Composite propeller spar

A method for manufacturing a composite structure, the method comprising:

• forming a composite spar comprising a root section and a main section comprising an open channel along a length of the composite spar via:
• laying up a first type of layers comprising a first number of weave plies comprising composite material;
• laying up a group of second type of layers of composite material on the first number of weave plies;
• laying up a second number of weave plies on the second type of layers;
• forming the root section of the composite spar via the group of second type of layers of composite material filling the open channel at the root section to form a closed wedge shape for the root section, and maintaining the channel in the main section.via a number of groups of second type of layers of composite material increasing a thickness of a cap, a first flange, and a second flange for the composite spar in the root section and folding over the first number of weave plies after the second number of weave plies are laid up, wherein the first number of weave plies are folded over in a reverse order from an order in which the first number of weave plies was laid up;
• and
• repeating the steps of laying up the first number of weave plies comprising composite material for the composite spar and laying up the group of second type of layers of composite material for the composite spar until a plurality of layers of composite material for the composite spar is complete, wherein the root section has a shape configured to be connected to a blade retention system.

A method for operating a vehicle, the method comprising:

• rotating a propeller with blades;
• forming a composite spar comprising a root section and a main section comprising an open channel along a length of the composite spar via:
• laying up a first type of layers comprising a first number of weave plies comprising composite material;
• laying up a group of second type of layers of composite material on the first number of weave plies;
• laying up a second number of weave plies on the second type of layers;
• forming the root section of the composite spar via the group of second type of layers of composite material filling the open channel at the root section to form a closed wedge shape for the root section, and maintaining the channel in the main section.via a number of groups of second type of layers of composite material increasing a thickness of a cap, a first flange, and a second flange for the composite spar in the root section and folding over the first number of weave plies after the second number of weave plies are laid up, wherein the first number of weave plies are folded over in a reverse order from an order in which the first number of weave plies was laid up;
• repeating the steps of laying up the first number of weave plies comprising composite material for the composite spar and laying up the group of second type of layers of composite material for the composite spar until a plurality of layers of composite material for the composite spar is complete;
• and
• retaining a blade of the blades through the root section of a spar in the blade of the blades being retained to a blade retention system, wherein the root section is shaped and configured to be retained within a corresponding shape for the blade retention system entirely by the shape of the root section and the corresponding shape of the blade retention system.

A blade system comprising:

• a blade having a root section shaped and configured to be retained within a correspondingly shaped blade retention system entirely by a shape of the root section and a corresponding shape of the blade retention system, such that the root section comprises:
• a central group of composite material layers configured as a central axis of a wedge, the central group of composite material layers encircled by a layer that comprises a first number of weave plies, such that after a first ply in the first number of weave plies wraps around the central group, a first end of each ply of the first number of weave plies overlaps a second end of each ply of the first number of weave plies;
• a second group of composite material layers set around the first number of weave plies;
• additional alternating layers of additional weave plies such that each additional layer of weave plies wraps around an immediately interior second group of composite material layers that set around an immediately interior layer of additional weave plies until a final layer of weave plies forms an outer layer of the root section, such that after a first ply in the final layer of weave plies wraps around the immediately interior group of composite material, a first end of each ply of the final layer of weave plies overlaps a second end of each ply of the final layer of weave plies, and the root section comprises layers that form a wedge shape, such that a compilation of the groups of composite material layers extend from the root section and increase a thickness of a cap, a first flange, and a second flange, of a main section of a spar in the blade, and fills a channel in the main section at the root section.