Incombustible Non-Telegraphing Aviation Panel Substrate

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Solution Overview

Problem

Conventional aviation panels exhibit telegraphing, where the wood grain pattern becomes visible through the decorative veneer, leading to aesthetic issues, customer returns, replacements, and waste.

Innovation Solution

An incombustible, non-telegraphing substrate comprising a polymer resin-impregnated paper backing layer with a fire-retardant chemical, adhered to the decorative aviation veneer using adhesive layers, preventing the visibility of the grain pattern and ensuring compliance with fire safety regulations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a wood substrate is used for aviation panels, then the panel provides structural support, but the wood grain pattern becomes visible through the decorative veneer causing telegraphing

Engineering Contradiction:

Improvestructural supportVSAvoidaesthetic quality

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The substrate is divided into multiple layers: a structural core layer providing strength and a separate facing layer (decorative veneer) providing aesthetics. This segmentation allows each layer to perform its specific function without interfering with the other, preventing telegraphing while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediary layer or treatment is introduced between the wood substrate and the decorative veneer to prevent the grain pattern from telegraphing through. This intermediary element acts as a barrier that blocks the visual transmission of the wood grain while allowing the structural properties to remain intact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If conventional materials are used for aviation panels, then the panel provides aesthetic appearance, but the material is combustible failing fire safety standards

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidfire safety

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The aviation panel uses composite materials combining decorative veneer with fire-retardant treated substrates or fire-resistant core materials. This composite structure maintains the aesthetic appearance of the veneer while the fire-retardant properties of the underlying materials ensure compliance with fire safety standards.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The material properties are modified by applying fire-retardant treatments or selecting materials with specific fire-resistance parameters. This changes the combustion characteristics of the panel materials from combustible to fire-retardant, while preserving the aesthetic qualities of the decorative surfaces.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If wood substrates are used for aviation panels, then the panel provides structural integrity, but customer returns and waste increase due to telegraphing

Engineering Contradiction:

Improvestructural integrityVSAvoidwaste

Core Design Contradiction:

Stability of the object's compositionVSLoss of substance

Solution Approach 1:

The panel is constructed with a non-telegraphing substrate or treated wood substrate before applying the decorative veneer. This preliminary action of selecting or treating the substrate prevents telegraphing issues before they occur, eliminating the need for customer returns and replacements, thereby reducing waste.

Inventive Principle:

Principle #10Preliminary action

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 prevents telegraphing, reduces customer returns and waste, and meets fire safety standards by creating an aesthetically pleasing, incombustible aviation panel assembly for aircraft interiors.

Implementation Method 1

a backing layer comprising a polymer resin-impregnated paper and a fire-retardant chemical included in the backing layer and rendering the backing layer incombustible

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

a first adhesive layer between the backing layer and the decorative aviation veneer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS9878771B2Incombustible, non-telegraphing substrates for aviation panel assemblies and methods for installing the incombustible, non-telegraphing substrate into an aviation panel assembly

Publication Date: 2018.01.30 GOODRICH CORP

AI summary

An incombustible, non-telegraphing substrate for facing with a decorative aviation veneer is provided. The incombustible, non-telegraphing substrate comprises a backing layer comprising a polymer resin-impregnated paper and a fire-retardant chemical included in the backing layer and rendering the backing layer incombustible. An aviation panel and a method for installing the incombustible, non-telegraphing substrate in the aviation panel assembly are also provided.