Low inertia laminated rotor

Abstract

A rotor assembly having a plurality of rotor plates mounted to a shaft, and methods of construction for a rotor assembly are disclosed. Each rotor plate in the assembly may be provided with a central opening extending between the first and second sides through which the shaft extends. In one aspect, the rotor plates are provided with a plurality of lobes extending away from the central opening, wherein each of the lobes has a lobe opening extending through the thickness of the plates. In one embodiment, the rotor plates are rotationally stacked to form a helical rotor.

1 .- 21 . (canceled) 
     
     
         21 . A rotor assembly comprising:
 a. a plurality of metal rotor plates, each including:
 i. a first side and a second opposite side separated by a first thickness; 
 ii. a central opening extending between the first and second sides; 
 iii. a plurality of lobes extending away from the central opening, 
 iv. wherein the lobes of at least some of the plurality of rotor plates has a lobe opening extending between the first and second sides; and 
   b. a shaft extending through the central opening of each of the plurality of rotor plates;   c. wherein the plurality of rotor plates are stacked and secured together to form the rotor assembly such that at least one of the first and second sides of one rotor plate is adjacent to and in contact with at least one of the first and second sides of another rotor plate and such that the rotor plates are secured together at multiple locations about an outer perimeter of each rotor plate.   
     
     
         22 . The rotor assembly of  claim 21 , wherein the rotor plates are rotated with respect to each other to form a helical rotor. 
     
     
         23 . The rotor assembly of  claim 21 , wherein the plurality of rotor plates are secured together at least at tips of each rotor plate lobe. 
     
     
         24 . The rotor assembly of  claim 23 , wherein each of the plurality of lobes of each of the plurality of rotor plates is secured together at least at three locations. 
     
     
         25 . The rotor assembly of  claim 22 , wherein the helical rotor has an overall length that is generally equal to the sum of the first thicknesses of the plurality of stacked rotor plates. 
     
     
         26 . The rotor assembly of  claim 21 , wherein the rotor plates are secured together by welding. 
     
     
         27 . The rotor assembly of  claim 21 , wherein the metal rotor plates are stamped sheet metal rotor plates. 
     
     
         28 . The rotor assembly of  claim 21 , further including an abradable coating covering the outer perimeter of each of the plurality of rotor plates. 
     
     
         29 . A rotor assembly comprising:
 a. a plurality of stamped sheet metal rotor plates, each including:
 i. a first side and a second opposite side separated by a first thickness; 
 ii. a central opening extending between the first and second sides; 
 iii. a plurality of lobes extending away from the central opening, 
 iv. wherein the lobes of at least some of the plurality of rotor plates has a lobe opening extending between the first and second sides; and 
   b. a shaft extending through the central opening of each of the plurality of rotor plates;   c. wherein the plurality of rotor plates are stacked and secured together to form the rotor assembly such that at least one of the first and second sides of one rotor plate is adjacent to and in contact with at least one of the first and second sides of another rotor plate.   
     
     
         30 . The rotor assembly of  claim 21 , wherein the rotor plates are rotated with respect to each other to form a helical rotor. 
     
     
         31 . The rotor assembly of  claim 21 , wherein the rotor plates are secured together secured together at multiple locations about an outer perimeter of each rotor plate. 
     
     
         32 . The rotor assembly of  claim 21 , further including an abradable coating covering the outer perimeter of each of the plurality of rotor plates. 
     
     
         33 . The rotor assembly of  claim 21 , wherein the plurality of stamped sheet metal rotor plates are steel metal rotor plates. 
     
     
         34 . A rotor assembly comprising:
 a. a plurality of metal rotor plates, each including:
 i. a first side and a second opposite side separated by a first thickness; 
 ii. a central opening extending between the first and second sides; 
 iii. a plurality of lobes extending away from the central opening, 
 iv. wherein the lobes of at least some of the plurality of rotor plates has a lobe opening extending between the first and second sides; 
   b. an abradable coating covering an outer perimeter of each of the plurality of metal rotor plates; and   c. a shaft extending through the central opening of each of the plurality of rotor plates;   d. wherein the plurality of rotor plates are stacked and secured together to form the rotor assembly such that at least one of the first and second sides of one rotor plate is adjacent to and in contact with at least one of the first and second sides of another rotor plate.   
     
     
         35 . The rotor assembly of  claim 21 , wherein the rotor plates are rotated with respect to each other to form a helical rotor. 
     
     
         36 . The rotor assembly of  claim 21 , wherein the rotor plates are secured together secured together at multiple locations about an outer perimeter of each rotor plate. 
     
     
         37 . The rotor assembly of  claim 21 , wherein the metal rotor plates are stamped sheet metal rotor plates. 
     
     
         38 . A rotor assembly comprising:
 a. a plurality of metal rotor plates, each including:
 i. a first side and a second opposite side separated by a first thickness; 
 ii. a central opening extending between the first and second sides; 
 iii. a plurality of lobes extending away from the central opening, each of the plurality of lobes having a convex outline and being separated by a root portion having a concave outline, wherein the convex outline includes a flat tip section at a distal end of each of the plurality of lobes; and 
   b. an abradable coating covering an outer perimeter of each of the plurality of metal rotor plates; and   c. a shaft extending through the central opening of each of the plurality of rotor plates;   d. wherein the plurality of rotor plates are stacked and secured together to form the rotor assembly such that at least one of the first and second sides of one rotor plate is adjacent to and in contact with at least one of the first and second sides of another rotor plate.   
     
     
         39 . The rotor assembly of  claim 38 , wherein a plurality of the lobes has a lobe opening extending between the first and second sides. 
     
     
         40 . The rotor assembly of  claim 39 , wherein each lobe opening has an outer perimeter generally following the convex outline of the lobe.