Joggled Composite Panel Manufacturing with Metal Inserts
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Solution Overview
Problem
Current manufacturing processes for composite panels used in aircraft interiors are labor-intensive and costly, often resulting in inconsistent quality due to kerf cutting, which also eliminates the use of elongated honeycomb cores necessary for compliance with flammability requirements.
Innovation Solution
A method involving pinning metal inserts onto a tool, positioning core portions adjacent to the inserts, and curing with a plate to form a composite panel that meets flammability standards while reducing labor and cost, using a honeycomb core material like aramid fiber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If kerf cutting is used to create joggled panels, then the panel can be formed without elongated core material (meeting flammability requirements), but the manufacturing process becomes labor intensive and time consuming
Solution Approach 1:
The patent applies preliminary action by pre-forming the core material into segmented portions with recesses before assembly. The core portions are prepared in advance with specific geometries (recesses and protrusions) that enable automatic alignment and joining during panel assembly, eliminating the need for labor-intensive kerf cutting operations while maintaining flammability compliance through the use of standard core material
2Reliability
If kerf cutting is used to create joggled panels, then the panel can be formed without elongated core material, but the manufacturing cost increases due to labor intensity
Solution Approach 1:
The core portions are pre-fabricated with recesses and geometric features that facilitate automated assembly. This preliminary preparation allows for standardized production of core components that can be quickly assembled with inserts using simple joining mechanisms, significantly reducing labor costs while maintaining the ability to meet flammability requirements
Solution Approach 2:
The panel is divided into modular segments (core portions and inserts) that can be manufactured separately and assembled efficiently. The segmentation allows each component to be optimized for its specific function and assembled through simple mechanical joining rather than complex cutting operations, reducing overall manufacturing cost and time
3Ease of manufacture
If traditional assembly methods are used without pins, then the process may be simpler, but the inserts and core portions cannot be securely positioned during curing
Solution Approach 1:
Pins are introduced as intermediary elements that connect the inserts to the core portions during assembly and curing. The pins serve as mechanical mediators that transmit and distribute forces between components, ensuring precise positioning and secure bonding without requiring complex assembly mechanisms or sacrificing manufacturing simplicity
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 method enhances bonding between metal inserts and core material, reduces post-cure surface preparation time, and produces panels that meet FAA regulatory flammability requirements while being more efficient and cost-effective.
Implementation Method 1
inserting the plurality of pins into the tool; positioning a plurality of inserts on the first layer, wherein the plurality of inserts are adapted to connect to the plurality of pins; connecting the plurality of inserts to the pins
Implementation Method 2
curing the non-cured composite panel in order to form a non-trimmed composite panel
Implementation Method 3
Such panels are typically made of aramid fiber honeycomb core material
Data Source
AI summary
Methods for manufacturing composite panels for use in the interior of an aircraft are disclosed, specifically, methods of manufacturing joggled composite panels comprising metal inserts and the resulting composite panels and inserts.