Composite Vane With Weight Inserts for Vane Cell Sealing
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Solution Overview
Problem
The manufacturing process of vanes for vane cell machines is cost-intensive and lacks flexibility due to the need for customized over-molding tools, which are expensive and time-consuming, especially for small quantities, and the use of steel cores complicates recycling and mass adjustment.
Innovation Solution
Vanes made entirely of solid fiber polymeric composite with strategically placed weight inserts to adjust mass and enhance centrifugal force for sealing, eliminating the need for over-molding and allowing for flexible, cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If vanes are manufactured by over-molding polymer onto steel cores, then mechanical stability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The invention removes the steel core from the vane structure entirely, extracting the unnecessary metallic component that required over-molding operations. The vane is manufactured as a single piece of polymer composite material, eliminating the complex multi-material manufacturing process while maintaining adequate mechanical properties through optimized composite material selection and structural design.
Solution Approach 2:
The invention uses fiber-reinforced polymer composite materials to create a unified vane structure that replaces the steel core + polymer coating approach. The composite material provides sufficient mechanical strength and stability through its inherent properties, eliminating the need for separate steel reinforcement and complex over-molding operations.
2Manufacturing precision
If customized over-molding tools are used for each vane type, then manufacturing precision is improved, but device complexity and production time increase
Solution Approach 1:
The invention employs a universal molding tool design that can produce multiple vane types and configurations through adjustable or reconfigurable elements. This single multi-functional tool replaces the need for separate customized tools for each vane type, reducing tooling complexity while maintaining manufacturing precision through programmable or adjustable molding parameters.
Solution Approach 2:
The molding tool incorporates dynamic or adjustable elements that can be reconfigured to produce different vane geometries and dimensions. This allows the same physical tool to adapt to various vane types through parameter adjustment rather than requiring physical customization for each design, thereby reducing overall tooling complexity.
3Strength
If steel cores are used in vane manufacturing, then structural strength is improved, but recyclability and mass adjustment flexibility deteriorate
Solution Approach 1:
The invention enables mass adjustment by changing the parameters of the polymer composite material itself, such as fiber-to-resin ratio, fiber type, or material density, rather than adding or removing steel components. This allows flexible mass customization while maintaining structural integrity through material property optimization rather than mechanical reinforcement.
Solution Approach 2:
The invention eliminates the steel core component entirely, discarding the non-recyclable metallic material that complicated disposal and recycling processes. The polymer composite vane can be fully recycled or disposed of more easily, and the design allows for flexible mass adjustment without the constraints of metal reinforcement.
4Ease of operation
If polymer over-molding is used on steel cores, then friction properties are improved, but manufacturing time and cost increase
Solution Approach 1:
The invention merges the friction-modifying polymer layer with the structural vane body into a single integrated polymer composite component. This eliminates the separate steel core and polymer coating steps, combining manufacturing operations into a single molding process that produces the final friction-optimized surface directly without requiring sequential assembly operations.
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
The solution provides efficient, cost-effective, and recyclable vanes with precise mass adjustment, ensuring proper sealing and reduced friction, enhancing the performance and manufacturability of vane cell machines.
Implementation Method 1
at least one weight insert (42) is inserted into the at least one cavity (41), wherein the at least one weight insert (42) increases a mass of the vane (30)
Data Source
AI summary
The present disclosure relates to a vane (30) for a vane cell machine (1). The vane (30) includes a body (31) extending in a longitudinal direction (LD), a traverse direction (TVD), and a thickness direction (THD), wherein all directions (LD, TVD, THD) are at least substantially perpendicular to each other. It includes two opposite longitudinal end surfaces (32) along the longitudinal direction (LD) and an outer side (33) for sealing against an inner circumferential wall surface (12) of the stator (10), wherein the outer side (33) constitutes one end of the body (31) in the traverse direction (TVD). For optimizing the efficiency of the vane cell machine and to improve the manufacturability of the vanes, the body (31) is made of solid fiber polymeric composite and the vane (30) includes at least one weight insert (42), wherein at least one cavity (41) for insertion of the at least one weight insert (42) into the body (31) is formed in the body (31). The present disclosure further relates to a vane cell machine (1) and a method for producing vanes (30).