UNMANNED AIRCRAFT SYSTEM USING METALIZED CARBON FIBRE REINFORCED POLYMER FOR OUTER SPACE MISSION

Abstract

UNMANNED AIRCRAFT SYSTEM USING METALIZED CARBON FIBRE REINFORCED POLYMER FOR OUTER SPACE MISSION The present invention relates to an unmanned aircraft system for outer space mission, comprising a quadcopter metalized carbon fibre reinforced polymer composite frame [100]. The metalized carbon fibre reinforced polymer composite frame [100] includes at least four motor mount arms [102]; a top plate [104]; a middle plate [106]; and a bottom plate [108]. The metalized carbon fibre reinforced polymer composite frame [100] has a X-shape configuration, and the carbon fibre reinforced polymer is metallized using a mixture of titanium nano powder and epoxy resin in the ratio of 5:100. The metalized carbon fibre reinforced polymer composite frame [100] has materials consisting of Carbon fiber sheets-189 gm; Epoxy resin, Ly556-150 gm; Titanium nano powder (5% by weight)- 15 gm; and Hardener, Hy951-16 gm. Figure 1

Specification

Description:UNMANNED AIRCRAFT SYSTEM USING METALIZED CARBON FIBRE REINFORCED POLYMER FOR OUTER SPACE MISSION

FIELD OF THE INVENTION
The present invention generally relates to unmanned aircraft systems, particularly to unmanned aircraft systems for outer space mission. More particularly, the present invention relates to unmanned aircraft systems made using metalized carbon fibre reinforced polymer for improved durability and performance.

BACKGROUND OF THE INVENTION
Drones, also known as unmanned aircraft vehicles, or UAVs, have transformed a number of industries on Earth. Nevertheless, using them in the harsh environment of space comes with special difficulties. For space missions, the conventional materials and drone designs used for terrestrial applications are insufficient. Due to their limitations, traditional drone materials perform poorly in space: metals are strong but heavy, and lightweight composites are not strong enough to withstand launch stresses. Bulky materials also make manoeuvrability more difficult because a high thrust-to-weight ratio is required in space due to the lack of air. Lastly, the extreme temperature swings from sunlight to shade present thermal challenges for materials used in drones today. Due to these constraints, there exists a need for a novel material approach for space-worthy UAVs. Conventional drone designs are unable to meet the requirement, even if materials are able to withstand the harshness of space. Since there is no atmosphere in space, traditional wings cannot provide lift, necessitating the development of completely new aerodynamic concepts and propulsion strategies. Moreover, lack of gravity dramatically affects controllability and manoeuvrability, rendering existing drone designs unsuitable for the precise navigation and delicate tasks involved in space travel.

The majority of previous art in the field of unmanned aircraft systems for space exploration uses conventional materials like aluminium or non-metallized composite materials. However, said materials don't have the strength-to-weight ratio and thermal stability needed for extended space operations. Furthermore, for effective planetary exploration, current designs might not maximise stability, manoeuvrability, and payload capacity.

US10272986 disclosed an unmanned aerial vehicle that includes a body and a heat source disposed in the body. The heat source includes at least one of an electronic controller system and a motor. The unmanned aerial vehicle further includes a plurality of rotor blades. The vehicle has a tri copter configuration, in which the body is partly made up off strong carbon fibers, and disclosed about the thermally conductive portions.

US8146861 disclosed a spacecraft, comprising a component having a resin matrix in which carbon nanotubes are embedded for providing a high conductivity of the component, wherein a current source is provided, the current source being adapted to produce an electric current in the component for heating-up the same in order to defrost the component or an area adjacent to the component.

US10358213B2 disclosed an unmanned aerial vehicle (UAV) that includes a frame that provides structural support for the UAV, the frame may be formed of any suitable material, such as graphite, carbon fiber, aluminum, titanium, etc., or any combination thereof. However, said prior art described a UAV configuration with structural support, protection of propellers from foreign objects, and weather resilience. Further, it emphasised more on robustness and versatility than on material advancements.

CN111361180B provides a carbon fiber structural component comprising chopped carbon fibers, polymethyl methacrylate powder, metal titanium powder, liquid epoxy resin, a curing agent and a surfactant; the mass ratio of the polymethyl methacrylate powder to the chopped carbon fibers is 1: 10-25; the mass ratio of the metal titanium powder to the chopped carbon fibers is 1: 3-75; the mass ratio of the sum of the mass of the liquid epoxy resin and the curing agent to the mass of the short carbon fibers is 2-6: 1; the surfactant is 1-5% of the sum of the mass of the chopped carbon fibers, the polymethyl methacrylate powder, the metal titanium powder, the liquid epoxy resin and the curing agent. However, the prior art focused on low-density carbon fibre felt with particular thermal characteristics for industrial furnaces.

CN208897308U relates to a light unmanned aerial vehicle wing. The carbon fiber composite material comprises a layer of titanium mesh, two layers of carbon fiber unidirectional cloth and two layers of carbon fiber woven cloth, the titanium mesh is fixed between the two layers of carbon fiber unidirectional cloth, the two layers of carbon fiber unidirectional cloth are fixed to the surfaces of the two sides of the titanium mesh through adhesives respectively, and the two layers of carbon fiber woven cloth are fixed to the surfaces of the outer sides of the two layers of carbon fiber unidirectional cloth through adhesives respectively; And the titanium mesh, the carbon fiber unidirectional cloth and the carbon fiber woven cloth are filled with resin. However, the prior art disclosed a UAV wing with titanium mesh and carbon fibre for stiffness and corrosion resistance alone.

KR20220039870A relates to a drone kit made of laminated carbon fiber reinforced plastic (CFRP) and a manufacturing method thereof. The drone kit includes a body part, a wind part, and a wing protection part. However, the kit as disclosed in said prior art is for ease of assembly and mechanical strength.

CN108485205A discloses a light unmanned aerial vehicle shell body material formula which is characterized by comprising the following ingredients in parts by weight: 40 to 73 parts of novolac epoxy resin, 30 to 65 parts of bisphenol F type epoxy resin, 6 to 14 parts of titanium nanoparticle, 15 to 27 parts of carbon fiber, 8 to 15 parts of aramid fiber, 10 to 20 parts of graphene, 2 to 8 parts of sodium dodecyl sulfate and 1 to 4 parts of pigment. However, the prior art claims only a comprehensive material formula for UAV shells.

None of the prior arts focused on advanced structural optimization to improve payload capacity, manoeuvrability, stability, and space missions. Accordingly, there exists a need for an unmanned aircraft system made using metalized carbon fibre reinforced polymer for outer space mission.

OBJECTS OF THE INVENTION
One or more of the problems of the conventional prior arts may be overcome by various embodiments of the system and method of the present invention.

It is the primary object of the present invention to provide an unmanned aircraft system for outer space mission.

It is another object of the present invention to provide an unmanned aircraft system made using metalized carbon fibre reinforced polymer (CFRP) for improved durability and performance.

It is another object of the present invention, wherein the unmanned aircraft system used metalized carbon fibre reinforced polymer (CFRP) composite material that is hand-layup constructed with titanium added for enhanced strength and thermal properties.

It is another object of the present invention, wherein the unmanned aircraft system has a X-shaped quadcopter frame made of metalized carbon fibre reinforced polymer (CFRP), which is optimized for improved stability, manoeuvrability, and payload capacity.

It is another object of the present invention, wherein the unmanned aircraft system has increased strength-to-weight ratio, thrust to weight ratio and thermal characteristics of the composite material make it suitable for the harsh conditions found in space environments.

SUMMARY OF THE INVENTION
Thus according to the basic aspect of the present invention, there is provided an unmanned aircraft system for outer space mission, comprising:
a quadcopter metalized carbon fibre reinforced polymer (CFRP) composite frame,
wherein the metalized carbon fibre reinforced polymer composite (CFRP) frame includes at least four motor mount arms; a top plate; a middle plate; and a bottom plate,
wherein the metalized carbon fibre reinforced polymer (CFRP) composite frame has a X-shape configuration, and
wherein the carbon fibre reinforced polymer is metallized using a mixture of titanium nano powder and epoxy resin in the ratio of 5:100.

It is another aspect of the present invention, wherein the metalized carbon fibre reinforced polymer (CFRP) composite frame has materials consisting of Carbon fiber sheets-189 gm; Epoxy resin, Ly556-150 gm; Titanium nano powder (5% by weight)-15 gm; and Hardener, Hy951-16 gm.

It is another aspect of the present invention, wherein the metalized carbon fibre reinforced polymer (CFRP) composite frame has weight around 111 grams.

It is another aspect of the present invention, wherein the unmanned aircraft system for outer space mission has a thrust-to-weight ratio of 4.97:1.

It is another aspect of the present invention, wherein the quadcopter metalized carbon fibre reinforced polymer (CFRP) composite frame could bear up to 60N of total thrust ensuring a safety factor of 15N per motor.

BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1: illustrates a prototype of unmanned aircraft system according to the present invention.
Figure 2: illustrates quadcopter according to the present invention.
Figure 3: illustrates top plate of quadcopter according to the present invention.
Figure 4: illustrates middle plate of quadcopter according to the present invention.
Figure 5: illustrates bottom plate of quadcopter according to the present invention.
Figure 6: illustrates arm of quadcopter according to the present invention.
Figure 7: illustrates Metalized CFRP specimen according to the present invention.
Figure 8: illustrates prototype top plate of quadcopter from the specimen after cutting according to the present invention.
Figure 9: illustrates prototype middle plate of quadcopter from the specimen after cutting according to the present invention.
Figure 10: illustrates prototype bottom plate of quadcopter from the specimen after cutting according to the present invention.
Figure 11: illustrates prototype arm of quadcopter from the specimen after cutting according to the present invention.
Figure 12: illustrates method of preparing and assembling of unmanned aircraft system according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING FIGURES
The present invention as herein described relates to an unmanned aircraft system made using metalized carbon fibre reinforced polymer (CFRP) for outer space missions.

Referring to Figures 1 and 2, the unmanned aircraft system comprising of a X-shaped configuration quadcopter frame [100] made of metalized carbon fibre reinforced polymer (CFRP) composite material. The quadcopter frame [100] includes at least four motor mount arms [102], a top plate [104], a middle plate [106], and a bottom plate [108] as depicted in Figures 2 to 6.

Material Composition
Materials:
Carbon fiber sheets-189gm;
Epoxy resin, Ly556-150gm;
Titanium nano powder (5% by weight)-15gm; and
Hardener, Hy951-16gm

Carbon fibre is the foundation material because of its high strength and low weight. Up to 5% titanium is added to the Carbon Fibre Reinforced Polymer (CFRP) matrix to improve material's overall durability, its thermal properties, strength-to-weight ratio, and thrust-to-weight ratio, making it more suited to the harsh conditions found in space environments. The CFRP sheets are layered with a titanium-epoxy mixture, compressed, and shaped into quadcopter components using a straightforward hand layup method. The unmanned aircraft system's overall performance is the X-shaped frames' reduced weight, which is due to their effective material usage.

Trials and Results:
A number of trials were conducted to achieve the ideal composition of metalized CFRP for the drone frame, especially in strength-to-weight ratio, thermal properties, and overall performance. Here is a summary of key trials and their output:

Composition Trials:
The trial was aimed at getting the right epoxy resin and titanium nano powder mixture that would be helpful in enhancing the strength-to-weight ratio and thermal properties in the case of CFRP material.

Materials Used:
Carbon Fiber sheets- (189 gm);
Epoxy resin, Ly556- (150 gm);
Titanium nano powder (different concentrations); and
Hardener, Hy951- (16 gm)
Method:
Preparation:
Referring to Figure 12a, carbon fiber sheets were cut in to desired dimensions. Epoxy resin and titanium nano powder was taken in bowl as depicted in Figure 12b. Hardener was added to the epoxy resin and titanium nano powder mixture as shown in 12c. A mixture of epoxy resin and titanium nano powder was prepared by stirring for 3 hours as shown in 12d to ensure even distribution.
Layup Process:
The carbon fiber sheets were layered sequentially. The prepared titanium-epoxy mixture was applied between layers of the carbon fiber sheets as shown in 12e. The layers were rolled to ensure even distribution of the mixture as shown in 12f. The layering procedure is repeated until the required thickness is reached.
Compression:
The layered carbon fiber sheets were compressed to promote bonding and avoid delamination. The composite was allowed to cure. Figure 7 shows the composite specimen [110].
Cutting and Shaping:
The cured composite specimen [110] was cut using a water jet facility to ensure accuracy and precise shaping. Figures 8-11 shows the top plate [104], middle plate [106], bottom plate [108], and arms [102] cut from the cured composite specimen [110].
Assembly:
The cut components were assembled into the quadcopter frame [100]. An electric propulsion system was integrated for flight testing.
After meticulous cutting and assembly, flight testing is done to analyze performance.
Variation trials: Different concentrations of titanium nano powder are tested ranging from 2% to 7 % by weight as shown in Table 1. For the test, the concentration of 5% titanium nano powder has been taken.

Table 1:
Trial No. Titanium nano powder (%) Observations Strength-to-weight ratio Thermal stability Thrust-to-weight ratio (TWR) Weight reduction (%) Result
1 2% Slight improvement in strength, minimal thermal stability Moderate Insufficient thermal properties 3.1:1 10% Not optimal
2 3% Strength increased slightly, better thermal stability Moderate high Improved, but still not suitable for space 3.8:1 15% Not optimal
3 4% Noticeable improvement in strength and thermal stability High Better thermal stability, lightweight 4.2:1 20% Close to optimal
4 5% Optimum strength-to-weight ratio, excellent thermal stability Very high Superior thermal properties, no cracks 4.97:1 30% Optimal composition
5 6% Material began to crack, reduced overall strength Low Thermal stability maintained, but weaker 3.9:1 25% Over-saturation of titanium, not optimal
6 7% Increased brittleness, significant cracking Low No improvement in thermal properties 3.4:1 22% Decreased strength, not optimal

Best method with illustration:
The best method for creating and assembling the unmanned aircraft system made using metalized carbon fibre reinforced polymer (CFRP) involves the following steps: material preparation, hand-layup method, compression, cutting, assembly, and testing as depicted in Figure 12. Referring to Figure 12a, 189 gm of carbon fiber sheets were cut in to desired dimensions. 150 gm of Ly556 epoxy resin and 15 gm of titanium nano powder was taken in bowl as depicted in Figure 12b. 16g m of Hardener, Hy951 was added to the epoxy resin and titanium nano powder mixture as shown in 12c. A mixture of epoxy resin and titanium nano powder in the ratio of 100:5 was prepared by stirring for 3 hours as shown in 12d to ensure even distribution. The carbon fiber sheets were layered sequentially. The prepared titanium-epoxy mixture was applied between layers of the carbon fiber sheets as shown in 12e. The layers were rolled to ensure even distribution of the mixture as shown in 12f. The layering procedure is repeated until the required thickness is reached. The layered carbon fiber sheets were compressed to promote bonding and avoid delamination. The composite was allowed to cure. Figure 7 shows the composite specimen [110]. The cured composite specimen [110] was cut using a water jet facility to ensure accuracy and precise shaping. Figures 8-11 shows the top plate [104], middle plate [106], bottom plate [108], and arms [102] cut from the cured composite specimen [110]. The cut components were assembled into the quadcopter frame [100].

Results:
Strength-to-Weight Ratio:
The inclusion of titanium nano powder increased the strength-to-weight ratio compared to traditional carbon fiber composites.
A regular 250mm wheel base quadcopter frame typically weighs around 140 to 160 grams, but the metalized CFRP quadcopter frame weight is around 111 grams which is almost 30% reduction in weight.

Thermal Characteristics:
The unmanned aircraft systems made using metalized carbon fibre reinforced polymer exhibited superior thermal stability, making it suitable for the extreme temperature fluctuations in space environments.
Thrust to weight ratio:
Total weight = 823 g = 8.07 N
Total thrust = 4 × 1024g = 4096 = 40.17N
TWR = Total thrust/Total weight = 40.17/8.07 = 4.97: 1
A good thrust-to-weight ratio for a drone is generally considered to be 2:1. The unmanned aircraft systems made using metalized carbon fibre reinforced polymer has a thrust-to-weight ratio of 4.97:1, almost 5 times the thrust of the drone weight.

Flight Testing:
The True X-design configuration of the quadcopter frame provided improved stability and manoeuvrability.
The drone demonstrated enhanced performance in terms of payload capacity and aerodynamic efficiency during flight tests.

Simulation analysis:
The results shown in the stress, displacement and strain analysis gives the safety factor of 15N for each motor. So up to 60N of total thrust the quadcopter frame can bear.

Table 2 illustrates how the metalized CFRP frame with 5% titanium nano powder provides substantial advantages over standard CFRP materials in terms of weight, thrust performance, thermal stability, and structural integrity, making it highly suitable for outer space missions.





Table 2:
Parameter Standard CFRP Metalized CFRP (5% Ti Nano Powder)
Weight 140-160 grams 111 grams (30% reduction)
Thrust-to-Weight Ratio (TWR) ~2:1 4.97:1
Thermal Stability Moderate Superior (Minimal changes in space)
Flight Stability Decent Enhanced
Payload Capacity Limited Increased
Stress/Thrust Capacity Standard 60N total thrust, 15N per motor
Strength-to-Weight Ratio Standard Significantly improved

These results highlight the technical advancements of unmanned aircraft systems made using metalized carbon fibre reinforced polymer, including its enhanced thermal properties, superior strength-to-weight ratio, exceptional thrust-to-weight ratio, and improved stability, aerodynamics, and payload capacity.

Thus the unmanned aircraft system according to the present invention when compare to conventional materials such as aluminum or non-metalized composites, the metalized CFRP composite offers superior strength-to-weight ratio, thrust to weight ratio and thermal stability required for extended space operations. Moreover, the X-shaped quadcopter frame maximizes stability, aerodynamics, and payload capacity, essential for effective planetary exploration.

Technical advancements:
The addition of titanium nano powder to the metalized CFRP quadcopter frame significantly improved its strength-to-weight ratio, reducing the frame weight by 30% to 111 grams compared to the typical 140-160 grams for regular frames.
The metalized CFRP also exhibited superior thermal stability, maintaining structural integrity with minimal dimensional changes during thermal cycling tests, making it ideal for extreme temperature fluctuations in space.
The thrust-to-weight ratio of the quadcopter was exceptionally high at 4.97:1, greatly surpassing the generally considered good ratio of 2:1, indicating excellent performance.
Flight testing demonstrated that the True X-shaped configuration provided enhanced stability and manoeuvrability, with improved payload capacity and aerodynamic efficiency.
Simulation analysis confirmed the frame could bear up to 60N of total thrust, ensuring a high safety factor of 15N per motor.
, Claims:WE CLAIM:
1. An unmanned aircraft system for outer space mission, comprising:
a quadcopter metalized carbon fibre reinforced polymer (CFRP) composite frame [100],
wherein the metalized carbon fibre reinforced polymer composite (CFRP) frame [100] includes at least four motor mount arms [102]; a top plate [104]; a middle plate [106]; and a bottom plate [108],
wherein the metalized carbon fibre reinforced polymer (CFRP) composite frame [100] has a X-shape configuration, and
wherein the carbon fibre reinforced polymer is metallized using a mixture of titanium nano powder and epoxy resin in the ratio of 5:100.

2. The unmanned aircraft system for outer space mission as claimed in claim 1, wherein the metalized carbon fibre reinforced polymer (CFRP) composite frame [100] has materials consisting of Carbon fiber sheets-189 gm; Epoxy resin, Ly556-150 gm; Titanium nano powder (5% by weight)- 15 gm; and Hardener, Hy951-16 gm.

3. The unmanned aircraft system for outer space mission as claimed in claim 1, wherein the metalized carbon fibre reinforced polymer (CFRP) composite frame [100] has weight around 111 grams.

4. The unmanned aircraft system for outer space mission as claimed in claim 1 has a thrust-to-weight ratio of 4.97:1.

5. The unmanned aircraft system for outer space mission as claimed in claim 1, wherein the quadcopter metalized carbon fibre reinforced polymer (CFRP) composite frame [100] could bear up to 60N of total thrust ensuring a safety factor of 15N per motor.

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