FLIGHT MODULE

Abstract

A flight module for a vertical take-off and landing aircraft comprises multiple drive units arranged on a supporting framework structure that comprises struts interconnected at node points. Each drive unit comprises an electric motor and a propeller that is operatively connected to the electric motor. Some of the drive units are arranged outside the node points.

Claims

1.-20. (canceled)

21. A flight module for a vertical take-off and landing aircraft, wherein the flight module comprises a plurality of drive units arranged on a supporting framework structure which comprises framework struts connected to one another at node points, each drive unit comprising an electric motor and at least one propeller operatively connected to the electric motor, and some of the drive units being arranged outside the node points.

22. The flight module of claim 21, wherein the flight module further comprises a central unit.

23. The flight module of claim 21, wherein the flight module further comprises a coupling device for connecting the flight module to a transport module.

24. The flight module of claim 21, wherein the flight module further comprises a charging module.

25. The flight module of claim 21, wherein a tilt angle of the flight module is variable.

26. The flight module of claim 21, wherein the flight module further comprises one or more air guiding devices.

27. The flight module of claim 26, wherein an angle of incidence of the one or more air guiding devices is variable.

28. The flight module of claim 21, wherein several of the drive units are arranged concentrically around a center axis (M) of the flight module.

29. The flight module of claim 21, wherein several of the drive units are arranged in one or more rings around a center axis (M) of the flight module.

30. The flight module of claim 29, wherein the rings have different ring diameters.

31. The flight module of claim 21, wherein rotors of the propellers of the drive units have different diameters.

32. The flight module of claim 29, wherein rotors of the propellers of the drive units of a ring have a uniform diameter.

33. The flight module of claim 29, wherein rotors of the propellers of the drive units of a ring have different diameters.

34. The flight module of claim 21, wherein some of the framework struts have a hollow profile.

35. The flight module of claim 34, wherein the hollow profile of a framework strut has a longitudinally extended profile cross-section in an effective direction of the drive units.

36. The flight module of claim 34, wherein the hollow profile of a framework strut has a variable wall thickness in a circumferential direction of the framework strut and/or a variable wall thickness along a longitudinal extension of the framework strut.

37. The flight module of claim 21, wherein the supporting framework structure and/or a central unit thereof and/or at least some of the drive units comprise components made of fiber-reinforced composite or consist of fiber-reinforced composite.

38. The flight module of claim 37, wherein the fiber-reinforced composite has textile reinforcing elements and/or monodirectionally arranged reinforcing fibers.

39. The flight module of claim 21, wherein several of the drive units are connected to the supporting framework by a force-fitting and/or form-fitting fastening element.

40. The flight module of claim 39, wherein the fastening element is designed as a bracket which at least partially encloses a framework strut.

Description

[0130] Further advantages of the present invention are evident from the illustrations and the associated description. They show:

[0131] FIG. 1 Exemplary depiction of a flight module with central unit;

[0132] FIG. 2 Exemplary depiction of a flight module with central unit and coupled transport module;

[0133] FIGS. 3a, 3b Detailed views of a connecting piece;

[0134] FIGS. 3c, 3d Detailed views of the ends of slot-together framework struts;

[0135] FIG. 4 Schematic depiction of the plan view of the supporting framework structure of a flight module;

[0136] FIG. 5 Schematic depiction of the plan view of a flight module with supporting framework structure, drive units arranged on it, and central unit;

[0137] FIG. 6 Schematic depiction of the side view of the supporting framework structure of a flight module with central unit;

[0138] FIG. 7 Schematic depiction of the airspace covered by the propellers of the drive units of a flight module in a first variant;

[0139] FIG. 8 Schematic depiction of the airspace covered by the propellers of the drive units of a flight module in a further variant;

[0140] FIGS. 9a-c Schematic view of various framework strut cross-sections;

[0141] FIGS. 10a-c Schematic view of various brackets for attaching the drive units to the supporting framework structure;

[0142] FIG. 11 Schematic depiction of the plan view of a supporting framework structure of a flight module with air guiding devices; and

[0143] FIG. 12 Schematic view of a tilted flight module with adjusted air guiding devices.

[0144] In the examples explained below, reference is made to the accompanying drawings, which form part of the examples and in which specific embodiments in which the invention can be put into practice are shown for illustrative purposes. In this respect, directional terminology such as top, bottom, front, back, forward, rear etc. is used with reference to the orientation of the described figures. Since components of embodiments can be positioned in a number of different orientations, the directional terminology is used for illustrative purposes and is in no way restrictive.

[0145] It is to be understood that other embodiments can be used and structural or logical changes made without departing from the protective scope of the present invention. It is to be understood that the features of the various example embodiments described herein can be combined with each other, unless specifically stated otherwise. The following detailed description is therefore not to be understood in a restrictive sense, and the protective scope of the present invention is defined by the appended claims.

[0146] For the purposes of this description, the terms connected, joined, attached and coupled are used to describe both a direct and an indirect connection, a direct or indirect joint, a direct or indirect attachment, and a direct or indirect coupling. In the figures, identical or similar elements are provided with identical reference marks, where appropriate.

[0147] FIG. 1 shows an example depiction of a flight module 1 for a vertical take-off and landing aircraft according to FIG. 2. In addition to a central unit 8 arranged centrally to the vertical axis of the flight module 1, the flight module 1 has a supporting framework structure 2 with multiple framework struts 5, which are joined to each other at node points 4 by means of connecting pieces 11 designed as T-pieces as well as to the central unit 8.

[0148] As shown in FIG. 2, the aircraft comprises the flight module 1 and a transport module 9 connected to the flight module 1 for the transportation of persons and/or payloads.

[0149] This supporting framework structure 2 and the central unit 8 of the flight module 1 according to FIG. 1 are shown schematically in FIG. 4 in the plan view and in FIG. 6 in the side view. The supporting framework structure 2 is formed by six framework struts 5 extending radially outwards from the central unit 8 and by six further framework struts which join together, at the node points 4, the ends of the radially extending framework struts 5 opposite to the central unit 8, forming a hexagon.

[0150] The framework struts 5 are connected to each other in a form-fitting manner at the node points 4 by means of T-piece-shaped connecting pieces 11.

[0151] The connecting pieces 11 in the example embodiment are made of a fiber-reinforced composite.

[0152] To simplify installation and maintenance, the connecting pieces 11 in the example embodiment are made in two parts comprising an upper and a lower shell (see detailed view according to FIG. 3a).

[0153] The ends of the framework struts 5 are for example inserted or placed at least 100 mm deep into the T-piece-shaped connecting pieces, where in the closed state of the two-part connecting pieces 11 the ends of the framework struts 5 are held in a fully enclosed manner.

[0154] The flush fit of the framework struts 5 in the connecting pieces 11 improves the alignability of the framework struts 5. In addition, the bearing forces are distributed more evenly.

[0155] To form the hexagonal shape of the supporting framework structure 2, the connecting pieces 11 have three arms, with two arms in each case enclosing an angle of 60 between each other (see detailed diagram according to FIG. 3b).

[0156] The framework struts 5 to be joined to each other can additionally be connected to each other inside the T-piece-shaped connecting piece in a form-fitting manner. For this purpose, the ends of the framework struts 5 can have slots and tabs by means of which the framework struts 5 can be slotted together at a defined angle to each other (FIG. 3c, 3d).

[0157] The slotted-together ends of the framework struts 5 can be placed into the upper or lower shell of the two-part T-piece-shaped connecting piece 11, and after closing the T-piece-shaped connecting piece 11 can be completely enclosed by the T-piece-shaped connecting piece 11.

[0158] Furthermore, FIG. 4 shows brackets as a fastening means 10, which serve to fasten drive units 3 to the struts 5 of the supporting framework structure 2. The fastening means 10 are arranged both approximately centrally on each supporting framework structure strut 5 and at the outer end of the framework struts 5 extending radially outwards from the central unit 8, but outside the node points 4. In the example embodiment, a total of 18 fastening means 10 are provided for attaching 18 drive units, however a different number of fastening means 10 and drive units 3 can be provided.

[0159] The fastening means 10 can for example be designed as shown in FIGS. 10a to 10c.

[0160] FIG. 10a shows a two-part bracket 10 as a fastening element 10 comprising two half-shell-shaped bracket parts, each with ends angled to one side, which are clamped to the supporting framework structure strut 5 (not shown) by means of a bolted connection in the horizontal direction. The angled ends provide an area for joining the bracket parts to the drive unit 3 (not shown), where the bracket parts can be joined to the drive unit 3 by a bolted or riveted connection.

[0161] FIG. 10b shows a bracket as a fastening means 10, which has an omega-shaped lower bracket part with angled ends on both sides, a U-shaped upper bracket part and a flat cover element.

[0162] The omega-shaped lower bracket part encloses the framework strut at least partially at the sides and in the lower area. The omega-shaped lower bracket part encloses the framework strut 5 at least partially at the sides and in the lower area.

[0163] The cover element of the bracket is joined via a bolted or riveted connection to the angled ends of the omega-shaped bracket part, as a result of which the bracket is clamped in the vertical direction to the framework strut 5. Furthermore, the cover element serves to attach the drive unit 3 (not shown).

[0164] In addition, a compression piece (intermediate layer element) is provided, which supports the U-shaped upper bracket part against the cover element, as a result of which, when the bracket is closed, the omega-shaped lower bracket part and the U-shaped upper bracket part are pressed both against each other and against the framework strut 5, thus creating the force-fitting and form-fitting connection between the bracket and the framework strut 5. The compression piece can also be an integral part of the cover element or of the U-shaped bracket part.

[0165] The bracket according to FIG. 10b therefore is formed of four parts.

[0166] FIG. 10c shows a bracket as a fastening means 10, which has an omega-shaped lower bracket part with angled ends on both sides, a U-shaped upper bracket part and a compression piece (intermediate layer element).

[0167] The omega-shaped lower bracket part encloses the framework strut 5 at least partially at the sides and in the lower area, with the angled ends of the omega-shaped lower bracket part providing an area for joining to the drive unit 3.

[0168] The U-shaped upper bracket part encloses the framework strut 5 at least partially at the sides and in the upper area.

[0169] The angled ends of the omega-shaped bracket part can be attached by means of a bolted or riveted connection to the drive unit 3 (not shown), as a result of which the bracket is clamped in the vertical direction to the framework strut 5.

[0170] The additionally provided compression piece (intermediate layer element) supports the angled ends of the omega-shaped bracket part above the framework strut 5 and, when the bracket is closed and the drive unit 3 is fitted, it causes the omega-shaped lower bracket part and the U-shaped upper bracket part to be clamped against the framework strut 5, thus creating the force-fitting and form-fitting connection between the bracket and the framework strut 5. The compression piece can be an integral part of the U-shaped bracket part.

[0171] The bracket according to FIG. 10c therefore is formed of three parts.

[0172] In the upper area, the fastening means 10 according to FIGS. 10a to 10c each have angled ends for direct attachment of the drive units 3 (FIG. 10a, 10c), or for indirect attachment of the drive units 3 (FIG. 10b) via the cover element.

[0173] The drive units 3 can be bolted or riveted to the angled ends or to the cover element.

[0174] The fastening means 10 according to FIGS. 10a to 10c each form an omega shape when assembled, i.e. their outer shape approximately corresponds to the Greek capital letter omega. In addition, the fastening means 10 are designed in such a way that they follow the outer contour of the framework struts 5 as far as possible and at least partially surround the framework strut at the sides and at the bottom, so that a force-fitting and form-fitting connection with the framework strut 5 is ensured in the connected state.

[0175] The framework struts 5 consist of a pultruded hollow profile made from fiber-reinforced plastic, e.g. carbon-fiber-reinforced plastic.

[0176] Favourable designs of the hollow profiles of the framework strut each have a longitudinally extended profile cross-section as shown in FIGS. 9a, 9b and 9c. FIGS. 9a to 9c show three hollow profiles in sectional view, of which the hollow profile according to FIG. 9a has a preferably oval cross-section, the hollow profile according to FIG. 9b has an elliptical cross-section, and the hollow profile according to FIG. 9c has an oblong cross-section. The longitudinal sides of the hollow profiles each point in a vertical effective direction of the drive units 3 (not shown).

[0177] The hollow profile of the framework struts 5 according to FIGS. 9a, 9b and 9c in each case has a variable wall thickness in the circumferential direction of the framework strut 5.

[0178] The wall thickness is greater in areas of the circumference with high stress due to forces acting on it than in areas of lower stress. For example, as can be seen in FIG. 9a, 9b, 9c the wall thickness can be greater in the area of the small sides of the circumference (top and bottom in the depiction according to FIG. 9a, 9b, 9c) than in the area of the longitudinal sides of the circumference. Furthermore, the wall thickness can vary not only in the circumferential direction along the cross-section, but also along the longitudinal extension of the strut 5. For example, the wall thickness of the framework struts extending radially outwards from the central unit 8 can increase from the outside to the inside in the direction of the central unit 8. The occurring loads can be computer-simulated to calculate the required minimum wall thickness.

[0179] Cables for signal connections and the power supply run through the hollow profile.

[0180] Referring again to FIG. 1, it can be seen that the flight module 1 has drive units 3 that each have a propeller 7 with a rotor of two rotor blades and a brushless DC motor as electric motor 6, with the propeller 7 being driven by the electric motor 6. By means of a hub of the respective propeller 7, the propeller is rotatably mounted on the electric motor 6.

[0181] Optionally a cover, e.g. in the form of a spinner, can be present to seal the drive unit 3 against water and dirt and to improve the aerodynamics. The propellers 7, in particular its rotors, have a fiber-reinforced composite material, e.g. carbon-fiber-reinforced plastic.

[0182] FIG. 5 shows a schematic plan view of the flight module 1 according to FIG. 1.

[0183] The drive units 3, in the example embodiment 18 drive units 3, are arranged in a plane E of the supporting framework structure 2 outside the node points 4 in a first, a second and a third ring (R1, R2, R3) each with six drive units 3 concentrically around the vertical central axis (M) of the flight module 1. The first, second and third ring R1, R2, R3 have a different ring diameter DR1, DR2, DR3 (also shown in FIG. 7).

[0184] The drive units 3 are attached directly to the framework struts 5 of the supporting framework structure 2 by means of the fastening means 10 designed as brackets.

[0185] The rotors of the propellers 7 of the drive units 3 have different diameters d1, d2, d3. In the example embodiment, the rotors of the six propellers 7 of the drive units 3 of the first (inner) ring R1 have a first uniform diameter d1 of 1800 mm. The rotors of the six propellers 7 of the drive units 3 of the second ring R2 have a second diameter d2, which in the example embodiment is equal to the diameter d1 of the rotors of the propellers 7 of the inner first ring of 1800 mm. The rotors of the six propellers 7 of the drive units 3 of the third ring R3 have a third diameter d3 of 1300 mm (FIG. 7). In other words, the flight module 1 has twelve propellers 7 with rotors with a diameter d1, d2 of 1800 mm and six propellers 7 with rotors with a diameter d3 of 1300 mm.

[0186] According to this exemplary embodiment, the arrangement of the drive units around the vertical centre axis (M) and the size of the propeller rotors results in an overall maximum diameter of the flight module of 8.14 m.

[0187] FIG. 7 is a schematic plan view of the flight module 1 showing the airspace coverage achievable by the rotors of the propellers 7

[0188] of the drive units 3 of the flight module 1. It can be seen that the described selection of the rotors of the propellers 7 achieves a high concentration of the coverable area above the supporting framework structure 2 and hence very good airspace coverage, even though only two rotor types of different diameter have to be manufactured.

[0189] The very good airspace coverage improves the performance of the flight module 1 and at the same time minimises the space requirements of the flight module 1 for take-off and landing and while on the ground, which is advantageous particularly when operating the flight module 1 in an urban environment.

[0190] The central unit 8 of the flight module 1 is designed in the form of a hemisphere made of carbon-fiber-reinforced or glass-fiber-reinforced plastic. The communication and control technology of the flight module 1 is located in the central unit 8. In addition, the central unit 8 contains rechargeable batteries for supplying energy to the drive units 3 and other electrical consumers.

[0191] Optionally, the central unit 8 can also accommodate a rescue system with a parachute for shooting out.

[0192] The central unit 8 of the flight module 1 has a coupling device, e.g. a coupling counterpart of an articulated coupling between a couplable transport module 9 and the flight module 1 (not shown), for the detachable and directionally flexible connection of the flight module 1 to a transport module 9.

[0193] FIG. 8 is a schematic plan view of the flight module 1 showing the airspace coverage by the propellers 7 of the drive units 3 of a flight module 1 in another variant. In this embodiment, the drive units 3 are arranged in two rings R1, R2 around the centre axis (M) of the flight module 1, with the two rings R1, R2 having different ring diameters DR1, DR2. The inner ring R1 with a smaller ring diameter DR1 than the outer ring R2 has six drive units 3. The outer ring R3 has twelve drive units 3.

[0194] The rotors of the propellers 7 of the drive units 3 of a ring R1, R2 as well as of rings R1, R2 have a uniform diameter d1. Therefore the diameter d1 of all rotors is the same size, which simplifies the manufacturing and assembly of the flight module 1.

[0195] Furthermore, the ring diameters DR1, DR2 and the diameter d1 of the rotors are selected in such a way that the airspace is covered in an overlapping manner. In other words, the airspaces used by the rotors overlap at least partially in the plan view of the flight module 1.

[0196] FIG. 2 shows the flight module 1 according to FIG. 1 with a transport module 9 coupled in this way. The coupling device is arranged centrally on the underside of the central unit 8, so that the transport module 9 is also located centrally below the flight module 1. The transport module 9 can have a transportation capsule and an attached longitudinally extending shaft; the shaft, as shown in FIG. 2, can be arranged in extension of the centre axis (M) of the flight module 1.

[0197] By means of the articulated coupling, the inclination of the flight module 1 relative to the coupled transport module 9 can be varied. In this way, a vertical alignment of the transport module 9 can be largely maintained during flight operation even if the orientation of the flight module 1 varies, and the aircraft's centre of gravity can be centred on a limited central area of the flight module, which improves the comfort and the controllability of the aircraft.

[0198] FIG. 11 shows a flight module 1 of FIG. 4 with four air guiding devices 12, which act as a means of lift. The air guiding devices 12 have flat wings. They can be attached to the framework struts 5 of the supporting framework structure 2 of the flight module 1 or to the connecting pieces 11 for connecting the framework struts 5 of the supporting framework structure 2.

[0199] They can be designed to be rotatably mounted so that the air guiding devices 12 can be folded up against the supporting framework structure 2 and unfolded from it (dotted line with double arrow).

[0200] The air guiding devices 12 each have a flat wing 12, which for example is mounted so as to be rotatable about its longitudinal axis.

[0201] When flying forward at an appropriate high speed in the direction indicated, the wings are folded out and assist the propellers 7 of the drive units 3 (not shown here) to generate additional lift.

[0202] In addition, the wings can be rotated around their longitudinal axis to change the angle of incidence relative to the airflow and thus adjust the lift.

[0203] Preferably the wings are located in the upper or lateral region of the supporting framework structure 2 of the flight module 1 on the framework struts 5, because here the influence of the downflow from the propellers 7 is lowest.

[0204] The air guiding devices 12 can be designed to be controllably adjustable in their orientation to the transport module 9, or rather to the supporting framework structure 2 of the flight module 1, so that their function can be optimally adapted to the flow conditions etc. during flight operation.

[0205] FIG. 12 shows a side view of a flight module 1 tilted downward in the flight direction with a tilt angle of approximately 75. The tilt angle is enclosed by the plane E of the supporting framework structure 2 and the vertical line of gravity S. Such a tilt angle can be set, for example, during the acceleration of the flight module 1.

[0206] The flight module 1 has four air guiding devices 12, which are arranged on the supporting framework structure 2 of the flight module 1 as shown in the plan view in FIG. 11, and of which only two can be seen in FIG. 12. The air guiding devices 12 are set at an angle of incidence of approximately 150 with respect to the plane E of the supporting framework structure 2. The angle of incidence is enclosed by the plane E of the supporting framework structure 2 and the central cross-sectional plane of the air guiding device 12.

[0207] In a braking situation (not shown), the tilt of the flight module 1 with respect to the line of gravity S and the set position of the air guiding devices 12 can be reversed, so that for example a tilt angle of approximately 105 and an angle of incidence of approximately 235 can result.

[0208] With regard to the other elements of the flight module 1 of FIG. 12, reference is made to the previous explanations.

[0209] The term and/or used here, when used in a series of two or more elements, means that any of the listed elements may be used alone, or any combination of two or more of the listed elements may be used.

[0210] For example, if a relationship is described that contains the components A, B and/or C, the relationship can contain the component A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B and C in combination.

LIST OF REFERENCE NUMERALS

[0211] 1 Flight module [0212] 2 Supporting framework structure [0213] 3 Drive unit [0214] 4 Node point [0215] 5 Framework strut [0216] 6 Electric motor [0217] 7 Propeller [0218] 8 Central unit [0219] 9 Transport module [0220] 10 Fastening means [0221] 11 Connecting piece [0222] 12 Air guiding device [0223] R1, R2, R3 First, second, third ring [0224] d1, d2, d3 Diameter of the rotor [0225] DR1, DR2, DR3 Diameter of the ring [0226] M Centre axis of the flight module [0227] E Plane of the supporting framework structure [0228] S Line of gravity [0229] Tilt angle [0230] Angle of incidence