Thermoplastic Composite Aircraft Floor Paneling
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Solution Overview
Problem
There is a need for lightweight, damage-tolerant, and cost-efficient composite floor paneling for aircraft that can withstand impact resistance, while existing thermoset and thermoplastic resin composites have limitations such as high processing costs and inability to be re-processed.
Innovation Solution
The use of thermoplastic C-shaped stringers, a consolidated deltoid filler, and upper and lower facing sheets, integrally consolidated using a uniformly-applied compressive force and heat, forming a unitary construction with carbon and/or glass fibers and specific thermoplastic polymers like PEEK or PPS, along with a tool assembly for manufacturing that applies multi-axis pressure and heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoset resins are used to manufacture composite flooring, then less pressure and heat are required for forming, but the cured resin cannot be re-processed
Solution Approach 1:
The patent changes the material parameter from thermoset resin to thermoplastic resin, which fundamentally alters the processing characteristics. Thermoplastic resins allow the composite to be re-heated and re-formed multiple times, providing re-processability while maintaining manageable forming conditions through controlled heating and pressing cycles.
Solution Approach 2:
The patent introduces dynamic re-processability to the composite flooring system. The thermoplastic resin enables the material to transition between solid and moldable states through temperature control, allowing for repair, reconfiguration, or correction of manufacturing defects after initial formation, thus adding adaptability to the system.
2Adaptability or versatility
If thermoplastic resins are used to manufacture composite flooring, then re-processing is enabled, but higher pressure and heat are required for forming
Solution Approach 1:
The patent employs preliminary consolidation of the thermoplastic resin matrix with the reinforcement fibers before final forming. This pre-impregnation step ensures proper material distribution and bonding, reducing the overall pressure and heat requirements during the subsequent forming operation while maintaining the re-processability advantage of thermoplastic resins.
Solution Approach 2:
The patent implements a continuous forming process where the thermoplastic resin is heated to its processing temperature, formed under pressure, and then cooled while maintaining continuous contact with the tooling. This continuous action minimizes energy losses and reduces peak temperature and pressure requirements compared to batch processing methods.
3Reliability
If composite floor paneling is designed for high impact resistance, then damage tolerance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes a composite material system consisting of thermoplastic resin matrix combined with reinforcement fibers (such as carbon fiber, glass fiber, or aramid). This composite structure provides enhanced impact resistance and damage tolerance through the synergistic effect of the ductile thermoplastic matrix and the high-strength fiber reinforcement, while the integration of these materials into a unified manufacturing process manages the complexity.
Solution Approach 2:
The patent implements local quality enhancement by concentrating reinforcement fibers in specific regions or orientations within the composite flooring where impact resistance is most critical. This targeted reinforcement approach achieves high damage tolerance in key areas without requiring uniform complexity throughout the entire structure, thereby managing manufacturing complexity.
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 provides a lightweight, damage-tolerant, and cost-effective floor paneling with improved impact resistance and manufacturing efficiency, eliminating issues like crushing and delamination in corner radii and skin thickness variations, suitable for high-energy impact loads in aircraft.
Implementation Method 1
The stringers, the deltoid filler, and the upper and lower facing sheets may be integrally consolidated by being heated to a temperature between approximately 700° F. and approximately 800° F. while simultaneously undergoing the uniformly-applied compressive force
Implementation Method 2
The stringers, the deltoid filler, and the upper and lower facing sheets are integrally consolidated forming a unitary construction through uniformly-applied compressive force
Data Source
AI summary
A floor panel for installation in an aircraft includes a plurality of thermoplastic C-shaped stringers, a consolidated thermoplastic deltoid filler, a thermoplastic upper facing sheet, and a thermoplastic lower facing sheet. The stringers are disposed in a parallel arrangement with one another. The deltoid filler is disposed within a longitudinally-extending notch defined by a pair of adjacent stringers. The upper facing sheet covers an upper surface of the stringers and the deltoid filler. The lower facing sheet covers a lower surface of the stringers and the deltoid filler. The stringers, the deltoid filler, and the upper and lower facing sheets are integrally consolidated forming a unitary construction.