Aircraft Panel Assembly with Crush Section for Energy Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing aircraft interior panels are inadequate in absorbing energy during crashes, particularly in impact susceptible areas where passenger head strikes occur, necessitating a material that can effectively distribute and absorb impact forces.
Innovation Solution
A panel assembly with a glass weave front skin featuring pre-preg stage cuts and a core assembly with laminated layers and elongated voids, designed to absorb energy by distributing impact forces orthogonally and reducing rigidity, utilizing a low-density core with a thinner resin coating for optimal energy absorption in crash scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional solid panel materials are used in aircraft interior monuments and bulkheads, then structural strength and rigidity are maintained, but energy absorption capability during crash impacts is insufficient
Solution Approach 1:
The patent employs a honeycomb core structure with controlled porosity that enables energy absorption through cell collapse mechanisms during impact. The porous honeycomb configuration allows the panel to dissipate crash energy while maintaining overall structural integrity through the distributed cell geometry.
Solution Approach 2:
The patent utilizes a composite panel construction combining face sheets with a honeycomb core, creating a multi-material structure that optimizes both strength and energy absorption. The composite design allows the face sheets to provide structural rigidity while the honeycomb core provides energy dissipation through controlled deformation.
2Object-affected harmful factors
If the panel structure is made more rigid to protect passengers, then impact resistance improves, but energy distribution capability during crash reduces
Solution Approach 1:
The patent divides the panel into a face sheet layer and a honeycomb core layer, with the core segmented into numerous individual cells. This segmentation allows the structure to resist impact through the collective response of many discrete elements, distributing energy throughout the panel rather than concentrating it in a single rigid structure.
Solution Approach 2:
The patent modifies the panel's mechanical parameters by introducing a honeycomb core with specific cell geometry and density. This parameter change transforms the panel from a purely rigid structure to one with controlled compliance, enabling energy distribution through cell wall deformation while maintaining adequate impact resistance.
3Loss of energy
If pre-preg stage cuts are made in the glass weave layer to create crush sections, then energy absorption is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates cut patterns into the glass weave layer during the pre-preg stage, before final panel assembly. This preliminary action allows the crush section geometry to be established early in manufacturing, ensuring precise positioning and integration with the honeycomb core while the materials are still in a workable state.
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 panel assembly effectively absorbs energy during crashes, reducing the risk of passenger injury by distributing impact forces and providing enhanced abuse load resistance, as demonstrated in quasi-static and dynamic testing simulations.
Implementation Method 1
pre-preg stage cuts formed in the glass weave layer so as to make the fibers in the glass weave discontinuous
Implementation Method 2
distributing impact forces orthogonally and reducing rigidity
Implementation Method 3
designed to absorb energy by distributing impact forces
Implementation Method 4
at least one crush section portion comprising a plurality of elongated voids defined therein wherein the front surface of the second layer is bonded to the back surface of the first layer
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A panel assembly that includes a front skin having a front surface, a back surface and at least one crush section portion, a core assembly that includes first, second, third, fourth and fifth layers laminated together, and at least a first crush section. The first, second, third, fourth and fifth layers each include a front surface, a back surface and at least one crush section portion. The front surface of the first layer of the core assembly includes a plurality of scores defined therein. The second layer includes a plurality of elongated voids defined therein and the fourth layer includes a plurality of elongated voids defined therein.