Methods of coupling a flywheel rim and a shaft

Patent metadata

Field	Value
Publication number	US-2016377148-A1
Application number	US-201615261337-A
Country	US
Kind code	A1
Filing date	Sep 9, 2016
Priority date	Feb 7, 2013
Publication date	Dec 29, 2016
Grant date	—

Abstract

A dome connector for a flywheel rim to shaft attachment is provided. The dome connector includes a helically wound composite band that extends from a first port to a second port. The helically wound composite band has a helical angle in relation to a line perpendicular to a center of axis of the dome connector. The helical angle is selected to at least in part achieve a desired stiffness in the dome connector.

First claim

1 . A method of coupling a composite flywheel rim and a metal shaft, the method comprising:
laying up a continuous band of composite fibers in a helical pattern from a first port to a second port to form a central passage with a first band layer; laying up subsequent layers with the continuous band of composite fibers over at least a portion of the first band layer to form a body of a dome connector; curing the continuous band of composite fibers to form the dome connector; and coupling the composite flywheel rim to the metal shaft with the dome connector.

2 . The method of claim 1 , further comprising:
bonding an attaching collar within the central passage of the dome connector; and bonding the dome connector within a central passage of the composite flywheel rim.

3 . The method of claim 2 , wherein bonding the dome connector within the central passage of the composite flywheel rim further comprises:
forming the flywheel rim over the dome connector; and curing the flywheel rim and the dome connector simultaneously.

4 . The method of claim 2 , wherein bonding the dome connector within the central passage of the composite flywheel rim further comprises applying an adhesive between the dome connector and the central passage of the composite flywheel rim.

5 . The method of claim 1 , further comprising bonding the metal shaft within the central passage of the dome connector by applying an adhesive between the metal shaft and the central passage of the dome connector.

6 . The method of claim 1 , further comprising bonding the metal shaft within the central passage of the dome connector, comprising:
cooling the metal shaft; placing the cooled shaft in the central passage of the dome connector; and heating up the metal shaft.

7 . The method of claim 1 , further comprising removing a central portion of the continuous band of composite fibers.

8 . The method of claim 1 , further comprising:
defining an opening between an inner surface of the composite flywheel rim and an outer portion of the dome connector at at least one axial end of the dome connector; and disposing at least one connector in the opening having a wedge shape comprising a first axial end positioned adjacent to an interface between the composite flywheel rim and the dome connector and a second axial end positioned relatively further away from the interface where the inner surface of the composite flywheel rim and the outer portion of the dome connector are spaced apart to define the opening, the second axial end exhibiting a width that is greater than a width of the first axial end.

9 . A method of coupling a composite flywheel rim and a shaft, the method comprising:
coupling the shaft to a dome connector comprising at least one band of composite fibers; coupling the dome connector to the composite flywheel rim; defining an opening between an inner surface of the composite flywheel rim and an outer portion of the dome connector at an axial end of the dome connector; and disposing at least one connector in the opening having a wedge shape comprising a first axial end positioned adjacent to an interface between the composite flywheel rim and the dome connector and a second axial end positioned relatively further away from the interface where the composite flywheel rim and the dome connector are spaced apart to define the opening.

10 . The method of claim 9 , further comprising defining the at least one connector such that the second axial end of the at least one connector exhibits a width that is greater than a width of the first axial end of the at least one connector.

11 . The method of claim 9 , further comprising inserting the shaft into an opening in a central passage of the dome connector.

12 . The method of claim 9 , further comprising selecting the at least one connector to be relatively more flexible than the composite flywheel rim and the dome connector.

13 . The method of claim 12 , further comprising selecting the at least one connector to comprise at least one of a rubber, a elastomer, or an adhesive.

14 . The method of claim 9 , further comprising positioning the at least one connector at a location where the dome connector begins to curve away from the composite flywheel rim.

15 . The method of claim 9 , further comprising:
defining another opening between the inner surface of the composite flywheel rim and the outer portion of the dome connector at another, opposing axial end of the dome connector; and disposing another connector in the another opening having a wedge shape.

16 . The method of claim 9 , further comprising defining a convex surface at each outward axial end of the dome connector.

17 . The method of claim 9 , further comprising defining a concave surface at each outward axial end of the dome connector.

18 . A method of coupling a composite flywheel rim and a shaft, the method comprising:
coupling the shaft to a dome connector comprising at least one band of composite fibers; coupling the dome connector to the composite flywheel rim; and disposing at least one connector in an opening formed between an inner surface of the composite flywheel rim and an outer portion of the dome connector, the at least one connector being relatively more flexible than the composite flywheel rim and the dome connector.

19 . The method of claim 18 , further comprising positioning the at least one connector in a location where the dome connector begins to curve away from the composite flywheel rim, the at least one connector having a first, narrow end positioned within the opening at the location where the dome connector begins to curve away from the composite flywheel rim and a second, wider end positioned in an annular space extending between the dome connector and the composite flywheel rim where the dome connector separates from the composite flywheel rim.

20 . The method of claim 18 , wherein coupling the dome connector to the composite flywheel rim further comprises:
forming the flywheel rim over the dome connector; curing the flywheel rim and the dome connector simultaneously; and after curing the flywheel rim and the dome connector simultaneously, disposing the at least one connector in the opening.

Assignees

• Orbital Atk Inc

Inventors

• Christensen Brian R
• Darais Marcus A

Classifications

• F16F2230/0005

  Attachment, e.g. to facilitate mounting onto confer adjustability · CPC title

• F16F15/3153 Primary

  Securing inertia members to the shafts · CPC title

• F16F2226/04

  Assembly or fixing methods; methods to form or fashion parts · CPC title

• F16F2226/042

  Gluing · CPC title

• Y10T74/2132

  Structural detail, e.g., fiber, held by magnet, etc. · CPC title