US 11,851,176 B1
Injection molded wing structure for aerial vehicles
Adam Woodworth, Mountain View, CA (US); Adem Rudin, Mountain View, CA (US); and Stephen Benson, Mountain View, CA (US)
Assigned to WING AVIATION LLC, Palo Alto, CA (US)
Filed by Wing Aviation LLC, Mountain View, CA (US)
Filed on Mar. 2, 2021, as Appl. No. 17/190,071.
Application 17/190,071 is a continuation of application No. 15/836,782, filed on Dec. 8, 2017, granted, now 10,933,971.
Int. Cl. B64C 3/24 (2006.01); B64C 3/18 (2006.01); B29C 45/00 (2006.01); B64C 29/02 (2006.01); B64C 39/02 (2023.01)
CPC B64C 3/24 (2013.01) [B29C 45/0053 (2013.01); B64C 3/18 (2013.01); B29C 2045/0079 (2013.01); B29C 2045/0093 (2013.01); B64C 29/02 (2013.01); B64C 39/024 (2013.01)] 9 Claims
OG exemplary drawing
 
1. A method of manufacturing a wing, comprising:
providing a wing frame, wherein the wing frame comprises a primary spar, secondary spar, a plurality of transverse frame elements coupled between the primary spar and the secondary spar, and a plurality of mounting elements configured to couple one or more components to the wing, wherein the plurality of transverse frame elements comprise a spar joiner, wherein the primary spar is coupled to the secondary spar via the spar joiner, and wherein mounting elements are each part of a transverse frame element;
placing the wing frame into a mold, wherein the mold defines a shape of the wing;
injecting the mold with an uncured material; and
allowing the uncured material to cure to form a body comprising 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.