Aircraft Cabin Panel Additive Manufacturing Inner Core
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Solution Overview
Problem
Conventional methods for manufacturing aircraft cabin panels are costly and time-consuming, requiring expensive tooling, labor-intensive processes, and post-machining steps, which can lead to increased production time and reduced service lifetime due to the need for custom tooling and border application.
Innovation Solution
The use of an additively manufactured inner core with integrally formed thermoplastic body and border portions, coupled with honeycomb and skin layers, eliminates the need for shaping dyes and routing devices by allowing the inner core to dictate the final shape, and includes integral insert provisions and border formation through additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If steel dye tooling is used to form the honeycomb and skin layers, then the panel can be formed into the desired shape, but the tooling is expensive to machine and requires replacement when design changes occur
Solution Approach 1:
The patent uses a negative mold that is a copy or replica of the desired panel shape, rather than expensive custom-machined steel dyes. This negative mold can be easily reproduced and modified for design changes, eliminating the need to machine new steel tooling for each panel variant.
Solution Approach 2:
The patent changes the material parameter from traditional steel dye tooling to alternative molding materials that are less expensive and more adaptable. The forming process maintains shape accuracy while using materials that can be easily modified or replaced when design parameters change.
2Manufacturing precision
If layers are laid up by hand into a mold with vacuum bagging, then the panel can be formed, but the process is time consuming and results in high labor costs
Solution Approach 1:
The patent applies release agent to the negative mold before placing the honeycomb and skin layers, which facilitates easier and faster removal of the formed panel. This preliminary action reduces the time required for panel extraction and prepares the mold for immediate reuse, increasing manufacturing throughput.
Solution Approach 2:
The vacuum bagging process is improved by using a release agent that allows the panel to release itself from the mold automatically after curing, reducing the need for manual extraction operations and decreasing labor time for panel removal.
3Ease of operation
If routing tools are used for post-manufacture machining, then insert provisions can be machined into the panel, but the process is costly and time consuming
Solution Approach 1:
The patent forms the insert provisions as integral features of the negative mold itself, so that the mold geometry directly creates the recesses and cavities needed for inserts. This preliminary formation of insert provisions eliminates the need for subsequent routing or machining operations to create these features.
Solution Approach 2:
The patent combines the formation of insert provisions with the panel forming process itself, rather than treating them as separate operations. The negative mold simultaneously forms both the panel shape and the insert provision geometries in a single operation, reducing total production time.
4Shape
If a border is added around the honeycomb and skin layers, then the seams are covered and appearance is improved, but the manufacture is labor intensive and may shorten service lifetime
Solution Approach 1:
The patent merges the border formation with the panel forming process by incorporating border geometry directly into the negative mold. The border is formed as an integral part of the panel structure during the same curing process, eliminating separate border manufacturing and attachment operations.
Solution Approach 2:
The negative mold is designed with border geometry built-in, so the border is preliminarily formed along with the main panel structure. This preliminary formation of the border eliminates the need for separate border manufacturing steps and reduces labor intensity.
Data Source
AI summary
An interior panel for use in an aircraft cabin includes an inner core including a first surface and an opposing second surface. The interior panel also includes a first honeycomb layer coupled to the first surface and a second honeycomb layer coupled to the second surface. The inner core includes an integral forming tool configured to shape the first honeycomb layer and the second honeycomb layer. The interior panel also includes a first skin layer coupled to the first honeycomb layer and a second skin layer coupled to the second honeycomb layer.