Composite rotors and methods of making composite rotors

A method of making a composite rotor, comprising,

• placing a first grouping of composite filaments and/or composite tape on a first mandrel of a first diameter in a first direction relative to an axis of the first mandrel;
• placing a second grouping of composite filaments and/or composite tape on the first mandrel in a second direction relative to the axis of the first mandrel, the second direction being different from the first direction to form a first rotor portion having a first u-shape in radial cross-section having a first straight section, a second straight section, and a rounded section extending between the first and second straight sections;
• cutting the first rotor portion along a cut line perpendicular to the axis of the first mandrel into a first rotor portion first half and a first rotor portion second half and removing the first mandrel from the first rotor portion to form the first rotor portion;
• placing a third grouping of composite filaments and/or composite tape on a second mandrel of a second diameter in a first direction relative to an axis of the second mandrel;
• placing a fourth grouping of composite filaments and/or composite tape on the second mandrel in a second direction relative to the axis of the second mandrel, the second direction being different from the first direction to from a second rotor portion having a second u-shape in radial cross-section having a first straight section, a second straight section, and a rounded section extending between the first and second straight sections;
• cutting the second rotor portion along a cut line perpendicular to the axis of the second mandrel into a second rotor portion first half and a second rotor portion second half and removing the second mandrel from the second rotor portion;
• and
• inserting the second rotor portion first half into the first rotor portion first half such that the rounded section of the second rotor portion sits within the rounded section of the first rotor portion.

A composite rotor, comprising:

• a first rotor portion defining a first rotational axis and having a first magnet therein;
• a second rotor portion defining a second rotational axis and having a second magnet therein, wherein the first rotor portion and the second rotor portion are comprised of composite filaments and/or composite tape;
• and
• a stator portion disposed radially between the first rotor portion and the second rotor portion,
• wherein the first rotor portion defines a first u-shape in radial cross-section having a first straight section a second straight section, and a rounded section extending between the first and second straight sections,
• wherein the second rotor portion defines a second u-shape in radial cross-section having a first straight section, a second straight section and a rounded section extending between the first and second straight sections, and
• wherein the second rotor portion is disposed with the first rotor portion such that the rounded section of the second rotor portion sits within the rounded section of the first rotor portion, and wherein a third magnet is disposed between the rounded section of the first rotor portion and the stator portion.