Turbomolecular Pump Stator Disk Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing stator disks for turbomolecular pumps face challenges such as high tool costs, low rigidity with thin sheet metal, and limited geometrical flexibility due to the bending process, which affects the vacuum performance and assembly stability.
Innovation Solution
The stator disk is composed of partially ring-shaped sections formed from individual sheet metal part segments connected via injection molding, particularly using polymers like liquid crystal polymers, which reduces the complexity of forming tools and allows for more flexible geometries and improved rigidity without increasing thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional bending, punching, and cutting forming processes are used to manufacture stator disks, then economic advantages are achieved, but increasing the dimensions of stator disks introduces disadvantages such as expensive tooling, insufficient stiffness with thinner sheets, and complicated forming processes with thicker sheets
Solution Approach 1:
The stator disk is divided into multiple individual sheet metal segments that are arranged circumferentially to form a complete stator disk. Each segment can be manufactured separately using simple forming tools, and the segments are then connected using injection-molded connecting elements. This segmentation allows thin sheets to be used while maintaining overall structural stiffness through the distributed segment structure.
Solution Approach 2:
The stator disk combines sheet metal segments with injection-molded connecting elements to create a composite structure. The connecting elements, made from polymer materials, provide additional structural support and stiffness to the assembly, allowing the use of thinner sheet metal while maintaining the required mechanical properties.
2Ease of manufacture
If traditional bending processes are used to form blades, then manufacturing is simplified, but open gaps are created between blades which affects vacuum performance
Solution Approach 1:
By dividing the stator disk into separate segments with connecting elements, the structure allows for precise positioning of each blade segment. The connecting elements can be designed to minimize gaps between adjacent blades, improving vacuum performance while still allowing each segment to be formed using simple bending processes.
3Strength
If thicker sheets are used to increase stiffness, then structural integrity is improved, but conductivity deteriorates and the forming process is significantly complicated
Solution Approach 1:
The stator disk is divided into multiple individual sheet metal segments that are arranged circumferentially to form a complete stator disk. Each segment can be manufactured separately using simple forming tools, and the segments are then connected using injection-molded connecting elements. This segmentation allows thin sheets to be used while maintaining overall structural stiffness through the distributed segment structure.
4Stability of the object's composition
If the stator disk is manufactured as a single piece, then structural integrity is maintained, but geometrical flexibility is severely limited
Solution Approach 1:
The stator disk is divided into multiple individual sheet metal segments that are arranged circumferentially to form a complete stator disk. Each segment can be manufactured separately using simple forming tools, and the segments are then connected using injection-molded connecting elements. This segmentation allows thin sheets to be used while maintaining overall structural stiffness through the distributed segment structure.
Solution Approach 2:
The connecting elements serve multiple functions: they join the sheet metal segments together, provide additional structural support, allow for geometrical flexibility in blade positioning, and can accommodate different stator disk configurations. This multi-functionality enables geometrical flexibility while maintaining structural integrity.
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 approach simplifies the production process, enhances the rigidity and flexibility of stator disks, reduces axial gaps, and improves vacuum performance by minimizing backflow and rotor/stator clearance, making it economically feasible even for small quantities.
Implementation Method 1
the individual sheet metal segments of a respective partially annular stator disk section are connected to one another in the region of their inner and/or outer circumference via a common injection-molded part, in particular by a positive-locking connection
Data Source
Figure 1
Figure 2
AI summary
A stator disk (86) of a turbomolecular pump (10, 84) comprises at least two annular stator disk sections (92), preferably two stator disk halves, each with several circumferentially arranged sheet metal blades. The annular stator disk sections (92) are each formed from several individual sheet metal segments (94), and the individual sheet metal segments (94) of each annular stator disk section (92) are connected to one another in the region of their inner and/or outer circumference (96 or 98) via a common injection-molded part (100). A turbomolecular pump (10, 84) with at least one such stator disk (86) and a method for manufacturing such a stator disk (86) are also described.