Patent ID: 8163219

Claim:
A method for molding a helicopter rotor blade wherein said rotor blade includes a spar that extends parallel to the longitudinal axis of said rotor blade, said longitudinal axis extending from the root of said rotor blade to the tip of said rotor blade, said spar having interior surfaces that defines a spar cavity that also extends longitudinally from the root of said rotor blade to the tip of said rotor blade, said spar interior surfaces including a leading edge surface that comprises an upper leading edge portion and a lower leading edge portion, a trailing edge surface that comprises an upper trailing edge portion and a lower trailing edge portion, an upper surface that extends between said leading edge upper portion and said trailing edge upper portion and a lower surface that extends between said leading edge lower portion and said trailing edge lower portion, said method comprising the steps of: A) providing a mandrel that comprises: a forward component that comprises an exterior surface that is shaped to provide said leading edge surface of said spar interior surfaces, said forward component comprising an upper rear edge comprising an outer surface that is shaped to provide said upper leading edge portion and a lower rear edge that is shaped to provide said lower leading edge portion; a rearward component that is shaped to provide said trailing edge surface of said spar interior surfaces, said rearward component comprising an upper forward edge that is shaped to provide said upper trailing edge portion and a lower forward edge that is shaped to provide said lower trailing edge portion; an upper component that is shaped to provide said upper surface of said spar interior surfaces, said upper component comprising a forward edge that is connected to said upper rear edge of said forward component and a rearward edge that is connected to said upper forward edge of said rearward component; a lower component that is shaped to provide said lower surface of said spar interior surfaces, said lower component comprising a forward edge that is connected to said lower rear edge of said forward component and a rearward edge that is connected to said lower forward edge of said rearward component; and a collapsible support structure located between said upper component and said lower component, said support structure being collapsible when a tensioning force is applied to said support structure along the longitudinal axis of said rotor blade, said collapsible support structure comprising corrugated material that comprises ridges which extend substantially perpendicular to said longitudinal axis wherein said ridges are friction fit against the upper and lower components; B) applying uncured composite material to the exterior surface of said mandrel to form an uncured spar; C) collapsing said collapsible support structure; D) removing said mandrel from said spar cavity; and E) curing said uncured spar.