Fan blade reinforcement using bonded hollow spheres

A method of forming a fan blade utilizing a preformed mold and comprising

• inserting into the cavity of said mold until full a plurality of closely packed rigid hollow spheres, all being approximately the same size;
• inserting into said mold an adhesive matrix material, filling interstices between said spheres contained in said mold;
• implementing curing of matrix material by suitable means;
• bonding said spheres, one to another;
• and separating said blade from said mold;
• thereby forming a lightweight, reinforced fan blade.

A method of reinforcement comprising of providing a plurality of closely packed rigid hollow spheres, all being approximately the same size;

• inserting an adhesive matrix material into the open interstices adjacent to points of contact between said spheres;
• curling of matrix material by suitable means;
• thus bonding said spheres, one to another;
• thereby providing a lightweight, high strength reinforcement.

A method of reinforcement comprising of

• providing a plurality of closely packed rigid hollow spheres, all being approximately the same size;
• blending said spheres with a matrix material, forming a homogeneous mixture prior to insertion into a preformed hollow shape;
• inserting said homogeneous mixture into said preformed hollow shape;
• and
• curing of matrix material by suitable means, thus bonding said spheres, one to another.