Radial Compressor Housing Composite Injection Molding
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Solution Overview
Problem
Conventional turbocharger housings face challenges with high impermeability, dimensional stability, and manufacturing complexity, particularly when made from thermoplastic materials, which lack structural strength and are prone to damage under high pressures and temperatures.
Innovation Solution
A housing for radial flow compressors made from fiber-reinforced thermoplastic polymer compositions, assembled via an integrated 2-step injection molding process, comprising upper and lower housing members that are injection molded together to form a robust, impermeable, and complexly shaped housing with enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a plastic housing is used to reduce weight, then weight is reduced, but structural strength and pressure resistance deteriorate
Solution Approach 1:
The patent applies composite materials by combining thermosetting plastic (for structural strength and heat resistance) with thermoplastic material (for weight reduction and functional integration). This composite construction allows the housing to achieve both lightweight properties and sufficient structural strength to withstand high pressures, resolving the contradiction between weight reduction and strength requirements.
2Reliability
If a single-piece housing is used to ensure impermeability, then leak resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent segments the housing into multiple components (thermosetting plastic body and thermoplastic reinforcement) that are assembled together. This segmentation allows each component to be manufactured separately with optimized processes, reducing overall manufacturing complexity while maintaining impermeability through proper joint design and sealing.
3Temperature
If thermosetting plastic is used for high temperature resistance, then heat resistance is improved, but susceptibility to damage from fan impeller splinters worsens
Solution Approach 1:
The patent uses composite materials where the thermosetting plastic provides high temperature resistance while the thermoplastic reinforcement layer provides impact resistance and damage tolerance. This composite structure allows the housing to withstand both thermal conditions and mechanical impacts from fan impeller failures, resolving the contradiction between heat resistance and impact resistance.
4Weight of moving object
If thermoplastic material is used for weight reduction, then weight is reduced, but dimensional stability and performance stability deteriorate
Solution Approach 1:
The patent combines thermosetting plastic (providing dimensional stability and heat resistance) with thermoplastic material (providing weight reduction). The composite structure ensures that the housing maintains stable dimensions and performance characteristics while achieving the desired weight reduction, resolving the contradiction between weight reduction and stability.
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 a lightweight, durable, and precisely dimensioned housing that can withstand high pressures and temperatures, with improved stability and reduced manufacturing complexity, enabling efficient production of complex shapes while maintaining structural strength and impermeability.
Implementation Method 1
made of a fiber-reinforced thermoplastic polymer composition
Implementation Method 2
injection molded together to form
Implementation Method 3
assembled via an integrated 2-step injection molding process
Implementation Method 4
injection molded together to form a robust, impermeable, and complexly shaped housing
Implementation Method 5
can withstand high pressures and temperatures
Implementation Method 6
enhanced structural integrity
Implementation Method 7
can withstand high pressures and temperatures
Implementation Method 8
long-term heat resistance against relatively high temperatures
Data Source
AI summary
The invention relates to a housing (1) of a radial flow compressor, comprising an intake pipe (4), a compressor duct (7) and an outlet pipe (5), wherein the housing comprises a housing body (basic construction) comprising at least an upper housing member (3) and a lower housing member (2) made of a fiber-reinforced thermoplastic polymer composition, and wherein the members (2, 3) are made, assembled together and fixed to each other in an integrated 2-step injection molding process. The invention also relates to a process for producing a housing for a radial flow compressor, comprising an intake pipe, a compressor duct and an outlet pipe, comprising steps of a) melt processing of a fiber-reinforced thermoplastic polymer composition thereby forming a polymer melt, b) injection molding the polymer melt into a molding die comprising at least two cavities, thereby forming at least two members comprising at least an upper housing member and a lower housing member, c) assembling the at least two members together, thereby forming a housing body defining the intake pipe, the compressor duct and the outlet pipe, and d) fixing the assembled at least two members to each other.