For us, the consistent development of technologies and related innovations is key to take the air bearing out of its niche into a widely used application. It is therefore in our DNA to design technical solutions that leave you impressed and inspired with the endless potential of air bearings. This is because solutions that are considered technically impossible, or only with a disproportionate amount of effort, can be made possible, such as:
- perform motions with the highest dynamics (acceleration and jerk) without wear;
- carry out complex motions (kinematics) of a body without joints between individual axes to maintain very low moving masses and extremely high stiffness;
- integrate functionalities with air bearings structurally, e.g. contactless relative-motion seals, high magnetic forces kept at a close distance, or sensory properties (force, displacement, etc.)
All of our ideas based on air bearings differentiate themselves from any other alternative if we conceptually let go of the familiar. Doing so, our customers can set themselves apart with distinct advantages in the market. For topics that require budget and time exceeding our personal resources, we prefer to work on them in collaboration with partners. Should this be of interest, we would be delighted to discuss your entrepreneurial ideas with a roadmap from development to market launch, amongst others.
Micro Compressor
Initial Situation:
Inspired by the Covid-19 crisis which has changed the way people live together in unprecedented ways all around the world, we designed a micro compressor that provides mobile pressure and/or oxygen-assisted ventilation therapy for respiratory or pulmonary diseases. It aims to prevent the progression into a more severe disease by providing a timely and suitable noninvasive ventilation to patients. Existing ventilation interventions based on different devices (CPAP, BiPAP, oxygen concentrators) will be integrated with this novel micro compressor. Doing so, it will enable applications based on artificial intelligence (AI) and targeted interventions by the clinician with remote monitoring.
Air-guided solution:
Thanks to the compact size and low weight of this technologically novel micro compressor, there are no concerns to use it in the mobile setting. The required pressures and volumes for different ventilation modes are delivered without particles and oil.
The high degree of compressor efficiency comes from the resonant oscillating compressor system at frequencies around 100 Hz. Self-sufficient aerostatic bearings (air bearings), that enable high frequencies without wear, make use of the low viscosity of the lubricating medium air, whilst also forming a contactless seal of the compressor area with a small bearing gap between the piston and cylinder wall.
The patent for this micro compressor is currently pending; though the design is based on numerous patents for compressors with self-sufficient bearing technology that we already own and have implemented technically.
Carbon fiber recycling
Market situation – problem definition:
For years, there has been a continuous global increase in the use of carbon fibre as a stiffening component in the lightweight construction. High manufacturing costs and the lack of a sustainable recycling process, however, counteract the desired increase in growth. Recycled materials from carbon fibre components result in down-cycling, i.e. the initial material and technological value of the material is far from being restored. For this reason, despite significant advantages such as weight and resulting energy savings, it inhibits the expected breakthrough of carbon fibre in numerous industries, for example in automotive engineering and automation technology.
Disruptive solution with patented technology:
AeroLas GmbH patented a process with ease of scalability that was developed up to preproduction stage together with a renowned research institute, through which hybrid materials with excellent properties derived from recycled carbon fibre, can be extracted. Innovative materials from upcycling not only provide a high economic and ecological added value, but also product solutions which cannot currently be produced efficiently. The patented process is based on the traditional ring spinning process used in textile technology. It can therefore be used for large quantities. So far, numerous attempts to spin carbon fibre for industrial use have failed. The air bearing solution patented by AeroLas revolutionises the market with ease of scalability with a continuous recycling chain from end-of-life product or production waste to the reusable hybrid material.
Initial market applications of the hybrid material:
A successful market introduction of the hybrid material is expected in three selected applications:
Automotive engineering:
The low formability of textile semi-finished parts made from continuous fibres results in long production times for complex components produced in hot presses. Organic sheets made from recycled hybrid fibre drastically reduce these. That is because the component to be formed can flexibly adjust to the mould whilst hardening thanks to the spun basic material used. The closed loop recycling process offers a reduction in material and production costs, as well as compliance with product sustainability legislations.
Construction:
The production of UHPC concrete based on steel sticks is sensitive to corrosion. The use of non-corrosive carbon sticks has been widely researched but remains too expensive. Recycled carbon sticks therefore provide a cost-effective solution for widespread use with a high market potential.
3D printing:
Currently used filaments, usually made of fibre lengths < 1mm, have a low strength despite their high cost. In contrast, the long fibres used in the patented carbon recycling process achieve approximately 80% of the strength of continuous fibres. Novel hybrid fibres with titanium or PEAK spun into them can be used for lucrative applications, for example in medical technology.
Power Motor
Initial Situation:
In search of a suitable concept towards pollution-free aviation, AeroLas, together with a university developed a propulsion system that combines the following advantages unlike any other:
- high efficiency
- high specific power (kW per kg)
- cooling directly in the stator winding, which is designed as a hollow body
- use of liquid hydrogen as a cooling medium
- scalable motor concept
- small air gap for consistency and spacing of magnets and coils with air bearings
- insulation faults (short circuits) are virtually eliminated.
Air-guided solution:
The motor is designed as an axial transverse flux motor. Instead of copper windings or strands with indirect cooling and a relatively low fill factor, wave guides with direct, effective cooling are used. An increase in power density is achieved by a small air gap, realised with an airbearing. It also stabilises the air gap.
The short axial design allows scaling by coupling several individual motors in the longitudinal direction. The motor principle is not only destined for pollution-free aviation, but will also contribute to electro-mobility with ships, trucks, buses or trains.