Sandwich Window Panel with Foam Core for Aircraft
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Solution Overview
Problem
Current production and assembly techniques for fibre-reinforced polymer composite window panels in aircraft and spacecraft are labor-intensive and time-consuming, requiring complex riveting procedures and substantial production effort.
Innovation Solution
A sandwich-structured window panel with fibre-reinforced polymer skins and a lightweight foam core, allowing for a simplified assembly process by eliminating the need for rigid window frames and enabling integration of insulation and system components through the panel core, using a method that includes resin infusion and curing to form a monolithic structure with reduced residual stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid window frames with riveting procedures are used, then structural strength is ensured, but production time and assembly effort increase substantially
Solution Approach 1:
The patent merges the window frame structure with the panel skin by integrating the aperture surround directly into the composite panel manufacturing process. The reinforcement layers are embedded within the composite structure during resin infusion, eliminating the need for separate frame assembly and riveting operations. This integration maintains structural strength while dramatically reducing production time and assembly effort.
Solution Approach 2:
The patent employs fibre-reinforced polymer composite materials with embedded reinforcement layers (such as glass fibre, carbon fibre, or aramid fibre mats) to create a monolithic panel structure that incorporates the aperture surround. This composite construction provides both structural strength and aperture definition in a single manufactured component, replacing traditional multi-part metal frame assemblies.
2Reliability
If complex riveting procedures are employed for window assembly mounting, then reliable attachment is achieved, but assembly effort and time delays increase
Solution Approach 1:
The window aperture surround is merged into the panel structure itself through embedded reinforcement layers that are cured as part of the composite manufacturing process. This creates a permanent, integrated attachment point that eliminates the need for separate riveting or fastening operations, thereby maintaining reliable attachment while greatly simplifying assembly procedures.
3Strength
If substantial production effort is invested in traditional composite panel assembly, then structural integrity is maintained, but production efficiency decreases
Solution Approach 1:
The reinforcement layers for the aperture surround are placed and embedded into the panel during the initial composite manufacturing process, before final curing. This preliminary integration of structural elements into the monolithic panel structure eliminates subsequent assembly steps, thereby maintaining structural integrity while significantly improving production efficiency.
4Reliability
If traditional window frame structures are used, then aerodynamic performance is maintained, but vehicle mass increases
Solution Approach 1:
The patent uses fibre-reinforced polymer composite materials for the panel structure, which provide high strength-to-weight ratio and can be tailored to maintain aerodynamic performance. The integrated aperture surround design eliminates heavy metal frames while preserving the necessary structural and aerodynamic characteristics through optimized composite layup and reinforcement placement.
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 approach significantly simplifies and accelerates the mounting of window assemblies, reduces thermal insulation needs, and provides a lighter aircraft structure with increased cabin space and reduced mass, while maintaining structural integrity and aerodynamic performance.
Implementation Method 1
the layers of reinforcement fibres are impregnated with a polymer resin material
Implementation Method 2
the impregnated layers of reinforcement fibres are cured to bond together with minimal residual stresses in the foam core
Data Source
Figure 1~4
Figure 5(a)~7
Figure 8(a)~9
AI summary
The present invention provides a window panel (1) for a body structure of a vehicle (V), especially an airframe of an aircraft or spacecraft, comprising: a first skin (2) which extends over a first side (3) of the panel (1) to form an outer skin of the vehicle body structure; a second skin (4) which extends over a second side (5) of the panel (1) to form an inner skin of the vehicle body structure; and a core (6), especially a foam core, located between and covered by the first and second skins (2, 4) in a sandwich structure. The window panel (1) includes at least one window aperture (7) formed through the first layer (2), the core (6), and the second layer (4). The core (6) may be confined to or extends over a limited extent, region or part of the panel (1). Thus, the first skin (2) and/or the second skin (4) may extend over or cover/s a greater area of the panel (1) than the core (6).