Spirally Wound Composite Flywheel Containment
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Solution Overview
Problem
Current containment solutions for high-speed flywheels are expensive, heavy, and not mass-production viable, as they are typically bespoke-manufactured and prone to fracturing upon failure, releasing lethal kinetic energy and secondary fragments.
Innovation Solution
A tubular containment part made of spirally wound continuous layers of different materials, including high-strength steel and fibre materials, which absorb kinetic energy and prevent fragment penetration, allowing for cost-effective and scalable manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional monolithic cast aluminium or machined steel containment vessels are used, then strength and containment capability are improved, but weight increases and manufacturing cost rises due to bespoke production
Solution Approach 1:
The containment vessel uses composite materials consisting of multiple layers of fibre-reinforced plastic materials wound in different directions (0°, ±45°, 90°) around a mandrel. This composite structure provides high strength-to-weight ratio, containing flywheel fragments effectively while significantly reducing weight compared to traditional monolithic steel or aluminium casings.
Solution Approach 2:
The containment vessel is segmented into multiple distinct layers with different fibre orientations, each layer contributing specific mechanical properties. The multi-layer composite structure is manufactured in modular sections that can be assembled together, enabling weight optimization while maintaining containment strength through distributed structural functionality.
2Strength
If traditional bespoke-manufactured containment vessels are used, then strength and containment capability are improved, but manufacturing cost increases and production time extends
Solution Approach 1:
The containment vessel layers are pre-formed by winding fibre-reinforced materials around a reusable mandrel in a controlled manufacturing process. This preliminary formation allows for standardized production of containment sections that can be quickly assembled, dramatically increasing manufacturing productivity while maintaining strength through consistent layering and resin saturation.
Solution Approach 2:
The containment vessel design uses universal modular sections that can be assembled in different configurations to accommodate various flywheel sizes and energy storage requirements. The standardized composite layers and assembly procedures enable mass production while maintaining containment capability across different applications, reducing both cost and production time.
3Strength
If traditional monolithic containment vessels are used, then containment capability is improved, but adaptability to different flywheel designs decreases
Solution Approach 1:
The containment vessel is divided into multiple modular sections that can be assembled in different numbers and configurations depending on the specific flywheel design requirements. Each section maintains full containment capability independently, allowing the system to be adapted to various flywheel diameters, lengths, and energy storage capacities without redesigning the entire containment structure.
Solution Approach 2:
The composite containment sections are designed as universal components that can serve multiple flywheel applications. By varying the number of sections, layer thicknesses, and fibre orientation angles, the same basic containment technology can be adapted to different flywheel designs, sizes, and performance requirements, maximizing versatility while maintaining containment strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively absorbs kinetic energy and contains flywheel fragments, reducing the risk of lethal releases while being lighter and more cost-effective than traditional monolithic casings, enabling mass production and customization for specific flywheel designs.
Implementation Method 1
the continuous layers comprising a first layer of a structural material and one or more successive layers made up of one or more different materials wherein the inside wall of the tubular casing part is formed by the structural material of the first layer
Data Source
AI summary
A tubular containment part used in a flywheel containment assembly, wherein the tubular containment part is built up of easily configurable layers of different materials and wherein the containment casing is included a spirally wound tubular structure formed from layers made of one or more different materials. The invention further relates to a method for manufacturing such a tubular containment part.