Abradable Sealing Element Assembly for Dry Gas Pump Rotor Sealing
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Solution Overview
Problem
Existing non-lubricated gas pumping systems, such as compressors and vacuum pumps, face challenges in achieving a cost-effective and time-efficient seal between rotor elements and the housing, often requiring abradable coatings that are costly and time-consuming to apply.
Innovation Solution
A non-lubricated gas pumping system incorporating self-supporting sealing elements with an abradable coating, where the coating is applied to the sealing elements rather than the housing, allowing for controlled wear during run-in and improved sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If abradable coatings are applied to rotor surfaces or housing interior wall to create sealing, then sealing effectiveness is improved, but manufacturing time and cost increase
Solution Approach 1:
The sealing function is segmented from the housing structure by introducing separate sealing elements that can be independently manufactured and installed. These sealing elements contain the abradable coating material but are produced as discrete components rather than requiring coating of the entire housing interior, thereby reducing manufacturing complexity and time while maintaining sealing effectiveness.
Solution Approach 2:
The sealing elements are designed as replaceable components with embedded abradable material that can be easily replaced when worn. This approach is more economical than maintaining permanent housing coatings, as the sealing elements can be manufactured using cost-effective processes and replaced without requiring expensive re-coating operations on the housing.
2Reliability
If abradable coatings are applied to rotor surfaces or housing interior wall to create sealing, then sealing effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The sealing function is segmented from the housing structure by introducing separate sealing elements that can be independently manufactured and installed. These sealing elements contain the abradable coating material but are produced as discrete components rather than requiring coating of the entire housing interior, thereby reducing manufacturing complexity and time while maintaining sealing effectiveness.
Solution Approach 2:
The sealing elements are designed as replaceable components with embedded abradable material that can be easily replaced when worn. This approach is more economical than maintaining permanent housing coatings, as the sealing elements can be manufactured using cost-effective processes and replaced without requiring expensive re-coating operations on the housing.
3Productivity
If sealing disks from sintered PTFE-mica mixture are used at rotor end faces, then contact-free operation is achieved, but sealing adequacy deteriorates
Solution Approach 1:
The sealing elements utilize composite materials combining abradable coating material with a supporting matrix structure. This composite construction provides both the wear characteristics needed for run-in period sealing and the structural integrity required for adequate sealing performance, overcoming the limitations of single-material solutions like PTFE-mica mixtures.
Solution Approach 2:
The sealing elements act as intermediary components between the rotor end faces and the housing interior wall. These intermediaries provide the necessary sealing function while allowing controlled wear during run-in, bridging the gap between the rotating rotor and stationary housing without requiring direct contact or complex sealing mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the production and assembly of the system, reduces costs, and provides a more effective seal that is resistant to high temperatures and corrosion, extending the system's operational life.
Implementation Method 1
an abradable coating is applied to the rotor surfaces and/or the interior wall of the housing, which partially wears off during a run-in period of the compressor to create as tight a seal as possible
Implementation Method 2
During operation, these sealing disks are worn by the rotor elements to such an extent, that the end faces of the rotor elements run contact-free along the sealing disks
Data Source
AI summary
A non-lubricated system for pumping a gas, includes a stationary stator with a housing that includes a rotor cavity and at least one rotatable rotor element incorporated within the rotor cavity. The stator includes at least one self-supporting sealing element, incorporated within the rotor cavity between an end face of at least one of the rotor elements and an interior wall of the housing to form a seal along the corresponding end face. At least one self-supporting sealing element is provided with an abradable coating on at least one side facing the rotor.