Patent Application
20220316494
The technical field relates to an axial air moving device, and more particularly relates to a manufacturing method of a blade for an axial air moving device with high-performance.
Generally, the axial air moving device is composed of a motor, a hub and a plurality of blades arranged around the hub. The motor drives the hub to rotate to let the blades push the fluid flowing. Moreover, the axial air moving device has to generate not only high air volume, but also sufficient air pressure to effectively overcome the flow resistance of the environment. Accordingly, in order to improve the characteristics of static pressure-air volume of the axial air moving device, the optimal performance is mostly obtained by adjusting the size and angle of the blades. When high air pressure is required, the designs of the blades with blades overlapped in the axial direction projection may be needed.
In the situation of blades overlapped in the axial direction projection, the radial demolding method was commonly adopted because the blades cannot be demolded from the axial direction in mass production. However, when the radial demolding method is adopted, the blades need to be designed with relatively simple geometry, such as a straight airfoil, due to the restriction of the demolding path, and that causes the geometrical shape of blades failing to be in the ideal shapes. Therefore, the blades having overlapped area in axial projection of varied geometries, such as varying blade angle at different radius positions, twisted blades with high skew angles or blades configured by non-planar stacking, etc., are restricted to be embodied because such blades cannot be manufactured by the radial demolding method. Thus, the better fluid performance cannot be achieved.
In view of the above drawbacks, the inventor proposes this disclosure based on his expert knowledge and elaborate researches in order to solve the problems of related art.
One object of this disclosure is to provide a manufacturing method of an axial air moving device with blades overlapped in the axial projection. The shapes of the blades of the axial air moving device manufactured by proposed method are not restricted by the radial demolding method, and the better fluid performance is then achieved when the axial air moving device is in operation.
In order to achieve the object mentioned above, this disclosure provides a manufacturing method of an axial air moving device with blades overlapped in the axial projection. The method includes: providing a model of the axial air moving device which includes a hub and a plurality of blades arranged annularly on a peripheral surface of the hub spacedly, and each of the blades is overlapped in the axial direction of the hub; parting off the model of the axial air moving device in the axial direction of the hub to divide the blades into at least one first blade and at least one second blade non-overlapped in the axial projection respectively and to form a plurality of parting models; performing a mold manufacture using axial demolding to the parting models to form at least one first mold and at least one second mold; performing an injection molding by using the first mold and the second mold, the first mold forming a first parting model including a plurality of first blades and a second parting model including a plurality of second blades; and connecting the first parting model and the second parting model to form the complete axial air moving device; wherein, the second blades are connected to the first blades forming the continuous blade surface as a whole.
Comparing with the related art, the edge of the blades of this disclosure can be non-linear manner, and each blade has a partially overlapped projection in the axial direction, such kind of axial air moving device cannot be manufactured by the radial demolding method of previous art. Moreover, the axial air moving device of this disclosure are parted in the axial direction to form a plurality of parting models, and each blade is divided into multiple sub-blades having non-overlapped area in the axial projection and to form a plurality of parting models. Then, the mold manufacture using axial demolding to the parting models and an injection molding with the molds are performed to form the parting models. Finally, the parting models are connected to form the blades with a curved surface in a continuous manner. Therefore, the blades overlapped in the axial projection are produced through the axial demolding method instead of the radial demolding method. The limitation on the blade geometry in radial demolding method is removed by this disclosure. Thus, the axial air moving device could achieve better aerodynamic performance.
The features of the disclosure believed to be novel are set forth with particularity in the appended claims. The disclosure itself, however, may be best understood by reference to the following detailed description of the disclosure, which describes a number of exemplary embodiments of the disclosure, taken in conjunction with the accompanying drawings, in which:
The technical contents of this disclosure will become apparent with the detailed description of embodiments accompanied with the illustration of related drawings as follows. It is intended that the embodiments and drawings disclosed herein are to be considered illustrative rather than restrictive.
Please refer to
It is worth noting that the edge of each blade 20 is not arranged in a linear manner, and each blade 20 has an axial projection 20′ overlapped partially in the axial direction 100. In some embodiments, the ratio of the diameter of the hub 10 to the diameter of the blades 20 is greater than 0.25.
Please further refer to
Specifically, one end of each first blade is connected to the hub 10 and the other end of each first blade is located on the same height with respect to the top surface of the hub 10. Moreover, each of the second blades 22 is connected to each first blade 21 correspondingly, so that each blade 20 is formed to have a curved surface in a continuous manner.
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Moreover, the peripheral surface 12 includes a first peripheral surface 121 connected to the first blades 21 and a second peripheral surface 122 connected to the second blades 22. The first hub 101 includes the first peripheral surface 121 and the top surface 11. The second hub 102 includes the second peripheral surface 122.
Please further refer to
It should be noted that the processes of parting and dividing of the axial air moving device 1 of this disclosure 1 may be performed by the aforementioned rules to make a plurality of parting models 300. In one embodiment of this disclosure, the number of parting models 300 of the axial air moving device 1 is two. In some embodiments, the number of parting models 300 of the axial air moving device 1 may be equal to or more than two by the aforementioned rules. Moreover, in this embodiment, the blades 20 of the axial air moving device 1 are designed with different skew angles on the cross sections in different radius positions.
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The difference between this embodiment and the previous embodiment is that the axial air moving device 1c is parted into a plurality of parting models 300c in the axial direction 100c in a non-coplanar manner. The parting models 300c include one first parting model 301c and one second parting model 302c, and each blade 20c is divided into at least one first blade 21c and at least one second blade 22c, which are non-overlapped in the axial projection respectively. Furthermore, the manufacturing method of the axial air moving device with the blades overlapped in the axial projection of this disclosure is as follows. First, a model of an axial air moving device is provided (step a). The model of the axial air moving device model 1 includes a hub and a plurality of blades arranged annularly on the peripheral surface of the hub, and each blade has an axial projection overlapped in the axial direction of the hub. Additionally, the model of the axial air moving device is parted in the axial direction of the hub to divide the blades into at least one first blade and at least one second blade, which are non-overlapped in the axial projection and to form a plurality of parting models (step b). It is worth noting that in some embodiments, the blade is divided into a plurality of sub-blades non-overlapped in the axial projection, and the number of the sub-blades may be equal to or more than two.
Subsequently, a mold manufacture using axial demolding of the parting models is performed to form at least one first mold and one second mold (step c) and an injection molding by the first mold and the second mold is performed. The first mold forms a first parting model including a plurality of first blades and a second parting model including a plurality of second blades (step d). It should be noted that the number of the molds in this example is two, and the number of the molds is corresponding to the number of sub-blades non-overlapped in the axial projection. It is worth noting that using the first parting mold and the second parting mold of this disclosure for the injection molding does not have to use the complex sliders applied in the radial demolding method. Therefore, the cost of molds, working hours and production cost may be reduced.
Finally, the first parting model and the second parting model are connected (refer to
It should be noted that the connection method of the first parting model and the second parting model is not limited. In some embodiments, the connection is achieved by hot pressing, tight fitting, ultrasonic welding, bonding or engaging, etc.
While this disclosure has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of this disclosure set forth in the claims.
