Sealed Impeller Rotor Assembly for Caustic Fluid Balancing
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Solution Overview
Problem
Traditional impellers in respiratory therapy systems operating at high rotational speeds in caustic environments face challenges due to the need for balancing, which is time-consuming and costly, and are prone to failure from human error and corrosion from corrosive fluids, leading to increased manufacturing costs and reduced longevity.
Innovation Solution
A rotatable impeller assembly with a sealed magnetic ring and locked structural components that automatically balance the rotor, eliminating the need for periodic centering and balancing, and a hermetic seal to protect the magnetic ring from corrosive fluids, using materials like polyphenylene sulfide (PPS) and neodymium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional impellers are used in caustic environments, then they can operate at high rotational speeds, but they require time-consuming balancing operations and are prone to corrosion from corrosive fluids
Solution Approach 1:
The patent extracts the magnetic ring from direct exposure to the caustic environment by sealing it within the impeller assembly. The magnetic ring is positioned inside a sealed cavity formed by the impeller hub and back plate, isolating it from corrosive fluids while maintaining its function for rotor balancing and impeller rotation control.
Solution Approach 2:
The patent employs composite material construction for the impeller assembly, combining corrosion-resistant materials (such as PTFE, PPS, or other chemically inert polymers) for components exposed to caustic fluids, while using traditional magnetic materials for the sealed magnetic ring. This composite approach allows the structure to resist corrosion while maintaining magnetic functionality.
2Ease of operation
If traditional impellers require balancing operations, then quiet operation can be achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent implements self-balancing through the sealed magnetic ring that automatically centers itself within the rotor cup during assembly. The magnetic attraction between the magnetic ring and the rotor cup creates a self-centering force that eliminates the need for manual balancing operations, achieving both quiet operation and reduced manufacturing time.
Solution Approach 2:
The magnetic ring is pre-positioned and sealed within the impeller assembly during manufacturing, establishing the balanced configuration before the impeller is installed. This preliminary positioning ensures that the rotor is pre-balanced, eliminating the need for subsequent balancing operations and ensuring quiet operation from the first use.
3Duration of action of stationary object
If secondary assembly operations are performed for balancing, then component longevity can be improved, but assembly errors increase due to human error
Solution Approach 1:
The sealed magnetic ring provides self-alignment and self-centering functionality, eliminating the need for skilled manual balancing operations. The magnetic attraction automatically positions the magnetic ring correctly within the rotor cup, removing human error from the assembly process while ensuring proper alignment for long component longevity.
Solution Approach 2:
The patent combines the balancing function and the magnetic coupling function into a single sealed magnetic ring component. This integration eliminates the need for separate balancing operations and reduces the number of assembly steps, thereby reducing assembly errors while maintaining component longevity through proper balancing.
4Power
If magnets are exposed to corrosive fluids, then magnetic function can be maintained, but the materials used to seal magnets deteriorate over time
Solution Approach 1:
The patent extracts the magnetic ring from direct contact with corrosive fluids by sealing it within a protected cavity. The magnetic ring remains exposed to the magnetic field necessary for its function, but is physically isolated from the caustic environment, preventing deterioration of sealing materials while maintaining magnetic functionality.
Solution Approach 2:
The patent uses composite material construction with corrosion-resistant materials (such as PTFE, PPS, or other chemically inert polymers) for the impeller hub and back plate that form the seal around the magnetic ring. These materials provide both the sealing function and resistance to caustic fluids, while the magnetic ring itself remains protected from direct exposure to corrosive substances.
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 streamlined manufacturing process with reduced assembly errors, increased durability, and versatility in handling a broad range of fluids, while ensuring quiet operation and extended component longevity.
Implementation Method 1
a magnetic ring seated within the rotor cup, the magnetic ring comprising a first contact surface that is configured to mate with an inner surface of the rotor cup, and a second contact surface that is configured to mate with the rotor contacting surface of the impeller, the magnetic ring thereby being locked in position
Implementation Method 2
the rotor contacting surface of the impeller is attached to the rotor cup to hermetically seal the magnetic ring within the impeller assembly
Data Source
AI summary
There is provided a rotatable impeller assembly for pumping caustic fluid byproducts in a medical device. The assembly comprises a rotor having a rotor cup, and an impeller having a rotor contacting surface and impeller blades. The assembly further comprises a magnetic ring seated within the cup. The magnetic ring comprises a first contact surface that is configured to mate with an inner surface of the cup, and a second contact surface that is configured to mate with the rotor contacting surface of the impeller. In such an arrangement, the magnetic ring is locked in position by the rotor cup and the impeller, thereby preventing any independent rotation of the magnetic ring relative to the rotor and the impeller while automatically balancing the rotor. Further, the rotor contacting surface of the impeller is attached to the cup to hermetically seal the magnetic ring within the impeller assembly.