Rotor assembly and method of forming

Abstract

A rotor assembly for a supercharger is provided having a first rotor section and at least one other rotor section affixed to the first rotor section. The first rotor section and the at least one other rotor section are formed from powdered metal and are substantially similar in shape. Each of the first rotor section and the at least one other rotor section has a plurality of lobes that are substantially hollow. The first rotor section and the at least one other rotor section are affixed through one of brazing, copper infiltration, and welding. A supercharger assembly incorporating the disclosed rotor assembly is also provided. Furthermore, a method of forming the disclosed rotor assembly is provided.

1 . A rotor assembly for a supercharger comprising:
 a first rotor section; and   wherein said first rotor section is formed from powdered metal.   
     
     
         2 . The rotor of  claim 1 , further comprising:
 at least one other rotor section affixed to said first rotor section; and   wherein said at least one other rotor section are formed from powdered metal and is substantially similar in shape to that of said first rotor section   
     
     
         3 . The rotor of  claim 2 , wherein each of said first rotor section and said at least one other rotor section have a plurality of lobes and wherein said plurality of lobes are substantially hollow. 
     
     
         4 . The rotor of  claim 2 , wherein each of said first rotor section and said at least one other rotor section has at least one axially extending locating feature and at least one recess sufficiently configured to receive said at least one axially extending feature and wherein said at least one recess of said first rotor section cooperates with said at least one axially extending locating feature of said at least one other rotor section to locate said first rotor section with respect to said at least one other rotor section. 
     
     
         5 . The rotor of  claim 2 , wherein each of said first rotor section and said at least one other rotor section are affixed through one of brazing, copper infiltration, and welding. 
     
     
         6 . The rotor of  claim 2 , wherein each of said first rotor section and said at least one other rotor section have a plurality of lobes and wherein said plurality of lobes are straight in shape. 
     
     
         7 . The rotor of  claim 2 , wherein each of said first rotor section and said at least one other rotor section have a plurality of lobes and wherein said plurality of lobes are helical in shape. 
     
     
         8 . The rotor of  claim 2 , further comprising a shaft and wherein said first rotor section and said at least one other rotor section are mounted on said shaft. 
     
     
         9 . The rotor of  claim 2 , wherein each of said first rotor section and said at least one other rotor section are formed from one of steel, aluminum, and aluminum alloys. 
     
     
         10 . A supercharger assembly comprising:
 a housing defining an inlet passage operable to induct intake air into the supercharger assembly, an outlet passage operable to exhaust said intake air from the supercharger assembly, and a rotor cavity;   a first rotor assembly rotatably disposed within said rotor cavity;   a second rotor assembly rotatably disposed within said rotor cavity and interleaved with said first rotor assembly;   wherein each of said first and second rotor assemblies include:
 a first rotor section; 
 at least one other rotor section affixed to said first rotor section; and 
 wherein said first rotor section and said at least one other rotor section are formed from powdered metal and are substantially similar in shape; and 
   wherein said first and second rotor assemblies cooperate to communicate said intake air from said inlet passage to said outlet passage.   
     
     
         11 . The supercharger assembly of  claim 10 , wherein each of said first rotor section and said at least one other rotor section have a plurality of lobes and wherein said plurality of lobes are substantially hollow. 
     
     
         12 . The supercharger assembly of  claim 10 , wherein each of said first rotor section and said at least one other rotor section has at least one axially extending locating feature and at least one recess sufficiently configured to receive said at least one axially extending feature and wherein said at least one recess of said first rotor section cooperates with said at least one axially extending locating feature of said at least one other rotor section to locate said first rotor section with respect to said at least one other rotor section. 
     
     
         13 . The supercharger assembly of  claim 10 , wherein each of said first rotor section and said at least one other rotor section are affixed through one of brazing, copper infiltration, and welding. 
     
     
         14 . The supercharger assembly of  claim 10 , wherein each of said first rotor section and said at least one other rotor section have a plurality of lobes and wherein said plurality of lobes are one of straight and helical in shape. 
     
     
         15 . A method of forming a rotor assembly for a supercharger assembly, the method comprising:
 forming a first rotor section and at least one other rotor section from powdered metal; and   affixing said at least one other rotor section with respect to said first rotor section to form the rotor assembly.   
     
     
         16 . The method of  claim 15 , wherein each of said first rotor section and said at least one other rotor section have a plurality of lobes and wherein said plurality of lobes are substantially hollow. 
     
     
         17 . The method of  claim 15 , wherein said affixing said at least one other rotor section with respect to said first rotor section to form the rotor assembly is performed by one of brazing, copper infiltration, and welding. 
     
     
         18 . The method of  claim 15 , further comprising mounting said first rotor section and said at least one other rotor section on a shaft. 
     
     
         19 . The method of  claim 15 , further comprising indexing said at least one other rotor section with respect to said first rotor section prior to affixing said at least one other rotor section with respect to said first rotor section. 
     
     
         20 . The method of  claim 19 , wherein each of said first rotor section and said at least one other rotor section has at least one axially extending locating feature and at least one recess sufficiently configured to receive said at least one axially extending feature and wherein said at least one recess of said first rotor section cooperates with said at least one axially extending locating feature of said at least one other rotor section to aid in indexing said at least one other rotor section with respect to said first rotor section.