Rotor and manufacturing method thereof
A manufacturing method of a rotor includes the following steps. A substrate is processed to form a first patterned area, a second patterned area and a third patterned area. The second patterned area is formed around the first patterned area, and the third patterned area is connected to the second patterned area. The first patterned area is processed to form a case. The third patterned area is bent towards the case along a joint line between the second patterned area and the third patterned area to form the blades. The rotor includes a case, a connecting portion and the blades. The case is cylindrical and has a sidewall. The connecting portion is extended from one end of the sidewall of the case. The blades are extended from the connecting portion.
Latest Patents:
This Non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No(s). 095118732 filed in Taiwan, Republic of China on May 26, 2006, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION1. Field of Invention
The invention relates to a fan and a manufacturing method thereof, and in particular, to a fan integrally formed as a single piece and the manufacturing method thereof.
2. Related Art
The Fans are indispensable components in the applications of life or technology. They are the first choice for dissipating heat or flowing fluid.
The blades are very important for a fan, because they can affect the pressure, air quantity and noise of the fan. Conventionally, the blades are formed by plastic injection molding method. In practice, an injective envelope, which forms the blades, is formed on a case to be a rotor. However, the plastic blades are not rigid so that the characters, such as the pressure, air quantity or noise are worse if the fan is under the higher rotation speed or the blades are thinner.
To solve the rigid problem of blades, the manufacturers disclosed the blades, which are made of metal.
As above-mentioned, the conventional fan uses the metal blades for the purpose of faster rotation speed or thinner blades design. However, the application and manufacturing of the conventional metal blades still have the problem of poor adaptation. Therefore, it is an important subject to provide a rotor and manufacturing method thereof which can reduce the blades deformation issue while assembling the blades and the case so as to maintain the efficiency of the fan.
SUMMARY OF THE INVENTIONIn view of the foregoing, the invention is to provide a rotor having better efficiency and manufacturing method thereof.
To achieve the above, the invention discloses a manufacturing method of a rotor, which includes the following steps. A substrate is processed to form a first patterned area, a second patterned area and a third patterned area. The second patterned area is formed around the first patterned area, and the third patterned area is connected to the second patterned area. The first patterned area is processed to form a cylindrical case. The third patterned area is bent towards the cylindrical case along a joint line between the second patterned area and the third patterned area to form a blade.
To achieve the above, the invention also discloses a rotor, which includes a case, a connecting portion and a blade. The case, which is cylindrical, has a sidewall. The connecting portion is extended from one end of the sidewall of the case. The blade is integrally formed with the connecting portion.
As mentioned above, the case, blade and connecting portion of the rotor of the invention are integrally formed. Thus, the conventional fixing elements are unnecessary. Moreover, the blade deforms causing by connecting the blade to the case in the prior art is prevented. In addition, the case of the invention is formed with a cylindrical. Therefore, the rotor is able to apply to the radial-flux induction motor, which has the higher efficient. Furthermore, because the rotor of the invention is integrally formed, the conventional process with riveting or locking is not necessary. Accordingly, the manufacturing time and the manufacturing cost are reduced.
The invention will become more fully understood from the detailed description given herein below illustration only, and thus is not limitative of the present invention, and wherein:
The present invention will be apparent from the following detailed description, which proceeds with reference to the accompanying drawings, wherein the same references relate to the same elements.
Refer to
With reference to
In the embodiment, the first patterned area 31, the second patterned area 32 and the third patterned area 33 are formed by punching the substrate 30.
With reference to
Alternatively, the cylindrical case 31′ and the first patterned area 31, the second patterned area 32 and the third patterned area 33 can be simultaneously formed. The cylindrical case 31′ is formed by the punching process. In other words, the step S2 and step S3 above mentioned can be performed simultaneously. As shown in
Referring to
It is noted that, the axial portion H1 is used to connect a shaft if the rotor is combined with a stator. In the embodiment, the axial portion H1 is a through hole.
With reference to
As shown in
In summary, the case, the blades and the connecting portion of the rotor of the invention are integrally formed. Thus, the conventional fixing elements are unnecessary, and the blades deformed causing by connecting the blades to the case in the prior art is prevented. In addition, the case of the invention is formed with a cylindrical case so that the rotor is applied to the radial-flux induction motor having higher efficient. Furthermore, the rotor of the invention is integrally formed so that the conventional process with riveting or locking is not necessary. Accordingly, the manufacturing time and the manufacturing cost are reduced.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments, will be apparent to persons skilled in the art. It is, therefore, contemplated that the appended claims will cover all modifications that fall within the true scope of the invention.
Claims
1. A manufacturing method of a rotor, comprising steps of:
- processing a substrate to form a first patterned area, a second patterned area and a third patterned area, wherein the second patterned area is formed around the first patterned area, and the third patterned area is connected to the second patterned area;
- forming a cylindrical case by processing the first patterned area; and
- bending the third patterned area towards the cylindrical case along a joint line between the second patterned area and the third patterned area to form a blade.
2. The method according to claim 1, wherein the first patterned area, the second patterned area and the third patterned area are formed by punching process.
3. The method according to claim 1, wherein the cylindrical case is formed by processing the first patterned area with a drawing process, a vacuum drawing process or a punching process.
4. The method according to claim 1, wherein the third patterned area is bent towards the cylindrical case along the joint line by about 90 degrees.
5. The method according to claim 1, further comprising a step of:
- forming an axial portion on the first patterned area.
6. The method according to claim 5, wherein the axial portion is a through hole.
7. The method according to claim 1, wherein the substrate is made of metal, iron, steel, aluminum or aluminum alloy.
8. A rotor comprising:
- a case having a sidewall;
- a connecting portion connected to one end of the sidewall of the case; and
- a blade connected to the connecting portion, wherein the blade and the connecting portion are integrally formed as a single piece.
9. The rotor according to claim 8, wherein the case is cylindrical.
10. The rotor according to claim 8, wherein the case, the connecting portion and the blade are made of metal, iron, steel, aluminum or aluminum alloy.
11. The rotor according to claim 8, wherein a first angle is formed between the connecting portion and the sidewall of the case.
12. The rotor according to claim 11, wherein the first angle is about 90 degrees.
13. The rotor according to claim 8, wherein a second angle is formed between the blade and the connecting portion.
14. The rotor according to claim 13, wherein the second angle is about 90 degrees.
15. The rotor according to claim 8, wherein the case and the connecting portion are integrally formed as a single piece.
16. The rotor according to claim 8, wherein the rotor is applied to a fan.
17. The rotor according to claim 8, wherein the case further comprises an axial portion.
18. The rotor according to claim 17, wherein the axial portion is a through hole.
Type: Application
Filed: May 8, 2007
Publication Date: Nov 29, 2007
Applicant:
Inventors: Wen-Shi Huang (Taoyuan Hsien), Lee-Long Chen (Taoyuan Hsien), Chun-Hua Yang (Taoyuan Hsien), Wen-Cheng Chen (Taoyuan Hsien)
Application Number: 11/797,858
International Classification: F04D 29/34 (20060101);