Composite impeller, method for forming the same, and method for forming a molded composite product

Abstract

An impeller for use with a centrifugal compressor or pump is provided and described along with a method for producing such multi-component polymer articles, such as open or closed impellers and other assembled molded articles, which may optionally include an opening therein. The impeller comprises a composite comprising a matrix material selected from at least one thermoplastic polymer or at least one thermosetting polymer, and at least one continuous reinforcing fiber. The impeller comprises at least one first flange comprising the composite, having an outer surface and an inner surface, the first flange defining a first opening extending longitudinally through it, and at least one rib having a first end and a second end, the first end of which is positioned to engage with at least one first flange.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This U.S. non - provisional patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 503,161, filed on May 18, 2023, the entire disclosure of which is incorporated herein by reference under 35 U.S.C. § 119(e).

[0002] The field of the present invention includes the formation of articles from components formed of polymer matrix composites that can be reshaped in a mold to form articles such as impellers for use in compressors or pumps that are subject to high stresses for the compression of light gases and for use in other end - use applications.

Background Art

[0003] Compression molding for engineering thermoplastic composites related to high temperature and high pressure is known in the art to require the use of steel molds due to the high molding pressure and temperature conditions used in the molding operation.

[0004] Attempts have also been made to form composite impellers for use in various industries. Metal impellers are known in the art to have high precision, but polymer composite impellers have been found to be difficult to mold. U.S. Patent No. 6,854,960 discloses a proposed segmented composite impeller that uses a resin transfer molding technique to achieve precision in the parts and reduce costs. The reference proposes molding of 1 - blade segments, which engage with other adjacent segments of the same and are then assembled. Each segment is machined to fit the design and is machined. They are assembled by joining at the engagement surfaces using a bonding agent such as an adhesive or resin.

[0005] International Patent Application Publication No. WO2015 / 062802 describes a compressor wheel in which elements are used to form a compressor wheel for use around a shaft, the wheel back being formed separately from the blades, and the two being joined together such that they have a cavity in between, thereby reducing weight and avoiding the use of excessive mass near the shaft area. The parts are formed using a die-casting process.

[0006] U.S. Patent No. 4,759,690 teaches a blade-type impeller for a centrifugal pump using several contacting, adjacent, and interconnected components. Some of the components are formed from a wear-resistant ceramic material. The device is claimed to be improved by using layers of elastically flexible material between each of the ceramic material components. The parts are assembled with adhesive and layers of polyurethane, and the entire assembly, including a dome-shaped insert, is held together by pins through the structure.

[0007] U.S. Patent No. 9,797,255 discloses a rotating machine having a stator and a mechanical rotor having a metal shaft portion and a composite impeller portion, held together by a metal ring. The metal ring is heated and then placed on the metal shaft, allowing it to cool and shrink, engage with the composite impeller, and fix it to the metal shaft. The impeller may be made from an engineering thermoplastic polymer and may be filled with a thermosetting material. The composite may also contain ceramic and / or metal and fibers such as carbon and glass fibers. Other embodiments show variations in which the composite portion is bonded to the metal portion using an adhesive. The impeller elements may be made individually or as a single part, and more than one ring may be used. The ring is formed to have a surface that contacts the metal portion and a surface that contacts the composite portion.

[0008] U.S. Patent No. 5,464,325 discloses a radial coolant compressor having an impeller with blade elements for use with water vapor as a coolant or refrigerant under vacuum. The impeller is designed to operate under these conditions and for high volumetric flow and high peripheral velocity. The blade elements are individually connected to a hub by pin insertion members, etc., and are made of a polymer composite material, which may contain reinforcing fibers. The blade elements have a curved configuration with extensions at their bases, which are engaged by support elements. The reinforcing fibers are arranged radially in the disk elements and circumferentially in the support elements.

[0009] U.S. Patent No. 5,632,601 teaches a compressor with an impeller, having a plastic hub and impeller formed using a fiber-reinforced thermoplastic material. The impeller blades are separately pre-fabricated from the composite and connected to the hub with shape conformity. The side walls of the movable blades are formed from a composite sheet, formed to enclose cavities that can be filled with foam for vibration damping. The walls are bonded to a base plate or welded in assembly.

[0010] In the energy sector, hydrogen-based energy is a rapidly developing area. However, the costs of transporting and storing hydrogen are high due to its low compressibility. Hydrogen storage requires compression to store large volumes. Compressors for gas compression include both reciprocating and centrifugal compressors. Centrifugal compressors operate at much higher flow rates and nearly the same efficiency and are less expensive, but are currently not suitable for light gases such as helium and hydrogen. The reason is that the compression ratio (Q) from one stage to the next in the impeller within the compressor is such that the tip velocity (V) is different, as follows: tip This is because it is a squared function of ) and is proportional to the molecular weight (MW) of the compressed gas. [ka] Therefore, given Q, when compressing H2, V tip This is the V that will be used to compress CH4.tip This is 2.8 times. Metal impellers have a maximum tip speed limit due to their low strength-to-weight ratio, which hinders the efficient compression of light gases.

[0011] A typical centrifugal compressor is constructed using a metal impeller and, during operation, provides a maximum tip speed of 360 m / s with a closed impeller and approximately 500 m / s with an open impeller.

[0012] In the art, there is a need for improved methods for forming molded compressors to meet new demands in various technological fields, including the energy sector, where there is a need for materials that can withstand high loads and / or high temperature and pressure materials, not only to perform more efficiently in standard impeller applications, but also to reduce weight, compress light gases more efficiently, and / or withstand harsh conditions. [Prior art documents] [Patent Documents]

[0013] [Patent Document 1] U.S. Patent No. 6,854,960 [Overview of the project] [Means for solving the problem]

[0014] The applicant has developed a method for forming multi-component polymer composite articles such as impellers or other composite components, and a method for fabricating impellers that may be open or closed impeller designs. Further embodiments include novel composite impellers formed using the methods herein. The methods and components herein, including the impellers exemplified herein, use thermoplastic or thermosetting polymer composites, such as engineering thermoplastic polymers and / or high-performance thermoplastic polymers, or thermosetting polymers, preferably those polymers suitable when the end application requires high temperature and / or high pressure conditions. Such composites incorporate continuous fibers, such as long continuous fibers, which can be matched at least substantially or completely.

[0015] In one exemplary end use described herein, the impeller is suitable for use in compressing light gases such as helium and hydrogen to achieve higher tip speeds of 500 m / s or more, and even more than approximately 600 m / s or more than approximately 700 m / s.

[0016] Such designs may also be used for more efficient and faster rotational speeds in standard compressor applications. Due to the strength and speed of composites that can be achieved by employing this process and materials, impellers that improve the single-stage compression ratio compared to the compression of conventional impellers may be provided. This makes it possible for compressors to achieve the same level of performance with fewer impeller stages in both open and closed impeller designs, providing economic advantages in the manufacture and use of impellers. By increasing the speed of a standard impeller, more compression occurs in a single stage, enabling a reduction in the number of impellers and increased operating efficiency at speeds of 300 m / s, 400 m / s, 500 m / s or higher.

[0017] In the applicant's method for forming polymer composites such as impellers, individual composite components are prepared by composite molding or the like, then assembled into assemblies such as multi-component assemblies, and placed in a mold. In embodiments in which the assembly has openings or voids, the assembly is positioned in the mold using removable cores in the openings or voids. The assembly in the mold is remolded, and the removable cores are removed. Such removable cores may be pulled out from the openings, removed, machined, or dissolved, for example, using a salt core, or removed using any other technique known to those skilled in the art or to be developed in the future.

[0018] One embodiment of this specification includes an impeller for use with a centrifugal compressor or pump, comprising a composite, which may be a matrix polymer selected from at least one thermoplastic polymer or at least one thermosetting polymer, and at least one continuous reinforcing fiber.

[0019] The matrix material may be one or more thermoplastic polymers, for example, a high-performance thermoplastic polymer selected from the group consisting of polycarbonate, linear aromatic polyester, linear aromatic polyimide, polyurethane, polyphenylene oxide, polyphenylene ether, polyphenylene ester, polyphenylene ether ester, polyphenylene sulfide, polysulfone, polyethersulfone, polyphenylsulfone, polymethylpentene, polyketone, aramid, polyaryl ether, polyarylether ketone, and combinations and copolymers thereof. In further embodiments, the matrix material may also include at least one polyarylether ketone selected from polyetherketone, polyetherketone ketone, polyetheretherketone, polyetheretherketone ketone, polyetherketone etherketone ketone, and combinations and copolymers thereof. The material may also be a thermoplastic engineering polymer selected from the group consisting of polybutadiene, polyacrylonitrile, poly(butadiene-styrene), poly(styrene-acrylonitrile), melt-processable fluoropolymer, liquid crystalline polymer, polyacetal, polyacrylate, polyamide, polyolefin, polyalkylene terephthalate, polyphthalimide, polyimide, polyetheramide, and combinations and copolymers thereof. Alternatively, the matrix material may be a thermosetting polymer selected from the group consisting of one or more thermosetting polymers, such as ethylene propylene diene rubber, ethylene propylene rubber, thermosetting polyurethane elastomer, epoxy resin, thermosetting biscitraconimide, bismaleimide (BMI), bismaleimide / triazine / epoxy resin, cyanate ester, cyanate resin, furan resin, phenol resin, urea-formaldehyde resin, melamine-formaldehyde resin, phthalocyanine resin, polybenzoxazole resin, acetylene-terminated polyimide resin, silicone, polytriazine, thermosetting polyvinyl ester, thermosetting polyurethane, polytetrafluoroethylene, melamine, polyalkyd, xylene resin, and combinations and copolymers thereof.

[0020] At least one continuous reinforcing fiber may comprise fibers that are at least substantially aligned within the matrix polymer. The at least one continuous reinforcing fiber may be selected from the group consisting of carbon, glass, aramid, metal, metal alloy, and natural fibers.

[0021] The impeller is preferably formed from a separate element made of a polymer composite, and within the separate element, at least a portion of the fibers of at least one continuous fiber may be substantially aligned in one embodiment.

[0022] In one embodiment, the impeller comprises a polymer composite and at least one first flange having an outer surface and an inner surface, defining a first opening that extends longitudinally therethrough, a first flange, and at least one rib positioned on the at least one first flange such that the at least one rib engages the inner surface of the at least one first flange. The at least one rib may also comprise a polymer composite. The impeller may also further comprise at least one ring member positioned on at least one flange and contacting at least one of the flanges. In one embodiment, the impeller is a re-molded assembly of the first flange, at least one rib, and at least one ring member.

[0023] The impeller described above in such an embodiment may optionally further include a second flange that includes a composite material, has an outer surface and an inner surface, the second flange has at least one surface feature on its inner surface, the second flange may include a second flange that defines a second opening that extends longitudinally therethrough, each of the at least one rib has a first end and a second end, the second end of the at least one rib engages at least one surface feature on the inner surface of the second flange, and the first and second openings are positioned so as to be at least substantially aligned. Also, in one embodiment of the present specification, there may be a plurality of surface features on the inner surface of the second flange and a plurality of ribs.

[0024] The inner surface of the at least one first flange may also include at least one surface feature, and the first end of the at least one rib may engage at least one surface feature on the inner surface of the at least one first flange.

[0025] The at least one surface feature on each of the inner surfaces of the first and second flanges described above is preferably at least substantially aligned to engage the first and second ends of the at least one rib. There may be a plurality of surface features on the inner surface of the first flange and the inner surface of the second flange and a plurality of ribs.

[0026] The impeller may further include at least one ring member that contacts at least one of the at least one flange. The at least one ring member includes a first ring member, the first ring member may have an opening that extends longitudinally therethrough, and the first ring member is configured to engage the outer surface of the first flange such that the first opening in the first flange and the opening in the first ring member are at least substantially aligned. The first ring member may be the same as or different from the composite material and may include a second composite material having fibers oriented in one direction that extend circumferentially.

[0027] The impeller may also include a second ring member having an opening that extends longitudinally through it, the second ring member being configured to engage with the outer surface of the second flange such that the second opening in the second flange and the opening in the second ring member are at least substantially aligned. The second ring member and the second flange may each define one or more openings for receiving fasteners for securing the second ring member to the second flange. The second ring member may be made of metal or a metal alloy.

[0028] In further embodiments, the first flange and the second flange may each have a circumferential outer surface extending longitudinally between their inner and outer surfaces, and the impeller may further comprise at least one upper or lower ring member and optionally at least one outer banding ring, the outer banding ring being circumferentially positioned around the circumferential outer surface of the first flange and configured to engage with the circumferential outer surface of the first flange. The outer banding ring may include a third composite material which may be identical to or different from the composite material and have at least some reinforcing fibers that are unidirectionally oriented and extend circumferentially. A second outer banding ring may be present which is circumferentially positioned around the circumferential outer surface of the second flange and configured to engage with the circumferential outer surface of the second flange, and the second outer banding ring may also optionally include the third composite material.

[0029] In the above embodiment, the impeller may be a reshaped assembly of first and second flanges, at least one rib, and at least one ring member, and optionally at least one outer banding ring.

[0030] In various embodiments of the impellers and methods described herein, the outer surfaces of the first and / or second flanges may be provided with Hirth tooth profiles formed on the inner annular portion of the flange, such as on the outer surface of the second flange, which may be used to mesh with and engage with meshing Hirth tooth features on a drive component, such a drive component may be fixed to the impeller herein using mating pieces and fasteners as described herein.

[0031] The composite may contain engineering polymers or high-performance polymers, and the openings in the impeller may be formed using removable core molding.

[0032] The present invention also includes a method for forming a multi-component composite, comprising the steps of: preparing at least two moldable polymer composite components; assembling the at least two moldable polymer composite components into an assembly; positioning the assembly in a mold; and remolding the assembly in the mold to form a multi-component composite.

[0033] In this method, the assembly may have at least one opening, and the method may further include the steps of incorporating a removable core into each of the at least one opening prior to positioning the assembly in the mold, and removing the removable core from at least one opening after forming a multi-component composite. The removable core may be removed by machining or by other techniques or methods as described elsewhere in this specification.

[0034] The assembly in this method may be an impeller assembly, and the multi-component composite may be an impeller, and at least two molded polymer composite components may comprise at least one first flange and at least one rib. In such embodiments, the method may further include the steps of: preparing at least one first composite flange defining an opening extending longitudinally through it, wherein the first flange comprises a polymer composite; preparing at least one rib having a first end and a second end; assembling the first composite flange and the at least one rib such that the first end of at least one rib engages with the first composite flange to form an impeller assembly; positioning the impeller assembly in a mold and incorporating a removable core into the opening in at least one first flange; and remolding the impeller assembly, removing the removable core, and forming an impeller.

[0035] The impeller assembly in this method may further include at least one ring member when assembled in the mold.

[0036] The method also further includes the step of preparing a second composite flange defining an opening extending longitudinally through it, wherein the second flange comprises a polymer composite, and the method further includes the step of assembling at least one first composite flange and at least one rib with the second composite flange, so that the opening in at least one first composite flange and the opening in the second composite flange are substantially aligned, and at least one rib is fitted between one of the at least one first composite flanges and the second composite flange, so that the second end of at least one rib engages with the second composite flange, and the formed impeller assembly comprises at least one first flange, at least one second flange and at least one rib.

[0037] The impeller assembly in this method may further include at least one ring member when assembled in a mold. The at least one ring member may include a first ring member having an opening extending longitudinally through it, the first ring member being configured to engage with the first composite flange on the side of the first composite flange opposite to the side of the first composite flange that engages with the first end of at least one rib, and the opening in the first flange and the opening in the first ring member are at least substantially aligned. The at least one ring member may include a second ring member defining an opening extending longitudinally through it to engage with the second composite flange on the side of the second composite flange opposite to the side of the second composite flange that engages with the second end of at least one rib, and the opening in the second flange and the opening in the second ring member are at least substantially aligned.

[0038] The at least one ring member in this method may comprise at least one outer banding ring positioned circumferentially around the outer circumferential surface of the first composite flange and / or the second composite flange, and engaging with the outer circumferential surface of the first composite flange and / or the second composite flange. The at least one banding ring may define an opening extending longitudinally through it, configured on its outer surface to engage with either the first composite flange and / or the second composite flange, and the opening in the at least one banding ring and the opening in the first and / or second composite flange are substantially aligned axially.

[0039] In this method, at least one ring member may include a metal, a metal alloy, or a polymer composite having long, continuous unidirectional fibers. In one embodiment, the second ring member may include a metal or a metal alloy. In another embodiment, the first ring member may include a polymer composite having long, continuous unidirectional fibers.

[0040] One or more of the first composite flange, the second composite flange, and at least one rib in this method may include a polymer composite having continuous fibers. The polymer composite in this method may comprise a thermoplastic or thermosetting matrix polymer and at least one continuous long fiber. The at least one continuous long fiber may comprise at least a portion of fibers that are at least substantially matched and selected from the group consisting of carbon, glass, aramid, metal, metal alloy, and natural fibers.

[0041] The matrix polymer in this method may be a high-performance thermoplastic polymer selected from the group consisting of polycarbonate, linear aromatic polyester, linear aromatic polyimide, polyurethane, polyphenylene oxide, polyphenylene ether, polyphenylene ester, polyphenylene ether ester, polyphenylene sulfide, polysulfone, polyethersulfone, polyphenylsulfone, polymethylpentene, polyketone, aramid, polyaryl ether, polyarylether ketone, and combinations and copolymers thereof. In a preferred embodiment, it may include at least one polyarylether ketone selected from polyetherketone, polyetherketone ketone, polyetheretherketone, polyetheretherketone ketone, polyetherketone etherketone ketone, and combinations and copolymers thereof.

[0042] The matrix polymer in this method may also be an engineering thermoplastic polymer selected from the group consisting of polybutadiene, polyacrylonitrile, poly(butadiene-styrene), poly(styrene-acrylonitrile), melt-processable fluoropolymer, liquid crystalline polymer, polyacetal, polyacrylate, polyamide, polyolefin, polyalkylene terephthalate, polyphthalimide, polyolefin, polyimide, polyetheramide, and combinations and copolymers thereof.

[0043] The matrix polymer in this method may be one or more thermosetting polymers selected from the group consisting of ethylene propylene diene rubber, ethylene propylene rubber, thermosetting polyurethane elastomer, epoxy resin, thermosetting biscitraconimide, bismaleimide, bismaleimide / triazine / epoxy resin, cyanate ester, cyanate resin, furan resin, phenol resin, urea-formaldehyde resin, melamine-formaldehyde resin, phthalocyanine resin, polybenzoxazole resin, acetylene-terminated polyimide resin, silicone, polytriazine, thermosetting polyvinyl ester, thermosetting polyurethane, polytetrafluoroethylene, melamine, polyalkyd, xylene resin, and combinations and copolymers thereof.

[0044] Impellers formed by this method may be capable of achieving tip speeds of at least about 600 m / s or at least about 700 m / s or higher during operation for the compression of light gases such as hydrogen or helium. The impellers may also be used in end applications where the compression ratio is increased for other standard uses at speeds of 300 m / s, 400 m / s, 500 m / s or higher.

[0045] The present invention also includes a method for forming a polymer composite having at least one opening, comprising the steps of: preparing a polymer composite assembly of at least two composite components, wherein the polymer composite assembly has at least one opening therein; positioning the polymer composite assembly in a mold and incorporating a removable core into at least one opening in the polymer composite assembly; and remolding the polymer composite assembly in the mold, removing the removable core, and forming a polymer composite.

[0046] The polymer composite may be an impeller, and may be an open or closed impeller.

[0047] In this method, at least two composite components may include a polymer composite having at least one continuous reinforcing fiber. The at least one continuous reinforcing fiber may be selected from the group consisting of carbon, glass, aramid, metal, metal alloy, and natural fibers. The fibers in the at least one continuous reinforcing fiber may be matched.

[0048] The polymer composite may include a thermoplastic or thermosetting matrix polymer. The matrix polymer may be a high-performance thermoplastic polymer selected from the group consisting of polycarbonate, linear aromatic polyester, linear aromatic polyimide, polyurethane, polyphenylene oxide, polyphenylene ether, polyphenylene ester, polyphenylene ether ester, polyphenylene sulfide, polysulfone, polyethersulfone, polyphenylsulfone, polymethylpentene, polyketone, aramid, polyaryl ether, polyarylether ketone, and combinations and copolymers thereof. In one preferred embodiment, it may include at least one polyarylether ketone selected from polyetherketone, polyetherketone ketone, polyetheretherketone, polyetheretherketone ketone, polyetherketone etherketone ketone, and combinations and copolymers thereof.

[0049] The matrix polymer may be an engineering thermoplastic polymer selected from the group consisting of polybutadiene, polyacrylonitrile, poly(butadiene-styrene), poly(styrene-acrylonitrile), melt-processable fluoropolymer, liquid crystalline polymer, polyacetal, polyacrylate, polyamide, polyolefin, polyalkylene terephthalate, polyphthalimide, polyimide, polyetheramide, and combinations and copolymers thereof.

[0050] The matrix polymer may also be one or more thermosetting polymers selected from the group consisting of ethylene propylene diene rubber, ethylene propylene rubber, thermosetting polyurethane elastomer, epoxy resin, thermosetting biscitraconimide, bismaleimide, bismaleimide / triazine / epoxy resin, cyanate ester, cyanate resin, furan resin, phenol resin, urea-formaldehyde resin, melamine-formaldehyde resin, phthalocyanine resin, polybenzoxazole resin, acetylene-terminated polyimide resin, silicone, polytriazine, thermosetting polyvinyl ester, thermosetting polyurethane, polytetrafluoroethylene, melamine, polyalkyd, xylene resin, and combinations and copolymers thereof. The removable core may be removed by machining. [Brief explanation of the drawing]

[0051] The following summary and detailed description of preferred embodiments of the invention will be better understood when read in conjunction with the accompanying drawings. For illustrative purposes, these preferred embodiments are shown in the drawings. However, it should be understood that the invention is not limited to the precise arrangements and means shown.

[0052] [Figure 1] Figure 1 is a top plan view of a first embodiment of a reformed composite impeller formed using the method described herein prior to machining.

[0053] [Figure 2] Figure 2 is a cross-sectional side elevation view of the impeller shown in Figure 1, obtained along line 2-2.

[0054] [Figure 3] Figure 3 is an exploded perspective view of the bottom of the impeller shown in Figure 1.

[0055] [Figure 4] Figure 4 is a top view of the impeller shown in Figure 1 after assembly and machining.

[0056] [Figure 5] Figure 5 is a cross-sectional side elevation view of the impeller shown in Figure 4, obtained along line 5-5.

[0057] [Figure 6] Figure 6 is a top perspective view of the impeller shown in Figure 4.

[0058] [Figure 7] Figure 7 is a top perspective view of the upper composite flange of the impeller shown in Figure 1.

[0059] [Figure 8] Figure 8 is a side elevation view of the composite flange of Figure 7, obtained along line 8-8.

[0060] [Figure 9] Figure 9 is an enlarged view of the top elevation of the composite impeller rib from the impeller in Figure 1.

[0061] [Figure 10] Figure 10 is an enlarged side elevation cross-sectional view of the rib in Figure 9, obtained along line 10-10.

[0062] [Figure 11] Figure 11 is a top elevation view of a further embodiment of a molded impeller formed using the method described herein.

[0063] [Figure 12] Figure 12 is a side elevation view of the impeller of Figure 11, obtained along line 12-12.

[0064] [Figure 13] Figure 13 is an exploded top elevation view of the impeller shown in Figure 11.

[0065] [Figure 14] Figure 14 is a top perspective view of the impeller shown in Figure 11.

[0066] [Figure 14A] Figure 14A shows an example of a closed impeller that can be formed using the methods described herein.

[0067] [Figure 15] Figure 15 is an exploded view of the components of the impeller embodiment shown in Figure 1.

[0068] [Figure 16] Figure 16 is a representation of a flange mold useful for forming a composite flange for use in the present invention as herein.

[0069] [Figure 16A] Figure 16A is a photographic image of a molded composite flange for use in the present invention, having machined surface features therein.

[0070] [Figure 17] Figure 17 is a representative perspective view of a mold for forming a curved composite plate for use in preparing the impeller ribs described herein.

[0071] [Figure 18] Figure 18 is a photographic image of a curved flange formed using a curved mold surface.

[0072] [Figure 18A] Figure 18A is a magnified view of a portion of Figure 18, showing a long continuous reinforcing fiber in which substantial portions of individual fibers within a stack of long reinforcing fibers are substantially aligned within that component.

[0073] [Figure 19] Figure 19 is a photographic image of a rib cut from the curved flange shown in Figure 17.

[0074] [Figure 20]Figure 20 is a photographic image of a ring for use as at least one compression member, having at least a portion of continuous long fibers in a matrix that are substantially aligned in the circumferential direction.

[0075] [Figure 21] Figure 21 is a photographic image of an assembly of impeller component parts that are remolded in a mold and the method described herein.

[0076] [Figure 22] Figure 22 is an exploded perspective view of a molded composite component and a removable mold insert for use when assembling components for remolding.

[0077] [Figure 23] Figure 23 shows a representation of the component parts of Figure 22, which are assembled in the mold for the remolding step of this method.

[0078] [Figure 24] Figure 24 is a partial cross-sectional perspective view of the impeller of Figure 11, which has two outer banding rings molded on it as compression members.

[0079] [Figure 25] Figure 25 is a rear perspective view of a further embodiment in which the Hirth tooth profile is provided for connecting the impeller to a drive component such as a shaft line or similar device.

[0080] [Figure 26] Figure 26 is a longitudinal cross-sectional view of the impeller design of Figure 25, modified to include an optional banding ring.

[0081] [Figure 27] Figure 27 is an exploded view of the impeller of Figure 25, showing the arrangement of drive components for meshing with the Hirth tooth profile on the impeller and mating pieces for fastening the impeller to the drive components.

[0082] [Figure 28] Figure 28 is a photographic image of an impeller formed from the process herein using the design of Figure 25 and the composite described in the embodiments herein. [Modes for carrying out the invention]

[0083] Detailed description of the present invention The present invention relates to a novel multi-component composite that can be formed by a molding method which uses a polymer composite comprising a polymer matrix material and continuous fibers as a reinforcing material, assembles component parts in a mold, and then remoldes the component parts. In one embodiment, the present invention exemplified such a multi-component component as an impeller, which in one embodiment herein is shown as a closed impeller for use in compressors and pumps and may be used to compress light gases, including helium and hydrogen. An impeller of the present invention which is an open impeller having only one flange and / or comprising a composite as described herein may also be manufactured. The present invention further relates to a method for forming a multi-component polymer composite such as an impeller as shown and described herein, the article may have one or more openings or voids. Such an article may have multiple component composite parts and / or may contain many voids. The method uses such individual molded component parts or elements, assembles them to form an assembly of components, places them in a mold, remoldes the assembly, and forms a composite. An opening or void in one embodiment of this specification may contain a removable core within the opening prior to reshaping. The assembly of components is reshaped under heat and pressure, and the removable core to be removed is then removed by removing a crushable mandrel or similar core, or by machining or by other removable core techniques known or to be developed in the art, etc., to form the article. It should be understood by those skilled in the art based on this disclosure that this method can be used to produce a variety of articles and is not limited to impellers exemplified herein.

[0084] With respect to articles and impellers as described herein, such articles include polymer composites having a polymer matrix material and a reinforcing agent, and with respect to impellers, they may be open or closed impeller designs, all of which can be formed using the methods and materials described herein. Impellers may be formed using a single flange design or impellers having two or more flanges. In one embodiment herein, the flanges are exemplified to show an impeller with two flanges, but such designs may be modified to have an additional flange or may be formed by omitting one of the two flanges.

[0085] Preferred matrix polymers for use in the composites described herein are preferably polymeric plastics and resins suitable for molding and loading or filling continuous long fiber reinforcements, and capable of accepting other fillers as needed. Such matrix polymers may be thermoplastic or thermosetting materials.

[0086] Preferably, the matrix polymer is at least one thermoplastic polymer that flows under the application of heat. Preferred thermoplastic matrix polymers are selected from engineering and high-performance polymers. Once reinforced, such materials are preferably suitable for use in end applications that are also performed at high temperatures and / or high pressures, with the understanding that they will be under high mechanical loads and the temperature or pressure levels will vary depending on the selected polymer matrix material, depending on the polymer matrix material.

[0087] Exemplary engineering thermoplastics include polybutadiene, polyacrylonitrile (PAN), poly(butadiene-styrene) (PBS), poly(styrene-acrylonitrile) (SAN), fluoropolymers (including melt-processable fluoroplastics (such as copolymers of tetrafluoroethylene (TFE) and at least one perfluoroalkyl vinyl ether (PAVE) (PFA), copolymers of TFE and at least one other perfluoroalkylene (such as hexafluoropropylene) (FEP)), poly(chlorotrifluoroethylene), polyethylchlorotrifluoroethylene (ECTFE), polyethyltrifluoroethylene (ETFE), polyvinyl fluoride (PVF), and polyvinylidene fluoride (PVDF)), ionomers, liquid crystalline polymers (LCP), polyacetals, polyacrylates, and polyamides (NYLON 12, NYLON 12). 6) Polyolefins such as polyethylene or polypropylene and their copolymers, polyalkylene terephthalates (polyethylene terephthalate and polybutylene terephthalate, etc.), polyphthalimides, polyimides, polyetheramides, and polyamideimides, as well as copolymers or combinations (compounds or alloys, etc.) of such polymers.

[0088] Examples of high-performance thermoplastic polymers include, for example, polycarbonate, linear aromatic polyester, linear aromatic polyimide, such as polymethacrylimide (PMI), polyamide-imide (PAI), polyether(ether-imide) (PEI), and poly(imido-sulfone) (PISO), polyurethane, polyphenylene oxide (PPO), polyphenylene ether, polyphenylene ester, polyphenylene ether ester, polyphenylene sulfide (PPS), polysulfone (PSU), polyethersulfone (PES), polyphenylsulfone (PPSU), polymethylpentene, polyketone, polyarylethersulfone (PES), and polyaryl ether This includes polyaryl ethers (PAEs) such as ternitrile (PEN), aramids, such as poly(p-phenylene terephthalamide) and poly(m-phenylene isophthalamide), and polyaryl ether ketones (PAEK), and other similar PAEs and PAEKs, such as polyether ketones (PEK), polyether ketone ketones (PEKK), polyether ether ketones (PEEK), polyether ether ketone ketones (PEEKK), polyether ketone ether ketone ketones (PEKEKK), and similar PAEs and PAEKs. Copolymers and combinations (compounds or alloys, etc.) of these materials with other polymers may also be used.

[0089] For environments with less stringent requirements, the matrix material may include more standard thermoplastic matrix resins such as standard thermoplastic polyolefins (polyethylene, polybutylene, polypropylene, high-density polyethylene, low-density polyethylene, etc.), poly(acrylonitrile-butadiene-styrene) (ABS), standard polystyrene, cellulosic resins (ethylcellulose, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, and cellulose nitrate, etc.), polyethylene vinyl alcohol (EVA), polyvinyl chloride (PVC), and polyethylene vinyl acetate (PVA).

[0090] Furthermore, thermosetting materials such as certain epoxy and thermosetting materials are considered as possible matrix materials within the present invention. Preferably, such materials can achieve properties similar to engineering and high-performance thermoplastic properties in terms of composite performance when intended for use under demanding end-use conditions such as high temperature and high pressure. Suitable thermosetting matrix materials include certain elastomers (ethylene propylene diene monomer (EPDM), ethylene propylene rubber (EPR), and thermosetting polyurethane elastomers, etc.), epoxy resins, thermosetting biscitraconimide (BCI), bismaleimide (BMI), bismaleimide / triazine / epoxy resins, cyanate esters, cyanate resins, furan resins, phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, phthalocyanine resins, polybenzoxazole resins, acetylene-terminated polyimide resins, silicones, polytriazines, thermosetting polyvinyl esters, thermosetting polyurethanes, polytetrafluoroethylenes, melamines, polyalkyds, and xylene resins.

[0091] While the polymers described above are preferred, the list described above should not be considered exhaustive, and those skilled in the art will understand that, based on this disclosure, other thermoplastic or thermosetting materials may also be used in the present invention without departing from its scope, provided that they are suitable for forming the composites described herein.

[0092] Copolymers of any or all of the above polymers (polymers formed from two or more monomer species in random or block form, or graft copolymers, where any of them may have multiple monomer components or reactants) may also be used within the scope of the present invention, whether known or to be developed in the future. In addition, depending on the selected polymer, the polymer may be derivatized and / or include functional groups (either terminal and / or on the chain), branched and / or linear skeletal structures, additional unsaturated sites along the chain or side groups, and equivalents. Functional groups that may be provided include aryl, ketone, acetylene, acid group, hydroxyl, sulfur-containing group, sulfate, sulfite, mercapto, phosphat, carboxyl, cyano, phosphate, oxygen / ether or ester (which can also be incorporated into the chain or side chain), carboxylic acid, nitrate, ammonium, amide, amidine, benzamidine, imidazole, and equivalents. The selected polymer may also be used in mixtures, formulations, or alloys, or copolymerized with each other or other monomers, to form new random, block, or graft copolymers.

[0093] Preferred embodiments of this specification include matrix materials which are high-performance plastics such as polyamides, melt-processable fluoropolymers, and thermosetting materials such as epoxy resins, as well as PAE and PAEK polymers, including polyphenylene sulfide, polyetherimide, polysulfone, and PEEK, PEK, PEKK, PEEKK, and PEKEKK.

[0094] The composite materials provided herein preferably include long fiber reinforcements, which are preferably continuous long fibers. It is within the scope of the invention that more than one composite may be used and compounded in forming the articles herein. For example, multiple composite flanges may be used and compounded prior to or in the mold. In such cases, the second or other composite used may include the same or different thermoplastic and / or thermosetting matrix materials with the same or different forms of fiber or filler reinforcements.

[0095] Examples of suitable long reinforcing fiber materials include, but are not limited to, various long reinforcing fibers that are inorganic fibers such as ceramic fibers, glass fibers, graphite fibers, carbon fibers, quartz fibers, alumina fibers, silicon carbide fibers, basalt fibers, boron fibers, aramid fibers, metal fibers, metal alloy fibers, natural fibers, and combinations thereof such as glass / carbon, glass / graphite / carbon, graphite / carbon, ceramic / glass, etc. Further organic fibers such as thermoplastic and thermosetting long reinforcing fibers having a first fibrous material such as aramid fibers, polybenzoxazole fibers, and equivalents may be used, either alone or in combination with glass, metal, ceramic, or carbon fibers.

[0096] Preferred long fiber materials include ceramic, glass, graphite, carbon, and / or plastic (thermoplastic and thermosetting) fibers (such as aramid fibers (available as Kevlar, Twaron, and Technora) or polybenzoxazole fibers available as Zylon).

[0097] Fiber and matrix composites may be provided in various forms, including unidirectional tapes, fabrics, mats, filaments, and other long-fiber materials. Laminates of such materials may also be formed using various methods known or to be developed in the art, such as manual deposition, automated tape layup, 3D filament printing, and equivalents.

[0098] In fiber formulations or combined fiber reinforcements, additional fibers may be provided to the fiber matrix in the form of chopped strands, filaments, or whiskers prior to impregnation. Furthermore, such formulations may include bundles, tows, and braids extending in the long fiber direction and / or various woven or blended fiber materials extending in one or more directions to provide strength and / or other desired properties.

[0099] The continuous fibers may be unidirectional or bidirectional continuous fibers (preferably, bidirectional fibers will have about 50% of the fibers in the parallel direction and about 50% in the perpendicular direction), spun fibers, towed fibers, braided fibers, and woven continuous fibers. In addition, the fibers may be braided and / or blended fibers.

[0100] In one embodiment, the reinforcing fibers are unidirectional, and at least a portion of them may be substantially aligned within one or more elements of the article, or circumferentially aligned for additional ring members or clamping or banding ring elements. Examples of fiber diameters for some long fibers useful in the present invention include, but are not limited, about 0.1 microns, about 5 to about 15 microns, and about 7 to about 10 microns. For example, boron fibers ranging from 100 to about 140 microns may be used, and glass fibers ranging from about 5 to about 25 microns, but such ranges are not intended to be limiting. For example, basalt fibers ranging from about 10 to about 20 microns may also be used. Not all fibers need to be aligned in their longest dimension, as other fiber orientations may also be used for preferred final results. In embodiments herein, desired article properties can be achieved when at least a portion of the fibers are at least substantially aligned in a direction within a component or article to provide strength, for example, in the longest dimension or in round or arched components in a more circumferential direction. Such combinations of orientations, along with fibers extending in other directions, may be used to improve the desired results.

[0101] In embodiments of this specification, the long fiber reinforcements may be about 30% or more than 30%, preferably 40% or more than 40%, more preferably 50% or more than 50%, for example, about 60% to about 90%, in terms of the volume ratio of the composite used to form the prepreg, or in the resulting articles and / or component parts formed herein relative to the total volume of the composite. Understanding that different fibers having different diameters may result in higher or lower preferred volumes, it is preferable that the long fibers constitute about 40% to about 80% of the volume ratio of the composite, and most preferably about 50% to about 70% of the volume ratio of the composite.

[0102] Elements or components of articles made herein may be formed from composites herein, which are provided as is or which can be used to form elements using long-fiber-containing prepregs such as flakes, plates, sheets, rods, fabrics, tapes, or equivalents. However, any suitable technique or structure known or to be developed in the art may be used to provide components using composites herein, provided that the resulting composite structural components are suitable for use in assemblies having a modular structure, particularly those in which one or more openings may be present, and / or for forming assembled products, such as impellers herein. In one embodiment, a continuous fiber structure may be used to form one or more structural elements of an assembly such as an impregnated continuous fiber tape, fabric, or equivalent. Such tapes or other continuous fabrics, tapes, rods, and equivalents may be cut to various lengths, but the long-fiber structure should be reserved. Structures having reinforcing fibers, primarily having a length-to-diameter ratio greater than about 100, are useful herein.

[0103] As used herein, continuous fibers in such structures generally have a length of at least about 0.20 inches, and in embodiments, long continuous fibers may have a length of at least about 0.5 inches (1.27 cm). In some embodiments herein, a length of at least 0.5 inches may contribute to improved mechanical properties in the resulting article. Since processing such fibers may not be as easy as processing shorter lengths, those skilled in the art will understand that fiber length may be selected to balance mechanical properties and processing conditions with respect to a given process. When forming elements of an article from such structures or directly from composites by molding, it is preferable that the resulting components retain at least a portion, preferably a large portion, of their original long reinforcing fiber lengths, and in certain aspects as further described below herein, at least some portions of the long fibers may be substantially aligned along the structural features of the article, such as when forming a ring for use in an assembly, the ring is molded to have at least a portion of continuous and substantially aligned long reinforcing fibers extending circumferentially. The fibrous portions within the matrix, which are in a conforming state, may be tuned to be consistent with the ability of the selected matrix material to accept the fiber loading and to regulate the final properties of the resulting article and / or its constituent parts.

[0104] The polymer composite matrix may also incorporate various other additives that can be incorporated by compounding with the polymer matrix material. Examples of such additives include other reinforcing agents other than continuous fibers, pigments, dyes, glass, ceramics, mesh, honeycomb, mica, clay, organic colorants, plasticizers, thixotropes, flame retardants, UV absorbers, fillers, stabilizers, silicon dioxide, silica, alumina, talc, glass fibers, barium sulfate, glass spheres, PTFE short fibers, TFE copolymer short fibers, other reinforcing fibers of various lengths, ribbons or platelets, wollastonite, titanate whiskers, compatibilizers, rheological or thixotropes, antistatic agents (which can also be incorporated through the use of functional groups and / or graft copolymers provided to the thermoplastic matrix), chopped carbon fibers, and other similar fillers, tribological additives, and reinforcing agents. It is preferable that such additives (in addition to the presence of the first thermoplastic composite material) are present in an amount of about 10% or less of the composite based on the total weight of the composite, however, more or less may be used.

[0105] In addition, it is within the scope of the invention that the fibrous material may be a compounded material, i.e., one or more fibers may be used in combination for impregnation with a polymer matrix material to form a composite material to be used herein, for example, but not limited to glass / carbon, glass / graphite / carbon, graphite / carbon, aramid / glass, ceramic / glass, and PTFE or TFE copolymer fiber / carbon compound. In the fibrous compound or combined fibrous reinforcement, additional fibers may be provided to the fibrous matrix in the form of chopped strands, filaments, or whiskers. Furthermore, such compound may include any range of potential woven or compounded fibrous materials, provided that sufficient strength and other desired properties are retained.

[0106] The components of the impeller may also incorporate pre-formed elements. For example, a commercially available component, such as a fiber-reinforced ring, formed from the desired composite according to this specification, having long, continuous fiber reinforcements extending in a unidirectional circumferential direction, may be incorporated into the assembly to be molded without the use of specially prepared composite components. Similarly, a commercially available molded sheet of the desired composite, having at least a portion of long, continuous reinforcing fibers substantially matched to the desired thickness and shape, may be used or machined to size for use in the assembly according to this specification.

[0107] When forming the constituent parts of this specification from such polymer composites (including prepregs, unidirectional tapes, and equivalents), the constituent parts may first be molded using various types of suitable molds known in the art in order to obtain the composite in the best possible way and, preferably, to achieve the best orientation of the fibers within the constituent parts of this specification.

[0108] Articles such as impellers described herein may preferably be formed from separate elements (components) as described above, formed from the same or compatible polymer composite. In preferred embodiments herein, composites with the same or similar molding conditions with respect to various components are used for uniform strength and molding conditions. With respect to strength, preferred fibrous reinforcements include continuous reinforcing fibers (bundles or tows and / or individual fibers therein, etc.) extending through the polymer matrix. Such fibers are long fibers that are substantially or completely aligned in one direction, or at least substantially aligned, and in other embodiments they may extend in a direction along a particular dimension or in a direction within one or more of the component parts. With respect to round parts such as rings or hoops, the fibers may extend circumferentially around the components in the polymer matrix. This is a preferred arrangement for forming the impeller as described herein, but other types of reinforcing fiber techniques may be used, such as using a prepreg composite and pressing the part in a two-cavity mold, in which the polymer in the composite is consumed and the long fibers are randomly dispersed, as described in detail in U.S. Patent No. 10,160,146. Other suitable component part molding techniques for composites may be used to form the individual components of the article assembly. Any suitable molding technique known in the art or to be developed in the future may be used, using preferred molding temperatures and techniques for matrix polymer materials or composites, and preferably adjusted according to the knowledge of the art to achieve the desired fiber orientation.

[0109] The present invention will be further described herein in relation to the exemplary impeller as a composite, formed by the method herein, comprising a number of components (flanges, ribs, and preferably several compression members). Although the method is described herein in relation to an impeller for convenience, it will be understood by those skilled in the art that the molding method and technique herein may be applied to other assemblies having one or more voids, using various mold designs.

[0110] In general, the impeller described herein, referred to as impeller 100, and in some embodiments of its modifications thereof, will be described with reference to Figures 1-10 and 15-23. The impeller 100 after remolding and formation is shown in Figure 6. Figure 1-3 shows an assembly 102 prepared to form the impeller 100 from component parts prior to machining. In Figure 1-3, the first composite flange 104 can be shown on the upper portion of the assembly. The first composite flange has an opening 114 extending longitudinally through it. A first ring member 106 is shown, formed from a composite having a polymer matrix material and unidirectional continuous fibers extending in a manner that at least a portion thereof is substantially aligned through the composite. The first ring member 106 is preferably axially centered in the first ring member and substantially aligned with, preferably perfectly axially aligned with, the opening 114 in the first composite flange 104, defining an opening 112 extending longitudinally through it. The first flange has an outer surface 118 and an inner surface 120. As shown, embodiment 100 includes two composite flanges 104, 108. The second composite flange 108 has an outer surface 122 and an inner surface 124. It should be understood that an open impeller with only one flange can be manufactured according to the method herein. A preferred open impeller design is shown in Figure 14A as an embodiment herein. The first ring member 106 and the first composite flange 104 are shown as separate parts for formation, but may also be formed as a single component composite part, or formed as such.

[0111] The second flange in Embodiment 100 may have at least one surface feature 126 on its inner surface 124 to seat at least one rib 128. Preferably, there may be multiple such features 126, and they are preferably equal to the number of ribs 128. One or more ribs may be present, as well as the surface features 126. The surface features may be machined or molded into the inner surface 124 of the second composite flange 108 and may be positioned to conform to a design shape such as the curvature of the impeller rib 128. Such features help to align the impeller rib and facilitate the reshaping of the assembly.

[0112] The second composite flange 108 defines an opening 110 that extends longitudinally through it, substantially aligned with, and preferably perfectly axially aligned with, the opening 112 through the first ring member and the opening 114 through the first composite flange. The rib 128 has a first end 130 and a second end 132. The rib is preferably positioned between the first flange 104 and the second flange 108 such that the second end 132 of each rib 128 engages with one of the surface features 126 on the inner surface 124 of the second flange 108.

[0113] The ribs are formed from a polymer composite material having the same or similar molding conditions as those used to form the first and second composite flanges and / or the first ring member, but the molding conditions may be modified or changed as desired depending on the specific article design being manufactured according to the method herein. Preferably, for consistency, the same composite material is used for each component part, but the properties of the polymer matrix material and reinforcing fibers or other additives may vary depending on the design properties. In preferred embodiments herein, an engineering polymer and more preferably a high-performance polymer is used as the matrix polymer, or a thermosetting material is used, and the continuous fibers used are preferably long continuous carbon fibers in the composite material used for the various components as described above, and the component parts are preferably formed with fiber matching for suitable reinforcement in the component parts, consistent with the desired matching in the final assembly.

[0114] The inner surface 120 of the first composite flange 104 may also include at least surface features 134 such that each first end 130 of the impeller rib 128 engages with the surface features 134 on the inner surface 120 of the first flange 104 in the same manner as the ribs 128 on their second ends 132 engage with the surface features 126 on the inner surface 122 of the second flange 108.

[0115] The surface features 134, 126 on each of the individual inner surfaces 120, 124 of the first and second flanges 104, 108 are preferably at least substantially aligned to engage with the first end 130 and the second end 132 of at least one rib, and preferably perfectly axially aligned when the rib is designed to be perpendicular to the inner surfaces 120, 124 of the first and second flanges 104, 108, as shown. If the rib is configured to connect the two flanges at a certain angle for design purposes, the surface features do not need to be aligned, but should be designed to engage with the individual ends of the rib.

[0116] An impeller as shown may include one or more ring members. Once remolded into an article and placed in use, the ring members are intended to be used in or on the impeller, if desired, to account for stress on the component parts, or for use, for example, fretting or other wear issues, and may be added to the molded impeller after they have been formed.

[0117] One such ring member for incorporation into the impeller may be, for example, a first ring member 106 as described above, incorporated into the assembly to reduce stress concentration occurring near the center of the flange, based on the model made by the applicant.

[0118] Further ring members may be introduced, as shown, to further serve the purpose of fretting while the impeller is in use. In this embodiment, a second ring member 136 may be added to the impeller, as shown in most detail in Figures 6 and 15. The second ring member defines an opening 138 extending longitudinally through it, which is also preferably axially aligned with the composite flange and the opening in the first ring member 106. The second ring member 136 is preferably configured to engage with the outer surface 122 of the second flange 108 after the impeller is formed by remolding as further described below herein, such that the opening 110 in the second flange 108 and the opening 138 in the second ring member 136 are at least substantially aligned, preferably fully axially aligned.

[0119] As shown in most detail in Figure 15, the second flange 108 may have a fastener extension 140 having a hole 142 through which it receives a fastener 146, and the second ring member 136 may have a series of meshing fastener holes 141, which are similarly machined through it, and may also include a drive pin 144, as shown in Figure 15, for transmitting torque to the impeller. The second flange and the second ring member may be meshed and machined to fit together for stability when used in the end application. The second ring member may be formed from a composite material or from metal or a metal alloy. In this embodiment, metal or a metal alloy is preferred. The fastener 142 may be incorporated to securely attach the second ring member to the second composite flange.

[0120] As shown in Figure 16, the composite flange may be formed from a flat composite flange FP in a mold SM, for example, having a molding piston MP capable of applying downward pressure to the flange FP in the heated mold. The flange FP may be round, square, or other shapes, or may be machined into a desired shape, for example, a 1 square foot flange may be formed and used in a square mold, or machined into a desired shape. The flange may be machined or molded into a certain shape, and features may be molded or machined into the flange as described above. 60% volume fraction of fiber ([45 / 90 / -45 / 0] NS Figure 16A shows an image of one of the machined flanges according to the present invention, formed from a polyether ether ketone high-performance polymer with substantially aligned carbon fibers, using AS4 fibers in a PEEK matrix having a layup (QI laminate). Two such sample flanges were fabricated. In a preferred embodiment, a flat mold, such as the one shown in the representation in Figure 16, can provide component parts that can be machined into the desired flange shape, and the fibers may be oriented to form a quasi-isotropic laminate.

[0121] When forming the ribs 128, the curved molded plate CP may be formed to have the desired curvature of the rib design. Each rib 128 may be cut from one or more curved plate CPs. A typical curved mold CM, having the curved mold piston CMP of this specification for forming the curved plate CP as shown in Figure 18, is shown in Figure 17 and may be subjected to pressure in a mold heated by the piston CMP. The curved plate in Figure 18 in this embodiment was made from the same composite as described above, which is used when forming the first and second composite flanges 104, 108. Figure 18A shows a greatly enlarged portion of the image of the curved plate in Figure 18, illustrating the alignment of the long continuous carbon fibers AF therein. The ribs 128, as shown in Figure 9, are machined from the curved plate CP. The plate shown was used to form nine ribs, and the curved plate was formed using a polymer plate having a stack of at least substantially aligned continuous carbon fibers (see Figure 18A) ([(0 / 45 / 90 / -45)x]s) within a polyether ether ketone polymer matrix. In a preferred embodiment, a curved mold was then used to form the curved plate from which the ribs were machined. The curvature allows for the selection of a 0° fiber orientation according to the chord line of the ribs, and the laminate is quasi-isotropic.

[0122] While these molds are preferred, various other types of molds may be used to form component parts and elements of different article designs, including different impeller designs.

[0123] Figure 20 shows a composite ring formed from polyetheretherketone, with circumferentially aligned carbon fibers, used as a ring member 106 in the exemplary composite impeller shown.

[0124] A metal ring was provided and, after the impeller was formed, attached to the outer surface of a machined second composite flange. The sample component parts described above, with the exception of the second ring member (metal ring), were assembled in a mold to form an assembly of component parts, in this case, an impeller assembly. A removable core was placed in the mold where there should be openings or voids in the assembled and remolded article. The assembly was placed in the mold and remolded to form a final composite impeller embodiment according to Embodiment 100 as shown in the photographic image of Figure 21. The molded sides are described with reference to Figures 22 and 23. The second ring was then attached to the composite impeller.

[0125] In Figure 22, component parts are shown in disassembled parts in a representative manner. The flange plates, shown as items F1 and F2, are formed using a mold as shown in Figure 16 and machined into a certain shape (no features are shown in the representative drawing). The ribs are machined from curved plates, formed using a mold as shown representatively in Figure 17. This provides the rib R. The parts are preferably reassembled into a mold base M and an optional mold insert MI having the desired shape for the final article. The cavity in the assembly structure, filled with a removable core RC, is shown here representatively as a crushable mandrel. A ram RM then applies pressure over the completed assembly.

[0126] The assembled parts are shown in cross-section in Figure 23. The completed assembly is remolded in the mold, and the removable core RC is removed.

[0127] Various mold designs, as known in the art, may be used and designed for any of several different multi-component articles, such as impellers, as illustrated herein.

[0128] Other component compression parts may be employed, or one or more flanges may be used in designs as shown. Furthermore, the number of ribs may vary in the impeller without departing from the present invention.

[0129] Wherever an opening exists in the final component, a removable core is used in the assembly. As will be known to those skilled in the art, based on this disclosure and depending on the polymer matrix material used, the removable core may be an extractable core, a crushable mandrel, a machinable core, a dissolvable core, a meltable core, an expandable bladder, or any other removable core known or to be developed in the art.

[0130] Molding conditions, including temperature and pressure, will vary depending on the polymer matrix polymer with various fillers and reinforcing fibers, as will be known in the art. For example, when using carbon / PEEK composites, in one exemplary impeller, the mold was heated to about 400°C in a hot press, although a processing temperature of about 360°C to 430°C may be used. Typical process pressures of about 10 bar to about 150 bar may also be used on this particular material. This is a high-temperature performance thermoplastic material, and therefore, those skilled in the art will understand that the temperature and pressure are adjusted for less demanding or more demanding materials according to their melting and molding profiles.

[0131] Once the mold is removed, it is cooled. Cooling may be done through a controlled cooler exchanger, cooler tank, convection, or other preferred method. The molded impeller component is then removed from the mold, and the removable core is then removed by machining, melting, or other acceptable techniques, or otherwise disposed of. At this stage, further machining to the final or near-final shape may be performed if required.

[0132] From sample impellers formed according to the method herein, the applicant determined that the results in use could be further improved by modifying the initial impeller design to correct the thickness of the ring members on the individual upper and lower outer surfaces of the flange, and / or optionally by incorporating an outer banding ring around the circumferential outer surface of the flange.

[0133] Further embodiments 200 shown in Figure 11-14 include a modified impeller design. This embodiment differs from the previous embodiments and their modifications with respect to flange orientation, with Embodiment 100 using an upper first ring member on a quasi-isotropic laminate (which may be joined or molded integrally with the flange), while Embodiment 200 uses a quasi-isotropic laminate extending through the entire flange, including upper and lower ring members that are integral within the structure. The embodiments also illustrate modifications in flange shape and provide different machined features to enable mounting of the impeller to the shaft. Both Embodiments 100 and 200 and their modified features herein are merely embodiments that can be considered as two possible impellers as claimed, and represent only a few examples of multi-component parts that can be fabricated using the methods herein.

[0134] On one modified side of the impeller, the upper and lower ring members 250, 252 were incorporated such that the first upper ring member 250 is formed as part of the outer surface of the modified first composite flange 204. The composite flange was modified to extend upward within an internal area defining an opening 214 through the composite flange 204. The second lower ring member 252 was similarly formed as part of the outer surface of the modified second composite flange 208 to engage with the modified interior of the flange and define an opening 210 extending through it. The upper and lower ring members 250, 252 are each formed as a single component from the same composite as the flange, and in the ring members, they include long continuous fibers that are substantially aligned so that at least a portion of them extends substantially circumferentially. The ring members 250, 252 designed in this way have reduced stress concentration in the periphery area inside the flange during operation.

[0135] The thickness, as measured longitudinally along the first and second composite flanges, is also formed to gradually and generally increase in thickness along the radius of the flange, without altering any other features of the flange, compared to the previously shown embodiments. For example, the flanges are inclined as they move laterally inward from the outer circumference of the flange toward the central area of ​​the flange defining the opening through it, structurally increasing the flange longitudinally as they approach the axial center of the assembly, while maintaining the inner surfaces 220 of the first composite flange 204 and 224 of the second composite flange 208 substantially planar, each incorporating surface features 226 for engaging with the impeller rib 228. The first side 230 of the rib engages with the surface feature 226 of the inner surface 220 of the first composite flange 204, and the second side 232 of the rib 228 engages with the surface feature 226 on the inner surface 224 of the second composite flange 208. The thicker central area on the outside of the flange near the axial center of the impeller when it is formed further contributes to reducing stress when the impeller is used in very high-speed operation.

[0136] In a further preferred optional modification, additional features are provided on the periphery of the first composite flange 204 and the second flange 208 in the assembly 202, as shown in Figure 24. Each composite flange in assembly 202 has a preferred circumferential outer periphery (similar to embodiment 102). The outer periphery of each flange is defined as separate outer surfaces 262, 264. Each outer surface 262, 264 extends longitudinally between the respective separate inner surfaces 220, 224 and separate outer surfaces 218, 222 of the composite flanges 204, 208, respectively. The outer surfaces 262, 264 of the first and second flanges are also engaged by a further larger outer banding ring, as shown in the embodiment of Figure 24, in a preferred embodiment. The first outer banding ring 260 is mounted around the first composite flange and engages with its outer surface 262. The second outer banding ring 258 is mounted around the second composite flange and engages with its outer surface 264. The banding rings 260, 258 may also be fabricated to be substantially inclined upward in the direction from the outer periphery toward the axial center assembly, if desired. The outer banding rings are circumferentially positioned around the outer surfaces of the first and second flanges and are configured to engage with the outer surfaces of the first and second flanges. The outer banding rings may also help reduce stress in the inner diameter (ID) axial direction of the composite flange in the impeller for high-speed operation. The banding rings described herein help to secure the rib 228 within feature 228 by engaging with the meshing area in which the rib and flange are molded together in the assembly.

[0137] The outer banding ring may be identical to the composite material used to form other components in the assembly and the finished structure, and preferably also include a third composite material having at least a portion of unidirectionally oriented fibers extending circumferentially. As described above, one or two such outer banding rings may be employed in the impeller, which may further include at least one ring member including the ring described above, and one or two outer banding rings positioned circumferentially around the outer surface of the second flange and configured to engage with the outer surface of the second flange.

[0138] When forming the outer banding rings 260, 258, automated tape layup, preferably tape winding, may be used to prepare the laminate. However, any suitable laminate for forming these features may be used. When preparing the banding rings, those skilled in the art will preferably try to achieve substantially unidirectional fiber orientation in the banding rings, although other orientations are also possible. Regardless of the technique used to form the banding rings 260, 258, this is formed into an assembly of component parts to be reformed and incorporated therein, and the reformed assembly may then be machined.

[0139] An impeller molded according to the embodiment shown in Figure 24 achieved a speed exceeding approximately 600 m / s.

[0140] An additional embodiment 300 shown in Figures 25-28 includes a modified impeller design. This embodiment differs from the previous embodiments and their variations in terms of the introduction of Hirth tooth profiles for engaging with the drive components, and, as with the previous embodiments, similar parts have similar reference numbers. The main body of the impeller is otherwise similar to that shown in Figure 200, with optional binding. Embodiment 300 also uses a quasi-isotropic laminate through the entire flange 304, 308, including upper and lower ring members 350, 352, which are integral in the structure and incorporated such that the first upper ring member 350 is formed as part of the outer surface of the modified first composite flange 304 in the same manner as in Embodiment 200. The composite flange 304 defines an opening 314 through the composite flange 304. The second lower ring member 352 is similarly formed as part of the outer surface of the modified second composite flange 308 to engage with the modified interior of the flange and define an opening 310 extending through it. The upper and lower ring members 350, 352 are each formed as a single component from the same composite as the flange, as in embodiment 200, and include long continuous fibers in the ring members that are substantially aligned so that at least a portion of them extends substantially circumferentially.

[0141] As shown in most detail in Figure 26, the thickness, as measured longitudinally along the first and second composite flanges, is also formed to gradually and generally increase in thickness along the radius of the flange, without altering any other features of the flange, compared to the previously shown embodiments. However, in Embodiment 300, the lower sloping portion is trimmed to be flatter in its inner annular portion 369 to receive the formed Hirth tooth profile 368, and its features may be molded onto the outer surface 322 of the second composite flange 308 in the area where the composite ring 352 is molded onto the flange 308. The second composite plate 308 defines an opening 310 through which it passes. The inner surface 320 of the first composite flange 304 and the inner surface 324 of the second composite flange 308 remain substantially flat and incorporate surface features 326 as shown in Figure 27 for engagement with the impeller rib 328. Feature 326 and rib 328 are manufactured in the same manner as those described above in previous embodiments 100, 200. As shown in most detail in Figures 26 and 27, the first side 330 of the rib engages with the surface feature 326 on the inner surface 320 of the first composite flange 304, and the second side 332 of the rib 328 engages with the surface feature 326 on the inner surface 324 of the second composite flange 308.

[0142] In a further preferred optional modification of Embodiment 300, as shown in Figure 26, a banding ring is included around the periphery of the first composite flange 304 and the second flange 308, on their outer circumferential periphery. The outer periphery of each flange is defined as separate outer surfaces 362, 364. Each outer surface 362, 364 extends longitudinally between the respective separate inner surfaces 320, 324 and separate outer surfaces 318, 322 of the composite flanges 304, 308. The outer surfaces 362, 364 of the first and second flanges are also engaged by a further optional larger outer banding ring, as shown in the embodiment of Figure 26, in a preferred embodiment. The first outer banding ring 360 is mounted around the first composite flange and engages with its outer surface 362. The second outer banding ring 358 is mounted around the second composite flange and engages with its outer surface 364. The banding rings 360 and 358 may also be fabricated to be inclined substantially upward in the direction from the outer periphery toward the axial center assembly, if desired. The outer banding ring may be circumferentially positioned around the outer surfaces of the first and second flanges and configured to engage with the outer surfaces of the first and second flanges. The outer banding ring may also help reduce stress in the inner diameter (ID) axial direction of the composite flange in the impeller for high-speed operation. The banding ring may also help to secure the rib 328 within the surface feature 326 for further stability, as described above with respect to Embodiment 200.

[0143] The outer banding ring may be identical to the composite material used to form other components in the assembly and the finished structure, and preferably also include a third composite material, as described above in the modified embodiment 200, which includes a banding ring having at least a portion of unidirectionally oriented fibers extending circumferentially. As described above, one or two such outer banding rings may be employed in the impeller, which may further include at least one ring member, including the ring described above, and one or two outer banding rings positioned circumferentially around the outer surface of the second flange and configured to engage with the outer surface of the second flange.

[0144] When forming the outer banding rings 360, 358, automated tape layup, preferably tape winding, may be used to prepare the laminate. However, any suitable laminate for forming these features may be used. When preparing the banding rings, those skilled in the art will preferably try to achieve substantially unidirectional fiber orientation in the banding rings, although other orientations are also possible. Regardless of the technique used to form the banding rings 360, 358, they are formed into an assembly of component parts to be reformed and incorporated therein, and the reformed assembly may then be machined.

[0145] When forming the Hirth tooth profile, a standard mold surface may be prepared to engage with the plate of the second flange 308 within the method herein to create the desired tooth profile design. A preferred design is shown in which the spirals are uniformly spaced around the annular portion 369. Alternatively, the Hirth tooth profile may be formed as a separately molded plate that can be included in an assembly of component parts to be installed within the molding area of ​​the mold as described herein. Thus, the Hirth tooth profile may be formed by a separately molded plate for later mounting, a separately molded plate for incorporation into an assembly to be remolded, or by a specially designed insert surface within the mold body that engages with the outer surface of the second flange plate in the molded component part assembly.

[0146] When in use, the impeller 300, as shown in Figure 27, may be fastened to a drive component 372, which has a meshing Hirth tooth profile 370 for engaging with a Hirth tooth profile 368 when it is installed. An opening 374 may be formed within the drive component 372 to receive a connecting fastener 378. Such a fastener 378 may be a snap-fit, plug-in meshing piece, threaded, or riveted fastener 378. The drive component 372 serves to center the impeller 300 and fasten it to the drive component in order to drive the impeller when in use. The Hirth tooth profile 368 on the outer surface 322 of the second composite flange 308 may engage with the drive component and then be fastened to the drive component using the fastener 378 and a mating piece 376 as shown in Figure 27. As the fastener and mating piece are tightened, the Hirth tooth meshing pieces are pushed together appropriately and seated in mesh engagement. This provides an alternative to the need to weld or otherwise fasten and seat the impeller as described herein, offering improved engagement and alignment for secure fastening of the impeller in use for smooth engagement and rotation, which may provide balanced and reduced vibration at higher speeds. Hirth tooth profiles are known in the art with respect to joints or couplings for forming mechanical connections, such as between two parts of a shaft, and incorporate tapered "teeth" that engage on each meshing portion of the shaft. By providing teeth in an annular configuration, the torque capacity increases with the diameter of the ring. The incorporation of the Hirth tooth profile fastener array described herein in composite impeller designs such as those described herein offers advantages in fastening and stability in use and is considered novel in the apparatus and methods described herein.

[0147] The composite component parts were formed as described in Embodiment 200. A removable core material was placed in the mold where openings or voids should remain in the assembled and remolded article. The assembly was placed in the mold using a mold plate for forming the Hirth tooth profile and remolded to form the final composite impeller embodiment according to Embodiment 300 as shown in the photographic image of Figure 28.

[0148] Impellers molded according to the embodiments shown in Figures 24 and 25 of this specification are designed to achieve speeds exceeding approximately 600 m / s and to reach even higher speeds exceeding 700 m / s or higher.

[0149] In each embodiment of this specification, the impeller is preferably a reformed assembly of at least one first composite flange and at least one rib, and preferably a plurality of ribs and at least one ring member. In a preferred embodiment, at least two flanges (a first flange and a second flange) or a plurality of such flanges may be present in series or in different interconnected impeller structures. Ring members may be used, including a composite first ring member as part of the assembly to be formed as described above. An additional optional second ring member of metal, as in Embodiment 100, may be provided to the reformed assembly once formed. The assembly to be reformed may also include flanges having an upper or lower ring, formed as part of a flange composite, as in Embodiment 200. The assembly may also include an optional outer banding ring on the circumferential outer surface of the first and second composite flanges. Such an outer banding ring is intended to reduce stress on higher load areas of the formed article.

[0150] The composites used in the various embodiments of this specification are preferably one or more engineering polymers or high-performance thermoplastic polymers or one or more thermosetting polymers as described above.

[0151] In a preferred embodiment, openings within the impeller and in the internal portion of the impeller in the final design may be formed using a removable core technique.

[0152] The present invention also includes a method for forming a multi-component polymer composite, such as an impeller as described herein in Embodiments 100, 200, comprising the step of preparing at least one first composite flange or two or more such flanges, each of which can define an opening extending longitudinally through it, as described above. The first flange, when making an impeller, includes a polymer composite having a polymer matrix material and continuous fibers extending through the longest dimension of the composite component, as described herein. Similarly, a second composite flange defining an opening extending longitudinally through it, as described above, may be prepared. The second flange may also include a polymer composite that is identical to or different from that in the first composite flange. Other elements or components may be formed to make other multi-component components.

[0153] When manufacturing the impeller, the method may further include the step of preparing at least one rib as described above, having a first end and a second end. The first composite flange and an optional second composite flange are then assembled so that the openings in the first composite flange and the openings in the second composite flange are substantially aligned, preferably perfectly axially aligned, and the rib is installed between the first composite flange and the second composite flange so that the first end of at least one rib engages with the first composite flange, for example by engaging with a surface feature on the inner surface of the first composite flange, and the second end of the rib engages with the second composite flange, for example by engaging with a surface feature on the inner surface of the second composite flange, and the impeller assembly is formed.

[0154] When manufacturing an impeller, these parts are then assembled to form an assembly, in this case an impeller assembly, which is positioned in a mold, and a removable core is introduced into one or more openings / voids in the composite assembly, so that such openings / voids will remain after remolding. The assembly in the mold is remolded under heat and pressure within the mold. The remolded assembly is cooled and removed from the mold, the removable core is removed, and a composite product such as a composite impeller is formed.

[0155] When the impeller assembly is fabricated, it may also include at least one ring member. The at least one ring member may include a first ring member having an opening that extends longitudinally through it, the first ring member being configured to engage with the first composite flange on one side of the first composite flange that engages with the first end of at least one rib and on the opposite side of the first composite flange, and the opening in the first flange and the opening in the first ring member are at least substantially aligned.

[0156] The at least one ring member may include a second ring member, which is a composite ring member if included prior to remolding or molded as a single component of the flange. Such a ring member defines an opening extending longitudinally through it to engage with the second composite flange on the side of the second composite flange opposite to the second end of at least one rib, and the opening in the second flange and the opening in the second ring member are at least substantially aligned, preferably perfectly axially aligned.

[0157] In the assembly, one or more such ring members (which may be described in detail above) may be incorporated as described above on the upper and lower portions of the assembly, axially aligned on the upper and lower outer surfaces of the first and second flanges. Furthermore, an outer banding ring may be provided. Such a banding ring may be circumferentially positioned around the circumferential outer surface of the first and / or second composite flange and may engage with the circumferential outer surface of the first and / or second composite flange. In addition, the flange thickness may increase as it approaches the central axial area of ​​the flange to reduce stress.

[0158] At least one ring member may be formed from a metal, a metal alloy, or a polymer composite, preferably containing long, continuous, substantially unidirectional fibers, where at least a portion of the fibers may, in one embodiment, be substantially matched with the component parts in the assembly. Once the component composite has been remolded and cooled, the metal ring may be added to the impeller.

[0159] Furthermore, the first composite flange, the second composite flange, and / or rib preferably also include a polymeric composite having similar long continuous fibers. The polymeric composite of the present invention in various embodiments herein may include a thermoplastic or thermosetting material polymer and at least one continuous long fiber.

[0160] The matrix polymer is one of those identified above in this specification, and a preferred matrix material may be a high-performance thermoplastic polymer as described above in this specification.

[0161] In another embodiment, the applicant applies its method to form a composite from individual composite component parts, the composite may have at least one opening or void. In this method, a polymer composite assembly is prepared using one or more polymer composite components, using the matrix material and fibers described above. The composite assembly is positioned in a mold with a removable core incorporated into the voids and openings within the composite assembly, which are intended to remain as openings or voids in the finished article. The polymer composite assembly is positioned in the mold with heat and pressure applied to remolde the assembly into an article. Once the article is formed and cooled, it is also removed from the mold, the removable core is then removed, and the polymer composite is formed.

[0162] In preferred embodiments of this specification, the article is an impeller, which may be open or closed; however, other articles may be made using similar materials, method steps, and techniques. The composite components used preferably include a polymer composite material as described above, having at least one continuous fiber in it. Such a continuous fiber may be a long continuous fiber, and at least a portion of the fibers in at least one continuous fiber may be at least substantially matched. However, other reinforcing fibers and fillers as mentioned above may also be used.

[0163] The polymer composite in the method described herein may include thermoplastic or thermosetting matrix polymers as described above. The removable core in this method may also be removed by the various techniques described above.

[0164] Those skilled in the art will understand that modifications can be made to the embodiments described above without departing from the broader concept of the present invention. Therefore, it should be understood that the present invention is not limited to the specific embodiments disclosed, but is intended to encompass modifications within the spirit and scope of the invention as defined by the appended claims.

Claims

1. An impeller for use with a centrifugal compressor or pump, A composite comprising a matrix material selected from at least one thermoplastic polymer or at least one thermosetting polymer, At least one continuous reinforcing fiber and An impeller equipped with the following features.

2. The impeller according to claim 1, wherein the matrix material is one or more thermoplastic polymers.

3. The impeller according to claim 1, wherein the matrix material is a high-performance polymer selected from the group consisting of polycarbonate, linear aromatic polyester, linear aromatic polyimide, polyurethane, polyphenylene oxide, polyphenylene ether, polyphenylene ester, polyphenylene ether ester, polyphenylene sulfide, polysulfone, polyethersulfone, polyphenylsulfone, polymethylpentene, polyketone, aramid, polyaryl ether, polyaryletherketone, and combinations and copolymers thereof.

4. The impeller according to claim 3, wherein the matrix material comprises at least one polyaryl ether ketone selected from polyether ketones, polyether ketone ketones, polyether ether ketones, polyether ether ketone ketones, polyether ketone ether ketone ketones, and combinations and copolymers thereof.

5. The impeller according to claim 1, wherein the matrix material is an engineering polymer selected from the group consisting of polybutadiene, polyacrylonitrile, poly(butadiene-styrene), poly(styrene-acrylonitrile), melt-processable fluoropolymer, liquid crystalline polymer, polyacetal, polyacrylate, polyamide, polyolefin, polyalkylene terephthalate, polyphthalimide, polyimide, polyetheramide, and combinations and copolymers thereof.

6. The impeller according to claim 1, wherein the matrix material is one or more thermosetting polymers.

7. The impeller according to claim 1, wherein the matrix material is a thermosetting polymer selected from the group consisting of ethylene propylene diene rubber, ethylene propylene rubber, thermosetting polyurethane elastomer, epoxy resin, thermosetting biscitraconimide, bismaleimide (BMI), bismaleimide / triazine / epoxy resin, cyanate ester, cyanate resin, furan resin, phenol resin, urea-formaldehyde resin, melamine-formaldehyde resin, phthalocyanine resin, polybenzoxazole resin, acetylene-terminated polyimide resin, silicone, polytriazine, thermosetting polyvinyl ester, thermosetting polyurethane, polytetrafluoroethylene, melamine, polyalkyd, xylene resin, and combinations and copolymers thereof.

8. The impeller according to claim 1, wherein the at least one continuous reinforcing fiber comprises at least a portion of fibers substantially aligned within the matrix polymer.

9. The impeller according to claim 8, wherein the at least one continuous reinforcing fiber is selected from the group consisting of carbon, glass, aramid, metal, metal alloy, and natural fibers.

10. The impeller according to claim 8, wherein the impeller is formed from separate elements made of the composite, and within the separate elements, at least a portion of the fibers of the at least one continuous fiber are substantially aligned.

11. The impeller is, At least one first flange comprising the composite, wherein the at least one first flange has an outer surface and an inner surface, and the first flange defines a first opening extending longitudinally through it, At least one rib, the at least one rib is positioned on the at least one first flange such that the at least one rib engages with the inner surface of the at least one first flange. The impeller according to claim 1, comprising:

12. The impeller according to claim 11, wherein the at least one rib includes the composite material.

13. The impeller according to claim 11, further comprising at least one ring member that contacts at least one of the at least one flanges.

14. The impeller according to claim 11, wherein the impeller is a remolded assembly of the first flange, the at least one rib, and the at least one ring member.

15. The impeller further, A second flange comprising the composite material, wherein the second flange has an outer surface and an inner surface, the second flange has at least one surface feature on its inner surface, and the second flange defines a second opening extending longitudinally through it. Equipped with, Each of the at least one rib has a first end and a second end, the second end of the at least one rib engaging with the at least one surface feature on the inner surface of the second flange, and the first and second openings are positioned to be at least substantially aligned. The impeller according to claim 11.

16. The impeller according to claim 15, wherein a plurality of surface features and a plurality of ribs are present on the inner surface of the second flange.

17. The impeller according to claim 15, wherein the inner surface of the first flange also comprises at least one surface feature, and the first end of the at least one rib engages with the at least one surface feature on the inner surface of the first flange.

18. The impeller according to claim 17, wherein the at least one surface feature on each of the inner surfaces of the first and second flanges is at least substantially aligned to engage with the first and second ends of the at least one rib.

19. The impeller according to claim 18, wherein a plurality of surface features on the inner surface of the first flange and the inner surface of the second flange, and a plurality of ribs are present.

20. The impeller according to claim 15, wherein the outer surface of the second flange has a high tooth profile formed in the inner annular portion of the second flange.

21. The impeller according to claim 15, further comprising at least one ring member that contacts at least one of the at least one flanges.

22. The impeller according to claim 21, wherein the at least one ring member comprises a second ring member, the second ring member having an opening extending longitudinally through it, and the second ring member is configured to engage with the outer surface of the second flange such that the second opening in the second flange and the opening in the second ring member are at least substantially aligned.

23. The impeller according to claim 22, wherein the second ring member and the second flange each define one or more openings for receiving fasteners for securing the second ring to the second flange.

24. The impeller according to claim 22, wherein the second ring member comprises metal or a metal alloy.

25. The impeller according to claim 21, wherein the at least one ring member further comprises a first ring member, the first ring member defining an opening extending longitudinally through it, and the first ring member engaging with the outer surface of the first flange such that the first opening in the first flange and the opening in the first ring member are substantially aligned.

26. The impeller according to claim 25, wherein the first ring member comprises a second composite material.

27. The impeller according to claim 26, wherein the second composite material is the same as the composite material and comprises fibers oriented in one direction that extend in the circumferential direction.

28. The impeller according to claim 21, wherein the first flange and the second flange each have a circumferential outer surface extending longitudinally between their inner surface and outer surface, and the impeller comprises an outer banding ring, the outer banding ring being circumferentially positioned around the outer surface of the first flange and configured to engage with the outer surface of the first flange.

29. The impeller according to claim 28, wherein the outer banding ring comprises a third composite material.

30. The impeller according to claim 29, wherein the third composite material is the same as the composite material and has fibers that are oriented in one direction and extend in the circumferential direction.

31. The impeller according to claim 29, further comprising a second outer banding ring positioned circumferentially around the outer surface of the second flange and configured to engage with the outer surface of the second flange, wherein the second outer banding ring comprises the third composite material.

32. The impeller according to claim 21, wherein the impeller is a remolded assembly of the first and second flanges, the at least one rib, and the at least one ring member.

33. The impeller according to claim 32, wherein the assembly further comprises at least one outer banding ring.

34. The impeller according to claim 11, wherein the composite comprises an engineering polymer or a high-performance polymer, and the opening in the impeller is formed by removable core molding.

35. The impeller according to claim 11, wherein the impeller is capable of achieving a tip speed of at least 400 m / s or higher during operation.

36. The impeller according to claim 35, wherein the impeller is capable of achieving a tip speed of at least about 600 m / s during operation.

37. The impeller according to claim 36, wherein the impeller is capable of achieving a tip speed of at least about 700 m / s during operation.

38. A method for forming a multi-component composite product, To prepare at least two molded polymer composite components, Assembling the aforementioned at least two molded polymer composite components into an assembly, Positioning the assembly inside the mold, The assembly in the mold is remolded to form a multi-component composite product. Methods that include...

39. The method according to claim 38, wherein the assembly comprises at least one opening, and the method further comprises incorporating a removable core into each of the at least one opening prior to positioning the assembly in the mold, and removing the removable core from the at least one opening after the multi-component composite has been formed.

40. The method according to claim 39, wherein the removable core is removed by machining.

41. The assembly is an impeller assembly, the multi-component composite is an impeller, the at least two molded polymer composite components comprise at least one first flange and at least one rib, and the method further The present invention relates to preparing the at least one first composite flange, wherein the at least one first composite flange defines an opening extending longitudinally through it, and the first flange comprises the polymer composite. To prepare the at least one rib having a first end and a second end, The first composite flange and the at least one rib are assembled such that the first end of the at least one rib engages with the first composite flange to form the impeller assembly. Position the impeller assembly within the mold and incorporate the removable core into the opening in the at least one first flange, The impeller assembly is reshaped, the removable core is removed, and the impeller is formed. The method according to claim 38, including the method described in claim 38.

42. The method according to claim 41, wherein the impeller assembly further comprises at least one ring member when assembled in the mold.

43. The above method further, The present invention relates to the preparation of a second composite flange, wherein the second composite flange defines an opening extending longitudinally through it, and the second flange comprises the polymer composite. Includes, The method further includes assembling the at least one first composite flange and the at least one rib with the second composite flange, thereby substantially aligning the opening in the at least one first composite flange and the opening in the second composite flange, and mounting the at least one rib between one of the at least one first composite flanges and the second composite flange, thereby engaging the second end of the at least one rib with the second composite flange, so that the formed impeller assembly comprises the at least one first flange, the at least one second flange, and the at least one rib. The method according to claim 41.

44. The method according to claim 43, wherein the outer surface of the second flange is formed to have a high tooth profile in the inner annular portion of the second flange.

45. The method according to claim 43, wherein the impeller assembly further comprises at least one ring member when assembled in the mold.

46. The method according to claim 44, wherein the at least one ring member comprises a polymer composite having long, continuous, unidirectional fibers.

47. The method according to claim 44, wherein the at least one ring member comprises a first ring member, the first ring member having an opening extending longitudinally through it, the first ring member being configured to engage with the first composite flange on the side of the first composite flange opposite to the side of the first composite flange that engages with the first end of the at least one rib, and the opening in the first flange and the opening in the first ring member are at least substantially aligned.

48. The method according to claim 47, further comprising providing the impeller with a second ring member after reshaping, the second ring member defining an opening extending longitudinally through it, the second ring member for engaging with the second composite flange on the side of the second composite flange opposite to the side of the second composite flange that engages with the second end of at least one rib, the opening in the second flange and the opening in the second ring member being at least substantially aligned, and the second ring member comprising metal or a metal alloy.

49. The method according to claim 43, wherein the assembly comprises at least one outer banding ring, the at least one outer banding ring being circumferentially positioned around the circumferential outer surface of the first composite flange and / or the second composite flange, and engaging with the circumferential outer surface of the first composite flange and / or the second composite flange.

50. The method according to claim 49, wherein the at least one banding ring defines an opening extending longitudinally through it, and the at least one banding ring is configured to engage with either the first composite flange and / or the second composite flange on the outer surface of the first composite flange, and the opening in the at least one banding ring and the opening in the first and / or second composite flange are substantially aligned axially.

51. The method according to claim 43, wherein one or more of the first composite flange, the second composite flange, and the at least one rib comprises a polymer composite having continuous fibers.

52. The method according to claim 38, wherein the impeller is capable of achieving a tip speed of at least about 400 m / s during operation.

53. The method according to claim 53, wherein the impeller is capable of achieving a tip speed of at least about 600 m / s during operation.

54. The method according to claim 53, wherein the impeller is capable of achieving a tip speed of at least about 700 m / s during operation.

55. The method according to claim 38, wherein the polymer composite comprises a thermoplastic or thermosetting matrix polymer and at least one continuous long fiber.

56. The method according to claim 55, wherein the at least one continuous long fiber comprises at least a portion of fibers selected from the group consisting of carbon, glass, aramid, metal, metal alloy, and natural fibers, which are at least substantially matched.

57. The method according to claim 55, wherein the matrix polymer is a high-performance thermoplastic polymer selected from the group consisting of polycarbonate, linear aromatic polyester, linear aromatic polyimide, polyurethane, polyphenylene oxide, polyphenylene ether, polyphenylene ester, polyphenylene ether ester, polyphenylene sulfide, polysulfone, polyethersulfone, polyphenylsulfone, polymethylpentene, polyketone, aramid, polyaryl ether, polyarylether ketone, and combinations and copolymers thereof.

58. The method according to claim 57, wherein the matrix polymer comprises at least one polyaryl ether ketone selected from polyether ketones, polyether ketone ketones, polyether ether ketones, polyether ether ketone ketones, polyether ketone ether ketone ketones, and combinations and copolymers thereof.

59. The method according to claim 55, wherein the matrix polymer is an engineering thermoplastic polymer selected from the group consisting of polybutadiene, polyacrylonitrile, poly(butadiene-styrene), poly(styrene-acrylonitrile), melt-processable fluoropolymer, liquid crystalline polymer, polyacetal, polyacrylate, polyamide, polyolefin, polyalkylene terephthalate, polyphthalimide, polyolefin, polyimide, polyetheramide, and combinations and copolymers thereof.

60. The method according to claim 55, wherein the matrix polymer is one or more thermosetting polymers.

61. The method according to claim 60, wherein the thermosetting polymer is selected from the group consisting of ethylene propylene diene rubber, ethylene propylene rubber, thermosetting polyurethane elastomer, epoxy resin, thermosetting biscitraconimide, bismaleimide, bismaleimide / triazine / epoxy resin, cyanate ester, cyanate resin, furan resin, phenol resin, urea-formaldehyde resin, melamine-formaldehyde resin, phthalocyanine resin, polybenzoxazole resin, acetylene-terminated polyimide resin, silicone, polytriazine, thermosetting polyvinyl ester, thermosetting polyurethane, polytetrafluoroethylene, melamine, polyalkyd, xylene resin, and combinations and copolymers thereof.

62. A method for forming a polymer composite having at least one opening, The present invention relates to the preparation of a polymer composite assembly of at least two composite components, wherein the polymer composite assembly has at least one opening therein. Position the polymer composite assembly within the mold, and incorporate a removable core into at least one opening within the polymer composite assembly. The polymer composite assembly in the mold is remolded, the removable core is removed, and the polymer composite product is formed. Methods that include...

63. The method according to claim 62, wherein the polymer composite is an impeller.

64. The method according to claim 62, wherein the at least two composite components include a polymer composite having at least one continuous reinforcing fiber therein.

65. The method according to claim 64, wherein the at least one continuous reinforcing fiber is selected from the group consisting of carbon, glass, aramid, metal, metal alloy, and natural fibers.

66. The method according to claim 65, wherein at least a portion of the fibers in the at least one continuous reinforcing fiber are at least substantially aligned.

67. The method according to claim 62, wherein the polymer composite comprises a thermoplastic or thermosetting matrix polymer.

68. The method according to claim 67, wherein the matrix polymer is a high-performance thermoplastic polymer selected from the group consisting of polycarbonate, linear aromatic polyester, linear aromatic polyimide, polyurethane, polyphenylene oxide, polyphenylene ether, polyphenylene ester, polyphenylene ether ester, polyphenylene sulfide, polysulfone, polyethersulfone, polyphenylsulfone, polymethylpentene, polyketone, aramid, polyaryl ether, polyarylether ketone, and combinations and copolymers thereof.

69. The method according to claim 68, wherein the matrix polymer comprises at least one polyaryl ether ketone selected from polyether ketones, polyether ketone ketones, polyether ether ketones, polyether ether ketone ketones, polyether ketone ether ketone ketones, and combinations and copolymers thereof.

70. The method according to claim 67, wherein the matrix polymer is an engineering thermoplastic polymer selected from the group consisting of polybutadiene, polyacrylonitrile, poly(butadiene-styrene), poly(styrene-acrylonitrile), melt-processable fluoropolymer, liquid crystalline polymer, polyacetal, polyacrylate, polyamide, polyolefin, polyalkylene terephthalate, polyphthalimide, polyimide, polyetheramide, and combinations and copolymers thereof.

71. The method according to claim 67, wherein the matrix polymer is one or more thermosetting polymers.

72. The method according to claim 70, wherein the thermosetting polymer is selected from the group consisting of ethylene propylene diene rubber, ethylene propylene rubber, thermosetting polyurethane elastomer, epoxy resin, thermosetting biscitraconimide, bismaleimide, bismaleimide / triazine / epoxy resin, cyanate ester, cyanate resin, furan resin, phenol resin, urea-formaldehyde resin, melamine-formaldehyde resin, phthalocyanine resin, polybenzoxazole resin, acetylene-terminated polyimide resin, silicone, polytriazine, thermosetting polyvinyl ester, thermosetting polyurethane, polytetrafluoroethylene, melamine, polyalkyd, xylene resin, and combinations and copolymers thereof.

73. The method according to claim 62, wherein the removable core is removed by machining.

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