Composite Vehicle Panel Assembly Without a Metal Frame
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing panel assemblies for vehicles, such as aircraft, are complex, heavy, and costly, making them inefficient and difficult to install.
Innovation Solution
A panel assembly composed of a layered composite structure without a discrete metal frame, using a composite panel with a core layer of honeycomb and base material, and fasteners that extend through the panel itself for mounting, allowing tool-less installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal frame is used to hold the composite panel, then the panel assembly achieves structural stability and mounting capability, but the weight of the panel assembly increases significantly
Solution Approach 1:
The patent removes the discrete metal frame from the panel assembly, extracting the heavy supporting structure while maintaining the essential functions of structural stability and mounting capability through the composite panel's integrated design
Solution Approach 2:
The mounting flange is integrated directly into the composite panel structure, merging the previously separate frame and panel components into a unified structure that eliminates the need for additional metal framing
2Reliability
If a metal frame with receiver section and mounting flange is used, then the panel assembly achieves proper panel retention and mounting capability, but the device complexity increases
Solution Approach 1:
The receiver section and mounting flange are integrated into the composite panel structure, merging multiple functional components into a single unified structure that reduces assembly complexity while maintaining retention and mounting capabilities
Solution Approach 2:
The composite panel structure serves multiple functions simultaneously - it provides the panel surface, structural support, mounting attachment, and retention mechanism, eliminating the need for separate dedicated components for each function
3Reliability
If fasteners are spaced apart from the composite panel via the metal frame, then the panel assembly achieves proper mounting distribution, but the manufacturing cost and assembly difficulty increase
Solution Approach 1:
The metal frame intermediary is removed, allowing fasteners to be directly attached to the composite panel structure, which simplifies manufacturing and reduces costs while maintaining proper mounting distribution through the integrated flange design
Data Source
Figure 1A~1b
Figure 2
Figure 3
AI summary
A panel assembly (100) for use in a vehicle (202) includes a first face sheet (116), a second face sheet (118), and a core layer (120) disposed between the first and second face sheets. The core layer is defined by a base material (126) along a first section (124) of the panel assembly, and the core layer is defined by a honeycomb structure (130) along a second section (128) of the panel assembly. The first section and the second section are discrete, and the first section that includes the base material extends along a perimeter (222) of the panel assembly.