Extruded Wing Protection Structure for Lightweight UAV Control Surfaces
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Solution Overview
Problem
Existing methods for manufacturing flight control surfaces for unmanned aerial vehicles (UAVs) are labor-intensive, costly, and result in heavy, thick parts, while molded foam wings are prone to damage and require frequent repairs or replacements.
Innovation Solution
The use of an extruded control surface with a channel, knuckle, voids, and separators, along with clips and cuffs, allows for lightweight, inexpensive, and easily replaceable control surfaces made from UV-resistant plastic or PC-ABS, which can absorb impacts and protect the wings during take-off and landing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional lay-up method with aluminum or steel mold is used, then structural integrity is achieved, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent employs disposable foam wings with integrated control surfaces that are designed to be replaced rather than repaired. This eliminates the need for complex molds and assembly processes, as each wing assembly is pre-manufactured as a complete unit. The foam material itself serves as the structural core, eliminating the need for separate aluminum or steel molds in the lay-up process.
2Productivity
If injection molding is used to construct control surfaces, then manufacturing efficiency improves, but part weight and thickness increase
Solution Approach 1:
The patent uses composite construction where foam material serves as the structural core and control surface material is integrated directly onto the foam. This composite approach eliminates the need for separate injection-molded control surface parts, thereby reducing overall weight while maintaining manufacturing efficiency. The control surfaces are made from the same material as the wing structure, creating a unified lightweight component.
3Weight of moving object
If molded foam wings are used, then weight reduction is achieved, but susceptibility to damage increases
Solution Approach 1:
The patent explicitly designs the foam wings as disposable components that are replaced rather than repaired when damaged. This approach accepts the vulnerability of foam material in exchange for eliminating complex repair processes and reducing overall system cost. The wings are manufactured to be inexpensive enough that replacement is more economical than maintenance.
4Adaptability or versatility
If control surfaces are made as separate assembled parts, then manufacturing flexibility improves, but assembly complexity and time increase
Solution Approach 1:
The patent merges the control surface construction into the wing manufacturing process itself. The control surfaces are integrated directly onto the foam wings during the same manufacturing cycle, eliminating separate assembly steps. This combining of functions reduces assembly time while maintaining the flexibility to produce different wing configurations.
Data Source
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.