Injection-Molded Structural Panel with Embedded Attachment Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercial aircraft require heavy structures to support windows, which increase weight and cost, and there is a need for a lighter and more cost-effective structural skin panel that can incorporate windows without these heavy supports.
Innovation Solution
A structural panel is designed with a frame that includes attachment members, where a polymeric material is injection-molded around composite framework elements to create a lightweight and strong panel that can be easily attached to a structure, potentially incorporating windows without the need for heavy window support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy window support structures are used, then structural strength is improved, but weight increases
Solution Approach 1:
The patent combines the frame, attachment members, and structural reinforcement into a single integrated injection-molded panel assembly. The attachment members are embedded directly into the molded panel, eliminating the need for separate heavy window support structures while maintaining structural strength through the integrated design and distribution of load across the entire panel.
Solution Approach 2:
The patent utilizes composite materials in the frame construction and injection-molded panel, combining materials with different properties to achieve high strength-to-weight ratio. The frame may use composite framework elements that provide structural strength without the weight of traditional solid metal structures.
2Strength
If heavy window support structures are used, then structural integrity is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple components (frame, attachment members, panel) into a single integrated assembly that can be manufactured in one injection molding process. This eliminates the need for separate manufacturing and assembly steps for window support structures, reducing manufacturing complexity and cost while maintaining structural integrity.
Solution Approach 2:
The attachment members are pre-positioned and embedded into the frame during the injection molding process itself, rather than being added as separate post-assembly steps. This preliminary integration of attachment features into the molded part reduces assembly operations and manufacturing cost while ensuring proper structural integrity.
3Strength
If traditional window support structures are used, then structural strength is improved, but device complexity increases
Solution Approach 1:
The patent combines the functions of the frame, window support, and attachment mechanisms into a single integrated injection-molded panel. The attachment members are embedded directly into the panel structure, eliminating the need for separate support structures and reducing overall device complexity while maintaining structural strength through the unified design.
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 provides a lightweight and cost-effective structural panel that can be easily integrated into aircraft fuselages, reducing weight and manufacturing costs while maintaining structural integrity and allowing for the inclusion of windows with minimal additional weight and complexity.
Implementation Method 1
a polymeric material is injected into the mold at least partially around the frame
Data Source
AI summary
A structural panel includes a frame having one or more attachment members. A material injection-molded onto at least a portion of the frame fills one or more openings at least partly defined by the frame and defines at least a portion of a shape of the panel. The attachment member(s) are at least partially embedded in the injection-molded material for attaching the panel relative to the structure. Because attachment members can be embedded in this panel, little if any post-processing is needed to install the panel.