Luminous Composite Floor Panel for Aircraft Weight Reduction
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Solution Overview
Problem
Existing light-transmissive carpet tiles are unsuitable for commercial aircraft due to their weight, bulkiness, and vulnerability to structural loading, which increases fuel consumption and poses risks to LEDs and electrical elements.
Innovation Solution
A scalable distributed carpet display system comprising luminous composite floor panels with a cover sheet, base sheet, and core layer, featuring light sources between the cover sheet and core layer, protected by a rigid cover sheet and integrated with light transmissive carpet that transmits light through unpigmented fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light-transmissive carpet tiles are used in commercial aircraft, then lighting effects and branding are improved, but weight increases and fuel consumption increases
Solution Approach 1:
The floor panel is segmented into multiple functional layers: a rigid cover sheet, a core layer with honeycomb structure, and a base sheet. This segmentation allows each layer to perform its specific function while minimizing overall weight - the honeycomb core provides structural support with minimal material, and the thin cover sheet protects LEDs without adding significant weight.
Solution Approach 2:
The patent uses thin film structures including a thin rigid cover sheet and translucent carpet layers that provide the necessary protective and optical functions with minimal weight. The thin film approach replaces bulkier traditional lighting structures while maintaining structural integrity and light transmission properties.
2Illumination intensity
If existing carpet tiles with integrated LEDs are used, then lighting functionality is achieved, but the structure becomes vulnerable to structural loading and damage
Solution Approach 1:
The patent implements protective structures before the LEDs are exposed to operational conditions. The rigid cover sheet is positioned above the LEDs to protect them from impact and structural loading, while the honeycomb core layer provides additional cushioning and structural support. This beforehand protection ensures the LEDs remain vulnerable-free during the entire service life of the aircraft floor panel.
Solution Approach 2:
The floor panel uses composite material structures combining rigid cover sheets, honeycomb core layers, and translucent carpet materials. This composite approach creates a multi-functional structure that simultaneously provides mechanical protection, structural support, and optical transmission, making the LED integration both functional and durable against structural loading.
3Adaptability or versatility
If traditional carpet replacement methods are used to change aesthetics, then carpet appearance can be updated, but installation time and cost increase
Solution Approach 1:
The patent enables dynamic reconfigurability of the floor panel appearance by integrating controllable LED lighting systems that can change colors, patterns, and intensities electronically. This dynamic control allows the same physical floor panel to provide multiple aesthetic configurations without physical replacement, dramatically reducing the time and cost associated with changing carpet appearances while maintaining high adaptability.
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
Provides customizable, energy-efficient, and durable lighting effects on aircraft carpets, enhancing branding, passenger experience, safety, and wayfinding while minimizing weight and risk of damage.
Implementation Method 1
The light sources are configured to emit light through the cover sheet to provide lighting effects above the user-facing side of the cover sheet
Implementation Method 2
integrated with light transmissive carpet that transmits light through unpigmented fibers
Data Source
Figure 1
Figure 2A~2B
Figure 3~5
AI summary
A composite floor panel includes a cover sheet, a base sheet, a core layer, and a plurality of light sources. The cover sheet has a user-facing side and an underside that is opposite from the user-facing side. The base sheet is below the underside of the cover sheet. The core layer includes a plurality of honeycomb cells bonded to one another. The core layer is disposed between the cover sheet and the base sheet. The light sources are configured to emit light through the cover sheet to provide lighting effects above the user-facing side of the cover sheet. The light sources are disposed between the user-facing side of the cover sheet and the core layer.