3D Plastic Centrifugal Pump Impeller With One-Piece Twisted Blades
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Solution Overview
Problem
Conventional 2-dimensional impellers are inefficient and face challenges in manufacturing 3-dimensional twisted blade portions due to mold interference and structural weaknesses, leading to high costs and reduced mechanical strength, especially at high temperatures and loads.
Innovation Solution
A manufacturing method for a 3-dimensional plastic impeller using a mold with a fixed die and moving die to form twisted blade portions, allowing for seamless integration of the hub and shroud with blades, enabling efficient production and high structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional 2-dimensional impeller manufacturing methods are used, then production cost is low and manufacturing is easy, but pump efficiency is low
Solution Approach 1:
The patent transitions from manufacturing 2-dimensional impeller blades to 3-dimensional twisted blade structures. The 3-dimensional blades feature varying blade angles along the span from hub to shroud, with the leading edge twisted at a greater angle than the trailing edge. This dimensional change enables better flow guidance and higher pump efficiency while the injection molding process makes the complex geometry manufacturable.
2Productivity
If 3-dimensional twisted blade portions are manufactured using conventional methods, then pump efficiency is improved, but material waste is high and processing cost increases
Solution Approach 1:
The patent uses injection molding parameters to directly form 3-dimensional twisted blade portions within the mold cavity. By controlling injection pressure, temperature, and mold design, the complex 3-D geometry is created with minimal material waste. The process transforms the manufacturing approach from subtractive (machining) to additive (injection molding), significantly reducing material loss.
3Strength
If 3-dimensional plastic impeller is manufactured with seamless integration, then structural strength is high, but manufacturing process complexity increases
Solution Approach 1:
The patent integrates the hub rim part, shroud rim part, and twisted blade portions into a single seamless 3-dimensional structure through injection molding. The mold design combines multiple cavities and core components that form all impeller elements in one injection cycle, eliminating the need for separate manufacturing and assembly steps. This merging approach achieves high structural strength while managing process complexity through integrated mold design.
4Extent of automation
If conventional molding methods are used, then manufacturing is simple, but automatic demolding is difficult
Solution Approach 1:
The patent segments the mold into movable components including a moving die and fixed die that can separate after injection. The mold design incorporates ejection mechanisms and parting surfaces that allow automatic demolding of the 3-dimensional impeller. The segmented mold structure enables the complex shaped impeller to be automatically ejected without manual intervention while maintaining manufacturing simplicity.
Data Source
Figure 1A~1B
Figure 1C
Figure 1D
AI summary
The disclosed embodiment is related to a manufacturing method of a die-formed 3-dimensional plastic impeller of a centrifugal pump and the impeller manufactured thereby, including a mold for twisted blade (M1) and a mold for impeller outlet (M2), the mold for twisted blade is configured to form a twisted blade portion (530a) of each blade (53) of the impeller (5), the mold for impeller outlet is configured to form a rear portion (530b) of each blade, a hub rim part (521) of the impeller, and a shroud rim part (511) of the impeller so that the hub rim part, the shroud rim part, and the blades are formed in a single piece at the same molding process.