FAN BLADE DEVICE

Abstract

A fan blade device includes a fan blade having a hub portion and a plurality of blade portions connected to the hub portion, each blade portion having a front surface and a back surface opposite to each other, a plurality of first airflow guiding structures disposed on the front surface and including first guiding protrusions with first microchannels formed between adjacent protrusion parts, and a plurality of second airflow guiding structures disposed on the back surface and including second guiding protrusions with second microchannels formed between adjacent protrusion parts.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. application claims the benefits of priority to Taiwan application No. 114200515, filed on January 14, 2025, titled “Fan Blade Device” of which is incorporated herein by reference in its entirety.

BACKGROUND

A fan is a device configured for circulating air via rotating blades. Fans have a wide variety of applications. For example, fans may be household electric fans used for cooling and heat dissipation, as well as cooling fans employed to dissipate heat from electronic components, such as CPUs, in electronic devices.

Generally, a fan includes fan blades for generating airflow and a drive motor for rotating the fan blades. The structure of the fan blades considerably influence the performance and efficiency of the fan. However, when fan blades rotate, they generate high-speed airflow zones, and airflow vortexes formed in these high-speed zones deteriorate the fan blades and generate noise, which degrades user experience. Therefore, minimizing noise generated during fan operation is one of the issues that researchers need address.

SUMMARY

The present disclosure relates to a fan blade device, and more particularly to a fan blade device having airflow guiding structures.

In one aspect, a fan blade device comprises a fan blade including a hub portion and a plurality of blade portions, the blade portions being connected to the hub portion, each of the blade portions having a front surface and a back surface opposite to each other, a plurality of first airflow guiding structures disposed on the front surface of the blade portions and including a plurality of first guiding protrusions, the first guiding protrusions protruding from the front surface, each of the first guiding protrusions having a plurality of first protrusion parts, a first microchannel being formed between any two adjacent first protrusion parts, and a plurality of second airflow guiding structures disposed on the back surface of the blade portions and including a plurality of second guiding protrusions, the second guiding protrusions protruding from the back surface, each of the second guiding protrusions having a plurality of second protrusion parts, a second microchannel being formed between any two adjacent second protrusion parts.

In some embodiments, the first protrusion parts include a first sub-protrusion part and two second sub-protrusion parts, the first sub-protrusion part being located between the two second sub-protrusion parts, a height of the first sub-protrusion part being greater than a height of the two second sub-protrusion parts, the second protrusion parts including a third sub-protrusion part and two fourth sub-protrusion parts, the third sub-protrusion part being located between the two fourth sub-protrusion parts, a height of the third sub-protrusion part being greater than a height of the two fourth sub-protrusion parts.

In some embodiments, a maximum height of the first sub-protrusion part and the third sub-protrusion part is 0.6 millimeters and a maximum height of the second and fourth sub-protrusion parts is 0.42 millimeters.

In some embodiments, a maximum spacing between the first sub-protrusion part and either of the two second sub-protrusion parts and a maximum spacing between the third sub-protrusion part and either of the two fourth sub-protrusion parts are 0.45 millimeters.

In some embodiments, a maximum spacing between the first sub-protrusion part and either of the two first microchannels and a maximum spacing between the third sub-protrusion part and either of the two second microchannels are 0.25 millimeters.

In some embodiments, an angle between a vertical line from a vertex of each first sub-protrusion part to the corresponding front surface and a line from the vertex of the first sub-protrusion part to either of the two first microchannels is 37 degrees, and an angle between a vertical line from a vertex of each third sub-protrusion part to the corresponding back surface and a line from the vertex of the third sub-protrusion part to either of the two second microchannels is 37 degrees.

In some embodiments, an angle between a centerline parallel to the first sub-protrusion part of each first guiding protrusion on the front surface and a straight line extending radially from the hub portion is greater than or equal to 10 degrees and less than or equal to 170 degrees, and an angle between a centerline parallel to the third sub-protrusion part of each second guiding protrusion on the back surface and a straight line extending radially from the hub portion is greater than or equal to 10 degrees and less than or equal to 170 degrees.

In some embodiments, each of the blade portions has a first reference line and a second reference line on both the front surface and the back surface, the first reference line extending from one side where the blade portion connects to the hub portion to one side of the blade portion away from the hub portion, an angle between the first reference line and a tangent line intersecting at a connection point of the first reference line and the hub portion being an acute angle, the second reference line extending from one windward side of the blade portion to one leeward side of the blade portion, the second reference line being located at 1/5 of the first reference line from the hub portion, the first guiding protrusions being distributed between the side of the blade portion away from the hub portion and the second reference line on the front surface, the second guiding protrusions being distributed between the side of the blade portion away from the hub portion and the second reference line on the back surface.

In some embodiments, each of the blade portions further has a third reference line and a fourth reference line on both the front surface and the back surface, the third reference line being parallel to the second reference line, the fourth reference line being parallel to the first reference line, the fourth reference line being closer to the windward side of the blade portion as compared to the first reference line L1 and being located at 3/4 of the third reference line from the leeward side of the blade portion, at least some of the first guiding protrusions being distributed between the leeward side of the blade portion and the fourth reference line on the front surface, at least some of the second guiding protrusions being distributed between the leeward side of the blade portion and the fourth reference line on the back surface.

In some embodiments, a length of each first guiding protrusion and each second guiding protrusion is 1.8 millimeters and a width of each first guiding protrusion and each second guiding protrusion is 1.2 millimeters.

In some embodiments, a spacing between a centerline parallel to a center sub-protrusion part of each first guiding protrusion on the front surface and an adjacent first guiding protrusion is greater than or equal to the width of each first guiding protrusion, and a spacing between a centerline parallel to a center sub-protrusion part of each second guiding protrusion on the back surface and an adjacent second guiding protrusion is greater than or equal to a width of each second guiding protrusion.

In some embodiments, a bottom of each first microchannel and each second microchannel is acute angular shaped.

In some embodiments, a top of the first sub-protrusion part and tops of the second sub-protrusion parts are acute angular shaped.

In some embodiments, the fan blade further includes an outer ring portion connected to sides of the blade portions away from the hub portion and surrounding the blade portions.

In some embodiments, the first airflow guiding structures and the second airflow guiding structures are integrally formed with the blade portions through injection molding.

In another aspect, a guiding protrusion for a fan blade device includes at least two lateral protrusion parts disposed on opposite sides of the guiding protrusion, and a central protrusion part disposed between the lateral protrusion parts, wherein the central protrusion part has a greater height than the lateral protrusion parts, and wherein the guiding protrusion is configured to be dispose on a blade portion.

In some embodiments, the central protrusion part has a maximum height of 0.6 millimeters, each lateral protrusion part has a maximum height of 0.42 millimeters, and a maximum spacing between the central protrusion part and the lateral protrusion parts is 0.45 millimeters.

In some embodiments, a centroid of the guiding protrusion is offset toward one end of the guiding protrusion.

In some embodiments, structured microchannels are defined between adjacent protrusion parts and are configured to guide airflow and reduce airflow vortexes during fan blade rotation.

In another aspect, a method of fabricating a fan blade device includes providing a fan blade including a hub portion and a plurality of blade portions connected to the hub portion, each blade portion having a front surface and a back surface opposite to one another, forming a plurality of first airflow guiding structures on the front surface of the blade portions, including forming a plurality of first guiding protrusions that protrude from the front surfaces, wherein forming each of the first guiding protrusions comprises forming a plurality of first protrusion parts such that a first microchannel is formed between any two adjacent first protrusion parts, and forming a plurality of second airflow guiding structures on the back surface of the blade portions, including forming a plurality of second guiding protrusions that protrude from the back surfaces, wherein forming each of the second guiding protrusions comprises forming a plurality of second protrusion parts such that a second microchannel is formed between any two adjacent second protrusion parts.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a fan blade device according to an embodiment of the present disclosure.

FIG. 2 is another perspective view of the fan blade device.

FIG. 3 is a partial enlarged plan view of the fan blade device.

FIG. 4 is another partial enlarged plan view of the fan blade device.

FIG. 5 is yet another partial enlarged plan view of the fan blade device.

FIG. 6 is another partial enlarged plan view of the fan blade device.

FIG. 7 is a cross-sectional view of a first guiding protrusion of the fan blade device of FIG. 1.

FIG. 8 is a schematic diagram showing noise distribution on a front surface of a fan blade of an example fan blade device.

FIG. 9 is a schematic diagram showing noise distribution on a front surface of the fan blade of the fan blade device according to an embodiment of the present disclosure.

FIG. 10 is a schematic diagram showing noise distribution on a back surface of a fan blade of another example fan blade device.

FIG. 11 is a schematic diagram showing noise distribution on a back surface of the fan blade of the fan blade device according to an embodiment of the present disclosure.

FIG. 12 is a schematic diagram showing airflow distribution of a fan blade of yet another example fan blade device.

FIG. 13 is a schematic diagram showing airflow distribution of the fan blade of the fan blade device according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.

Referring to FIGS. 1 and 2, a fan blade device 10 according to an embodiment of the present disclosure is illustrated. FIG. 1 is a perspective view of the fan blade device 10, and FIG. 2 is another perspective view of the fan blade device 10.

The fan blade device 10 of the present embodiment is used in, for example, personal computers, servers, household appliances, or similar equipment, and includes a fan blade 20, a plurality of first airflow guiding structures 30, and a plurality of second airflow guiding structures 40. The fan blade 20 includes a hub portion 21 and a plurality of blade portions 22. The blade portions 22 are connected to the hub portion 21. Each blade portion 22 has a front surface 221 and a back surface 222, the front surface 221 and the back surface 222 are opposite to one another.

Referring to FIGS. 3 to 6, FIG. 3 is a partial enlarged plan view of the fan blade device of FIG. 1; FIG. 4 is a partial enlarged plan view of the fan blade device of FIG. 2; FIG. 5 is a partial enlarged plan view of the fan blade device of FIG. 3; and FIG. 6 is a partial enlarged plan view of the fan blade device of FIG. 4.

The first airflow guiding structures 30 are disposed on the blade portions 22, for example, through injection molding, and include a plurality of first guiding protrusions 31. The first guiding protrusions 31 protrude from the front surfaces 221. Each first guiding protrusion 31 has a plurality of first protrusion parts 311. The second airflow guiding structures 40 are disposed on the blade portions 22, for example, through injection molding, and include a plurality of second guiding protrusions 41. The second guiding protrusions 41 protrude from the back surfaces 222. Each second guiding protrusion 41 has a plurality of second protrusion parts 411.

A first microchannel C1 is formed between any two adjacent first protrusion parts 311, and a second microchannel C2 is formed between any two adjacent second protrusion parts 411. The first microchannels C1 and the second microchannels C2 are configured to guide the airflow generated by the fan blade device 10. Specifically, the first microchannels C1 and the second microchannels C2 are arranged, for example, along the flow angle of the airflow generated by the rotation of the fan blade 20. In one embodiment, a bottom of the first microchannel C1 and a bottom of the second microchannel C2, respectively, have an acute angular shape.

In the present embodiment, each of the blade portions 22 has a first reference line L1 and a second reference line L2 on both the front surface 221 and the back surface 222. The first reference line L1 extends from a side where the blade portion 22 connects to the hub portion 21 to a side of the blade portion 22 away from the hub portion 21. A tangent line T is a line intersecting at the connection point of the first reference line L1 and the hub portion 21. An angle R1 between the first reference line L1 and the tangent line T is, for example, an acute one. The second reference line L2 extends from a windward side 223 of the blade portion 22 to a leeward side 224 of the blade portion 22. The second reference line L2 is located, for example, at 1/5 of the first reference line L1 from the hub portion 21. The first guiding protrusions 31 are distributed between the side of the blade portion 22 away from the hub portion 21 and the second reference line L2 on the front surface 221. The second guiding protrusions 41 are distributed between the side of the blade portion 22 away from the hub portion 21 and the second reference line L2 on the back surface 222.

Furthermore, each of the blade portions 22 has a third reference line L3 and a fourth reference line L4 on both the front surface 221 and the back surface 222. The third reference line L3 is parallel to the second reference line L2. The fourth reference line L4 is parallel to the first reference line L1. The fourth reference line L4 is closer to the windward side 223 of the blade portion 22 as compared to the first reference line L1 and is located, for example, at 3/4 of the third reference line L3 from the leeward side 224. At least some of the first guiding protrusions 31 are distributed between the leeward side 224 of the blade portion 22 and the fourth reference line L4 on the front surface 221. At least some of the second guiding protrusions 41 are distributed between the leeward side 224 of the blade portion 22 and the fourth reference line L4 on the back surface 222.

In the present embodiment, the first protrusion parts 311 include a first sub-protrusion part 3111 and two second sub-protrusion parts 3112. The first sub-protrusion part 3111 is located between the two second sub-protrusion parts 3112. A height of the first sub-protrusion part 3111 is, for example, greater than a height of the two second sub-protrusion parts 3112. The second protrusion parts 411 include a third sub-protrusion part 4111 and two fourth sub-protrusion parts 4112. The third sub-protrusion part 4111 is located between the two fourth sub-protrusion parts 4112. A height of the third sub-protrusion part 4111 is, for example, greater than a height of the two fourth sub-protrusion parts 4112. In one embodiment, a top of the first sub-protrusion part 3111 and tops of the two second sub-protrusion parts 3112 have an acute angular shape.

In the present embodiment, an angle R2 between a centerline L5 parallel to the first sub-protrusion part 3111 of each first guiding protrusion 31 on the front surface 221 and a straight line L6 extending radially from the hub portion 21 is, for example, greater than or equal to 10 degrees and less than or equal to 170 degrees. An angle R3 between a centerline L7 parallel to the third sub-protrusion part 4111 of each second guiding protrusion 41 on the back surface 222 and a straight line L8 extending radially from the hub portion 21 is, for example, greater than or equal to 10 degrees and less than or equal to 170 degrees.

Referring to FIG. 7, which is a cross-sectional view of a first guiding protrusion of the fan blade device of FIG. 1. Since the structures of the first guiding protrusions 31 and the second guiding protrusions 41 are the same, the following description uses one of the first guiding protrusions 31 as an example.

In the present embodiment, a length L of each first guiding protrusion 31 is, for example, 1.8 millimeters. A width W of each first guiding protrusion 31 is, for example, 1.2 millimeters. In addition, a maximum height H1 of the first sub-protrusion part 3111 is, for example, 0.6 millimeters. A maximum height H2 of each second sub-protrusion part 3112 is, for example, 0.42 millimeters. A maximum spacing D1 between the first sub-protrusion part 3111 and either of the two second sub-protrusion parts 3112 is, for example, 0.45 millimeters. A maximum spacing D2 between the first sub-protrusion part 3111 and either of the two first microchannels C1 is, for example, 0.25 millimeters.

In the present embodiment, an angle R4 between a vertical line L9 from a vertex of each first sub-protrusion part 3111 to the corresponding front surface 221 and a line L10 from the vertex of the first sub-protrusion part 3111 to either of the two first microchannels C1 is, for example, 37 degrees. Similarly, an angle (not shown) between a vertical line from a vertex of each third sub-protrusion part 4111 to the corresponding back surface 222 and a line from the vertex of the third sub-protrusion part 4111 to either of the two second microchannels C2 is also, for example, 37 degrees.

In the present embodiment, a spacing D3 between a centerline L11 parallel to the first sub-protrusion part 3111 of each first guiding protrusion 31 on the front surface 221 and an adjacent first guiding protrusion 31 is, for example, equal and is greater than or equal to the width W of each first guiding protrusion 31. Similarly, a spacing (not shown) between a centerline parallel to the third sub-protrusion part 4111 of each second guiding protrusion 41 on the back surface 222 and an adjacent second guiding protrusion 41 is, for example, equal and is greater than or equal to the width of each second guiding protrusion 41.

Referring again to FIGS. 1 and 2, in the present embodiment, the fan blade device 10 may further include an outer ring portion 50. The outer ring portion 50 is connected to the side of the blade portions 22 away from the hub portion 21 and surrounds the blade portions 22. By providing the outer ring portion 50, noise generated during rotation of the fan blade 20 can be reduced and the structural strength of the fan blade device 10 can be enhanced.

Referring again to FIGS. 3 and 5, since the structures of the first guiding protrusions 31 and the second guiding protrusions 41 are the same, the following description uses one of the first guiding protrusions 31 as an example. In the present embodiment, when the fan blade 20 rotates and generates airflow, the airflow flows from the windward side 223 of the fan blade 20 along direction A toward the first guiding protrusion 31. Then, the airflow divides at one side of the first guiding protrusion 31 close to the windward side 223 and flows along directions B and C through the two first microchannels C1, respectively. Subsequently, the airflow converges at one side of the first guiding protrusion 31 close to the leeward side 224 and flows along direction D toward the leeward side 224 of the fan blade 20. By directing the flow of airflow through the first microchannels C1, a flow rectification effect can be achieved.

Referring to FIGS. 8 to 13, FIG. 8 is a schematic diagram showing noise distribution on a front surface of a fan blade of a comparative example fan blade device; FIG. 9 is a schematic diagram showing noise distribution on a front surface of the fan blade of the fan blade device according to an embodiment of the present disclosure; FIG. 10 is a schematic diagram showing noise distribution on a back surface of a fan blade of a comparative example fan blade device; FIG. 11 is a schematic diagram showing noise distribution on a back surface of the fan blade of the fan blade device according to an embodiment of the present disclosure; FIG. 12 is a schematic diagram showing airflow distribution of a fan blade of a comparative example fan blade device; and FIG. 13 is a schematic diagram showing airflow distribution of the fan blade of the fan blade device according to an embodiment of the present disclosure.

As shown in FIGS. 8, 10, and 12, since the fan blade is not provided with the first airflow guiding structures and the second airflow guiding structures as compared to the present embodiment, when the fan blade rotates and generates airflow, airflow vortexes are generated in high-speed airflow zones A1 and A2 of the fan blade, generating noise at the windward side and leeward side of the fan blade.

In the present embodiment, as shown in FIGS. 9, 11, and 13, since the fan blade 20 of the fan blade device 10 is provided with the first airflow guiding structures 30 and the second airflow guiding structures 40, the airflow generated by the rotation of the fan blade 20 can be adjusted through the first microchannels C1 and the second microchannels C2, making the airflow flow more smoothly. This significantly reduces airflow vortexes generated in high-speed airflow zones A1a and A2a at the front surface 221 and back surface of the fan blade 20, i.e., causing the airflow to split from the front surface 221 and back surface of the fan blade 20 during high-speed rotation to reduce airflow impact on the fan blade 20. As a result, noise generated during rotation of the fan blade 20 can be reduced, thereby improving user experience.

Furthermore, by providing the first airflow guiding structures 30 and the second airflow guiding structures 40 on the fan blade 20 to reduce noise generated during rotation of the fan blade 20, the rotational speed of the fan blade 20 can be further increased to generate greater airflow volume and higher air pressure. Consequently, the heat dissipation capability of the fan blade device 10 can be further improved.

In the present embodiment, the first guiding protrusions 31 are distributed between the side of the blade portion 22 away from the hub portion 21 and the second reference line L2 on the front surface 221, and at least some of the first guiding protrusions 31 are distributed between the leeward side 224 of the blade portion 22 and the fourth reference line L4 on the front surface 221; and the second guiding protrusions 41 are distributed between the side of the blade portion 22 away from the hub portion 21 and the second reference line L2 on the back surface 222, and at least some of the second guiding protrusions 41 are distributed between the leeward side 224 of the blade portion 22 and the fourth reference line L4 on the back surface 222. However, the present disclosure is not limited thereto. In other embodiments, the first guiding protrusions and the second guiding protrusions may be adjusted in distribution according to the shape of the fan blade or the application environment of the fan blade device.

In the present embodiment, the number of first sub-protrusion parts 3111 of the first protrusion parts 311 and the number of third sub-protrusion parts 4111 of the second protrusion parts 411 are each only one, and the number of second sub-protrusion parts 3112 of the first protrusion parts 311 and the number of fourth sub-protrusion parts 4112 of the second protrusion parts 411 are each two. However, the present disclosure is not limited thereto. In other embodiments, the number of first sub-protrusion parts of the first protrusion parts and the number of third sub-protrusion parts of the second protrusion parts may each be plural, and the number of second sub-protrusion parts of the first protrusion parts and the number of fourth sub-protrusion parts of the second protrusion parts may each be only one or each be three or more.

In the present embodiment, the height of the first sub-protrusion part 3111 is greater than the height of the two second sub-protrusion parts 3112, and the height of the third sub-protrusion part 4111 is greater than the height of the two fourth sub-protrusion parts 4112. However, the present disclosure is not limited thereto. In other embodiments, the height of the first sub-protrusion part may be equal to the height of the two second sub-protrusion parts, and the height of the third sub-protrusion part may be equal to the height of the two fourth sub-protrusion parts.

In the present embodiment, opposite ends of the guiding protrusion are disposed along the centerline of the guiding protrusion, for example L11. In some embodiments, a centroid of at least one guiding protrusion 31 or 41 is offset toward one end of the guiding protrusion rather than being centered along the centerline of the guiding protrusion. Referring to FIGS. 5-6, the centerline extends along a direction in which the central protrusion part (i.e., the first sub-protrusion part 3111 or the third sub-protrusion part 4111) extends. In some embodiments, the first sub-protrusion part 3111 or the third sub-protrusion part 4111 is positioned asymmetrically along the centerline of each guiding protrusion 31 or 41, respectively, and the maximum height of the first sub-protrusion part 3111 or the third sub-protrusion part 4111 is closer to one end of the guiding protrusion than to an opposite end. This asymmetric configuration causes the centroid of the entire guiding protrusion structure to be offset from a geometric center of the guiding protrusion along its length.

The offset centroid configuration provides optimized airflow guidance during fan blade rotation. As airflow approaches the guiding protrusion from the windward side 223 (as shown in direction A in FIG. 5), the asymmetric positioning of the central protrusion part 3111 allows for efficient airflow splitting into the two microchannels C1. The airflow then converges on the opposite side before flowing toward the leeward side 224 (in direction D). By positioning the central protrusion part closer to the windward side, the guiding protrusion is better adapted to the velocity gradient and pressure distribution of the incoming airflow, thereby reducing turbulence and minimizing noise generation.

In the present embodiment, the bottom of the first microchannel C1, the bottom of the second microchannel C2, the top of the first sub-protrusion part 3111, and the tops of the two second sub-protrusion parts 3112 are acute angular shaped. However, the present disclosure is not limited thereto. In other embodiments, the bottom of the first microchannel C1, the bottom of the second microchannel C2, the top of the first sub-protrusion part, and the tops of the two second sub-protrusion parts may be arc shaped.

In the present embodiment, each spacing D3 between the centerline L11 parallel to the first sub-protrusion part 3111 of each first guiding protrusion 31 on the front surface 221 and an adjacent first guiding protrusion 31 is constant, and each spacing (not shown) between the centerline parallel to the third sub-protrusion part 4111 of each second guiding protrusion 41 on the back surface 222 and an adjacent second guiding protrusion 41 is constant. However, the present disclosure is not limited thereto. In other embodiments, each spacing between the centerline parallel to the first sub-protrusion part of each first guiding protrusion on the front surface and an adjacent first guiding protrusion may be varied, and each spacing between the centerline parallel to the third sub-protrusion part of each second guiding protrusion on the back surface and an adjacent second guiding protrusion may be varied.

According to the fan blade device of the above embodiments, since the fan blade of the fan blade device is provided with the first airflow guiding structures and the second airflow guiding structures, the airflow generated by the rotation of the fan blade can be adjusted through the first microchannels and the second microchannels, thereby making the airflow flow more smoothly. This significantly reduces airflow vortexes generated in high-speed airflow zones at the front and back surfaces of the fan blade, i.e., causing the airflow to split from the front and back surfaces of the fan blade during high-speed rotation to reduce airflow impact on the fan blade. As a result, noise generated during fan blade operation can be reduced, thereby improving user experience.

Moreover, by providing the first airflow guiding structures and the second airflow guiding structures on the fan blade to reduce noise generated during fan blade operation, the rotational speed of the fan blade can be further increased to generate greater airflow volume and higher air pressure. Consequently, the heat dissipation capability of the fan blade device can be further improved.

A method of fabricating a fan blade device 10 according to an embodiment of the present disclosure comprises providing a fan blade 20 including a hub portion 21 and a plurality of blade portions 22 connected to a periphery of the hub portion 21, each blade portion 22 has a front surface 221 and a back surface 222 opposite to one another. The method further comprises forming a plurality of first airflow guiding structures 30 on the blade portions 22, including forming a plurality of first guiding protrusions 31 that protrude from the front surfaces 221. Forming each of the first guiding protrusions 31 comprises forming a plurality of first protrusion parts 311 such that a first microchannel C1 is formed between any two adjacent first protrusion parts 311. The method also comprises forming a plurality of second airflow guiding structures 40 on the blade portions 22, including forming a plurality of second guiding protrusions 41 that protrude from the back surfaces 222. Forming each of the second guiding protrusions 41 comprises forming a plurality of second protrusion parts 411 such that a second microchannel C2 is formed between any two adjacent second protrusion parts 411. By forming the first airflow guiding structures 30 on the front surfaces 221 and the second airflow guiding structures 40 on the back surfaces 222, the manufactured fan blade device 10 is capable of guiding airflow through the first microchannels C1 and the second microchannels C2 during rotation, thereby reducing airflow vortexes and noise while maintaining airflow performance.

Therefore, embodiments disclosed herein are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the embodiments disclosed may be modified and practiced in different but equivalent manners apparent to those of ordinary skill in the relevant art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope and spirit of the present disclosure. Of course, the disclosed embodiments are merely exemplary embodiments and that various modifications can be made without departing from the spirit and scope of the disclosure. Further, it should be understood that various aspects of the embodiment are not mutually exclusive of each other and can be combined as desired by a person of ordinary skill in the art as a matter of design choices.

The embodiments illustratively disclosed herein suitably may be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some number. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces.

Claims

1. A fan blade device, comprising:

a fan blade including a hub portion and a plurality of blade portions, the blade portions being connected to the hub portion, each of the blade portions having a front surface and a back surface opposite to each other;

a plurality of first airflow guiding structures disposed on the front surface of the blade portions and including a plurality of first guiding protrusions, the first guiding protrusions protruding from the front surface, each of the first guiding protrusions having a plurality of first protrusion parts, a first microchannel being formed between any two adjacent first protrusion parts; and

a plurality of second airflow guiding structures disposed on the back surface of the blade portions and including a plurality of second guiding protrusions, the second guiding protrusions protruding from the back surface, each of the second guiding protrusions having a plurality of second protrusion parts, a second microchannel being formed between any two adjacent second protrusion parts.

2. The fan blade device of claim 1, wherein the first protrusion parts include a first sub-protrusion part and two second sub-protrusion parts, the first sub-protrusion part being located between the two second sub-protrusion parts, a height of the first sub-protrusion part being greater than a height of the two second sub-protrusion parts, the second protrusion parts including a third sub-protrusion part and two fourth sub-protrusion parts, the third sub-protrusion part being located between the two fourth sub-protrusion parts, a height of the third sub-protrusion part being greater than a height of the two fourth sub-protrusion parts.

3. The fan blade device of claim 2, wherein a maximum height of the first sub-protrusion part and a maximum height of the third sub-protrusion part are 0.6 millimeters, a maximum height of each of the two second sub-protrusion parts and a maximum height of each of the two fourth sub-protrusion parts are 0.42 millimeters.

4. The fan blade device of claim 2, wherein a maximum spacing between the first sub-protrusion part and either of the two second sub-protrusion parts and a maximum spacing between the third sub-protrusion part and either of the two fourth sub-protrusion parts are 0.45 millimeters.

5. The fan blade device of claim 2, wherein a maximum spacing between the first sub-protrusion part and either of the two first microchannels and a maximum spacing between the third sub-protrusion part and either of the two second microchannels are 0.25 millimeters.

6. The fan blade device of claim 2, wherein an angle between a vertical line from a vertex of each first sub-protrusion part to the corresponding front surface and a line from the vertex of the first sub-protrusion part to either of the two first microchannels is 37 degrees, and an angle between a vertical line from a vertex of each third sub-protrusion part to the corresponding back surface and a line from the vertex of the third sub-protrusion part to either of the two second microchannels is 37 degrees.

7. The fan blade device of claim 2, wherein an angle between a centerline parallel to the first sub-protrusion part of each first guiding protrusion on the front surface and a straight line extending radially from the hub portion is greater than or equal to 10 degrees and less than or equal to 170 degrees, and an angle between a centerline parallel to the third sub-protrusion part of each second guiding protrusion on the back surface and a straight line extending radially from the hub portion is greater than or equal to 10 degrees and less than or equal to 170 degrees.

8. The fan blade device of claim 1, wherein each of the blade portions has a first reference line and a second reference line on both the front surface and the back surface, the first reference line extending from one side where the blade portion connects to the hub portion to one side of the blade portion away from the hub portion, an angle between the first reference line and a tangent line intersecting at a connection point of the first reference line and the hub portion being an acute angle, the second reference line extending from one windward side of the blade portion to one leeward side of the blade portion, the second reference line being located at 1/5 of the first reference line from the hub portion, the first guiding protrusions being distributed between the side of the blade portion away from the hub portion and the second reference line on the front surface, the second guiding protrusions being distributed between the side of the blade portion away from the hub portion and the second reference line on the back surface.

9. The fan blade device of claim 8, wherein each of the blade portions further has a third reference line and a fourth reference line on both the front surface and the back surface, the third reference line being parallel to the second reference line, the fourth reference line being parallel to the first reference line, the fourth reference line being closer to the windward side of the blade portion as compared to the first reference line L1 and being located at 3/4 of the third reference line from the leeward side of the blade portion, at least some of the first guiding protrusions being distributed between the leeward side of the blade portion and the fourth reference line on the front surface, at least some of the second guiding protrusions being distributed between the leeward side of the blade portion and the fourth reference line on the back surface.

10. The fan blade device of claim 1, wherein a length of each first guiding protrusion and a length of each second guiding protrusion are 1.8 millimeters, and a width of each first guiding protrusion and a width of each second guiding protrusion are 1.2 millimeters.

11. The fan blade device of claim 10, wherein a spacing between a centerline parallel to a center sub-protrusion part of each first guiding protrusion on the front surface and an adjacent first guiding protrusion is greater than or equal to the width of each first guiding protrusion, and a spacing between a centerline parallel to a center sub-protrusion part of each second guiding protrusion on the back surface and an adjacent second guiding protrusion is greater than or equal to a width of each second guiding protrusion.

12. The fan blade device of claim 1, wherein a bottom of the first microchannel and a bottom of the second microchannel are acute angular shaped.

13. The fan blade device of claim 2, wherein a top of the first sub-protrusion part and tops of the two second sub-protrusion parts are acute angular shaped.

14. The fan blade device of claim 1, wherein the fan blade further includes an outer ring portion, the outer ring portion being connected to one side of the blade portions away from the hub portion and surrounding the blade portions.

15. The fan blade device of claim 1, wherein the first airflow guiding structures and the second airflow guiding structures are integrally formed with the blade portions through injection molding.

16. A guiding protrusion for a fan blade device, comprising:

at least two lateral protrusion parts disposed on opposite sides of the guiding protrusion, and

a central protrusion part disposed between the lateral protrusion parts,

wherein the central protrusion part has a greater height than the lateral protrusion parts, and

wherein the guiding protrusion is configured to be dispose on a blade portion.

17. The fan blade device of claim 16, wherein the central protrusion part has a maximum height of 0.6 millimeters and each lateral protrusion part has a maximum height of 0.42 millimeters, a maximum spacing between the central protrusion part and either of the lateral protrusion parts is 0.45 millimeters.

18. The guiding protrusion of claim 16, wherein a centroid of the guiding protrusion is offset toward one end of the guiding protrusion.

19. The fan blade device of claim 16, wherein at least two structured microchannels are defined between adjacent protrusion parts, the structured microchannels are configured to guide airflow and reduce airflow vortexes during fan blade rotation.

20. A method of fabricating a fan blade device, comprising:

providing a fan blade including a hub portion and a plurality of blade portions connected to the hub portion, each blade portion having a front surface and a back surface opposite to one another;

forming a plurality of first airflow guiding structures on the front surface of the blade portions, including forming a plurality of first guiding protrusions that protrude from the front surfaces, wherein forming each of the first guiding protrusions comprises forming a plurality of first protrusion parts such that a first microchannel is formed between any two adjacent first protrusion parts; and

forming a plurality of second airflow guiding structures on the back surface of the blade portions, including forming a plurality of second guiding protrusions that protrude from the back surfaces, wherein forming each of the second guiding protrusions comprises forming a plurality of second protrusion parts such that a second microchannel is formed between any two adjacent second protrusion parts.