阅读说明：本技术 旋转叶片泵 (Rotary vane pump ) 是由 苏克鲁·埃里斯根 克里斯·夸克 于 2020-10-26 设计创作，主要内容包括：一种旋转叶片泵,包括壳体和马达。所述马达包括耦接至转子的轴。所述转子限定多个狭槽。多个自由移动的叶片设置在所述狭槽内。在一个示例中,所述转子由第一材料形成,并且所述多个叶片由所述第一材料形成并用第二材料浸渍。所述第一材料可以是碳材料。所述第二材料可以是树脂材料、锑材料、铜材料或银材料。(A rotary vane pump includes a housing and a motor. The motor includes a shaft coupled to a rotor. The rotor defines a plurality of slots. A plurality of freely moving vanes are disposed within the slot. In one example, the rotor is formed from a first material and the plurality of blades are formed from the first material and impregnated with a second material. The first material may be a carbon material. The second material may be a resin material, an antimony material, a copper material, or a silver material.)

1. A rotary vane pump comprising:

a) a motor having a motor shaft;

b) a pump body mounted to the motor;

c) a rotor coupled to the motor shaft and disposed within the pump body; and

d) a plurality of vanes slidably received into slots defined within the rotor;

e) wherein the rotor is formed from a first material and the plurality of blades are formed from the first material and impregnated with a second material.

2. The rotary vane pump of claim 1 wherein the first material is a carbon material.

3. A rotary vane pump as set forth in claim 2 or any other preceding claim wherein said first material is a graphite material.

4. A rotary vane pump as set forth in claim 1 or any other preceding claim wherein said second material is a resin material.

5. A rotary vane pump as set forth in claim 1 or any other preceding claim wherein said second material is a metallic material.

6. The rotary vane pump of claim 5 or any other preceding claim wherein the second material is one of antimony, copper and silver.

7. A rotary vane pump as set forth in claim 1 or any other preceding claim wherein said first material is graphite and said second material is resin.

8. A rotary vane pump as set forth in claim 1 or any other preceding claim wherein the weight percent of the first material is 95% and the weight percent of the second material is 5%.

9. A rotary vane pump as set forth in claim 1 or any other preceding claim wherein said pump body is made of stainless steel.

10. A rotary vane pump as set forth in claim 1 or any other preceding claim, further comprising a filter for filtering air received by the pump.

11. The rotary vane pump of claim 1 or any other preceding claim wherein the first material has an initial pre-impregnation porosity of at least 5 volume percent and is impregnated with the second material to have a post-impregnation porosity of less than 5 volume percent.

12. The rotary vane pump of claim 11 or any other preceding claim, wherein the pre-impregnation porosity is between about 5 volume percent and about 10 volume percent, and the post-impregnation porosity is up to about 5 volume percent.

13. The rotary vane pump of claim 12 or any other preceding claim, wherein the pre-impregnation porosity is about 10 volume percent and the post-impregnation porosity is about 1 volume percent.

14. A rotary vane pump comprising:

a) a rotor defining a plurality of slots; and

b) a plurality of vanes slidably received into the slot;

c) wherein the plurality of blades are formed from a first material and the first material has been impregnated with a second material, and the rotor is formed from the first material and is free of the second material.

15. A rotary vane pump as set forth in claim 14 or any other preceding claim wherein the first material is a carbon material.

16. A rotary vane pump as set forth in claim 15 or any other preceding claim wherein said first material is a graphite material.

17. A rotary vane pump as set forth in claim 14 or any other preceding claim wherein said second material is a resin material.

18. A rotary vane pump as set forth in claim 14 or any other preceding claim wherein said second material is a metallic material.

19. A rotary vane pump as set forth in claim 14 or any other preceding claim wherein said second material is one of antimony, copper, and silver.

20. A rotary vane pump as set forth in claim 14 or any other preceding claim wherein said first material is graphite and said second material is resin.

21. A rotary vane pump as set forth in claim 14 or any other preceding claim wherein the weight percent of the first material is 95% and the weight percent of the second material is 5%.

22. A rotary vane pump as set forth in claim 14 or any other preceding claim wherein said first material has an initial pre-impregnation porosity of at least 5% by volume and is impregnated with said second material to have a post-impregnation porosity of less than 5% by volume.

23. The rotary vane pump of claim 22 or any other preceding claim, wherein the pre-impregnation porosity is between about 5 volume percent and about 10 volume percent, and the post-impregnation porosity is up to about 5 volume percent.

24. The rotary vane pump of claim 23 or any other preceding claim, wherein the pre-impregnation porosity is about 10 volume percent and the post-impregnation porosity is about 1 volume percent.

Technical Field

The present disclosure relates generally to rotary vane air pumps, such as those used in conjunction with portable heaters.

Background

Self-lubricated rotary vane air pumps are commonly used in many industries throughout the world. Most self-lubricated rotary vane air pumps use a graphite rotor having a slot and a plurality of vanes slidably received in the slot. Such pumps typically have a housing and at least two plates to contain the rotor and vanes inside. In one particular application, a sliding rotary vane air pump is used for kerosene/diesel air heaters (i.e., KFA heaters). In such applications, a rotary vane air pump is used to pump fuel out of the KFA heater fuel tank. In a typical arrangement, the fuel tank is attached to the bottom of a kerosene/diesel heater and the burner is located above the fuel tank. The air pump outlet pressure can be adjusted for various heights and heat capacities.

Conventional rotors and blades are often made from compressed graphite powder in various ways to provide the desired tensile strength. In essence, self-lubricating graphite rotary vane pumps are self-destructing in that the graphite within the rotor and vanes is deposited on the surface to provide lubrication when the pump is in operation. Over time, the graphite slowly erodes to provide such lubrication. Such erosion causes carbon dust to enter the air stream. Therefore, air filters must be used to filter out carbon dust from entering the fuel system and, more importantly, from entering the fuel nozzles. Furthermore, the compressed carbon rotor and blades are very susceptible to grease and excessive moisture. Thus, when the components are subjected to oil and moisture, residue builds up on the surface (i.e., the components begin to stick) and may cause the pump to stall.

To address these concerns, methods have been developed that involve the use of laminating or impregnating materials (e.g., PTEF (polytetrafluoroethylene), PEEK (polyetheretherketone), etc.) to reduce friction and wear, such as the methods described in U.S. patent No. 6,364,646 and U.S. patent No. 5,181,844. However, such an approach does not address all of the problems associated with wear, heat and friction issues. With some PEEK and other options, excessive heat may actually cause these components to fail prematurely.

Disclosure of Invention

In one aspect, the present disclosure relates to a rotary vane pump. The rotary vane pump includes a main body housing including a cover at a first end. The cover includes an inlet and an outlet. In another aspect, the rotary vane pump includes a shaft that rotates about an axis of rotation, the shaft being coupled to a motor to rotate the shaft. Another aspect of the rotary vane pump includes a rotor attached to the shaft for rotation of the rotor about the axis of rotation. The rotor is made of a carbon material and defines a plurality of slots. The rotary vane pump further includes a plurality of vanes mounted into the slots. The vanes are free to move and are slidable from the rotor out of a pump body that is secured in the housing body by a plurality of fasteners. The fastener is fixed to the motor housing. The plurality of blades are made of a carbon material that has been impregnated with a material.

In another aspect, the present disclosure is directed to a method of manufacturing a carbon vane for a rotary vane pump. To make the carbon blade, 5-10% by weight resin, 5-20% by weight antimony (such as FH42A), 5-15% by weight copper, 5-10% by weight silver and 10% by weight (other metals) are used.

In one example, a rotary vane pump includes: a motor having a motor shaft;

a pump body mounted to the motor; a rotor coupled to the motor shaft and disposed within the pump body; and a plurality of vanes slidably received into slots defined within the rotor; wherein the rotor is formed from a first material and the plurality of blades are formed from the first material and impregnated with a second material.

In some examples, the first material is a carbon material.

In some examples, the first material is a graphite material.

In some examples, the second material is a resin material.

In some examples, the second material is a metallic material.

In some examples, the second material is one of antimony, copper, and silver.

In some examples, the first material is graphite and the second material is a resin.

In some examples, the weight percentage of the first material is 95% and the weight percentage of the second material is 5%.

In some examples, the pump body is made of stainless steel.

In some examples, the pump further comprises a filter for filtering air received by the pump.

In some examples, the first material has an initial pre-impregnation porosity of at least 5 volume percent, and is impregnated with the second material to have a post-impregnation porosity of less than 5 volume percent.

In some examples, the pre-impregnation porosity is between about 5% and about 10% by volume, and the post-impregnation porosity is up to about 5% by volume.

In some examples, the pre-impregnation porosity is about 10 volume percent and the post-impregnation porosity is about 1 volume percent.

In one example, a rotary vane pump includes a rotor defining a plurality of slots, and a plurality of vanes slidably received into the slots, wherein the rotor is made of a first material and the plurality of vanes are made of the first material and impregnated with a second material.

In some examples, the first material is a carbon material.

In some examples, the first material is a graphite material.

In some examples, the second material is a resin material.

In some examples, the second material is a metallic material.

In some examples, the second material is one of antimony, copper, and silver.

In some examples, the first material is graphite and the second material is a resin.

In some examples, the weight percentage of the first material is 95% and the weight percentage of the second material is 5%.

In some examples, the first material has an initial pre-impregnation porosity of at least 5 volume percent, and is impregnated with the second material to have a post-impregnation porosity of less than 5 volume percent.

In some examples, the pre-impregnation porosity is between about 5% and about 10% by volume, and the post-impregnation porosity is up to about 5% by volume.

In some examples, the pre-impregnation porosity is about 10 volume percent and the post-impregnation porosity is about 1 volume percent.

A rotary vane pump may include a rotor defining a plurality of slots, and a plurality of vanes slidably received into the slots. In one aspect, the plurality of blades are formed from a first material and the first material has been impregnated with a second material, and the rotor is formed from the first material and is free of the second material.

Numerous additional aspects will be set forth in the description that follows. These aspects relate to individual features and combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the broad inventive concepts upon which the examples disclosed herein are based.

Drawings

The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present disclosure. The drawings are briefly described as follows:

FIG. 1 is a perspective view of a first example of a portable heater including a blower-pump assembly having a rotary vane pump, the portable heater having features according to the present disclosure.

FIG. 2 is an exploded view of the blower-pump assembly and the rotary vane pump of the portable heater of FIG. 1.

Fig. 3 is an exploded view of a portion of fig. 2, showing only the rotor and vanes of the rotary vane pump.

Fig. 4 is a cross-sectional front view of the rotary vane pump shown in fig. 2.

Detailed Description

Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

Fig. 1 illustrates an example heater 100. The heater 100 shown is a forced air heater 100, such as a kerosene/diesel air heater (KFA heater) 100. In one aspect, the heater 100 includes a fuel tank 102, a heater frame 104, and a heater assembly 105. As shown, the heater assembly 105 includes a tubular housing 106, the tubular housing 106 defining an interior volume extending between a first end 106a and a second end 106 b. A burner assembly 107 and a blower-pump assembly 108 are disposed within the interior volume of the housing 106. In one aspect, the fuel tank 102 is typically configured to store liquid fuel (such as kerosene or diesel) as fuel for use by a burner assembly 107 within the housing 106 to heat air passing through the housing 106. The blower-pump assembly 108 performs two functions. First, the blower-pump assembly 108 provides compressed air so that fuel may be delivered from the fuel tank 102 to the burner assembly 107, for example, by a venturi effect. Second, the blower-pump assembly 108 forces air through the housing 106 so that the air can be heated by the burner assembly 107. Thus, in operation, relatively cool air is drawn into the first end 106a, heated within the housing 106, and discharged as heated air out of the second end 106 b.

Referring to fig. 2, the blower-pump assembly 108 of the heater 100 is shown in further detail. In one aspect, the blower-pump 108 includes a pump assembly 109 and a motor assembly 120. The motor assembly 120 is shown to include a support frame 122 that supports an electric motor 124. The support frame 122 is mounted to the interior of the housing 106 such that the electric motor 124 is supported within the housing 106. In one aspect, the electric motor 124 includes a drive shaft 126, the drive shaft 126 extending through the front and rear ends of the motor 124. At one end, a fan 128 is mounted to the drive shaft 120 c. Thus, when the motor 124 is activated, the fan 128 is rotated by the drive shaft 126 to draw air through the housing 106. The motor assembly 120 is also shown to include a support plate or panel 130, the support plate or panel 130 serving as an interface surface for the pump assembly 109, as described later. The support plate or panel 130 may include openings such that fasteners 115 may be used to secure the support plate or panel 130 to the housing of the electric motor 124 and to secure the pump assembly 109 to the support plate or panel 130 and/or the electric motor 124.

Referring to fig. 2-4, the pump assembly 109 is shown as a rotary vane type pump. As configured, the pump assembly 109 comprises: a first housing portion 110, a filter 111, a second housing portion 112, an outlet chamber cover 113, a rotor 114, various fasteners 115, a pump body 116, a pressure gauge 117, a plurality of vanes 118, and a motor 120.

In one aspect, the first housing portion 110 of the rotary vane pump assembly 109 includes an inlet opening 110a and an outlet opening 110 b. The inlet opening 110a defines a path for atmospheric air to enter the pump assembly 109. The outlet opening 110b is configured as a port so that a pressure gauge 117 can be installed to indicate the pressure of the compressed air. In one aspect, the first housing portion 110 and the second housing portion 112 are secured together, such as with fasteners 115, to form an interior volume. The filter 111 is disposed within the interior volume such that atmospheric air entering through the inlet opening 110a is filtered prior to being compressed. In one aspect, the second housing portion 112 includes an open frame or support structure 112a and an opening 112b, the open frame or support structure 112a for receiving the filter 111, and filtered air may pass through the opening 112b to the pump body 116. The filter 111 prevents foreign particles from entering the interior 116a of the rotary vane pump 109, which may cause damage. In one aspect, the second housing portion 112 further defines an outlet volume or chamber 112c, the outlet volume or chamber 112c having one or more apertures to receive compressed air from the pump body 116. The second housing portion 112 also defines a second outlet chamber 112d, the second outlet chamber 112d having an outlet 112e for connection to a hose or conduit which in turn is connected to the burner assembly 107. An air discharge cover 113 is shown disposed over the outlet chambers 112c, 112e such that the chambers 112c, 112d are disposed in fluid communication with each other. In one aspect, the discharge cover 113 may include a filter 113a such that air exiting the chamber 112c is filtered before entering the chamber 112 d.

In one aspect, the rotor 114, vanes 118, and pump body 116 collectively define a pump, wherein the rotor 114 rotates eccentrically within the pump body 116 such that the vanes 118 slide in and out of the pump body 116 to alternately receive, compress, and expel air.

As presented, the rotor 114 defines a shaft opening 114 b. The shaft opening 114b allows the shaft 126 of the motor 120 to extend through the rotor 114. In one aspect, the shaft opening 114b is offset from the center of the rotor 114 such that the rotor 114 rotates in an eccentric manner when the motor 120 is activated. The rotor 114 also includes a plurality of circumferentially spaced slots 114 a. The slots 114a slidably receive the blades 118, each slot being shaped as a prism having first and second faces 118a, 118b extending between side walls 118c, 118d, 118e, 118 f. In this particular example, there are four different slots 114a in the rotor 114 having four vanes 118, one vane for each slot. The slots 114a and vanes 118 are equally spaced around the diameter of the rotor 114 and are positioned in a linear configuration. The following scenarios are within the scope of the present disclosure: the vanes 118 are configured in different directions, spaced differently around the rotor 114, and there are more or less than four vanes 118.

The rotor 114 typically has a circular cross-section. In one aspect, the slot 114a and central opening 114b extend between the first face 114c and the second face 114d of the rotor 114. The slots 114b also extend radially outward to a circumferential sidewall 114 e. In operation, the rotor 114 rotates about the axis 20. The shaft axis 20 extends through the shaft opening 114b and through the shaft 126 of the motor 120. As the rotor 114 rotates, the face 114c contacts the opposite face of the second housing portion 112, the face 114d contacts the face 130a of the plate 130 mounted to the motor 120, and the circumferential side wall 114e contacts the inner surface of the pump body 116.

Referring to fig. 4, a front sectional view showing the rotary vane pump 109 is presented, in which the cover 110, the rotor cover 112, the inlet and outlet filters 111 and 113, and the filter 113a are removed. As presented, the pump body 116 has a cylindrical body defining an interior opening or volume 116 a. The pump body 116 includes a plurality of openings 116b that are circumferentially spaced about a region between the opening 116a and an outer wall 116c of the pump body 116. Some of the openings 116b serve as inlet ports to allow atmospheric air to enter the openings 116a, while some of the openings 116b serve as outlet ports to allow compressed air to exit the openings 116 a. As shown, the pump body 116 is fastened to the motor 120 by fasteners 115. The pump body 116 is typically made of stainless steel.

In operation, the rotor 114 rotates with the shaft 126. The vanes 118 move freely in the slots 114a and rotate with the rotor 114. As the vanes 118 rotate, they extend outward to engage the pump body 116 due to centrifugal force. As the rotor 114 rotates eccentrically within the opening 116a, the volume defined between adjacent vanes 118 continuously changes such that air is drawn into the volume as the volume increases and such that air is compressed and eventually expelled as compressed air as the volume decreases.

In one aspect, the rotor 114 and blades 118 may be at least partially formed from a carbon material (such as graphite). With such materials, the rotor 114 and blades 118 are self-lubricating, meaning that the composition helps to reduce the coefficient of friction and the coefficient of wear, such that the wear of the rotor 114 is self-distributed to lubricate the system. Since the rotor 114 is self-lubricating, carbon particles can exit through the outlet 112 d. The air discharge filter 113a is used to prevent them from completely leaving the rotary vane pump 109 and interfering with the operation.

In one aspect, the rotor 114 and blades 118 may be formed from a first material and impregnated with a second material to extend the operating life and operational performance of the pump. In some examples, the following process is used: wherein the blade itself is first integrally formed using the first material, or a larger body (such as a sheet of material) is formed from which the blade 118 may then be cut or otherwise defined. Using such a method, an integrally formed blade or panel formed from the first material has the resulting porosity, wherein the pores of the first material are subsequently partially or wholly impregnated with the second material, for example by a vacuum process. In one example, the first material is a carbon graphite material and the second material is one or more of a resin, antimony, copper, silver, or various grades of other metals. In many examples, the blade 118 is impregnated with 5% by weight resin, 5% by weight antimony, 5% by weight copper, or 4% by weight silver. Other examples include various grades of other materials, metals, etc. at 10% by weight. In many examples, the initial bulk density of the first material is about 108 pounds per cubic foot (Lbs/Ft)³) And the final bulk density of the first material (after impregnation with the second material) is about 110Lbs/Ft³. In many examples, the first material has a porosity of about 10% and is impregnated with the second material to have a porosity of less than 5%, more preferably less than 3%, and still more preferably 1% or less than 1%.

In a particular example, the first material is carbon graphite and the second material is a resin. The carbon graphite may have a thickness of about 108Lbs/Ft³An initial bulk density of about 80 shore a hardness and an initial volume porosity of about 10%. The carbon graphite may be impregnated with a resin (e.g., by a vacuum process) such that the blade 118 has approximately 110Lbs/Ft³A final bulk density of 95, a final hardness of about 1% and a volume porosity. With such a configuration, the compressive strength increases from 25,000 pounds per square inch (psi) of the unimpregnated carbon graphite to impregnation with resin32,000psi increase after immersion of 28%.

In one example, the rotor 114 is formed from only a first material, while the blades 118 are formed from the first and second materials. In one example, the blade 118 includes a second material that is not present in the rotor 114. In one example, the rotor 114 is formed solely of graphite, while the blades 118 are formed of a graphite material and one or more of a resin, antimony, copper, and silver material. Such a configuration is already known: wherein the rotor 114 is not impregnated with the second material and the blades are impregnated with the second material, provides sufficient lubrication while still significantly increasing the useful life of the rotor and blade assembly. With such a configuration, the rotor 114 is able to provide adequate lubrication for the entire assembly while the impregnated blades 118 are provided with increased durability. Such a method is particularly advantageous because the vanes in a rotary vane pump are typically subject to more wear than the rotor. Similar effects can be found with impregnating the rotor 114 with the second material, but at a lower level or extent than impregnating the blades 118 with the second material.

For reference, typical prior art rotor and blade configurations require frequent replacement, typically after about 500 hours of use. However, when the blade 118 is impregnated with resin, antimony, copper or other metal having the degree of self-lubricity described above, it has been found that the life can be extended. In some examples, the life cycle has been extended to 2000 to 3000 hours using resin and antimony to impregnate the blade 118. On the other hand, the blades 118 may also have thermal properties that allow for better heat dissipation when they are impregnated, compared to blades 118 made only of carbon or impregnated with other materials. In yet another aspect, the blade 118 may contribute to frictional losses when the blade 118 is impregnated. Tests carried out on the disclosed invention prove that: a significant improvement in air pump performance is also obtained when the vane 118 is impregnated with one of these materials. In addition, the pump having the vane does not start to deteriorate immediately and the deterioration curve of the vane 118 becomes very gentle longer. This has the additional benefit of: reducing the accumulation of carbon in the air discharge filter 113a and thus extending the service life of the filter 113 a.

It will be apparent from the foregoing detailed description that modifications and variations can be made in various aspects of the disclosure without departing from the spirit and scope of these aspects. While the best modes for carrying out many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims.