Propeller blade with lightweight insert and bulkheads

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 an insert disposed in the foam core in operable contact with the face side and the camber side of the structural layer and one or more bulkheads disposed in the form core and oriented normal to the insert.

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;   an insert disposed in the foam core in operable contact with the face side and the camber side of the structural layer; and   one or more bulkheads disposed in the form core and oriented normal to the insert.   
     
     
         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 face component and a camber component connected by a connecting member. 
     
     
         4 . The propeller blade of  claim 3 , wherein the insert further includes another connecting member that connects the face component and the camber component 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 face component and the camber component. 
     
     
         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 , wherein the foam core is formed of one or more of: polyurethane (PU), polyisocyanurate, and polymethacrylimide (PMI). 
     
     
         9 . The propeller blade of  claim 1 , wherein the structural layer is formed of a resin-impregnated fiber material. 
     
     
         10 . The propeller blade of  claim 1 , wherein the insert is formed of one of:
 fiberglass, carbon, or a combination thereof.   
     
     
         11 . The propeller blade of  claim 1 , wherein the insert is formed of a composite material. 
     
     
         12 . The propeller blade of  claim 1 , wherein the bulkhead includes a face component and a camber component connected by a connecting member. 
     
     
         13 . The propeller blade of  claim 12 , wherein the bulkhead further includes another connecting member that connects the face component and the camber component and is separate from the connecting member. 
     
     
         14 . The propeller blade of  claim 12 , wherein the connecting member is located at ends of one or both of the face component and the camber component. 
     
     
         15 . The propeller blade of  claim 12 , 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. 
     
     
         16 . A method of forming a propeller blade comprising:
 providing a mold;   disposing an insert in the mold;   disposing a first bulkhead near an end of the insert and oriented normal to the insert;   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 insert and the bulkhead.   
     
     
         17 . The method of  claim 16 , further comprising:
 disposing a second bulkhead near another end of the insert and oriented normal to the insert.