Integrated LED Composite Panel for Aircraft Interiors
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Solution Overview
Problem
Existing aircraft interior lighting solutions are not functionally improved and are costly to produce, with separate attachment of lighting devices requiring additional manufacturing steps and housing, which increases complexity and weight.
Innovation Solution
A light-emitting composite arrangement with integrated lighting devices in a sandwich composite structure, where the lighting device is embedded in a support core and adhesive within the core section, allowing for captive fixation and reduced production steps, and a translucent outer layer for unobtrusive appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lighting devices are separately attached to aircraft interior panels, then lighting functionality is achieved, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent merges the lighting device with the composite panel structure by integrating LEDs directly into the core section during the composite manufacturing process. This eliminates separate attachment steps and reduces production complexity by combining multiple functions (structural panel + lighting device) into a single integrated component.
Solution Approach 2:
The lighting devices are positioned and fixed within the core section before the final curing stage of the composite material. This preliminary action allows the lighting devices to be incorporated into the structural assembly process itself, rather than requiring separate post-manufacturing installation steps.
2Weight of moving object
If housing and separate attachment components are used for lighting devices, then lighting functionality is achieved, but weight increases
Solution Approach 1:
The lighting device is merged with the composite panel structure, eliminating the need for separate housing and attachment components. The core section of the composite panel serves as both the structural element and the mounting substrate for the LEDs, reducing total component quantity and weight.
Solution Approach 2:
The patent extracts the lighting function from separate components and integrates it directly into the composite panel structure. By removing the need for discrete housing and mounting brackets, the design reduces overall weight while maintaining lighting functionality.
3Productivity
If lighting devices are integrated during composite curing, then manufacturing steps are reduced, but lighting device fixation reliability must be ensured
Solution Approach 1:
The lighting devices are positioned and preliminarily fixed within the core section using positioning elements before the final curing stage. This preliminary positioning ensures correct placement and orientation, while the subsequent curing process provides permanent fixation, combining manufacturing efficiency with fixation reliability.
Solution Approach 2:
Positioning elements and adhesive materials serve as intermediaries between the lighting devices and the composite structure during the curing process. These intermediaries ensure proper positioning and reliable fixation while allowing the integrated manufacturing process to proceed efficiently.
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 reduces manufacturing costs and weight while ensuring reliable and efficient light output, with a seamless integration of lighting that maintains structural integrity and aesthetic appeal.
Implementation Method 1
The cover layer is cured with the lighting device integrated in the core section. The base layer, in particular as the prepreg layer, is optionally additionally cured with the lighting device integrated in the core section.
Data Source
Figure 1~3
Figure 4
AI summary
The invention is based on the objective of providing a functionally improved and easy-to-manufacture light-emitting composite arrangement. A light-emitting composite arrangement 1 for stationary installation in the interior of an aircraft is proposed, comprising a base layer and a top layer 2, 3, wherein the top layer 3 is a prepreg layer, with a core section 4 which is arranged at least partially between the base layer and the top layer 2, 3, and with at least one light-emitting device 5 which is integrated in the core section 4, wherein the top layer 3 is cured with the light-emitting device 5 integrated in the core section 4.