Woven Impeller Structure for Low-Cost Multifunction Integration
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Solution Overview
Problem
Existing compressor impellers are expensive to produce in volume and lack multifunctional component integration, with prior methods involving costly metal coatings and composite materials that are complex to manufacture.
Innovation Solution
A woven impeller fabricated using fibers or bundles of fibers, integrating conductive or magnetic components, and electric motor elements, with a simplified manufacturing process that eliminates the need for molds and post-weaving coatings, allowing for improved fluid flow and geometric flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional casting or molding methods are used to manufacture impellers, then production volume can be achieved, but manufacturing cost is high and component integration is limited
Solution Approach 1:
The invention changes the manufacturing parameter from traditional casting/molding to automated fiber placement weaving. This parameter change enables cost-effective production while maintaining the capability to produce impellers at scale through automation, directly resolving the contradiction between manufacturing cost and production volume.
Solution Approach 2:
The weaving process integrates multiple components (blades, hub, shroud, and functional elements like heating elements or sensors) into a single impeller structure. This multi-functional integration reduces the number of separate manufacturing steps and assemblies needed, lowering manufacturing cost while maintaining productivity through automated single-step production.
2Strength
If metal coatings or composite materials are applied after fiber placement, then structural strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention merges the structural fiber placement with the application of functional materials (conductive, magnetic, or coating materials) into a single integrated weaving process. This eliminates separate post-processing steps, reducing manufacturing complexity while maintaining structural strength through the combined material system.
Solution Approach 2:
The invention uses composite materials that are applied during the weaving process itself, combining structural and functional properties in a single integrated material system. This approach maintains structural strength while simplifying manufacturing by eliminating separate coating or composite application steps.
3Adaptability or versatility
If traditional impeller fabrication methods are used, then manufacturing process is established, but component integration and multifunctionality are limited
Solution Approach 1:
The automated fiber placement weaving process creates a universal manufacturing platform that can integrate multiple components (blades, hub, shroud, heating elements, sensors) into a single impeller structure. This multifunctional integration capability is achieved through a single automated process, maintaining manufacturing simplicity while dramatically improving adaptability and versatility.
Solution Approach 2:
The invention segments different functional requirements (structural support, heating, sensing, magnetic properties) into separate material layers or fiber types that are all integrated during the single weaving process. This segmentation allows for easy modification of individual functions without redesigning the entire manufacturing process, enhancing adaptability while keeping the process simple.
Data Source
AI summary
An impeller is provided that may be used in compressors or turbines. In another aspect of the present invention, a fiber or a bundle of fibers is woven to form at least two blades of an impeller. Yet another aspect of the present invention employs a peripheral component woven around impeller blades. An additional conductive fiber or bundle of fibers is woven into the impeller in a further aspect of the present invention. Moreover, an aspect of the present invention provides a chilling system that includes at least one compressor, at least one wave rotor, and a refrigerant.