Carbon Fiber Motor Rotor Integrating Propeller Mount

1 . An aerial vehicle comprising:

a main wing;

a rotor connected to the main wing and a propeller mounted to the rotor;

wherein the rotor comprises:

a front flange;

a can;

a rear flange; and

a rigid insert comprising a propeller mount;

wherein the front flange, can, and rear flange comprise one of carbon fiber and spun aluminum;

wherein a rear end of the front flange is attached to a front end of the can, and the rear flange is mounted to a rear end of the can;

wherein the rigid insert is bonded to the front flange;

wherein the rigid insert comprises a tube that axially extends within the rotor to allow for the positioning of a driveshaft therethrough; and

wherein the rotor has a front surface that is attached to a root of the propeller.

2 . The aerial vehicle of claim 1 , wherein a front surface of the front flange is shaped to conform to a shape of a rear surface of the root of the propeller.

3 . The aerial vehicle of claim 1 , wherein the rigid insert includes a nut plate for attachment to the root of the propeller.

4 . The aerial vehicle of claim 3 , wherein the front surface of the front flange includes divots around bolt holes in the nut plate to provide an out-of-plane shape to the front surface of the front flange.

5 . The aerial vehicle of claim 4 , wherein the tube is tapered downwardly as it extends towards the rear flange.

6 . The aerial vehicle of claim 1 , wherein a locating flange extends rearwardly from the rear flange for sealing engagement with a stator positioned on the main wing.

7 . The aerial vehicle of claim 1 , wherein the rigid insert comprises a metal.

8 . The aerial vehicle of claim 1 , wherein the rigid insert comprises carbon fiber.

9 . The aerial vehicle of claim 1 , wherein the front flange is mounted to the front end of the can by bonding to a middle flange extending forwardly from the front end of the can.

10 . The aerial vehicle of claim 1 , wherein the front flange has a conical shape as it tapers outwardly from a front surface of the front flange to a rear surface of the front flange.

11 . The aerial vehicle of claim 5 , wherein the driveshaft is bonded to or press fit to an inner surface of the can.

12 . The aerial vehicle of claim 10 , wherein the can has a cylindrical outer surface.

13 . A rotor for use with an aerial vehicle wherein the rotor comprises:

a front flange;

a can;

a rear flange; and

a rigid insert comprising a propeller mount;

wherein the front flange, can, and rear flange comprise one of carbon fiber and spun aluminum;

wherein a rear end of the front flange is attached to a front end of the can, and the rear flange is mounted to a rear end of the can;

wherein the rigid insert is bonded to the front flange;

wherein the rigid insert comprises a tube that axially extends within the rotor to allow for the positioning of a driveshaft therethrough; and

wherein the rotor has a front surface that is adapted for attachment to a root of a propeller.

14 . The rotor of claim 13 , wherein a front surface of the front flange is shaped to conform to a shape of a rear surface of the root of the propeller.

15 . The rotor of claim 13 , wherein the rigid insert includes a nut plate for attachment to the root of the propeller.

16 . The rotor of claim 15 , wherein the front surface of the front flange includes divots around bolt holes in the nut plate to provide an out-of-plane shape to the front surface of the front flange.

17 . The rotor of claim 13 , wherein the rotor is adapted to receive a driveshaft that is tapered downwardly towards the rear flange.

18 . The rotor of claim 13 , wherein a locating flange extends rearwardly from the rear flange for sealing engagement with a stator positioned on a main wing of the aerial vehicle.

19 . The rotor of claim 13 , wherein the rigid insert comprises carbon fiber.

20 . The rotor of claim 13 , wherein the front flange is mounted to the front end of the can by bonding to a middle flange extending forwardly from the front end of the can.

21 . The rotor of claim 13 , wherein the front flange has a conical shape as it tapers outwardly from a front surface of the front flange to a rear surface of the front flange.