Composite flywheel rim having commingled layers with macroscopically uniform patterns of fiber arrangement and methods for manufacturing same

• US 20040076809A1
• Filed: 07/03/2003
• Published: 04/22/2004
• Est. Priority Date: 09/13/2001
• Status: Abandoned Application

• Current Assignee: Beacon Power (RGA Labs, Inc.)
• Original Assignee: Beacon Power (RGA Labs, Inc.)
• Inventors: Spears, Ward R.
• Application Number:
  US10/613,984
• Publication Number:
  US 20040076809A1
• Time in Patent Office: Days
• US Class Current: 428/292.1
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2433/00 Closed loop articles
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/08 the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/28 impregnated with or embedded in a plastic substance not used
• CPC Class Codes: D04H 1/56 in association with fibre formation, e.g. immediately following extrusion of staple fibres
• CPC Class Codes: D04H 3/00 Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
• CPC Class Codes: D04H 3/07 otherwise than in a plane, e.g. in a tubular way
• CPC Class Codes: F16C 15/00 Construction of rotary bodies to resist centrifugal force flywheels, correction weights F16F15/30, F16F15/32
• CPC Class Codes: F16F 15/305 made of plastics, e.g. fibre reinforced plastics [FRP] , i.e. characterised by their special construction from such materials
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 74/2132 Structural detail, e.g., fiber, held by magnet, etc.

Abstract

A composite-based rim includes multiple fiber-based, commingled layers wherein the strength and/or stiffness increases from the innermost to the outermost layer of the rim, but wherein the radial stress and strain generated in the rim decreases from the innermost to the outermost layer. At least some layers have a mixture of carbon fiber tows and glass fiber tows. The ratio of carbon fiber tows to glass fiber tows in each layer is constant, and the distribution of carbon fiber tows is macroscopically uniform in each layer.

Claims

1. (ORIGINAL) a hybrid composite flywheel rim comprising:

at least two different types of fibers impregnated with a thermosetting resin such as epoxy resin and wound in an annulus on a mandrel, said two different fibers having different elastic moduli;

one of said two fiber types being randomly distributed amongst the other fiber macroscopically.

2. (ORIGINAL) The hybrid composite flywheel rim of claim 1, further comprising a plurality of layers, at least one layer of said plurality of layers being composed of at least two different types of fibers impregnated with a thermosetting resin, said two different fibers having different elastic moduli;

one of said two fiber types being randomly distributed amongst the other fiber macroscopically in said at least one layer.

3. (ORIGINAL) The hybrid composite flywheel rim of claim 2, wherein at least one of the strength and stiffness of each layer increases in each layer from an innermost layer of the rim to an outermost layer of the rim.

4. (ORIGINAL) The hybrid composite rim of claim 2, wherein the elastic moduli of the two different elastic moduli differ by at least 5 Msi.

5. (ORIGINAL) The hybrid composite flywheel rim of claim 2, wherein at least one layer of said plurality of layers being formed entirely from one of a low modulus fiber and a high modulus fiber, and another layer of said plurality of layers being formed from both the low modulus fiber and the high modulus fiber.

6. (ORIGINAL) A hybrid composite flywheel rim as defined claim 1, wherein the following equations are satisfied:

W_L=(N+B/A)*L_R. and W_L+L_R<

L_M and M*L_R=N*S_p

and wherein;

N=Maximum integer obtained when W_L is divided by L_R

A=integer larger than B

B=integer smaller than A

B/A≠

1, ½

, ⅓

, ¼

W_L=Winding Length (inch)

L_R=Lead Rate (inch)

L_M=Distance between inner faces of two mandrel flanges (inch)

M=integer≧

2

N=integer≧

2

S_p=fiber space amongst other fibers (inch)

7. (ORIGINAL) The hybrid composite flywheel rim of claim 1, wherein said one of said two fiber types is distributed amongst the other fiber in a cross hatch pattern macroscopically.

8. (ORIGINAL) The hybrid composite flywheel rim of claim 7, further comprising a plurality of layers, at least one layer of said plurality of layers being composed of at least two different types of fibers impregnated with a thermosetting resin, said two different fibers having different elastic moduli;

one of said two fiber types being randomly distributed amongst the other fiber macroscopically in said at least one layer.

9. (ORIGINAL) The hybrid composite flywheel rim of claim 8, wherein at least one of the strength and stiffness of each layer increases in each layer from an innermost layer of the rim to an outermost layer of the rim.

10. (ORIGINAL) The hybrid composite rim of claim 8, wherein the elastic moduli of the two different elastic moduli differ by at least 5 Msi.

11. (ORIGINAL) The hybrid composite flywheel rim of claim 8, wherein at least one layer of said plurality of layers being formed entirely from one of a low modulus fiber and a high modulus fiber, and another layer of said plurality of layers being formed from both the low modulus fiber and the high modulus fiber.

12. (ORIGINAL) A hybrid composite flywheel rim as defined claim 7, wherein the following equations are satisfied:

W_L=(N+B/A)*L_R. and W_L+L_R<

L_M and M*L_R=N*S_p

and wherein;

N=Maximum integer obtained when W_L is divided by L_R

A=integer larger than B

B=integer smaller than A

B/A≠

1, ½

, ⅓

, ¼

W_L=Winding Length (inch)

L_R=Lead Rate (inch)

L_M=Distance between inner faces of two mandrel flanges (inch)

M=integer≧

2

N=integer≧

2

S_p=fiber space amongst other fibers (inch)

13. (ORIGINAL) A hybrid composite flywheel rim, comprising:

fibers having different elastic moduli, said fibers including carbon fiber, glass fiber, said fibers fixed in a matrix of thermosetting resin such as epoxy resin;

said carbon fiber is distributed amongst the other fiber in a cross hatch pattern macroscopically.

14. (ORIGINAL) A hybrid composite flywheel rim as defined claim 13, wherein the following equations are satisfied:

W_L=(N+B/A)*L_R. and W_L+L_R<

L_M and M*L_R=N*S_p

and wherein;

N=Maximum integer obtained when W_L is divided by L_R

A=integer larger than B

B=integer smaller than A

B/A≠

1, ½

, ⅓

, ¼

W_L=Winding Length (inch)

L_R=Lead Rate (inch)

L_M=Distance between inner faces of two mandrel flanges (inch)

M integer≧

2

N=integer≧

2

S_p=fiber space amongst other fibers (inch)

15. (ORIGINAL) The hybrid composite flywheel rim of claim 13, further comprising a plurality of layers, at least one layer of said plurality of layers being composed of said fibers having different elastic moduli and wherein said carbon fiber is randomly distributed amongst the other fiber type macroscopically in said at least one layer.

16. (ORIGINAL) The hybrid composite flywheel rim of claim 15, wherein at least one of the strength and stiffness of each layer increases in each layer from an innermost layer of the rim to an outermost layer of the rim.

17. (ORIGINAL) The hybrid composite rim of claim 15, wherein the elastic moduli of said fibers having different elastic moduli differ by at least 5 Msi.

18. (ORIGINAL) A composite flywheel rim, comprising:

an annular structure having a plurality of zones, each with multiple fiber layers in a resin matrix, each said fiber layer having a mixture of carbon fiber tows and glass fiber tows at a ratio of tows that is constant in each layer of any single zone, and said ratio incrementally increases zone-by-zone radially toward outside zones of said rim; and

wherein said carbon fiber tows lie in a macroscopically uniform distribution in each zone by controlling the correlation between lead rate of the fiber band as it is wound onto the mandrel per mandrel revolution and the winding length.