Simplified roots-type blower

Abstract

The present disclosure relates to a simplified roots-type blower having an improved sound signature. The roots-type blower includes a rotor bore housing having a molded, one-piece polymeric construction. The rotor bore housing defines a first rotor bore and a second rotor bore. The rotor bore housing also defines a first bearing pocket corresponding to the first rotor bore and a bearing pocket corresponding to the second rotor bore axis. The rotor bore housing further defining a timing gear chamber.

1 . A roots-type blower comprising:
 rotor bore housing having a molded, one-piece polymeric construction, the rotor bore housing defining a first rotor bore and a second rotor bore, the rotor bore housing also defining a first bearing pocket corresponding to the first rotor bore and a bearing pocket corresponding to the second rotor bore axis, the rotor bore housing further defining a gear chamber;   a first bearing mounted within the first bearing pocket and a second bearing mounted within the second bearing pocket;   a first roots-type rotor having a first rotor shaft aligned along a first rotor axis and a second roots-type rotor having a second rotor shaft aligned along a second rotor bore axis, the first and second roots-type rotors being respectively positioned within the first and second rotor bores, the first and second roots-type rotors being rotatable relative to the rotor bore housing about their respective first and second rotor axes, the first and second rotor bore axes being relatively positioned such that the first and second roots-type rotors intermesh with one another when the first and second roots-type rotors are rotated about their respective first and second rotor axes, the first rotor shaft being supported by the first bearing and the second rotor shaft being supported by the second bearing; and   first and second gears positioned within the gear chamber, the first gear being coupled to the first rotor shaft and the second gear being coupled to the second rotor shaft, the first and second gears intermeshing with one another and being configured for transferring torque between the first and second rotor shafts.   
     
     
         2 . The roots-type blower of  claim 1 , wherein the first and second rotor bores each have a draft angle less than 2 degrees. 
     
     
         3 . The roots-type blower of  claim 1 , wherein the first and second rotor bores each have a draft angle equal to zero. 
     
     
         4 . The roots-type blower of  claim 1 , wherein the molded polymeric construction includes a polymeric base material and reinforcing fibers embedded within the base material. 
     
     
         5 . The roots-type blower of  claim 4 , wherein the rotor bore housing includes first and second cylindrical pocket-defining walls that respectively define the first and second bearing pockets, and wherein the reinforcing fibers are aligned in a circumferential orientation within each of the first and second cylindrical pocket defining walls. 
     
     
         6 . The roots-type blower of  claim 5 , wherein the rotor bore housing includes first and second rotor bore-defining walls that respectively define the first and second rotor bores, and wherein the reinforcing fibers within the first and second rotor bore-defining walls are oriented parallel with respect to the first and second rotor bore axes. 
     
     
         7 . The roots-type blower of  claim 1 , wherein the first and second rotor bores have a combined volume less than 250 cubic centimeters. 
     
     
         8 . The roots-type blower of  claim 1 , wherein the rotor bore housing defines an outlet in fluid communication with the first and second rotor bores, and wherein the outlet and the first and second bearings are relatively positioned such that a reference plane perpendicular to the first and second rotor bore axes intersects the outlet and the first and second bearings. 
     
     
         9 . The roots-type blower of  claim 1 , wherein the first and second bearings are insert-molded into their respective first and second bearing pockets. 
     
     
         10 . The roots-type blower of  claim 9 , further comprising a first bearing shield surrounding the first bearing and a second bearing shield surrounding the second bearing, the first and second bearing shields being configured to prevent plastic from contaminating the first and second bearings when the first and second bearings molded within the rotor bore housing. 
     
     
         11 . The roots-type blower of  claim 1 , wherein the first and second rotors have cutting edges that cut the rotor bore housing during an initial run-in period to shape the first and second rotor bores. 
     
     
         12 . The roots-type blower of  claims 1 , wherein the rotor bore housing has first and second opposite ends spaced-apart from one another along the first and second rotor bore axes, wherein the gear chamber is positioned adjacent the first end, wherein the first bearing is positioned between the first rotor bore and the first gear, wherein the second bearing is positioned between the second rotor bore and the second gear, wherein the rotor bore housing defines an outlet between the first sand second ends, wherein the roots-type blower also includes an inlet housing that mounts to the second end of the rotor bore housing, the inlet housing defining an inlet in fluid communication with the first and second rotor bores. 
     
     
         13 . The roots-type blower of  claim 12 , wherein the inlet housing defines a third bearing pocket co-axially aligned with the first rotor axis, wherein the inlet housing defines a bearing mounting stub co-axially aligned with the second rotor axis, wherein the roots-type blower includes third and fourth bearings, wherein the third bearing supports the first rotor shaft and is mounted within the third bearing pocket, wherein the fourth bearing supports the second rotor shaft and is mounted on the bearing mounting stub, and wherein the roots-type blower further includes a pulley mounted on the fourth bearing and coupled to the second rotor shaft by a splined connection. 
     
     
         14 . The roots-type blower of  claim 12 , wherein the inlet housing is metal. 
     
     
         15 . The roots-type blower of  claim 14 , wherein the rotor bore housing and the inlet housing interconnect at an alignment interface, and wherein the alignment interface is configured such that the inlet housing enhances concentricity of the first and second rotor bore about their respective first and second rotor axes. 
     
     
         16 . The roots-type blower of  claim 15 , wherein the alignment interface includes a axial projection at the second end of the rotor bore housing that is received within an alignment receptacle defined by the inlet housing. 
     
     
         17 . The roots-type blower of  claim 16 , wherein the axial projection and the alignment receptacle include first curved portions that extend about the first rotor axis and second curved portions that extend about the second rotor axis. 
     
     
         18 . The roots-type blower of  claim 17 , further comprising a plurality of axial ribs provided on an exterior of the axial projection. 
     
     
         19 . A method for making a roots-type blower having rotors mounted within rotor bores defined by a polymeric rotor housing, the rotors being rotatable about rotor axes, the method comprising:
 injection molding the polymeric rotor housing;   mounting the rotors within the rotor bores; and   defining a final interior shape of the rotor bores by cutting away portions the polymeric rotor housing with the rotors as the rotors are rotated about their respective axes.   
     
     
         20 . A roots-type blower comprising:
 rotor bore housing having a fiber reinforced polymeric construction, the rotor bore housing defining a first rotor bore and a second rotor bore, the rotor bore housing also defining a first bearing pocket corresponding to the first rotor bore and a second bearing pocket corresponding to the second rotor bore, the rotor bore housing further defining a gear chamber and a blower outlet, the blower outlet being in fluid communication with the first and second rotor bores;   a first bearing mounted within the first bearing pocket and a second bearing mounted within the second bearing pocket;   a first roots-type rotor having a first rotor shaft aligned along a first rotor axis and a second roots-type rotor having a second rotor shaft aligned along a second rotor bore axis, the first and second roots-type rotors being respectively positioned within the first and second rotor bores, the first and second roots-type rotors being rotatable relative to the rotor bore housing about their respective first and second rotor axes, the first and second rotor bore axes being relatively positioned such that the first and second roots-type rotors intermesh with one another when the first and second roots-type rotors are rotated about their respective first and second rotor axes, the first rotor shaft being supported by the first bearing and the second rotor shaft being supported by the second bearing; and   first and second gears positioned within the gear chamber, the first gear being coupled to the first rotor shaft and the second gear being coupled to the second rotor shaft, the first and second gears intermeshing with one another and being configured for transferring torque between the first and second rotor shafts.   
     
     
         21 . The roots-type blower of  claim 20 , further comprising an inlet housing that attaches to the rotor bore housing, the inlet housing having a metal construction, wherein the inlet housing defines an inlet of the roots-type blower that is in fluid communication with the first and second rotor bores. 
     
     
         22 . The roots-type blower of  claim 21 , further comprising a pulley coupled to the second rotor shaft and rotatably mounted on the inlet housing, and wherein the inlet housing is connected to a first end of the rotor bore housing and the gear chamber is positioned at an opposite second end of the rotor bore housing. 
     
     
         23 . The roots-type blower of  claim 22 , wherein the inlet is positioned at a top side of the roots-type blower and the outlet is positioned at a bottom side of the roots-type blower, and wherein at least a portion of the outlet is positioned directly beneath the first and second bearing pockets.