Panel element and aircraft interior component

Abstract

The invention relates to a panel element and an aircraft interior component. A panel element, in particular for use as an aircraft interior component, comprising at least one panel component having a front side and a rear side, and a reinforcing structure forming a reinforced region of the panel component, wherein the reinforcing structure comprises at least one edge protection frame surrounding an outer edge of the at least one panel component and a local reinforcing element extending over an adjacent surface region of the front side and an adjacent surface region of the rear side, wherein the reinforcing structure is visible on both sides in the final state of the panel element, and an aircraft interior component comprising at least one panel element.

Description

Technical Field

[0001] The present invention relates to panel elements, particularly panel elements used as internal components of aircraft, and internal components of aircraft, wherein the panel element comprises: at least one plate member having a front side and a rear side; and a reinforcing structure forming a reinforced region of at least one plate member. Background Technology

[0002] Aircraft interior components, such as partition walls, are typically installed within aircraft cabins to create a comfortable environment for passengers. Generally, aircraft interior components are planar elements comprising plate members locally reinforced by invisible reinforcing structures. An exemplary partition wall is shown in the applicant's German patent DE 10 2009 010 861 B4. An exemplary sidewall is also shown in the applicant's European patent application EP 4 296 156 A1. Summary of the Invention

[0003] The object of the present invention is to provide an alternative panel element, particularly a panel element for internal components of an aircraft.

[0004] This objective is achieved by a panel element having features in one aspect and an aircraft internal component having features in another aspect. Advantageous embodiments are disclosed in other aspects of the invention, the specification, and the drawings.

[0005] According to the invention, a panel element, particularly a panel element used as an internal component of an aircraft, comprises at least one plate member having a front side and a rear side, and a reinforcing structure. The reinforcing structure forms a reinforced region of the at least one plate member. The reinforcing structure includes at least one edge protection frame surrounding the outer edge of the at least one plate member. Additionally, the reinforcing structure includes local reinforcing elements. The reinforcing elements extend over adjacent surface regions of the front side and the rear side. Specifically, in the reinforced region, the panel element is thickened on the front and rear sides compared to adjacent panel member regions.

[0006] The reinforcing structure represents the primary load path, a result of structural optimization. Specifically, in the final state of the panel element, the reinforcing structure is visible on both sides. This panel element offers several advantages. For example, stiffness is improved due to the reinforcing elements being located on both sides and due to the greater thickness at the locations of the reinforcing elements. Therefore, lighter materials or materials with reduced density can be used for the panel element, even if these materials have lower performance (stiffness / weight ratio) than commonly used materials, resulting in a weight reduction for the panel element according to the invention. Furthermore, the topology and morphology of the panel element can be improved; the geometry and their cross-sections can be individually adapted to specific load requirements.

[0007] Exemplary aircraft components that include at least one panel element according to the invention are partition walls, side walls, kitchen walls, or trolleys.

[0008] In a preferred embodiment, at least one panel component has a sandwich design comprising a core defining a front side and a rear side, and at least one outer surface layer located on the front and rear sides. The sandwich design allows each portion of the panel element to be easily and perfectly adjusted to its specific functional requirements. For example, the surface layer may include not only fiber reinforcement but also fiber reinforcement with different fiber orientations, while the core contains no fiber reinforcement.

[0009] Preferably, the panel components (core layer and surface layer) and reinforcing structures (frame and reinforcing elements, and joints for the reinforcing elements, if necessary) are made of the same material or material composition with different densities. By using the same material / material composition for all panel component components, the panel components have improved recycling compatibility. An exemplary material composition is polyethersulfone (PESU). Thus, the panel components can be made of PESU foam, the surface layer can be made of glass fiber reinforced PESU, such as PESU GF33, and the reinforcing structure can also be made of glass fiber reinforced PESU, such as PESU GF30. However, both can contain the same amount of fiber.

[0010] In one embodiment, the reinforcing element partially overlaps with the surface layer regions of the front and rear sides. This creates an enlarged reinforcing region.

[0011] In another embodiment, the reinforcing element extends at least partially through the panel. This improves load transfer because the load is directed within the panel structure, not just along the outer front or rear sides. To further enhance load transfer, the reinforcing element may extend fully through the panel member.

[0012] By dividing a single plate component into multiple individual plate components spaced apart from each other by reinforcing elements, each plate component can be optimally adapted to local requirements. The reinforcing elements form a skeleton for each plate component, which supports the plate components and holds them in place.

[0013] In one embodiment, the core has a varying density along its entire length in the thickness direction. This allows the core to be optimized and tailored to specific load conditions. Specifically, the density is adjusted to allow for the application of a reduced number of reinforcing elements.

[0014] In one embodiment, the reinforcing element may be a region of the core that has a greater thickness than laterally adjacent core regions. Such a core can be integrally formed. Furthermore, additional reinforcing elements, such as H-shaped profiles or strips, can be disposed thereon.

[0015] According to another embodiment, the reinforcing elements are core regions with a higher density compared to laterally adjacent core regions. These reinforcing elements can be integrally fabricated with adjacent core regions, allowing the fabrication of a single plate component. Alternatively, these reinforcing elements are fabricated separately and subsequently bonded to individual plate components. In this case, for example, the plate component region can be made of crushed core material.

[0016] In another embodiment, the reinforcing element is a combination of a core region with a higher density than the laterally adjacent core region and an outer flat reinforcing profile. This provides additional reinforcement to the high-density board component area.

[0017] In another embodiment, the reinforcing element is profiled such that a hollow space is created between at least a portion of the reinforcing element and at least one outer surface layer. By partially lifting the reinforcing element, the moment of inertia of the panel element is enhanced, resulting in weight reduction due to the use of less material.

[0018] In another embodiment, the contour-defined reinforcing element is an integral part of the core of the plate component.

[0019] To avoid any pressure difference between the hollow space and its environment, a pressure compensation system can be provided. An example of a pressure compensation system is an air passage that establishes a fluid connection between the hollow space and its environment. These can be directly guided through the reinforcing elements and / or through the plate components.

[0020] In other words, the present invention results in a panel element (structure) with homogeneous material (intended for recyclability) for the purpose of weight-optimized structure (intended to improve resource efficiency). The homogeneous material can be used simultaneously under at least two or three different conditions. In subsequent recycling and melting processes, these conditions can be combined into a single secondary raw material condition. The component combines reinforcing elements (such as profiles) with a classic sandwich panel. The reinforcing structure (here, a load path via topology optimization) is visible from both sides. The panel element according to the invention is preferably intended to depart from a hybrid / monolithic structure with the following exemplary options: a) H-shaped profile / C-shaped profile plus panel: The outer C-shaped profile and the inner H-shaped profile define the main load path. The profile is designed to be a straight profile and a design of difference beyond nodes. The profile can also be designed as a monolithic profile (straight elements and nodes). The combination of several separate sandwich panels and rib structures as H-shaped and C-shaped profiles can also be an alternative. b) Profile and visible added reinforcing elements: A sandwich panel as a component having laminated sheets such as organic sheets or disposed via automated belts as reinforcing elements. Attached Figure Description

[0021] Preferred embodiments of the invention are explained below with reference to the accompanying drawings. It should be understood that various elements and components are depicted by way of example only and may be combined in alternative and / or different ways than those depicted. Reference numerals for related elements are used collectively to some extent, and it is not necessary to define each drawing again, and this also applies to obvious analogies between the drawings.

[0022] The following diagram illustrates this schematically:

[0023] Figure 1a : A partition wall made of panel elements according to the invention installed in the aircraft cabin;

[0024] Figure 1b : A single 3D view of the partition wall;

[0025] Figures 2a to 2c Support structure for partition walls (panel elements);

[0026] Figures 3a to 3m A cross-section of an exemplary embodiment of a panel element according to the present invention; and

[0027] Figure 4 A handcart made from a panel element according to the invention. Detailed Implementation

[0028] exist Figure 1aThe image shows a partition wall 2 installed in the cabin of a passenger aircraft. The partition wall 2 is made of panel element 4 according to the invention and visually separates the cabin portions from each other, for example, separating the first-class portion from the economy-class portion. Another application of panel element 4 is, for example, a galley wall 5.

[0029] In the vertical direction, the partition wall 2 extends from the floor area 6 to the ceiling area 8, and is connected to the floor area 6 and the ceiling area 8 via a lower attachment 9 and an upper attachment 10. In the horizontal direction, the partition wall 2 extends between the side wall area 11 and the passageway of the aircraft cabin. Here, the partition wall 2 is equipped with a window 13.

[0030] The panel element 4 forming the partition wall 2 according to the present invention includes a reinforced strengthening structure 12 and at least one plate member 14, which forms the outer edge, front side 16 and opposite rear side 18 of the partition wall 2 (see...). Figures 3a to 3k In the final state of the partition wall 2, the reinforcing structure 12 is visible from both sides of the front side 16 and from the rear side 18.

[0031] Reference Figure 2a , Figure 2b and Figure 2c The reinforcing structure 12 includes a C-shaped edge protection frame 20 surrounding the outer edge and adjacent surface regions 24a, 24b, 26a, 26b on the front side 16 and the rear side 18 (see...). Figures 3a to 3k Local reinforcing elements 22 extend from the plate. The reinforcing elements 22 extend along the main load path. Depending on the type of reinforcing element 22, mechanical nodes 28 may be provided as joint points between the reinforcing elements 22. Preferably, the nodes 28 are 3D printed parts. The panel component 4 may be a single plate component 14 or may have multiple separately formed plate components 14a, 14b, as will be discussed below. Figures 3a to 3k Detailed description is provided.

[0032] All embodiments of panel element 4 share at least one plate member 14 and a visible reinforcing structure 12 that extends along the main load path on the front side 16 and rear side 18 in adjacent side regions, such that the panel element 4 has a greater thickness in the region of the reinforcing structure 12 compared to the side adjacent to it. Additionally, all embodiments of panel element 4 share the common feature that at least one plate member 14 has a sandwich structure made of the same material and material composition as the reinforcing structure 12. For example, the differences between them lie only in their form, density, and added fibers. A preferred material is polyethersulfone (PESU). It should be noted that materials other than PESU are also suitable. A key characteristic of the selected material is its good recyclability.

[0033] The sandwich structure (plate component 14) itself has a core 30 defining a front side 16 and a rear side 18, and at least one outer surface layer 32, 34 covering the front side 16 and the rear side 18 (see, for example, [link to relevant documentation]). Figure 3c Preferably, the core 30 comprises a foam made of a selected material. The pores of the foam can be open and / or closed. The surface layers 32, 34 are composed of the same material of a different density and preferably include a specific amount and orientation of fibers. The fibers themselves are glass fibers, carbon fibers, aramid fibers, etc.

[0034] Reference Figures 3a to 3k This document describes some exemplary embodiments of panel elements according to the present invention. For clarity, only the main differences between these embodiments are described. Furthermore, it is mentioned that features of these exemplary embodiments can be combined with embodiments not illustrated herein. All such embodiments are covered by the scope of the invention.

[0035] exist Figure 3a In this structure, multiple individual panel components 14a, 14b are joined together by reinforcing elements 22a shaped into an H-shape. Each panel component 14a, 14b has a core 30 with a surface layer 32 on its front side 16 and a surface layer 34 on its rear side 18. The reinforcing element 22a has a front flange 36 and a rear flange 38, which are connected to each other by a web 40 extending through the panel component 4. By means of its flanges 36, 38, the reinforcing element 22a overlaps with the surface layer regions 42a, 42b of the front side 16 and the surface layer regions 44a, 44b of the rear side 18. The reinforcing element 22a may have the highest density. The core 30 may have the lowest density, which is constant throughout its thickness. For example, the core may be PESU foam. The surface layers 34, 36 (skin) may be PESU GF33, with eight layers on each side 16, 18. For example, reinforcing element 22a can be PESU GF30.

[0036] and Figure 3a The single H-shaped profile in the middle is the opposite, in Figure 3b The diagram illustrates the process steps for manufacturing an H-shaped profile reinforcing element 22b from two T-shaped profiles 22b', 22b''. The T-shaped profiles 22b', 22b'' are introduced from different sides between plate members 14a, 14b and can be joined together at their free web ends 46, 48.

[0037] Figure 3cAn embodiment of panel element 4 is shown, wherein panel element 4 includes a single plate component 14, and wherein reinforcing elements 22c', 22c'' have a strip shape. The strip reinforcing elements 22c', 22c'' do not extend between adjacent plate components 14, but are disposed on the front side 16 and rear side 18 above surface layers 32, 34. The reinforcing elements 22c', 22c'' are, for example, unidirectional prepreg strips based on thermoplastic material. An exemplary thickness of a single strip is 0.15 mm to 0.30 mm. Alternatively, the strip reinforcing elements 22c', 22c'' are made of thermoplastic-based organic sheets. As another alternative, the strip reinforcing elements 22c', 22c'' can be made of thermoplastic substrate elements with a thickness greater than 1 mm. Waterjet cutting may be a suitable manufacturing means for cutting the strip reinforcing elements 22c', 22c'' from organic sheets or thermoplastic plate elements.

[0038] exist Figure 3d The diagram illustrates an embodiment of panel element 4, wherein the reinforcing element 22d is formed as a partial thickening 30d of the core 30. The thickened reinforcing element 22d may be formed as an integral part of a single panel component 14, or alternatively, the thickened reinforcing element 22d may be formed separately and then joined to adjacent panel components 14a, 14b.

[0039] Figure 3e An embodiment of panel element 4 is shown, wherein additional strip-shaped surface layers are partially added as reinforcing elements 22e', 22e'' to the lower surface layer 32 and the upper surface layer 34. Similar to [the previous embodiment]... Figure 3c In one implementation, a single plate component 14 is provided.

[0040] Figure 3f It shows Figure 3c The embodiment illustrated is combined with a higher core density. Here, the core 30 has a higher density in the reinforced region where the strip-shaped reinforcing elements 22c', 22c'' are provided compared to the adjacent core regions 30a, 30b. This high-density core region 30c can be integrally formed with the adjacent core regions 30a, 30b, or alternatively, the core region 30a can be manufactured separately and then joined with the core regions 30a, 30b of the adjacent plate components 14a, 14b. One way to increase core density is by compressing the foam material. If the core has a honeycomb structure, the density can be increased by crushing it.

[0041] Figure 3g An embodiment of panel element 4 is shown, wherein a single panel component 14 has a reduced core central region 30d, which is covered on both sides by at least a single strip-shaped surface layer 22e', 22e'' (see also) Figure 3eOnce the original core thickness is reached, the outer surface layers 32, 34 are laminated onto the core 30, extending over the strip surface layers 22e', 22e''. Then, finally, reinforcing element strips 22c', 22c'' are provided on the surface layers 32, 34 in the region of the reduced core region 30d (see also...). Figure 3c ).

[0042] exist Figure 3h The diagram illustrates an embodiment of panel element 4, wherein the H-shaped reinforcing element 22a ( Figure 3a Combined with plate components 14 and 14b, the core density of the plate components varies in its thickness direction. Here, each plate component 14a, 14b has a core 30, which has a low-density central region 30d and high-density regions 30a, 30b near the front side 16 and the rear side 18. The different regions 30a, 30b, 30d can be formed integrally, or alternatively, the different regions 30a, 30b, 30d are manufactured separately and then joined together to construct the core 30 of each plate component 14a, 14b.

[0043] Additionally, an outer sealing layer 50 may be provided on the front side 14 and / or the rear side 16 in the region of the reinforcing element 22a. The outer sealing layer 50 covers the flanges 36, 38 of the reinforcing element 22a and prevents them from accidentally detaching. As illustrated, the covering layer 50 does not make the different thicknesses of the panel element 4 in its reinforcing region equal compared to the surface areas adjacent to the flanges 36, 38.

[0044] Figure 3i It shows something similar to Figure 3d The embodiment shown is of panel element 4. The main difference is that, according to... Figure 3i The thickened reinforcing element 22i is the core region 30c, which has a higher density compared to the adjacent core regions 30a and 30b.

[0045] Figure 3j An embodiment of a panel element 4 with a single plate component 14 is shown, which has a reduced central core region 30d. By means of this, vertical grooves 52a and 52b are formed on the two side portions 14 and 16 of the core 30. In the grooves 52a and 52b, T-shaped reinforcing elements 22b' and 22b'' (see...) are... Figure 3b It is introduced together with its webs 40' and 40''. The webs 40' and 40'' are spaced apart from each other via the central core region 30d. The flange 36 of the reinforcing element 22b' and the flange 38 of the reinforcing element 22b'' overlap with the surface layers 32 and 34 on the front side 14 and the rear side 16, respectively.

[0046] exist Figure 3kThe diagram illustrates an embodiment of panel element 4, wherein the strip-shaped reinforcing elements 22c' and 22c'' on the two sides 14 and 16 (see [reference]). Figure 3c They are joined together by multiple connecting elements 54, such as pins. For clarity, as part of the reinforcing structure 12, the pins 54 are made of the same material as the other parts / components of the panel element 4.

[0047] Figure 3l An embodiment of the panel element 4 according to the present invention is shown, wherein the reinforcing elements 22f', 22f'' are partially raised from the outer surface layers 32, 34 of at least one sandwich panel member 14 of the panel element 4. A hollow space 27 is formed below the raised portion 23, whereby the middle portion of each reinforcing element 22f', 22f'' is located.

[0048] exist Figure 3m Another embodiment of the invention is shown in the figure. In this embodiment, the reinforcing elements 22g', 22g'' are integral portions of the core 30 of the panel element 4. The core 30 is partially profiled such that its front side 16 and rear side 18 both form a hollow space 27. No further details are provided as per [the previous description]. Figure 3l The outer surface layer shown in the embodiment (reference numerals 32, 34). In particular, the density of the core 30 can be varied to provide a robust front side 16 and rear side 18 with sufficient mechanical stability.

[0049] exist Figure 3l and Figure 3m In the embodiment shown, the hollow space 27 has a trapezoidal cross-section (Omega-shaped profile). It should be noted that the hollow space 27 is not limited to this cross-section, but other cross-sections can be used.

[0050] In addition, according to Figure 3l and Figure 3m In both embodiments, in order to achieve pressure compensation between the hollow space 27 and its environment, a pressure compensation system 29 may be provided, such as an air passage through the reinforcing elements 22f', 22f'', 22g', 22g''.

[0051] To reduce stress loads, in both embodiments, the inner corners / inner edges 31a and outer corners / outer edges 31b of the reinforcing elements 22f', 22f'', 22g', 22g'' can be rounded.

[0052] like Figure 4 As shown, the panel element 4 according to the invention can be used not only for aircraft interior components such as partition walls and side walls, but also for components such as kitchen walls 5 (see...). Figure 1aAnd partition walls such as washroom walls. Another application of the panel element 4 according to the invention is a box, such as this kitchen trolley 56. Here, at least some of the walls 58 of the trolley 56 are made of the panel element 4.

[0053] A panel element, particularly a panel element used as an internal component of an aircraft, is disclosed. The panel element includes: at least one plate member having a front side and a rear side; and a reinforcing structure forming a reinforcing region of the plate member, wherein the reinforcing structure includes at least one edge protection frame surrounding the outer edge of the at least one plate member and local reinforcing elements extending on adjacent surface regions of the front side and the rear side, wherein the reinforcing structure is visible on both sides in the final state of the panel element. An internal component of an aircraft is also disclosed, which includes at least one panel element.

[0054] List of reference numerals

[0055] 2. Partition wall

[0056] 4 Panel Components

[0057] 5. Kitchen walls

[0058] 6. Base Plate Area

[0059] 8. Ceiling area

[0060] 9. Lower attachment

[0061] 10. Attached parts

[0062] 11 Sidewall Region

[0063] 12. Strengthen the structure

[0064] 13 windows

[0065] Components 14, 14a, and 14b

[0066] 16. Front side

[0067] 18 Rear side

[0068] 20 Framework

[0069] 22 Reinforcing Components

[0070] 22a Reinforcing element

[0071] 22b, 22b', 22b'' Reinforcing elements

[0072] 22c', 22c'' Reinforcing Components

[0073] 22d reinforcing element

[0074] 22e', 22e'' Reinforcing Components

[0075] 22f', 22f'' Reinforcing elements

[0076] 22g', 22g'' Reinforcing Components

[0077] The part mentioned in 23

[0078] Surface areas 24a and 24b

[0079] Surface areas 26a and 26b

[0080] 27 Hollow Space

[0081] 28 nodes

[0082] 29 Pressure Compensation System

[0083] 30 cores

[0084] 31a, 31b Corners / Edges

[0085] Core areas 30a, 30b, 30c, and 30d

[0086] 32 Surface layer on the front side

[0087] 34 Surface layer on the rear side

[0088] 36 Anterior flange

[0089] 38. Rear flange

[0090] 40, 40', 40'' web

[0091] Overlapping surface regions of 42a and 42b

[0092] Overlapping surface regions of 44a and 44b

[0093] 46. ​​End of the web

[0094] 48. End of the web

[0095] 50 closed layers

[0096] 52a, 52b grooves

[0097] 54 Connecting elements

[0098] 56 handcarts

[0099] 58 Handcart wall

Claims

1. A panel element (4), particularly a panel element (4) used as an internal component of an aircraft, said panel element (4) comprising: At least one plate member (14, 14a, 14b), said plate member (14, 14a, 14b) having a front side (16) and a rear side (18); and Reinforcing structure (12), said reinforcing structure (12) forming a reinforcing region of said at least one plate member (14, 14a, 14b), The reinforcing structure (12) is characterized in that it comprises: At least one edge protection frame (20) surrounding the outer edge of the at least one plate member (14, 14a, 14b); and Local reinforcing elements extend over adjacent surface regions of the front side portion (16) and the rear side portion (18).

2. The panel element according to claim 1, wherein, At least one plate component (14, 14a, 14b) has a sandwich design, the sandwich design comprising: Core (30), the core (30) defining the front side portion (16) and the rear side portion (18); and At least one outer surface layer (32, 34) is located on the front side (16) and the rear side (18).

3. The panel element according to claim 1 or 2, wherein, The plate components (14, 14a, 14b) and the reinforcing structure (12) are made of the same material or material composition with different densities.

4. The panel element according to any one of the preceding claims, wherein, In its thickness direction, the core (30) has a varying density throughout its entire extension.

5. The panel element according to any one of the preceding claims, wherein, The reinforcing elements (22a; 22b', 22b''; 22c, 22c''; 22e, 22e'') partially overlap with the surface layer regions (42a, 42b) of the front side (16) and the surface layer regions (44a, 44b) of the rear side (18).

6. The panel element according to the preceding claim, wherein, The reinforcing elements (22a; 22b', 22b''; 22c, 22c'') extend at least partially through the at least one plate member (14, 14a, 14b).

7. The panel element according to claim 6, wherein, The plate component (14) includes a plurality of individual plate components (14a, 14b) which are spaced apart from each other by the reinforcing elements (22a; 22b', 22b''; 22c, 22c'').

8. The panel element according to any one of claims 1 to 4, wherein, The reinforcing elements (22d, 22i) are core regions (30c, 30d) with a greater thickness than the laterally adjacent core regions (30a, 30b).

9. The panel element according to any one of claims 8, wherein, The reinforcing element (22i) is a core region (30c) with a higher density than the laterally adjacent core regions (30a, 30b).

10. The panel element according to any one of claims 1 to 5, wherein, The reinforcing elements (22e', 22e''; 22c', 22c'') are combinations of the following: Compared to the laterally adjacent core regions (30a, 30b), it has a higher density core region; and External flattened reinforced profile (22).

11. The panel element according to any one of claims 1 to 5, wherein, The reinforcing elements (22f', 22f'') are profiled such that a hollow space (27) is created between at least one portion (23) of the reinforcing elements (22f', 22f'') and the at least one outer surface layer (32, 34).

12. The panel element according to any one of claims 1 to 5, wherein, The reinforcing elements (22g', 22g'') are profiled such that hollow spaces (27) are created between at least one portion (23) of the reinforcing elements (22g', 22g'') and the front side portion (16) and between at least one portion (23) of the reinforcing elements (22g', 22g'') and the rear side portion (18).

13. The panel element according to claim 11 or 12, wherein, The hollow space (27) is equipped with a pressure compensation system (29).

14. An aircraft interior component comprising at least one panel element (4) according to any one of the preceding claims.

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