Adhesive joint features

Abstract

A fan assembly having a reduced dimension formed by several modifications is described. The fan assembly includes a stator having stator coils positioned within a recessed portion of a pillow that receives the motor. The stator may include wire connections positioned between adjacent stator coils and designed to terminate wires of the stator coils. The wire terminations may be on a protrusion or a post positioned between adjacent stator coils, or alternatively, the wire terminations may be disposed on protruding features of a bushing. The protrusion may be formed from an electrically conductive material and electrically connected to a motor control circuit via a flexible printed circuit. In some embodiments, the protrusion is part of an electrically neutral stator bushing having several pins. Also, a gap region between the bushing and a flange feature is designed to improve an adhesive joint.

1 . A fan assembly, comprising:
 a pillow including a flange portion extending from the pillow, wherein the flange portion is characterized by a curved profile; and   a cover disposed over the pillow, wherein the cover defines a channel configured to receive the flange portion of the pillow, and wherein the cover comprises a chamfered region configured to accommodate the curved profile of the flange portion of the pillow.   
     
     
         2 . The fan assembly of  claim 1 , wherein the flange portion is integrally formed with the pillow. 
     
     
         3 . The fan assembly of  claim 1 , wherein the flange portion is a first flange portion and the curved profile is a first curved profile, and wherein the pillow comprises a second flange portion characterized by a second curved profile. 
     
     
         4 . The fan assembly of  claim 3 , wherein the channel and the chamfered region are configured to receive the first flange portion and the second flange portion. 
     
     
         5 . The fan assembly of  claim 3 , wherein the channel is a first channel configured to receive the first flange portion, and wherein the cover comprises a second channel configured to receive the second flange portion. 
     
     
         6 . The fan assembly of  claim 1 , wherein the channel and the chamfered region extend along an outer perimeter of the cover. 
     
     
         7 . The fan assembly of  claim 1 , further comprising an adhesive joint defined within the channel and extending around a portion of the flange portion. 
     
     
         8 . The fan assembly of  claim 7 , wherein the adhesive joint is formed from an adhesive that extends along multiple axial surfaces of the flange portion. 
     
     
         9 . A fan assembly, comprising:
 a pillow including a curved flange portion; and   a cover configured to mate with the pillow, wherein a channel is formed in the cover, and wherein the channel comprises a chamfered region configured to accommodate the curved flange portion of the pillow when the curved flange portion is inserted into the channel.   
     
     
         10 . The fan assembly of  claim 9 , further comprising an impeller positioned between the pillow and the cover. 
     
     
         11 . The fan assembly of  claim 9 , wherein the channel comprises an inner wall nearer a center of the cover and an outer wall further from the center of the cover, and wherein the chamfered region extends along an perimeter of the inner wall. 
     
     
         12 . The fan assembly of  claim 9 , further comprising an adhesive disposed within the channel. 
     
     
         13 . The fan assembly of  claim 12 , wherein the adhesive comprises:
 a first thickness defined by a first gap thickness between a first axial surface of the curved flange portion and a first surface of the channel;   a second thickness defined by a second gap thickness between a radial surface of the curved flange portion and a second surface of the channel; and   a third thickness defined by a third gap thickness between a second axial surface of the curved flange portion and a third surface of the channel.   
     
     
         14 . The fan assembly of  claim 13 , wherein the second gap thickness is less than the first gap thickness. 
     
     
         15 . The fan assembly of  claim 13 , wherein the third gap thickness is less than the second gap thickness. 
     
     
         16 . The fan assembly of  claim 9 , wherein a first clearance of the fan assembly is defined in part by a first divergence rate between a first axial surface of the channel including the chamfered region and an inner surface of the curved flange portion of the pillow. 
     
     
         17 . The fan assembly of  claim 16 , wherein a second clearance of the fan assembly is defined in part by a second divergence rate between a second axial surface of the channel including the chamfered region and an outer surface of the curved flange portion of the pillow. 
     
     
         18 . The fan assembly of  claim 17 , wherein first dimensions of a first meniscus formed from an adhesive disposed within the channel during a pre-cured state are controlled by the first clearance, and wherein second dimensions of a second meniscus formed from the adhesive disposed within the channel during the pre-cured state are controlled by the second clearance. 
     
     
         19 . The fan assembly of  claim 17 , wherein the first clearance is about the same as the second clearance. 
     
     
         20 . A method of forming a fan assembly, comprising:
 forming a pillow including a flange portion extending from the pillow, wherein the flange portion is characterized by a curved profile;   forming a cover, wherein the cover defines a channel configured to receive the flange portion of the pillow, and wherein the cover comprises a chamfered region configured to accommodate the curved profile of the flange portion of the pillow; and   connecting the pillow and the cover by at least inserting the flange portion into the channel.