Integrated Burnthrough Resistant Floor Panels for Aircraft

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Solution Overview

Problem

Current aircraft floor panels fail to meet burnthrough resistance standards while adding weight and increasing manufacturing costs, as they require separate fire retardant materials and insulation blankets, which complicate installation, inspection, and maintenance.

Innovation Solution

Incorporating a burnthrough resistant layer or material into the floor panels, which can be applied to or integrated within the skin or core of the panels, using materials like ceramic paper or fiber-reinforced composites, to resist heat flux and meet regulatory standards without additional weight or cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate fire retardant materials and insulation blankets are added to meet burnthrough standards, then burnthrough resistance is improved, but aircraft weight increases

Engineering Contradiction:

Improveburnthrough resistanceVSAvoidaircraft weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent combines the fire retardant material and insulation blanket functions into a single integrated floor panel assembly. The fire retardant material is incorporated within the floor panel structure itself, eliminating the need for separate insulation blankets and reducing overall weight while maintaining burnthrough resistance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The floor panel uses composite materials that integrate fire retardant properties with structural functionality. The fire retardant material is combined with insulating and structural components to create a multi-functional panel that reduces weight compared to separate traditional components.

Inventive Principle:

Principle #40Composite materials

2Reliability

If separate fire retardant materials and insulation blankets are added to meet burnthrough standards, then burnthrough resistance is improved, but manufacturing cost increases

Engineering Contradiction:

Improveburnthrough resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple functions (fire retardancy, insulation, and structural support) into a single floor panel assembly, reducing the number of separate components that need to be manufactured, handled, and installed. This integration simplifies the manufacturing process and reduces overall cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The floor panel is designed as a multi-functional component that provides fire retardancy, thermal insulation, and structural support simultaneously. This universality eliminates the need for multiple specialized components, reducing manufacturing complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If separate fire retardant materials and insulation blankets are added to meet burnthrough standards, then burnthrough resistance is improved, but installation complexity increases

Engineering Contradiction:

Improveburnthrough resistanceVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the fire retardant material and insulation blanket into a single integrated floor panel assembly, reducing the number of separate installation steps. The unified structure simplifies installation procedures and reduces the complexity of handling and positioning multiple separate components.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If separate fire retardant materials and insulation blankets are added to meet burnthrough standards, then burnthrough resistance is improved, but inspection and maintenance complexity increases

Engineering Contradiction:

Improveburnthrough resistanceVSAvoidinspection and maintenance complexity

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent combines the fire retardant material and insulation blanket into a single floor panel assembly, reducing the number of separate components that require inspection and maintenance. This integration simplifies inspection procedures and reduces the complexity of repair operations.

Inventive Principle:

Principle #5Merging (Combining)

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 effectively resists burnthrough for at least 4 minutes with a heat flux of less than 2.0 BTU/ft2/sec, meeting Federal Aviation Regulation (FAR) 25.856(b) standards, reducing the need for separate fire retardant structures and simplifying maintenance, while maintaining structural integrity and reducing aircraft weight.

Implementation Method 1

a burnthrough resistant layer is located proximate to at least one of the skins that cover the internal support structure first and/or second surfaces

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11130560B2Burnthrough resistant floor panels and method of manufacturing and installation

Publication Date: 2021.09.28 THE BOEING CO

AI summary

Aspects of the present disclosure present floor panels and floor panel assemblies that include incorporated burnthrough resistant materials and/or include burnthrough resistant layers applied to floor panels used in floor panel assemblies, along with methods for inhibiting fire penetration into compartments and methods of making and installing burnthrough resistant floor panels and floor assemblies including such apparatuses and methods as they relate to vehicles, including aircraft.