SCREW ROTOR AND METHOD FOR MANUFACTURING SUCH SCREW ROTOR

Abstract

A screw rotor is made out of polymer. The screw rotor includes a shaft with a rotor body on it. The polymer of the shaft is reinforced with fibers. The shaft features elements that engage the rotor body or corresponding elements on the rotor body, such that the elements prevent an axial and/or rotational movement of the shaft with respect to the rotor body.

Claims

1.-25. (canceled)

26. A screw rotor comprising a shaft with a rotor body on the shaft wherein the screw rotor is made out of a polymer, wherein the polymer of the shaft is reinforced with fibers, and wherein the shaft features elements that engage the rotor body or corresponding elements in the rotor body, such that the elements prevent an axial and/or rotational movement of the shaft with respect to the rotor body.

27. The screw rotor according to claim 26, wherein the elements comprise at least one groove, ring, protrusion, or similar, wherein a projection on a surface perpendicular to the shaft in the axial direction is cyclically symmetrical and coaxial with the center line of the shaft.

28. The screw rotor according to claim 26, wherein the elements comprise at least one groove, ring, protrusion, or similar extending in the axial direction, whereby this element is situated at a location on the shaft upon which the rotor body is arranged.

29. The screw rotor according to claim 26, wherein the shape of the rotor body is cylindrical or conical.

30. The screw rotor according to claim 26, wherein the shaft is hollow.

31. The screw rotor according to claim 26, wherein the elements comprise at least one groove, protrusion, or similar, having the shape of a helix around the shaft.

32. The screw rotor according to claim 26, wherein the fibers in the shaft primarily extend in the axial direction.

33. The screw rotor according to claim 26, wherein the rotor body is at least partially made out of a polymer manufactured reinforced with fibers.

34. The screw rotor according to claim 33, wherein the fibers in the rotor body are arbitrarily or randomly oriented.

35. The screw rotor according to claim 26, wherein the polymer is a polyamide, a polyimide, or PEEK.

36. The screw rotor according to claim 26, wherein the polymer is a thermo-setting polymer, or more specifically, an epoxy, a vinyl ester or an unsaturated polyester.

37. The screw rotor according to claim 26, wherein the fibers comprise carbon fibers or glass fibers.

38. The screw rotor according to claim 26, wherein the fibers comprise an organic polymer.

39. The screw rotor according to claim 38, wherein the fibers made out of an organic polymer are aramid fibers.

40. The screw rotor according to claim 26, wherein the polymer is a self-reinforced polymer of aramid fibers in an aramid polymer matrix.

41. The screw rotor according to claim 26, wherein the shaft is made of a different polymer than the rotor body.

42. The screw rotor according to claim 41, wherein the polymer of the shaft has an identical or higher softening temperature than the polymer of the rotor body.

43. The screw rotor according to claim 26, wherein at the location of a face, the shaft features a coupling piece that features a screw thread in which an bolt can be arranged.

44. The screw rotor according to claim 26, wherein the rotor body consists of two or more concentric layers, wherein an inner layer features elements engaging the following layer, such that the elements prevent an axial and/or rotational movement of the one layer relative to the following layer.

45. A method for manufacturing a screw rotor comprising a shaft and a rotor body, wherein the screw rotor is made out of a polymer, said method comprising the following steps: A) providing a shaft; and B) injection molding the rotor body using a designated mold, wherein the shaft is used as an insert into the mould.

Description

[0030] With the understanding to better demonstrate the features of the invention, in the following, without these descriptions having any restrictive character, some examples of preferred variants are described of a method according to the invention for manufacturing a screw rotor, with reference to the enclosed drawings, in which:

[0031] FIG. 1 shows a schematic and perspective view of a possible embodiment of a screw rotor according to the invention;

[0032] FIG. 2 shows the shaft of the screw rotor of FIG. 1;

[0033] FIG. 3 schematically shows a cross section along the line III-III in FIG. 2;

[0034] FIG. 4 schematically shows a cross section along the line IV-IV in FIG. 1;

[0035] FIGS. 5 through 7 schematic show variant embodiments of FIG. 2.

[0036] The screw rotor 1 according to the invention schematically shown in FIG. 1 consists of a shaft 2 with a rotor body 3 on it.

[0037] The screw rotor 1 may be used in a fluid-injected compressor, expander, or vacuum pump.

[0038] In the example shown, the rotor body 3 is cylindrical in form. However, it is not excluded that the rotor body 3 have a conical form. Using a conical rotor has the advantage that the forces are better distributed, and that the compression can be increased.

[0039] In FIG. 2, the shaft 2 is shown separately.

[0040] According to the invention, the screw rotor 1 is made out of a polymer.

[0041] In this case, for the invention, at least the shaft 2 is made out of a polymer reinforced with fibers 4, and the rotor body 3 may be made out of a polymer without fibers 4, but in the example shown here and described below, the rotor body 3 is made out of a polymer reinforced with fibers 4 as well.

[0042] The polymer may be a polyamide, for instance, or a polyimide. However, the invention is not limited to these. For instance, the polymer may also be polyether ether ketone (PEEK).

[0043] Possibly, the polymer may also be a thermo-setting polymer, for instance an epoxy, a vinyl ester, or an unsaturated polyester.

[0044] The fibers 4 preferably, but not necessarily, comprise carbon fibers or glass fibers. The fibers may also comprise an organic polymer such as aramid fibers, for instance. Carbon nanotubes are a possibility as well.

[0045] In a possible embodiment, the polymer reinforced with fibers 4 is a so-called self-reinforced polymer, in which the fibers are made out of the same polymer as the mould.

[0046] Preferably, it is polymer polyamide, polyimide, or PEEK reinforced with between 10 and 60 percent of fibers 4 by weight. Preferably, the weight percentage of the fibers is between 25 and 45 percent.

[0047] It is not excluded that the shaft 2 is made from a different polymer than the rotor body 3, wherein the rotor body 3 may be made out of a polymer that may or may not be reinforced with fibers 4.

[0048] Thus, for instance, the polymer reinforced with fibers 4 of the shaft 2 may have an identical or a higher softening temperature than the polymer reinforced with fibers 4 of the rotor body 3.

[0049] The difference in the softening temperature of different layers preferably varies between zero and twenty degrees Celsius.

[0050] This will lead to benefits in particular in terms of the production or manufacturing of the screw rotor 1, as will be clarified below.

[0051] In this case, without this being necessary for the invention, the fibers 4 in the shaft 2 extend primarily in the axial direction X-X′.

[0052] This is shown schematically in the cross section in FIG. 3.

[0053] Due to this orientation of the fibers 4, the shaft 2 will have the necessary rigidity. It is well known that during the operation of the machine, the shaft 2 is exposed to strong axial forces and gas forces at the location where the screw rotor 1 is mounted.

[0054] As can be seen in FIG. 3, the shaft 2 is a full shaft 2. It is not excluded that the shaft 2 is hollow, meaning that there a longitudinal cavity extends through the shaft 2. This will prevent so-called flow problems in the production of the shaft 2.

[0055] In this case, but not necessarily, the fibers 4 in the rotor body 3 are oriented arbitrarily or randomly.

[0056] According to the invention, and as can be seen clearly in FIGS. 2, 3, and 4, the shaft 2 features elements 5a, 5b.

[0057] Some of these elements 5a may engage the rotor body 3, some of these elements 5b may engage corresponding elements 5c in the rotor body 3, all this being designed such that the elements 5a, 5b, 5c prevent an axial and/or a rotational movement of the shaft 2 relative to the rotor body 3.

[0058] This will be explained via the figures.

[0059] As can be seen in FIGS. 2 and 3, the shaft 2 features two elements 5a in the form of an ring shaped protrusion, wherein the projection onto the shaft 2 according to the axial direction X-X′ is cyclically symmetrical and coaxial with the center line X-X′ of the shaft 2.

[0060] Cyclically symmetrical means: sections or segments that repeat rotationally around the center line.

[0061] Even though these elements 5a pertain in this case to a ring shaped protrusion, these elements 5a may also comprise a differently shaped protrusion, groove, or ring.

[0062] These elements 5a may engage the rotor body 3 itself, as shown in FIG. 1.

[0063] Such elements 5a will be able to transmit axial forces from the shaft 2 to the rotor body 3, and vice versa.

[0064] Effectively, they constitute a stop for the rotor body 3 on the shaft 2 and vice versa, such that when an axial force is exerted onto the rotor body 3, it can be transmitted via this stop to the shaft 2.

[0065] It is not excluded that these elements 5a are arranged at a different location, farther away from the end 6 of the shaft 2. In that case, these elements 5a will not engage the rotor body 3 itself, but corresponding elements 5c of the rotor body 3.

[0066] Furthermore, the shaft 2 also features a number of elements 5b that may engage corresponding elements 5c of the rotor body 3.

[0067] In that case, these elements 5b pertain to protrusions along the axial direction X-X′ of the shaft 2, which cause the cross section of the shaft 2 to be hexagonal.

[0068] These elements 5b are located at a place on the shaft 2 above which the rotor body 3 is arranged, such as follows from the comparisons of FIGS. 1 and 2.

[0069] As can be seen in FIG. 4, the rotor body 3 features corresponding elements 5c, which engage the elements 5b of the shaft 2.

[0070] Via such elements 5b, 5c the torque may be transmitted from the shaft 2 to the rotor body 3. This will be relevant in particular for the driving of the screw rotor 1 by a motor via the shaft 2.

[0071] Instead of protrusions extending in the axial direction X-X′, a groove, ring, or similar may be used by way of elements 5b, 5c as well.

[0072] As can be seen in FIGS. 1 and 2, in this case, the shaft 2 is featured at its face 7 a coupling piece 8, which features a screw thread 9 in which a bolt can be arranged.

[0073] By means of this bolt, the shaft 2 may be connected to a drive shaft of a motor, for instance, or something similar.

[0074] Even though in the example shown, the screw rotor 1 consists of a shaft 2 with a rotor body 3, it is not excluded that the rotor body 3 itself consist of two or more concentric layers, wherein an inner layer features elements 5b, 5c engaging the following layer, such that the elements 5b, 5c prevent an axial and/or rotational movement of the one layer relative to the following layer.

[0075] In other words, the principle is very similar in nature to the principle of the shaft 2 and the rotor body 3 as explained above.

[0076] In the case of a large screw rotor 1, this will be advantageous in particular during the production process, as will be explained below.

[0077] The screw rotor of FIGS. 1 through 4 can be manufactured according to a method according to the invention.

[0078] The method for producing the screw rotor 1, made out of a polymer reinforced with fibers 4, by way of injection molding, essentially comprises two steps: [0079] A) providing a shaft; [0080] B) the injection molding of the rotor body 3 using a designated mould, wherein the aforementioned shaft 2 is used as an insert into the mould.

[0081] Preferably, but not necessarily, the aforementioned step A comprises the injection molding of the shaft 2 of the screw rotor 1, using a designated mould.

[0082] This is not necessary for the invention, however. The shaft 2 may also be extruded, for instance.

[0083] In step A, for the injection molding of the shaft 2, a mould will be used here with elements 5a, 5b, such that the aforementioned elements 5a, 5b are created on the shaft 2.

[0084] In order to ensure that the fibers 4 extend in the shaft 2 in the axial direction X-X′, the polymer reinforced with fibers 4 may be injected into the mould in the axial direction X-X′.

[0085] By then using the shaft 2 as an insert in the mould of the rotor body 3, corresponding elements 5c will effectively be created automatically in the rotor body 3.

[0086] By using a different polymer reinforced with fibers 4 for the shaft 2 than the polymer reinforced with fibers 4 used for the rotor body 3, such that the polymer reinforced with fibers 4 used for the shaft 2 has an identical or a higher softening temperature than the polymer used for the rotor body 3, the shaft 2 as a whole will not melt or soften when the rotor body 3 is cast around it. This way, the mechanical properties of the shaft 2 remain intact, and the fibers 4 of the shaft 2 may be prevented from losing their orientation if the polymer of the shaft 2 were to soften somewhat.

[0087] It is not excluded for step B, the injection molding of the rotor body 3, to be executed in two or more steps, in each of which more material is added to the rotor body 3 through the use of successive matrices, wherein the rotor body part manufactured in the previous step is used as an insert in the following mould.

[0088] Thus, the rotor body 3 itself can be made out of two or more concentric layers, wherein the use of matrices with elements 5c may cause elements 5c to be provided on an inner layer to engage the following layer cast around it.

[0089] This approach is particularly advantageous with large screw rotors 1, because this may provide for the material added to be more limited with each step, so that the cooling can be monitored, such that no or much fewer mechanical tensions are created.

[0090] If the rotor body 3 has a conical form, this has the advantage that it can be demolded, i.e. removed from the mold, much more easily.

[0091] In order to insert the aforementioned coupling piece 8 into the face 7 of the shaft 2, the coupling piece 8 is arranged in the mould of the shaft 2 at the location of the respective face 7 of the shaft 2.

[0092] Thus, the coupling piece 8 can be integrated into the shaft 2 during the casting process.

[0093] Alternatively, after step B, the aforementioned coupling piece 8 may be arranged through self-tapping in a designated cavity in a face 7 of the shaft 2.

[0094] It should be clear that in the examples shown and described in FIGS. 1 through 5, only some possible examples of possible embodiments of elements 5a, 5b are shown.

[0095] Another possible embodiment is shown in FIG. 5, in which the elements 5a, 5b comprise at least one protrusion 5b, having the form of a helix or a spiral around the shaft 2.

[0096] Instead of a protrusion, this may also be a helix- or spiral-shaped groove.

[0097] The protrusion, or element 5b, is situated at a location of the shaft 2 above which the rotor body 3 is arranged, so that during the injection molding process, corresponding elements are formed in the rotor body 3.

[0098] The helix-shaped elements 5b will be able to transmit a combination of rotational as well as axial forces in order to prevent an axial and rotational movement of the shaft 2 relative to the rotor body 3.

[0099] FIG. 6 shows an additional embodiment, wherein the shaft 2 features an element 5b that may engage a corresponding element 5c of the rotor body 3.

[0100] In this case, this element 5b is a ring shaped protrusion around the shaft 2.

[0101] This element 5b is situated at a location on the shaft 2 above which the rotor body 3 is arranged. This element 5b will be able to transmit axial forces from the shaft 2 to the rotor body 3, and vice versa.

[0102] FIG. 7 shows yet another variation, wherein the shaft 2 features multiple elements 5b in the form of elongated protrusions that extend in the axial direction along the shaft 2 and are dispersed around the shaft 2.

[0103] Based on the aforementioned variants, it is clear that the elements 5a, 5b may be embodied in various manners, and that the examples shown are not restrictive in any way.

[0104] The present invention is in no way limited to the exemplary embodiments described and shown in the figures. Rather, a method and a screw rotor according to the invention may be realized in different variants without exceeding the scope of the invention.