Rotary element and compressor device comprised thereof

Abstract

This disclosure describes new construction for rotary elements that find use in compressor devices, e.g., centrifugal compressors and blowers. This construction utilizes composite materials (e.g., carbon fiber composites) that require less machine time and reduce the weight of the rotary element, while meeting the operational characteristics of compressor devices for use in a wide range of industrial applications. In one embodiment, the rotary element has a bi-furcated material design, which uses a first material (e.g., carbon fiber) to form blades and other features of an impeller and a second material (e.g., metal) to form a sleeve with properties that can securely affix the impeller to a drive shaft of the compressor device.

What is claimed is: 
     
         1 . An impeller, comprising
 a body element comprising a first material and having a blade disposed thereon, the first material comprising a woven component with a first fiber and a second fiber forming a first fiber layer and a second fiber layer and a third fiber coupling the first fiber layer and the second fiber layer; and   a sleeve element disposed in the body element, the sleeve element comprising a second material that is different from the first material.   
     
     
         2 . The impeller of  claim 1 , wherein the first fiber, the second fiber, and the third fiber are disposed in, respectively, a first direction, a second direction, and a third direction in the woven component, and wherein the first direction is different from the second direction and the third direction. 
     
     
         3 . The impeller of  claim 2 , wherein the first direction, the second direction, and the third direction are mutually orthogonal to one another. 
     
     
         4 . The impeller of  claim 1 , wherein the first fiber, the second fiber, and the third fiber comprise carbon fibers. 
     
     
         5 . The impeller of  claim 1 , wherein the first fiber, the second fiber, and the third fiber are disposed in a resin. 
     
     
         6 . The impeller of  claim 1 , wherein the first material is homogenous throughout the body element. 
     
     
         7 . The impeller of  claim 1 , wherein the second material comprises a metal. 
     
     
         8 . The impeller of  claim 1 , further comprising a first material layer disposed on a surface of the body element and a surface of the sleeve element. 
     
     
         9 . The impeller of  claim 1 , further comprising a second material layer disposed on a surface of the body element. 
     
     
         10 . The impeller of  claim 9 , wherein the second material layer comprises chrome nickel metal. 
     
     
         11 . An impeller, comprising:
 a body element having a rotary axis and a plurality of blades disposed circumferentially about the rotary axis, the body element comprising a composite having a resin and a plurality of fibers disposed in the resin, the plurality of fibers comprising a first set of fibers in a first direction, a second set of fibers in a second direction, and a third set of fibers in a third direction, and wherein the first direction, the second direction, and the third direction are mutually orthogonal to one another.   
     
     
         12 . The impeller of  claim 11 , wherein fibers in the first set of fibers and fibers in the second set of fibers interweave with one another to form a first fiber layer and a second fiber layer. 
     
     
         13 . The impeller of  claim 12 , wherein fibers in the third set of fibers interweave with the fibers in the first layer and the second layer. 
     
     
         14 . The impeller of  claim 11 , wherein the plurality of blades are formed integrally with the body element. 
     
     
         15 . The impeller of  claim 14 , wherein the composite is homogenous throughout the body element and the plurality of blades. 
     
     
         16 . The impeller of  claim 11 , further comprising a coating disposed on one or more of the body element and the plurality of blades, wherein the coating is different from the composite. 
     
     
         17 . A compressor device, comprising:
 a rotary element having a body element and a sleeve element disposed in the body element, the body element comprising a first material and the sleeve element comprising a second material that is different from the first material, wherein the first material comprises a carbon fiber composite with a first set of fibers and a second set of fibers disposed orthogonally to the first set of fibers to form a first fiber layer and a second fiber layer adjacent the first fiber layer and a third set of fibers disposed orthogonally to the first set of fibers and the second set of fibers.   
     
     
         18 . The compressor device of  claim 17 , wherein the third set of fibers couple the first fiber layer and the second fiber layer 
     
     
         19 . The compressor device of  claim 17 , further comprising a drive unit with a drive shaft, wherein the sleeve element comprises a bore with a section that has a locking profile that matches a profile on the drive shaft 
     
     
         20 . The compressor device of  claim 17 , wherein the carbon fiber composite is homogenous throughout the body element.