Universal parachute recovery system for a drone

Abstract

The present specification relates to a universal parachute recovery system for a drone, comprising: a housing including a cavity having an upper portion for storing a folded parachute and a lower portion; a riser connected to the parachute and the housing; a gas expansion chamber within the lower portion of the cavity; a piston positioned between the parachute and the gas expansion chamber to eject the parachute when gas expands in the chamber; a gas-generating device disposed within the gas expansion chamber to trigger gas expansion; a base configured to support the housing and mount to the drone; and a controller operably connected to the gas-generating device for activation.

Description

P13425PC00UNIVERSAL PARACHUTE RECOVERY SYSTEM FOR A DRONEFIELD

[0001] The present specification relates generally to parachute recovery systems and more particularly to a universal parachute recovery system for a drone.BACKGROUND

[0002] Unmanned aerial vehicles such as drones are increasingly used in commercial and industrial applications. Many civil aviation authorities require drones to have a back up safety system, such as a parachute recovery system, to reduce the likelihood of a drone causing injuries to bystanders in the case of a system failure. Existing systems often suffer from complexity, bulkiness, or excessive weight, limiting their applicability across diverse drone platforms.SUMMARY

[0003] An aspect of the specification provides a universal parachute recovery system for a drone, comprising: a housing including a cavity having an upper portion for storing a folded parachute and a lower portion; a riser connected to the parachute and the housing; a gas expansion chamber within the lower portion of the cavity; a piston positioned between the parachute and the gas expansion chamber to eject the parachute when gas expands in the chamber; a gas-generating device disposed within the gas expansion chamber to trigger gas expansion; a base configured to support the housing and mount to the drone; and a controller operably connected to the gas-generating device for activation.

[0004] An aspect of the specification provides a universal parachute recovery system wherein the housing and the base are separate units affixed to one another.P13425PC00

[0005] An aspect of the specification provides a universal parachute recovery system wherein the base is connected to the housing via an anchoring system configured to transfer deployment forces from the housing to the base.

[0006] An aspect of the specification provides a universal parachute recovery system wherein the anchoring system comprises axially aligned fasteners along a common load path to transfer the deployment forces.

[0007] An aspect of the specification provides a universal parachute recovery system wherein the anchoring system comprises a housing fastener configured to secure the riser to the housing.

[0008] An aspect of the specification provides a universal parachute recovery system wherein the anchoring system further comprises a base fastener configured to attach a securing mechanism to the base for mounting to the drone.

[0009] An aspect of the specification provides a universal parachute recovery system wherein a volume of the gas expansion chamber is about 7.5 cm3or greater.

[0010] An aspect of the specification provides a universal parachute recovery system wherein the riser is secured to the housing via the anchoring system.

[0011] An aspect of the specification provides a universal parachute recovery system wherein the housing and the base are integrally formed as a single unit.

[0012] An aspect of the specification provides a universal parachute recovery system wherein the cavity is defined by tapered walls that increase in thickness from a top of the walls toward a bottom of the walls.

[0013] An aspect of the specification provides a universal parachute recovery system wherein the cavity is defined by walls having a uniform thickness from a top of the walls to a bottom of the walls.P13425PC00

[0014] An aspect of the specification provides a universal parachute recovery system wherein the cavity is defined by walls, a bottom of the walls having a thickness of about 2.5 mm or greater.

[0015] An aspect of the specification provides a universal parachute recovery system further comprising one or more spacers positioned within the gas expansion chamber to maintain a gap between the piston and the gas-generating device.

[0016] An aspect of the specification provides a universal parachute recovery system further comprising a protective cover attached to the piston, configured to shield the parachute during deployment.

[0017] An aspect of the specification provides a universal parachute recovery system further comprising a protective sleeve positioned around a portion of the riser exposed to the gas-generating device, configured to protect the portion of the riser after the gasgenerating device is activated.

[0018] An aspect of the specification provides a universal parachute recovery system wherein the housing further comprises a lid, wherein the lid is secured with a sealing mechanism to provide controlled ejection and prevent accidental removal and ingress.BRIEF DESCRIPTION OF THE FIGURES

[0019] Figure 1 shows a perspective view of a universal parachute recovery system for a drone in accordance with a first embodiment.

[0020] Figure 2 shows a front view of the universal parachute recovery system of Figure 1.

[0021] Figure 3 shows a back view of the universal parachute recovery system of Figure 1.

[0022] Figure 4 shows a top view of the universal parachute recovery system of Figure 1.P13425PC00

[0023] Figure 5 shows a bottom view of the universal parachute recovery system of Figure 1.

[0024] Figure 6 shows a side view of the universal parachute recovery system of Figure 1.

[0025] Figure 7 shows another side view of the universal parachute recovery system of Figure 1.

[0026] Figure 8 shows a cross-sectional view of the universal parachute recovery system of Figure 1.

[0027] Figure 9 shows a perspective view of the universal parachute recovery system of Figure 1 mounted to a drone.

[0028] Figure 10 shows a perspective view of a universal parachute recovery system for a drone in accordance with a second embodiment.

[0029] Figure 11 shows a front view of the universal parachute recovery system of Figure 10.

[0030] Figure 12 shows a back view of the universal parachute recovery system of Figure 10.

[0031] Figure 13 shows a top view of the universal parachute recovery system of Figure 10.

[0032] Figure 14 shows a bottom view of the universal parachute recovery system of Figure 10.

[0033] Figure 15 shows a side view of the universal parachute recovery system of Figure 10.

[0034] Figure 16 shows another side view of the universal parachute recovery system of Figure 10.P13425PC00

[0035] Figure 17 shows a cross-sectional view of the universal parachute recovery system of Figure 10.

[0036] Figure 18 shows a perspective view of the universal parachute recovery system of Figure 10 mounted to a drone.

[0037] Figure 19 shows a perspective view of a universal parachute recovery system for a drone in accordance with a third embodiment.

[0038] Figure 20 shows a front view of the universal parachute recovery system of Figure 19.

[0039] Figure 21 shows a back view of the universal parachute recovery system of Figure 19.

[0040] Figure 22 shows a top view of the universal parachute recovery system of Figure 19.

[0041] Figure 23 shows a bottom view of the universal parachute recovery system of Figure 19.

[0042] Figure 24 shows a side view of the universal parachute recovery system of Figure 19.

[0043] Figure 25 shows another side view of the universal parachute recovery system of Figure 19.

[0044] Figure 26 shows a cross-sectional view of the universal parachute recovery system of Figure 19.DETAILED DESCRIPTION

[0045] Figures 1 to 7 depict a first embodiment of a universal parachute recovery system for a drone, which is indicated generally at 100. The universal parachute recovery system 100 includes a housing 104, a base 108 and a securing mechanism 112.P13425PC00

[0046] As shown in Figure 8, which is a cross-sectional view of the universal parachute recovery system 100, the housing 104 includes a cavity 800 having an upper portion for storing a folded parachute 804 and a lower portion. The housing 104 is designed to provide structural integrity while minimizing weight. The materials and methods used to construct the housing 104 are not particularly limited, but in a present embodiment, the housing 104 is made of plastic, such as polycarbonate-acrylonitrile butadiene styrene (PC-ABS), and is injection molded. The upper portion of the cavity 800 is dimensioned to accommodate the parachute 804 based on its size, while ensuring a tight fit.

[0047] The cavity 800 is defined by walls 808 which can have varying thicknesses. For example, the walls 808 can have a thickness of about 1.5 mm or greater. In a present embodiment, the walls 808 are tapered, increasing in thickness from a top of the walls 808 toward a bottom of the walls 808. In one example, the top of the walls 808 are about 1.5 mm thick and the bottom of the walls 808 are about 3.5 mm thick. In other embodiments, a bottom of the walls can have a thickness of about 2.5 mm or greater. However, the thickness of the walls 808 is not limited to these dimensions and can vary. The top of the walls 808 are thinner to facilitate smooth parachute deployment, while the bottom of the walls 808 are thicker to prevent the housing 104 from breaking as the parachute 804 is deployed. In a present embodiment, the walls 808 have a taper of about 2.5 degrees to reduce the friction of the components inside the cavity 800, though other taper angles can be used.

[0048] The parachute 804 is stored in a folded configuration and is connected to the housing 104 via a riser 812. The riser 812 is connected to the parachute 804 and the housing 104, securing the parachute 804 to the housing 104 during deployment. The riser 812 is made of a high-strength, heat-resistant fiber such as Vectran™. In a present embodiment, the riser 812 is internally routed within the housing 104 to protect the riser 812 from environmental exposure. However, other configurations for the riser 812 are possible. To store the parachute 804, the parachute 804 is folded and then inserted into upper portion of the cavity 800 so that the parachute 804 is aligned with a fastening location on the riser 812.P13425PC00

[0049] A gas expansion chamber 816 is positioned within the lower portion of the cavity 800. A gas-generating device 820, disposed within the gas expansion chamber 816, triggers gas expansion upon activation. This expansion drives a piston 824, which is positioned between the parachute 804 and the gas expansion chamber 816, forcing the parachute 804 out of the cavity 800 for deployment.

[0050] The gas expansion chamber 816 defines a volume in which the gas expands when deployment is initiated. The volume of the gas expansion chamber 816 is proportional to a size of the parachute 804 and a size of the gas-generating device 820. In one embodiment, the volume of the gas expansion chamber 816 can be about 7.5 cm3or greater. The volume of the gas expansion chamber 816 can be adjusted by modifying parameters such as the diameter of the gas expansion chamber 816, the angle of the walls of the gas expansion chamber 816, and the height of the piston 824. In a present embodiment, the gas expansion chamber 816 is conical. The radii at the base of the gas expansion chamber 816 reduces the stress concentration in this area, preventing the housing 104 from breaking during parachute deployment. However, the shape of the gas expansion chamber 816 is not limited to a conical design.

[0051] One or more spacers 828 can be positioned within the gas expansion chamber 816 to maintain a gap between the piston 824 and the gas-generating device 820. This gap assists in creating the desired gas expansion volume for controlled deployment.

[0052] The gas-generating device 820 can be an initiator, such as a pyrotechnic initiator that generates gas expansion upon ignition of a combustible charge. However, other gasgenerating devices that trigger gas expansion can be used. A controller 832, housed within the base 108, is operably connected to the gas-generating device 820 and activates the gas-generating device 820. In an embodiment where the gas-generating device is a pyrotechnic initiator, the controller activates the initiator by delivering an electrical pulse to ignite the pyrotechnic charge. In a present embodiment, the gasgenerating device 820 is placed in a groove at the base of the gas expansion chamber 816 to secure the gas-generating device 820 in place. However, the position of the gasgenerating device 820 is not limited and can be placed elsewhere within the gasP13425PC00expansion chamber 816. The gas-generating device 820 can be further secured using an adhesive, such as glue.

[0053] A protective sleeve is positioned around a portion of the riser 812 exposed to the gas-generating device 820 to protect the portion of the riser 812 from potential damage after the gas-generating device 820 is activated. For example, the protective sleeve can be a heat shrink that wraps around this portion of the riser 812 and extends upward past the piston 824 to provide greater coverage and protection.

[0054] The piston 824 is positioned within the housing 104 such that there is space between an outer edge of the piston 824 and the walls 808 of the cavity 800, preventing the piston 824 from scratching or binding to the walls of the cavity 800 as it moves, and allowing gas to pass through. The piston 824 also has a cutout to allow the riser 812 to extend from the upper portion of the cavity 800 into the lower portion of the cavity 800. The piston 824 is made of a high-strength, heat-resistant material such as carbon fiber, although other materials can be used.

[0055] The universal parachute recovery system 100 can include a protective cover 836 that wraps around the parachute 804 and attaches to the piston 824 to shield the parachute 804 from heat exposure during deployment. The protective cover 836 also assists in keeping the piston 824 level during installation and deployment. In a present embodiment, the protective cover 836 is attached to the piston 824 with adhesive tape, though other attachment methods can be used. The protective cover 836 is tethered to the riser 812, ensuring the protective cover 836 remains attached to the housing 104 when the parachute 804 is deployed. The protective cover 836 is made of a lightweight, durable and heat-resistant material capable of shielding the parachute 804, such as polyurethane coated nylon, although other materials can be used.

[0056] The housing 104 has a lid 840 that forms a secure, friction-fit seal with the walls 808 of the cavity 800. The materials and methods used to construct the lid 840 are not particularly limited, but in a present embodiment, the lid 840 is made of nylon plastic and is 3D printed. In other embodiments, the lid can be made of PC-ABS and injection molded,P13425PC00for example. The lid 840 has a lip 844 that overlaps with the walls 808 of the cavity 800 for ingress protection, preventing moisture, dust and debris from entering the cavity 800.

[0057] The lid 840 is secured by a sealing mechanism to provide controlled ejection and prevent accidental removal and ingress. In one embodiment, the sealing mechanism comprises tape 848 wrapped around a perimeter of the housing 104, contacting both the lid 840 and the walls 808 of the cavity 800 to provide a secure seal. The sealing mechanism controls ejection by increasing the force required to eject the lid 840 from the housing 104, as the sealing mechanism must rupture and / or tear during deployment to eject the lid 840 from the walls 808 of the housing 104.

[0058] The base 108 is configured to support the housing 104 and mount to a drone. Similar to the housing 104, the materials and methods used to construct the base 108 are not particularly limited, but in a present embodiment, the base 108 is made of plastic, such as PC-ABS, and is injection molded. In some embodiments, the housing 104 and the base 108 are separate units affixed to one another. In other embodiments, the housing 104 and the base 108 are integrally formed as a single unit.

[0059] In a present embodiment, the base 108 is connected to the housing 104 via an anchoring system 852 configured to transfer deployment forces from the housing 104 to the base 108. In a present embodiment, the anchoring system 852 comprises axially aligned fasteners along a common load path to transfer the deployment forces, as described in more detail below. More specifically, the anchoring system 852 includes a housing fastener 856 and a base fastener 860. However, in other embodiments, the anchoring system 852 comprises a single fastener, such as the housing fastener 856. In one embodiment, the housing fastener 856 and the base fastener 860 are screws, however, other types of fasteners can be used.

[0060] The housing fastener 856 is configured to secure the riser 812 to the housing 104. In a present embodiment, the gas expansion chamber 816 has a recess for receiving the housing fastener 856 and securing the riser 812 underneath a head of the housing fastener 856. The housing fastener 856 is held in place using an insert 864 positioned in the base 108 to connect the riser 812, the housing 104 and the base 108. The insert 864P13425PC00can form part of the anchoring system 852. In a present embodiment, the insert 864 is a heat set insert. However, other inserts can be used. The housing fastener 856 can further be secured using an adhesive, such as glue.

[0061] When the parachute 804 is deployed, the shock load created from the force of the parachute opening and decelerating the drone is transferred from the riser 812 to the housing fastener 856, to the insert 864, and through the base 108 to the drone. This allows the loads to be efficiently transferred through the universal parachute recovery system 100 without putting excessive loads on the housing 104 and the base 108.

[0062] The base fastener 860 is configured to attach the securing mechanism 112 to the base 108 for mounting to the drone. In a present embodiment, the base fastener 860 attaches the securing mechanism 112, which comprises one or more attachment straps 868, to a bottom of the base 108. However, the securing mechanism 112 can be attached to the base 108 at other locations, depending on mounting requirements. The base 108 also has a plurality of holes 400, as best seen in Figures 4 and 5, to allow the universal parachute recovery system 100 to be mounted to a drone with mounting fasteners such as screws. In a present embodiment, the base 108 has four holes that serve as attachment points to the drone. Figure 9 depicts the universal parachute recovery system 100 mounted to a drone 900.

[0063] The base 108 further encloses electronic components, including the controller 832, which is responsible for managing the activation of the deployment system. The base 108 can also incorporate electrical connectors, such as USB ports, to facilitate power delivery, data transfer, or system diagnostics.

[0064] The universal parachute recovery system 100 operates as follows. When it is time to deploy the parachute, the controller 832 activates the gas-generating device 820, which generates a rapid expansion of gas within the gas expansion chamber 816. This sudden expansion of gas forces the piston 824 upward, pushing against the protective cover 836 and the parachute 804. The piston 824, guided within the cavity 800, moves freely without binding due to the clearance between the outer edge of the piston 824 and the walls 808 of the cavity 800.P13425PC00

[0065] As the piston 824 travels upward, the force causes the lid 840 to eject from the housing 104. The sealing mechanism, such as the tape 848 wrapped around the perimeter of the housing 104, ensures that the lid 840 is retained until a sufficient deployment force is applied, preventing accidental removal while maintaining ingress protection prior to deployment. As the lid 840 separates from the housing 104, the parachute 804 is ejected.

[0066] Once ejected from the cavity 800, the parachute 804 begins to unfold. The parachute lines, which were tucked in with sufficient slack during assembly, extend as the parachute fully inflates. The alignment of the parachute 804 with the fastening location on the riser 812 ensures that the parachute lines emerge from the center, facilitating an even and controlled deployment.

[0067] The riser 812, secured within the housing 104 by the housing fastener 856 and the insert 864, absorbs the initial forces of deployment. The anchoring system 852 then effectively transfers the shock load from the housing fastener 856 to the insert 864, and through the base 108 to the drone 900 via the mounting fasteners, allowing the force to be directed away from the rest of the housing 104 and the base 108. This design ensures that shock loads do not compromise the integrity of the housing 104 or the base 108, improving durability and reliability.

[0068] The mounting fasteners mount the base 108 to the drone 900 through the plurality of holes 400 to keep the universal parachute recovery system 100 affixed to the drone 900 during descent. The securing mechanism 112, such as the attachment straps 868, also ensures that the universal parachute recovery system 100 remains affixed to the drone 900, acting as a backup retention method in case the mounting fasteners that mount the base 108 to the drone 900 fail.

[0069] Below, other embodiments of the universal parachute recovery system are discussed. Unless otherwise stated, these other embodiments include similar components having similar functions as the first embodiment. However, features such as the volume of the gas expansion chamber, the size of the cavity and the parachute, and the shape of the base can differ between embodiments.P13425PC00

[0070] Referring now to Figures 10 to 16, these figures depict a second embodiment of a universal parachute recovery system, indicated generally at 100A. The universal parachute recovery system 100A is a variant on the universal parachute recovery system 100 of Figures 1 to 9, and so like elements bear like references followed by the suffix “A”. The universal parachute recovery system 100A includes a housing 104A, a base 108A and a securing mechanism 112A. In this second embodiment, the securing mechanism 112A attaches to the base 108A via slots in the base 108A. The securing mechanism 112A can be, for example, a hook and loop strap. As best seen in Figures 13 and 14, the base 108A also has a plurality of holes 400A to allow the universal parachute recovery system 100A to be mounted to a drone with mounting fasteners such as screws. In a present embodiment, the base 108A has two holes 400Athat serve as attachment points. Together, the hook-and-loop strap and the mounting fasteners secure the base 108A to the drone. Figure 18 shows the universal parachute recovery system 100A mounted to a drone 900A.

[0071] As seen in Figure 17, the walls 808A of the cavity 800A are tapered, increasing in thickness from a top of the walls 808A toward a bottom of the walls 808A. The anchoring system 852A comprises a housing fastener 856A but does not include a base fastener. In this second embodiment, when the parachute 804A is deployed, the forces are transferred from the riser 812A, to the housing fastener 856A, to the insert 864A, and through the base 108A to the drone 900A via the mounting fasteners and the hook-and-loop strap.

[0072] Referring now to Figures 19 to 25, these figures depict a third embodiment of a universal parachute recovery system, indicated generally at 100B. The universal parachute recovery system 100B is a variant on the universal parachute recovery system 100 of Figures 1 to 9, and so like elements bear like references followed by the suffix “B”. The universal parachute recovery system 100B includes a housing 104B and a base 108B. In this third embodiment, the walls 808B of the cavity 800B have a uniform thickness from a top of the walls 808B to a bottom of the walls 808B. For example, the walls 808B can have a thickness of about 2.5 mm or greater. However, the thickness of the walls 808B is not limited to this dimension and can vary. Further, the base 108B doesP13425PC00not have an attachment strap. As best seen in Figures 22 and 23, the base 108B has a plurality of holes 400B to allow the universal parachute recovery system 100B to be mounted to a drone with mounting fasteners such as screws. In the third embodiment, the base 108B has four holes 400B that serve as attachment points.

[0073] As seen in Figure 26, anchoring system 852B comprises a housing fastener 856B and does not include a base fastener. In this third embodiment, when the parachute 804B is deployed, the forces are transferred from the riser 812B, to the housing fastener 856B, to the insert 864B, and through the base 108B to the drone via the mounting fasteners.

[0074] The present specification provides a universal parachute recovery system that has various advantages over the prior art.

[0075] The universal parachute recovery system is designed to be compact and lightweight, incorporating lightweight plastic materials to reduce overall weight while maintaining structural strength.

[0076] The system is scalable, allowing it to be adapted to different drone sizes by adjusting parachute and housing dimensions. Its modular nature enables compatibility with various drone models without requiring significant design modification.

[0077] The system is designed with a minimal part count, reducing the number of components necessary for full functionality. This simplifies both assembly and maintenance while lowering manufacturing costs and improving reliability by reducing potential points of failure.

[0078] The design of the lid with the sealing mechanism helps prevent moisture, debris and contaminants from interfering with system operation. These measures enable consistent functionality across different operating environments.

[0079] The system is designed for effective load transfer, with the riser, anchoring system and fasteners distributing deployment forces efficiently. Shock loads are directed through these components to the drone, preventing excessive stress on the housing and the base and providing structural integrity.P13425PC00

[0080] The scope of the monopoly of this specification is defined by the claims, properly construed in relation to the narrative and drawings. Any limiting phrases should not be viewed in isolation but in view of the broader context of the entire teachings and advantages afforded by the specification.

Claims

P13425PC00CLAIMS1. A universal parachute recovery system for a drone, comprising:a housing including a cavity having an upper portion for storing a folded parachute and a lower portion;a riser connected to the parachute and the housing;a gas expansion chamber within the lower portion of the cavity;a piston positioned between the parachute and the gas expansion chamber to eject the parachute when gas expands in the chamber;a gas-generating device disposed within the gas expansion chamber to trigger gas expansion;a base configured to support the housing and mount to the drone; anda controller operably connected to the gas-generating device for activation.

2. The universal parachute recovery system of claim 1 , wherein the housing and the base are separate units affixed to one another.

3. The universal parachute recovery system of claim 2, wherein the base is connected to the housing via an anchoring system configured to transfer deployment forces from the housing to the base.

4. The universal parachute recovery system of claim 3, wherein the anchoring system comprises axially aligned fasteners along a common load path to transfer the deployment forces.

5. The universal parachute recovery system of claim 3, wherein the anchoring system comprises a housing fastener configured to secure the riser to the housing.P13425PC006. The universal parachute recovery system of claim 5, wherein the anchoring system further comprises a base fastener configured to attach a securing mechanism to the base for mounting to the drone.

7. The universal parachute recovery system of claim 1 , wherein a volume of the gas expansion chamber is about 7.5 cm3or greater.

8. The universal parachute recovery system of claim 2, wherein the riser is secured to the housing via the anchoring system.

9. The universal parachute recovery system of claim 1 , wherein the housing and the base are integrally formed as a single unit.

10. The universal parachute recovery system of claim 1 , wherein the cavity is defined by tapered walls that increase in thickness from a top of the walls toward a bottom of the walls.11.The universal parachute recovery system of claim 1 , wherein the cavity is defined by walls having a uniform thickness from a top of the walls to a bottom of the walls.

12. The universal parachute recovery system of claim 1 , wherein the cavity is defined by walls, a bottom of the walls having a thickness of about 2.5 mm or greater.

13. The universal parachute recovery system of claim 1 , further comprising one or more spacers positioned within the gas expansion chamber to maintain a gap between the piston and the gas-generating device.

14. The universal parachute recovery system of claim 1 , further comprising a protective cover attached to the piston, configured to shield the parachute during deployment.

15. The universal parachute recovery system of claim 1 , further comprising a protective sleeve positioned around a portion of the riser exposed to the gas-generatingP13425PC00device, configured to protect the portion of the riser after the gas-generating device is activated.

16. The universal parachute recovery system of claim 1, wherein the housing further comprises a lid, wherein the lid is secured with a sealing mechanism to provide controlled ejection and prevent accidental removal and ingress.

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