Impeller design and manufacturing method with pentagonal channel geometry

A method of forming an impeller, wherein the method comprises:

• forming a body by layer-by-layer additive manufacturing, wherein forming the body comprises:
• forming, by layer-by-layer additive manufacturing, a circular base of the body on a build plate;
• forming, by layer-by-layer additive manufacturing, an interior channel extending from forward to aft along a centerline axis of the impeller that passes through a center of the body, wherein the interior channel is configured to mate with a drive shaft;
• forming, by layer-by-layer additive manufacturing, an array of pentagonal channels in the body, wherein each pentagonal channel of the array of pentagonal channels extends symmetrically outward from the center of the body in a spiral pattern, wherein the array of pentagonal channels includes an array of inlets surrounding the center of the impeller, and wherein an overhang angle between a downward-sloping surface of an individual pentagonal channel and a horizontal plane extending perpendicular to the centerline axis of the impeller is at least 35 degrees;
• and
• forming, by layer-by-layer additive manufacturing, a plurality of blades that is disposed around the interior channel, wherein the plurality of blades is fluidly connected with the array of inlets and wherein the plurality of blades extends from the body of the impeller.

An impeller for use in a fuel pump, wherein the impeller comprises:

• a body disposed along a centerline axis of the impeller, wherein the body comprises:
• an interior channel formed by an inner radial surface of the body, wherein the interior channel surrounds a void running along the centerline axis throughout the body, wherein the interior channel is configured to mate with a rotating element;
• a plurality of blades integrally formed with and connected to the body, wherein the plurality of blades is oriented in a spiral pattern around the interior channel;
• a plurality of inlets connected to the body and located around a perimeter of the plurality of blades, wherein the plurality of inlets is fluidly connected to the plurality of blades allowing for fluid flow from the blades to the inlets;
• and
• an array of pentagonal channels disposed in the body, wherein the array of pentagonal channels extends symmetrically outward in a spiral pattern through an angled surface of the body, wherein the array of pentagonal channels is fluidly connected to the plurality of inlets allowing a flow of fluid from the plurality of blades to the array of pentagonal channels.