Avionics Light Plate Translucency via Additive Layer Deposition

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Solution Overview

Problem

Current methods for manufacturing avionics light plates lack the ability to effectively balance light transmission and control the translucency of materials, leading to inconsistent illumination and visual clarity in cockpit interfaces.

Innovation Solution

The method involves creating a three-dimensional model of the light plate with a translucency map that guides additive layer deposition, using a combination of adhering and cross-linking techniques with a laser to form layers with varying translucency, allowing for precise control over light transmission and distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional manufacturing methods are used for light plates, then production is simpler, but light transmission balance and translucency control are insufficient

Engineering Contradiction:

Improvetranslucency controlVSAvoidmanufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies local quality by varying the translucency of different regions within the light plate. The additive layer deposition process enables different material properties to be deposited in different locations, allowing certain areas to have higher or lower light transmission based on the specific optical requirements of each region of the cockpit interface.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes material parameters during the manufacturing process by adjusting deposition conditions, material composition, and layer density to achieve varying translucency levels. This enables precise control over light transmission properties without requiring post-manufacturing adjustments or multiple manufacturing steps.

Inventive Principle:

Principle #35Parameter changes

2Illumination intensity

If uniform material deposition is used, then manufacturing is easier, but light balance and illumination uniformity deteriorate

Engineering Contradiction:

Improvelight balanceVSAvoiddeposition process

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The system implements local quality by controlling the deposition process to create regions with different optical properties. The additive layer deposition device can adjust material properties, layer thickness, and density at different locations to achieve uniform light balance across the entire light plate, compensating for variations in the optical path.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If single material composition is used, then material selection is simpler, but translucency control and visual clarity are reduced

Engineering Contradiction:

Improvevisual clarityVSAvoidmaterial properties

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent employs composite materials by combining multiple materials with different optical properties within the same light plate structure. The additive layer deposition process enables precise placement of different materials in specific layers and regions, creating a composite structure that optimizes both translucency and visual clarity for different portions of the light plate.

Inventive Principle:

Principle #40Composite 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

This approach enables the creation of light plates with uniform and balanced light transmission, enhancing visual clarity and illumination, particularly in avionics systems, by strategically cross-linking or adhering materials to achieve desired translucency and illumination patterns.

Implementation Method 1

The additive layer device uses the model to guide the deposition of the materials forming the light plate and to determine which layers or portions of layers to adhere, sinter, deposit, and which to cross-link

Methodology Applied

Scientific EffectLaser sintering: Selective Laser Sintering

Implementation Method 2

Additive layer deposition is a manufacturing process in which layers of materials are combined to form a finished product

Methodology Applied

Scientific EffectAdditive layer deposition: 3D Printing

Data Source

PatentUS10279543B1Method for constructing avionics panel using additive layer deposition

Publication Date: 2019.05.07 ROCKWELL COLLINS INC

AI summary

A method of manufacturing a light plate includes defining a three-dimensional model of the light plate. The model includes a translucency map configured to light balance the light plate. The translucency map defines a first portion having a first translucency. The method includes providing the model to an additive layer device; selecting at least one material based on the model; and depositing the at least one material in a layer based on the model. The method includes at least one of adhering the at least two layers of material with one another and cross-linking the at least two layers of material with one another to form a first region of the light plate corresponding to the first portion of the translucency map.