Woven turbomachine impeller

• US 7,938,627 B2
• Filed: 11/11/2005
• Issued: 05/10/2011
• Est. Priority Date: 11/12/2004
• Status: Active Grant

• Current Assignee: The Board of Trustees of Michigan State University (Michigan State University)
• Original Assignee: The Board of Trustees of Michigan State University (Michigan State University)
• Inventors: Müller, Norbert
• Primary Examiner(s): Nguyen; Ninh H
• Application Number:
  US11/667,373
• Publication Number:
  US 20070297905A1
• Time in Patent Office: 2,006 Days
• Field of Search: 416/230, 416/229.A, 416/234, 416/241.A, 416/241.R, 416/189, 416/175, 416/198.R, 416/198.A, 298/892, 625/06, 621/14
• US Class Current: 416/230
• CPC Class Codes: F01D 5/34 Rotor-blade aggregates of unitary construction , e.g. formed of sheet laminae; discs formed of sheet laminae F01D5/028; ceramic materials F01D5/284, composite materials F01D5/282
• CPC Class Codes: F04D 29/023 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/321 for axial flow compressors
• CPC Class Codes: F05D 2300/44 Resins
• CPC Class Codes: F05D 2300/603 Composites; e.g. fibre-reinforced
• CPC Class Codes: F05D 2300/614 Fibres or filaments
• CPC Class Codes: F05D 2300/702 Reinforcement
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 29/4932 Turbomachine making
• CPC Class Codes: Y10T 29/49321 Assembling individual fluid flow interacting members, e.g., blades, vanes, buckets, on rotary support member
• CPC Class Codes: Y10T 29/49332 Propeller making

Abstract

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.

Claims

1. An impeller comprising:

at least one continuous fiber woven to create at least two blades;

a peripheral shroud around the blades also being created by the at least one continuous fiber;

segments of the at least one continuous fiber at the blades being elongated substantially transverse to a rotational axis of the blades; and

at least one electromagnetic fiber attached to the peripheral shroud.

2. The impeller according to claim 1 wherein the at least one electromagnetic fiber is elongated substantially perpendicular to the elongated fiber direction of the peripheral shroud.

3. The impeller according to claim 1 wherein the at least one electromagnetic fiber is elongated substantially parallel to the elongated fiber direction of the peripheral shroud.

4. The impeller according to claim 1 wherein the at least one electromagnetic fiber comprises a material from the group consisting essentially of magnetic fiber, metallic fiber, charged fiber, and quartz.

5. The impeller according to claim 1 wherein the at least one continuous fiber radially extends from one peripheral point of the impeller to a substantially opposite peripheral point of the impeller and defines the at least two blades between the peripheral points.

6. The impeller according to claim 1 wherein elongated fiber segment directions of the at least one continuous fiber defines a star-pattern with the blades.

7. The impeller according to claim 1 wherein elongated fiber segment directions of the at least one continuous fiber defines a sliced pie-pattern with the blades.

8. The impeller according to claim 1 further comprising a resin wetted onto the fiber and the fiber being woven before full curing of the resin, the resin and fiber essentially defining the final structure of the impeller, free of additional metallic or polymeric coatings or layers after weaving.

9. An impeller comprising:

at least one continuous fiber woven to create at least two blades;

a peripheral shroud around the blades also being created by the at least one continuous fiber;

segments of the at least one continuous fiber at the blades being elongated substantially transverse to a rotational axis of the blades; and

at least one conductive member woven into the peripheral shroud.

10. The impeller according to claim 9 wherein the at least one conductive member is elongated substantially perpendicular to the elongated fiber direction of the peripheral shroud.

11. The impeller according to claim 9 wherein the at least one continuous fiber radially extends from one peripheral point of the impeller to a substantially opposite peripheral point of the impeller and defines the at least two blades between the peripheral points.

12. The impeller according to claim 9 wherein elongated fiber segment directions of the at least one continuous fiber define a star-pattern with the blades.

13. The impeller according to claim 9 wherein elongated fiber segment directions of the at least one continuous fiber define a sliced pie-pattern with the blades.

14. The impeller according to claim 9 further comprising a resin wetted onto the fiber and the fiber being woven before full curing of the resin, the resin and fiber essentially defining the final structure of the impeller, free of additional metallic or polymeric coatings or layers after weaving.

15. A rotatable apparatus comprising:

at least one continuous and elongated filament including multiple stacked segments defining multiple fluid-working blades; and

a resin placed on the at least one filament to affix the segments together and to assist in filling in gaps between the segments;

the at least one filament and resin essentially defining the final structure of the apparatus free of additional metallic or polymeric coatings or layers; and

the filament segments defining a star-pattern with the blades such that each of the blades intersects another of the blades.

16. The apparatus according to claim 15 further comprising at least one magnetic member attached to the filament.

17. The apparatus according to claim 15 further comprising at least one conductive member attached to the filament.

18. The apparatus according to claim 15 wherein the filament crosses itself as it continuously extends along the intersecting blades.

19. The apparatus according to claim 15 wherein the blades are part of an impeller in a condensing wave rotor system.

20. The apparatus according to claim 15 further comprising a shaft attaching to a hub area and a shroud surrounding the blades, the filament continuously attaching the shroud to the blades.

21. An impeller comprising:

an elongated fiber defining at least segments of multiple blades, the blades being flexible even when manufacturing of the blades is completed; and

at least one of;

(a) a conductive member and (b) a magnetic member, being attached to the fiber adjacent outer portions of the impeller.

22. The impeller according to claim 21 further comprising a shroud attached to and rotatable with the blades, wherein the member is only attached to the shroud.

23. The impeller according to claim 22 wherein the shroud includes the fiber and the shroud is also flexible even when manufacturing of the shroud is completed.

24. The impeller according to claim 21 wherein the member includes a magnetic fiber attached to and being elongated substantially perpendicular to the elongated fiber direction adjacent thereto.

25. The impeller according to claim 21 wherein the member includes a conductive member woven into the elongated fiber.

26. The impeller according to claim 21 wherein the continuous fiber radially extends from one peripheral point of the impeller to a substantially opposite peripheral point of the impeller and defines the blades between the peripheral points.

27. The impeller according to claim 21 further comprising:

a resin wetted onto the fiber and the fiber is woven before full curing of the resin;

the resin, member and fiber essentially defining the final structure of the impeller, free of additional metallic or polymeric coatings or layers after weaving.

28. The impeller according to claim 21 wherein the blades rotate in a condensing wave rotor system.

29. An impeller apparatus comprising at least one continuous and elongated filament including multiple stacked segments defining blades, the filament crossing itself in its final manufactured state, and at least one member being attached to and rotatable with the impeller, the member being at least one of:

(a) magnetic, and (b) electrically conductive.

30. The impeller apparatus according to claim 29 wherein the member is an elongated magnetic fiber.

31. The impeller apparatus according to claim 29 wherein the member is an elongated electrically conductive fiber.

32. The impeller apparatus according to claim 29 wherein the member comprises particles substantially suspended in a resin matrix.

33. The impeller apparatus according to claim 29 further comprising a substantially stationary stator disposed adjacent the impeller.

34. The impeller apparatus according to claim 29 wherein the filament segments define a star-pattern with the blades.

35. The impeller apparatus according to claim 29 wherein the filament segments define a sliced pie-pattern with the blades.

36. The impeller apparatus according to claim 29 wherein the blades are part of a condensing wave rotor system.

37. A chilling system comprising at least one compressor, at least one condensing wave rotor, and a primarily water-based refrigerant.

38. The system according to claim 37 further comprising a housing containing the compressor and an evaporator, the outer dimension of the housing and wave rotor combination being less than about two meters by five meters.

39. The system according to claim 37 wherein the at least one wave rotor has three ports.

40. The system according to claim 37 wherein the at least one compressor further comprises an impeller woven from at least one elongated and continuous fiber.

41. The system according to claim 40 wherein the impeller further comprises a hub with a curved end and a substantially frusto-conical side surface.

42. The system according to claim 37 further comprising an electromagnetic stator substantially surrounding an impeller of the compressor, the impeller including at least one of:

(a) a conductive member, and (b) a magnetic member.

43. A compressor system comprising:

a first impeller created from a fiber;

a second impeller created from a fiber, the impellers being coaxially aligned; and

a water refrigerant flowing through the impellers.

44. The compressor system according to claim 43 wherein the first impeller further comprises at least two blades and a shroud all of which are defined, at least in part, by the same fiber.

45. The compressor system according to claim 43 further comprising a magnetic member attached to the fiber in the second impeller.

46. The compressor system according to claim 43 further comprising an electromagnetic member attached to the first impeller, the member comprising a material from the group consisting essentially of magnetic fiber, metallic fiber, charged fiber, and quartz.

47. The compressor system according to claim 43 further comprising a second and conductive fiber attached to the main fiber in the first impeller.

48. The compressor system according to claim 47 wherein the conductive fiber is woven substantially perpendicular to the main fiber adjacent thereto.

49. The compressor system according to claim 47 wherein the conductive fiber is attached substantially parallel to the main fiber adjacent thereto.

50. The compressor system according to claim 43 further comprising a conductive fiber attached to the first impeller, the fiber comprising a material from the group consisting essentially of magnetic fiber, metallic fiber, charged fiber, and quartz.

51. The compressor system according to claim 43 wherein the fiber in each of the impellers comprises a material from the group consisting essentially of nylon, carbon fiber, Kevlar, resin wetted carbon fiber, metallic fiber, and polymer based fibers.

52. The compressor system according to claim 43 further comprising at least one wave rotor and the water refrigerant flowing through the wave rotor.

53. The compressor system of claim 43 further comprising a condenser, an evaporator, a wave rotor, and a tank-like housing, the condenser, evaporator, wave rotor and impellers all being located inside the housing.

54. The compressor system of claim 43 wherein each of the impellers includes a hub having at least one protruding curved end.

55. The compressor system of claim 43 wherein each of the impellers includes a shroud and blades made from the associated fiber in a continuous manner, and a resin coating the fiber.

56. The compressor system of claim 43 wherein the impellers rotate in opposite directions.

57. The compressor system of claim 43 further comprising a condenser, an evaporator and a tank-like housing, the condenser, evaporator and impellers all being located inside the housing.

58. A compressor system comprising an impeller created from a fiber, the impeller further comprising at least two blades and a shroud all of which are defined, at least in part, by the same fiber, and a magnetic member woven into the shroud.

59. The compressor system of claim 58 further comprising a water-based refrigerant acting upon the impeller.

60. The compressor system of claim 58 wherein the fiber creating the at least two blades is located in an intersecting and crossing manner.

61. A compressor system comprising an impeller created from a fiber, and a magnetic member attached to the fiber, wherein the magnetic member is woven substantially perpendicular to the fiber adjacent thereto.

62. The compressor system of claim 61 further comprising a water-based refrigerant acting upon the impeller.

63. A method of manufacturing an impeller, the method comprising:

layering at least one fiber to create at least two vanes and a peripheral component, with a majority of the fiber layers in the vanes inwardly extending in a substantially radial direction; and

wetting the at least one fiber with a resin,

wherein the resin comprises a material that is electrically conductive.

64. The method according to claim 63 wherein the resin comprises a magnetic material.

65. The method according to claim 63 further comprising layering at least one electrically conductive member in the peripheral component.

66. The method according to claim 63 further comprising layering at least one magnetic member in the peripheral component.

67. The method according to claim 63 further comprising automatically weaving the fiber through a tube.

68. A method of manufacturing an impeller, the method comprising:

weaving at least one fiber to construct at least two blades and a shroud; and

placing at least one member into the shroud, the member being at least one of;

(a) electrically conductive, and (b) magnetic.

69. The method according to claim 68 further comprising weaving a conductive member into the shroud.

70. The method according to claim 68 further comprising wetting the fiber with a resin before the weaving.

71. The method according to claim 70 further comprising hardening the resin after the weaving.

72. The method according to claim 68 further comprising filling gaps between layers of the fiber with a resin, wherein the resin includes the member.

73. The method according to claim 68 further comprising attaching a drive shaft to the impeller.

74. The method according to claim 73 further comprising weaving the drive shaft into a centerpoint of the impeller.

75. A method according to claim 73 further comprising constructing the at least two blades by crossing the fiber at a centerpoint of the impeller.

76. The method according to claim 73 further comprising constructing the at least two blades by creating an opening in a center area of the impeller.

77. A method of making a machine, the method comprising:

(a) layering segments of at least one filament in a stacked manner to create fluid-working blades; and

(b) mounting a wave rotor in fluid communication with the blades.

78. The method according to claim 77 further comprising weaving the filament segments defining the blades in a star-pattern.

79. The method according to claim 77 further comprising weaving the filament segments defining the blades in a sliced pie-pattern.

80. The method according to claim 77 further comprising making the filament as a rotatable member inside of an electric motor.

81. The method according to claim 77 further comprising assembling a water-based refrigerant, condensing wave rotor.

82. The method according to claim 77 further comprising making an impeller from the filament without additional coating or molding after weaving the filament.

83. A system comprising a first impeller and at least a second impeller rotating about a common axis, each of the impellers comprising multiple blades including at least one continuous fiber having a stacked arrangement on the blades, and a shroud attached to and surrounding a periphery of the blades of one of the impellers, the shroud rotating with the attached impeller.

84. The system of claim 83, wherein the common axis is substantially vertically elongated.

85. The system of claim 83, wherein the impellers act as refrigerant compressors.

86. A system comprising a first impeller and at least a second impeller rotating about a common axis, each of the impellers comprising multiple blades including at least one continuous fiber having a stacked arrangement on the blades, and the continuous fiber extending from at least a pair of the blades to a segment of a shroud so the shroud and blades are integral and a single piece.

87. A system comprising a first impeller and at least a second impeller rotating about a common axis, each of the impellers comprising multiple blades including at least one continuous fiber having a stacked arrangement on the blades, and the second impeller rotating in an opposite direction than the first impeller.

88. The system of claim 87, further comprising a shroud attached to and surrounding a periphery of the blades of one of the impellers, the shroud rotating with the attached impeller.

89. The system of claim 87, wherein the common axis is substantially vertically elongated.

90. The system of claim 87, wherein the impellers act as refrigerant compressors.

91. The system of claim 87, wherein the fiber crosses itself as it continuously extends along the intersecting blades in each of the impellers.

92. A system comprising:

a first impeller and at least a second impeller rotating about a common axis;

each of the impellers comprising multiple blades including at least one continuous fiber having a stacked arrangement on the blades;

the first impeller rotating at a different speed than the second impeller;

at least a second elongated fiber also defining part of the blades of the first impeller, and stacked layers of the fibers of the first impeller being adhered together; and

each of the fibers of the first impeller having a length of at least five cm.