Plastic fan shroud and cone assembly and method

摘要

A manufacturing method and assembly for providing ventilation to a selected structure is disclosed. The assembly may include various features such as flexible portions, rigid portions, and assembly portions. Further, various steps may be used to form the assembly to achieve selected results, such as single piece formation, inclusion of various positioning members, and packaging or shipping considerations.

主权项

1. A method of manufacturing a housing assembly for a fan portion, comprising:
forming a three dimensional shroud assembly as a single piece, comprising:
a shroud having a face-wall that substantially defines a face-wall plane and an orifice wall extending from the face-wall in a first direction;a door configured to at least partially close a passage through the shroud defined at least by the orifice wall and formed to be separated from the shroud;a magnet pocket formed with one of the orifice wall or the door, wherein the magnetic pocket includes at least one open end to receive a magnetic assembly;a striker pocket on one of the door or the orifice wall, wherein the striker pocket is configured to contain a striker member;a plurality of spacers surrounding an exterior of the orifice wall and having a sidewall extending from the face-wall in the first direction, wherein the plurality of spacers are configured to space the formed three dimensional shroud assembly; forming the magnetic assembly to be fixed within the magnet pocket without additional fasteners; forming the striker member to be fixed within the striker pocket without additional fasteners; fixing the magnetic assembly in the magnetic pocket at least by passing a first j-shaped portion of a first side plate into the magnet pocket, engaging a top of the magnet pocket with a first t-shaped portion of the first side plate, passing a second j-shaped portion of a second side plate into the magnet pocket, engaging the top of the magnet pocket with a second t-shaped portion of the second side plate, positioning a magnet between the first side plate and the second side plate within the magnet pocket; providing a plurality of hinge pins to operably interconnect the door and the shroud to allow movement of the door relative to the face-wall; and providing a plurality of substantially flat diffuser members, wherein each flat diffuser member includes a tab at a first edge and a slot formed near a second edge, wherein the provided plurality of substantially flat diffuser members are configured to be connected with the respective tab and slot to form a diffuser configured to be connected to the formed shroud; wherein the orifice wall and the magnet pocket on the orifice wall are formed together as one piece.