Thermoacoustic Insulation Mat with Bendable Load-Bearing Structure

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Solution Overview

Problem

Current thermal and acoustic insulation systems for aircraft cabins are labor-intensive and costly to install, requiring numerous manually assembled panels that lead to inefficiencies and increased production time, weight, and thermal bridges.

Innovation Solution

A method involving a single large mat with a bendable structure that forms a load-bearing shape, reducing the number of edges and allowing for automated manufacturing and easier installation by giving the mat a curved shape, which aligns with the aircraft structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple padded panels are used to constitute the thermoacoustic insulation system, then the insulation can be adapted to the aircraft structure, but the installation time increases and production efficiency decreases

Engineering Contradiction:

Improveadaptation to aircraft structureVSAvoidinstallation efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent merges multiple separate padded panels into a single large-format mat that can be installed as one continuous piece. This consolidation maintains the adaptability to aircraft structure while dramatically reducing installation time and the number of assembly operations required, directly resolving the contradiction between adaptability and productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mat is designed with segmented or modular characteristics that allow it to be adapted to different aircraft structures while remaining a single continuous insulation layer. This segmentation enables customization for different aircraft models without requiring multiple separate panels, thus maintaining adaptability while improving installation efficiency.

Inventive Principle:

Principle #1Segmentation

2Area of stationary object

If multiple adjacent panels are used, then the insulation system can cover the aircraft surface, but the weight increases due to overlaps

Engineering Contradiction:

Improvecoverage areaVSAvoidinsulation system weight

Core Design Contradiction:

Area of stationary objectVSWeight of stationary object

Solution Approach 1:

By combining multiple panels into a single large mat, the patent eliminates the overlapping sections that would be required between adjacent panels. This merging reduces the total material weight while maintaining full coverage of the aircraft surface, directly addressing the contradiction between coverage area and weight.

Inventive Principle:

Principle #5Merging (Combining)

3Area of stationary object

If multiple panels with numerous edges are used, then the insulation can be installed on the aircraft, but thermal bridges and leaks increase

Engineering Contradiction:

Improveinsulation coverageVSAvoidthermal bridges and leaks

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent merges multiple panels into a single continuous mat, eliminating the edges and joints that create thermal bridges and leaks. This continuous insulation layer maintains full coverage while removing the harmful thermal pathways that occur at panel boundaries, resolving the contradiction between coverage area and thermal performance.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of operation

If manual assembly of panels is used, then the insulation system can be installed, but the installation cost and time increase

Engineering Contradiction:

Improveinstallation feasibilityVSAvoidinstallation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent merges multiple manually assembled panels into a single large mat that can be installed as one piece. This dramatically reduces the manual assembly operations required, cutting installation time and labor costs while maintaining ease of installation through the simplified single-piece approach.

Inventive Principle:

Principle #5Merging (Combining)

5Productivity

If a single large mat is used, then installation time and weight are reduced, but the mat must be adapted to curved aircraft surfaces

Engineering Contradiction:

Improveinstallation efficiencyVSAvoidcurved surface adaptation

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

The patent incorporates curvature into the mat design, allowing it to conform to the curved surfaces of aircraft structures. This curvature adaptation enables the single large mat to maintain its installation efficiency benefits while successfully adapting to the three-dimensional shaped surfaces required by aircraft geometry.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The mat is designed with dynamic flexibility that allows it to be shaped and contoured during installation to match various aircraft surface geometries. This dynamic adaptability enables the single mat to conform to curved surfaces while maintaining the installation efficiency advantages of a unified insulation piece.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10640195B2Method for manufacturing a thermoacoustic insulation module for an aircraft comprising a bending step

Publication Date: 2020.05.05 AIRBUS OPERATIONS (SAS)

AI summary

In order to facilitate the thermoacoustic insulation of an aircraft portion, a method for manufacturing a thermoacoustic insulation module for an aircraft comprises a step of providing a mat configured to provide thermoacoustic insulation of an aircraft portion, followed by a step of attaching a bendable structure to the mat, followed by a step of bending the bendable structure, along a bending axis parallel to a longitudinal direction of the mat, such that the bendable structure forms a load-bearing structure supporting the mat in a curved shape.