The invention herein relates to a flywheel capable of high speed rotational operation in excess of 15,000 rpm, the flywheel comprising a composite rotor having a polymeric matrix in which are embedded fibers helically wound at an initial angle with respect to the axis of rotation of the rotor of from about 50° to about 80° and increasing in a stepwise or continuous manner to about 90°.

The invention herein relates to a flywheel capable of high speed rotational operation in excess of 15,000 rpm, the flywheel comprising a composite rotor having a polymeric matrix in which are embedded fibers helically wound at an initial angle with respect to the axis of rotation of the rotor of from about 50° to about 80° and increasing in a stepwise or continuous manner to about 90°.

An example flywheel energy storage device includes a fiber-resin composite shell having an elliptical ovoid shape. The example device also includes an axially oriented internal compressive support between the axial walls of the shell. The example device also includes an inner boss plate and an outer boss plate on each side of the shell. The example device also includes a plurality of radially oriented, fiber-resin composite helical wraps forming the shell and coupling the shell to the inner and outer boss plates for co-rotation and torque transfer. The example device also includes boss plate attachments on internal boss plate supports to mount the shell for co-rotation and torque transfer via resin bonding, friction, and compression between the inner and outer boss plates.

An example flywheel energy storage device includes a fiber-resin composite shell having an elliptical ovoid shape. The example device also includes an axially oriented internal compressive support between the axial walls of the shell. The example device also includes an inner boss plate and an outer boss plate on each side of the shell. The example device also includes a plurality of radially oriented, fiber-resin composite helical wraps forming the shell and coupling the shell to the inner and outer boss plates for co-rotation and torque transfer. The example device also includes boss plate attachments on internal boss plate supports to mount the shell for co-rotation and torque transfer via resin bonding, friction, and compression between the inner and outer boss plates.

Flywheel system properties are enhanced with rim designs that control stress at operational rotational velocities. The tensile strength of fiber-resin composites can be aligned with radial forces to improve radial stress loading. Loops with composite casings can be arranged around the flywheel circumference with a majority of the fibers being aligned in the radial direction. The loops can enclose masses that contribute to energy storage in the flywheel system. Masses can be arranged around the hub circumference with a hoop wound composite casing enclosing the masses and hub. The masses subjected to radial forces are radially displaced with increasing rotational velocity and can provide compressive force to the fiber-resin composite to contribute to maintaining composite integrity. With the alignment of fibers in hoop or radial directions, higher loading permits increase rotational velocities, which can significantly add to the amount of energy stored or produced with the flywheel.

Flywheel system properties are enhanced with rim designs that control stress at operational rotational velocities. The tensile strength of fiber-resin composites can be aligned with radial forces to improve radial stress loading. Loops with composite casings can be arranged around the flywheel circumference with a majority of the fibers being aligned in the radial direction. The loops can enclose masses that contribute to energy storage in the flywheel system. Masses can be arranged around the hub circumference with a hoop wound composite casing enclosing the masses and hub. The masses subjected to radial forces are radially displaced with increasing rotational velocity and can provide compressive force to the fiber-resin composite to contribute to maintaining composite integrity. With the alignment of fibers in hoop or radial directions, higher loading permits increase rotational velocities, which can significantly add to the amount of energy stored or produced with the flywheel.

Apparatuses, systems and methods are described for a flywheel system incorporating a rotor made from a high-strength material in an open-core flywheel architecture with a high-temperature superconductive (HTS) bearing technology to achieve the desired high energy density in the flywheel energy storage devices, to obtain superior results and performance, and that eliminates the material growth-matching problem and obviates radial growth and bending mode issues that otherwise occur at various high frequencies and speeds.

Apparatuses, systems and methods are described for a flywheel system incorporating a rotor made from a high-strength material in an open-core flywheel architecture with a high-temperature superconductive (HTS) bearing technology to achieve the desired high energy density in the flywheel energy storage devices, to obtain superior results and performance, and that eliminates the material growth-matching problem and obviates radial growth and bending mode issues that otherwise occur at various high frequencies and speeds.

The flywheel energy storage device (3) comprises a rotor (2) with at least two hubs (11, 12) and a drive (33) for the rotor (2), whereby the rotary element (23) is mounted at least via the first hub (11) with the first journal (21) in a first bearing (31) of the flywheel energy storage device (3), and at least via the second hub (12) with the second journal (22) in a second bearing (32) of the flywheel energy storage device (3), and the rotor (2) can be made to rotate by means of the drive (33) via the first and/or second journals (21, 22), whereby the journals (21, 22) in the rotor (2) are connected to each other exclusively via the hubs (11, 12) and via the rotary element (23).

The flywheel energy storage device (3) comprises a rotor (2) with at least two hubs (11, 12) and a drive (33) for the rotor (2), whereby the rotary element (23) is mounted at least via the first hub (11) with the first journal (21) in a first bearing (31) of the flywheel energy storage device (3), and at least via the second hub (12) with the second journal (22) in a second bearing (32) of the flywheel energy storage device (3), and the rotor (2) can be made to rotate by means of the drive (33) via the first and/or second journals (21, 22), whereby the journals (21, 22) in the rotor (2) are connected to each other exclusively via the hubs (11, 12) and via the rotary element (23).