Collapsible flying device

Abstract

A foldable flight device is provided, comprising: a housing including a first housing portion and a second housing portion forming an enclosed space; and a motor drive assembly including a drive motor and a drive shaft driven by the drive motor. The drive shaft receives the first housing portion and is coupled to the second housing portion, wherein operation of the drive motor drives the drive shaft to move the first housing portion from a closed position adjacent to the second housing portion to an open position spaced apart from the second housing portion. A rotor hub is rotatably driven by the drive motor. When the first housing portion is in the closed position, at least two rotor blades are coupled thereto and positioned within the enclosed space in a folded position, and when the first housing portion is in the open position, at least two rotor blades extend beyond the enclosed space in an extended position.

Description

[0001] This application is a divisional application of the invention application filed with the State Intellectual Property Office on June 25, 2018, entitled "Foldable Flying Device", with application number 201810660168.3. Technical Field

[0002] This application generally relates to flight devices. Specifically, it relates to a foldable flight device. Summary of the Invention

[0003] In one aspect, a foldable flight device is provided, the flight device comprising: a housing having a first housing portion and a second housing portion forming an enclosed space with the first housing portion; and a motor drive assembly having: a drive motor device including at least one drive motor; a drive shaft driven by the drive motor device, the drive shaft receiving the first housing portion and coupled to the second housing portion, wherein operation of the drive motor device drives the drive shaft to move the first housing portion from a closed position adjacent to the second housing portion to an open position spaced apart from the second housing portion; a rotor hub rotatably driven by the drive motor device; and at least two rotor blades coupled to the rotor hub, wherein when the first housing portion is in the closed position, the at least two rotor blades are located within the enclosed space in a folded position, and when the first housing portion is in the open position, the at least two rotor blades extend beyond the enclosed space in an extended position, the at least two rotor blades being rotated by the drive motor device to provide lift to the foldable flight device.

[0004] The foldable flight device may further have a shell rotation limiting structure coupled to a first shell portion and a second shell portion, and prevent the first shell portion from rotating relative to the second shell portion about the rotation axis of a drive shaft, wherein the drive shaft has a threaded portion and the first shell portion has a complementary threaded portion, such that rotation of the drive shaft causes the first shell portion to move relative to the second shell portion along the rotation axis.

[0005] The drive motor device may include a drive motor.

[0006] The foldable flight device may further have a motor rotation limiting structure connected to the second housing portion and the drive motor, preventing the drive motor from rotating relative to the second housing portion about the rotation axis of the drive shaft. A rotor hub may be mounted on the drive shaft.

[0007] At least one of the drive shaft and the first housing portion may have a threadless portion, wherein the drive shaft can rotate freely relative to the first housing portion when one of the threaded portions on the drive shaft and the threaded portions on the first housing portion is axially positioned on the threadless portion.

[0008] The foldable flight device may further include a retainer feature that restricts the first housing portion and the second housing portion from axial separation relative to the axis of rotation of the drive shaft.

[0009] The foldable flight device may further include a biasing member that, when the unthreaded portion is axially positioned on one of the threaded portions of the drive shaft and the threaded portion of the first housing portion, axially biases the first housing portion toward the second housing portion.

[0010] The drive shaft may be a first drive shaft, and the foldable flight device may further include a second drive shaft that is rotatably driven in a second rotational direction opposite to the first rotational direction, while the first drive shaft is simultaneously driven by a drive motor in the first rotational direction; and at least two rotor blades that are coupled to the second drive shaft and rotate together with the second drive shaft.

[0011] The second housing portion may have complementary threaded portions, such that rotation of the drive shaft causes the second housing portion to translate relative to the drive shaft along the axis of rotation. At least one of the drive shaft and the first housing portion may have a first unthreaded portion, and at least one of the drive shaft and the second housing portion may have a second unthreaded portion, wherein the drive shaft is freely rotatable relative to the first and second housing portions when one of the threaded portions on the drive shaft and the first housing portion is axially positioned on the first unthreaded portion, and when one of the threaded portions on the drive shaft and the second housing portion is axially positioned on the second unthreaded portion. The foldable flight device may further include a retainer feature that restricts the first and second housing portions from axially separating relative to the axis of rotation of the drive shaft.

[0012] On the other hand, a foldable flight device is provided, the foldable flight device comprising: a drive motor; a drive shaft driven rotatably by the drive motor; a rotor hub extending from the drive shaft to be rotated together with the drive shaft by the drive motor; and at least two rotor blades coupled to the rotor hub such that each of the at least two rotor blades is pivotable through a pivot range between a folded position of the rotor blade oriented toward the rotor hub and an extended position of the rotor blade away from the rotor hub orientation, wherein each of the at least two rotor blades is stable in both the folded and extended positions when the drive shaft rotates at a constant rotational speed.

[0013] The foldable flight device may further include at least one biasing element coupled to the at least two rotor blades, which biases the at least two rotor blades toward the folded position when the at least two rotor blades are in a first portion of a pivot range adjacent to the folded position, and biases the at least two rotor blades toward the extended position when the at least two rotor blades are in a second portion of a pivot range adjacent to the extended position.

[0014] Each of the at least one biasing element may be an elastic member connected to a bias point on one of the at least two rotor blades and a corresponding base point on the rotor hub, wherein the distance between the corresponding base point and the bias point has a local maximum value when one of the at least two rotor blades is between the first and second portions of the pivot range. The elastic member may be a tension spring.

[0015] The foldable flight device may further include a controller for controlling the operation of the drive motor, wherein, when the at least two rotor blades are in the extended position, the controller sufficiently accelerates the rotation of the drive shaft and the rotor hub in a rotational direction to cause each of the at least two rotor blades to pivot toward the folded position and exceed the local maximum value, so that the at least two rotor blades are biased toward the folded position by means of the elastic member. This rotational direction may be a first rotational direction, and the controller may sufficiently accelerate the rotation of the drive shaft and the rotor hub in a second rotational direction opposite to the first rotational direction, so that each of the at least two rotor blades pivots toward the extended position and exceeds the local maximum value, so that the at least two rotor blades are biased toward the extended position by means of the elastic member. Attached Figure Description

[0016] To better understand the various embodiments described herein and to more clearly illustrate how they can be implemented, reference will now be made to the accompanying drawings, which are shown by way of example only:

[0017] Figure 1 This is a side view of the foldable flight device in a folded state according to one embodiment;

[0018] Figure 2 yes Figure 1 A side view of the foldable flight device in its extended state; and

[0019] Figure 3 yes Figure 1 and Figure 2 A sectional view of the motor drive assembly of the foldable flight device shown; and

[0020] Figure 4 Show Figure 3 A partial cross-sectional view of the motor drive assembly shown, in a partially folded-back state;

[0021] Figure 5A Show Figure 3 The side view shown shows the motor drive assembly in a partially extended state inside the housing, with a portion of the housing removed.

[0022] Figure 5B Show Figure 3 The motor drive assembly shown is in a partially extended state, top perspective view;

[0023] Figure 6 Show Figure 3 A partial cross-sectional view of the motor drive assembly in an extended state.

[0024] Figure 7A yes Figures 1 to 6 A plan view of one rotor blade in the folded position relative to the upper rotor hub of the foldable flight device.

[0025] Figure 7B This shows the position after the rotor blades pivot to a point where the distance between the anchor hooks on the upper rotor hub and the anchor hooks on the rotor blades reaches a local maximum. Figure 7A The rotor blades shown;

[0026] Figure 7C This shows the rotor blades after they have pivoted to an extended position in which they are oriented away from the upper rotor hub. Figure 7A and Figure 7B The rotor blades shown; and

[0027] Figure 8 Show Figure 3The image shows a top perspective view of the motor drive assembly in an extended position. Detailed Implementation

[0028] For the sake of simplicity and clarity, reference numerals may be repeated in the accompanying drawings to indicate corresponding or similar elements where deemed appropriate. Furthermore, numerous specific details are set forth to provide a thorough understanding of the embodiments described herein. However, those skilled in the art will understand that the embodiments described herein can be practiced without these specific details. In other instances, well-known methods, processes, and components have not been described in detail so as not to obscure the embodiments described herein. Moreover, this description is not intended to limit the scope of the embodiments described herein.

[0029] Unless the context otherwise indicates, the various terms used throughout this specification may be read and understood as follows: “or” as used throughout is inclusive, as written as “and / or”; singular articles and pronouns as used throughout include their plural forms, and vice versa; similarly, gender pronouns include their corresponding pronouns, and therefore the pronouns should not be construed as limiting any use, implementation, and performance described herein by a single gender; “exemplary” should be understood as “illustrative” or “exemplary”, and not necessarily as “preferred” over other embodiments. Further definitions of terms may be set forth herein; these may apply to prior and subsequent examples of those terms, as will be understood from reading this specification.

[0030] Any module, unit, component, server, computer, terminal, engine, or device executing instructions illustrated herein may include or otherwise access computer-readable media, such as storage media, computer storage media, or data storage devices (removable and / or non-removable), such as magnetic disks, optical disks, or magnetic tapes. Computer storage media may include volatile and non-volatile, removable and non-removable media implemented using any method or technology for storing information such as computer-readable instructions, data structures, program modules, or other data. Examples of computer storage media include RAM, ROM, EEPROM, flash memory or other storage technologies, CD-ROM, digital versatile disc (DVD) or other optical storage devices, cassette tape, magnetic tape, disk storage devices or other magnetic storage devices, or any other medium that can be used to store desired information and is accessible by an application, module, or both. Any such computer storage media may be part of a device or accessible from or connected to that device. Furthermore, unless the context clearly indicates otherwise, any processor or controller described herein may be implemented as a single processor or multiple processors. Multiple processors may be arranged in an array or distributed, and any processing function mentioned herein may be executed by one or more processors, even if a single processor is used as an example. Any method, application, or module described herein may be implemented using computer-readable / executable instructions, which may be stored or otherwise preserved by such computer-readable medium and executed by one or more processors.

[0031] According to one embodiment, the foldable flight device 20 is... Figure 1 As shown in the figure, the foldable flight device 20 has a slightly oval-shaped shell 24, which is formed by an upper shell portion 28 having an upper outer shell 30 and a lower shell portion 32 having a lower outer shell 34, the shell portions being shown in a folded state, wherein the upper shell portion 28 is in a closed position relative to and abuts the lower shell portion 32. The upper shell portion 28 and the lower shell portion 32 are formed of any suitable elastic material (such as plastic). As shown, the upper shell portion 28 and the lower shell portion 32 mate to generally seal around a sealing line 36. The upper shell portion 28 and the lower shell portion 32 are generally hollow and define an enclosed space between them. The upper shell portion 28 and the lower shell portion 32 may be decorated to provide a particular appearance, such as a person, animal, or object. In a particular embodiment, the upper shell portion 28 and the lower shell portion 32 are decorated so that the foldable flight device has the appearance of a bird, particularly an owl.

[0032] Figure 2A foldable flight device 20 in an extended state is shown, wherein a first housing portion 28 is in an open position relative to a lower housing portion 32, with the upper housing portion 28 spaced apart from the lower housing portion 32 to open an enclosed space defined therebetween. The open housing 24 exposes a motor drive assembly 40 extending from the enclosed space to the outside of the housing 24. When the housing 24 is in the folded state, the motor drive assembly 40 is folded and enclosed within the enclosed space, in which the upper housing portion engages with the lower housing portion 32, as shown... Figure 1 As shown, however, the motor drive assembly 40 extends to Figure 2 The stretched state shown in the figure.

[0033] The motor drive assembly 40 includes an upper rotor assembly 44 and a lower rotor assembly 48. The upper rotor assembly 44 includes a set of upper rotor blades 52, and the lower rotor assembly 48 includes a set of lower rotor blades 56. Furthermore, a stabilizer bar assembly 60 is used to stabilize the upper rotor assembly 44. It should be understood that when the retractable flight device 20 is in the extended state, the sets of upper rotor blades 52 and lower rotor blades 56, as well as the stabilizer bar of the stabilizer bar assembly 60, extend from the housing 24 to provide lift to the retractable flight device 20. Lift is provided by the rotation of the upper rotor assembly 44 in a first rotational direction and the rotation of the second rotor assembly 48 in a second rotational direction, in response to the torque acting on the upper rotor assembly 44.

[0034] The motor drive assembly 40 manages the extension and retraction of the motor drive assembly 40 and thus the extension and retraction of the flight device 20. Specifically, the motor drive assembly 40 controls the opening and closing of the housing 24 by separating the upper housing portion 28 from the lower housing portion 32, as will be explained below. Additionally, the motor drive assembly 40 controls the extension and retraction of the upper rotor assembly 44 and the lower rotor assembly 48, as well as their rotation for generating lift, also as will be explained below.

[0035] Figure 3 The diagram shows a motor drive assembly 40 used in the foldable flight device 20, as well as elements of the upper and lower housing portions. The upper housing portion 28 includes an upper threaded rod 104 with a rod cap 108 for securing the upper threaded rod 104 to the upper housing 30 via epoxy resin or other suitable adhesive or interlocking mechanism. The upper threaded rod 104 has a threaded portion 112 and terminates in an unthreaded portion 116.

[0036] The upper threaded rod 104 is received within a drive shaft, which takes the form of the upper rotor shaft 120 of the motor drive assembly 40. The upper rotor shaft 120 acts as a drive shaft for driving the housing 24 and the retraction and extension of the upper rotor blades 52 and lower rotor blades 56, as well as driving the rotation of the upper rotor blades 52 and lower rotor blades 56. The upper rotor shaft 120 has an internal through-hole 124 coaxial with the axis of rotation, which is the central longitudinal axis LA of the upper rotor shaft 120. The threads of the threaded portion of the upper rotor shaft 120 within the internal through-hole 124 are complementary to the threads of the threaded portion 112 of the upper threaded rod 104.

[0037] An upper rotor assembly 44 is mounted on an upper rotor shaft 120. The upper rotor assembly 44 includes an upper rotor hub 132 with a central through-hole, the diameter of which is larger than the outer diameter of the upper rotor shaft 120, in which the upper rotor shaft 120 is received. Two upper rotor blades 52 are pivotally connected to the upper rotor hub 132 via a bracket 140. Specifically, the upper rotor blades 52 pivot about a pivot axis substantially parallel to the longitudinal axis LA of the upper rotor shaft 120, and thus pivot in a plane perpendicular to the longitudinal axis LA. The shape of the bracket 140 of the upper rotor hub 132 and the upper rotor blades 52 provides a pivoting range for the upper rotor blades 52 between a folded position oriented toward the upper rotor hub 132 and an extended position oriented away from the upper rotor hub 132. The upper rotor hub 132 is mounted on the upper rotor shaft 120 at its lower end 144 and slides upward thereon. Two protrusions 148 on the outer side of the upper rotor shaft 120 are received within recesses 152 of the upper rotor hub 132. A top hub retainer plate 156 is secured to the upper rotor hub 132 above the protrusions 148 via a set of small rotating straight threaded screws 160. When secured together, the top hub retainer plate 156 and the upper rotor hub 132 are held in a pivoting manner to the protrusions 148 at the upper end 162 of the upper rotor shaft 120, about its axis. As the upper rotor shaft 120 rotates, the protrusions 148 fixed within the recesses of the upper rotor hub 132 force the upper rotor assembly 44 to rotate with it.

[0038] The first ends of two biasing elements, in the form of blade tension springs 164, are hooked onto a base point, which is in the form of an anchor hook 168 on the side of the top hub retainer plate 156. The second ends of the two blade tension springs 164 are hooked onto a bias point, which is in the form of an anchor hook 172 on the top of the upper rotor blade 52. As described below, the blade tension springs 164 bias the upper rotor blade 52 so that the upper rotor blade 52 can be held in a folded position and an extended position and can pivot controllably between the folded and extended positions.

[0039] The stabilizer bar assembly 60 is also mounted on the upper rotor shaft 120 and includes a stabilizer bar hub 180 with a central through-hole, the diameter of which is larger than the outer diameter of the upper rotor shaft 120, which is received in the central through-hole. Two stabilizer bars 184 are pivotally connected to the stabilizer bar hub 180 via brackets 188. Specifically, the stabilizer bars 184 pivot about a pivot axis that is generally parallel to the longitudinal axis LA of the upper rotor shaft 120, and thus pivot in a plane perpendicular to the longitudinal axis LA. Each stabilizer bar 184 has a stabilizer bar end 192 that supports a stabilizer bar counterweight 196 inserted therein to provide inertia to the stabilizer bar end 192. The shape of the brackets 188 of the stabilizer bar hub 180 and the stabilizer bars 184 provides a relatively free range of pivoting for the stabilizer bars 184. The first ends of the two biasing elements, in the form of balance bar tension springs 200, are hooked onto a base point in the form of anchor hooks 204 on the side of the balance bar hub 180, and the second ends of the two balance bar tension springs 200 are hooked onto a biasing point in the form of anchor hooks 208 on the top of the balance bar 184. As will be described below, the balance bar tension springs 200 bias the balance bar 184 so that the balance bar 184 can stabilize the rotation of the upper rotor blades 52.

[0040] The balance bar assembly 60 is connected to the upper rotor assembly 44 via a pair of balance bar links 212 to stabilize the operation of the upper rotor assembly 44.

[0041] The lower rotor assembly 48 is mounted on the upper rotor shaft 120 below the upper rotor assembly 44 and the balance bar assembly 60. The lower rotor assembly 48 includes a lower rotor hub 220 with a central through-hole, the diameter of which is larger than the outer diameter of the upper rotor shaft 120, which is received within the central through-hole. Two lower rotor blades 56 are pivotally connected to the lower rotor hub 220 via a bracket 228. Specifically, the lower rotor blades 56 pivot about a pivot axis substantially parallel to the longitudinal axis LA of the upper rotor shaft 120, and thus pivot in a plane perpendicular to the longitudinal axis LA. The shape of the bracket 228 of the lower rotor hub 220 and the lower rotor blades 56 provides a pivoting range for the lower rotor blades 56 between a folded position oriented toward the lower rotor hub 220 and an extended position oriented away from the lower rotor hub 220. The first end of the two biasing elements, in the form of a blade tension spring 232, is hooked onto a base point, which is in the form of an anchor hook 236 on the side of the lower rotor hub 220, and the second end of the blade tension spring 232 is hooked onto a biasing point, which is in the form of an anchor hook 240 on the top of the lower rotor blade 56. Similar to the blade tension spring 164, the blade tension spring 232 biases the lower rotor blade 56 so that the lower rotor blade 56 can be held in a folded position and an extended position and can pivot controllably between the folded and extended positions.

[0042] A bearing 244, made of metal or other suitable material, is mounted on the upper rotor shaft 120.

[0043] The upper motor shaft 120 interfaces with a gearbox 248, which includes a gearbox top 252 having an opening 256 on its top surface. A motor rotation limiting structure in the form of an alignment post 260 extends toward the lower housing portion 32. A lower rotor bearing 264 is inserted from below into the opening 256 and is made of metal or other suitable material. A drive shaft in the form of the lower rotor shaft 268 has a sleeve 272 that fits within the lower rotor bearing 264 and extends toward the upper housing portion 28 through the opening 256 in the gearbox top 252. In this position, the lower rotor shaft 268 has a longitudinal axis extending through and defined by the sleeve, which is coaxial with the longitudinal axis LA of the upper rotor shaft 120. In some embodiments, the upper rotor shaft 120 may be considered a first drive shaft, and the lower rotor shaft 268 may be considered a second drive shaft. An annular recess 276 surrounds the sleeve 272 at its upper end and has two clamping portions 280 at the top. The annular recess 276 is sized to receive a lower rotor hub 220, which is then secured in the annular recess 276 via the clamping portions 280. A lower rotor gear 284 extends radially at the lower end of the lower rotor shaft 268. The upper rotor shaft 120 has two axially extending grooves 288 at its lower end 144, which receive two ridges within an axially extending bore in the sleeve 290 of the upper rotor gear 292. The axially extending grooves 288 and the ridges cooperate to secure the upper rotor shaft 120 in the rotational direction relative to the upper rotor gear 292 about the longitudinal axis LA. A bearing 296 is mounted from below within the axially extending bore of the upper rotor gear 292. The lower rotor gear 284 and the upper rotor gear 292 are received within the gearbox housing 300 and coaxially aligned with the longitudinal axis LA, wherein the lower rotor gear 284 is positioned above the upper rotor gear 292. The gearbox housing 300 is secured to the gearbox top 252 by a set of screws 302.

[0044] A drive motor 304 is mounted within a motor bracket 308 of the gearbox housing 300. The motor bracket 308 has a pair of clamping portions 312 to securely hold the drive motor 304 therein. A gear torque shaft 316 extends from the drive motor 304 into the gearbox housing 300. The gear torque shaft 316 interfaces with a stepped gear 320 within the gearbox 248. When the gear torque shaft 316 rotates in a first rotational direction, the stepped gear 320 rotates in a second rotational direction opposite to the first rotational direction. Furthermore, the stepped gear 320 causes a rotation direction reversing gear 324 in the gearbox 248 to rotate in the first rotational direction. The stepped gear 320 meshes with an upper rotor gear 292, and the rotation direction reversing gear 324 meshes with a lower rotor gear 284 to drive the upper rotor shaft 120 and the lower rotor shaft 268 to rotate about the longitudinal axis LA in opposite rotational directions.

[0045] A square-profile central shaft 328 extends axially through the motor drive assembly 40. The upper rotor shaft 120 has a through-hole with a circular profile through which the central shaft 328 extends. The upper threaded rod 104 has a square-profile bore in which the central shaft 328 is received at its apex. The corresponding non-circular profiles of the bores of the central shaft 328 and the upper threaded rod 104 prevent rotation of the upper housing portion 28 relative to the central shaft 328.

[0046] The lower base 332 of the lower housing assembly 32 is fixed to the inner surface of the lower housing 34 via epoxy resin or other suitable means, and has a lower threaded rod 336 that extends coaxially with the longitudinal axis LA toward the upper housing portion 28. The lower threaded rod 336, like the upper threaded rod 104, has a threaded portion 340 and terminates at its upper end in a non-threaded portion 344. In some embodiments, the non-threaded portion 116 may be a first non-threaded portion, and the non-threaded portion 344 may be a second non-threaded portion. The lower threaded rod 336 is received within an internal through-hole 124 of the upper rotor shaft 120 of the motor drive assembly 40. The threads of the threaded portion of the upper rotor shaft 120 within the internal through-hole 124 are complementary to the threads of the threaded portion 340 of the lower threaded rod 336.

[0047] The rotational alignment guide 348 of the lower base 332 extends upward toward the upper housing portion 28. The alignment guide 348 is a sleeve having a bore for receiving the alignment post 260 of the gearbox 248. The rotational alignment guide 348 and the alignment post 260 serve as a motor rotation limiting structure that connects the drive motor 304 to the second housing portion 32 to prevent the drive motor 304 from rotating relative to the second housing portion 32 about a rotational axis (i.e., the longitudinal axis LA). The insertion of the alignment post 260 of the gearbox 248 maintains the rotational orientation of the gearbox 248 and thus maintains the rotational orientation of the drive motor 304 about the longitudinal axis LA relative to both the upper housing portion 28 and the lower housing portion 32. As a result, the torque applied by the drive motor 304 through the gearbox 248 is directly applied to the upper rotor shaft 120 and the lower rotor shaft 268, causing the upper rotor shaft 120 to rotate relative to the housing 24 in a first rotational direction, and causing the lower rotor shaft 268 to rotate relative to the housing 24 in a second rotational direction opposite to the first rotational direction.

[0048] The battery holder 352 of the lower base 332 is sized to receive a battery 356, which powers the drive motor 304 via wires (not shown) extending between them. The board holder 360 of the lower base 332 is sized to receive a printed circuit board (“PCB”) 364, which provides a controller for controlling the operation of the drive motor 304 by controlling the power supplied to the drive motor by the battery 356, and thus controlling the operation of the foldable flight device 20.

[0049] The lower threaded rod 336 has a hole that is axially oriented relative to its length and has a square profile to receive the central shaft 328 and prevent its rotation relative to the lower threaded rod 336.

[0050] The non-circular profile central shaft 328 and the corresponding profile holes in the upper threaded rod 104 and the lower threaded rod 336 provide a housing rotation restriction structure that prevents the first housing portion from rotating relative to the second housing portion about the rotation axis (i.e., the longitudinal axis LA) of the upper rotor shaft 120.

[0051] Figure 4 The motor drive assembly 40 is shown in a partially folded state, as if it were in such a state as Figure 1 As shown in the enclosed housing 24. As illustrated, the upper rotor shaft 120 has a first threaded portion 368 at its upper end 162 within an internal through-hole 124, the thread corresponding to the threaded portion 112 of the upper threaded rod 104. Additionally, the upper rotor shaft 120 has a second threaded portion 372 at its lower end 144 within the internal through-hole 124, the thread corresponding to the threaded portion 340 of the lower threaded rod 336. The central shaft 328 has an upper cap 376 fixed at its upper end, extending within the upper threaded rod 104 and the cap 108. The upper threaded rod 104 has a hole 380 with a larger profile than the central shaft 328, extending axially from its upper end and terminating on an inner surface 382 within the upper threaded rod 104. The upper cap 376 is sized to slide axially through the hole 380. A biasing member in the form of an uncompressed helical spring 383 is positioned within a bore 380 below an upper cap 376 about a central axis 328. A lower threaded rod 336 has a bore 384 with a larger profile than the central axis 328, extending axially from its lower end and terminating on an inner surface 386 within the lower threaded rod 336. The central axis 328 has a lower cap 388 fixed to its lower end, extending within the lower threaded rod 336. The lower cap 388 is sized to slide axially through the bore 384.

[0052] The wiring harness 392 extends through an axial through-hole in the central shaft 328 and connects at its lower end to the PCB 364 and to one or more lights and / or electric motors on the top surface of the upper housing portion 28. The lights and / or electric motors can, for example, be used to cause movement of a person or animal represented by the folding flight device 20.

[0053] When the foldable flight device 20 is in the like Figure 1 In the folded state shown, the upper housing portion 28 and the lower housing portion 32 are retracted together, with the upper outer shell 30 and the lower outer shell 34 abutting each other along their adjacent outer peripheral surfaces. The upper rotor assembly 44, the lower rotor assembly 48, and the balance bar assembly 60 are in the folded state, with the upper rotor blade 52 and the lower rotor blade 56 pivoting toward the upper rotor shaft 12.

[0054] Now refer to Figures 1 to 7C Describes the operation of the foldable flight device 20.

[0055] In order to change the foldable flight device 20 from the folded state to Figure 2 In the extended, flight-capable flight device 20 shown, the controller on PCB 364 controls the current supplied from battery 356 to drive motor 304, causing drive motor 304 to rotate gear torque shaft 316 in a first rotational direction. Gear torque shaft 316 meshes with stepped gear 320 to rotate it. Stepped gear 320 then meshes with upper rotor gear 292, causing upper rotor gear 292 to rotate. Additionally, stepped gear 320 also meshes with rotation direction reversing gear 324, causing rotation direction reversing gear 324 and its meshing lower rotor gear 284 to rotate.

[0056] When the alignment post 260 of the gearbox 300 is positioned within the rotation alignment guide 348 of the lower base 332, the gearbox 300 is restricted from rotating relative to the lower housing portion 32 about the longitudinal axis LA. Furthermore, because the upper threaded rod 104 of the upper housing portion 28 and the lower threaded rod 336 of the lower housing portion 32 have holes with a profile that restricts rotation relative to the square central axis 328, the upper housing portion 28 is restricted from rotating about the longitudinal axis LA relative to the lower housing portion 32. Therefore, the torque generated by the drive motor 304 is applied to rotate the upper rotor shaft 120 and the lower rotor shaft 268 relative to the upper housing portion 28 and the lower housing portion 32, respectively.

[0057] When the upper rotor shaft 120 rotates relative to the lower threaded rod 336 and the upper threaded rod 104, the threads of the threaded portion 112 of the upper threaded rod 104 and the first threaded portion 368 of the rotating upper rotor shaft 120 cause the upper threaded rod 104 to move axially outward on the upper rotor shaft 120. Similarly and simultaneously, the threads of the threaded portion 340 of the lower threaded rod 336 and the second threaded portion 372 of the rotating upper rotor shaft 120 cause the lower threaded rod 336 to move axially outward on the upper rotor shaft 120. As the upper threaded rod 104 and the lower threaded rod 336 extend outward on the upper rotor shaft 120, the holes 380 in the upper threaded rod 104 and 384 in the lower threaded rod 336 receive the upper cap 376 and the lower cap 388, respectively.

[0058] Since the upper threaded rod 104 and the lower threaded rod 336 are fixed to the upper housing portion 28 and the lower housing portion 32, the upper housing portion 28 and the lower housing portion 32 are separated until, in the extended state, the first threaded portion 368 is positioned on the unthreaded portion 116 of the upper threaded rod 104 and the second threaded portion 372 is positioned on the unthreaded portion 344 of the lower threaded rod 336. Figure 6 As shown in the diagram. At this time, the continued rotation of the upper rotor shaft 120 causes the first threaded portion 368 and the second threaded portion 372 to rotate on the unthreaded portion 116 of the upper threaded rod 104 and the unthreaded portion 344 of the lower threaded rod 336, respectively. The direction of the threads and the continued rotation of the upper rotor shaft 120 prevent the threads of the corresponding portions from re-engaging.

[0059] During the extension of housing 24, gearbox 300 and thus drive motor 304 move axially away from lower base 332 along longitudinal axis LA, such that gearbox 300 and drive motor 304 are positioned approximately centrally between upper housing portion 28 and lower housing portion 32 and the interval between them.

[0060] Figure 5A and Figure 5B The retractable flight device 20 and the motor drive assembly 40 are shown in a partially extended state. Since the upper cap 376 and lower cap 388 are fixed in position along the length of the central axis 328, the lower cap 388 abuts against the inner surface 386 within the hole 384 of the lower threaded rod 336, and the helical spring 383 is slightly compressed between the upper cap 376 and the inner surface 382 of the hole 380 of the upper threaded rod 104. In its compressed state, the helical spring 383 applies a slight downward force to the upper threaded rod 104.

[0061] When the housing 24 is being opened or has been opened, in order to fly, the upper rotor blade 52 and the lower rotor blade 56 move from the folded position to the extended position, wherein in the folded position, the upper rotor blade 52 and the lower rotor blade 56 are oriented toward the rotor hubs 132, 220, and in the extended position, the upper rotor blade 52 and the lower rotor blade 56 are oriented away from the rotor hubs 132, 220.

[0062] Figure 5B and Figure 7A This diagram shows the position of the upper rotor blade 52 relative to the upper rotor hub 132 when the upper rotor blade 52 is in the folded position. The upper rotor blade 52 is pivotally connected to the upper rotor hub 132 at the bracket 140 and can pivot through a pivot range PR. The pivot range PR is defined by the abutment of the rear abutment surface 396 of the upper rotor blade 52 with the inner abutment surface 400 of the bracket 140. Furthermore, the upper rotor blade 52 has a limiting ridge 404, and the bracket 140 has a lateral surface 408. As previously described, the upper rotor blade 52 is held in place by a blade tension spring 164 (…). Figure 7A (Not shown in the image) biased, the blade tension spring 164 extends between the anchor hook 168 on the upper rotor hub 132 and the anchor hook 172 on the upper rotor blade 52. The blade tension spring 164 is an elastic member that applies tension, which increases and decreases accordingly as the length of the blade tension spring 164 increases and decreases.

[0063] As the upper rotor blade 52 pivots through the pivot range PR (which also represents the path of the anchor hook 172 on the upper rotor blade 52), the distance between the anchor hook 168 on the upper rotor hub 132 and the anchor hook on the upper rotor blade 52 increases toward position DM on either side of position DM. Position DM defines a local maximum distance between the anchor hook 168 on the upper rotor hub 132 and the anchor hook 172 on the upper rotor blade 52. Therefore, when the anchor hook 172 on the upper rotor blade 52 is in the first part PR1 of the pivot range PR, the upper rotor blade 52 is biased toward a folded position to shorten the blade tension spring 164. When the anchor hook 172 on the upper rotor blade 52 is in the second part PR2 of the pivot range PR, the upper rotor blade 52 is biased toward an extended position to shorten the blade tension spring 164. When the upper rotor blade 52 is in the folded position, the blade tension spring 164 pulls the upper rotor blade 52 into contact with the bracket 140 to hold the upper rotor blade 52 in that position.

[0064] The lower rotor blade 56 and the bracket 228 of the lower rotor hub 220 have corresponding limiting ridges and lateral surfaces that limit the pivoting range of the lower rotor blade 56 relative to the bracket 228.

[0065] Figure 7B The position of the upper rotor blade 52 is shown, with the anchor hook 172 on the upper rotor blade 52 at position DM. At this position, the tension applied by the blade tension spring 164 is at its maximum during the pivot range PR.

[0066] Figure 7C The rotor blade 52 is shown in the extended position. In this position, the tension of the blade tension spring 164 holds the upper rotor blade 52 in the extended position because the tension of the blade tension spring 164 pulls the limiting ridge 404 of the upper rotor blade 52 abutting against the lateral surface 408 of the bracket.

[0067] Once the housing 24 extends, the upper rotor blades 52 and lower rotor blades 56, along with the stabilizer bar 184, can pivot to extend the enclosed space defined by the upper housing portion 28 and the lower housing portion 32 for flight. It should be noted that the stabilizer bar 184 is coupled to the upper rotor blades 52, such that the stabilizer bar 184 and the upper rotor blades 52 move in cascade.

[0068] To pivot the upper rotor blades 52 and the balance bar 184, the controller operates the drive motor 304 to rapidly accelerate the rotation of the upper rotor shaft 120 in a second rotational direction opposite to the first rotational direction, wherein the upper rotor blades 52 rotate in the first rotational direction during flight. This is achieved by rapidly decelerating the rotation of the upper rotor shaft 120, such as by stopping the rotation of the upper rotor hub 132, slowing its rotation, or causing the upper rotor hub 132 to rotate in the second rotational direction. While the upper rotor hub 132 is rapidly accelerating in the second rotational direction, the inertia of the upper rotor blades 52 causes them to continue rotating in the first rotational direction. Inertia causes the upper rotor blades 52 to pass through the first portion PR1 of the pivot range PR, through position DM, and into the second portion PR2 of the pivot range PR, wherein the upper rotor blades 52 are pulled toward the extended position by the blade tension spring 164.

[0069] The lower rotor blades 56, pivotally connected to the lower rotor hub 220, are oriented such that they operate in the same manner as the upper rotor blades 52 of the upper rotor hub 132, but in the opposite rotational orientation. When the lower rotor hub 220 rotates by the lower rotor shaft 268, which operates at the same rotational speed as the upper rotor shaft 120 but in the opposite rotational direction, the lower rotor blades 56 operate simultaneously like the upper rotor blades 52, but in the opposite rotational direction.

[0070] This rotational deceleration is achieved by controlling the drive motor 304 via a controller on the PCB 364. For example, the controller can operate the drive motor 304 to rotate, causing the upper housing portion 28 and the lower housing portion 32 to move apart, and then the drive motor 304 can be rapidly decelerated to move the upper rotor blade 52 and the lower rotor blade 56 from a folded position to an extended position. Figure 2 As shown, the interruption of the continuous rotational speed of the upper rotor hub 132 and the lower rotor hub 220 can be instantaneous, so as to allow the upper rotor blade 52 and the lower rotor blade 56 to reach the extended position. Thereafter, the rotation of the drive motor 304 can be controlled as needed by the controller to control the rotation of the extended upper rotor blade 52 and the lower rotor blade 56 for flight.

[0071] Figure 8 The motor drive assembly 40 is shown in an extended state.

[0072] To retract the retractable flight device 20, the controller operates the drive motor 304 to rapidly accelerate the rotation of the upper rotor shaft 120 in a first rotational direction in which the upper rotor blades 52 rotate during flight. As the upper rotor hub 132 rapidly accelerates in the first rotational direction, the inertia of the upper rotor blades 52 causes them to lag behind the rotation of the upper rotor hub 132. This inertia causes the upper rotor blades 52 to rotate through the second portion PR2 of the pivot range PR, past position DM, and into the first portion PR1 of the pivot range PR, where the upper rotor blades 52 are pulled toward the retracted position by the blade tension springs 164. It should be understood that, by simultaneously accelerating the lower rotor shaft 268 in the second rotational direction in the same manner, the lower rotor blades 56 simultaneously move toward the retracted position.

[0073] Once the upper and lower rotor blades move toward the folded position, the controller can decelerate the drive motor 304 and reverse its rotation direction, causing the upper threaded rod 104 and lower threaded rod 336 to screw into the upper rotor shaft 120. The helical spring 383 pushes the upper threaded rod 104 into the upper rotor shaft 120, and the weight of the motor drive assembly 40 and the upper housing portion 28 forces the upper rotor shaft 120 to engage the threads on the lower threaded rod 336. The drive motor 304 continues to rotate in the opposite direction until the upper housing portion 28 and lower housing portion 32 are pulled together into the folded state.

[0074] It should be understood that when the drive motor 304, and therefore the upper rotor shaft 120 and the lower rotor shaft 268, operate at a substantially constant rotational speed, the upper rotor blades 52 and the lower rotor blades 56 are stable in both the folded and extended positions.

[0075] The controller can execute instructions stored in a memory device on PCB 364 to control drive motor 304. Alternatively or additionally, the controller can receive instructions for controlling the operation of drive motor 304 via wired or wireless communication (such as RF). Furthermore, the controller can control the operation of drive motor 304 in response to sensor inputs received from one or more sensors (such as light sensors and / or audio sensors and / or any other suitable type of sensor).

[0076] Although the foldable flight device has two rotor assemblies in the above embodiments, in other embodiments, the foldable flight device may have one, three or more rotor assemblies.

[0077] Alternatively, the rotor shaft may have an unthreaded portion, and the threaded rods extending from the upper housing portion and the lower housing portion may be threaded all the way to their ends.

[0078] The drive motor 304 can be more broadly referred to as a drive motor device including at least one motor. In alternative embodiments, the drive motor device includes multiple drive motors. In some of these alternative embodiments, one of the multiple drive motors can drive a drive shaft that moves the upper housing portion and the lower housing portion separately, and another of the multiple drive motors can drive the upper rotor assembly and the lower rotor assembly.

[0079] Those skilled in the art will understand that many other alternative implementations and variations exist, and the above examples are merely examples of one or more implementations. Therefore, the scope of protection is limited only to the appended claims.

Claims

1. A collapsible flying device, characterized by, include: Housing, the housing comprising: First shell portion; and The second housing portion, which cooperates with the first housing portion to define the internal volume of the retractable flight device; and Motor drive assembly, the motor drive assembly comprising: A drive motor device, the drive motor device comprising at least one drive motor; A rotor hub, wherein a drive motor is operatively connected to the rotor hub to rotate the rotor hub about an axis; A drive shaft, wherein a drive motor device is operably connected to the drive shaft, wherein the drive shaft is operably connected between the first housing portion and the second housing portion, wherein operation of the drive motor device drives the drive shaft to move the first housing portion from a closed position adjacent to the second housing portion to an open position, wherein in the open position, the first housing portion and the second housing portion are axially spaced by a certain gap; The rotor hub has a central through-hole through which a drive shaft passes between the first housing portion and the second housing portion; and a rotor assembly comprising at least two rotor blades coupled to the rotor hub and capable of being positioned in a folded position when the first housing portion is in the closed position, in which the at least two rotor blades are positioned within the internal volume, and capable of being positioned in an extended position when the first housing portion is in the open position, in which the rotor blades extend radially beyond the internal volume through the gap, and in which the at least two rotor blades are rotatably driven by the drive motor to provide lift to the foldable flight device. A stabilizer bar assembly, mounted to the drive shaft, includes a stabilizer bar hub having a central through-hole through which the drive shaft passes, and includes at least two stabilizer bars, each stabilizer bar having a stabilizer bar end with a stabilizer bar counterweight thereon, wherein the at least two stabilizer bars are pivotable between a folded state and an extended state, and wherein the stabilizer bar assembly is connected to the rotor assembly via a pair of stabilizer bar links to stabilize the operation of the rotor assembly.

2. The foldable flight device according to claim 1, characterized in that, Also includes: A housing rotation limiting structure is coupled to the first housing portion and the second housing portion and prevents the first housing portion from rotating relative to the second housing portion about the rotation axis of the drive shaft. The drive shaft has a threaded portion, and the first housing portion has a complementary threaded portion, such that rotation of the drive shaft causes the first housing portion to move relative to the second housing portion along the axis of rotation.

3. The foldable flight device according to claim 2, characterized in that, The drive motor device includes a drive motor.

4. The foldable flight device according to claim 3, characterized in that, Also includes: A motor rotation limiting structure is connected to the second housing portion and the drive motor, and prevents the drive motor from rotating relative to the second housing portion about the rotation axis of the drive shaft.

5. The foldable flight device according to claim 4, characterized in that, The rotor hub is mounted on the drive shaft.

6. The foldable flight device according to claim 5, characterized in that, At least one of the drive shaft and the first housing portion has a threadless portion, wherein the drive shaft can rotate freely relative to the first housing portion when one of the threaded portions on the drive shaft and the threaded portions on the first housing portion is axially positioned on the threadless portion.

7. The foldable flight device according to claim 6, characterized in that, It also includes a retainer feature that restricts the first housing portion and the second housing portion from axial separation relative to the axis of rotation of the drive shaft.

8. The foldable flight device according to claim 7, characterized in that, It also includes a biasing member that, when the unthreaded portion is axially positioned on one of the threaded portions of the drive shaft and the first housing portion, axially biases the first housing portion toward the second housing portion.

9. The foldable flight device according to claim 1, characterized in that, The drive shaft is a first drive shaft, and the foldable flight device further includes: A second drive shaft, the second drive shaft being rotatably driven in a second rotational direction opposite to the first rotational direction, wherein the first drive shaft is simultaneously driven by the drive motor device in the first rotational direction; and At least two rotor blades are connected to the second drive shaft and rotate therewith.

10. The foldable flight device according to claim 2, characterized in that, The second housing portion has complementary threaded portions, such that rotation of the drive shaft causes the second housing portion to translate relative to the drive shaft along the axis of rotation.

11. The foldable flight device according to claim 10, characterized in that, At least one of the drive shaft and the first housing portion has a first unthreaded portion, and at least one of the drive shaft and the second housing portion has a second unthreaded portion, wherein the drive shaft is freely rotatable relative to the first housing portion and the second housing portion when one of the threaded portions on the drive shaft and the threaded portions on the first housing portion is axially positioned on the first unthreaded portion and when one of the threaded portions on the drive shaft and the threaded portions on the second housing portion is axially positioned on the second unthreaded portion.

12. The foldable flight device according to claim 11, characterized in that, It also includes a retainer feature that restricts the first housing portion and the second housing portion from axial separation relative to the axis of rotation of the drive shaft.

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