Aircraft interior panels and methods of panel fabrication

• US 10,076,895 B2
• Filed: 03/04/2015
• Issued: 09/18/2018
• Est. Priority Date: 11/14/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Patel, Jayant Dahyabhai, Harris, John N., Sanchez, Sergio H., Fullerton, James A.
• Primary Examiner(s): Tolin, Michael A
• Application Number:
  US14/638,952
• Publication Number:
  US 20150174874A1
• Time in Patent Office: 1,294 Days
• CPC Class Codes: B29C 2043/189 the parts being joined
• CPC Class Codes: B29C 2043/561 under vacuum conditions
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 43/206 by pressing the material between two preformed layers, e.g. deformable layers
• CPC Class Codes: B29C 43/56 Compression moulding under special conditions, e.g. vacuum
• CPC Class Codes: B29C 44/146 Shaping the lining before foaming
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/105 Twin sheet thermoforming, i.e. deforming two parallel opposing sheets or foils at the same time by using one common mould cavity and without welding them together during thermoforming B29C51/267, B29C49/0691 take precedence
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 51/267 Two sheets being thermoformed in separate mould parts and joined together while still in the mould B29C49/0691 takes precedence
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/16 Laser beams
• CPC Class Codes: B29C 69/004 making articles by joining parts moulded in separate cavities, said parts being in said separate cavities during said joining B29C45/006, B29C51/267 take precedence
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29D 99/0021 provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3076 : Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B32B 2038/0084 : Foaming
• CPC Class Codes: B32B 2305/022 : Foam
• CPC Class Codes: B32B 2305/024 : Honeycomb
• CPC Class Codes: B32B 2305/08 : Reinforcements
• CPC Class Codes: B32B 2307/102 : Insulating
• CPC Class Codes: B32B 2307/304 : Insulating
• CPC Class Codes: B32B 2310/028 : using vibration, e.g. sonic or ultrasonic
• CPC Class Codes: B32B 2310/0843 : using laser
• CPC Class Codes: B32B 2451/00 : Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 2605/18 : Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 37/02 : characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 37/06 : characterised by the heating method
• CPC Class Codes: B32B 37/18 : involving the assembly of discrete sheets or panels only
• CPC Class Codes: B32B 37/24 : with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 38/0036 : Heat treatment for heating or cooling of layers during lamination B32B37/06, B32B37/08
• CPC Class Codes: B32B 5/20 : foamed in situ
• CPC Class Codes: B64C 1/066 : Interior liners
• CPC Class Codes: Y02T 50/40 : Weight reduction
• CPC Class Codes: Y10T 156/1002 : with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1031 : with preshaping of lamina
• CPC Class Codes: Y10T 428/23 : Sheet including cover or casing
• CPC Class Codes: Y10T 428/233 : Foamed or expanded material encased
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/24744 : Longitudinal or transverse tubular cavity or cell
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249976 : Voids specified as closed
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]

Abstract

A multifunctional fully integral panel system design, a unique material configuration, and a process for fabricating a net shape (or nearly net shape) panel in one production cycle. The panel may comprise a base facing with an outer perimeter, a decorative film applied to the exterior of the base facing, an aft facing having an outer perimeter fused to the base facing, and a reinforcement core disposed between the unfused portions of the base and aft facings, which reinforcement core also acts as acoustic insulation (i.e., a noise attenuator). Alternatively or additionally, a foam core or blanket having thermal and/or acoustic insulation properties is attached to the external surface of the aft facing. The fabrication process involves the application of different heat treatments to panel components having different forming temperature or rubbery/elastic plateaus.

Claims

1. A method of making a panel:

bonding a plurality of polymer rods to one surface of a base facing;

heating the base facing to a softened state;

placing the softened base facing in a first tool having a shape defining one surface of a panel with the polymer rods being on a side of the base facing which faces away from the first tool;

heating an aft facing to a softened state;

placing a surface of the softened aft facing against a second tool having a shape defining another surface of the panel;

placing an insulation layer adjacent to the one surface of the base facing;

vacuum forming the base and aft facings to take the respective shapes of the first and second tools; and

pressing the base and aft facings together such that they contact each other and fuse along a perimeter to form a panel having an interior volume with the insulation layer and polymer rods inside.

2. The method as recited in claim 1, further comprising applying a foaming film to the one surface of the base facing prior to vacuum forming and then applying heat to the film to cause the film to convert to foam that coats the one surface of the base facing to form the insulation layer.

3. The method as recited in claim 1, wherein the polymer rods are hollow.

4. The method as recited in claim 3, wherein the insulation layer comprises foam that encapsulates the hollow polymer rods.

5. The method as recited in claim 1, wherein the base facing is a composite sheet having a fiber layer encapsulated in a polymer matrix.

6. The method as recited in claim 1, further comprising attaching a decorative film to another surface of the base facing.

7. A method of making a panel:

placing a surface of a base facing against a first tool having a shape defining one surface of a panel;

placing a surface of an aft facing against a second tool having a shape defining another surface of the panel;

vacuum forming the base and aft facings to take the respective shapes of the first and second tools;

pressing the base and aft facings together such that they contact each other and fuse along a perimeter; and

attaching an insulation layer to an exterior surface of one of the base and aft facings,

wherein the insulation layer is attached to the exterior surface of the aft facing using an ultrasonic or laser welding technique.

8. The method as recited in claim 7, wherein the base facing is a composite sheet having a fiber layer encapsulated in a polymer matrix.

9. A method of making a panel:

placing a surface of a base facing against a first tool having a shape defining one surface of a panel;

placing a surface of an aft facing against a second tool having a shape defining another surface of the panel;

vacuum forming the base and aft facings to take the respective shapes of the first and second tools;

pressing the base and aft facings together such that they contact each other and fuse along a perimeter; and

attaching an insulation layer to an exterior surface of one of the base and aft facings,

wherein the step of attaching the insulation comprises;

positioning a layer of batting material over the exterior surface of the aft facing;

positioning a thin film over the layer of batting material; and

fusing the thin film to the exterior surface of the aft facing.

10. The method as recited in claim 9, wherein the base facing is a composite sheet having a fiber layer encapsulated in a polymer matrix.