring and a plurality of fan blades. The first fixing ring includes a plurality of first recesses radially arranged on the first fixing ring. One side of the fan blades is coupled to the first recesses of the first fixing ring. The first fixing ring includes a stamped part and a non-stamped part, in which the stamped part is in contact with the fan blades, and the thickness of the stamped part is smaller to the thickness of the non-stamped part.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to Taiwan Application Serial Number 105134444, filed Oct. 25, 2016, which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

Field of Invention

The present disclosure relates to a fan structure and a manufacturing method thereof.

Description of Related Art

Electronic devices, such as computers and laptops, have their performance improved with the technology development. However, high processing speed of the electronic devices brings along with excessive thermal energy that affects the performance of the electronic devices. Typical plastic blades of a dissipating fan have limitation in heat dissipation due to the material properties and thickness of the blades. Metal blades may reduce the thickness of blades, and the performance of the fan may also be improved. However, the fabrication of metal fan structures exist many challenges. Thus, a structure and a manufacturing method for simplifying and improving the strength of fan structures are needed.

SUMMARY OF THE INVENTION

An embodiment of the present disclosure provides a fan structure a first fixing ring including a plurality of first recesses radially arranged on the first fixing ring; a plurality of blades, one side of the blades is coupled to the first recesses, wherein the first fixing ring includes a stamped part and a non-stamped part, and the stamped part is thinner than the non-stamped part.

Another embodiment of the present disclosure provides a method for manufacturing a fan structure, including placing a plurality of blades into a plurality of first recesses of a first fixing ring, wherein each of the blades and the each of the corresponding first recesses include a gap therebetween; and stamping the first fixing ring, such that a material of the first fixing ring is squeezed and extends into the gap to fix the blades.

The present disclosure provides a fan structure and a manufacturing method thereof. A plurality of blades are placed into a recess of a fixing ring and followed with a stamping process, such that the fan structure with thin blade may be able to achieve. In addition, through the stamping process, the manufacturing process may be simplified, and the strength of the fan structure may also be improved.

DETAILED DESCRIPTION

FIGS. 1A and 1Bare perspective view and top view of a fan structure according to some embodiments of the present disclosure, respectively. A fan structure10includes a plurality of blades100, a first fixing ring200, and a second fixing ring300. The first fixing ring200and the second fixing ring300are circles with identical center, in which a diameter of the first fixing ring200is smaller than that of the second fixing ring300. A plurality of first recesses201with same spacing therebetween are radially arranged on the circumference of the first fixing ring200. Similarly, a plurality of second recesses301with same spacing therebetween are radially arranged on the circumference of the second fixing ring300. One side of the blades is coupled to the first recesses201of the first fixing ring200, and another side the blades is coupled to the second recesses301of the second fixing ring300. In some embodiments, the numbers of the blades, the first recesses201, and the second recesses301are the same. In some other embodiments, the second fixing ring300may be omitted.

The blades100, first fixing ring200, and the second fixing ring300are made of malleable materials. In some embodiments, the blades100, first fixing ring200, and the second fixing ring300are made of metals, such as stainless steels (alloy of iron), Cu, Al, or other suitable metals. The blades100, first fixing ring200, and the second fixing ring300may be made of same material or different materials. In some embodiments, the malleability of blades100is smaller than the malleability of the first fixing ring200and the second fixing ring300.

InFIG. 1B, the blades100are straight, and are radially arranged on the circumferences of the first fixing ring200and the second fixing ring300. In detail, the blades100are respectively perpendicular (i.e. 90 degree) to a corresponding one of the tangent lines of the circumferences of the first fixing ring200and the second fixing ring300. From another view, the blades100are arranged along with the radii of the first fixing ring200and the second fixing ring300, but the present disclosure are not limited thereto. Since the blades100are made of malleable materials, the thickness of the blades100may be very thin. In some embodiments, the thickness of the blades100ranges from 0.05 mm to 0.1 mm.

FIGS. 2A and 2Bare schematic view of assembling a fan structure according to some embodiments of the present disclosure. InFIG. 2, a first fixing ring200and a second fixing ring300are provided. The first fixing ring200includes a plurality of first recesses201arranged along the circumference of the first fixing ring200. The second fixing ring300includes a plurality of second recesses301arranged along the circumference of the second fixing ring300. In this embodiment, the number of the first recesses201is equal to the number of the second recesses301, and each of the first recesses201corresponds to each of the second recesses301. The first recesses201and the second recesses301may be formed by recessing the first fixing ring200and the second fixing ring300through stamping or forging. In the present embodiments, the first recesses201and the second recesses301are vertically penetrate through the first fixing ring200and the second fixing ring300, respectively, but the present disclosure is not limited thereto.

Subsequently, a plurality of blades100are provided. One side of the blades100corresponds to the first recesses201, and another side of the blades100corresponds to the second recesses301. In the present embodiment, the first recesses201and second recesses301are arranged on the outer side of the circumferences of the first fixing ring200and the second fixing ring300, respectively. One side of the blades100is engaged into the first recesses201. In addition, another side the blades100, which is close to the second fixing ring300, has at least one notches120and at least one protrusion part110. The protrusion part110is engaged into the one of the second recesses301disposed on the outer side of the circumference of the second fixing ring300. On the other hand, a portion302of the inner side of the second fixing ring300(the side without the second recesses301) is engaged into the notch102.

In the present embodiment, the shape of the blades100is a gradual structure, in which the size of the blades100increases from the first fixing ring200to the second fixing ring300. It should be understood that the shapes and the positions of the blades100, the first recesses201, and the second recesses301may be modified according to desired design. For example, in some other embodiments, the second recesses301may be arranged on the inner side of the circumference the second fixing ring300, and the protrusion part100of the blades100may be omitted.

InFIG. 2, the blades100are placed into the first recesses201and the corresponding second recesses301. In the present embodiment, since the first recesses201and the second recesses301are respectively perpendicular to a corresponding one of the tangent lines of the circumferences of the first fixing ring200and the second fixing ring300, the length direction of the blades100is also perpendicular to a corresponding one of the tangent lines of the circumferences of the first fixing ring200and the second fixing ring300. Accordingly, the blades100may be directly placed into the first recesses201and the second recesses301without bending. That is, the blades100are arranged along the radii of the first fixing ring200and the second fixing ring300. It should be understood that only one blade100shown inFIG. 2is merely used for explanation. In practice, people skilled in this art may place the blades100into the recesses201,301in sequence, or may place all of the blades100into the recesses201,301at one time by jigs.

FIGS. 3A and 3Bare partially perspective view and sectional view of a fan structure according to some embodiments of the present disclosure, respectively.FIG. 3Ais a perspective view in that a blade100is placed into a first recess201of a first fixing ring200.FIG. 3Bis a sectional view along line A-A′ ofFIG. 3A. In the present embodiment, the first recess201vertically penetrates through the first fixing ring200. In some other embodiments, the first recess201may partially penetrate through the first fixing ring200. In addition, the height of the blade100is slightly larger than the height of the first recess201(the height of the first fixing ring200), but the present disclosure is not limited thereto. In practice, people skilled in this art may design profiles, shapes, and sizes of blades and recesses according to requirements.

InFIG. 3A, the first fixing ring200may be separated into an outer ring200A and an inner ring200B, in which the boundary between the outer ring200A and the inner ring200B is the end of the first recess201. That is, the outer ring200A is a part including the first recesses201, but the inner ring200B is a part without the first recesses201.

InFIG. 3B, the blade100has a width 100W, and the first recess201has a width 201W. In some embodiments, the width 100W of the blade100ranges from about 0.05 mm to about 0.1 mm. In addition, the width 201W of the first recess201is slightly larger than the width 100W of the blade100. Therefore, the blade100may be easily placed into the first recess201in assembling step. Accordingly, after the blade100is placed into the first recess201, the blade100and the first recess201includes a gap g therebetween.

FIG. 4Ais a sectional view of a method of manufacturing a fan structure according to some embodiments of the present disclosure.FIG. 4Bis a perspective view of fan structure formed by the method ofFIG. 4A. InFIG. 4A, the top surface of the outer ring200A of the first fixing ring200(as shown inFIG. 3A) near the blade100is stamped. It should be noted thatFIG. 4Aonly shows one blade100and the first ring200at the opposite side of the blade100. In practice, all of the blades100and first fixing ring200may be stamped simultaneously. In some embodiments, the stamping process may include placing a fan structure10(as shown inFIG. 1A) on a stamping substrate, and stamping the top surface of the first fixing ring200with a stamping tool600. In the present embodiment, the stamping tool600is applied to a part of the outer ring200A near the blade100. Since the first fixing ring200is made of malleable materials, the gap g between the blade100and the first recess201may be filled through the extension of the stamped materials after stamping. Accordingly, all of the blades100are tightly combined with the first fixing ring200.

In some embodiment, the blades100and the first fixing ring200may be metals, such as stainless steels (alloy of iron), Cu, Al, or other suitable metals. The blades100and the first fixing ring200may be made of same material or different materials. In some embodiments, the malleability of blades100is smaller than the malleability of the first fixing ring200. That is, the hardness of the blades100is larger than that of the first fixing ring200. Therefore, the blades100with larger hardness (or lower malleability) are hard to be deformed during the stamping process.

FIG. 4Bis a perspective view of fan structure formed by the method ofFIG. 4A. The stamped first fixing ring200may be separated into a stamped part210and a non-stamped part212. In the present embodiment, only the part of the outer ring200A near the blades100are stamped, such that the stamped part210is substantially equal to the part of the outer ring200A near the blades100, and the non-stamped part212includes the inner ring200B and another part the outer ring200A. The stamped part210is squeezed by the stamping tool, and extending toward the blades100and further filling the gap g (as shown inFIG. 4A). The stamped part210is in contact with the blades100. Therefore, the blades100are tightly fixed, and the overall structure is stable and balanced.

Moreover, due to squeeze, the stamped part210has a shrunk profile. Overall, the thickness T2 of the stamped part210is smaller than the thickness T1 of the non-stamped part212, in which the thickness T1 is also equal to the thickness of the first fixing ring200without stamped. It should be noted that the profile of the stamped part210described herein is merely used to explain. In practice, the profile of the stamped part210may vary according to the operating situation, such as the shape of molding tools or the strength of stamping.

FIG. 5Ais a sectional view of a method of manufacturing a fan structure according to some embodiments of the present disclosure.FIG. 5Bis a perspective view of fan structure formed by the method ofFIG. 5A.FIGS. 5A and 5Bare similar toFIGS. 4A and 4B. Some details are omitted for simplification.FIG. 5Adiffers fromFIG. 4A, in that the stamping process ofFIG. 5Aincludes stamping the top surface of the outer ring200A (as shown inFIG. 3A) of the first fixing ring200. It should be noted thatFIG. 5Aonly shows one blade100and the first ring200at the opposite side of the blade100. In practice, all of the blades100and first fixing ring200may be stamped simultaneously. Since the first fixing ring200is made of malleable materials, the gap g between the blade100and the first recess201may be filled through the extension of the stamped materials after stamping. Accordingly, all of the blades100are tightly combined with the first fixing ring200.

In some embodiment, the blades100and the first fixing ring200may be metals, such as stainless steels (alloy of iron), Cu, Al, or other suitable metals. The blades100and the first fixing ring200may be made of same material or different materials. In some embodiments, the malleability of blades100is smaller than the malleability of the first fixing ring200. That is, the hardness of the blades100is larger than that of the first fixing ring200. Therefore, the blades100with larger hardness (or lower malleability) are hard to be deformed during the stamping process.

FIG. 5Bis a perspective view of fan structure formed by the method ofFIG. 5A. The stamped first fixing ring200may be separated into a stamped part210and a non-stamped part212. In the present embodiment, the overall surface of the outer ring200A near the blades100are stamped, such that the stamped part210is substantially equal to the outer ring200A, and the non-stamped part212is substantially equal to the inner ring200B. The stamped part210is squeezed by the stamping tool, extending toward the blades100and further filling the gap g (as shown inFIG. 5A). The stamped part210is in contact with the blades100. Therefore, the blades100are tightly fixed, and the overall structure is stable and balanced.

Moreover, due to squeeze, the stamped part210has a shrunk profile. Overall, the thickness T3 of the stamped part210is smaller than the thickness T1 of the non-stamped part212, in which the thickness T1 is also equal to the thickness of the first fixing ring200without stamped. It should be noted that the profile of the stamped part210described herein is merely used to explain. In practice, the profile of the stamped part210may vary according to the operating situation, such as the shape of molding tools or the strength of stamping.

In some other embodiments, the stamping process includes stamping the overall surface of the first fixing ring. That is, both the outer ring200A and the inner ring200B are stamped. Thus, the stamped part is substantially equal to the overall first fixing ring. Since the stamping process is applied to the overall surface of the first fixing ring200, the overall thickness of the first fixing ring are substantially the same after stamping. In addition, the shrunk thickness is smaller than the thickness of the original first fixing ring before stamping process.

The above description only show the stamping method between the blades100and the first fixing ring200, but the disclosure is not limited thereto. Similar method or different method may also be applied to the blades100and other rings (i.e. the second fixing ring300).

FIG. 6is a perspective view of a fan structure according to some embodiments of the present disclosure. The fan structure10further includes a third fixing ring400. In the present embodiment, the third fixing ring400may be equal to the second fixing ring300in structure. Moreover, the blades100have symmetric profile, in which each of the blades100includes two notches120and two protrusion part110disposed oppositely. Thus, the third fixing ring400may be disposed on another side of the blades100opposite to the second fixing ring300with similar method described inFIGS. 2A and 2B. Such design may improve the overall strength of the fan structure.

FIG. 7is a top view of a fan structure according to some embodiments of the present disclosure. Similar toFIG. 1B, a fan structure20includes a first fixing ring250, a second fixing ring350, and a plurality of blades150. The first fixing ring250includes a plurality of first recesses251radially arranged on the circumference of the first fixing ring250, and the second fixing ring350includes a plurality of second recesses351radially arranged on the circumference of the second fixing ring350, in which each of the first recesses251corresponds to each of the second recesses351. In the present embodiment, the second recesses351are not perpendicular to a corresponding one of the tangent line of the circumference of the second fixing ring350. Since the thin blades150(i.e. about 0.05 mm to about 0.1 mm) are made of malleable materials, the blades150may be bent into an arc shape for engaging into the first recesses251and the corresponding second recesses351.

FIG. 8is a top view of a fan structure according to some embodiments of the present disclosure. Similar toFIG. 1B, a fan structure30includes a first fixing ring260, a second fixing ring360, and a plurality of blades160. The first fixing ring260includes a plurality of first recesses261radially arranged on the circumference of the first fixing ring260, and the second fixing ring360includes a plurality of second recesses361radially arranged on the circumference of the second fixing ring360, in which each of the first recesses261corresponds to each of the second recesses361. In the present embodiment, the second recesses361are not perpendicular to a corresponding one of the tangent line of the circumference of the second fixing ring361. The present disclosure provides a fan structure and a manufacturing method thereof. A plurality of blades are placed into recesses of a fixing ring. Through a stamping process, a fan structure with thin blade may be able to achieve. In addition, through the stamping process, the manufacturing process may be simplified, and the strength of the fan structure may also be improved. In the present disclosure, the fan structure30further includes a third fixing ring500disposed between the first fixing ring260and the second fixing ring360. Accordingly, the third fixing ring500is larger than the first fixing ring260and is smaller than the second fixing ring360. The third fixing ring500has a plurality of third recesses501. The third recesses501may be designed in an inflection shape, such that the blades160engaged in the third recesses501may be reversely bent. Thus, the blades160may be bent into a wave-like shape through the first fixing ring260, the second fixing ring360, and the third fixing ring500. In the present disclosure, the third fixing ring500may be applied to reversely bend the blades, and the strength of the fan structure30may also be improved by the third fixing ring500.

The present disclosure provides a fan structure and a manufacturing method thereof. A plurality of blades are placed into a recess of a fixing ring and followed with a stamping process, such that the fan structure with thin blade may be able to achieve. In addition, through the stamping process, the manufacturing process may be simplified, and the strength of the fan structure may also be improved.

It should be noted that the number of the fixing rings, the number of the recesses, the shape of the recesses, the shaped of the blades, and the material described above are merely used to explain, and are not going to limited the present disclosure. In practice, people skilled in this art may design different fan structures according to requirements.