A reinforced emergency light cover for aviation

Abstract

The utility model discloses a kind of for aviation's reinforced emergency lampshade, including lampshade body;At least one weak area, form in the wall thickness thinning area of lampshade body;Reinforced core, embedded in lampshade body inside and located weak area, reinforced core and lampshade body are integrally consolidated, for improving the local structural strength of weak area.The utility model precisely arranges aluminum alloy reinforced core at the fillet transition of lampshade body most likely to appear crack, and it is once clamped between two carbon fiber prepreg and co-solidification, the utility model increases additional assembly process under the premise of not obvious weight gain, the strength of the weak area that is most likely to crack originally is improved more than half, both ensure the reliability of aircraft emergency lighting, also avoid the weight and light loss caused by traditional thickening.

Description

Technical Field

[0001] This utility model relates to the field of aviation lighting equipment technology, and in particular to a reinforced emergency lampshade for aviation. Background Technology

[0002] During operation, emergency light covers in existing aircraft often crack or even break at the thinner rounded corners due to insufficient material strength and structural design flaws. Traditional solutions involve thickening the entire cover or using metal components, but these result in increased weight, light obstruction, and complex installation. Furthermore, single-layer carbon fiber laminate structures are prone to failure due to stress concentration in weak areas, making it difficult to balance strength and weight. Therefore, there is an urgent need for a new type of emergency light cover structure that can effectively reinforce weak areas without significantly increasing weight, while maintaining a smooth appearance. Utility Model Content

[0003] The purpose of this invention is to provide a reinforced emergency light cover for aviation, thereby solving the aforementioned problems existing in the prior art.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0005] A reinforced emergency light cover for aviation, comprising:

[0006] Lampshade body;

[0007] At least one weak area is formed in the area where the wall thickness of the lampshade body is reduced;

[0008] The reinforcing core is embedded inside the lampshade body and located in the weak area. The reinforcing core is integrally fixed with the lampshade body to improve the local structural strength of the weak area.

[0009] In some specific embodiments, the lampshade body is integrally molded from a carbon fiber prepreg press plate, and the reinforcing core is a 2A12 aluminum alloy plate; the reinforcing core is placed in the mold before molding, and after molding, it forms an irremovable composite structure with the resin matrix of the lampshade body.

[0010] In some specific embodiments, the weak area is located at the rounded corner where the side wall and top wall of the lampshade body transition. The reinforcing core extends continuously along the arc direction of the rounded corner. The upper surface of the reinforcing core is bonded to the inner resin layer of the top wall of the lampshade body, and the lower surface is bonded to the inner resin layer of the side wall of the lampshade body.

[0011] In some specific embodiments, the thickness of the reinforcing core is 1.0mm–2.0mm, the width is 80%–100% of the arc length of the weak area, and the distance from both ends of the reinforcing core to the edge of the lampshade body is 5mm–10mm.

[0012] In some specific embodiments, the lampshade body is installed at the opening of the boarding gate decorative panel, and the weak area is aligned with the edge of the opening of the boarding gate decorative panel; the boarding gate decorative panel has a decorative panel weak area at the corresponding weak area.

[0013] In some specific embodiments, the weak area is distributed in a "U"-shaped strip and is located at the four rounded corners where the top wall of the lampshade body intersects with the four side walls; the reinforcing core is a closed ring piece that is completely identical to the "U"-shaped weak area, the width of the ring piece is centered along the thickness direction of the lampshade body, and the outer edge of the ring piece is 2mm to 4mm away from the outer contour edge of the lampshade body.

[0014] In some specific embodiments, the outer side of the lampshade body is wrapped with two layers of carbon fiber prepreg fabric. The carbon fiber prepreg fabric layers are wrapped upward at the flange of the lampshade body, and the wrapping height is 5mm to 10mm. The outer edge of the reinforcing core extends into the wrapped area, and the distance between the outer edge of the reinforcing core and the wrapped end is 2mm to 4mm.

[0015] The beneficial effects of this utility model are:

[0016] This utility model discloses a reinforced emergency light cover for aviation, comprising a light cover body; at least one weak area formed in the thinned area of ​​the light cover body; and a reinforcing core, pre-embedded inside the light cover body and located at the weak area, the reinforcing core being integrally fixed to the light cover body to improve the local structural strength of the weak area. This utility model precisely arranges aluminum alloy reinforcing cores at the rounded corner transitions of the light cover body, where cracks are most likely to occur, and then sandwiches them between two layers of carbon fiber prepreg for co-curing. Without adding extra assembly steps or significantly increasing weight, this utility model increases the strength of the weakest area, which is most prone to cracking, by more than half. This ensures the reliability of aircraft emergency lighting while avoiding the weight and light loss associated with traditional thickening methods. The outer surface of the light cover retains its original streamlined curve, without steps or gaps, making it both aesthetically pleasing and easy to clean. It significantly improves the fatigue life of the light cover under vibration, impact, and temperature cycling. Maintenance only requires disassembling and installing countersunk rivets for complete replacement, making maintenance simple and quick, fully meeting the comprehensive requirements of modern aviation for lightweight, high strength, and easy maintenance. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the weak point of the emergency lamp cover of this utility model;

[0018] Figure 2 This is a schematic diagram of the emergency lamp cover reinforcement scheme of this utility model;

[0019] Figure 3 This is a schematic diagram of the weak point of the boarding door decorative panel of this utility model;

[0020] Figure 4 This is a schematic diagram of the reinforcement scheme for the boarding door decorative panel of this utility model.

[0021] In the attached diagram: 1. Lampshade body; 2. Weak area; 3. Reinforcing core; 4. Boarding door decorative panel; 41. Weak area of ​​the decorative panel; 5. Carbon fiber prepreg fabric laminate. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the scope of the present utility model.

[0023] Reference Figures 1 to 4 The illustrated reinforced emergency light cover for aviation includes:

[0024] Lampshade body 1;

[0025] At least one weak area 2 is formed in the area where the wall thickness of the lampshade body 1 is reduced;

[0026] The reinforcing core 3 is embedded inside the lampshade body 1 and located in the weak area 2. The reinforcing core 3 is integrally fixed with the lampshade body 1 to improve the local structural strength of the weak area 2.

[0027] This invention employs a "one-time co-curing" process: first, the aluminum alloy reinforcing core 3 is precisely positioned in the predetermined weak area 2 within the mold; then, carbon fiber prepreg is laid on its upper and lower surfaces. After mold closing, heating and pressure are applied, and the resin, reinforcing core, and carbon fiber fabric simultaneously cure within the mold cavity, forming an unremovable composite whole. The entire process eliminates the need for secondary gluing or riveting, avoiding assembly errors and reducing weight.

[0028] In some specific embodiments, the lampshade body 1 is integrally molded from a carbon fiber prepreg press plate, and the reinforcing core 3 is a 2A12 aluminum alloy plate; the reinforcing core 3 is placed in the mold before molding, and after molding, it forms an irremovable composite structure with the resin matrix of the lampshade body 1.

[0029] In some specific embodiments, the weak area 2 is located at the transition rounded corner between the side wall and the top wall of the lampshade body 1. The reinforcing core 3 extends continuously along the arc direction of the transition rounded corner. The upper surface of the reinforcing core 3 is bonded to the inner resin layer of the top wall of the lampshade body 1, and the lower surface is bonded to the inner resin layer of the side wall of the lampshade body 1.

[0030] In this embodiment, the weak area (2) is precisely defined as "the four rounded transition surfaces where the side wall and top wall of the lampshade body (1) intersect" - where the original wall thickness naturally thins from 1.2 mm to 0.8 mm, forming a continuous 3-D curved ring. In order to provide continuous rigid support on this curved surface, the reinforcing core (3) is processed into a "U"-shaped closed ring conforming to the rounded corner.

[0031] In some specific embodiments, the thickness of the reinforcing core 3 is 1.0mm–2.0mm, the width is 80%–100% of the arc length of the weak area 2, and the distance between the two ends of the reinforcing core 3 and the edge of the lampshade body 1 is 5mm–10mm.

[0032] In some specific embodiments, the lampshade body 1 is installed at the opening of the boarding gate decorative panel 4, and the weak area 2 is aligned with the edge of the opening of the boarding gate decorative panel 4; the boarding gate decorative panel 4 is provided with a decorative panel weak area 41 at the corresponding weak area 2.

[0033] 1. Installation Interface

[0034] 1.1 Location

[0035] The lampshade body (1) is recessed: its outer flange sits on the stepped surface of the rectangular opening (length × width ≈ 150mm × 100mm) of the boarding door decorative panel (4) and is fixed by a ring of countersunk rivets (Ф3mm, titanium alloy).

[0036] 1.2 Alignment Relationship

[0037] The weak area of ​​the rounded corner of the lampshade (2) The corresponding arc of the "U" shaped ring and the edge of the opening of the decorative panel are coaxial and have the same curvature, with a deviation of ≤0.3mm.

[0038] On a top-down projection, the outer contour of the weak area (2) of the lampshade coincides with the edge line of the opening of the decorative panel, forming a continuous visual dividing line.

[0039] 2. Weak areas of the decorative panel (41)

[0040] 2.1 Definition

[0041] In the area directly opposite the weak area (2) of the lampshade, the wall thickness of the decorative panel (4) is reduced from 2.0mm to 1.2mm, forming the “weak area (41) of the decorative panel” – which is also in the form of a “U” shaped ring with a width of 8mm.

[0042] 2.2 Functions

[0043] Visual integration: The lampshade and decorative panel are on the same curved surface, with no step shadows.

[0044] Deformation coordination: When the cabin door is subjected to aerodynamic loads or passenger impact, the two weak areas simultaneously produce controllable elastic deformation, avoiding local high stress concentration.

[0045] Maintenance in sync: If the lampshade needs to be replaced, the weak area (41) of the decorative panel can be used as a "tear guide groove" to realize the lampshade and decorative panel to be replaced together as a whole, shortening the downtime.

[0046] 3. Tolerances and Compensation

[0047] The width difference between the weak area (2) of the lampshade and the weak area (41) of the decorative panel is controlled within 0–+0.5mm to ensure that the flange of the lampshade can completely cover the steps of the decorative panel and prevent light leakage.

[0048] A 0.2mm thick rubber pad is reserved in the Z direction (thickness direction) to absorb manufacturing tolerances and door vibration displacement.

[0049] 4. Typical assembly process

[0050] ①Place the lampshade body (1) into the opening of the decorative panel from top to bottom;

[0051] ② Rotate and align to make the two "U"-shaped weak areas aligned;

[0052] ③ Insert 12 countersunk rivets with a torque of 1.2 N·m;

[0053] ④ Apply a ring of sealant (Sikaflex-291) to the back of the decorative panel and complete the airtightness test after curing for 24 hours.

[0054] Through the above structure, the weak area (2) of the lampshade and the weak area (41) of the decorative panel are mapped one-to-one in terms of geometry, stress and maintenance, which not only ensures the seamless appearance, but also improves the overall reliability and maintenance convenience.

[0055] In some specific embodiments, the weak area 2 is distributed in a "U"-shaped strip and is located at the four rounded corners where the top wall of the lampshade body 1 intersects with the surrounding side walls; the reinforcing core 3 is a closed ring piece that is completely identical to the "U"-shaped weak area 2, and the width of the ring piece is set in the center along the thickness direction of the lampshade body 1, with the outer edge of the ring piece 2mm to 4mm away from the outer contour edge of the lampshade body 1.

[0056] In some specific embodiments, the outer side of the lampshade body 1 is wrapped with two layers of carbon fiber prepreg fabric 5, and the carbon fiber prepreg fabric 5 is wrapped upward at the flange of the lampshade body 1, with a wrapping height of 5mm to 10mm; the outer edge of the reinforcing core 3 extends into the wrapping area, and the distance between the outer edge of the reinforcing core 3 and the wrapping end is 2mm to 4mm.

[0057] Working principle of this utility model:

[0058] This aviation-grade reinforced emergency light cover incorporates a 2A12 aluminum alloy closed-loop reinforcing core, perfectly aligned with the rounded corner of the carbon fiber light cover, by embedding it in the most dangerous rounded corner area. A single co-curing process is used to create an integral, non-removable composite structure between the aluminum core and the resin matrix, achieving high strength, fatigue resistance, and easy maintenance while maintaining localized reinforcement without increasing overall weight.

[0059] 1. Stress transfer principle

[0060] Under cabin pressure fluctuations, passenger impacts, or vibration loads, the rounded corners of the lampshade become the points of maximum bending moment concentration due to the reduced wall thickness. The elastic modulus of the aluminum alloy reinforcing core is approximately 70 GPa, which is much higher than that of the carbon fiber / epoxy laminate (approximately 45 GPa). When external loads are applied, the bending moment is preferentially transferred to the stiffer aluminum core. The carbon fiber layer only bears shear and secondary tensile and compressive stresses, and the maximum principal stress at the rounded corners decreases by more than 50%, significantly reducing the probability of crack initiation.

[0061] 2. Continuous closed-loop plate effect

[0062] The reinforcing core uses a seamless "U"-shaped closed ring that extends continuously along the four rounded corners, eliminating the end stress concentration that may occur with segmented reinforcement. At the same time, the ring is centrally arranged in the thickness direction, so that the bending neutral axis coincides with the middle surface of the lampshade, avoiding additional bending moment and improving overall buckling stability.

[0063] 3. Reverse Anchoring Principle

[0064] The outer carbon fiber prepreg laminate wraps upwards 5–10 mm at the flange, and covers the outer edge of the reinforcing core 2–4 mm inside, forming a "carbon fiber-aluminum-carbon fiber" sandwich anchoring structure. This structure not only prevents the aluminum core edge from peeling off under impact or vibration, but also provides additional reinforcement for rivet installation and avoids cracking at the hole edge.

[0065] 4. Deformation Synergy Principle

[0066] The weak areas of the lampshade and the boarding door decorative panel are geometrically aligned, and the two undergo synchronous micro-deformation under load to avoid local high stress caused by rigid steps. At the same time, the two weak areas can act as "sacrificial" energy absorption zones, so that high loads cause controllable elastic deformation before other parts of the lampshade, thereby protecting the main optical area.

[0067] 5. Integrated process and structure

[0068] One-time co-curing allows the anodized micropores on the aluminum alloy surface to be completely wetted with epoxy, forming a mechanical and chemical double bond with an interfacial shear strength ≥35MPa. After curing, the aluminum core and carbon fiber layer are seamless and rivet-free, maintaining a streamlined curved surface, which not only meets the requirements of lightweight aerospace but also simplifies the assembly process.

[0069] Through the above multiple effects, this utility model increases the strength of the most vulnerable area of ​​the lampshade by more than half without significantly increasing the weight or reducing the light transmittance, and has the maintenance advantages of overall replacement and no on-site repair.

[0070] By adopting the above-disclosed technical solution of this utility model, the following beneficial effects are obtained:

[0071] This invention embeds a closed aluminum alloy ring piece with the same shape as the curved surface at the rounded corner transition of the lamp cover, which is most prone to cracking. Through one-time co-curing, it forms an unremovable composite structure with carbon fiber prepreg, which increases the local strength by more than 50% while increasing the weight by only a few grams. The light transmittance, appearance and assembly process are not affected. Moreover, no secondary gluing or riveting is required. On-site maintenance can be completed by replacing a single rivet, which significantly improves the reliability, lightweight and maintenance convenience of aviation emergency lamp covers.

[0072] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A reinforced emergency light cover for aviation, characterized in that, include: Lampshade body (1); At least one weak area (2) is formed in the area where the wall thickness of the lampshade body (1) is reduced; A reinforcing core (3) is embedded inside the lampshade body (1) and located in the weak area (2). The reinforcing core (3) is integrally fixed with the lampshade body (1) to improve the local structural strength of the weak area (2).

2. The reinforced emergency light cover according to claim 1, characterized in that: The lampshade body (1) is integrally molded from a carbon fiber prepreg board, and the reinforcing core (3) is a 2A12 aluminum alloy plate. The reinforcing core (3) is placed in the mold before molding, and after molding, it forms an irremovable composite structure with the resin matrix of the lampshade body (1).

3. The reinforced emergency light cover according to claim 2, characterized in that: The weak area (2) is located at the transition rounded corner between the side wall and the top wall of the lampshade body (1). The reinforcing core (3) extends continuously along the arc direction of the transition rounded corner. The upper surface of the reinforcing core (3) is bonded to the inner resin layer of the top wall of the lampshade body (1), and the lower surface is bonded to the inner resin layer of the side wall of the lampshade body (1).

4. The reinforced emergency light cover according to claim 3, characterized in that: The thickness of the reinforcing core (3) is 1.0mm–2.0mm, the width is 80%–100% of the arc length of the weak area (2), and the distance between the two ends of the reinforcing core (3) and the edge of the lampshade body (1) is 5mm–10mm.

5. The reinforced emergency light cover according to any one of claims 1 to 4, characterized in that: The lampshade body (1) is installed at the opening of the boarding gate decorative panel (4), and the weak area (2) is aligned with the edge of the opening of the boarding gate decorative panel (4); the boarding gate decorative panel (4) has a decorative panel weak area (41) at the corresponding weak area (2).

6. The reinforced emergency light cover according to claim 5, characterized in that: The weak area (2) is distributed in a "U"-shaped strip and is located at the four rounded corners where the top wall of the lampshade body (1) intersects with the four side walls; the reinforcing core (3) is a closed ring piece that is completely identical to the "U"-shaped weak area (2). The width of the ring piece is set in the center along the thickness direction of the lampshade body (1), and the outer edge of the ring piece is 2mm to 4mm away from the outer contour edge of the lampshade body (1).

7. The reinforced emergency light cover according to claim 6, characterized in that: The lampshade body (1) is wrapped with two layers of carbon fiber prepreg fabric (5) on the outside. The carbon fiber prepreg fabric is wrapped upward at the flange of the lampshade body (1) with a wrapping height of 5mm to 10mm. The outer edge of the reinforcing core (3) extends into the wrapping area, and the distance between the outer edge of the reinforcing core (3) and the wrapping end is 2mm to 4mm.

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