Impact and knife cut resistant pre-impregnated woven fabric for aircraft heated floor panels
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Solution Overview
Problem
Existing impact layers in aircraft heated floor panels have lower mechanical strength due to resin modifications for flammability, smoke, and toxicity requirements, compromising their ability to withstand punctures and damages.
Innovation Solution
A heated floor panel assembly featuring a woven high temperature thermoplastic fiber matrix or composite fiber matrix impregnated with a resin, which includes structural layers, a core layer, and a heating layer, providing enhanced mechanical strength and meeting stringent FST requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin is modified with additives to meet flammability, smoke, and toxicity requirements, then FST requirements are satisfied, but mechanical strength of the impact layer decreases
Solution Approach 1:
The patent uses a composite fiber matrix combining high temperature thermoplastic fibers (such as PEEK, PPS, or aramid) with resin. This composite structure allows the material to simultaneously achieve high mechanical strength from the fiber reinforcement and FST compliance from the resin matrix, resolving the contradiction between strength and regulatory compliance.
Solution Approach 2:
The patent changes the chemical composition parameters of the resin by incorporating flame retardant additives, smoke suppressants, and toxicity reducers into the fiber matrix. These parameter modifications enable the material to meet FST requirements while the overall composite structure maintains mechanical integrity through the fiber reinforcement.
2Ease of manufacture
If loose fibers are used in the fiber matrix, then ease of impregnation is improved, but resistance to punctures and damages decreases
Solution Approach 1:
The patent employs a woven fabric structure where fibers are arranged in an interlaced pattern forming a continuous load-bearing network. This woven architecture provides both puncture resistance through the interlaced fiber structure and adequate impregnation capability through the fabric's porosity, resolving the contradiction between mechanical protection and manufacturing ease.
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 achieves increased mechanical strength, improved resistance to punctures and damages, while meeting stringent flammability, smoke, and toxicity (FST) requirements, ensuring the panel's durability and safety in aircraft environments.
Implementation Method 1
The woven impact layer includes a woven high temperature thermoplastic fiber matrix and a resin infiltrating the woven fiber matrix
Implementation Method 2
a resin infiltrating the woven fiber matrix
Implementation Method 3
The core layer absorbs shear stress
Implementation Method 4
heated floor panels are often used in aircraft to mitigate the effects of cold underfloor temperatures
Data Source
AI summary
A heated floor panel assembly for aircraft includes an impact layer made from a 2-D or 3-D woven high temperature thermoplastic fiber matrix impregnated with a resin. The impact layer can further include woven metallic fibers. The assembly also includes a stack of structural layers, a heating layer, and a core layer for absorbing shear stress.