Propeller blade with lightweight insert

Abstract

A propeller blade includes a foam core and a structural layer that surrounds at least a portion of the foam core and includes a face side and a camber side is disclosed. The propeller blade also includes a bulkhead disposed in the foam core in operable contact with the face side and the camber side of the structural layer and extending in a chord wise direction of the propeller blade.

1 . A propeller blade comprising:
 a foam core;   a structural layer that surrounds at least a portion of the foam core and includes a face side and a camber side; and   a bulkhead disposed in the foam core in operable contact with the face side and the camber side of the structural layer and extending in a chord wise direction of the propeller blade.   
     
     
         2 . The propeller blade of  claim 1 , further comprising:
 a layer of fiberglass or carbon at least partially disposed between the foam core and the structural layer.   
     
     
         3 . The propeller blade of  claim 1 , wherein the insert includes a camber component and two camber to face components extending therefrom. 
     
     
         4 . The propeller blade of  claim 3 , wherein the insert further includes another camber component that connects the camber to face components and is separate from the connecting member. 
     
     
         5 . The propeller blade of  claim 3 , wherein the connecting member is located at ends of one or both of the camber to face components. 
     
     
         6 . The propeller blade of  claim 3 , wherein the connecting member is located at a location that is not at an end of one or both of the face component and the camber component. 
     
     
         7 . The propeller blade of  claim 3 , wherein the connecting member is substantially perpendicular to the one or both of the face component and the camber component. 
     
     
         8 . The propeller blade of  claim 1 , further comprising:
 a root disposed within the structural layer at an end of the propeller blade.   
     
     
         9 . The propeller blade of  claim 8 , wherein a void exists between an end of the root and an end of the foam core. 
     
     
         10 . The propeller blade of  claim 9 , wherein the end of the foam core is closer than an end of the insert to the end of the root. 
     
     
         11 . The propeller blade of  claim 1 , wherein the foam core is formed of one or more of: polyurethane (PU), polyisocyanurate, and polymethacrylimide (PMI). 
     
     
         12 . The propeller blade of  claim 1 , wherein the structural layer is formed of a resin-impregnated fiber material. 
     
     
         13 . The propeller blade of  claim 1 , wherein the bulkhead is formed of one of: fiberglass, carbon, or a combination thereof. 
     
     
         14 . The propeller blade of  claim 1 , wherein the bulkhead is formed of a composite material. 
     
     
         15 . The propeller blade of  claim 1 , further comprising:
 another bulkhead disposed in the foam core in a different location than the bulkhead and in operable contact with the face side and the camber side of the structural layer and extending in a chord wise direction of the propeller blade.   
     
     
         16 . A method of forming a propeller blade comprising:
 providing a mold;   disposing a bulkhead in a chord wise direction of the mold;   forming a foam core; and   forming a structural layer that surround the foam core and includes a face side and a camber side such that the face side and the camber side are in operable contact with the bulkhead.   
     
     
         17 . The method of  claim 16 , wherein the foam core is formed after the bulkhead has been disposed in the mold. 
     
     
         18 . The method of  claim 16 , further comprising:
 coupling a root to the foam core;   wherein forming a structural layer includes disposing the structural layer over at least a portion of the root.   
     
     
         19 . The method of  claim 15 , further comprising:
 removing a portion of the foam core between an end of the root and an end of the insert after the structural layer has been formed.   
     
     
         20 . The method of  claim 15 , wherein forming the foam core includes:
 machining the foam core at a location outside of the mold; and   disposing the foam core in the mold.