Composite Sandwich Panel Cabinetry Door with Over-Crush Edge

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Solution Overview

Problem

Existing cabinetry doors in aircraft lavatories are prone to frequent replacement due to wear and lack customization options for a decorative face, while also being visible and attention-drawing to passengers.

Innovation Solution

The use of composite sandwich panels with over-crushed edges, integrated seals, and continuous hinges to form cabinetry doors that are durable, aesthetically pleasing, and discreet from a passenger's perspective.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If injection-molded or thermoformed plastics are used for cabinetry doors, then the doors can be easily manufactured, but they lack durability and require frequent replacement

Engineering Contradiction:

Improveease of manufactureVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies composite materials by combining a plastic substrate with a decorative laminate layer bonded to its surface. This composite structure integrates the manufacturing advantages of injection-molded or thermoformed plastics with the durability and aesthetic qualities of laminate materials, creating a door assembly that is both easy to manufacture and highly durable resistant to wear and moisture

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent merges multiple components into a single integrated door assembly: the plastic door substrate, the decorative laminate face, edge bands, and sealing elements are combined through bonding processes. This merging creates a unified structure that maintains the ease of manufacture of individual components while achieving enhanced durability through their integrated combination

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If solid color paint is applied to cabinetry doors, then the manufacturing process is simple, but the decorative appearance is limited and doors remain visible to passengers

Engineering Contradiction:

Improvesimplicity of painting processVSAvoidcustomization options

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies parameter changes by transforming the surface characteristics of the door through laminate application. Instead of relying on simple paint colors, the laminate provides varied surface parameters including different patterns, textures, and decorative finishes that enhance customization while maintaining manufacturing efficiency through standardized laminate materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses decorative laminates that can replicate various aesthetic appearances including wood grains, stone patterns, or custom designs on the door surface. This copying of desirable aesthetic patterns allows diverse decorative appearances without complex manufacturing processes, enabling customization while keeping production straightforward

Inventive Principle:

Principle #26Copying

3Adaptability or versatility

If gaps between cabinetry panels are reduced for aesthetic purposes, then the decorative appearance improves, but the visibility of door edges and construction details increases

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidvisibility of door edges

Core Design Contradiction:

Adaptability or versatilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent employs thin film edge bands laminated to the door edges that extend slightly beyond the panel surfaces. These thin film elements effectively mask the door edges and construction gaps, maintaining tight aesthetic gaps while preventing visibility of door construction details from passenger perspectives

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of operation

If cabinetry doors are made visible and accessible to passengers, then accessibility is improved, but the decorative appearance and discretion are compromised

Engineering Contradiction:

ImproveaccessibilityVSAvoiddiscretion from passenger perspective

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The patent applies color changes and pattern variations through decorative laminates that allow the door surface to blend with surrounding cabinetry. The laminate can match adjacent panel colors and patterns, making the door less visually distinct and more discreet from passenger perspectives while maintaining full accessibility through normal operation

Inventive Principle:

Principle #32Color changes

Data Source

PatentEP3524508B1Hinged composite sandwich panels

Publication Date: 2025.02.05 THE BOEING CO

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AI summary

An apparatus comprises a composite sandwich panel (100), a seal (110), and a hinge (112). The composite sandwich panel has a first edge (104) in a first over-crush edge region (106), wherein a thickness (108) of the composite sandwich panel decreases within the first over-crush edge region in a direction towards the first edge. The seal is bonded to the first over-crush edge region of the composite sandwich panel and extending past the first edge. The hinge is connected to the composite sandwich panel such that an axis of rotation (114) of the hinge is positioned over the first over-crush edge region of the composite sandwich panel.