# US 11,077,643 B1 · Frame material for drones and other unmanned aircraft, and drone frame made from such material

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- Number: US 11,077,643 B1
- Document ID: US11077643B1
- Status: Granted
- Kind: B1
- Application number: 16/601,986
- Filed: 2019-10-15
- Granted: 2021-08-03
- Earliest claimed: 2018-10-15
- Applicants: Tarek Maalouf
- Inventors: Tarek Maalouf
- Web page: https://patentgrep.com/patent/US11077643B1

## CPC

- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B29C 70/34: and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation}
- B29C 70/545: {Perforating, cutting or machining during or after moulding}
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- B32B 15/043: {of metal (B32B15/01 takes precedence)}
- B32B 15/046: {of foam}
- B32B 15/082: comprising vinyl resins; comprising acrylic resins
- B32B 15/09: comprising polyesters
- B32B 15/10: of wood
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 21/042: {of wood (B32B21/13 takes precedence)}
- B32B 21/047: {of foam}
- B32B 21/08: of synthetic resin
- B32B 21/10: Next to a fibrous or filamentary layer
- B32B 21/13: all layers being exclusively wood
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/365: {comprising polycarbonates}
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B 37/12: characterised by using adhesives
- B32B 37/142: {Laminating of sheets, panels or inserts, e.g. stiffeners, by wrapping in at least one outer layer, or inserting into a preformed pocket}
- B32B 37/18: involving the assembly of discrete sheets or panels only
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B64D 47/02: Arrangements or adaptations of signal or lighting devices
- B64D 47/06: for indicating aircraft presence
- B64F 5/10: Manufacturing or assembling aircraft, e.g. jigs therefor
- B64U 20/65: Composite materials
- B64U 20/80: Arrangement of on-board electronics, e.g. avionics systems or wiring
- B32B 38/10: Removing layers, or parts of layers, mechanically or chemically
- B32B 2038/0076: {Curing, vulcanising, cross-linking}
- B32B 2250/03: 3 layers
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2305/34: Inserts
- B32B 2305/72: Cured, e.g. vulcanised, cross-linked
- B32B 2307/412: Transparent
- B32B 2307/422: Luminescent, fluorescent, phosphorescent
- B32B 2307/732: Dimensional properties
- B32B 2313/04: Carbon
- B32B 2333/04: Polymers of esters
- B32B 2369/00: Polycarbonates
- B32B 2457/00: Electrical equipment
- B32B 2605/006: Transparent parts other than made from inorganic glass, e.g. polycarbonate glazings
- B32B 2605/18: Aircraft
- B64C 2001/0072: {from composite materials}
- B64D 2203/00: Aircraft or airfield lights using LEDs
- B64U 10/14: with four distinct rotor axes, e.g. quadcopters
- Y02T 50/40: Weight reduction
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B64D: EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- B64U: UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
- B64C: AEROPLANES; HELICOPTERS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A drone frame includes first and second carbon fiber layers, and a center clear layer positioned between the first and second carbon fiber layers. A cutout is formed through an entire thickness of the first carbon fiber layer so as to expose a portion of the center clear layer. An LED unit is positioned in the cutout. The LED unit has a plurality of LEDs on a bottom thereof such that the LEDs abut the center clear layer. Light is transmitted from the LEDs through the center clear layer so as to illuminate the perimeter of the drone frame. A composite material used in the drone frame and a method of forming the composite material and drone frame are also disclosed.

## Claims

### Claim 1

A composite material for use with drones or other unmanned aircraft, the composite material comprising:
a top carbon fiber sheet;
a bottom carbon fiber sheet; and
a center sheet of clear material positioned between said top carbon fiber sheet and said bottom carbon fiber sheet, wherein adhesives are applied between said top carbon fiber sheet and said center sheet of clear material and said bottom carbon fiber sheet such that the sheets are secured together; a recess formed in the composite material in said top carbon fiber sheet or said bottom carbon fiber sheet so as to expose a portion of said center sheet of clear material, and wherein a plurality of LEDs of an LED unit are positioned within said recess, the composite material forming part of a drone or unmanned aircraft.

### Claim 2 (depends on 1)

The composite material of claim 1, further comprising:
wherein, said plurality of LEDs being positioned adjacent said center sheet of clear material.

### Claim 3 (depends on 2)

The composite material of claim 2, a top of said LED unit being flush with said top carbon fiber sheet or said bottom carbon fiber sheet.

### Claim 4 (depends on 1)

The composite material of claim 1, said adhesives comprising layers of resin applied between the respective sheets.

### Claim 5 (depends on 1)

The composite material of claim 1, said center sheet of clear material being selected from a group consisting of: acrylic and polycarbonate.

### Claim 6 (depends on 1)

The composite material of claim 1, wherein each of said top carbon fiber sheet and said bottom carbon fiber sheet and said center sheet of clear material have a thickness of approximately 2 millimeters.

### Claim 7

A drone frame comprising:
a first carbon fiber layer;
a second carbon fiber layer;
a center clear layer positioned between said first carbon fiber layer and said second carbon fiber layer;
a cutout formed through an entire thickness of said first carbon fiber layer so as to expose a portion of said center clear layer; and
an LED unit positioned in said cutout, said LED unit having a plurality of LEDs on a bottom thereof; said bottom of said LED unit abutting said center clear layer, and wherein said drone frame is part of a drone or unmanned aircraft.

### Claim 8 (depends on 7)

The drone frame of claim 7, further comprising:
a plurality of arms extending outwardly from a center of the drone frame, said cutout being formed at said center of the drone frame.

### Claim 9 (depends on 8)

The drone frame of claim 8, each of said plurality of arms having a plurality of mounting holes formed at respective ends thereof remote from said center.

### Claim 10 (depends on 7)

The drone frame of claim 7, wherein a first adhesive layer is provided between said first carbon fiber layer and said center clear layer, and wherein a second adhesive layer is provided between said center clear layer and said second carbon fiber layer.

### Claim 11 (depends on 10)

The drone frame of claim 10, said first and second adhesive layers comprising resin layers.

### Claim 12 (depends on 7)

The drone frame of claim 7, said LED unit mounted flush with an exposed top surface of said first carbon fiber layer.

### Claim 13 (depends on 7)

The drone frame of claim 7, said LED unit being programmable.

### Claim 14 (depends on 7)

The drone frame of claim 7, said center clear layer formed of a material selected from a group consisting of: acrylic and polycarbonate.

### Claim 15 (depends on 7)

The drone frame of claim 7, each of said first carbon fiber layer and said second carbon fiber layer and said center clear layer having a thickness of approximately 2 millimeters.

### Claim 16 (depends on 8)

The drone frame of claim 8, further comprising:
a plurality of cutouts formed on respective arms of said plurality of arms; and
a plurality of LED units positioned in respective cutouts of said plurality of cutouts.

### Claim 17 (depends on 7)

The drone frame of claim 7, said center clear layer being visible along an entirety of a perimeter of the drone frame.

### Claim 18

A method of constructing a frame for an unmanned aircraft comprising the following steps:
providing a top carbon fiber sheet, a bottom carbon fiber sheet and a clear sheet;
applying a resin to the various sheets and layering them such that the center clear sheet is positioned over the bottom carbon fiber sheet, and the top carbon fiber sheet is positioned over the center clear sheet;
curing the layered sheets;
pressing the cured layered sheets so as to form a composite material;
forming at least one recess in one of said top carbon fiber sheet and said bottom carbon fiber sheet so as to expose a portion of said clear sheet;
positioning an LED unit within said at least one recess; and
cutting the composite material in a desired shape so as to form the frame for the unmanned aircraft.