PATENT DOCUMENT

Publication Number: US-11215193-B2
Application Number: US-202016792034-A
Country: US
Kind Code: B2

Title: Fan assembly with a self-adjusting gap and electronic devices with a fan assembly

Abstract:
An electronic device with a fan assembly is disclosed. The fan assembly includes an impeller and an insert separated from the impeller by a gap. The fan assembly increases airflow by rotationally driving the impeller. For a sufficient rotational speed of the impeller, the airflow reaches a level that provides a force that displaces the insert. The displacement may include movement and/or compression of the insert. As a result of the displacement, the gap between the impeller and the insert increases. The increased gap reduces the pressure and associated noise that is otherwise caused by the airflow. When the rotational speed of the impeller reduces or ceases, the insert returns to its initial position. In this manner, the fan assembly includes a self-adjusting gap that changes based on the airflow.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 an enclosure that defines an internal volume; and 
 a fan assembly located in the internal volume, the fan assembly comprising:
 a fan housing, 
 an impeller positioned in the fan housing, and 
 an insert positioned in the fan housing and separated from the impeller by a gap,
 wherein airflow by the impeller into the gap causes displacement of the insert such that the insert changes from a first size to a second size that is less than the first size. 
 
 
 
     
     
       2. The electronic device of  claim 1 , wherein the gap comprises a self-adjusting gap based upon compression of the insert, wherein the compression of the insert is based upon a rotational speed of the impeller. 
     
     
       3. The electronic device of  claim 1 , wherein the insert comprises an elastomeric insert. 
     
     
       4. The electronic device of  claim 3 , wherein the elastomeric insert comprises a spring force, and wherein the airflow provides a force that is greater than the spring force. 
     
     
       5. The electronic device of  claim 1 , wherein rotational movement of the impeller drives the airflow that causes the insert to transition to the second size, and wherein the insert is configured to transition to the first size when the rotational movement ceases. 
     
     
       6. The electronic device of  claim 1 , wherein the insert comprises foam. 
     
     
       7. The electronic device of  claim 1 , wherein the first size comprises a first cross sectional area, and wherein the second size comprises a second cross sectional area less than the first cross sectional area. 
     
     
       8. An electronic device, comprising:
 an enclosure that defines an internal volume; and 
 a fan assembly located in the internal volume, the fan assembly comprising:
 a fan housing, 
 an impeller located in the fan housing, and 
 an insert located in the fan housing, wherein:
 a decompressed state of the insert comprises a separation between the insert and the impeller by a gap having a first dimension, and 
 a compressed state of the insert comprises the separation between the insert and the impeller increasing to a second dimension of the gap that is greater than the first dimension. 
 
 
 
     
     
       9. The electronic device of  claim 8 , wherein the gap comprises a self-adjusting gap that transitions from a first size in the decompressed state to a second size in the compressed state based upon airflow generated by the impeller, and the first size is greater than the second size. 
     
     
       10. The electronic device of  claim 9 , wherein the insert is configured to transition from the compressed state to the decompressed state when the airflow ceases. 
     
     
       11. The electronic device of  claim 9 , wherein the insert comprises an elastomeric insert. 
     
     
       12. The electronic device of  claim 11 , wherein the elastomeric insert comprises a spring force, and wherein the airflow provides a force that is greater than the spring force. 
     
     
       13. The electronic device of  claim 8 , wherein the insert comprises foam. 
     
     
       14. The electronic device of  claim 8 , wherein rotational movement of the impeller generates airflow that causes the insert to transition to the compressed state, and wherein the insert is configured to transition to the decompressed state when the rotational movement ceases. 
     
     
       15. A method for operating a fan assembly in an electronic device, the method comprising:
 by the fan assembly:
 rotating an impeller; 
 driving airflow, by the impeller, through a fan housing having an insert separated from the impeller by a gap; and 
 compressing the insert, based on the airflow, such that the insert transitions from a first size to a second size less than the first size. 
 
 
     
     
       16. The method of  claim 15 , wherein the gap comprises a self-adjusting based upon compressing the insert. 
     
     
       17. The method of  claim 15 , further comprising decompressing the insert when the impeller ceases rotation. 
     
     
       18. The method of  claim 15 , wherein compressing the insert comprises compressing a foam insert. 
     
     
       19. The method of  claim 15 , wherein compressing the insert comprises compressing an elastomeric insert. 
     
     
       20. The method of  claim 19 , wherein compressing the elastomeric insert comprises providing a force that overcomes a spring force of the elastomeric insert.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority to U.S. Provisional Application No. 62/906,653, filed on Sep. 26, 2019, titled “FAN ASSEMBLY WITH A SELF-ADJUSTING GAP AND ELECTRONIC DEVICES WITH A FAN ASSEMBLY,” the disclosures of which are incorporated herein by reference in their entirety. 
    
    
     FIELD 
     The following description relates to fan assemblies in consumer electronic devices. In particular, the following description relates to a fan assembly that includes a self-adjusting throat gap designed to mitigate noise levels generated by the fan assembly during operation, as well as maintain an airflow threshold out of the fan assembly. 
     BACKGROUND 
     Electronic devices can use a fan to cool components that undergo temperature increase during operation. As some components (such as central processing units and graphics processing units) become more advanced, the components can undergo temperature increases that last longer and/or cause the components to run hotter. In order to mitigate these effects, the fan can run at higher speeds, thereby drawing more heated air away from the components. 
     However, running the fan at higher speeds has some drawbacks. For instance, noise generation is proportional to fan speed (measured in revolutions per minute). Accordingly, as the fan speed increases, the noise generation by the fan also increases. This can lead to a less desirable user experience. One solution for reducing noise levels is to increase the gap between the impeller blades of the fan and the housing walls that defines the fan scroll, thereby increasing the cross-sectional area through which the air flows and reducing air pressure. There are instances when a tonal blade passing noise becomes prominent only at elevated fan speeds. In these instances, it can be beneficial to increase the radial gap between impeller blades and housing walls to reduce this noise at high speeds. However, the increased radial gap will penalize transmitted airflow at lower fan speeds, where there was no tonal noise to mitigate. 
     SUMMARY 
     In one aspect, an electronic device is described. The electronic device may include an enclosure that defines an internal volume. The electronic device may further include a fan assembly located in the internal volume. The fan assembly may include a fan housing. The fan assembly may further include an impeller positioned in the fan housing. The fan assembly may further include an insert positioned in the fan housing and separated from the impeller by a gap. In some embodiments, airflow by the impeller into the gap causes displacement of the insert such that the gap changes from a first size to a second size that is greater than the first size. 
     In another aspect, an electronic device is described. The electronic device may include an enclosure that defines an internal volume. The electronic device may further include a fan assembly located in the internal volume. The fan assembly may include a fan housing. The fan assembly may include an impeller located in the fan housing. The fan assembly may further include an insert located in the fan housing. In some embodiments, a decompressed state of the insert may include a separation between the insert and the impeller by a gap having a first dimension. In some embodiments, a compressed state of the insert may include the separation between the insert and the impeller increasing to a second dimension of the gap that is greater than the first dimension. 
     In another aspect, a method for operating a fan assembly in an electronic device is described. The method may include rotating an impeller of the fan assembly. The method may further include driving airflow, by the impeller, through a fan housing having an insert separated from the impeller by a gap. The method may further include compressing the insert, based on the airflow, such that the gap transitions from a first size to a second size greater than the first size. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  illustrates an isometric view of an embodiment of an electronic device, in accordance with some described embodiments; 
         FIG. 2  illustrates an isometric view of an embodiment of a fan assembly for use in electronic devices, in accordance with some described embodiments; 
         FIG. 3  illustrates an exploded view of the fan assembly shown in  FIG. 2 , showing various features of the fan assembly; 
         FIG. 4  illustrates a plan view of the fan assembly; 
         FIG. 5  illustrates a cross sectional view of the fan assembly shown in  FIG. 4 , showing a gap between the impeller and the insert; 
         FIG. 6  illustrates a plan view of the fan assembly shown in  FIG. 4 , showing displacement of the insert in response to airflow generated by the impeller; 
         FIG. 7  illustrates a cross sectional view of the fan assembly shown in  FIG. 6 , showing the gap based on the airflow displacing the insert; 
         FIG. 8  illustrates a graph plotting amplitude vs. fan order a fan assembly during operation, in accordance with some described embodiments; 
         FIG. 9  illustrates a plan view of an alternate embodiment of a fan assembly; 
         FIG. 10  illustrates a cross sectional view of the fan assembly shown in  FIG. 9 , showing structural features of the tip; 
         FIG. 11  illustrates a cross sectional view of the fan assembly shown in  FIG. 10 , showing displacement of the tip in response to the airflow; 
         FIG. 12  illustrates a cross sectional view of an alternate embodiment of a fan assembly, showing the fan assembly with a tip modified with a recess; 
         FIG. 13  illustrates a cross sectional view of the fan assembly shown in  FIG. 12 , showing displacement of the tip in response to airflow; 
         FIG. 14  illustrates a cross sectional view of an alternate embodiment of a fan assembly, showing the fan assembly with an insert modified with a flexible material; 
         FIG. 15  illustrates a cross sectional view of the fan assembly shown in  FIG. 14 , showing displacement of the tip in response to airflow; 
         FIG. 16  illustrates a cross sectional view of an alternate embodiment of a fan assembly, showing the fan assembly with an insert controlled by magnets; 
         FIG. 17  illustrates a cross sectional view of the fan assembly shown in  FIG. 16 , showing the displacement of the insert in response to airflow; 
         FIG. 18  illustrates a flowchart showing a method for operating a fan assembly in an electronic device, in accordance with some described embodiments; and 
         FIG. 19  illustrates a block diagram of an electronic device, in accordance with some described embodiments. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to fan assemblies in consumer electronic devices. A fan assembly described herein is modified to reduce noise levels while also providing a minimum airflow threshold. The gap is defined as a separation or space between an impeller and a fan scroll (defined by the fan housing). In particular, the location of interest of is the throat gap defined by a minimum separation between the impeller and the fan scroll. Generally, the fan assembly, including the fan housing, includes a rigid structure, such as plastic. However, the fan assembly is modified with an insert located at the throat gap. Using the insert, the fan assembly includes a self-adjusting throat gap that is regulated by pressure applied by the airflow into the fan assembly by the impeller. For example, when the impeller is rotationally driven at or above a threshold speed (measured in revolutions per minute, or RPM), the force provided by the airflow is sufficient to compress, or otherwise displace, the insert. As a result, the throat gap widens and the air pressure through the gap decreases, thereby mitigating the tonal component of the noise level the fan assembly. 
     In order to displace (e.g., deform or compress) the insert, the force of the airflow must overcome the compressive strength of the insert such that
 
F a &gt;F i   (1)
 
where F a  is the force provided by the airflow and F i  is the opposing force of the material of the insert. In order to move the insert a distance x, the impeller must achieve rotation speed such that
 
F a =kx  (2)
 
where k is the spring constant of the material of the insert. Accordingly, the displacement of the insert is proportional to the force provided by the airflow. Further, the size (cross sectional area) of the throat gap is proportional to the displacement of the insert, and accordingly, the gap size is proportional to the airflow provided by the impeller.
 
     As the airflow increases, the air pressure at the gap also increases. The air pressure at the gap is a function of the cross sectional area of the gap, and can be approximated by 
                   P   =       F   a       A   g               (   3   )               
where P is the air pressure at the gap (due to airflow) and A g  is the area of the gap. Accordingly, the pressure is inversely proportional to the area of the gap. Thus, by allowing displacement of the insert, the gap can increase and relieve pressure at the gap. When the air pressure reduces, the noise level generated by the fan assembly is mitigated. While the fan assembly generates an overall broadband noise, the tonal component of the noise level generated by the fan assembly is mitigated, and the noise heard by a user is lower.
 
     While it is beneficial to increase the throat gap size to reduce the tonal component, it is also beneficial for the fan assembly to drive airflow at lower fan speeds (in terms of RPM). In this regard, once the components begin to cool, the fan speed may lower. When the fan speed is sufficiently lowered, the air pressure reduces, the insert returns to its original position, and the throat gap returns to its original size. By reducing the throat gap size, additional airflow leaves the fan assembly rather than passing through the throat gap and remaining in the fan assembly. Accordingly, the insert may undergo an elastic deformation and is not permanently deformed from the airflow. 
     The insert may include a compliant material, such as foam or some membrane material. The foam may include open-cell foam or closed-cell foam. Alternatively, or in combination, the insert may include a spring-loaded material or a structure connected to the fan housing by a hinge. In any event, the insert is integrated into the fan assembly and calibrated to provide allow the highest flow rate as well as the lowest sound pressure and best sound quality. 
     These and other embodiments are discussed below with reference to  FIGS. 1-19 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  illustrates an isometric view of an embodiment of an electronic device  100 , in accordance with some described embodiments. As shown, the electronic device  100  may include a desktop, or “tower,” computing device designed for use with a display and other accessories (not shown in  FIG. 1 ), such as a display/monitor, a mouse, and/or a keyboard. The electronic device  100  includes an enclosure  102 , or housing, that defines an internal volume that can carry several internal components including, as non-limiting examples, processing circuitry (such as a central processing unit and a graphics processing unit), memory circuits, circuit boards, an audio component (or components), a microphone (or microphones), a battery, and flexible circuitry that connects together the aforementioned components. As an example, the electronic device  100  includes a heat-generating component  103  (representative one or more heat-generating components) that undergoes a temperature increase and heat the surrounding air within the internal volume during operation of the electronic device  100 . At least some of these components may generate heat during operation of the electronic device  100 , thereby increase the temperate of the components. 
     The electronic device  100  may include one or more fan assemblies, such as a fan assembly  104   a , a fan assembly  104   b , and a fan assembly  104   c . Each of the fan assemblies can draw the heated air away from heat-generating component  103 . Further, each of the fan assemblies can receive ambient air via openings  106   a  formed in the enclosure  102 , and subsequently drive the heated air out of the enclosure  102  via openings  106   b  formed in the enclosure  102 . As a result, the fan assemblies can reduce the temperature of the components within the internal volume of the enclosure  102 . In order to activate and deactivate the fan assemblies, the processing circuitry can provide a signal to turn on one or more of the fan assemblies and terminate the signal to turn off one or more of the fan assemblies. The input information provided to the processing circuitry may include one or more temperature sensors (not shown in  FIG. 1 ) that determine(s) the temperature of the components within the internal volume of the enclosure  102 . As a result, when a threshold temperature is reached or exceeded, the processing circuitry can provide the signal to turn on one or more of the fan assemblies. Alternatively, or in combination, the input information provided to the processing circuitry may include an amount of time the heat-generating component  103  is in use. For example, after 10 minutes of operation of the heat-generating component  103 , the processing circuitry can provide the signal to turn on one or more of the fan assemblies. The time is intended to be exemplary only, and a different time (or times) may be used. 
       FIG. 2  illustrates an isometric view of an embodiment of a fan assembly  204  for use in electronic devices, in accordance with some described embodiments. The fan assembly  104   a , the fan assembly  104   b , and the fan assembly  104   c  (all shown in  FIG. 1 ) may include any features described herein for the fan assembly  204 . As shown, the fan assembly  204  includes a fan housing  210 . The fan housing  210  may include a housing part  212   a  and a housing part  212   b  that is coupled to the housing part  212   a . The housing part  212   a  and the housing part  212   b  may be referred to as a first housing part and a second housing part, respectively. Also, while the fan housing  210  is shown as a two-piece structure, the number of pieces can vary. 
     The fan assembly  204  further includes a fan inlet  214   a  and a fan inlet  214   b , each of which provides a pathway for air into the fan assembly  204 . The fan inlet  214   a  and the fan inlet  214   b  may be referred to as a first fan inlet and a second fan inlet, respectively. As shown, the fan inlet  214   a  and the fan inlet  214   a  are formed in the housing part  212   a  and the housing part  212   b , respectively. The fan assembly  204  further includes a fan outlet  216  that is defined by the housing part  212   a  and the housing part  212   b . The fan inlet  214   a  and the fan inlet  214   b  may each include a circular fan inlet and the fan outlet  216  may include a rectangular fan outlet. However, other shapes are possible. The fan assembly  204  further includes an impeller  218 . The impeller  218  may include several blades (not labeled) connected to an impeller hub  222 . The number of blades of the impeller  218  may be approximately in the range of 25-100 blades. The fan assembly  204  further includes a motor (shown below) that is coupled to the impeller  218  via the impeller hub  222 . During operation, the motor rotationally drives the impeller  218  (including the blades), which draws heated air away from heat-generating component  103  of the electronic device  100  (shown in  FIG. 1 ) and into the fan housing  210  via the fan inlet  214   a  and the fan inlet  214   b . The air received by the fan inlets passes through the fan housing  210  and out of the fan outlet  216 . In this manner, the fan assembly  204  provides cooling features for the heat-generating component  103 . 
     Also, the fan assembly  204  may include an insert  224  located in the fan housing  210 . The insert  224  may include foam (open cell foam or closed cell foam) or an elastomeric material, as non-limiting examples. Generally, the insert  224  may include any material, or materials, designed to deform, or undergo some form of displacement, during operation of the fan assembly  204 . In this regard, the insert  224  may be referred to as a deforming member, a deformable member, or a deformable membrane, as non-limiting examples. While the housing part  212   a  and the housing part  212   b  may include a rigid material (such as plastic or metal) designed to withstand any displacement from airflow from generated by the impeller  218 , the insert  224  is designed undergo some form of displacement during operation of the impeller  218 . This will be further shown and described below. 
       FIG. 3  illustrates an exploded view of the fan assembly  204  shown in  FIG. 2 , showing various features of the fan assembly  204 . As shown, the housing part  212   b  includes a platform  226  connected by several structures, such as a strut  228   a  and a strut  228   b . Although not shown, an additional strut may be present. The fan assembly  204  includes a motor  232  that can be positioned on the platform  226 . The motor  232  can couple to the impeller hub  222  and rotationally drive the impeller  218 . In order to provide power and control signals from processing circuitry of the electronic device  100  (shown in  FIG. 1 ), the motor  232  includes a flexible circuit  234  that electrically connects to the processing circuitry. The flexible circuit  234  can be routed through the fan inlet  214   b.    
     The housing part  212   a  and the housing part  212   b  of the fan housing  210  may each include an internal wall. For example, the housing part  212   a  and the housing part  212   b  include an internal wall  236   a  and an internal wall  236   b , respectively. When the housing part  212   a  is coupled with the housing part  212   b , the internal wall  236   a  and the internal wall  236   b  combine to define a fan scroll that collects and directs air taken in by the impeller  218  via the fan inlet  214   a  and the fan inlet  214   b . Moreover, the internal wall  236   a  and the internal wall  236   b  are each modified such that the insert  224  is integrated and defines, in part, the fan scroll. As a result, the insert  224  is exposed to airflow driven the impeller  218  during operation. 
       FIGS. 4-7  show and describe exemplary motion of the insert  224  during operation of the fan assembly  204  (and in particular, during operation of the impeller  218 ). For purposes of illustration, the housing part  212   a  is removed from the fan assembly  204  in  FIGS. 4-7 . 
       FIG. 4  illustrates a plan view of the fan assembly  204 . As shown in the enlarged view, the impeller  218  is separated from the insert  224  by a distance  238   a , which represents a dimension of the gap, or throat gap, between the impeller  218  and the insert  224 . The distance  238   a  may further represent the shortest distance between the impeller  218  and the insert  224 , prior to displacement of the insert  224 . Also, the impeller  218  may include a diameter  238   b . The ratio of the distance  238   a  to the diameter  238   b  may be approximately in the range of 1:33 to 1:20. In other words, the design of the fan assembly  204  may be specified such that the distance  238   a  is approximately in the range of 3% to 5% of the diameter  238   b.    
     The ratio of the distance  238   a  to the diameter  238   b  can be a contributing factor to noise generation by the fan assembly  204  during operation. For example, when the ratio increases, the gap between the impeller  218  and the insert  224  increases, resulting in reduced pressure and reduced acoustic (tonal) noise. However, the increased gap can also allow additional airflow to recirculate and remain in the fan assembly  204 , as compared to smaller gaps. In this regard, the insert  224  provides the fan assembly  204  with a self-adjusting gap that is based upon the airflow and corresponding air pressure applied to the insert  224 . For example, the insert  224  responds to increased air pressure by undergoing displacement (such as compression) and providing the fan assembly  204  with an increased gap size during instances of relatively high speed operation (in RPM) by the impeller  218 . Conversely, the insert  224  responds to decreased air pressure by returning to its original non-displaced (or decompressed) position and providing a decreased gap during instances of relatively low speed operation of the impeller  218 . Accordingly, the gap size is proportional to the speed of the impeller  218 . 
     The self-adjusting features of the gap are provided in part by the material makeup of the insert  224 . In this regard, the displacement if the insert  224  may be due solely to the airflow provided by the impeller  218 . As a result, the fan assembly  204  may not required external controllers or mechanical levers that actuate the insert  224 . 
       FIG. 5  illustrates a cross sectional view of the fan assembly  204  shown in  FIG. 4 , showing a gap  240  between the impeller  218  and the insert  224 . As shown, the gap  240  is defined in part by the distance  238   a  along the X-axis. The gap  240  (also defined in part by the housing part  212   a , the housing part  212   b , the impeller  218  and the insert  224 ) represents a cross sectional area through which airflow driven by the impeller  218  can pass. 
     The insert  224 , as shown in  FIGS. 4 and 5 , defines a decompressed state in which no airflow or an insufficient amount of airflow is acting upon the insert  224 . However, the insert  224  may transition from the decompressed stated to a compressed state. For example,  FIG. 6  illustrates a plan view of the fan assembly  204  shown in  FIG. 4 , showing displacement of the insert  224  in response to airflow generated by the impeller  218 . As shown, the impeller  218  is undergoing rotational movement. Further, the speed, in RPM, of the impeller  218  is sufficient to provide a force from the airflow such that the insert  224  is displaced. For example, as shown in the enlarged view, the airflow contacts the insert  224 , thereby causing the insert  224  to compress. The dotted line  241  indicates the initial position prior to the airflow displacing the insert  224 . The compression of the insert  224  causes the distance  238   a  to increase. 
       FIG. 7  illustrates a cross sectional view of the fan assembly  204  shown in  FIG. 6 , showing the gap  240  increased based on the airflow displacing the insert  224 . The dotted line  241  indicates the initial position prior to the airflow displacing the insert  224 . Based on the increase in the distance  238   a  between the impeller  218  and the insert  224 , the cross sectional area of the gap  240  is increased. The increased cross sectional area of the gap  240  results in reduced air pressure (from the airflow) at the gap  240 , and subsequently reduced acoustic noise generated by the fan assembly  204 . 
       FIG. 8  illustrates a graph  350  plotting amplitude vs. fan order for a fan assembly during operation, in accordance with some described embodiments. The (vertical) Y-axis represents the amplitude of the sound pressure level (“SPL”). The fan order on the (horizontal) X-axis represents the number of blades passing a reference point, or blade passing frequency, under a full rotation of an impeller of a fan assembly. The impeller speed, in RPM, is held constant. 
     The graph  350  illustrates a plot  352  (solid line) representing a fan assembly with a ratio of separation distance (between the impeller and the insert) to impeller diameter of 1:35. The graph  350  further illustrates a plot  354  (dotted line) representing a fan assembly with a ratio of separation distance to impeller diameter of 1:20. As indicated by the plot  352  and the plot  354 , the amplitude for the fan order between 10 and 50 is similar. However, when the fan order is in the range of 60 to 70, the amplitude is noticeably different. For instance, the plot  352  shows several spikes indicating an increased tonal component of the fan assembly separate from the broadband noise from the fan assembly. On the other hand, the plot  354  is smoother, indicating reduced tonal components. As shown in the graph  350 , the amplitude between the plot  352  and the plot  354  may differ by 10-15 dBa in this range of 60 to 70. As a result, a fan assembly using the ratio of separation distance to impeller diameter of 1:20 may generate less tonal noise as compared to a fan assembly with a ratio of 1:35. 
       FIGS. 9-17  show and describe additional embodiments of a fan assembly. The fan assemblies shown and described in  FIGS. 9-17  may include several, if not all, features previously described for fan assemblies. Further, the fan assemblies shown and described in  FIGS. 9-17  can be integrated with the electronic device (shown in  FIG. 1 ). 
       FIG. 9  illustrates a plan view of an alternate embodiment of a fan assembly  404 . As shown, the fan assembly  404  includes a fan housing  410  that includes a housing part  412 . The housing part  412  includes an internal wall  436 . For purposes of illustration, an additional housing part with an internal wall is not shown. The fan assembly  404  further includes an impeller  418  positioned within the perimeter of the internal wall  436 . As shown in the enlarged view, the internal wall  436  defines a tip  456  that is separated from the impeller  418 . The tip  456  may be integrally formed with the internal wall  436  such that the internal wall  436  and the tip  456  are part of a monolithic structure. However, the tip  456  can nonetheless undergo displacement when the impeller  418  is rotationally driven. 
       FIG. 10  illustrates a cross sectional view of the fan assembly  404  shown in  FIG. 9 , taken along line  10 - 10 , showing structural features of the tip  456 . As shown, the tip  456  is separated from the impeller  418  by a distance  438 . Also, a gap  440  is defined in part by the distance  438  along the X-axis. Further, the tip  456  is connected to the internal wall  436  in a cantilevered manner such that the tip  456  can bend or flex relative to the internal by, for example, airflow generated from the impeller  418 . 
       FIG. 11  illustrates a cross sectional view of the fan assembly  404  shown in  FIG. 10 , showing displacement of the tip  456  in response to the airflow. As shown, the distance  438  between the impeller  418  and the tip  456  increases based on the airflow displacing the tip  456 . The dotted line  441  indicates the initial position prior to the airflow displacing the tip  456 . Based on the increase in the distance  438  between the impeller  418  and the tip  456 , the cross sectional area of the gap  440  also increases. The increased cross sectional area of the gap  440  results in reduced air pressure (due the airflow) at the gap  440 , and subsequently reduced acoustic noise generated by the fan assembly  404 . 
     In some instances, the displacement of the tip can be altered by modifying/adjusting the tip. For example,  FIG. 12  illustrates a cross sectional view of an alternate embodiment of a fan assembly  504 , showing the fan assembly  504  with a tip  556  modified with a recess  558 . As shown, the tip  556  is separated from the impeller  518  by a distance  538 . Also, a gap  540  is defined in part by the distance  538  along the X-axis. The tip  556  is connected to an internal wall  536  of the fan assembly  504  in a cantilevered manner such that the tip  556  can bend or flex relative to the internal by, for example, airflow generated from an impeller  518 . However, the recess  558  is formed at the connection point between the tip  556  and the internal wall  536 , thereby allowing the tip  556  to bend or flex under a lower force from the airflow. 
       FIG. 13  illustrates a cross sectional view of the fan assembly shown in  FIG. 12 , showing displacement of the tip  556  in response to airflow. As shown, the distance  538  between the impeller  518  and the tip  556  increases based on the airflow displacing the tip  556 . The dotted line  541  indicates the initial position prior to the airflow displacing the tip  556 . The recess  558  can provide the tip  556  with a more responsive movement by requiring less airflow. In other words, based upon the recess  558 , the tip  556  may react more quickly and/or react using less airflow. Similar to prior embodiments, the cross sectional area of the gap  540  increases as a result of the displacement of the tip  556 , which may lead to reduced acoustic noise generated by the fan assembly  504 . 
       FIG. 14  illustrates a cross sectional view of an alternate embodiment of a fan assembly  604 , showing the fan assembly  604  with a tip  656  modified with a flexible material  662 . As shown, the tip  656  is separated from the impeller  618  by a distance  638 . Also, a gap  640  is defined in part by the distance  638  along the X-axis. The tip  656  is connected to an internal wall  636  of the fan assembly  604  by the flexible material  662 . The flexible material  662  may include a relatively less rigid material, as compared to the material that forms the internal wall  636  and the tip  656 . For example, the internal wall  636  and the tip  656  may include a rigid plastic, while the flexible material  662  includes foam, an elastomeric material, or a flexible adhesive, as non-limiting examples. The flexible material  662  defines the connection point between the tip  656  and the internal wall  636 . In this manner, the tip  556  may bend or flex under a lower force from the airflow based upon the spring constant of the flexible material  662  rather than the material of the internal wall  636 . 
       FIG. 15  illustrates a cross sectional view of the fan assembly shown in  FIG. 14 , showing displacement of the tip  656  in response to airflow. As shown, the distance  638  between the impeller  618  and the tip  656  increases based on the airflow displacing the tip  656 . The dotted line  641  indicates the initial position prior to the airflow displacing the tip  656 . By lower the spring constant required to displace the tip  656 , the flexible material  662  can provide the tip  556  with a more responsive movement and/or allow displacement of the tip  656  using less airflow. Similar to prior embodiments, the cross sectional area of the gap  640  increases as a result of the displacement of the tip  656 , which may lead to reduced acoustic noise generated by the fan assembly  604 . 
       FIG. 16  illustrates a cross sectional view of an alternate embodiment of a fan assembly  704 , showing the fan assembly  704  with an insert  724  controlled by magnets. As shown, the fan assembly  704  includes a fan housing  710  that includes a housing part  712 . The housing part  712  includes an internal wall  736 . For purposes of illustration, an additional housing part with an internal wall is not shown. The fan assembly  704  further includes an impeller  718  positioned within the perimeter of the internal wall  736 . The fan assembly  704  may include an insert  724  located in the fan housing  710 . The insert  724  may include a rigid material, such as metal or plastic. However, other materials described herein for an insert may be used. As shown in the enlarged view, the insert  724  is coupled to the fan housing  710  by a pivot  764 . In this regard, the insert  724  can rotate about the pivot  764 . 
     Further, the insert  724  may include a bi-stable configuration in which one configuration includes no airflow or relatively low airflow generated by the impeller  718 , and another configuration in which a relatively high airflow is generated by the impeller  718 . In this regard, the fan assembly  704  includes a magnet  766   a  and a magnet  766   b  carried by the fan housing  710 , as well as a magnet  768  carried by the insert  724 . As shown, the magnet  768  (of the insert  724 ) is magnetically coupled with the magnet  766   a  (in the fan housing  710 ), and the insert  724  is separated from the impeller  718  by a distance  738 . The distance  738  represents the closest distance between the impeller  718  and the insert  724 . The position of the insert  724  shown in  FIG. 16  represents an inactive state of the impeller  718 . Alternatively, the position of the insert  724  shown in  FIG. 16  represents low airflow generated by the impeller  718  that does not generate sufficient force to overcome the magnetic attraction force between the magnet  766   a  and the magnet  768 . 
       FIG. 17  illustrates a cross sectional view of the fan assembly  704  shown in  FIG. 16 , showing the displacement of the insert  724  in response to airflow. As shown, the impeller  718  is undergoing rotational movement. Further, the speed, in RPM, of the impeller  718  creates sufficient airflow such that the insert  724  is displaced. As shown in the enlarged view, the force generated by the airflow overcomes the magnetic attraction force between the magnet  766   a  and the magnet  768 , and causes the insert  724  to rotate counter-clockwise about the pivot  764  such that the magnet  768  magnetically couples with the magnet  766   b . The rotation of the insert  724  to the position shown in  FIG. 17  causes the distance  738  to increase, thereby increasing the cross sectional area of the gap between the impeller  718  and the insert  724 . The dotted line  741  indicates the initial position prior to the airflow displacing the insert  224 . In this manner, the gap between the impeller  718  and the insert  724  increases as a result of the displacement of the tip  656 , which may lead to reduced acoustic noise generated by the fan assembly  704 . It should be noted that when the airflow by the impeller  718  sufficiently reduces or stops, the pivot  764  may provide biasing force to the insert  724  that overcomes the magnetic attraction force between the magnet  766   b  and the magnet  768 , and causes the insert  724  to rotate clockwise about the pivot  764  such that the magnet  768  magnetically couples with the magnet  766   a.    
       FIG. 18  illustrates a flowchart  800  showing a method for operating a fan assembly in an electronic device, in accordance with some described embodiments. One or more of the fan assemblies (previously described) may carry out the method shown in the flowchart  800 . In step  802 , an impeller of the fan assembly is rotated. The impeller may include several blades. Also, the fan assembly may include a motor that rotationally drives the impeller. 
     In step  804 , the impeller drives airflow through a fan housing. The fan housing carries an insert that is separated from the impeller by a gap. The gap may define a space with a cross sectional area between the impeller and the insert. 
     In step  806 , the insert is compressed, based on the airflow. In this regard, the insert is compressed such that the gap transitions from a first size to a second size greater than the first size. The second size refers to a gap size that is greater than that of the first size. As a result of the second gap size, the cross sectional area between the impeller and the insert is greater, resulting in less air pressure and noise generation during operation of the fan assembly. 
       FIG. 19  illustrates a block diagram of an electronic device, in accordance with some described embodiments. The features in the electronic device  900  may be present in other electronic devices described herein. The electronic device  900  may include one or more processors  910  for executing functions of the electronic device  900 . The one or more processors  910  can refer to at least one of a central processing unit (CPU) and at least one microcontroller for performing dedicated functions. Also, the one or more processors  910  can refer to application specific integrated circuits. 
     According to some embodiments, the electronic device  900  can optionally include a display unit  920 . The display unit  920  is capable of presenting a user interface that includes icons (representing software applications), textual images, and/or motion images. In some examples, each icon can be associated with a respective function that can be executed by the one or more processors  910 . In some cases, the display unit  920  includes a display layer (not illustrated), which can include a liquid-crystal display (LCD), light-emitting diode display (LED), or the like. According to some embodiments, the display unit  920  includes a touch input detection component and/or a force detection component that can be configured to detect changes in an electrical parameter (e.g., electrical capacitance value) when the user&#39;s appendage (acting as a capacitor) comes into proximity with the display unit  920  (or in contact with a transparent layer that covers the display unit  920 ). The display unit  920  is connected to the one or more processors  910  via one or more connection cables  922 . 
     According to some embodiments, the electronic device  900  can include one or more sensors  930  capable of provide an input to the one or more processors  910  of the electronic device  900 . The one or more sensors  930  may include a temperature sensor, as a non-limiting example. The one or more sensors  930  is/are connected to the one or more processors  910  via one or more connection cables  932 . 
     According to some embodiments, the electronic device  900  can include one or more input/output components  940 . In some cases, the one or more input/output components  940  can refer to a button or a switch that is capable of actuation by the user. When the one or more input/output components  940  are used, the one or more input/output components  940  can generate an electrical signal that is provided to the one or more processors  910  via one or more connection cables  942 . 
     According to some embodiments, the electronic device  900  can include a power supply  950  that is capable of providing energy to the operational components of the electronic device  900 . In some examples, the power supply  950  can refer to a rechargeable battery. The power supply  950  can be connected to the one or more processors  910  via one or more connection cables  952 . The power supply  950  can be directly connected to other devices of the electronic device  900 , such as the one or more input/output components  940 . In some examples, the electronic device  900  can receive power from another power sources (e.g., an external charging device) not shown in  FIG. 19 . 
     According to some embodiments, the electronic device  900  can include memory  960 , which can include a single disk or multiple disks (e.g., hard drives), and includes a storage management module that manages one or more partitions within the memory  960 . In some cases, the memory  960  can include flash memory, semiconductor (solid state) memory or the like. The memory  960  can also include a Random Access Memory (“RAM”) and a Read-Only Memory (“ROM”). The ROM can store programs, utilities or processes to be executed in a non-volatile manner. The RAM can provide volatile data storage, and stores instructions related to the operation of the electronic device  900 . In some embodiments, the memory  960  refers to a non-transitory computer readable medium. The one or more processors  910  can also be used to execute software applications. In some embodiments, a data bus  962  can facilitate data transfer between the memory  960  and the one or more processors  910 . 
     According to some embodiments, the electronic device  900  can include wireless communications components  970 . A network/bus interface  972  can couple the wireless communications components  970  to the one or more processors  910 . The wireless communications components  970  can communicate with other electronic devices via any number of wireless communication protocols, including at least one of a global network (e.g., the Internet), a wide area network, a local area network, a wireless personal area network (WPAN), or the like. In some examples, the wireless communications components  970  can communicate using NFC protocol, BLUETOOTH® protocol, or WIFI® protocol. 
     According to some embodiments, the electronic device  900  can include a fan assembly  980 . The fan assembly  980  is designed to remove heat from one or more heat-generating components of the electronic device  900 , such as the one or more processors  910 . The fan assembly  980  may include modifications such as an insert designed to reduce air pressure and noise generation by the fan assembly  980  by promoting a self-adjusting gap between the insert and an impeller of the fan assembly  980 . In some embodiments, one or more cables  982  can facilitate signals between the fan assembly  980  and the one or more processors  910 . As a result, the one or more processors  910  may use information from the sensors  930  to control the fan assembly  980 . 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20200214
Publication Date: 20220104
Grant Date: 20220104
Priority Date: 20190926
Inventors: BERBEROGLU, HALIL
TAN, CHENG PING
NAGHIB LAHOUTI, ARASH
HERMS, RICHARD A.
DYBENKO, JESSE T.
RASOULI, ASHKAN
Assignee: APPLE INC
CPC Classifications: [{"code": "F04D29/4226", "inventive": true, "first": true, "tree": "[]"}, {"code": "F04D29/4226", "inventive": true, "first": true, "tree": "[]"}, {"code": "F04D29/602", "inventive": false, "first": false, "tree": "[]"}, {"code": "F04D17/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "F05D2300/501", "inventive": false, "first": false, "tree": "[]"}, {"code": "F04D29/422", "inventive": true, "first": false, "tree": "[]"}, {"code": "F04D17/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "F04D29/4226", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 75163109