Selective protective coating, system, and method for vehicle cabin interior structures

Abstract

To provide a vehicle cabin interior structure capable of allowing a vehicle cabin interior comprising vehicle cabin interior and exterior structures having areas of high-risk for damages from abrasion, to be protected from the damage.SOLUTION: A transparent and self-healing partial outer coating made from a self-healing thermoplastic polyurethane material protects high-risk abrasion regions.SELECTED DRAWING: Figure 5A

Description

[Technical field]

[0001]

[0001] The present disclosure relates generally to the field of vehicle cabin interiors and vehicle cabin interior structures, including aircraft cabin interiors and aircraft cabin interior structures. In particular, the present disclosure relates to the field of wear protection for vehicle interior structures. [Background technology]

[0002]

[0002] Vehicle cabin interiors, including passenger vehicle cabin interiors, may include cabin interior surfaces that may be subject to habitual or repetitive wear and tear, for example, due to wear and tear associated with abrasion of exterior surfaces. Over time, such cabin exterior surfaces may become damaged to a degree that may require rework and / or replacement. Such rework and / or replacement of such cabin area structures and structural surfaces may be time consuming and expensive, as the vehicle may be taken out of service while reworking and / or replacing structures within the damaged vehicle cabin interior areas that require rework and / or replacement.

[0003]

[0003] Unless expressly stated otherwise, statements in this specification are not admitted to be prior art by virtue of being included merely in the technical field and / or background art. Summary of the Invention

[0004]

[0004] Several of the present aspects are directed to a vehicle cabin interior structure having a protective coating layer that partially covers specific and selected areas of the vehicle cabin structure that are located in or otherwise within areas at high risk of damage, e.g., from abrasion.

[0005]

[0005] According to one present aspect, a vehicle cabin interior structure is disclosed, which includes a structural exterior surface including an identified first region of the structural exterior surface having a first area (e.g., a region at "high risk" of damage) and an identified second region of the structural exterior surface having a second area (e.g., a region at "low risk" of damage compared to the "high risk" of damage) and a partial outer coating layer. The partial outer coating layer is configured to coat only the first region of the structural exterior surface.

[0006] In another aspect, the first area comprises a smaller area than the second area.

[0007]

[0007] In another aspect, the structural exterior surface includes a decorative laminate coating layer.

[0008] In another aspect, the partial outer coating layer comprises a thermoplastic polyurethane.

[0009]

[0009] In a further aspect, a first region of the structural exterior is disposed within a vehicle cabin interior in an area at high risk of damage for structural exterior wear damage.

[0010] In another aspect, the partial outer coating layer is substantially transparent.

[0011] In another embodiment, the partial outer coating layer is a substantially transparent thermoplastic polyurethane layer film.

[0012] In another aspect, the partial outer coating layer comprises a UV / visible light resistant material.

[0013]

[0013] In another aspect, the structural exterior surface includes the exterior of at least one of a luggage bin, a ceiling, a partition wall, a lavatory wall, a galley wall, a side wall, a seat frame, a seat armrest, a seat assembly panel, and combinations thereof.

[0014] In a further aspect, the partial outer coating layer further comprises an adhesive layer.

[0015]

[0015] In a further aspect, the partial outer coating layer is a partial outer coating layer membrane.

[0016]

[0016] In another aspect, the partial outer coating layer is a self-adhesive partial outer coating layer film.

[0017] In a further aspect, the partial outer coating layer has a Young's modulus in the range of about 10 MPa to about 120 MPa.

[0018]

[0018] In another aspect, when the partial outer coating layer has an average thickness in the range of about 2 mils to about 6 mils, for UV / visible light wavelengths in the range of about 180 nm to about 800 nm, the partial outer coating layer has a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance.

[0019] In another aspect, the partial outer coating layer comprises a self-healing substantially transparent thermoplastic polyurethane film.

[0020]

[0020] In another aspect, the vehicle cabin interior is an aircraft cabin interior.

[0021]

[0021] Another aspect is directed to a vehicle comprising a vehicle cabin structure including a vehicle cabin structural exterior including a first region of the structural exterior having a first area (e.g., an area at "high risk" of damage) and a second region of the structural exterior having a second area, and a partial outer coating layer. The partial outer coating layer includes a self-healing material and is configured to coat only the first region of the structural exterior having the first area and is disposed adjacent to the second region of the structural exterior having the second area. The first area has an area smaller than the second area.

[0022]

[0022] In another aspect, the vehicle is an aircraft.

[0023]

[0023] Another present aspect is directed to a vehicle cabin interior structure, the vehicle cabin interior structure including a structural exterior surface. The structural exterior surface includes a touch-up patch area. The touch-up patch area includes a decorative laminate layer. The touch-up patch area further includes an abrasion-resistant outer coating layer disposed on the decorative laminate layer to form the touch-up patch area. The abrasion-resistant outer coating layer includes a self-healing thermoplastic polyurethane material.

[0024]

[0024] In another aspect, the vehicle cabin interior including the repair patch area is an aircraft cabin interior.

[0025]

[0025] A further aspect is directed to a vehicle including a vehicle cabin interior including a refurbished area including a self-healing thermoplastic polyurethane material.

[0026]

[0026] In another aspect, the vehicle is an aircraft.

[0027]

[0027] Another aspect of the present invention is directed to a vehicle cabin interior refinish patch comprising a decorative laminate material layer and a self-healing, wear-resistant outer coating layer disposed over the decorative laminate material layer to substantially cover the decorative laminate material layer.

[0028] In a further aspect, the abrasion-resistant outer coating layer is substantially transparent.

[0029] In another aspect, the wear-resistant outer coating layer comprises a self-healing thermoplastic polyurethane material film.

[0030] In another embodiment, the self-healing thermoplastic polyurethane material has a Young's modulus value in the range of about 10 MPa to about 120 MPa.

[0031]

[0031] A further present aspect is directed to a method for protecting a vehicle cabin interior structural region from surface damage. The method includes providing a vehicle cabin interior structure. The vehicle cabin interior structure includes a vehicle cabin structural exterior. The vehicle cabin structural exterior includes a first region of the structural exterior having a first area and a second region of the structural exterior having a second area. The first region of the structural exterior is disposed adjacent to the second region of the structural exterior. The first region of the structural exterior is disposed within a location of high risk of damage. The method further includes adhering a protective outer coating layer only to the first region of the structural exterior and protecting the first region of the structural exterior from abrasive damage.

[0032] In another embodiment, the protective outer coating layer comprises a thermoplastic polyurethane.

[0033] In another aspect, the protective outer coating layer comprises a substantially transparent thermoplastic polyurethane.

[0034] In a further aspect, the first region of the structural exterior surface further includes a decorative laminate coating disposed beneath the protective outer coating layer.

[0035] In another embodiment, the protective outer coating layer comprises a UV / visible light resistant material.

[0036]

[0036] In another aspect, the vehicle cabin interior structural area includes at least one of a luggage box exterior surface, a ceiling exterior surface, a partition wall exterior surface, a lavatory wall exterior surface, a lavatory door exterior surface, a galley area wall exterior surface, a seat assembly panel exterior surface, a cockpit door exterior surface, a closet exterior surface, a sidewall exterior surface, and combinations thereof.

[0037]

[0037] The above-described features, functions, and advantages can be realized alone in various aspects or can be combined in further multiple aspects, details of which can be confirmed by referring to the following description and the attached drawings.

[0038]

[0038] Having described the present disclosure in general terms, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0039] [Figure 1]

[0039] FIG. 1 is a diagram of a vehicle taking the form of an aircraft according to the present embodiment. [Diagram 2]

[0040] 2 is a cross-sectional view of a vehicle cabin interior in the form of an aircraft cabin interior of the type contained within the vehicle shown in FIG. 1 taken along line 2-2 according to the present embodiment. [Diagram 3]

[0041] FIG. 3 is an outboard view from within a vehicle cabin interior of the type shown in FIG. 2 according to a present embodiment. [Figure 4]

[0042] FIG. 2 is an enlarged view of a vehicle cabin interior structure disposed within the vehicle cabin interior according to the present embodiment. [Figure 5A]

[0043] FIG. 2 is an upward view of the vehicle cabin interior structure according to the present embodiment. [Figure 5B]

[0044] FIG. 2 is an upward view of the vehicle cabin interior structure according to the present embodiment. [Figure 5C]

[0045] FIG. 2 is an upward view of the vehicle cabin interior structure according to the present embodiment. [Figure 6A]

[0046] 1 is a perspective view of a vehicle cabin interior structure in the form of a seat assembly according to the present embodiment; FIG. [Figure 6B]

[0047] 1 is a perspective view of a vehicle cabin interior structure in the form of a seat assembly according to the present embodiment; FIG. [Figure 7]

[0048] 1 is a flow chart outlining a method according to the present embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040]

[0049] According to some present aspects, the aircraft cabin exposed surfaces of the aircraft cabin interior structure may be present or otherwise located within areas of the aircraft cabin interior that may be at locations where wear damage is likely to occur over time. Such locations are referred to herein as areas of high risk of wear damage within the aircraft cabin interior, and such areas of high risk of wear damage may include, for example, without limitation, areas immediately adjacent, proximate or otherwise close to the aircraft cabin floor, the aircraft cabin aisle, the aircraft cabin ceiling, etc., and may include portions of, for example, the aircraft cabin interior sidewall panel exposed surfaces, the aircraft cabin luggage bin exposed surfaces, the partition wall exposed surfaces, the ceiling exposed surfaces that may be adjacent to the luggage bins, the seat assemblies (which may include seat frames, seat armrests, seat assembly exterior panels that may be seat assembly exterior panels for seat suites, seat assembly panel dividers for fully reclining seating areas), etc.

[0041]

[0050] When a portion of an exposed surface of an aircraft cabin interior structure suffers from abrasion damage or is otherwise scratched, scored, dented, worn, etc., such structure, or the damaged surface area of ​​such damaged structure, must be reworked or replaced with a view to re-establishing at least an unblemished aesthetic appearance or "as good as new" exterior surface within the aircraft cabin interior. That is, sustained abrasion or other "abrasion" damage to a portion of an exposed surface (equivalently referred to herein as an "exterior" surface) of an aircraft cabin structure can be visually unattractive and otherwise make the structure appear "worn," "aged," etc., and can otherwise adversely affect the appearance of at least a portion of the aircraft cabin interior. However, attempting to rework and / or clean abraded structural surfaces can be time consuming, costly, and can interfere with the desired visually uniform appearance. In addition, treating the entire surface with a protective material layer can add significant undesirable weight and prohibitive cost to a larger structure, such as a vehicle that may include, for example, an aircraft.

[0042]

[0051] A number of present aspects are directed to a protective partial coating, which may be a self-healing protective partial coating, multiple coating layers, a single coating layer, or even a protective partial coating film for an aircraft cabin exposed surface, including an aircraft cabin exposed surface located in an area of ​​the aircraft cabin interior that is at high risk of wear damage. The protective partial coating may be applied to an aircraft cabin interior structure prior to structural installation, may be applied to the structure as an assembled partial protective coating, or may be applied to an installed structure as an exterior layer in conjunction with reworking a structure that has sustained damage and requires rework (including, for example, reworking a decorative laminate of the structure).

[0043]

[0052] Figure 1 illustrates a vehicle 10 in the form of an aircraft, which may be, for example, a passenger airliner having a fuselage 12. Figure 2 illustrates a cross-sectional view of the vehicle 10 taken along line 2-2 (shown in Figure 1). As shown in Figure 2, the aircraft cabin interior 14 is shown bounded by an aircraft cabin interior structure 16 having an aircraft cabin interior structure exposed surface 18. The aircraft cabin interior structure 16 may be, for example, structurally attached to the interior of the fuselage 12 or attached to a structure attached to the interior of the fuselage 12.

[0044]

[0053] As shown in Figure 2, the aircraft cabin interior structure 16 may include an aircraft cabin interior sidewall panel 20 having an aircraft interior sidewall panel exposed surface 21. The aircraft cabin interior structure 16 further includes an aircraft cabin interior ceiling 22 having a cabin ceiling exposed surface 22a, an aircraft cabin interior floor 24, and a luggage box 26 having a luggage box exposed surface 26a. Figure 2 further shows a cabin seat 27 having a seat frame 28 having a seat frame exposed surface 28a, and a seat armrest 29 having a seat armrest exposed surface 29a. An aircraft cabin interior structure "exposed surface" as referred to herein is understood to be a cabin interior structure exterior surface or outer surface of a structure that is "exposed" to the aircraft cabin interior environment and may equivalently be referred to as a cabin structure "exterior" surface and / or "outer" surface disposed within the aircraft cabin environment.

[0045]

[0054] Figures 3 and 4 are further views of a vehicle cabin interior 14 in the form of an aircraft cabin interior. Figure 3 is a partial outboard view from within the aircraft cabin interior 14 of an aircraft 10, which may be of the type shown in Figures 1 and 2, for example. As shown in Figure 3, the aircraft cabin interior sidewall panel 20 includes an aircraft interior sidewall panel exposed surface 21. The aircraft cabin interior 14 further includes an aircraft cabin interior ceiling 22 having a cabin ceiling exposed surface 22a, an aircraft cabin interior floor 24, and a luggage box 26 having a luggage box exposed surface 26a. Figure 3 further shows a cabin seat 27 having a seat frame 28 having a seat frame exposed surface 28a, and a seat armrest 29 having a seat armrest exposed surface 29a.

[0046]

[0055] Figure 4 is a partial outboard view from within aircraft cabin interior 14 of aircraft 10, which may be, for example, of the type shown in Figures 1, 2, and 3. As shown in Figure 4, aircraft cabin interior sidewall panel 20 includes an aircraft interior sidewall panel exposed surface 21. Sidewall panel exposed surface 21 further includes two distinct regions on exposed surface 21: 1) a first region 21a of the sidewall panel exposed surface (equivalently referred to herein as the "first region of the structural exterior surface"), and 2) a second region 21b of the sidewall panel exposed surface (equivalently referred to herein as the "second region of the structural exterior surface").

[0047]

[0056] 4 further illustrates an aircraft cabin interior luggage box (equivalently referred to herein as a "luggage box") 26 including a luggage box exterior surface 26a. The luggage box exterior surface 26a further includes two distinct regions on the luggage box exposed surface 26a: 1) a luggage box exposed surface first region 26b (equivalently referred to herein as the "structural exterior surface first region"), and 2) a luggage box exterior surface second region 26c (equivalently referred to herein as the "structural exterior surface second region").

[0048]

[0057] 4 further illustrates an aircraft cabin interior partition 30 that includes a partition exterior surface 31. The partition exterior surface 31 further includes two distinct regions: 1) a partition exterior first region 31a (equivalently referred to herein as the "structural exterior first region"), and 2) a partition exterior second region 31b (equivalently referred to herein as the "structural exterior second region").

[0049]

[0058] According to some present aspects, a first region of the structural exterior is disposed in an exterior region currently determined and identified as a "high risk" area of ​​abrasion and other localized exterior damage, etc. A second region of the structural exterior is disposed in an exterior region of the structural exterior (which may abut or be disposed proximate to the first region of the structural exterior) that exists beyond the "high risk of damage" region and instead occupies an area of ​​low risk of damage compared to the "high risk of damage" found within the first region.

[0050]

[0059] Areas of aircraft cabin interior structures considered to be at "high risk" of damage, including abrasion damage, may be adjacent to more than one type of cabin structure. For example, an area of ​​a luggage box identified as likely to be subjected to rough contact and / or repeated impacts when passengers place their luggage in and out of the luggage box may be considered to be identified as a high risk area or area of ​​damage where such luggage box exterior damage is expected. Similarly, an area of ​​the aircraft cabin ceiling adjacent or proximate to the luggage box when passengers place their luggage in and out of the luggage box may also be at risk of damage and may be considered to be within an area identified as being at high risk of damage from abrasion, etc. When luggage comes into contact with a first area of ​​the ceiling exterior, the identified high risk level of possible damage to such ceiling section includes abrasion and any impacts that may wear down and / or otherwise mar the initial appearance of the aircraft cabin ceiling located within the high risk area of ​​ceiling exterior damage.

[0051]

[0060] Additionally, areas at high risk of wear and abrasion damage (including, e.g., damage to "cosmetic" or aesthetic surfaces of the aircraft cabin structure exterior, including side walls, partition walls, suite walls, lavatory doors and wall cladding, etc.) may also be present in areas of the cabin structure, such as those in close proximity to the aircraft cabin floor, because passenger shoes, rolling passenger baggage, galley carts, maintenance carts and equipment, or other objects, etc., may violently and repeatedly contact, impact, and potentially damage, at least a first area of ​​these cabin structure exterior surfaces, e.g., aesthetically.

[0052]

[0061] Additionally, certain aircraft cabin structural exteriors may be located in or near areas with high risk of exterior damage, including structural surfaces that may be subjected to and incur repeatable motions, such as during taxiing, takeoff, landing, and flight. One example of such a structure is a header panel exterior that may house or otherwise support a divider curtain, for example, via an integral track or runner. According to aspects, the repeated deployment and retraction of the divider curtain exposes adjacent or adjacent structural exteriors to conditions identified as being at high or high risk of damage from abrasion, etc.

[0053]

[0062] Although specific vehicle cabin interior structures are illustrated herein, such examples are not intended to be limiting. Indeed, according to several present aspects, the disclosed improved vehicle cabin interior structures (which may be, for example, aircraft cabin interior structures) are intended to include any structural exteriors present within areas identified according to present aspects as being at "high risk" for being subject to everyday wear, rubbing, marking, and the like. Such structures include, without limitation, at least one of a luggage bin exterior, a ceiling exterior, a partition wall exterior, a lavatory wall exterior, a lavatory door exterior, a galley area wall exterior, a cockpit door exterior, a closet exterior, a sidewall exterior, a seat assembly exterior, and the like, and combinations thereof.

[0054]

[0063] For example, Figures 5A, 5B, and 5C show a number of present embodiments addressing ceiling and header panel damage to the exterior surface. Figure 5A is an upward view from within an aircraft cabin of an aircraft of the type shown in Figures 1, 2, 3, and 4, for example. The aircraft cabin structural exposed surface shown in Figure 5A does not incorporate a number of present embodiments. Instead, Figure 5A shows a "high risk area" of damage (equivalently referred to herein as the first area of ​​the structural exterior) that has suffered damage within this first area. Figure 5A shows an upward view within an aircraft cabin 14 directed toward an aircraft cabin ceiling 22, having an aircraft ceiling exposed surface 22a, a first area of ​​the ceiling exterior surface 22b, and a second area of ​​the ceiling exterior surface 22c. Figure 5A further shows the ceiling exposed surface 22a that has suffered ceiling wear 32, which may have been caused, for example, by removing luggage from a luggage box 26. FIG. 5A further illustrates the outline of a first area 22b (a "high risk" area of ​​damage) of the exterior ceiling surface of ceiling 22 within the "dotted line".

[0055]

[0064] 5A also shows header panel 23 including header panel track 34 supporting curtain divider 36. Header panel 23 further includes header panel exterior surface 23a, first region 23b of the header panel exterior surface (a "high risk" area of ​​damage), and second region 23c of the header panel exterior surface separated from first region 23b of "high risk" damage by a "dotted line." As shown in FIG. 5A, header panel exterior surface 23a has suffered wear damage within first region 23b of "high risk" damage, shown as header panel wear 33.

[0056]

[0065] According to some of the present aspects, areas of high risk of damage of various cabin structural exteriors may be determined and identified for each individual structure, for example, by evaluating rework schedules, reports, and the like. According to some of the present aspects, areas of high risk of damage for aircraft cabin structural exteriors may be protected by installing or otherwise providing an improved aircraft cabin interior structure having a protective outer coating layer film made of a self-healing material. The protective outer coating layer film is applied as a partial outer coating configured to be applied, present, and protected only on the exterior surface of selected aircraft cabin interior structural exterior areas identified and determined to be within areas on the structural exterior designated to be areas of "high risk" of damage. According to some of the present aspects, by applying a self-healing protective material coating layer, which may be a film, only to the "high risk" areas of damage of selected structural exteriors within the "high risk" areas of damage, a significantly enhanced protection of such structural exteriors from abrasion, chafing, marking, and the like may be provided, while also reducing costs, materials, labor, and overall coating weight that may be realized if the entire structural exterior were treated with a protective layer of a self-healing protective material.

[0057]

[0066] As shown in Figure 5B, an improved aircraft cabin structure (an improvement of the present disclosure made to the structure shown in Figure 5A) is shown having a cabin structural exterior including a partial outer coating layer including a self-healing material configured to significantly resist impact damage from abrasion, for example, via rubbing. In accordance with some present embodiments, Figure 5B shows the ceiling and header panel shown in Figure 5A, but with the determined and identified "high risk" areas of damage in the ceiling and header panel exterior now protected from abrasion and other rubbing damage because the first area of ​​the cabin structural exterior now includes a self-healing partial outer coating layer.

[0058]

[0067] More specifically, Figure 5B shows an upward view inside the aircraft cabin 14 (of an aircraft 10 of the type shown in Figures 1, 2, 3) directed towards the aircraft cabin ceiling 22, having an aircraft ceiling exterior surface 22a, a first region 22b of the ceiling exterior surface, and a second region 22c of the ceiling exterior surface. Unlike Figure 5A, Figure 5B further shows a protective partial outer coating layer 122 in place and covering substantially the entirety of the first region 22b of the ceiling exterior surface (the "high risk" area of ​​damage of the ceiling exterior surface 22a). As shown in Figure 5B, the low risk area of ​​damage of the cabin ceiling exterior surface 22a, indicated as the second region 22c of the ceiling exterior surface, is shown to be adjacent and outside (e.g., beyond) the boundary of the high risk area of ​​damage, indicated as the first region 22b of the ceiling exterior surface, and is not coated with the protective partial outer coating layer 122.

[0059]

[0068] FIG. 5B further illustrates a header panel 23 similar to that shown in FIG. 5A. The header panel 23 includes a header panel track 34 that supports a curtain divider 36. The header panel 23 further includes a header panel outer surface 23a. Unlike FIG. 5A, FIG. 5B further illustrates a protective partial outer coating layer 123 in place and covering substantially the entirety and / or the entirety of a first region 23b of the header panel outer surface (the "high risk" area of ​​damage of the header panel outer surface 23a). As shown in FIG. 5B, the low risk area of ​​the header panel 23, designated as a second region 23c of the header panel outer surface, is shown adjacent and outside (e.g., beyond) the boundary of the high risk area of ​​damage, designated as the first region 23b of the header panel outer surface, and is not coated with the protective partial outer coating layer 123.

[0060]

[0069] In addition, Figure 5B shows a luggage box 26 similar to that shown in Figure 5A. The luggage box 26 includes a luggage box exterior surface 26a. Unlike Figure 5A, Figure 5B further shows a protective partial outer coating layer 126 in place and covering substantially the entirety of a first region 26b of the ceiling exterior surface (the "high risk" area of ​​damage of the ceiling exterior surface 26a). As shown in Figure 5B, the low risk area of ​​the luggage box 26, designated as a second region 26c of the luggage box exterior surface, is shown adjacent and outside (e.g., beyond) the boundary of the high risk area of ​​damage, designated as the first region 26b of the luggage box exterior surface, and is not shown coated with the protective partial outer coating layer 126.

[0061]

[0070] According to several present aspects, by selectively adding a partial exterior coating layer to only those structural areas that have been determined and designated as "high risk" exterior areas of damage to selected cabin interior structures, cabin structures that were previously at risk of wear damage are now significantly improved, as is the overall aesthetics of the aircraft cabin structure including the improved partially coated structure, and the condition of the improved cabin and the overall aircraft housing the improved cabin structure. By adding a protective self-healing partial coating layer only to selected, designated areas of high risk of damage, the cabin structure is able to have significantly improved abrasion protection while avoiding the additional cost of including a protective coating layer in the selective high risk areas and reducing the weight increase that would otherwise be realized by providing an additional coating over the entire cabin structure exterior (e.g., beyond the high risk areas).

[0062]

[0071] According to some of the present aspects, an outer coating layer that covers only a selected designated portion (less than the entire area of ​​the cabin structural exterior) of the cabin structural exterior is considered to be a partial outer coating layer for the structural exterior. According to further some of the present aspects, the partial outer coating layer is made of an optically transparent material, such that the visual characteristics (e.g., color, design, visually perceptible texture, etc.) of the underlying exterior material (which may be a decorative laminate material) are not visually obstructed by the transparent partial outer coating layer. The transparent partial outer coating layer allows light to pass through without significant scattering of the light.

[0063]

[0072] According to further aspects of the present invention, the transparent partial outer coating layer preferably includes or is a self-healing polymeric material. According to aspects of the present invention, it is understood that the self-healing material dissipates energy incurred from contact or impact over its surface area. Without being bound by any particular theory, it is believed that in the case where the self-healing material layer is subjected to a surface dent or surface damage, at room temperature or slightly above room temperature, the self-healing material can generate covalent bonds at the molecular level, and the polymer can autonomously "recover" or reconstruct its structure (including its surface structure and appearance) while maintaining 90% or more of the original material strength initially applied, with little or no external energy provided.

[0064]

[0073] According to some embodiments, the partial outer coating of the present invention may include a thermoplastic polyurethane as the thermoplastic material. Thermoplastic polyurethane (TPU) is a melt-processable polymer that has high elasticity, high tensile strength, low temperature resistance, good abrasion resistance, and good corrosion resistance. In one embodiment, the partial outer coating layer includes a thermoplastic polyurethane, and the thermoplastic polyurethane material itself may each have a Young's modulus value in the range of about 10 MPa to about 120 MPa.

[0065]

[0074] According to several present aspects, the partial outer coating comprising a thermoplastic polyurethane material can undergo self-healing at room temperature, or the self-healing mechanism can be accelerated when a small amount of heat (e.g., in the form of hot water or heated air) in the range of about 100° F. to about 140° F. is provided to the partial outer coating layer on a first region of the cabin interior structural exterior surface (e.g., during routine cleaning and maintenance by personnel).

[0066]

[0075] According to one present embodiment, the partial outer coating layer may be a coating layer in the form of a film, and may further be a single layer film, and may include an acrylic adhesive layer. Thereby, the partial outer coating layer may be a self-healing partial outer coating layer. In one embodiment, the partial coating layer may include a thermoplastic polyurethane (TPU) layer having an average thickness over its area ranging from about 2 mm to about 8 mm. In another embodiment, the partial coating layer may include a thermoplastic polyurethane (TPU) layer having an average thickness over its area of ​​about 6 mm, and an adhesive layer on one side of the TPU layer. The adhesive layer, which may be an optically clear acrylic adhesive layer, has an average thickness ranging from about 1 mm to about 3 mm, and preferably has an average thickness of about 1.6 mm.

[0067]

[0076] According to some of the present aspects, the transparent partial outer coating layer may be self-healing or may be applied to the cabin structure exterior surface via an adhesive layer that is applied. The adhesive layer may be, for example, a spray adhesive that dries to a transparent adhesive layer, or a transparent pressure-sensitive adhesive film layer. The selected transparent adhesive layer will be compatible with the underlying cabin structure exterior surface material. The underlying cabin structure exterior surface material may also be a thermoplastic material, or may be a composite material, paint, fabric, etc. Materials such as TEDLAR® are one suitable cabin structure exterior surface treatment. According to some of the present aspects, the transparent partial outer coating layer does not interfere with the visual properties and aesthetics or the underlying cabin structure (original) exterior surface.

[0068]

[0077] According to some present aspects, the partial outer coating layer remains transparent and does not discolor over time. If desired, the partial outer coating layer can further protect the underlying cabin structural exterior surface from UV / visible light damage by incorporating a UV / visible light resistant material into the thermoplastic polyurethane material or by incorporating a separate UV / visible light resistant material layer into the partial outer coating.

[0069]

[0078] In one embodiment where complete transparency of the partial outer coating layer is not required, the partial outer coating layer may provide significant UV protection to the underlying (e.g., coated) cabin structural exterior surface. According to another embodiment, when the partial outer coating layer includes a UV / visible light resistant layer having an average thickness in the range of about 2 mils to about 6 mils, for UV / visible light wavelengths in the range of about 180 nm to about 800 nm, the partial outer coating layer of the present invention may provide all or nearly all of the UV protection to be provided to the cabin structural surface by having a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance.

[0070]

[0079] The partial exterior coating layer may be installed or otherwise incorporated in and on selected areas of the cabin structure pre-assembly, i.e., the partial exterior coating layer may be added to the cabin structure exterior surface in areas of the cabin structure that are at high risk of wear before the cabin structure is assembled in place during vehicle cabin manufacture, thereby allowing the improved cabin structure to incorporate enhanced surface wear protection from the time of delivery of a new vehicle (e.g., aircraft) incorporating the improved vehicle cabin that includes the improved cabin structure.

[0071]

[0080] Additionally, according to some of the present aspects, the partial outer coating layer can be retrofitted into an existing vehicle cabin to provide portions of the cabin structural exterior that would be in areas at high risk of damage with significantly enhanced wear protection, i.e., according to some of the present aspects, a first (high risk of damage) area of ​​the cabin structural exterior can be coated with the partial outer coating layer of the present invention, since the partial outer coating layer can be cut to a selected size for retrofitting purposes.

[0072]

[0081] Referring back to Figure 5A, as the aesthetic appearance of the ceiling and header exposed surfaces suffers cosmetic damage to the type of appearance shown and depicted in Figure 5A, rework of the affected areas exhibiting wear and tear may be desirable. A number of present embodiments are directed to reworking damaged aircraft cabin structural exposed surfaces within a number of regions of a first region of the ceiling exposed surface that may be designated and identified as a "high risk" area of ​​damage, which may include, for example, wear from impact of luggage stored within luggage box 26. Figure 5A illustrates first region 22b of the ceiling exposed surface of ceiling 22 as a "high risk" area of ​​damage within a "dotted line."

[0073]

[0082] According to several present aspects, an improved touch up patch for aircraft cabin interior exposed structural surfaces can be used to restore the aesthetics of exposed cabin structural surfaces (e.g., header panels, cabin ceilings, etc.) that have suffered wear damage, for example, as shown in Figure 5 A. According to several present aspects, when damage occurs within a "high risk" area of ​​damage on an exposed structural surface and rework is required, the touch up patch of the present invention including a partial outer coating layer can be installed to remove damage already incurred and eliminate future wear damage in the reworked area of ​​the cabin structural exterior.

[0074]

[0083] That is, the improved rework patch may include a material used for the aircraft cabin structure being reworked. In that case, for example, the material may be a replacement section of TEDLAR® or any other decorative laminate material typically used in conjunction with exterior decorative laminate exterior surfaces of aircraft cabin interior structures. In accordance with several present aspects, the improved rework patch further incorporates an outer layer or coating layer of a self-healing outer coating layer material. This layer is preferably a self-healing thermoplastic polyurethane material that is substantially transparent when applied at a selected thickness to the decorative laminate.

[0075]

[0084] Figure 5C shows an upward view from within the vehicle cabin as shown in Figure 5A. As shown in Figure 5C, in accordance with some present embodiments involving installation of the inventive touch-up patch (including a partial outer coating layer) via touch-up, the ceiling wear 32 and the header panel wear 33 (shown in Figure 5A) are now eliminated from the first area 22b of the ceiling exterior surface and the first area 23b of the header panel exterior surface, respectively.

[0076]

[0085] That is, as shown in FIG. 5C, within the first area 22b of the ceiling exterior, a structural surface touch up patch 40a is shown to be placed (e.g., "touched up") into the cabin ceiling exterior 22a (and within the first region 22b of the header panel exterior) in the structural surface touch up patch area 40. The touch up patch 42a may include a layer or layers of the cabin ceiling exterior, which may be, for example, a high performance polyvinyl fluoride film (e.g., TEDLAR® by DuPont) or other material used for vehicle exteriors. A partial exterior coating 42 of the present invention is provided to the touch up patch as a touch up patch outer layer.

[0077]

[0086] 5C further illustrates a touch up patch of the present invention that includes a partial outer coating material used to touch up an area of ​​the header panel 23. That is, as shown in FIG. 5C, within a first area 23b of the header panel exterior, a structural surface touch up patch 40a is shown to be placed (e.g., "touched up") within the cabin ceiling exterior 23a (and within the first area 23b of the header panel exterior) at a structural surface touch up patch area 43. The touch up patch 40a may include a layer or layers of the cabin ceiling exterior, which may be, for example, a high performance polyvinyl fluoride film (e.g., TEDLAR® by DuPont) or other material used for vehicle exteriors. A partial outer coating 44 of the present invention is provided to the touch up patch as a touch up patch outer layer.

[0078]

[0087] The type of resulting wear damage to aircraft cabin structural exterior surfaces (e.g., as shown in FIG. 5A) may also be incurred by other aircraft cabin structural exterior surfaces shown elsewhere in this figure. Thus, while not expressly shown, several present embodiments further contemplate a rework patch of the present invention comprising a partial outer coating layer useful for further reworking cabin structural exterior surfaces, including, but not limited to, cabin structural exterior surfaces having surface wear at least in areas identified as being at high risk of wear, such as, for example, luggage bins, bulkheads, lavatory walls, lavatory doors, cockpit doors, galley walls, side walls, seat frames, seat armrests, seat assembly panel exteriors, etc.

[0079]

[0088] As described herein, areas of high risk of wear may occur in vehicle cabin structures, including, for example, vehicle cabin seating structures that may include seating area walls or dividers, etc., which may be located adjacent to the cabin aisle and / or cabin floor, as well as on exterior surfaces, such as, for example, first class or business class seating "suites," "pod suites," or other fully reclining seating areas that may be "walled off" for additional privacy.

[0080]

[0089] 6A and 6B are diagrams of seating areas within a vehicle cabin that may further include multiple areas at high risk of wear damage from rolling luggage, galley carts, shoe scuffs from passengers, etc., including privacy areas with partitions adjacent to the cabin aisle and / or vehicle cabin floor. As shown in FIG. 6A and 6B, the seating "pods", "suites", etc. may further include areas at high risk of wear damage that may also occur within the seating area, and may include areas at "high risk" of wear damage that may occur within the "pods", "suites" with respect to partitions disposed adjacent to the cabin floor, etc. The exterior surfaces of the seating pods / suites may be painted and / or include a decorative laminate coating on the exterior surfaces, as described herein with respect to the partitions, walls, ceilings, etc.

[0081]

[0090] FIG. 6A illustrates a vehicle cabin seat assembly 50 including a seat that can be substantially and / or completely reclined (e.g., lie flat). The seat assembly 50 includes seat assembly dividers (equivalently referred to herein as seat assembly panels) 51, 52 that can partially surround the seat assembly 50 and can further be disposed adjacent or substantially adjacent to the vehicle cabin floor 24. As described herein, the divider exterior surfaces 51a, 52a include areas at high risk of damage from wear, referred to herein as first regions 51b, 52b of the structural exterior, and areas at low risk from wear, referred to herein as second regions 51c, 52c of the structural exterior. As described herein, according to a number of present embodiments, the divider exterior surfaces 51a, 52a (e.g., can be coated with a decorative laminate material or can be a painted exterior surface, etc.) can benefit from the addition of a partial outer coating layer of the present invention when applied to the first regions 51b, 52b of the structural exterior (areas at high risk of damage).

[0082]

[0091] As further shown in FIG. 6A , portions of the partition that are not positioned adjacent to the vehicle cabin aisle, but are positioned within the enclosed seating assembly 50, and that are positioned closely adjacent and / or directly adjacent to the vehicle cabin floor 24 (e.g., within the area of ​​the enclosed seating assembly 50), may further include structural outer surface first regions 52 b and may further benefit from the addition of a partial protective coating of the present invention applied to these additional structural outer surface first regions 52 b that may be more likely to be subject to wear damage, for example, from rubbing by passenger shoes, during floor washing / cleaning, etc.

[0083]

[0092] FIG. 6B illustrates a further vehicle cabin seat assembly 60. FIG. 6B illustrates the vehicle cabin seat assembly 60 including a seat in a suite or pod surrounded by a seat assembly panel 61. The seat assembly panel 61 may partially or substantially surround the area of ​​the seat assembly 60 and may further be disposed adjacent or substantially adjacent to the vehicle cabin floor 24. The partition exterior, referred to herein equivalently as the "structural exterior" or "seat assembly panel exterior" 61a, includes an area at high risk of damage from wear, referred to herein as the first region 61b of the structural exterior, and an area at low risk from wear, referred to herein as the second region 61c of the structural exterior. As described herein, according to a number of present embodiments, the structural exterior 61a (e.g., may be coated with a decorative laminate material or may be a painted exterior, etc.) may benefit from the addition of the partial outer coating layer of the present invention when applied to the first region 61b of the structural exterior (area at high risk of damage).

[0084]

[0093] As further shown in FIG. 6B, portions of the partition that are not positioned adjacent to the vehicle cabin aisle but are positioned within the enclosed seat assembly 60 and that are positioned close to and / or directly adjacent to the vehicle cabin floor 24 (e.g., within the area of ​​the enclosed seat assembly 60) may further include first regions 61b of the structural outer surface and may further benefit from the addition of the partial protective coating of the present invention applied to these additional first regions 61b of the structural outer surface.

[0085]

[0094] 7 is a flow chart outlining a method 100 for protecting a vehicle cabin interior structural region from surface damage, which may include surface abrasion damage. The method 100 includes providing 102 a vehicle cabin interior structure. The vehicle cabin interior structure includes a structural exterior surface. The structural exterior surface includes a first region of the structural exterior surface having a first area and a second region of the structural exterior surface having a second area. The first region of the structural exterior surface is disposed adjacent to the second region of the structural exterior surface. The first region of the structural exterior surface is disposed within a location with a high risk of damage. The method further includes adhering 104 a protective outer coating layer only to the first region of the structural exterior surface and protecting 106 the first region of the structural exterior surface from abrasion damage. According to some present embodiments, the protective outer coating layer can be a transparent, self-healing material. This material can be, for example, a thermoplastic polyurethane. Thermoplastic polyurethane can be self-healing at or near room temperature, and can further self-heal at temperatures ranging from about 70° F. to about 120° F. The method outlined in FIG. 7 is understood to incorporate vehicle cabin structures and vehicles incorporating cabin structures. These include aircraft and aircraft cabin structures described herein and shown at least in FIGS. 1, 2, 3, 4, 5A, 5B, 6A, and 6B.

[0086]

[0095] A further present embodiment is directed to a method for repairing a vehicle cabin interior structural region from surface damage, which may include surface abrasion damage. The method includes providing a vehicle cabin interior structure. The vehicle cabin interior structure includes a structural exterior surface. The structural exterior surface includes a first region of the structural exterior surface having a first area and a second region of the structural exterior surface having a second area. The first region of the structural exterior surface is disposed adjacent to the second region of the structural exterior surface. The first region of the structural exterior surface is disposed within a location of high risk of damage. The method includes adhering a repair patch to the vehicle cabin structural exterior surface. The repair patch includes a protective outer coating layer. According to some present embodiments, the protective outer coating layer can be a transparent self-healing material. The material can be, for example, a thermoplastic polyurethane. The thermoplastic polyurethane can be self-healing at or near room temperature and can further self-heal at temperatures ranging from about 70° F. to about 120° F.

[0087]

[0096] The term "substantially" as used herein means that a particular characteristic, parameter, or value need not be exactly achieved, but rather deviations or variations (including, for example, tolerances, measurement errors, measurement accuracy limits, and other factors known to those skilled in the art) may occur to the extent that they do not eliminate the effect intended to be brought about by the feature.

[0088]

[0097] The present aspects can, of course, be practiced in other ways than as specifically described herein without departing from the essential characteristics of the disclosure. The present aspects are to be considered in all respects as illustrative and non-restrictive, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.

Claims

1. A vehicle cabin interior structure (16)(20)(22)(23)(24)(26)(28)(29)(30), a structural exterior surface (18), (21), (22a), (23a), (26a), (28a), (29a), (31) including a structural exterior surface first region (21a), (22b), (23b), (26b), (31a) and a structural exterior surface second region (21b), (22c), (23c), (26c), (31b), wherein the structural exterior surface first region is disposed adjacent to the structural exterior surface second region; 1. A vehicle cabin interior structure comprising: a partial outer coating layer (122)(123)(126) comprising a self-healing material and configured to coat only a first region of the structural exterior surface, the partial outer coating layer being disposed adjacent a second region of the structural exterior surface.

2. The vehicle cabin interior structure of claim 1 , wherein the first region of the structural exterior further comprises a decorative laminate coating layer disposed beneath the partial exterior coating layer.

3. The vehicle cabin interior structure according to claim 1 , wherein the partial outer coating layer comprises a thermoplastic polyurethane.

4. The vehicle cabin interior structure according to claim 1 , wherein the first region of the structural exterior is disposed in an area at high risk of damage for structural exterior wear damage.

5. The vehicle cabin interior structure according to claim 1 , wherein the partial outer coating layer is a substantially transparent film layer.

6. The vehicle cabin interior structure of claim 1 , wherein the partial outer coating layer comprises a UV / visible light resistant material.

7. 2. The vehicle cabin interior structure of claim 1, wherein the structural exterior surface comprises an exterior surface of at least one of a luggage bin, a ceiling, a partition wall, a lavatory wall, a lavatory door, a galley wall, a side wall, a seat frame, a seat armrest, and combinations thereof.

8. The vehicle cabin interior structure of claim 1 , wherein the partial outer coating layer does not coat a second region of the structural exterior surface.

9. The vehicle cabin interior structure according to claim 3 , wherein the partial outer coating layer further comprises an adhesive layer.

10. The vehicle cabin interior structure according to claim 3 , wherein the partial outer coating layer is a self-healing partial outer coating layer film.

11. The vehicle cabin interior structure according to claim 3 , wherein the partial outer coating layer has a Young's modulus in the range of about 10 MPa to about 120 MPa.

12. 7. The vehicle cabin interior structure of claim 6, wherein the partial outer coating layer has a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance for UV / visible light wavelengths in the range of about 180 nm to about 800 nm.

13. An aircraft cabin (14) comprising a vehicle cabin interior structure according to claim 1.

14. A vehicle (10) comprising the vehicle cabin interior structure according to claim 1.

15. An aircraft (10) comprising a vehicle cabin interior structure according to claim 1.

16. A vehicle cabin interior structure (16), comprising: a structural exterior surface (18), said structural exterior surface comprising:

1. A vehicle cabin interior structure comprising a repair patch area including a decorative laminate layer, the repair patch area further comprising an abrasion-resistant outer coating layer disposed on the decorative laminate layer, the abrasion-resistant outer coating layer comprising a self-healing thermoplastic urethane material.

17. 20. The vehicle cabin interior structure of claim 16, wherein the wear-resistant outer coating layer comprises a UV / visible light resistant material.

18. 17. The vehicle cabin interior structure according to claim 16, wherein the wear-resistant outer coating layer has a Young's modulus in the range of about 10 MPa to about 120 MPa.

19. An aircraft cabin (14) comprising a vehicle cabin interior structure according to claim 16.

20. A vehicle (10) comprising a vehicle cabin interior structure according to claim 16.

21. A vehicle cabin interior structural repair patch (40a) (42a), A vehicle cabin interior structural rework patch comprising a substantially transparent, wear-resistant outer coating layer film comprising a self-healing thermoplastic urethane material.

22. 22. The vehicle cabin interior structural touch up patch of claim 21, wherein said substantially transparent, wear-resistant outer coating layer film comprises a UV / visible light resistant material.

23. 22. The vehicle cabin interior structural touch up patch of claim 21, wherein the substantially transparent, wear-resistant outer coating layer film has a Young's modulus in the range of about 10 MPa to about 120 MPa.

24. 22. An aircraft cabin (14) comprising a vehicle cabin interior structural rework patch according to claim 21.

25. A method (100) for protecting a vehicle cabin interior structural area from surface damage, comprising: Providing a vehicle cabin interior structure (102), the vehicle cabin interior structure including a structural exterior surface, the structural exterior surface including a first region of the structural exterior surface including an area at high risk of damage, and a second region of the structural exterior surface disposed adjacent the first region of the structural exterior surface; Adhering (104) a self-healing protective outer coating layer to only a first region of the structural exterior surface; and The method includes protecting (106) a first region of the exterior structural surface from surface damage.

26. 26. The method of claim 25, wherein the self-healing protective outer coating layer comprises a substantially transparent thermoplastic urethane film.

27. 26. The method of claim 25, wherein the first region of the structural exterior further comprises a decorative laminate layer disposed beneath the self-healing protective outer coating layer.

28. 27. The method of claim 26, wherein the self-healing protective outer coating layer comprises a UV / visible light resistant material.

29. 27. The method of claim 26, wherein the self-healing protective outer coating layer further comprises an adhesive layer.

30. 27. The method of claim 26, wherein the self-healing protective outer coating layer has a Young's modulus in the range of about 10 MPa to about 120 MPa.

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