Composite fiber reinforced propeller

Claim 1

A method of making a lightweight fiber reinforced propeller having a hub and at least two blades integrally attached to the hub and extending outwardly therefrom, the steps including: winding a reinforcing fiber around a first blade tip mandrel. the first mandrel positioned beyond the end of the tip of the first blade to be reinforced; winding the fiber around a portion of a circumferences of an annular shaped central mandrel, the central mandrel positioned where the propeller hub is to be formed; winding the fiber around a second blade tip mandrel, the second mandrel positioned beyond the end of the tip of the second blade to be reinforced; repeating the above three steps until sufficient fiber is received on the mandrels for the required strength of the propeller; placing the reinforcing fiber and the central mandrel between split halves of an injection mold, the mold having cavities therein for forming the propeller hub and blades; pouring the injection molding material into the mold for forming the propeller therein and curing the injection molding material and removing the fiber reinforced propeller therefrom during said winding steps said first and second mandrels being substantially parallel to said central mandrel and during said placing step rotating said first and second mandrels so as to be substantially perpendicular to said central mandrel.

Claim 2

A method of making a lightweight fiber reinforced propeller having a hub and at least two blades integrally attached to the hub and extending outwardly therefrom, the steps including: winding a reinforcing fiber around a first blade tip mandrel. the first mandrel positioned beyond the end of the tip of the first blade to be reinforced; winding the fiber around a portion of a circumferences of an annular shaped central mandrel, the central mandrel positioned where the propeller hub is to be formed; winding the fiber around a second blade tip mandrel, the second mandrel positioned beyond the end of the tip of the second blade to be reinforced; repeating the above three steps until sufficient fiber is received on the mandrels for the required strength of the propeller; placing the reinforcing fiber and the central mandrel between split halves of an injection mold, the mold having cavities therein for forming the propeller hub and blades; pouring the injection molding material into the mold for forming the propeller therein and curing the injection molding material and removing the fiber reinforced propeller therefrom during said winding steps said first and second mandrels being substantially parallel to said central mandrel and during said placing step rotating said first and second mandrels so as to be substantially perpendicular to said central mandrel.

Claim 6

A method of making a lightweight fiber reinforced propeller having a hub and at least two blades integrally attached to the hub and extending outwardly therefrom, the steps including: winding a reinforcing fiber around a first balde tip mandrel, the first mandrel positioned beyond the end of the tip of the first blade to be reinforced; winding the fiber around a portion of a circumference of an annular shaped central mandrel, the central mandrel positioned where the propeller hub is to be formed; winding the fiber around a second blade tip mandrel, the second mandrel positioned beyond the end of the tip of the second blade to be reinforced; repeating the above three steps until sufficient fiber is received in a spaced relationship from each other on the mandrels for providing the required strength of the propeller; rotating the first and second mandrels so the fiber is placed in the proper blade tip angle of attack; placing the reinforcing fiber and central mandrel between split halves of an injection old, the mold having cavities therein for forming the propeller hub and the blades; pouring the injection molding material into the mold for forming the propeller therein and curing the injection molding material and removing the fiber reinforced propeller therefrom; during said winding steps said first and second mandrels being substantially parallel to said central mandrel and the fibers being placed in the mold at said proper angle.

Claim 7

A method of making a lightweight fiber reinforced propeller having a hub and at least two blades integrally attached to the hub and extending outwardly therefrom, the steps including: winding a reinforcing fiber around a first balde tip mandrel, the first mandrel positioned beyond the end of the tip of the first blade to be reinforced; winding the fiber around a portion of a circumference of an annular shaped central mandrel, the central mandrel positioned where the propeller hub is to be formed; winding the fiber around a second blade tip mandrel, the second mandrel positioned beyond the end of the tip of the second blade to be reinforced; repeating the above three steps until sufficient fiber is received in a spaced relationship from each other on the mandrels for providing the required strength of the propeller; rotating the first and second mandrels so the fiber is placed in the proper blade tip angle of attack; placing the reinforcing fiber and central mandrel between split halves of an injection old, the mold having cavities therein for forming the propeller hub and the blades; pouring the injection molding material into the mold for forming the propeller therein and curing the injection molding material and removing the fiber reinforced propeller therefrom; during said winding steps said first and second mandrels being substantially parallel to said central mandrel and the fibers being placed in the mold at said proper angle.