Performance and durability improvement in compressor structure design

An integral assembly comprising:

• a continuous ring disposed coaxial with, and orthogonal to a central axis;
• said continuous ring comprising a plurality of contiguous surfaces;
• said plurality of contiguous surfaces having a continuous outer surface and a continuous inner surface characterized by a continuous cross-section having a plurality of cross sectional dimensions including a first cross sectional dimension that is longitudinally disposed parallel to said central axis and a second cross sectional dimension disposed orthogonal to said central axis,
• said plurality of contiguous surfaces comprising a bell mouth surface in physical communication with a compressor shroud surface,
• said compressor shroud surface in physical communication with a diffuser surface;
• said diffuser surface in physical communication with said bell mouth surface;
• said diffuser surface having a diffuser face on a portion of said continuous outer surface radially disposed about said central axis;
• said diffuser face being perpendicular to said central axis;
• said diffuser face comprising a plurality of vanes extending longitudinally away from said diffuser face in a direction of said central axis;
• said integral assembly further including a compressor shroud comprising a compressor shroud ring having a first side separated from a second side;
• and
• said first side of said compressor shroud ring being in physical communication with one or more of said vanes.

An integral assembly, comprising:

• a continuous ring disposed coaxial with, and orthogonal to a central axis;
• said continuous ring comprising a plurality of contiguous surfaces;
• said continuous ring having a plurality of mounting holes arranged annularly at an outer portion of said continuous ring;
• said plurality of contiguous surfaces having a continuous outer surface characterized by a continuous cross-section longitudinally disposed parallel to said central axis;
• said plurality of contiguous surfaces comprising a bell mouth surface in physical communication with a compressor shroud surface,
• said compressor shroud surface in physical communication with a diffuser surface;
• said diffuser surface in physical communication with said bell mouth surface;
• said bell mouth surface comprising a curved scalloped shaped portion arranged between said diffuser surface and said compressor shroud surface;
• said diffuser surface having a diffuser face on a portion of said continuous outer surface radially disposed about said central axis;
• said diffuser face being perpendicular to said central axis;
• said diffuser face comprising a plurality of vanes extending longitudinally away from said diffuser face in a direction of said central axis;
• said plurality of vanes each including a top surface that is parallel to said diffuser face,
• said integral assembly further including a compressor shroud comprising a compressor shroud ring having a first side separated from a second side;
• and
• said first side of said compressor shroud ring being in physical communication with each of said top surfaces of said plurality of vanes such that said first side of said compressor shroud ring is arranged parallel to said diffuser face.

An auxiliary power unit, comprising:

• a compressor module;
• said compressor module comprising an inlet in fluid communication with a bell mouth surface and with a compressor wheel;
• said compressor wheel being able to rotate, about a central axis, between a compressor housing and a compressor shroud surface;
• said compressor wheel having a trailing edge in fluid communication with a leading edge of a diffuser surface;
• wherein said bell mouth surface, said compressor shroud surface, and said diffuser surface comprise an integral assembly;
• said integral assembly comprising:
• a continuous ring disposed coaxial with, and orthogonal to said central axis;
• said continuous ring comprising a plurality of surfaces;
• said plurality of surfaces having a continuous outer surface and a continuous inner surface being characterized by a continuous cross section having a plurality of cross sectional dimensions including a first cross sectional dimension that is longitudinally disposed parallel to said central axis and a second cross sectional dimension disposed orthogonal to said central axis;
• said plurality of surfaces comprising said bell mouth surface in physical communication with said compressor shroud surface;
• said compressor shroud surface being in physical communication with said diffuser surface;
• and
• said diffuser sin-face being in physical communication with said bell mouth surface.

A method of making an integral assembly, comprising the steps of:

• forming a first sub-assembly having a first end and a second end;
• forming a second sub-assembly having a first end and a second end;
• attaching said first end of said first sub-assembly to said first end of said second sub assembly;
• and
• attaching said second end of said first sub-assembly to said second end of said second sub-assembly, to produce said integral assembly, wherein said integral assembly comprises:
• a continuous ring disposed coaxial with, and orthogonal to a central axis;
• said continuous ring comprising a plurality of surfaces;
• said plurality of surfaces having a continuous outer surface and a continuous inner surface;
• said plurality of surfaces being characterized by a continuous cross section having a plurality of cross sectional dimensions including a first cross sectional dimension that is longitudinally disposed parallel to said central axis and a second cross sectional dimension disposed orthogonal to said central axis;
• said plurality of surfaces comprising a bell mouth surface in physical communication with a compressor shroud surface,
• said compressor shroud surface being in physical communication with a diffuser surface;
• and
• said diffuser surface being in physical communication with said bell mouth surface.