Manufacturing process for a drone, drone and support structure for a drone

Abstract

Manufacturing process for a fixed-wing aircraft, in particular a drone (100, 200), comprising the steps: Manufacturing an outer shell (110, 210) for the fixed-wing aircraft, Manufacturing a supporting structure (120, 220) for the fixed-wing aircraft, wherein the supporting structure (120, 220) comprises an upper supporting structure part (121, 221) and a lower supporting structure part (122, 222), wherein the upper supporting structure part (121, 221) and the lower supporting structure part (122, 222) each comprise at least one supporting structure for a fuselage (113, 213) of the fixed-wing aircraft and a supporting structure for wings (114, 115, 214, 215) of the fixed-wing aircraft, wherein the supporting structure for the fuselage (113, 213) and the supporting structure for the wings (114, 115, 214, 215) each have struts, ribs, frames, through openings and / or recesses, and Assembling the outer shell and the supporting structure.

Description

[0001] The present invention relates to the field of drones and in particular to a manufacturing method for a drone, a drone and a support structure for a drone.

[0002] Drones are well known in the state of the art.

[0003] For example, US patent 2024 / 0010367 A1 describes an unmanned aerial vehicle (UAV) comprising a fuselage, a pair of wings attached to the fuselage, and a propulsion system mounted on the wings to power the UAV. The fuselage has an outer shell, which provides a primary mechanical support structure for the UAV's airframe. The pair of wings is attached to the fuselage and shaped to generate aerodynamic lift. The wings have outer wing skins, which provide secondary mechanical support for the airframe. The outer fuselage skin or wing skins are made of one or more shaped metal sheets.

[0004] US Patent 2009 / 0134273 A1 further describes an unmanned aerial vehicle (UAV) comprising an aircraft frame with a central body and wings extending from the central body, defining an interior space. The aircraft frame includes an upper and a lower shell, each made from a single piece of plastic. The upper and lower shells have walls between them, defining a fuel tank and a payload compartment in a stacked configuration. The UAV may also include a payload cover configured to enclose the payload compartment and contribute to the central body of the UAV. A launch device is also provided.

[0005] There are various manufacturing processes for producing drones.

[0006] For example, DE 198 41 799 A1 describes a process which consists in that an aircraft is first manufactured in parts and all essential parts of the aircraft, in particular the lower fuselage and the other parts of the fuselage, are joined together without fittings by gluing.

[0007] Drones, like airplanes, are typically made of fiber-reinforced composites or metals. However, this has several disadvantages, such as high weight and complex manufacturing processes. While these drawbacks may not be as significant in aircraft construction, they are particularly important for drones, especially since drones are now required in large numbers and the stability requirements are lower than in aircraft construction.

[0008] Therefore, some components of drones are now made of plastic, for example through the thermoforming process, also known as vacuum forming.

[0009] For example, it is known to manufacture an outer shell of a drone from plastic, for example by thermoforming, whereby, as in aircraft construction, a supporting structure is provided to ensure the necessary stability of the drone.

[0010] This is usually achieved using a support structure made of foam, for example in the form of foam sheets. However, foam as a support structure has only limited stability, which is sometimes insufficient for drones.

[0011] As an alternative to a foam support structure, a support structure made of struts, ribs, and / or frames can also be used. These elements are usually manufactured using other production methods, such as stamping or extrusion.

[0012] However, a disadvantage here is that a thermoformed outer shell with struts, ribs, and frames as a supporting structure results in a large number of sub-components, since the outer shell requires extensive reinforcement. Each individual sub-component must be assembled during installation and typically requires manual manufacturing steps, making production complex and expensive.

[0013] Joining thermoplastic materials together, for example by welding, is also complex and expensive.

[0014] It is therefore desirable to present a solution that eliminates the above disadvantages.

[0015] One objective underlying the present invention is therefore to enable the simple production of stable drones.

[0016] According to a first aspect of the invention, a manufacturing method is proposed as defined in claim 1, namely a manufacturing method for a fixed-wing aircraft, in particular a drone, comprising the steps of: (i) manufacturing an outer shell for the fixed-wing aircraft, (ii) manufacturing a support structure for the fixed-wing aircraft, wherein the support structure comprises an upper support structure part and a lower support structure part, wherein the upper support structure part and the lower support structure part each comprise at least one support structure for a fuselage of the fixed-wing aircraft and one support structure for wings of the fixed-wing aircraft, and (iii) joining the outer shell and the support structure.

[0017] According to a second aspect of the invention, a fixed-wing aircraft, in particular a drone, is proposed as defined in claim 12, namely a fixed-wing aircraft comprising an outer shell and a supporting structure, wherein the supporting structure comprises an upper supporting structure part and a lower supporting structure part, wherein each of the upper supporting structure part and the lower supporting structure part comprises at least one supporting structure for a fuselage of the fixed-wing aircraft and a supporting structure for wings of the fixed-wing aircraft.

[0018] According to a third aspect of the invention, a support structure for a fixed-wing aircraft, in particular a drone, is proposed as defined in claim 13, namely a support structure comprising an upper support structure part and a lower support structure part, wherein the upper support structure part and the lower support structure part each comprise at least a support structure for a fuselage of the fixed-wing aircraft and a support structure for wings of the fixed-wing aircraft.

[0019] The manufacturing process is intended for the production of a fixed-wing aircraft, in particular a drone, but can also be adapted for the production of another flying object, for example an airplane.

[0020] The following describes the characteristics in relation to a drone, but they apply to any type of fixed-wing aircraft.

[0021] Fixed-wing aircraft are flying objects that have a rigid wing, i.e., rigid wings, where "rigid" means that the wings are immovably connected to a fuselage of the flying object. A fixed-wing aircraft, or a drone according to the invention, therefore comprises a fuselage and two wings. For example, the fixed-wing aircraft is a VTOL (vertical take-off and landing) drone.

[0022] The outer shell comprises the outer surface of the drone, preferably the outer shell substantially encompassing the outer surface of the drone, where "substantially encompassing" means that at least a substantial area, i.e., more than 90% of the outer surface, is encompassed by the outer shell.

[0023] The drone can be divided along a horizontal axis of the drone into an upper half and a lower half, wherein the term "upper" in connection with the invention means that the corresponding element, here the upper half, is arranged at the top of the drone when the drone is properly positioned on the ground, wherein the term "lower" in connection with the invention means that the corresponding element, here the lower half, is arranged at the bottom of the drone when the drone is properly positioned on the ground.

[0024] In general, the supporting structure corresponds to a component of the drone that reinforces the drone, i.e., the outer shell of the drone.

[0025] The supporting structure comprises an upper supporting structure part and a lower supporting structure part, wherein the supporting structure is horizontally divided into the upper supporting structure part and the lower supporting structure part.

[0026] Preferably, the supporting structure comprises elements of the drone that are provided for stabilizing the drone, i.e., the outer shell, wherein the supporting structure according to the invention particularly preferably comprises all elements of the drone that are provided for stabilizing the drone, i.e., the outer shell.

[0027] Preferably, the outer shell surrounds the support structure of the drone, and particularly preferably, the outer shell essentially completely surrounds the support structure, i.e., the outer shell surrounds the support structure at least above and below the support structure.

[0028] The upper support structure comprises at least one support structure for the drone's fuselage and one support structure for the drone's wings. That is, the upper support structure can be divided into several (horizontally arranged) sections, each comprising a support structure for the fuselage and a separate support structure for the wings.

[0029] The same applies to the lower support structure. The lower support structure also comprises a support structure for the drone's fuselage and a support structure for the drone's wings. This means that the lower support structure can also be divided into several (horizontally arranged) sections, each comprising a support structure for the fuselage and a separate support structure for the wings.

[0030] In an advantageous embodiment of one aspect of the invention, at least one part, preferably all parts, of the outer shell and / or at least one part, preferably all parts, of the supporting structure is manufactured by thermoforming.

[0031] That is, it is preferred that at least part of the outer shell is manufactured by thermoforming. Additionally or alternatively, at least part of the supporting structure is also preferably manufactured by thermoforming.

[0032] Particularly preferred is the entire outer shell, i.e., all parts of the outer shell, manufactured by thermoforming. Additionally or alternatively, it is further particularly preferred that the entire supporting structure, i.e., all parts of the supporting structure, be manufactured by thermoforming. In this particularly preferred embodiment, the outer shell, the upper supporting structure part, and the lower supporting structure part each correspond to a part manufactured by thermoforming.

[0033] In a further advantageous embodiment, the upper support structure has a substantially planar extent. The planar extent of the upper support structure corresponds to the horizontal extent of the drone. "Planar" here means that the extent in two dimensions of the upper support structure is significantly greater than its extent in the third dimension. The upper support structure preferably has struts, ribs, and / or frames perpendicular to its planar extent. Additionally or alternatively, the upper support structure has openings that preferably have a honeycomb cross-section, but can also have other shapes, such as round or rectangular.Additionally or alternatively, the upper supporting structure part may have recesses which preferably have a honeycomb-shaped, round or angular cross-section, but may also have other shapes.

[0034] Additionally or alternatively, the lower support structure has a substantially planar extent. The planar extent of the lower support structure corresponds to the horizontal extent of the drone. "Planar" here means that the two-dimensional extent of the lower support structure is significantly larger than its three-dimensional extent. The lower support structure preferably has struts, ribs, and / or frames perpendicular to its planar extent. Additionally or alternatively, the lower support structure has openings, preferably with a honeycomb cross-section, but which may also have other shapes, such as round or rectangular.Additionally or alternatively, the lower supporting structure part may have recesses, which preferably have a honeycomb-shaped, round or angular cross-section, but may also have other shapes.

[0035] This results in a particularly stable design of the supporting structure.

[0036] In particular, the outer contour of an upper supporting structure part and a lower supporting structure part preferably corresponds essentially to an outer contour of the outer shell and thus essentially to an outer surface of the drone.

[0037] In a further advantageous embodiment of one aspect of the invention, the outer shell comprises an upper outer shell part and a lower outer shell part. That is, the outer shell can be horizontally divided into the upper outer shell part and the lower outer shell part. The upper outer shell part essentially corresponds to the upper half of the drone's outer shell, and the lower outer shell part essentially corresponds to the lower half of the outer shell.

[0038] The upper outer shell part and the lower outer shell part each comprise at least one outer shell for the drone's fuselage and one outer shell each for the drone's wings; i.e., the upper outer shell part and the lower outer shell part can each be divided into a section for the drone's fuselage and sections for the drone's wings.

[0039] In particular, it is preferred that the outer shell extends from one end of one wing of the drone to the other end of the other wing of the drone, i.e. over the entire wingspan or wing width of the drone.

[0040] Preferably, the upper supporting structure is designed as a single piece. Additionally or alternatively, the lower supporting structure is designed as a single piece.

[0041] In the case that the outer shell comprises an upper outer shell part and a lower outer shell part, it is further preferred that the upper outer shell part and / or the lower outer shell part is also designed as a single piece.

[0042] It is also preferred that the upper supporting structure extends over the entire span of the rigid-wing aircraft. Additionally or alternatively, the lower supporting structure also extends over the entire span of the rigid-wing aircraft.

[0043] In the case that the outer shell comprises an upper outer shell section and a lower outer shell section, the upper outer shell section and / or the lower outer shell section preferably also extend over the entire wingspan of the fixed-wing aircraft. "Over the entire wingspan" means that the respective component extends across the width of the drone from one end of the wing to the other end of the wing.

[0044] In a further advantageous embodiment of an aspect of the invention, the supporting structure consists of the upper supporting structure part and the lower supporting structure part. That is to say, the drone comprises no further supporting structure parts than the upper supporting structure part and the lower supporting structure part; in particular, all parts contributing to the supporting structure of the drone are formed by the upper supporting structure part and the lower supporting structure part.

[0045] In a further advantageous embodiment of an aspect of the invention, the outer shell, preferably an upper outer shell part and / or a lower outer shell part, and / or the supporting structure, preferably the upper supporting structure part and / or the lower supporting structure part, has a wall thickness of 0.1 mm to 12 mm.

[0046] In a further advantageous embodiment of an aspect of the invention, the outer shell and / or the supporting structure includes stabilizers for the drone. In particular, the upper supporting structure part and / or the lower supporting structure part include stabilizers for the drone. If the outer shell comprises an upper outer shell part and a lower outer shell part, it is further preferred that the upper outer shell part and / or the lower outer shell part include stabilizers for the drone. Stabilizers serve to maintain the drone's stable position in the air or during flight.

[0047] This allows the number of individual parts required for the production of the drone to be further reduced.

[0048] In a further advantageous embodiment of one aspect of the invention, joining the outer shell and the supporting component includes bonding the outer shell and the supporting component. This is particularly preferred if the outer shell comprises an upper outer shell part and a lower outer shell part.

[0049] By providing an upper and a lower support structure, and optionally an upper and a lower outer shell, it is possible to connect the respective parts at points on the drone that are not subjected to significant stress during flight. In particular, the connection plane of the corresponding parts corresponds to a horizontal cross-sectional plane of the drone, on which no significant force acts during operation. This allows adhesive bonding to be sufficient to join the respective parts together.

[0050] In a further advantageous embodiment of an aspect of the invention, the outer shell and / or the supporting structure consists of a plastic, preferably a transparent plastic, particularly preferably polycarbonate.

[0051] The use of plastic, for example processed by thermoforming, also allows the use of transparent plastic, thus reducing the visibility of a drone.

[0052] In a further advantageous embodiment of one aspect of the invention, the support structure is configured to at least accommodate a fuel tank. The fuel tank is preferably arranged between the upper and lower support structure sections. Additionally or alternatively, an engine mount is provided between the support structure and the outer shell. The engine mount can be attached to the support structure, particularly the lower support structure section, and / or to the outer shell, particularly a lower outer shell section. The engine mount preferably extends at least over the entire length of the lower support structure section or the lower outer shell section.

[0053] The support structure according to the invention makes it possible to leave areas of the support structure free that can be used for other drone components. This is particularly easy when a flat support structure is used.

[0054] In a further advantageous embodiment of one aspect of the invention, the supporting structure is designed to provide a crumple zone. That is, the supporting structure itself can then serve, at least partially, as a crumple zone. A crumple zone is designed such that it can absorb at least some of the kinetic energy generated during an impact. Particularly preferably, the outer shell, especially the upper outer shell section and / or the lower outer shell section, and the supporting structure, especially the upper and lower supporting structure sections, have a material thickness, i.e., a wall thickness, of 0.1 to 0.2 mm, for example, 0.1 mm. Preferably, the supporting structure, especially the upper and lower supporting structure sections, can be more voluminous in the fuselage section and / or enclose an engine and / or tail rotor.The outer shell and supporting structure thus become a crumple zone.

[0055] In a further advantageous embodiment of an aspect of the invention, the manufacturing process comprises the further step of attaching a front part to the outer shell and the supporting structure.

[0056] This front part can be understood as a nose of the drone and is attached to the front area of ​​the respective parts, in particular to the front area of ​​the upper support structure part, the lower support structure part and / or the outer shell, possibly the upper outer shell part and / or the lower outer shell part.

[0057] As an alternative to an attached front part, the front part can also be formed by the outer shell and / or the supporting structure, i.e., in particular, if applicable, by the upper outer shell part, the lower outer shell part, an upper supporting structure part and / or a lower supporting structure part.

[0058] Features of advantageous embodiments of the invention are defined in particular in the dependent claims, with further advantageous features, embodiments and configurations also being apparent to the person skilled in the art from the above explanation and the following discussion.

[0059] The present invention will now be further illustrated and explained with reference to exemplary embodiments shown in the figures. Here, Fig. 1a a perspective view to illustrate a first embodiment of a drone according to the invention, Fig. 1b a schematic representation to illustrate the first embodiment from the side, Fig. 2 a perspective exploded view to illustrate the first embodiment of the drone, Fig. 3a a perspective view to illustrate an upper outer shell part according to the first embodiment from a slant below, Fig. 3b a schematic representation to illustrate the upper outer shell part according to the first embodiment from the side, Fig. 3c a perspective view to illustrate the upper outer shell part according to the first embodiment from an oblique angle above, Fig. 4a a perspective view to illustrate an upper supporting structure part according to the first embodiment from a slant below, Fig. 4b a schematic representation to illustrate the upper supporting structure part according to the first embodiment from the side, Fig. 4c a perspective view to illustrate the upper supporting structure part according to the first embodiment from an oblique angle above, Fig. 5a a perspective view to illustrate a lower supporting structure part according to the first embodiment from a slant below, Fig. 5b a schematic representation to illustrate the lower supporting structure part according to the first embodiment from the side, Fig. 5c a perspective view to illustrate the lower supporting structure part according to the first embodiment from an oblique angle above, Fig. 6a a perspective view to illustrate a lower outer shell part according to the first embodiment from a slant below, Fig. 6b a schematic representation to illustrate the lower outer shell part according to the first embodiment from the side, Fig. 6c a perspective view to illustrate a lower outer shell part according to the first embodiment from an oblique angle above, Fig. 7 a perspective view to illustrate a lower supporting structure part according to the first embodiment with a motor suspension from an oblique angle below, Fig. 8 a perspective view to illustrate a lower outer shell part according to the first embodiment with an engine mounting from an oblique angle above, Fig. 9a a perspective view to illustrate a second embodiment of a drone according to the invention, Fig. 9b a schematic representation to illustrate the second embodiment from the side, Fig. 10. A perspective exploded view to illustrate the second embodiment of the drone, Fig. 11a a perspective view to illustrate an upper outer shell part according to the second embodiment from a slant below, Fig. 11b a schematic representation to illustrate the upper outer shell part according to the second embodiment from the side, Fig. 11c a perspective view to illustrate the upper outer shell part according to the second embodiment from an oblique angle above, Fig. 12a a perspective view to illustrate an upper supporting structure part according to the second embodiment from a slant below, Fig. 12b a schematic representation to illustrate the upper supporting structure part according to the second embodiment from the side, Fig. 12c a perspective view to illustrate the upper supporting structure part according to the second embodiment from an oblique angle above, Fig. 13a a perspective view to illustrate a lower supporting structure part according to the second embodiment from a slant below, Fig. 13b a schematic representation to illustrate the lower supporting structure part according to the second embodiment from the side, Fig. 13c a perspective view to illustrate the lower supporting structure part according to the second embodiment from an oblique angle above, Fig. 14a a perspective view to illustrate a lower outer shell part according to the second embodiment from a slant below, Fig. 14b a schematic representation to illustrate the lower outer shell part according to the second embodiment from the side, Fig. 14c a perspective view to illustrate a lower outer shell part according to the second embodiment from an oblique angle above, Fig. 15 a perspective view to illustrate a lower supporting structure part according to the second embodiment with a motor suspension from an oblique angle below, Fig. 16 a perspective view to illustrate a lower outer shell part according to the second embodiment with an engine mounting from an oblique angle above, and Fig. 17 a schematic flowchart of an embodiment of the method according to the invention.

[0060] In the accompanying drawings and the explanations relating to these drawings, corresponding or related elements are marked with corresponding or similar reference symbols, where appropriate, even if they are found in different embodiments.

[0061] Fig. Figure 1a shows a perspective view to illustrate a first embodiment of a drone according to the invention and Fig. 1b a schematic representation to illustrate the first embodiment from the side.

[0062] In particular, the drone 100 comprises an outer shell 110. In the embodiment shown, the outer shell 110 comprises an upper outer shell part 111 and a lower outer shell part 112.

[0063] The upper outer shell part 111 and the lower outer shell part 112 each comprise a planar extension, in particular according to a shape of the drone. In other words, the upper outer shell part 111 and the lower outer shell part 112 extend over the entire wingspan of the drone, that is, from one end of the wing to the other end of the wing.

[0064] In particular, the upper outer shell part 111 and the lower outer shell part 112 each comprise an outer shell section for a fuselage of the drone 113 and an outer shell section of a respective wing of the drone 114, 115.

[0065] The upper outer shell part 111 and the lower outer shell part 112 are each designed in one piece and are preferably manufactured by the thermoforming process.

[0066] In the embodiment shown, the outer shell 110 comprises stabilizers 116, 117 of the drone 100. The outer shell 110 can be joined by gluing together the upper outer shell part 111 and the lower outer shell part 112.

[0067] In particular, the outer shell 110 consists of a plastic, preferably a transparent plastic such as polycarbonate.

[0068] The drone 100 shown in the embodiment shown comprises a front part 130, which is attached to the front of the outer shell 110, in particular glued.

[0069] The wings of the Drone 100 are rigidly designed and have an ergonomic shape.

[0070] Fig. Figure 2 shows a perspective exploded view illustrating the first embodiment of the drone. The support structure 120 of the drone 100 is particularly visible. The support structure 120 comprises an upper support structure part 121 and a lower support structure part 122.

[0071] The upper support structure part 121 and the lower support structure part 122 each extend over a wingspan of the drone 100 and each comprise a support structure for a fuselage and a support structure for wings of the drone 100.

[0072] The upper supporting structure part 121 and the lower supporting structure part 122 are also each designed in one piece and are preferably manufactured by the thermoforming process.

[0073] The supporting structure 120, in particular the upper supporting structure part 121 and the lower supporting structure part 122, each comprises struts, ribs and / or frames. Additionally or alternatively, the supporting structure 120, in particular the upper supporting structure part 121 and / or the lower supporting structure part 122, may have openings, for example with a honeycomb-shaped, round or rectangular cross-section, and / or recesses, for example with a honeycomb-shaped, round or rectangular cross-section.

[0074] The supporting structure also includes 120 stabilizers for the Drone 100. Additionally, 118 rudders for the Drone 100 are also shown.

[0075] The support structure 120 according to the invention enables easy attachment of such components, since brackets and recesses for such and other components can be easily integrated.

[0076] Preferably, the parts, i.e., the upper supporting structure part, the lower supporting structure part, the upper outer shell part, the lower outer shell part and the front part, can be joined together by gluing.

[0077] Fig. Figure 3a shows a perspective view illustrating an upper outer shell part according to the first embodiment, viewed from a low angle. Fig. 3b a schematic representation to illustrate the upper outer shell part from the side and Fig. 3c is a perspective drawing to illustrate the upper outer shell part from a slant above.

[0078] It is evident that the upper outer shell part 111 (as well as the other parts 112, 121, 122, see below) has no angles or sharp edges, making it suitable for thermoforming. The upper outer shell part 111 comprises an outer shell section for a fuselage of the drone 113, which essentially corresponds to one longitudinal half of an elongated hollow cylinder, and an outer shell section for each wing of the drone 114, 115, which essentially correspond to the wing shape of the drone. The outer shell part 111 thus provides an upper outer surface for the drone.

[0079] The upper outer shell section 111 includes stabilizers 116 at the ends of the outer shell sections for the wings, which project vertically upwards from a planar extension of the upper outer shell section 111. Furthermore, the upper outer shell section 111 includes an opening 119, for example for filling a fuel tank that can be arranged inside the drone 100 (see below).

[0080] Fig. Figure 4a shows a perspective view illustrating an upper supporting structure part according to the first embodiment, viewed from a low angle. Fig. 4b a schematic representation to illustrate the upper supporting structure part from the side and Fig. 4c is a perspective view illustrating the upper supporting structure from a slant above.

[0081] In particular, the struts, ribs, and frames of the upper supporting structure section 121 are visible here. Also visible are a section for the fuselage 113, which is shaped according to the section of the outer skin for the fuselage, as well as two sections for the wings 114 and 115, which are shaped according to the sections of the outer skin for the wings. The struts, ribs, and frames are provided in the section for the fuselage 113 and in the sections for the wings 114 and 115.

[0082] The upper supporting structure part 121 comprises a recess for a fuel tank 128', which corresponds in particular to an upper part of the recess for the fuel tank, as well as an opening for filling a fuel tank which is arranged in the recess, corresponding to the opening 119 of the upper outer shell part 111. Furthermore, the upper supporting structure part 121 comprises stabilizers 126 which project vertically upwards from a planar extension of the upper supporting structure part 121.

[0083] Fig. Figure 5a shows a perspective view illustrating a lower supporting structure part according to the first embodiment, viewed from a low angle. Fig. 5b a schematic representation to illustrate the lower supporting structure part from the side and Fig. 5c a perspective view to illustrate the lower supporting structure part from a slant above.

[0084] Here, the struts, ribs, and frames of the lower supporting structure section 122 can be seen. Also visible are a section for the fuselage 113 and two sections for the wings 114 and 115, which are shaped according to the respective sections of the outer skin 110 of the drone 100. The struts, ribs, and frames are provided in the section for the fuselage 113 and in the sections for the wings 114 and 115.

[0085] The lower supporting structure part 122 includes a recess for the fuel tank 128", which corresponds in particular to a lower part of the recess for the fuel tank, as well as stabilizers 127, which extend vertically downwards from a planar extension of the lower supporting structure part 112.

[0086] Fig. Figure 6a shows a perspective view illustrating a lower outer shell part according to the first embodiment, viewed from a low angle. Fig. 6b a schematic representation to illustrate the lower outer shell part from the side and Fig. 6c a perspective drawing to illustrate a lower outer shell section from a slant above.

[0087] In particular, an outer shell section for the fuselage 113 can be seen here, as well as outer shell sections for the wings 114, 115.

[0088] The lower outer shell part 112 also has stabilizers 117 that extend perpendicularly from a planar extension of the lower outer shell part 112.

[0089] Fig. Figure 7 shows a perspective view illustrating a lower support structure part according to the first embodiment with a motor suspension viewed obliquely from below. In particular, the lower support structure part shown corresponds to the lower support structure part 122.

[0090] The motor mount 129 corresponds to an elongated, rectangular-section element that runs along the entire lower support structure part 122 from front to back through the drone 100 and extends beyond the lower support structure part 122 at the rear to allow the motor to be attached and at the same time ensure a stable arrangement of the motor mount.

[0091] Alternatively, the engine mounting can also be arranged on the lower outer shell part 112, as shown in Fig. 8 shown.

[0092] Fig. Figure 8 shows a perspective view to illustrate a lower outer shell part according to the first embodiment with an engine mounting from an oblique angle above.

[0093] A second embodiment of a drone is described below. Descriptions of features that are identical in both embodiments, as can be seen in the figures, are partially omitted.

[0094] Fig. Figure 9a shows a perspective view to illustrate a second embodiment of a drone according to the invention and Fig. 9b a schematic representation to illustrate the second embodiment from the side.

[0095] The wings of the Drone 200 are rigidly designed and have an ergonomic shape.

[0096] In particular, the drone 200 comprises an outer shell 210 with an upper outer shell part 211 and a lower outer shell part 212.

[0097] The upper outer shell part 211 and the lower outer shell part 212 each comprise a planar extension, in particular according to a shape of the drone 200. In other words, the upper outer shell part 211 and the lower outer shell part 212 extend over the entire wingspan of the drone 200, that is, from one end of the wing to the other end of the wing.

[0098] The upper outer shell part 211 and the lower outer shell part 212 each comprise an outer shell section for a fuselage of the drone 213 and an outer shell section of a respective wing of the drone 214, 215.

[0099] The upper outer shell part 211 and the lower outer shell part 212 are each designed in one piece and are preferably manufactured by the thermoforming process.

[0100] The outer shell 210 includes stabilizers 216, 217.

[0101] The outer shell 210 can be joined by bonding the upper outer shell part 211 and the lower outer shell part 212. In particular, the outer shell 110 consists of a plastic, preferably a transparent plastic such as polycarbonate.

[0102] In the second embodiment, the drone 200 comprises a front section 230, which is part of the outer shell 210. That is, the front section 230 is formed from the upper outer shell section 211, the lower outer shell section 212, the upper support structure section 221, and the lower support structure section 222 (as shown in particular in Fig. 10 to recognize).

[0103] In the second embodiment, the drone 200 comprises three propellers, i.e., it is configured as a tricopter. For this purpose, the drone 200, in particular its outer shell 210, includes propeller openings 241, 242, 243. The propeller opening 241 is arranged in a front section 230 of the drone 200, and the propeller openings 242, 243 are each arranged in a section for the wings 214, 215.

[0104] Fig. Figure 10 shows a perspective exploded view illustrating the second embodiment of the drone. The exploded view also shows the support structure 220 of the drone 200, which comprises an upper support structure part 221 and a lower support structure part 222.

[0105] The upper support structure part 221 and the lower support structure part 222 each extend over a wingspan of the drone 200 and each comprise a support structure for a fuselage and a support structure for wings of the drone 200.

[0106] The upper supporting structure part 221 and the lower supporting structure part 222 are each designed in one piece and are preferably manufactured by the thermoforming process.

[0107] The supporting structure 220, that is, the upper supporting structure part 221 and the lower supporting structure part 222, each comprises struts, ribs, and / or frames. Additionally or alternatively, the supporting structure 220, in particular the upper supporting structure part 221 and / or the lower supporting structure part 222, may have openings, for example with a honeycomb-shaped, round, or rectangular cross-section, and / or recesses, for example with a honeycomb-shaped, round, or rectangular cross-section.

[0108] Furthermore, the supporting structure includes 210 stabilizers 216, 217 of the drone, and rudders 218 for the drone 200 are also shown.

[0109] Preferably the parts, i.e. the upper supporting structure part 221, the lower supporting structure part 222, the upper outer shell part 211 and the lower outer shell part 212, can be joined together by gluing.

[0110] Fig. Figure 11a shows a perspective view illustrating an upper outer shell part according to the second embodiment, viewed from a low angle. Fig. 11b from the side and Fig. 11c from a slightly elevated angle.

[0111] In particular, the upper outer shell part 211 includes an opening 219, which is intended, for example, for filling a fuel tank that can be arranged inside the drone 200.

[0112] Again, the propeller openings 241, 242, 243 can also be seen, with the propeller opening 241 being arranged in a front part 230 which is provided as one piece with the upper outer shell part 211, and the propeller openings 242, 243 each being in an outer shell section of the wings, in particular a respective end of the wings.

[0113] Fig. Figure 12a shows a perspective view illustrating an upper supporting structure part according to the second embodiment, viewed from a low angle. Fig. 12b from the side and Fig. 12c from a slightly elevated angle.

[0114] The upper support structure part 221 also has propeller openings 241, 242 and 243, which are arranged accordingly in a front part 230 formed in one piece with the upper support structure part 221 and in respective sections of the upper support structure part 221 for the wings.

[0115] In addition, a recess for a fuel tank 228' can be seen, which corresponds in particular to an upper part of the recess for the fuel tank.

[0116] Fig. Figure 13a shows a perspective view illustrating a lower supporting structure part according to the second embodiment, viewed from a low angle. Fig. 13b from the side and Fig. 13c from a slightly elevated angle.

[0117] The lower support structure part 222 also has propeller openings 241, 242 and 243, which are arranged accordingly in a front part 230 formed in one piece with the lower support structure part 222 and in respective sections of the lower support structure part 221 for the wings.

[0118] A recess for the fuel tank 228', which corresponds in particular to a lower part of the recess for the fuel tank, is also shown.

[0119] Fig. Figure 14a shows a perspective view illustrating a lower outer shell part according to the second embodiment, viewed from a low angle. Fig. 14b from the side and Fig. 14c from a slightly elevated angle.

[0120] Here too, the propeller openings 241, 242, 243 are shown, as explained above.

[0121] Fig. Figure 15 shows a perspective view illustrating a lower support structure part according to the second embodiment with a motor suspension viewed obliquely from below and Fig. 16 a perspective view to illustrate a lower outer shell part according to the second embodiment with an engine suspension from an oblique angle above.

[0122] The motor mounting 229 corresponds, as in the first embodiment, to an elongated element with a rectangular cross-section, which runs along the entire lower support structure part 222 or the entire lower outer shell part 212 and extends at the rear over the lower support structure part 222 or the lower outer shell part 212 in order to enable the motor to be attached and at the same time to ensure a stable arrangement of the motor mounting.

[0123] Fig. Figure 17 shows a schematic flowchart of an embodiment of the method according to the invention.

[0124] The process 900 corresponds to a manufacturing process for a drone, as shown above.

[0125] Procedure 900 includes step 910 of manufacturing an outer shell for the drone.

[0126] Furthermore, method 900 comprises step 920 of manufacturing a support structure for the drone, wherein the support structure comprises an upper support structure part and a lower support structure part. Each of the upper and lower support structure parts comprises at least one support structure for a fuselage of the drone and one support structure for wings of the drone.

[0127] The order of step 910 and step 920 is arbitrary.

[0128] Method 900 further comprises a step 930 of joining the outer shell and the supporting structure. Preferably, step 930 of joining the outer shell and the supporting structure comprises bonding the outer shell and the supporting structure.

[0129] Additionally, the procedure may include step 940 of attaching a front part to the outer shell and / or the supporting structure.

[0130] Even though the figures show various aspects or features of the invention in combination, it is apparent to the person skilled in the art – unless otherwise stated – that the combinations shown and discussed are not the only possible ones. In particular, corresponding units or sets of features from different embodiments can be interchanged. The following are further considerations regarding the invention:

[0131] In aircraft construction, a wide variety of production methods and materials are used (fiber composites such as carbon fiber or glass fiber reinforced plastic, metals, plastics, etc.), with the thermoforming process also being used in various versions for plastics, for example for the production of sub-components such as cabin interior linings.

[0132] Compared to metal construction, plastics have a lower specific gravity, thus allowing for weight savings. Furthermore, metal is complex to process; for example, injection molding requires high temperatures. Cold-formed metal parts are also more complex to process, as they must be stamped, shaped, and assembled by welding or riveting.

[0133] However, when using plastics, it is important to ensure that the missile's stability requirements are met. This could be achieved, for example, through thicker walls.

[0134] The invention instead provides for positioning a supporting structure inside the missile to achieve the necessary mechanical stability. This allows for a lighter design than would be possible with thick-walled plastics.

[0135] Due to the inventive design of the supporting structure, the thermoforming process can be applied to the production of the supporting structure. This brings the following advantages:

[0136] In comparison to a foam support structure, further weight savings can be achieved while simultaneously increasing the mechanical load-bearing capacity of the support structure.

[0137] The use of plastic as the outer shell makes a transparent construction possible.

[0138] Compared to construction methods where a thermoformed outer shell is reinforced with struts, ribs, and frames, which in turn are manufactured using other processes (e.g., stamping or extrusion), the invention requires far fewer individual parts. Fewer parts simplify assembly and result in lower production costs.

[0139] Compared to construction methods using welded thermoplastics, production is less complex because the welding is not done at specific points, resulting in shorter production times.

[0140] Due to the single-cavity tooling, the thermoforming process only allows for one primary forming direction. Since an aircraft or drone has a complex hollow shape, it is preferably subdivided to enable the thermoforming process. It might seem logical that a hypothetical expert would divide the outer shell into top and bottom sections and adjust the wall thickness to achieve sufficient mechanical stability. However, this results in wall thicknesses that add unnecessary weight.

[0141] To solve the problem of high weight, a supporting structure is created for the outer shell according to the invention. A supporting structure can be implemented in various ways, for example, by means of struts, ribs, and frames. Since the outer shell is normally reinforced over a large area, a hypothetical person skilled in the art would provide many individual reinforcing elements, which would lead to a large number of components, but not to the supporting structure according to the invention.

[0142] The inventive method can find applications throughout aircraft construction, as it enables the production of components up to several meters in size. The focus is on drones, particularly for military use.

[0143] By preferentially using the mass-production-oriented thermoforming process to manufacture at least part of the supporting structure and by preferentially combining functions into just a few components, the production of aircraft, especially drones, becomes more cost-effective and easily scalable. Furthermore, weight savings and transparent designs become possible.

[0144] The core concept of the invention is to provide a supporting structure, preferably consisting of only two components, that covers the entire aircraft. The reinforcing elements are therefore not mounted as isolated individual parts into the respective components such as the fuselage, wings, and stabilizers, but preferably extend over the entire aircraft. Separating the upper and lower parts of the supporting structure enables cost-effective production using thermoforming processes with single-cavity molds, even though the overall shape is highly complex.

[0145] The following are further features of the method and / or the aircraft, which are preferred individually or in combination: The thermoforming process is preferably used for the production of the outer shell and / or the supporting structure.

[0146] The supporting structure is divided into an upper and a lower surface.

[0147] Additionally, the outer shell can also be divided into an upper and lower surface.

[0148] Transparent materials (e.g., polycarbonate) are preferably used for the outer shell. This makes flying objects more difficult to locate visually.

[0149] Additionally or alternatively, thermoforming can be used with very thin walls (see food packaging), especially below 12 mm, for example in a range of 0.1 mm to 12 mm. These wall thicknesses are not technically possible with fiber composites. This makes it possible to produce lighter aircraft (compared to fiber composite or metal construction).

[0150] Additionally or alternatively, a fuel tank can be integrated into the supporting structure. This eliminates the need for a separate fuel tank and saves a component.

[0151] Furthermore, or alternatively, thermoforming allows thermoplastic materials to be varied almost arbitrarily in terms of both material thickness and deformability, making it possible to implement crumple zones in civilian aircraft so that less damage is caused in the event of a crash or impact.

[0152] The benefits primarily concern civilian drones. It is foreseeable that autonomous drones will become more widespread in the future. However, a fundamental prerequisite is that they become safer. Safety is usually ensured through more sophisticated control systems. Nevertheless, crashes cannot be completely ruled out.

[0153] If drones are equipped with crumple zones, they can be designed so that upon impact with an object, some of the kinetic energy is absorbed by the crumple zone, thus reducing damage to the object. In principle, it is possible to design the maximum weight of a drone and the crumple zone in such a way that a person would always survive a collision with a drone (since the drone can only reach a limited speed in free fall, depending on its design and weight).

[0154] This means that the supporting structure and outer shell, or the respective parts, are preferably produced with the thinnest possible material (e.g., 0.1 mm), and the supporting structure in the fuselage area is made more voluminous; the engine and tail rotor can also be enclosed. The outer shell and supporting structure thus become a crumple zone.

[0155] This production method offers several advantages for drone manufacturing: Cycle times are only a few minutes (a fraction of the cycle time for composite materials). Production is largely automated (unlike composites, which require a high degree of manual labor). Since only one side of the mold is needed and low pressure is used, the requirements for mold design are minimal, and even large components can be produced (especially compared to injection molding). Only a few components are needed, simplifying final assembly. Transparent plastics (e.g., polycarbonate) can also be used, making the drones difficult to detect visually. Composite materials and metals, on the other hand, are always opaque and therefore easier to detect. Compared to metals, plastics have a lower radar cross-section.

[0156] As an example of a drone, a VTOL variant can be manufactured using the above method.

[0157] The VTOL variant has three horizontal propellers, making it a tricopter. This configuration offers the following advantages: no runway or catapult is required, making its use more flexible; multiple drones can be launched simultaneously in a swarm, whereas a runway or catapult only allows for serial takeoffs / landings.

[0158] Furthermore, for example, civilian drones, such as those used for deliveries, can drop off shipments at any location, regardless of a runway.

[0159] The combination with fixed wings allows for significantly more efficient horizontal flight movements than quadcopters. This makes this design, unlike quadcopters, suitable for medium and long distances, while still offering the flexibility of a quadcopter.

[0160] The implementation of the VTOL variant shows that adding further complex features, such as the three horizontal propellers, does not make the production of the missiles more expensive, since brackets and recesses for the propellers can be integrated into the existing components according to the invention.

[0161] The invention relates to a manufacturing method for a drone comprising the steps of: (i) manufacturing an outer shell for the drone, wherein the outer shell preferably comprises an upper outer shell part and a lower outer shell part; (ii) manufacturing a support structure for the drone, wherein the support structure comprises an upper support structure part and a lower support structure part, wherein the upper support structure part and the lower support structure part each comprise at least one support structure for a fuselage of the drone and one support structure for wings of the drone; and (iii) joining the outer shell and the support structure. The invention also relates to a drone manufactured by the manufacturing method according to the invention. This enables the simple production of stable drones. Reference symbol list 100, 200 drone 110, 210 Outer shell 111, 211 Upper outer shell part 112, 212 Lower outer shell part 113, 213 Hull 114, 115, 214, 215 wings 116, 117, 126, 127, 216, 217 Stabilizers 118, 218 oars 119, 219 Opening 120, 220 supporting structure 121, 221 Upper supporting structure part 122, 222 Lower supporting structure part 128', 128", 228' Fuel tank 129, 229 Engine mount 130, 230 front part 241, 242, 243 Propeller opening

Claims

[1] Manufacturing process for a fixed-wing aircraft, in particular a drone (100, 200), comprising the steps: Manufacturing an outer shell (110, 210) for the fixed-wing aircraft, Manufacturing a supporting structure (120, 220) for the fixed-wing aircraft, wherein the supporting structure (120, 220) comprises an upper supporting structure part (121, 221) and a lower supporting structure part (122, 222), wherein the upper supporting structure part (121, 221) and the lower supporting structure part (122, 222) each comprise at least one supporting structure for a fuselage (113, 213) of the fixed-wing aircraft and a supporting structure for wings (114, 115, 214, 215) of the fixed-wing aircraft, wherein the supporting structure for the fuselage (113, 213) and the supporting structure for the wings (114, 115, 214, 215) each have struts, ribs, frames, through openings and / or recesses, and Assembling the outer shell and the supporting structure. [2] Manufacturing method according to claim 1, wherein at least one part, preferably all parts, of the outer shell (110, 210) and / or at least one part, preferably all parts, of the supporting structure (120, 220) are manufactured by thermoforming. [3] Manufacturing method according to one of claims 1 and 2, wherein the upper supporting structure part (121, 221) and / or the lower supporting structure part (122, 222) each have a substantially planar extent, wherein the struts, ribs and / or frames, through openings and / or recesses are provided perpendicular to the planar extent. [4] Manufacturing method according to one of the preceding claims, wherein the outer shell (110, 210) comprises an upper outer shell part (111, 211) and a lower outer shell part (112, 212), wherein the upper outer shell part (111, 211) and the lower outer shell part (112, 212) each comprise at least one outer shell for a fuselage (113, 213) of the fixed-wing aircraft and one outer shell for wings (114, 115, 214, 215) of the fixed-wing aircraft. [5] Manufacturing method according to one of the preceding claims, wherein the upper supporting structure part (121, 221) and the lower supporting structure part (122, 222) are each formed in one piece. [6] Manufacturing method according to one of the preceding claims, wherein the upper support structure part (121, 221) and the lower support structure part (122, 222) each extend over an entire span of the rigid wing. [7] Manufacturing method according to one of the preceding claims, wherein the outer shell (110, 210) and / or the supporting structure (120, 220) comprises stabilizers (116, 117, 126, 127, 216, 217) of the fixed-wing aircraft. [8] Manufacturing method according to one of the preceding claims, wherein the joining of the outer shell (110, 210) and the supporting structure (120, 220) comprises bonding the outer shell (110, 210) and the supporting structure (120, 220). [9] Manufacturing method according to one of the preceding claims, wherein the outer shell (110, 210) and / or the supporting structure (120, 220) is made of a plastic, preferably a transparent plastic, particularly preferably polycarbonate. [10] Manufacturing method according to one of the preceding claims, wherein the supporting structure (120, 220) is configured to accommodate a fuel tank and / or wherein an engine suspension (129, 229) is provided between the supporting structure (120, 220) and the outer shell (110, 210). [11] Manufacturing process according to any of the preceding claims, comprising the further step of: Attaching a front part (130) to the outer shell (110) and / or the supporting structure (120). [12] Fixed-wing aircraft, in particular drones (100, 200), comprising an outer shell (110, 210) and a supporting structure (120, 220), wherein the supporting structure (120, 220) comprises an upper supporting structure part (121, 221) and a lower supporting structure part (122, 222), wherein the upper supporting structure part (121, 221) and the lower supporting structure part (122, 222) each comprise at least one supporting structure for a fuselage (113, 213) of the fixed-wing aircraft and a supporting structure for wings (114, 115, 214, 215) of the fixed-wing aircraft and wherein the supporting structure for the fuselage (113, 213) and the supporting structure for the wings (114, 115, 214, 215) each have struts, ribs, frames, through openings and / or recesses. [13] Support structure for a fixed-wing aircraft, in particular a drone (100, 200), wherein the supporting structure (120, 220) comprises an upper supporting structure part (121, 221) and a lower supporting structure part (122, 222), wherein the upper supporting structure part (121, 221) and the lower supporting structure part (122, 222) each comprise at least one supporting structure for a fuselage (113, 213) of the fixed-wing aircraft and a supporting structure for wings (114, 115, 214, 215) of the fixed-wing aircraft and wherein the supporting structure for the fuselage (113, 213) and the supporting structure for the wings (114, 115, 214, 215) each have struts, ribs, frames, through openings and / or recesses.

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