Rotary energy storage device

Claim 2

A rotary energy storage device comprising: (a) rotor means for storing energy when rotated about an axis that passes through said rotor means, the rotor means having a mounting surface and an outer periphery, at least a portion of the outer periphery being disposed farther from the axis of rotation in a direction generally perpendicular to the axis than substantially any other portion of the rotor means, the rotor means being free of any substantial increase in thickness adjacent said at least a portion of the outer periphery, the thickness of the rotor means being measured generally parallel to the axis of rotation, said rotor means within its outer periphery being a continuous member without any opening formed therethrough; (b) hub means for coupling to rotatable shaft means, the hub means having a mounting surface spaced from the mounting surface of the rotor means, the hub means also having a maximum dimension measured generally perpendicular to the axis of rotation which is less than a correspondingly measured maximum dimension of the rotor means; (c) interlayer means disposed between the mounting surfaces of the rotor means and the hub means, a first surface of the interlayer means being bonded to the mounting surface of the hub means and a second surface of the interlayer means being bonded to the mounting surface of the rotor means, the rotor means and hub means being constructed relative to each other such that upon rotation of the energy storage device the hub means experiences a strain at its mounting surface due to centrifugal force which is less than a corresponding strain experienced by the rotor means at its mounting surface due to centrifugal force, the difference between the strain at the mounting surface of the hub means and the strain at the mounting surface of the rotor means inducing a shear stress in the interlayer means, the interlayer means having (i) a thickness measured normal to at least one of its first and second surfaces and (ii) a shear modulus which have a predetermined interrelationship so as to permit the shear stress induced in the interlayer means to be accommodated through deformation of the interlayer means without structural failure and without bond failure due to said induced shear stress when the energy storage device is rotating at any speed up to a speed at which the rotor means would fail due to radially directed centrifugal loads imposed upon the rotor means.

Claim 3

A rotary energy storage device, according to claim 1, wherein the interlayer means is shaped and dimensioned to insure that it will fail due to generation within the interlayer means of stresses due to centrifugal force other than said induced shear stress at a rotational speed of the energy storage device less than the rotational speed at which the rotor means would fail.

Claim 4

A rotary energy storage device, according to claim 1, wherein the interlayer means includes a body of elastomer.

Claim 5

A rotary energy storage device, according to claim 1, wherein the rotor means includes at least one rotor element which extends generally across the rotor means and which is oriented transverse to the axis of rotation, the rotor element having an outer periphery and within said outer periphery being a continuous member without any opening formed therein.

Claim 6

A rotary energy storage device, according to claim 4, wherein the rotor means includes a multiplicity of rotor elements, each of said rotor elements being an elongated filamentary member and said filamentary members being embedded in a matrix material.

Claim 7

A rotary energy storage device, according to claim 1, wherein the rotor means and the hub means are constructed relative to each other such that (i) the difference between the strains experienced at the mounting surfaces of the hub means and the rotor means and (ii) the shear stress induced in the interlayer means both continuously increase with increasing rotational speed of the energy storage device.

Claim 8

A rotary energy storage device, according to claim 1, wherein the interlayer means is bonded to the mounting surfaces of the hub means and the rotor means in a manner such that the interlayer means experiences generally a maximum difference between the strain experienced by the hub means and the strain experienced by the rotor means.

Claim 9

A rotary energy storage device, according to claim 1, wherein the rotor means is rotatable about an axis that passes through the rotor means and wherein the interlayer means is fabricated and dimensioned to permit limited tilting motions of the rotor means about an axis transverse to said axis of rotation.

Claim 10

A rotary energy storage device, according to claim 1, wherein the rotor means has an energy storage capacity of at least ten watt-hours per pound.

Claim 11

A rotary energy storage device comprising: (a) rotor means having a mounting surface, an outer periphery and an ultimate speed at which the rotor means will fail due to centrifugal loads imposed on the rotor means, said rotor means within its outer periphery being a continuous member without any opening formed therethrough; (b) hub means for coupling to rotatable shaft means, the hub means having a mounting surface spaced from the mounting surface of the rotor means; (c) interlayer means disposed between the mounting surfaces of the rotor means and the hub means; (d) a first layer of adhesive bonding a first surface of the interlayer means to the mounting surface of the hub means; and (e) a second layer of adhesive bonding a second surface of the interlayer means to the mounting surface of the rotor means, the rotor means and hub means being constructed relative to each other such that upon rotation of the energy storage device the hub means experiences a strain at its mounting surface due to centrifugal force which is different from a corresponding strain experienced by the rotor means at its mounting surface due to centrifugal force, the difference between the strain at the mounting surface of the hub means and the strain at the mounting surface of the rotor means inducing shear stresses in the interlayer means and the adhesive layers, the difference between the two shear strains being such that at a rotational speed of the energy storage device less than the ultimate speed of the rotor means the difference between the shear strains would induce shear stresses in the adhesive layers if used without any interlayer means which would exceed the shear strength of the adhesive layers and would cause failure of said adhesive layers, the interlayer means having (i) a thickness measured normal to at least one of its first and second surfaces and (ii) a shear modulus which have a predetermined interrelationship such as to permit the interlayer means with the adhesive layers to accommodate shear stresses induced by said difference between the shear strains through deformation of said interlayer means without failure of the interlayer means due to said induced shear stresses and without failure of the adhesive layers due to said induced shear stresses at speeds of the energy storage device greater than said speed at which the adhesive layers would fail if used without any interlayer means.

Claim 12

A rotary energy storage device comprising: (a) rotor means having a mounting surface, an outer periphery and an ultimate speed at which the rotor means will fail due to centrifugal loads imposed on the rotor means, said rotor means within its outer periphery being a continuous member without any opening formed therethrough; (b) hub means for coupling to rotatable shaft means, the hub means having a mounting surface spaced from the mounting surface of the rotor means; (c) interlayer means disposed between the mounting surfaces of the rotor means and the hub means; (d) a first layer of adhesive bonding a first surface of the interlayer means to the mounting surface of the hub means; and (e) a second layer of adhesive bonding a second surface of the interlayer means to the mounting surface of the rotor means, the rotor means and hub means being constructed relative to each other such that upon rotation of the energy storage device the hub means experiences a strain at its mounting surface due to centrifugal force which is different from a corresponding strain experienced by the rotor means at its mounting surface due to centrifugal force, the difference between the strain at the mounting surface of the hub means and the strain at the mounting surface of the rotor means inducing shear stresses in the interlayer means and the adhesive layers, the difference between the two shear strains being such that at a rotational speed of the energy storage device less than the ultimate speed of the rotor means the difference between the shear strains would induce shear stresses in the adhesive layers if used without any interlayer means which would exceed the shear strength of the adhesive layers and would cause failure of said adhesive layers, the interlayer means having (i) a thickness measured normal to at least one of its first and second surfaces and (ii) a shear modulus which have a predetermined interrelationship such as to permit the interlayer means with the adhesive layers to accommodate shear stresses induced by said difference between the shear strains through deformation of said interlayer means without failure of the interlayer means due to said induced shear stresses and without failure of the adhesive layers due to said induced shear stresses at speeds of the energy storage device greater than said speed at which the adhesive layers would fail if used without any interlayer means.

Claim 13

A rotary energy storage device, according to claim 10, wherein the rotor means normally rotates at speeds greater than said speed at which the adhesive layers would fail if used without any interlayer means.

Claim 14

A rotary energy storage device, according to claim 10, wherein the interlayer means has a composition, shape, and dimensions such that it will fail at a speed greater than said speed at which the adhesive layers would fail if used without any interlayer means but less than the ultimate speed of the rotor means.

Claim 15

A rotary energy storage device, according to claim 10, wherein the rotor means and the hub means are constructed relative to each other such that (i) the difference between the strains experienced at the mounting surfaces of the hub means and the rotor means and (ii) the shear stress induced in the interlayer means both continuously increase with increasing rotational speed of the energy storage device.

Claim 16

A rotary energy storage device, according to claim 10, wherein the interlayer means includes a body of elastomer.

Claim 17

A rotary energy storage device, according to claim 14, wherein the first and second surfaces of said interlayer means are surfaces of said body of elastomer.

Claim 18

A rotary energy storage device, according to claim 10, wherein the hub means includes: (a) a first hub member for coupling to the rotatable shaft means, the first hub member having a first arcuate surface; (b) a second hub member for attachment to the interlayer means, the second hub member having a second arcuate surface which is presented to and spaced from the first arcuate surface; and (c) a layer of elastomer disposed between and secured to the first and second arcuate surfaces.

Claim 19

A rotary energy storage device, according to claim 10, wherein the rotor means is rotatable about an axis that passes through the rotor means, and wherein the rotor means includes a multiplicity of anisotropic filamentary members which are embedded in a resin matrix and which are oriented generally transverse to said axis of rotation.

Claim 20

A rotary energy storage device, according to claim 10, wherein the mounting surfaces of the hub means and the rotor means are disposed opposite and presented to each other, and wherein the first and second surfaces of the interlayer means are disposed opposite each other.

Claim 21

A rotary energy storage device, according to claim 10, wherein the interlayer means is bonded to the mounting surfaces of the hub means and the rotor means in a manner such that the interlayer means experiences generally a maximum difference between the strain experienced by the hub means and the strain experienced by the rotor means.

Claim 22

A rotary energy storage device, according to claim 10, wherein the rotor means has an outer periphery of which at least a portion is disposed farther from the axis of rotation in a direction generally perpendicular to the axis than substantially any other portion of the rotor means, the rotor means being free of any substantial increase in thickness adjacent said at least a portion of its outer periphery, the thickness of the rotor means being measured generally parallel to the axis of rotation, and wherein the hub means has a maximum dimension measured generally perpendicular to the axis of rotation which is less than a correspondingly measured maximum dimension of the rotor means.

Claim 23

A rotary energy storage device comprising: (a) a rotor having an outer periphery, said rotor being rotatable about an axis passing through said rotor, the rotor having an ultimate rotational speed at which the rotor will fail due to centrifugal loads imposed on the rotor, said rotor within its outer periphery being a continuous member without any opening formed therethrough; (b) hub means for mounting on a rotatable shaft, the hub means having a mounting surface presented to and speced from a generally parallel opposed surface of the rotor; (c) interlayer means disposed between the rotor and the hub means, the interlayer means including a body of elastomeric material; (d) a first layer of adhesive bonding a first surface of said body of elastomeric material to the mounting surface of the hub means; and (e) a second layer of adhesive bonding a second surface of said body of elastomeric material opposite the first surface to the opposed surface of the rotor, the rotor and the hub means being constructed relative to each other such that upon rotation of the energy storage device the hub means experiences a strain at its mounting surface due to centrifugal force which is different from a corresponding strain experienced by the rotor at its opposed surfaces due to centrifugal force, the difference between the strain at the mounting surface of the hub means and the strain at the opposed surface of the rotor inducing shear stresses in the interlayer means and the adhesive layers, both (i) the difference between the two shear strains and (ii) the resultant shear stress induced in the interlayer means continuously increasing with increasing rotational speed of the energy storage device, the difference between the shear strains also being such that at a rotational speed of the energy storage device less than the ultimate speed of the rotor the difference between the shear strains would induce shear stresses in the adhesive layers if used without any interlayer means which would exceed the shear strength of the adhesive layers and would cause failure of said adhesive layers, the interlayer means having (i) a thickness measured normal to at least one of its first and second surfaces and (ii) a shear modulus which have a predetermined interrelationship such as to permit the interlayer means with the adhesive layers to accommodate shear stresses induced by said difference between the shear strains through deformation of said interlayer means without failure of the interlayer means due to said induced shear stresses and without failure of the adhesive layers due to said induced shear stresses at speeds of the energy storage device greater than said speed at which the adhesive layers would fail if used without any interlayer means.

Claim 24

A rotary energy storage device comprising: (a) a rotor having an outer periphery, said rotor being rotatable about an axis passing through said rotor, the rotor having an ultimate rotational speed at which the rotor will fail due to centrifugal loads imposed on the rotor, said rotor within its outer periphery being a continuous member without any opening formed therethrough; (b) hub means for mounting on a rotatable shaft, the hub means having a mounting surface presented to and speced from a generally parallel opposed surface of the rotor; (c) interlayer means disposed between the rotor and the hub means, the interlayer means including a body of elastomeric material; (d) a first layer of adhesive bonding a first surface of said body of elastomeric material to the mounting surface of the hub means; and (e) a second layer of adhesive bonding a second surface of said body of elastomeric material opposite the first surface to the opposed surface of the rotor, the rotor and the hub means being constructed relative to each other such that upon rotation of the energy storage device the hub means experiences a strain at its mounting surface due to centrifugal force which is different from a corresponding strain experienced by the rotor at its opposed surfaces due to centrifugal force, the difference between the strain at the mounting surface of the hub means and the strain at the opposed surface of the rotor inducing shear stresses in the interlayer means and the adhesive layers, both (i) the difference between the two shear strains and (ii) the resultant shear stress induced in the interlayer means continuously increasing with increasing rotational speed of the energy storage device, the difference between the shear strains also being such that at a rotational speed of the energy storage device less than the ultimate speed of the rotor the difference between the shear strains would induce shear stresses in the adhesive layers if used without any interlayer means which would exceed the shear strength of the adhesive layers and would cause failure of said adhesive layers, the interlayer means having (i) a thickness measured normal to at least one of its first and second surfaces and (ii) a shear modulus which have a predetermined interrelationship such as to permit the interlayer means with the adhesive layers to accommodate shear stresses induced by said difference between the shear strains through deformation of said interlayer means without failure of the interlayer means due to said induced shear stresses and without failure of the adhesive layers due to said induced shear stresses at speeds of the energy storage device greater than said speed at which the adhesive layers would fail if used without any interlayer means.

Claim 25

A rotary energy storage device, according to claim 21, wherein the rotor is fabricated of a multiplicity of filamentary elements embedded in a resin matrix, the filamentary elements extending across the rotor and being oriented transverse to said axis of rotation.

Claim 26

A rotary energy storage device comprising: (a) rotor means including at least one rotor element and being rotatable about an axis that passes through said rotor means, the rotor element extending across the rotor means and being oriented transverse to said axis of rotation, the rotor means and the rotor element each having an outer periphery and each of said rotor means and said rotor element within their respective outer periphery being a continuous member without any opening formed therein, at least a portion of the outer periphery of the rotor means being disposed farther from the axis of rotation in a direction generally perpendicular to the axis than substantially any other portion of the rotor means, the rotor means being free of any substantial increase in thickness adjacent said at least a portion of the outer periphery, the thickness of the rotor means being measured generally parallel to the axis of rotation; (b) hub means for coupling to rotatable shaft means, the hub means having a mounting surface spaced from a mounting surface of the rotor means, the hub means also having a maximum dimension measured generally perpendicular to the axis of rotation which is less than a correspondingly measured maximum dimension of the rotor means; and (c) interlayer means disposed between the mounting surfaces of the rotor means and the hub means, a first surface of the interlayer means being bonded to the mounting surface of the hub means and a second surface of the interlayer means being bonded to the mounting surface of the rotor means whereby the rotor means is rotatable with the hub means about said axis of rotation, the interlayer means including at least one body of elastomeric material.

Claim 27

A rotary energy storage device comprising: (a) rotor means including at least one rotor element and being rotatable about an axis that passes through said rotor means, the rotor element extending across the rotor means and being oriented transverse to said axis of rotation, the rotor means and the rotor element each having an outer periphery and each of said rotor means and said rotor element within their respective outer periphery being a continuous member without any opening formed therein, at least a portion of the outer periphery of the rotor means being disposed farther from the axis of rotation in a direction generally perpendicular to the axis than substantially any other portion of the rotor means, the rotor means being free of any substantial increase in thickness adjacent said at least a portion of the outer periphery, the thickness of the rotor means being measured generally parallel to the axis of rotation; (b) hub means for coupling to rotatable shaft means, the hub means having a mounting surface spaced from a mounting surface of the rotor means, the hub means also having a maximum dimension measured generally perpendicular to the axis of rotation which is less than a correspondingly measured maximum dimension of the rotor means; and (c) interlayer means disposed between the mounting surfaces of the rotor means and the hub means, a first surface of the interlayer means being bonded to the mounting surface of the hub means and a second surface of the interlayer means being bonded to the mounting surface of the rotor means whereby the rotor means is rotatable with the hub means about said axis of rotation, the interlayer means including at least one body of elastomeric material.

Claim 28

A rotary energy storage device, according to claim 23, wherein the opposed surface of the rotor means is disposed adjacent to a portion of the rotor means which has generally the largest dimension measured (i) across said rotor means and (ii) generally normal to said axis of rotation.

Claim 29

A rotary energy storage device, according to claim 23, wherein the rotor means includes a multiplicity of rotor elements and wherein each of said rotor elements is an elongated filamentary member, the filamentary members being embedded in a resin matrix.

Claim 30

A rotary energy storage device, according to claim 23, wherein each of the first and second surfaces of the interlayer means is a surface of a body of elastomer.

Claim 31

A rotary energy storage device, according to claim 23, wherein the hub means includes; (a) a first hub member for attachment to the rotatable shaft means, the first hub member having a first arcuate surface; (b) a second hub member for attachment to the interlayer means, the second hub member having a second arcuate surface which is presented to and spaced from the first arcuate surface; and (c) a layer of elastomer disposed between and secured to the first and second arcuate surfaces.

Claim 32

A rotary energy storage device comprising: (a) a rotor rotatable about an axis passing through said rotor, the rotor being fabricated of a multiplicity of filamentary elements embedded in a resin matrix, the filamentary elements extending across the rotor and being oriented transverse to said axis of rotation, the rotor having an outer periphery of which at least a portion is disposed farther from the axis of rotation in a direction generally perpendicular to the axis than substantially any other portion of the rotor, the rotor being free of any substantial increase in thickness adjacent said at least a portion of the outer periphery, the thickness of the rotor being measured generally parallel to the axis of rotation; (b) hub means for mounting on a rotatable shaft, the hub means having a mounting surface presented to and spaced from a generally parallel opposed surface of the rotor, the hub means also having a maximum dimension measured generally perpendicular to the axis of rotation which is less than a correspondingly measured maximum dimension of the rotor means; and (c) interlayer means disposed between the rotor and the hub means, the interlayer means including a body of elastomeric material which has a first surface bonded to the mounting surface of the hub means and a second surface opposite the first surface and bonded to the opposed surface of the rotor so that the rotor is rotatable with the hub means about said axis of rotation, the opposed surface of the rotor being disposed adjacent to at least one filamentary element having a length measured across the rotor at least as great as the length of substantially any other filamentary element in the rotor, the rotor within its outer periphery being a continuous member without any opening formed therethrough.

Claim 33

A rotary energy storage device comprising: (a) a rotor rotatable about an axis passing through said rotor, the rotor being fabricated of a multiplicity of filamentary elements embedded in a resin matrix, the filamentary elements extending across the rotor and being oriented transverse to said axis of rotation, the rotor having an outer periphery of which at least a portion is disposed farther from the axis of rotation in a direction generally perpendicular to the axis than substantially any other portion of the rotor, the rotor being free of any substantial increase in thickness adjacent said at least a portion of the outer periphery, the thickness of the rotor being measured generally parallel to the axis of rotation; (b) hub means for mounting on a rotatable shaft, the hub means having a mounting surface presented to and spaced from a generally parallel opposed surface of the rotor, the hub means also having a maximum dimension measured generally perpendicular to the axis of rotation which is less than a correspondingly measured maximum dimension of the rotor means; and (c) interlayer means disposed between the rotor and the hub means, the interlayer means including a body of elastomeric material which has a first surface bonded to the mounting surface of the hub means and a second surface opposite the first surface and bonded to the opposed surface of the rotor so that the rotor is rotatable with the hub means about said axis of rotation, the opposed surface of the rotor being disposed adjacent to at least one filamentary element having a length measured across the rotor at least as great as the length of substantially any other filamentary element in the rotor, the rotor within its outer periphery being a continuous member without any opening formed therethrough.