Manufacturing method of unmanned aerial vehicle, unmanned aerial vehicle, and load support structure of unmanned aerial vehicle

Abstract

The invention relates to a method for manufacturing a fixed-wing aircraft, in particular a drone (100), (200), having the following steps: (i) manufacturing a housing (110), (210), (310) of the fixed-wing aircraft, (ii) manufacturing a support structure (120), (220), (320) of the fixed-wing aircraft, the support structure comprising an upper support structure part (121), (221), (321) and a lower support structure part (122), (222), (322), each comprising at least a support structure for a fuselage (113), (213) of the fixed-wing aircraft and a support structure for a wing (114), (115), (214), (215) of the fixed-wing aircraft, and (iii) joining the housing together with the support structure. The invention also relates to a fixed-wing aircraft, in particular a drone, which is manufactured using the manufacturing method according to the invention, so that a stable fixed-wing aircraft can be manufactured in a simple manner.

Description

Technical Field

[0001] This invention relates to the field of unmanned aerial vehicles (UAVs), and in particular, to a method for manufacturing a UAV, a UAV, and a load support structure for a UAV. Background Technology

[0002] There are various manufacturing methods for drones.

[0003] Similar to aircraft, drones are typically made of fiber composites or metals. However, this has some drawbacks, such as high weight and high production costs. These disadvantages may not be as significant in aircraft manufacturing, but they are particularly important in the drone industry, especially because today's drones have high demands and lower stability requirements than in aircraft manufacturing.

[0004] For this reason, some parts of drones are now made of plastic, for example, using thermoforming processes (also known as vacuum deep drawing).

[0005] For example, it is known that the shell of a drone is made of plastic, for example, through a thermoforming process, in which a load-bearing structure is provided to ensure the necessary stability of the drone, similar to the aircraft manufacturing process.

[0006] For this purpose, load-bearing structures made of foam are typically provided, such as load-bearing structures in the form of foam panels. However, foam used as a load-bearing structure has only limited stability, which is sometimes insufficient for drones.

[0007] As an alternative to load-bearing structures made of foam, load-bearing structures with struts, ribs, and / or spars can also be provided. These components are typically manufactured using other production methods, such as stamping or extrusion.

[0008] However, the downside is that using thermoforming processes to manufacture shells with struts, ribs, and spars as load-bearing structures results in a large number of sub-components because the shell must be reinforced over a large area. Each individual sub-component must be assembled during installation, often requiring manual manufacturing steps, which makes production complex and costly.

[0009] Joining thermoplastic materials (e.g., by welding) is also complex and expensive.

[0010] Therefore, it is hoped that a solution can be proposed to eliminate the above-mentioned shortcomings. Summary of the Invention

[0011] Therefore, one of the objectives of this invention is to enable the simple production of stable drones.

[0012] According to a first aspect of the invention, a manufacturing method as defined in claim 1 is provided, that is, a method for manufacturing a fixed-wing aircraft, particularly an unmanned aerial vehicle (UAV), the manufacturing method comprising the steps of: (i) manufacturing the outer shell of the fixed-wing aircraft, (ii) manufacturing a load-bearing structure for the fixed-wing aircraft, wherein the load-bearing structure includes an upper load-bearing structure portion and a lower load-bearing structure portion, wherein each of the upper and lower load-bearing structure portions includes at least a load-bearing structure for the fuselage of the fixed-wing aircraft and a load-bearing structure for the wings of the fixed-wing aircraft, and (iii) combining the outer shell with the load-bearing structure.

[0013] According to a second aspect of the invention, a fixed-wing aircraft as defined in claim 12 is provided, particularly, the fixed-wing aircraft is an unmanned aerial vehicle (UAV), that is, the fixed-wing aircraft includes an outer shell and a load-bearing structure, wherein the load-bearing structure includes an upper load-bearing structure portion and a lower load-bearing structure portion, wherein each of the upper load-bearing structure portion and the lower load-bearing structure portion includes at least a load-bearing structure for the fuselage of the fixed-wing aircraft and a load-bearing structure for the wings of the fixed-wing aircraft.

[0014] According to a third aspect of the invention, a load support structure for a fixed-wing aircraft as defined in claim 13 is provided, particularly, the fixed-wing aircraft being an unmanned aerial vehicle (UAV), that is, the load support structure includes an upper load support structure portion and a lower load support structure portion, wherein each of the upper load support structure portion and the lower load support structure portion includes at least a load support structure for the fuselage of the fixed-wing aircraft and a load support structure for the wings of the fixed-wing aircraft.

[0015] The manufacturing method is provided for manufacturing fixed-wing aircraft, specifically drones, but can also be provided for manufacturing other flying objects, such as airplanes.

[0016] These characteristics are described below with reference to drones; however, these characteristics apply to any type of fixed-wing aircraft.

[0017] A fixed-wing aircraft is a flying object with a rigid lifting surface, i.e., a rigid wing, where "rigid" here means that the wing is fixedly connected to the fuselage of the flying object. Therefore, the fixed-wing aircraft (or more precisely, a drone) according to the present invention comprises a fuselage and two wings. For example, a fixed-wing aircraft is a VTOL (vertical takeoff and landing) drone.

[0018] The shell includes the outer surface of the drone, wherein the shell preferably includes substantially the entire outer surface of the drone, where “substantially the entire” means at least the main part, that is, more than 90% of the outer surface is covered by the shell.

[0019] The drone can be divided into an upper part and a lower part along its horizontal axis. In this invention, the term "upper part" refers to the upper part of the drone when it is normally parked on the ground, and the term "lower part" refers to the lower part of the drone when it is normally parked on the ground.

[0020] Typically, load-bearing structures correspond to components of a drone that reinforce the drone, that is, reinforce the drone's outer shell.

[0021] The load support structure includes an upper load support structure and a lower load support structure, wherein the load support structure is horizontally divided into an upper load support structure and a lower load support structure.

[0022] Preferably, the load support structure includes elements of the UAV configured to stabilize the UAV, that is, to stabilize the shell. Particularly preferred is that the load support structure according to the invention includes all the elements of the UAV configured to stabilize the UAV, that is, to stabilize the shell.

[0023] Another preferred embodiment is that the outer shell surrounds the load support structure of the UAV, and particularly preferred embodiment is that the outer shell substantially completely surrounds the load support structure, that is, the outer shell surrounds the load support structure at least above and below the load support structure.

[0024] The upper load-bearing structure includes at least a load-bearing structure for the fuselage of the UAV and a load-bearing structure for the wings of the UAV. This means that the upper load-bearing structure can be divided into several sections (arranged horizontally adjacent to each other), including load-bearing structures for the fuselage and corresponding load-bearing structures for the wings.

[0025] The same applies to the lower load-bearing structure. The lower load-bearing structure also includes load-bearing structures for the fuselage and wings of the UAV. This means that the lower load-bearing structure can also be divided into several sections (arranged horizontally adjacent to each other), including load-bearing structures for the fuselage and corresponding load-bearing structures for the wings.

[0026] In an advantageous embodiment of one aspect of the invention, at least a portion of the housing and / or at least a portion of the load-bearing structure is manufactured by a thermoforming method; preferably, all portions of the housing and / or all portions of the load-bearing structure are manufactured by a thermoforming method.

[0027] That is, preferably, at least a portion of the outer casing is manufactured by thermoforming. Alternatively or additionally, it is also preferred that at least a portion of the load-bearing structure is manufactured by thermoforming.

[0028] Particularly preferred is that the entire outer shell—that is, all parts of the outer shell—is manufactured by thermoforming. Additionally or alternatively, it is also particularly preferred that the entire load-bearing structure—that is, all parts of the load-bearing structure—is manufactured by thermoforming. This means that, in this particularly preferred embodiment, each of the outer shell, the upper load-bearing structure portion, and the lower load-bearing structure portion is equivalent to a portion manufactured by thermoforming.

[0029] In another preferred embodiment, the upper load-bearing structure portion has a generally planar extension. The planar extension of the upper load-bearing structure portion is configured to correspond to the horizontal extension of the UAV. "Planar" here means that the extension dimension of the upper load-bearing structure portion in two dimensions is significantly larger than the extension dimension in a third dimension. The upper load-bearing structure portion preferably has struts, ribs, and / or spars perpendicular to the planar extension of the upper load-bearing structure portion. Additionally or alternatively, the upper load-bearing structure portion has through-holes, which preferably have a honeycomb-shaped cross-section, but may also have other shapes, such as circular or square. Furthermore, additionally or alternatively, the upper load-bearing structure portion may have recesses, which preferably have a honeycomb-shaped, circular, or square cross-section, but may also have other shapes.

[0030] Alternatively or additionally, the lower load support structure portion has a generally planar extension. The planar extension of the lower load support structure portion is configured to correspond to the horizontal extension of the UAV. "Planar" here means that the extension dimension of the lower load support structure portion in two dimensions is significantly larger than the extension dimension in a third dimension. The lower load support structure portion preferably has struts, ribs, and / or spars perpendicular to the planar extension of the lower load support structure portion. Alternatively or additionally, the lower load support structure portion has through-holes, which preferably have a honeycomb-shaped cross-section, but may also have other shapes, such as circular or square. Furthermore, alternatively or additionally, the lower load support structure portion may have recesses, which preferably have a honeycomb-shaped, circular, or square cross-section, but may also have other shapes.

[0031] This results in a particularly stable load-bearing structure design.

[0032] Particularly preferred are the supports, ribs, and / or spars to be circular. Particularly preferred are all supports and / or spars to be circular. Additionally or alternatively, through holes and / or recesses are circular. When the corresponding supports, ribs, spars, etc., have no corners, they exhibit a circular shape or circular profile.

[0033] The circular shape makes it particularly easy to manufacture the corresponding supports, ribs, and spars through thermoforming.

[0034] In particular, the outer contours of the upper load support structure and the lower load support structure preferably correspond to the outer contour of the shell, so that the outer contours of the upper load support structure and the lower load support structure generally correspond to the outer surface of the UAV.

[0035] In another advantageous embodiment of the invention, the housing includes an upper housing portion and a lower housing portion. This means that the housing can be horizontally divided into an upper housing portion and a lower housing portion. The upper housing portion generally corresponds to the upper half of the drone's housing, and the lower housing portion generally corresponds to the lower half of the housing.

[0036] The upper shell portion and the lower shell portion each include at least the shell of the drone's fuselage and the shell of each wing in the drone's wings. That is to say, the upper shell portion and the lower shell portion can also be divided into a portion for the drone's fuselage and a portion for the drone's wings.

[0037] In particular, preferably, the outer shell extends from one end of one wing of the drone to the other end of the other wing of the drone, that is, the outer shell extends over the entire wingspan or wing width of the drone.

[0038] Preferably, the upper load-bearing structure is integrally formed. Alternatively, the lower load-bearing structure is integrally formed.

[0039] In cases where the housing comprises an upper housing portion and a lower housing portion, it is more preferable that the upper housing portion and / or the lower housing portion are also integrally formed.

[0040] Preferably, the upper load-bearing structure extends over the entire wingspan of the fixed-wing aircraft. Alternatively or concurrently, the lower load-bearing structure also extends over the entire wingspan of the fixed-wing aircraft.

[0041] In cases where the outer shell comprises an upper outer shell portion and a lower outer shell portion, it is more preferable that the upper outer shell portion and / or the lower outer shell portion also extend over the entire wingspan of the fixed-wing aircraft. "Over the entire wingspan" means that the corresponding component extends from one end of the wing to the other end of the wing across the width of the UAV.

[0042] In another advantageous embodiment of the invention, the load support structure comprises an upper load support structure portion and a lower load support structure portion. This means that, apart from the upper and lower load support structure portions, the UAV does not include any load support structure portion; in particular, all portions constituting the load support structure of the UAV are formed by the upper and lower load support structure portions.

[0043] In another advantageous embodiment of the invention, the outer shell and / or load-bearing structure has a wall thickness of 0.1 mm to 12 mm. Preferably, the upper outer shell portion and / or the lower outer shell portion has a wall thickness of 0.1 mm to 12 mm. Preferably, the upper load-bearing structure portion and / or the lower load-bearing structure portion has a wall thickness of 0.1 mm to 12 mm.

[0044] In another advantageous embodiment of the invention, the outer shell and / or load-bearing structure includes a stabilizing surface for the drone. Specifically, the upper load-bearing structure portion and / or the lower load-bearing structure portion includes a stabilizing surface for the drone. In cases where the outer shell comprises an upper outer shell portion and a lower outer shell portion, it is more preferable that the upper outer shell portion and / or the lower outer shell portion include a stabilizing surface for the drone. The stabilizing surface serves to maintain the stability of the drone in the air or during flight.

[0045] This further reduces the number of individual parts required to manufacture the drone.

[0046] In another advantageous embodiment of the invention, the outer shell and / or load-bearing structure includes a rudder, particularly an elevator and an aileron. The rudder can be attached to the wing via a hinge. However, it is particularly preferred that the rudder be incorporated as part of the outer shell and / or load-bearing structure.

[0047] This means that the rudder is partially connected to the housing and / or load-bearing structure, and in particular, the rudder is partially connected to the housing and / or load-bearing structure by one or more strip structures. For example, the rudder may be formed from an upper housing portion, an upper load-bearing structure portion, a lower load-bearing structure portion, and / or a lower housing portion.

[0048] In a particularly preferred embodiment, the connection to the rudder is formed by the upper outer shell portion, wherein the rudder is connected to the upper outer shell portion, for example, by means of a connection across the entire width of the rudder. The upper load-bearing structure portion, the lower load-bearing structure portion, and the lower outer shell portion are not connected to the rudder (or are only connected after the outer shell is joined to the load-bearing structure).

[0049] Alternatively, the rudder can also be formed from two, three, or all parts, that is, from an upper shell section, an upper load-bearing structure section, a lower load-bearing structure section, and a lower shell section, wherein the rudder is only partially connected to the respective sections, which, for example, allows for a further reduction in the number of individual components.

[0050] In another advantageous embodiment of the invention, the connection between the housing and the load-bearing structure includes gluing the housing and the load-bearing structure together. This embodiment is particularly preferred when the housing comprises an upper housing portion and a lower housing portion.

[0051] By providing upper and lower load-bearing structures, and (as appropriate) upper and lower outer shells, the corresponding parts can be connected at locations on the drone where they will not be subjected to excessive loads during flight. Specifically, the connection planes of the corresponding parts correspond to the horizontal cross-section of the drone, where no force acts during drone use. This allows gluing to be sufficient to connect the parts to each other.

[0052] In another advantageous embodiment of the invention, the housing and / or load-bearing structure are made of plastic, preferably a transparent plastic, and particularly preferably, a polycarbonate plastic.

[0053] The use of plastics, such as those processed by thermoforming, also allows for the use of transparent plastics, thereby reducing the visibility of the drone.

[0054] In another advantageous embodiment of the invention, the load-bearing structure is configured to accommodate at least one fuel tank. The fuel tank is preferably located between the upper load-bearing structure portion and the lower load-bearing structure portion. Additionally or alternatively, an engine mount is provided between the load-bearing structure and the housing. The engine mount may be attached to the load-bearing structure and / or the housing, and in particular, the engine mount may be attached to the lower load-bearing structure portion and / or the lower housing portion. The engine mount preferably extends at least along the entire length of the lower load-bearing structure portion or the lower housing portion.

[0055] The load-bearing structure according to the invention allows for the provision of recesses in a region of the load-bearing structure, which can then be used for other components of the UAV. Providing recesses in a region of the load-bearing structure is particularly easy to achieve when a planar load-bearing structure is provided.

[0056] In another advantageous embodiment of the invention, the load-bearing structure is configured to provide an energy-absorbing zone. This means that the load-bearing structure itself can at least partially serve as an energy-absorbing zone. The energy-absorbing zone is configured to absorb at least a portion of the kinetic energy generated during the impact. Particularly preferred are the outer shell (particularly the upper and / or lower outer shell portions) and the load-bearing structure (particularly the upper and lower load-bearing structure portions) having a material thickness (i.e., wall thickness) of 0.1 mm to 0.2 mm (e.g., 0.1 mm). Preferably, the load-bearing structure (particularly the upper and lower load-bearing structure portions) can be configured to have a larger volume within the fuselage section; and / or the load-bearing structure can enclose the engine and tail rotor. Thus, the outer shell and load-bearing structure become energy-absorbing zones.

[0057] In another advantageous embodiment of the invention, the manufacturing method includes the additional step of attaching the front portion to the housing and load-bearing structure.

[0058] The front portion can be understood as the nose of the drone, and the front portion is attached to the front area of ​​the corresponding part, specifically, the front portion is attached to the front area of ​​the upper load support structure part, the lower load support structure part and / or the outer shell (as the case may be), the upper outer shell part and / or the lower outer shell part.

[0059] As an alternative implementation to attaching the front portion, the front portion may also be formed of a housing and / or a load-bearing structure. That is, in particular, depending on the circumstances, the front portion may be formed of an upper housing portion, a lower housing portion, an upper load-bearing structure portion, and / or a lower load-bearing structure portion.

[0060] The features of advantageous embodiments of the invention are defined, and in particular, the features of advantageous embodiments of the invention are defined in the dependent claims, wherein those skilled in the art can also derive other advantageous features, embodiments and designs from the foregoing description and the discussion below. Attached Figure Description

[0061] The invention will now be further described and explained with reference to the embodiments shown in the accompanying drawings.

[0062] Figure 1a A perspective view of a first embodiment of the UAV according to the present invention is shown. Figure 1b A schematic diagram of the first embodiment, viewed from the side, is shown. Figure 2 An exploded perspective view of the first embodiment of the UAV is shown. Figure 3a A perspective view of the upper outer casing portion according to the first embodiment, viewed from a bottom angle, is shown. Figure 3b A schematic diagram of the upper outer casing portion according to the first embodiment, viewed from the side, is shown. Figure 3c A perspective view of the upper outer casing portion according to the first embodiment, viewed from a top angle, is shown. Figure 4a A perspective view of the upper load support structure according to the first embodiment, viewed from an angle at the bottom, is shown. Figure 4b A schematic diagram of the upper load support structure portion according to the first embodiment, viewed from the side, is shown. Figure 4c A perspective view of the upper load support structure portion according to the first embodiment, viewed from a top angle, is shown. Figure 5a A perspective view of the lower load support structure portion according to the first embodiment, viewed from an angle at the bottom, is shown. Figure 5b A schematic diagram of the lower load support structure portion according to the first embodiment, viewed from the side, is shown. Figure 5c A perspective view of the lower load support structure portion according to the first embodiment, viewed from a top angle, is shown. Figure 6a A perspective view of the lower outer casing portion according to the first embodiment, viewed from a bottom angle, is shown. Figure 6b A schematic diagram of the lower outer casing portion according to the first embodiment, viewed from the side, is shown. Figure 6c A perspective view of the lower outer casing portion according to the first embodiment, viewed from a top angle, is shown. Figure 7 A perspective view of the lower load support structure portion with engine mount according to the first embodiment, viewed from a bottom at an angle, is shown. Figure 8 A perspective view of the lower housing portion with engine mount according to the first embodiment, viewed from a top angle, is shown. Figure 9a A perspective view of a second embodiment of the UAV according to the present invention is shown. Figure 9b A schematic diagram of the second embodiment, viewed from the side, is shown. Figure 10 An exploded perspective view of the second embodiment of the UAV is shown. Figure 11a A perspective view of the upper outer shell portion according to the second embodiment, viewed from a bottom angle, is shown. Figure 11b A schematic diagram of the upper outer casing portion according to the second embodiment, viewed from the side, is shown. Figure 11c A perspective view of the upper outer casing portion according to the second embodiment, viewed from a top angle, is shown. Figure 12a A perspective view of the upper load support structure portion according to the second embodiment, viewed from an angle at the bottom, is shown. Figure 12b A schematic diagram of the upper half of the load support structure according to the second embodiment, viewed from the side, is shown. Figure 12c A perspective view of the upper load support structure portion according to the second embodiment, as viewed from an inclined top, is shown. Figure 13a A perspective view of the lower load support structure portion according to the second embodiment, viewed from an angle at the bottom, is shown. Figure 13b A schematic diagram of the lower load support structure portion according to the second embodiment, viewed from the side, is shown. Figure 13c A perspective view of the lower load support structure portion according to the second embodiment, viewed from a top angle, is shown. Figure 14a A perspective view of the lower outer casing portion according to the second embodiment, viewed from a bottom angle, is shown. Figure 14b A schematic diagram of the lower outer casing portion according to the second embodiment, viewed from the side, is shown. Figure 14c A perspective view of the lower outer casing portion according to the second embodiment, viewed from a top angle, is shown. Figure 15 A perspective view of the lower load support structure portion with engine mount according to the second embodiment, viewed from a bottom at an angle, is shown. Figure 16 A perspective view of the lower housing portion with engine mount according to the second embodiment, viewed from a top angle, is shown. Figure 17 A schematic diagram of a third embodiment of a fixed-wing aircraft according to the present invention is shown. Figure 18 A schematic diagram of the casing according to the third embodiment is shown. Figure 19 A schematic diagram of the load support structure according to the third embodiment is shown. Figure 20 A schematic diagram of the upper outer casing portion according to the third embodiment is shown. Figure 21 A schematic diagram of the upper load support structure portion according to the third embodiment is shown. Figure 22 A schematic diagram of the lower load support structure portion according to the third embodiment is shown. Figure 23 A schematic diagram of the lower outer casing portion according to the third embodiment is shown. Figure 24 A schematic flowchart illustrating an embodiment of the method according to the present invention is shown. Detailed Implementation

[0063] In the accompanying drawings and their descriptions, corresponding or related elements are marked with corresponding or similar reference numerals where appropriate, even if the corresponding or related elements appear in different embodiments.

[0064] Figure 1a A perspective view of a first embodiment of the UAV according to the present invention is shown, and Figure 1b A schematic diagram of the first embodiment, viewed from the side, is shown.

[0065] Specifically, the drone 100 includes a housing 110. In the illustrated embodiment, the housing 110 includes an upper housing portion 111 and a lower housing portion 112.

[0066] The upper outer shell portion 111 and the lower outer shell portion 112 each include a planar extension, specifically a planar extension conforming to the shape of the drone. In other words, the upper outer shell portion 111 and the lower outer shell portion 112 extend over the entire wingspan of the drone, that is, the upper outer shell portion 111 and the lower outer shell portion 112 extend from one end of the wing to the other end of the wing.

[0067] Specifically, the upper outer shell portion 111 and the lower outer shell portion 112 each include the outer shell section of the fuselage 113 of the UAV and the corresponding outer shell sections of the wings 114 and 115 of the UAV.

[0068] The upper outer shell portion 111 and the lower outer shell portion 112 are each integrally formed and are preferably manufactured using a thermoforming process.

[0069] In the illustrated embodiment, the housing 110 includes stabilizing surfaces 116 and 117 of the drone 100. The housing 110 can be joined by gluing the upper housing portion 111 to the lower housing portion 112 together.

[0070] In particular, the outer casing 110 is made of plastic, preferably a transparent plastic, such as polycarbonate.

[0071] In the illustrated embodiment, the drone 100 includes a front portion 130 that is attached to the front of the housing 110, particularly glued to the front of the housing 110.

[0072] The wings of the drone 100 are fixed and have an ergonomic shape.

[0073] Figure 2 An exploded perspective view of a first embodiment of the UAV is shown. Specifically, the load support structure 120 of the UAV 100 can also be seen in the figure. The load support structure 120 includes an upper load support structure portion 121 and a lower load support structure portion 122.

[0074] The upper load support structure portion 121 and the lower load support structure portion 122 each extend along the wingspan of the UAV 100, and each includes a load support structure for the fuselage and a load support structure for the wings of the UAV 100.

[0075] The upper load-bearing structure portion 121 and the lower load-bearing structure portion 122 are also integrally formed, and are preferably manufactured using a thermoforming process.

[0076] The load-bearing structure 120 includes struts, ribs, and / or spars. Specifically, the upper load-bearing structure portion 121 and the lower load-bearing structure portion 122 each include struts, ribs, and / or spars. Additionally or alternatively, the load-bearing structure 120 may have openings and / or recesses. Specifically, the upper load-bearing structure portion 121 and / or the lower load-bearing structure portion 122 may have openings and / or recesses, such as having a honeycomb-shaped, circular, or polygonal cross-section, and the recesses having a honeycomb-shaped, circular, or polygonal cross-section, for example.

[0077] The load support structure 120 also includes a stabilizing surface for the UAV 100. Additionally, rudders 118 of the UAV 100 are also shown. These rudders can be attached to the housing 110 and / or the load support structure 120 via hinges. Alternatively, as described with respect to the third embodiment, the rudders can be formed as a single component with the housing 110 and / or the load support structure 120.

[0078] The load support structure 120 according to the invention can easily attach the component because the brackets and recesses for this component and other components can be easily integrated.

[0079] Preferably, the various parts, namely the upper load-bearing structure part, the lower load-bearing structure part, the upper shell part, the lower shell part, and the front part, can be joined together by gluing.

[0080] Figure 3a A perspective view of the upper outer casing portion according to the first embodiment, viewed from a bottom angle, is shown. Figure 3b A schematic diagram of the upper outer shell section as viewed from the side is shown, and Figure 3c A three-dimensional schematic diagram of the upper outer shell section is shown, viewed from a top angle.

[0081] Therefore, the upper outer shell portion 111 (along with other portions 112, 121, 122, see below) does not include any corners or sharp edges, meaning it is suitable for manufacture by thermoforming. The upper outer shell portion 111 includes a shell section for the drone fuselage 113 and corresponding shell sections for the drone's wings 114, 115. The shell section for the drone fuselage 113 roughly corresponds to half the longitudinal portion of an elongated hollow cylindrical body, and the shell sections for the corresponding wings 114, 115 roughly correspond to the wing shape of the drone. The outer shell portion 111 provides the upper outer surface of the drone.

[0082] The upper outer shell portion 111 includes stabilizing surfaces 116 located at the ends of the wing shell section, which project vertically upward from a planar extension of the upper outer shell portion 111. Furthermore, the upper outer shell portion 111 includes openings 119, for example, for refueling fuel tanks that may be disposed inside the UAV 100 (see below).

[0083] Figure 4a A perspective view of the upper load support structure according to the first embodiment, viewed from an angle at the bottom, is shown. Figure 4b A schematic diagram of the upper load-bearing structure section, viewed from the side, is shown, and Figure 4c A three-dimensional schematic diagram of the upper load-bearing structure section, viewed from an angle at the top, is shown.

[0084] Specifically, the figure shows the struts, ribs, and spars of the upper load-bearing structure 121. It also shows the section for the fuselage 113 and two sections for the wings 114 and 115. The section for the fuselage 113 conforms to the shape of a fuselage outer shell section, and the two sections for the wings 114 and 115 conform to the shape of a wing outer shell section. The struts, ribs, and spars are located in the section for the fuselage 113 and in the sections for the wings 114 and 115.

[0085] The upper load-bearing structure portion 121 includes a recess 128' for a fuel tank and an opening for filling the fuel tank disposed in the recess. The recess specifically corresponds to the upper portion of the recess for the fuel tank, and the opening corresponds to the opening 119 of the upper housing portion 111. The upper load-bearing structure portion 121 also includes a stabilizing surface 126 that projects vertically upward from a planar extension of the upper load-bearing structure portion 121.

[0086] Figure 5a A perspective view of the lower load support structure portion according to the first embodiment, viewed from an angle at the bottom, is shown. Figure 5b A schematic diagram of the lower load-bearing structure section, viewed from the side, is shown. Figure 5c A three-dimensional schematic diagram of the lower load-bearing structure section, viewed from an angle at the top, is shown.

[0087] The figure shows the struts, ribs, and spars of the lower load support structure 122. It also shows the fuselage section 113 and two sections for the wings 114 and 115, whose shapes correspond to the corresponding sections of the outer shell 110 of the UAV 100. The struts, ribs, and spars are located in the section for the fuselage 113 and in the sections for the wings 114 and 115.

[0088] The lower load support structure portion 122 includes a recess 128'' for the fuel tank and a stabilizing surface 127, the recess specifically corresponding to the lower portion of the recess for the fuel tank, and the stabilizing surface protruding vertically downward from a planar extension of the lower load support structure portion 112.

[0089] Figure 6a A perspective view of the lower outer casing portion according to the first embodiment, viewed from a bottom angle, is shown. Figure 6b A schematic diagram of the lower outer shell section as viewed from the side is shown. Figure 6c A perspective view of the lower outer shell section as seen from a top angle is shown.

[0090] In particular, the diagram also shows the outer shell section for fuselage 113 and the outer shell sections for wings 114 and 115.

[0091] The lower housing portion 112 also has a stabilizing surface 117 that protrudes vertically upward from the planar extension of the lower housing portion 112.

[0092] Figure 7 A perspective view of the lower load support structure portion with engine mount according to the first embodiment, viewed from a bottom angle, is shown. In particular, the lower load support structure portion shown corresponds to lower load support structure portion 122.

[0093] The engine mount 129 is equivalent to an elongated element with a rectangular cross-section that runs along the entire lower load support structure portion 122 from front to rear through the UAV 100 and extends beyond the lower load support structure portion 122 at the rear to enable engine attachment while ensuring a stable arrangement of the engine mount.

[0094] Alternatively, the engine mount can also be mounted on the lower housing portion 112, such as... Figure 8 As shown.

[0095] Figure 8 A perspective view of the lower housing portion with engine mount according to the first embodiment, viewed from a top angle, is shown.

[0096] The second embodiment of the drone is described below. As can be seen from the figures, the descriptions of features that are the same in both embodiments are omitted.

[0097] Figure 9a A perspective view of a second embodiment of the UAV according to the present invention is shown. Figure 9b A schematic diagram of the second embodiment, viewed from the side, is shown.

[0098] The wings of the UAV 200 are fixed and have an ergonomic shape.

[0099] Specifically, the drone 200 includes a housing 210 having an upper housing portion 211 and a lower housing portion 212.

[0100] The upper outer shell portion 211 and the lower outer shell portion 212 each include a planar extension, specifically a planar extension conforming to the shape of the UAV 200. In other words, the upper outer shell portion 211 and the lower outer shell portion 212 extend over the entire wingspan of the UAV 200, that is, from one end of the wing to the other end of the wing.

[0101] The upper outer shell portion 211 and the lower outer shell portion 212 each include an outer shell section for the fuselage of the drone 213 and an outer shell portion for the corresponding wings of the drones 214 and 215.

[0102] The upper outer shell portion 211 and the lower outer shell portion 212 are each integrally formed and are preferably manufactured using a thermoforming process.

[0103] The housing 210 includes stabilizing surfaces 216 and 217.

[0104] The outer casing 210 can be joined by gluing the upper outer casing portion 211 to the lower outer casing portion 212.

[0105] In the second embodiment, the drone 200 includes a front portion 230, which is part of the outer shell 210. This means that the front portion 230 is formed by an upper outer shell portion 211, a lower outer shell portion 212, an upper load-bearing structure portion 221, and a lower load-bearing structure portion 222 (as can be specifically in...). Figure 10 (See in the middle).

[0106] In the second embodiment, the drone 200 includes three propellers, that is, it is constructed as a tri-rotor drone. For this purpose, the drone 200 (specifically the outer shell 210) includes propeller openings 241, 242, and 243. Propeller opening 241 is located in the front portion 230 of the drone 200, while propeller openings 242 and 243 are each located in sections for the wings 214 and 215.

[0107] Figure 10 An exploded perspective view of a second embodiment of the UAV is shown. This exploded view also shows the load support structure 220 of the UAV 200, which includes an upper load support structure portion 221 and a lower load support structure portion 222.

[0108] The upper load support structure portion 221 and the lower load support structure portion 222 also extend along the wingspan of the UAV 200, and the upper load support structure portion 221 and the lower load support structure portion 222 each include a load support structure for the fuselage of the UAV 200 and a load support structure for the wings of the UAV 200.

[0109] The upper load-bearing structure portion 221 and the lower load-bearing structure portion 222 are each integrally formed and are preferably manufactured using a thermoforming process.

[0110] The load-bearing structure 220 includes struts, ribs, and / or spars; that is, the upper load-bearing structure portion 221 and the lower load-bearing structure portion 222 each include struts, ribs, and / or spars. Additionally or alternatively, the load-bearing structure 220 may have openings and / or recesses. In particular, the upper load-bearing structure portion 221 and / or the lower load-bearing structure portion 222 may have openings and / or recesses, such as having a honeycomb-shaped, circular, or polygonal cross-section, and the recesses having, for example, a honeycomb-shaped, circular, or polygonal cross-section.

[0111] The load support structure 120 also includes the stabilizers 216 and 217 of the UAV, and the rudder 218 of the UAV 200 is also shown.

[0112] Preferably, the various parts, namely the upper load support structure part 221, the lower load support structure part 222, the upper outer shell part 211, the lower outer shell part, and the front part 212, can be joined together by adhesive bonding.

[0113] Figure 11a A perspective view of the upper outer shell portion according to the second embodiment, viewed from a bottom angle, is shown. Figure 11b A perspective view of the upper outer casing portion according to the second embodiment, viewed from the side, is shown, and Figure 11c A perspective view of the upper outer shell portion according to the second embodiment, viewed from a top angle, is shown.

[0114] Specifically, the upper outer shell portion 211 includes an opening 219, which is configured, for example, to refuel a fuel tank that may be located inside the drone 200.

[0115] Furthermore, propeller openings 241, 242, and 243 can also be seen, with propeller opening 241 located in the front portion 230, which is integrally formed with the upper outer shell portion 211, and propeller openings 242 and 243 each located in the outer shell section of the wing, specifically, propeller openings 242 and 243 each located at the corresponding end of the wing.

[0116] Figure 12a A perspective view of the upper outer shell portion according to the second embodiment, viewed from a bottom angle, is shown. Figure 12b A perspective view of the upper outer casing portion according to the second embodiment, viewed from the side, is shown, and Figure 12c A perspective view of the upper outer shell portion according to the second embodiment, viewed from a top angle, is shown.

[0117] The upper load support structure component 221 also has propeller openings 241, 242 and 243, with propeller opening 241 correspondingly arranged in the front portion 230 integrally formed with the upper load support structure component 221, and propeller openings 242 and 243 correspondingly arranged in the corresponding sections of the upper load support structure component 221 for the wing.

[0118] In addition, a recess 228' for the fuel tank can be seen, which specifically corresponds to the upper part of the recess for the fuel tank.

[0119] Figure 13a A perspective view of the lower outer casing portion according to the second embodiment, viewed from a bottom angle, is shown. Figure 13b A perspective view of the lower outer casing portion according to the second embodiment, viewed from the side, is shown, and Figure 13c A perspective view of the lower outer casing portion according to the second embodiment, viewed from a top angle, is shown.

[0120] The lower load support structure component 222 also has propeller openings 241, 242 and 243, with propeller opening 241 correspondingly arranged in the front portion 230 integrally formed with the lower load support structure component 222, and propeller openings 242 and 243 correspondingly arranged in the corresponding sections of the lower load support structure component 221 for the wing.

[0121] In addition, a recess 228' for the fuel tank is also shown, which specifically corresponds to the lower portion of the recess for the fuel tank.

[0122] Figure 14a A perspective view of the lower outer casing portion according to the second embodiment, viewed from a bottom angle, is shown. Figure 14b A perspective view of the lower outer casing portion according to the second embodiment, viewed from the side, is shown, and Figure 14c A perspective view of the lower outer casing portion according to the second embodiment, viewed from a top angle, is shown.

[0123] The figure also shows the propeller openings 241, 242, and 243 as described above.

[0124] Figure 15 A perspective view of the lower load support structure portion with engine mount according to the second embodiment, viewed from a bottom at an angle, is shown, and Figure 16 A perspective view of the lower housing portion with engine mount according to the second embodiment, viewed from a top angle, is shown.

[0125] Similar to the first embodiment, the engine mount 229 corresponds to an elongated element with a rectangular cross-section that extends along the entire lower load support structure portion 222 or the entire lower housing portion 212 and extends beyond the lower load support structure portion 222 or the lower housing portion 212 to enable engine attachment while ensuring a stable arrangement of the engine mount.

[0126] Figure 17 A schematic diagram of a third embodiment of a fixed-wing aircraft according to the present invention is shown. The upper left figure shows the fixed-wing aircraft 300 according to the third embodiment as viewed from above. The upper right figure shows an exploded perspective view, the lower left figure shows an exploded view viewed from the front, and the lower right figure shows an exploded view viewed from the side. Each figure has an upper outer shell portion 311, an upper load-bearing structure portion 321, a lower load-bearing structure portion 322, and a lower outer shell portion 312.

[0127] In the third embodiment, the load support structure 320 has circular ribs, that is, the upper load support structure portion 321 and the lower load support structure portion 322 have circular ribs, that is, the circular ribs have a circular shape, that is, the circular ribs have no corners.

[0128] According to the third embodiment, Figure 18 A schematic diagram of the housing 310 is shown. Figure 19 A schematic diagram of the load support structure 320 is shown. Figure 20 A schematic diagram of the upper outer casing portion 311 is shown. Figure 21 A schematic diagram of the upper load support structure section 321 is shown. Figure 22 A schematic diagram of the lower load support structure portion 322 is shown, and Figure 23 A schematic diagram of the lower outer shell portion 312 is shown. Specifically, in the schematic diagrams of the load-bearing structure 320, the upper load-bearing structure portion 321, and the lower load-bearing structure portion 322 in the upper left corner of the figure, only the ribs are shown. The circular shape of the ribs makes them particularly easy to manufacture by thermoforming.

[0129] exist Figures 18 to 23Four rudders 318 can also be seen. The rudders 318 form a unit with the upper housing portion 311. In this example, each rudder 318 is connected to the upper housing portion 311 over its entire width. Alternatively, the connection could be achieved through a strip structure that does not extend over the entire width of the corresponding rudder 318.

[0130] In this example, the rudder 318 is formed by the upper outer shell portion 311, and the connection with the rudders 319', 319'', 319''' is interrupted at the load support structure 320 and the lower outer shell portion 312. Alternatively, the rudder 318 may also be formed by multiple portions of the outer shell 310 and the load support structure 320. In this case, the stiffness of the strip structure used for connection is adjusted accordingly.

[0131] Figure 24 A schematic flowchart illustrating an embodiment of the method according to the present invention is shown.

[0132] Method 900 corresponds to the manufacturing method of the UAV shown above.

[0133] Method 900 includes step 910 of manufacturing the drone shell.

[0134] Method 900 further includes step 920 of manufacturing a UAV load support structure, wherein the load support structure includes an upper load support structure portion and a lower load support structure portion. In this case, the upper load support structure portion and the lower load support structure portion each include at least a load support structure for the UAV fuselage and a load support structure for the UAV wings.

[0135] The order of steps 910 and 920 is arbitrary.

[0136] Method 900 further includes a step 930 of joining the housing to the load-bearing structure. Preferably, step 930 of joining the housing to the load-bearing structure includes gluing the housing to the load-bearing structure.

[0137] In addition, the method may include step 940 of attaching the front portion to the housing and / or load-bearing structure.

[0138] Even though the accompanying drawings illustrate different aspects or features of the invention, it will be apparent to those skilled in the art (unless otherwise stated) that the illustrated and discussed combinations are not the only possible combinations. In particular, corresponding combinations of units or features from different embodiments can be interchanged with each other.

[0139] Other considerations regarding the present invention are as follows: Aircraft manufacturing uses a variety of production methods and materials (such as fiber composites such as carbon fiber or glass fiber reinforced plastics, metals, plastics, etc.), and various thermoforming processes are also used for plastics, for example, to produce sub-components such as cabin interiors.

[0140] Compared to metal structures, plastics have a lower specific gravity, thus allowing for weight reduction. Furthermore, metal processing is expensive; injection molding, for example, requires high temperatures. Cold-formed metal parts are also more expensive to process because they must be stamped, formed, and assembled by welding or riveting.

[0141] However, when using plastics, it is essential to ensure that the stability requirements of the flying object are met. This can be achieved, for example, by using thicker walls.

[0142] Instead, this invention specifies that the load-bearing structure be located inside the flying object to achieve the necessary mechanical stability. This enables a lighter design compared to plastics with thick walls.

[0143] With the aid of the design of the load-bearing structure according to the present invention, thermoforming processes can be used to manufacture the load-bearing structure.

[0144] This design has the following advantages: Compared with foam support structures, it can reduce weight while improving the mechanical load-bearing capacity of the load-bearing structure.

[0145] Using plastic as the outer shell allows for a transparent design.

[0146] Compared to designs where the outer shell is manufactured using thermoforming processes and reinforced with struts, ribs, and spars, which are in turn manufactured using other processes (such as stamping or extrusion), this invention requires far fewer individual components. Fewer individual components make assembly easier and result in lower production costs.

[0147] Compared to construction methods using welded thermoplastics, this method is less complex to produce, resulting in shorter production times because it eliminates the need for welding at specific points.

[0148] Due to the single-cavity tooling (1-fach-Werkzeug), thermoforming processes only allow for one main forming direction. Given the complex hollow body shape of aircraft or drones, it is preferable to divide the aircraft or drone into sections to allow for the application of thermoforming processes. To hypothetical experts, dividing the shell into upper and lower sections and adjusting the wall thickness to achieve sufficient mechanical stability would seem obvious. However, this results in unnecessary wall thickness and added weight.

[0149] To address the issue of high weight, this invention provides a load-bearing structure for the outer shell. The load-bearing structure can be implemented in various ways, for example, by means of struts, ribs, and spars. Since outer shells are typically reinforced over a large area, it is hypothetical that experts would provide numerous individual reinforcing elements, resulting in a large number of components; however, in the load-bearing structure according to the invention, this large number of components is avoided.

[0150] The method according to the invention can be used in all areas of aircraft construction because it is capable of producing components several meters in size. This method is primarily applied to unmanned aerial vehicles (UAVs), especially military UAVs.

[0151] Preferably, at least some parts of the load-bearing structure are manufactured using thermoforming processes designed for mass production. The functional combination of only a few components makes the production of flying objects (especially drones) more cost-effective and easier to scale up. In addition, weight reduction and transparent design methods become possible.

[0152] The core idea of ​​this invention is to provide a load-bearing structure, which preferably consists of only two components covering the entire aircraft. Therefore, the reinforcing element is not installed as a single, isolated part in corresponding components such as the fuselage, wings, and stabilizer, but rather preferably extends throughout the entire aircraft. The separation of the upper and lower portions of the load-bearing structure allows for cost-effective production using thermoforming processes with single-cavity tools, even with highly complex overall shapes.

[0153] The process and / or other features of the flying object, preferably individually or in combination, are as follows: Thermoforming processes are preferably used to manufacture housings and / or load-bearing structures.

[0154] The load-bearing structure is divided into an upper part and a lower part.

[0155] In addition, the outer shell can be divided into an upper part and a lower part.

[0156] Transparent materials (such as polycarbonate) are preferred for manufacturing the outer shell. This makes the flying object more difficult to locate visually.

[0157] Alternatively, thermoforming can be used for applications with extremely thin walls (see food packaging), particularly for walls less than 12 mm, for example, in the range of 0.1 mm to 12 mm. These wall thicknesses are technically impossible to achieve with fiber composites. This makes it possible to produce lighter aircraft (compared to fiber composites or metal structures).

[0158] Alternatively, the fuel tank can be integrated into the load-bearing structure. This eliminates the need for a separate fuel tank and saves a component.

[0159] Elevators and ailerons can also be integrated. Elevators and ailerons are typically attached to the wing via hinges. This results in a large number of components, with not only the rudder being a separate unit, but also the hinges usually requiring an axle.

[0160] However, it is preferable to manufacture the rudder and wing as a single unit: in thermoforming, the rudder and wing are parts of one (or more) plastic sheets, and in the subsequent milling process, a connection is left at the transition between the wing and the rudder, which is one, two or more strip structures, or the connection is a strip structure spanning the entire width.

[0161] Because the material is thin and preferably has no curvature at critical points, it is flexible. For example, the rudder is formed from the upper shell portion, and the connection between the rudder and the wing is interrupted in the load-bearing structure and the lower shell portion so that the connection does not become too thick and rigid.

[0162] Therefore, flexibility can be achieved by using only one of the four layers as the connecting part. Alternatively, a multi-layer structure can be used, with only narrow strips remaining as the connecting parts, or a combination of both approaches can be combined.

[0163] The advantage of this design is that the components remain as a single unit during thermoforming and subsequent milling. This eliminates the production step of joining components via hinges. Furthermore, the design principle of hinges is complex, making them more prone to errors than simple plastic strip structures.

[0164] In addition, or alternatively, thermoplastic materials can be varied almost arbitrarily in terms of material thickness and deformability during thermoforming, thereby enabling the creation of energy-absorbing zones (Knautschzones) on civil aircraft to reduce damage in the event of a collision or impact.

[0165] These advantages primarily apply to civilian drones. It is foreseeable that autonomous drones will become more widespread in the future. However, a fundamental premise is that autonomous drones must become safer. Typically, safety is ensured through more complex control systems. However, collisions cannot be completely eliminated.

[0166] If a drone is equipped with an energy-absorbing zone, it can be designed so that when the drone collides with an object, some of the kinetic energy is absorbed by the energy-absorbing zone, thereby reducing damage to the object. In principle, the maximum weight of the drone and the energy-absorbing zone can be designed so that personnel will always survive a collision with the drone (drones can only reach a limited speed in free fall, depending on the drone's design and weight).

[0167] This means that the load-bearing structure and the outer shell or corresponding components are preferably manufactured using the thinnest possible material (e.g., 0.1 mm), and the load-bearing structure in the fuselage area is made larger; the engine and tail rotor can also be enclosed. In this way, the outer shell and load-bearing structure become energy-absorbing zones.

[0168] This manufacturing process offers several advantages for drone construction: cycle times are only a few minutes (a fraction of the cycle time for composite materials). Production is largely automated (unlike composites, which require significant manual labor). Mold design requirements are lower due to the need for only one side of the mold and the use of low pressure, and large parts can be produced (especially compared to injection molding). Only a few parts are needed, simplifying final assembly. Transparent plastics (such as polycarbonate) can also be used, making the drone difficult to locate visually. Composites and metals, on the other hand, are always opaque, making them easier to locate. Plastics have a lower radar cross-section compared to metals.

[0169] As an example of drones, the above-described process can be used to manufacture vertical takeoff and landing (VTOL) drone variants.

[0170] The VTOL drone variant features three horizontal propellers, making it a tri-rotor drone. This configuration offers the following advantages: no runway or catapult is required, allowing for more flexible deployment; multiple drones can be launched simultaneously in a swarm, whereas runways or catapults only allow for sequential takeoffs and landings.

[0171] Furthermore, in the case of civilian drones, such as delivery drones, the payload can be dropped anywhere without a runway.

[0172] Combining it with a fixed-wing aircraft allows for level flight efficiency far exceeding that of a quadcopter. This means that, unlike a quadcopter, this design is also suitable for medium and long distances, while still offering the flexibility of a quadcopter.

[0173] The implementation of the VTOL variant demonstrates that adding additional complex features (such as three horizontal propellers) does not increase the production cost of the aircraft, because according to the invention, the propeller supports and recesses can be integrated into existing components.

[0174] This invention relates to a manufacturing process for a drone, comprising the following steps: (i) manufacturing a drone shell, wherein the shell preferably includes an upper shell portion and a lower shell portion; (ii) manufacturing a load-bearing structure for the drone, wherein the load-bearing structure includes an upper load-bearing structure portion and a lower load-bearing structure portion, wherein each of the upper and lower load-bearing structure portions includes at least a load-bearing structure for the drone fuselage and a load-bearing structure for the drone wings; and (iii) combining the shell and the load-bearing structure. The invention also relates to a drone manufactured by the manufacturing method according to the invention. This method enables the simple manufacture of a stable drone.

Claims

1. A method for manufacturing a fixed-wing aircraft, particularly a drone (100, 200), the manufacturing method comprising the following steps: Manufacture the outer shell (110, 210, 310) of the fixed-wing aircraft. Manufacture the load support structure (120, 220, 320) of the fixed-wing aircraft. in, The load support structure (120, 220, 320) includes an upper load support structure (121, 221, 321) and a lower load support structure (122, 222, 322). Each of the upper load-bearing structure portions (121, 221, 321) and the lower load-bearing structure portions (122, 222, 322) includes at least a load-bearing structure for the fuselage (113, 213) of the fixed-wing aircraft and a load-bearing structure for the wings (114, 115, 214, 215) of the fixed-wing aircraft. The outer shell (110, 210, 310) is combined with the load support structure (120, 220, 320).

2. The manufacturing method according to claim 1, wherein, At least a portion of the outer shell (110, 210, 310) and / or at least a portion of the load-bearing structure (120, 220, 320) are manufactured by thermoforming. Preferably, all portions of the outer shell (110, 210, 310) and / or all portions of the load-bearing structure (120, 220, 320) are manufactured by thermoforming.

3. The manufacturing method according to any one of claims 1 and 2, wherein, Each of the upper load-bearing structure portions (121, 221, 321) and / or the lower load-bearing structure portions (122, 222, 322) has a generally planar extension, wherein a strut, rib and / or spar, through opening and / or recess are provided perpendicular to the generally planar extension.

4. The manufacturing method according to any one of the preceding claims, wherein, The support, the rib and / or the wing beam, and / or the through opening and / or the recess are circular.

5. The manufacturing method according to any one of the preceding claims, wherein, The outer shell (110, 210, 310) includes an upper outer shell portion (111, 211, 311) and a lower outer shell portion (112, 212, 312), wherein each of the upper outer shell portion (111, 211, 311) and the lower outer shell portion (112, 212, 312) includes at least an outer shell for the fuselage (113, 213) of the fixed-wing aircraft and an outer shell for the wings (114, 115, 214, 215) of the fixed-wing aircraft.

6. The manufacturing method according to any one of the preceding claims, wherein, Each of the upper load-bearing structure portion (121, 221, 321) and the lower load-bearing structure portion (122, 222, 322) is formed as a single unit.

7. The manufacturing method according to any one of the preceding claims, wherein, Each of the upper load-bearing structure portions (121, 221, 321) and the lower load-bearing structure portions (122, 222, 322) extends over the entire wingspan of the fixed-wing aircraft.

8. The manufacturing method according to any one of the preceding claims, wherein, The outer shell (110, 210, 310) and / or the load support structure (120, 220, 320) include the stabilizing surface (116, 117, 126, 127, 216, 217) of the fixed-wing aircraft, and / or the outer shell (110, 210, 310) and / or the load support structure (120, 220, 320) include a rudder (118, 218, 318), preferably, the rudder is connected to the outer shell (110, 210, 310) and / or the load support structure (120, 220, 320) by one or more strip structures.

9. The manufacturing method according to any one of the preceding claims, wherein, Combining the outer shell (110, 210, 310) with the load support structure (120, 220, 320) includes gluing the outer shell (110, 210, 310) with the load support structure (120, 220, 320).

10. The manufacturing method according to any one of the preceding claims, wherein, The outer shell (110, 210, 310) and / or the load support structure (120, 220, 320) are made of plastic, preferably transparent plastic, and particularly preferably polycarbonate.

11. The manufacturing method according to any one of the preceding claims, wherein, The load support structure (120, 220, 320) is configured to accommodate a fuel tank, and / or an engine bracket (129, 229) is provided between the load support structure (120, 220, 320) and the housing (110, 210, 310).

12. The manufacturing method according to any one of the preceding claims, further comprising the following steps: The front portion (130) is attached to the housing (110) and / or the load support structure (120).

13. A fixed-wing aircraft, particularly, the fixed-wing aircraft being an unmanned aerial vehicle (100, 200), the fixed-wing aircraft comprising an outer shell (110, 210, 310) and a load-bearing structure (120, 220, 320). in, The load support structure (120, 220, 320) includes an upper load support structure (121, 221, 321) and a lower load support structure (122, 222, 322). Each of the upper load-bearing structure portion (121, 221, 321) and the lower load-bearing structure portion (122, 222, 322) includes at least a load-bearing structure for the fuselage (113, 213) of the fixed-wing aircraft and a load-bearing structure for the wings (114, 115, 214, 215) of the fixed-wing aircraft.

14. A load support structure for a fixed-wing aircraft, particularly, the fixed-wing aircraft being an unmanned aerial vehicle (100, 200). in, The load support structure (120, 220, 320) includes an upper load support structure (121, 221, 321) and a lower load support structure (122, 222, 322). Each of the upper load-bearing structure portion (121, 221, 321) and the lower load-bearing structure portion (122, 222, 322) includes at least a load-bearing structure for the fuselage (113, 213) of the fixed-wing aircraft and a load-bearing structure for the wings (114, 115, 214, 215) of the fixed-wing aircraft.

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