Gas Permeable Layer for Bubble-Free Aircraft Decorative Laminates
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Solution Overview
Problem
Decorative laminates in aircraft passenger cabins often experience post-laminate-application bubble formation due to entrapped gases, making them aesthetically unacceptable and requiring costly replacement.
Innovation Solution
Incorporating a gas permeable layer between the decorative laminate and the substrate, which allows entrapped gases to escape, reducing or eliminating bubble formation and enabling easier application without air trapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a decorative laminate is applied to a substrate, then aesthetic appearance is improved, but air bubbles may form between the laminate and substrate making it aesthetically unacceptable
Solution Approach 1:
The patent introduces a gas permeable layer within the decorative laminate structure that allows entrapped air bubbles to escape or be absorbed during the lamination process. This porous/gas permeable structure prevents bubble accumulation while maintaining the aesthetic appearance of the decorative surface.
Solution Approach 2:
The gas permeable layer acts as an intermediary between the decorative surface layers and the substrate, facilitating the removal of air bubbles during application. This intermediate layer mediates the interaction between laminate and substrate, allowing gas transmission while maintaining structural integrity and aesthetic appearance.
2Illumination intensity
If post-laminate-application bubble formation occurs, then aesthetic appearance deteriorates, but repair is difficult requiring costly replacement
Solution Approach 1:
The gas permeable layer is incorporated into the laminate structure during manufacturing, before application to the substrate. This preliminary inclusion of gas escape pathways prevents bubble formation during and after application, eliminating the need for costly post-application repairs or replacements.
3Ease of manufacture
If conventional decorative laminate structure is used, then manufacturing is simple, but gas entrapment causes quality issues
Solution Approach 1:
The gas permeable layer can be integrated into the existing laminate manufacturing process using conventional materials and techniques. The porous or gas-permeable structure is incorporated during the layering process, maintaining manufacturing simplicity while significantly improving quality consistency by preventing bubble-related defects.
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 gas permeable layer effectively reduces bubble formation, simplifying the application process and reducing the need for costly laminate replacements by allowing gases to diffuse, thus enhancing the aesthetic and structural integrity of the decorative laminate.
Implementation Method 1
a gas permeable layer underlying the decorative layered structure
Implementation Method 2
allowing gases to diffuse
Data Source
AI summary
A decorative laminate including a decorative layered structure defining a first surface and a second surface opposed from the first surface, and a gas permeable layer underlying the decorative layered structure.