Powder Lacquer Coating for Aircraft Cabin Panels
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Solution Overview
Problem
Existing methods for creating three-dimensional surface structures and textures on aircraft internal panelling components are inflexible, requiring long lead times and high storage costs due to the limitations of film-based coatings, which struggle with local variations and have low texture change flexibility.
Innovation Solution
A coating method involving the application of a powder lacquer layer followed by an imprint, allowing for direct generation of desired textures and colors on the component using inkjet printing, enabling rapid and flexible changes without the need for extensive storage of films, and including a protective layer for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If film-based coating methods are used to generate textures and surface structures, then the component can be provided with decorative surfaces, but the lead time for producing altered textures becomes excessively long (up to 8 weeks) and storage costs increase due to the need to keep sufficient films available for each individual colour design and texture
Solution Approach 1:
The patent changes the fundamental parameter of the coating material from solid films to powder lacquer, which can be applied in powder form and cured to create textures. This parameter change enables rapid texture alterations without the need to produce and store physical films, reducing lead times from 8 weeks to much shorter durations while maintaining design flexibility
Solution Approach 2:
Instead of using physical films that must be stored and handled, the patent creates a digital/chemical copy of the texture through powder lacquer application. The texture is defined by the powder composition and application parameters rather than by physical film stock, eliminating the need for extensive film storage while maintaining the ability to produce various textures on demand
2Adaptability or versatility
If film-based coating methods are used to generate textures and surface structures, then the component can be provided with decorative surfaces, but high storage outlay and storage costs occur due to the need to keep sufficient films available for each individual colour design and texture
Solution Approach 1:
The patent replaces physical film storage with a powder-based system where textures are created through chemical composition and application rather than physical film handling. This eliminates the need to store large quantities of films for different designs, reducing storage outlay and costs while maintaining the ability to produce various decorations
Solution Approach 2:
By changing from solid film materials to powder lacquer, the patent transforms the storage requirement from physical film inventory to powder material storage. This parameter change significantly reduces the quantity of material that needs to be stored and handled, as powder can be stored in smaller, more efficient quantities compared to films
3Ease of manufacture
If traditional lacquer application is used for colour design, then the component can be provided with coloured surfaces, but textures or three-dimensional surface structures cannot be produced in a simple manner
Solution Approach 1:
The patent changes the material parameter from liquid lacquer to powder lacquer, which enables the incorporation of texturing agents and three-dimensional surface structure components directly into the coating material. This parameter change simplifies the manufacturing process by combining colour and texture application into a single powder coating operation rather than requiring separate steps
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
This method allows for rapid and flexible implementation of texture and color changes, reducing lead times and storage costs, achieving weight reductions of up to 50% compared to film-coated components and 20% compared to traditional lacquered components, while maintaining precision and adaptability for complex shapes.
Implementation Method 1
The colour design in the case of internal panelling elements for cabins of aircraft can be produced by application of coloured lacquers
Data Source
AI summary
A coating method wherein in order to simplify the coating method and increase the flexibility thereof with respect to respective desired coatings, provision is made that a powder lacquer layer (3) is applied to a surface (2) of the component (1), and an imprint (4) is applied to the powder lacquer layer (3), preferably by an inkjet method.