Ultra-Wide-Chord Propeller Tip Geometry for Vortex-Driven Thrust

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Solution Overview

Problem

Existing propeller designs do not effectively maximize thrust generation and efficiency by optimizing blade geometry and vortex formation at the tip region, leading to suboptimal performance and noise levels.

Innovation Solution

A propeller design with blades that feature varying chord lengths and camber percentages, maximizing chord length and camber at the tip region, allowing for efficient formation and utilization of blade tip vortices to enhance thrust and reduce noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If blade chord length is increased to maximize thrust generation, then thrust coefficient increases, but induced drag increases

Engineering Contradiction:

ImprovethrustVSAvoidinduced drag

Core Design Contradiction:

ForceVSLoss of energy

Solution Approach 1:

The patent applies local quality by varying the chord length along the blade span, with maximum chord length specifically at the blade tip region. This localized chord length optimization allows the blade tip to generate maximum thrust while the root region maintains appropriate chord dimensions to control induced drag, resolving the contradiction between thrust generation and energy loss.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements variable blade angle design where the blade angle varies along the span from root to tip, with maximum blade angle at the tip region. This dynamic geometric configuration allows different sections of the blade to operate at optimal angles, maximizing thrust at the tip while maintaining efficient flow characteristics that reduce induced drag overall.

Inventive Principle:

Principle #15Dynamics

2Force

If blade tip vortex strength is increased to enhance thrust, then thrust coefficient increases, but noise increases

Engineering Contradiction:

ImprovethrustVSAvoidnoise

Core Design Contradiction:

ForceVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful effect of strong blade tip vortices into a beneficial thrust-generating mechanism. By designing maximum camber and chord length at the blade tip, the strong vortices that would normally cause noise are instead harnessed to enhance mass flow and thrust coefficient, transforming the harmful vortex into a useful propulsive force.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the geometric parameters (chord length and camber) specifically at the blade tip region to optimize vortex formation. By increasing chord length and camber at the tip, the vortex strength is enhanced to improve thrust while the specific geometric configuration controls the vortex structure to minimize noise generation.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If blade camber is increased at tip region to maximize mass flow, then efficiency increases, but manufacturing complexity increases

Engineering Contradiction:

Improvemass flowVSAvoidblade fabrication

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by specifying maximum camber specifically at the blade tip region rather than uniformly across the entire blade. This localized camber optimization enhances mass flow and efficiency at the critical tip area where vortex formation occurs, while the root and intermediate sections maintain simpler geometries that are easier to manufacture.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the blade into distinct regions (root, intermediate, and tip sections) with different geometric characteristics. The tip region is segmented to have maximum camber and chord length for optimized mass flow, while other sections have progressively different geometries, allowing differential optimization of performance and manufacturability across the blade span.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design results in increased thrust and efficiency by smoothly transitioning blade tip vortices into an axial direction, minimizing their strength and noise, while maximizing mass flow and thrust coefficient.

Implementation Method 1

efficient formation and utilization of blade tip vortices to enhance thrust and reduce noise... smoothly transitioning blade tip vortices into an axial direction, minimizing their strength and noise

Methodology Applied

Scientific EffectVortex formation and transition: Vortex Ring

Implementation Method 2

propellers can be used to convert rotational motion into thrust... rotatable about the central axis of rotation by the central hub to generate a backward airflow

Methodology Applied

Scientific EffectAerodynamic thrust generation: Aerofoil

Data Source

PatentUS12503218B2Ultra-wide-chord propeller including varying blade angle

Publication Date: 2025.12.23 SKYDIO INC

AI summary

The propeller described herein may increase the pressure differential to be generated at/near a blade tip and, at least in some embodiments, to allow for the greatest pressure differential to be generated at/near the blade tip. Increasing the pressure differential in the blade tip region may promote formation of blade tip vortices when the propeller is in use. The propeller may utilize these blade tip vortices as effective mass flow, which can contribute to the thrust force generated by the propeller. That is, by designing the propeller to form and utilize blade tip vortices, the mass flow of air over the blades may be increased, thereby increasing the amount of thrust generated by the propeller.