Extruded Wing Control Surface for Lightweight Impact Protection

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Solution Overview

Problem

Existing methods for manufacturing flight control surfaces for unmanned aerial vehicles (UAVs) are costly, heavy, and prone to damage, particularly during vertical take-off and landing, due to the use of aluminum or steel molds and injection molding, which result in thicker and heavier parts that are susceptible to denting and require manual labor.

Innovation Solution

The use of an extruded control surface with a channel, knuckle, leading and trailing voids, and separators, along with clips and cuffs, allows for lightweight, UV-resistant plastic or polycarbonate-ABS construction that can pivot and detach easily, providing protection and reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If aluminum or steel molds with injection molding are used to manufacture flight control surfaces, then structural strength is improved, but weight increases and manufacturing complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The control surface is divided into multiple segments connected by knuckles, allowing each segment to be manufactured separately using lighter materials while maintaining overall structural integrity through the segmented architecture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control surface uses composite construction with foam core material combined with thinner shell layers, replacing solid aluminum or steel construction while maintaining structural strength through the composite architecture

Inventive Principle:

Principle #40Composite materials

2Strength

If aluminum or steel molds with manual labor are used to manufacture flight control surfaces, then structural strength is improved, but manufacturing cost and time increase

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The control surface design includes self-aligning features and snap-fit connections that allow assembly without complex tooling or manual adjustment, enabling the structure to assemble itself with minimal labor

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The control surface is divided into modular segments that can be manufactured independently using simple extrusion processes, eliminating the need for complex aluminum or steel mold assemblies and manual shaping operations

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If injection molding is used to manufacture flight control surfaces, then manufacturing capability is improved, but part thickness and weight increase

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidpart thickness

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The control surface uses thin-walled extruded profiles with hollow cross-sections that provide structural strength through geometric design rather than material thickness, replacing the thicker parts produced by injection molding

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The control surface transitions from solid thick-walled injection molded parts to hollow thin-walled extruded profiles, utilizing the third dimension (hollow interior) to reduce weight while maintaining strength through structural geometry

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Ease of operation

If traditional control surfaces are used during vertical take-off and landing, then flight control functionality is maintained, but wing protection is insufficient

Engineering Contradiction:

Improveflight control functionalityVSAvoidwing damage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The control surface is designed as a disposable protective element that can be easily replaced after impact during vertical landing, protecting the more valuable wing structure while maintaining flight control functionality throughout the service life of the disposable component

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The control surface acts as a sacrificial protective barrier positioned at the leading edge of the wing, absorbing impact forces during vertical landing before they can reach and damage the main wing structure

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12377958B2Extruded wing protection system and device

Publication Date: 2025.08.05 AEROVIRONMENT INC

AI summary

Systems, devices, and methods for an extruded wing protection and control surface comprising: a channel proximate a leading edge of the control surface, a knuckle disposed about the channel, a leading void, a trailing void, and a separator dividing the leading void and the trailing void; and a plurality of notches disposed in the extruded control surface proximate the leading edge of the control surface.