Carbon Fiber Motor Rotor Integrating Propeller Mount

Abstract

A rotor for use with an airborne wind turbine, wherein the rotor comprises a front flange, a can, a rear flange, and a rigid insert comprising a propeller mount, wherein the front flange, can, and rear flange comprise one of carbon fiber and spun aluminum, wherein a rear end of the front flange is attached to a front end of the can, and the rear flange is mounted to a rear end of the can, wherein the rigid insert is bonded to the front flange; and wherein the rigid insert comprises a tube that axially extends within the rotor to allow for the positioning of a driveshaft therethrough.

What is claimed is: 
     
         1 . An aerial vehicle comprising:
 a main wing;   a rotor connected to the main wing and a propeller mounted to the rotor;   wherein the rotor comprises:   a front flange;   a can;   a rear flange; and   a rigid insert comprising a propeller mount;   wherein the front flange, can, and rear flange comprise one of carbon fiber and spun aluminum;   wherein a rear end of the front flange is attached to a front end of the can, and the rear flange is mounted to a rear end of the can;   wherein the rigid insert is bonded to the front flange;   wherein the rigid insert comprises a tube that axially extends within the rotor to allow for the positioning of a driveshaft therethrough; and   wherein the rotor has a front surface that is attached to a root of the propeller.   
     
     
         2 . The aerial vehicle of  claim 1 , wherein a front surface of the front flange is shaped to conform to a shape of a rear surface of the root of the propeller. 
     
     
         3 . The aerial vehicle of  claim 1 , wherein the rigid insert includes a nut plate for attachment to the root of the propeller. 
     
     
         4 . The aerial vehicle of  claim 3 , wherein the front surface of the front flange includes divots around bolt holes in the nut plate to provide an out-of-plane shape to the front surface of the front flange. 
     
     
         5 . The aerial vehicle of  claim 4 , wherein the tube is tapered downwardly as it extends towards the rear flange. 
     
     
         6 . The aerial vehicle of  claim 1 , wherein a locating flange extends rearwardly from the rear flange for sealing engagement with a stator positioned on the main wing. 
     
     
         7 . The aerial vehicle of  claim 1 , wherein the rigid insert comprises a metal. 
     
     
         8 . The aerial vehicle of  claim 1 , wherein the rigid insert comprises carbon fiber. 
     
     
         9 . The aerial vehicle of  claim 1 , wherein the front flange is mounted to the front end of the can by bonding to a middle flange extending forwardly from the front end of the can. 
     
     
         10 . The aerial vehicle of  claim 1 , wherein the front flange has a conical shape as it tapers outwardly from a front surface of the front flange to a rear surface of the front flange. 
     
     
         11 . The aerial vehicle of  claim 5 , wherein the driveshaft is bonded to or press fit to an inner surface of the can. 
     
     
         12 . The aerial vehicle of  claim 10 , wherein the can has a cylindrical outer surface. 
     
     
         13 . A rotor for use with an aerial vehicle wherein the rotor comprises:
 a front flange;   a can;   a rear flange; and   a rigid insert comprising a propeller mount;   wherein the front flange, can, and rear flange comprise one of carbon fiber and spun aluminum;   wherein a rear end of the front flange is attached to a front end of the can, and the rear flange is mounted to a rear end of the can;   wherein the rigid insert is bonded to the front flange;   wherein the rigid insert comprises a tube that axially extends within the rotor to allow for the positioning of a driveshaft therethrough; and   wherein the rotor has a front surface that is adapted for attachment to a root of a propeller.   
     
     
         14 . The rotor of  claim 13 , wherein a front surface of the front flange is shaped to conform to a shape of a rear surface of the root of the propeller. 
     
     
         15 . The rotor of  claim 13 , wherein the rigid insert includes a nut plate for attachment to the root of the propeller. 
     
     
         16 . The rotor of  claim 15 , wherein the front surface of the front flange includes divots around bolt holes in the nut plate to provide an out-of-plane shape to the front surface of the front flange. 
     
     
         17 . The rotor of  claim 13 , wherein the rotor is adapted to receive a driveshaft that is tapered downwardly towards the rear flange. 
     
     
         18 . The rotor of  claim 13 , wherein a locating flange extends rearwardly from the rear flange for sealing engagement with a stator positioned on a main wing of the aerial vehicle. 
     
     
         19 . The rotor of  claim 13 , wherein the rigid insert comprises carbon fiber. 
     
     
         20 . The rotor of  claim 13 , wherein the front flange is mounted to the front end of the can by bonding to a middle flange extending forwardly from the front end of the can. 
     
     
         21 . The rotor of  claim 13 , wherein the front flange has a conical shape as it tapers outwardly from a front surface of the front flange to a rear surface of the front flange.