Advanced composite heated floor panel
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Solution Overview
Problem
Heated floor panels in aircraft suffer from poor out-of-plane mechanical properties, leading to surface cracking and delamination, and low thermal conductivity, requiring higher power input to maintain temperature.
Innovation Solution
A composite panel with a 3D woven face sheet and a metallic core layer, featuring z-fibers that interlock layers to prevent delamination and enhance thermal conductivity, improving both mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If 2D fabrics are used for the face sheet, then the panel structure is simple and easy to manufacture, but the out-of-plane mechanical properties are poor leading to surface cracking and delamination
Solution Approach 1:
The patent transitions from 2D fabric to 3D woven structure by adding z-direction fibers that extend through the thickness of the face sheet. This dimensional change creates through-thickness reinforcement that prevents delamination and surface cracking while maintaining manufacturability through established 3D weaving processes.
Solution Approach 2:
The patent employs a composite face sheet combining 2D fabric layers with through-thickness z-fibers created via 3D weaving. This composite structure integrates the simplicity of 2D fabrics with the out-of-plane strength of 3D reinforcement, resolving the contradiction between manufacturing ease and mechanical performance.
2Use of energy by stationary object
If materials with low thermal conductivity are used in underlying layers, then the panel structure is simpler, but greater power input is required to maintain panel surface temperature
Solution Approach 1:
The patent applies local quality enhancement by incorporating metallic fibers with high thermal conductivity specifically within the 3D woven face sheet structure. This localized thermal conductivity improvement at the surface level reduces the power input required for heating without requiring complete replacement of all underlying layers with high-conductivity materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides enhanced impact resistance and reduced power requirements for heating, making it suitable for aerospace and other applications with improved strength-to-weight ratio.
Implementation Method 1
The z-fiber extends along the plurality of weft layers across a full extent of the 3d woven structure in the first direction
Implementation Method 2
requiring greater power input to the heating element to maintain panel surface temperature
Data Source
AI summary
A composite panel suitable for heating an environment includes a face sheet having a 3D woven structure and abutting the environment, and a first core layer positioned on a side of the face sheet opposite the environment. The 3D woven structure includes at least one z-fiber extending in a first direction, the first direction representing a thickness of the face sheet. The woven structure further includes a plurality of weft layers, each having a weft fiber extending in a second direction, and a warp layer disposed between the plurality of weft layers, the warp layer having a warp fiber extending in a third direction. The z-fiber extends along the plurality of weft layers across a full extent of the 3d woven structure in the first direction.