Injection Molded Wing Structure for UAVs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Unmanned aerial vehicles (UAVs) face limitations in structural integrity, power, durability, and cost-effectiveness due to trade-offs in design for recreational or utilitarian purposes, which affect their battery life, range, and material usage.
Innovation Solution
A method of manufacturing UAV wings by injecting uncured material into a mold containing a pre-assembled wing frame, allowing the material to cure and form an air-filled matrix that encases the frame, providing torsional rigidity and integrating additional features like battery housing and avionics during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate manufacturing methods are used for wing frame and body, then assembly flexibility is maintained, but manufacturing time and labor costs increase
Solution Approach 1:
The patent combines the wing frame and body into a single integrated manufacturing process. The pre-assembled wing frame is placed into a mold, and uncured material is injected to form the body that encases the frame. This merging of components during manufacturing reduces assembly steps and labor requirements while maintaining design flexibility.
Solution Approach 2:
The wing frame is pre-assembled with transverse frame elements and mounting elements before being placed in the mold. This preliminary assembly allows for precise positioning and integration of structural components, while the subsequent material injection completes the wing structure in one operation, improving overall manufacturing efficiency.
2Strength
If heavy durable materials are used to improve structural integrity, then strength and durability are enhanced, but weight increases reducing battery life and range
Solution Approach 1:
The patent uses a composite structure consisting of a rigid wing frame made from durable materials and a body formed from uncured material that cures around the frame. This composite approach provides the necessary structural integrity while the material selection and design optimize the strength-to-weight ratio, avoiding excessive weight gain.
Solution Approach 2:
The wing frame uses transverse frame elements strategically positioned to provide torsional rigidity where needed, rather than uniformly strengthening the entire structure. This localized reinforcement approach maintains structural integrity while minimizing overall weight increase.
3Adaptability or versatility
If complex wing structures with multiple components are used to improve functionality, then adaptability and features are enhanced, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
Multiple wing components including the frame, body, and mounting elements are combined into a single integrated manufacturing process. The pre-assembled frame with integrated mounting elements is encased in the cured material body, ensuring precise alignment and reducing assembly errors while maintaining functional adaptability.
4Ease of manufacture
If recreational design priorities are used to reduce cost, then price effectiveness improves, but structural integrity and power are insufficient for utilitarian tasks
Solution Approach 1:
The composite construction of pre-assembled frame with integrated mounting elements encased in cured material provides utilitarian-level structural strength while maintaining manufacturing efficiency. This approach avoids the need for expensive alternative manufacturing methods while achieving the required structural integrity for payload delivery and other utilitarian tasks.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a sturdy, lightweight wing structure that enhances torsional stability and allows for easy incorporation of additional components, improving the overall performance and modularity of UAVs while reducing material costs.
Implementation Method 1
allowing the uncured material to cure to form an air-filled matrix material
Data Source
AI summary
An example method of manufacturing a wing includes providing a wing frame. The wing frame includes a primary spar, a drag spar, a plurality of transverse frame elements having at least one spar joiner, and a plurality of mounting elements. The primary spar is coupled to the drag spar via the at least one spar joiner. The method further includes placing the wing frame into a mold, wherein the mold defines a shape of the wing. The method also includes injecting the mold with an air-filled matrix material, such that the air-filled matrix material substantially encases the wing frame and fills the defined shape of the wing, and such that the plurality of transverse frame elements provide torsional rigidity to the wing.