Solid Composite Floor Panel Impact Resistance
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Solution Overview
Problem
Conventional aircraft composite floor systems are labor-intensive to manufacture and may suffer from moisture absorption due to the open cell structure of honeycomb core materials, leading to weight gain and performance degradation over time, while high-speed machined metallic floors do not achieve the weight benefits of composites.
Innovation Solution
A method of forming a composite panel using a support layer, a mid-plane impact layer, and upper and lower skin layers, all composed of prepreg plies, which are co-cured at elevated temperature and pressure to create a lightweight, impact-resistant structure with a box beam construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If honeycomb core structures are used in composite floor systems, then weight reduction is achieved, but moisture absorption occurs leading to weight gain and performance degradation
Solution Approach 1:
The patent removes the honeycomb core from the composite floor system, retaining only the outer skin layers. This extraction eliminates the moisture absorption issue inherent to open-cell honeycomb structures while preserving the lightweight characteristics of composite materials. The resulting solid composite panel maintains structural integrity without the problematic core material.
Solution Approach 2:
The invention uses multiple layers of composite material (fiberglass or graphite prepreg) bonded together to create a solid panel structure. This composite construction provides both the weight benefits of composite materials and the moisture resistance required for reliable performance, replacing the honeycomb core with a solid composite alternative.
2Weight of moving object
If conventional composite floor systems are manufactured using honeycomb core with prepreg skins, then lightweight structure is achieved, but manufacturing becomes labor intensive and expensive
Solution Approach 1:
By removing the honeycomb core and associated complex bonding processes, the manufacturing procedure is simplified. The solid composite panel can be manufactured using standard composite layup and curing processes, eliminating the need for specialized honeycomb core handling and multiple bonding operations.
3Manufacturing precision
If high speed machined metallic floors are used, then manufacturing tolerance and tooling requirements are improved, but weight benefits of composite materials are not achieved
Solution Approach 1:
The patent employs composite materials (fiberglass or graphite prepreg) to manufacture floor panels that achieve both the weight advantages of composites and the manufacturing precision required for aircraft applications. The composite laminates can be cured to tight tolerances while maintaining lightweight characteristics.
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 results in a lightweight, impact-tolerant composite panel that minimizes labor-intensive processes and reduces moisture absorption, maintaining performance and meeting design requirements.
Implementation Method 1
curing the support layer, the mid-plane layer, upper skin layer, and lower skin layer together at an elevated temperature and pressure
Implementation Method 2
each of the support layer, the mid-plane impact layer, upper skin layer, and lower skin layer includes a plurality of prepreg plies
Data Source
AI summary
A composite panel includes a support layer including a first plurality of prepreg plies wrapped around at least one mandrel; a mid-plane impact layer including a second plurality of prepreg plies, the mid-plane impact layer adjacent to the support layer; a upper skin layer including a third plurality of prepreg plies, the upper skin layer adjacent to the mid-place impact layer; and a lower skin layer including a fourth plurality of prepreg plies, the lower skin layer adjacent to the support layer; whereby each of the first, second, third, and fourth plurality of prepreg plies are co-cured to form the composite panel.