Patent Application
20170274974
This application claims priority to European Patent Application EP 16 162 245.1 filed Mar. 24, 2016, the entire disclosure of which is incorporated by reference herein.
The present disclosure pertains to a method for manufacturing a lining panel with an integrated electrical connector for an aircraft or spacecraft. The present disclosure further pertains to a lining panel of this type and a lining panel assembly employing such lining panels.
Although generally applicable to any kind of lining panel, e.g. for use in the transport industry in passenger cabins of landborne, airborne, or waterborne vehicles, the present disclosure and the problem on which it is based will be explained in greater detail with reference to lining panels for passenger cabins of commercial aircraft.
Common passenger aircraft comprise a fuselage that holds a passenger cabin, the latter containing the passenger seats, the hand luggage compartments, the sanitary facilities and so on. The inside of such a passenger cabin is usually separated from the fuselage, the skin, and other structural parts of the aircraft by a lining with a plurality of lining panels adjoining one another. The passenger cabin is supplied by a data and power infrastructure that is essentially built up of electrical wiring and corresponding connectors that are often placed between the aircraft structure and the lining panels, such that the electric infrastructure is ‘hidden’ from the passengers. Specifically, a multitude of wires may be arranged in cable bundles, each wire being solidly formed with a circular profile that is surrounded by an insulation. The cable bundles may be anchored within fixed locations using brackets or similar holding components that in turn may be attached to the lining panels. The cable bundles may have a finite length and may be connected to each other with electrical connectors, which may be likewise fastened to the lining panels. These connectors may be formed as box-like components of different sizes including connection ports for coupling various power cables or data cables from the cable bundles. Typically, strict requirements are put on the functionality, on the temperature and humidity resistance, as well as on the general safety precautions of such an electric infrastructure. Consequently, a strong focus is particularly placed on the robustness of the power and data cabling.
Recently, flexible electronics have been under close scrutiny within the regime of aerospace technology as these potentially offer lightweight and space saving alternatives to common cable systems. To this end, electronic devices may be mounted on flexible plastic substrates to provide flexible and flat cables for data and power transmission. These solutions typically require less space and weight than conventional cables. Moreover, such flat cables may simply be bonded to the outer surfaces of lining panels, wall segments, or the like. However, as in case of conventional cables, these solutions often involve laborious manufacturing and installation processes that are mostly separated from the assembly of the lining panels themselves. Convenient solutions have been suggested recently that integrate conductors directly into panel bodies, e.g. like the one disclosed in document US 2015/0053663 A1.
In general, any weight reduction can have significant impact on aircraft load and, in consequence, fuel consumption. In addition, it is desirable to provide an electric infrastructure with minimal installation and/or production effort. 3D printing provides extraordinary design freedom and hence it is widely used for manufacturing with multiple applications in engineering, construction, industrial design, automotive industries, and aerospace industries. Amongst various advantages, it offers the possibility to integrally form functional and structural elements into components, which otherwise—within conventional manufacturing—would necessarily require elaborate installation efforts.
According to a first aspect of the disclosure herein, a method for manufacturing a lining panel with an integrated electrical connector for a lining of a passenger cabin of an aircraft or spacecraft comprises using an additive manufacturing (AM) or 3D printing technique to laterally form electrically conductive pins on a panel body of the lining panel to provide an electrical connector. The electrically conductive pins are formed to connect to electric lines attached to or formed on or into the panel body of the lining panel.
According to a second aspect of the disclosure herein, a lining panel with an integrated electrical connector for a lining of a passenger cabin of an aircraft or spacecraft comprises a panel body, electric lines being attached to or formed on or into the panel body, and an electrical connector with electrically conductive pins formed laterally on the panel body of the lining panel using an AM or 3D printing technique. The electrically conductive pins are configured to connect to the electric lines.
According to a third aspect of the disclosure herein, a lining panel assembly comprises a first lining panel according to the second aspect of the disclosure herein and a second lining panel according to the second aspect of the disclosure herein. The electrically conductive pins of the first lining panel are complementary formed to the electrically conductive pins of the second lining panel. The first lining panel laterally joins the second lining panel such that the electrically conductive pins of the first lining panel establish an electrical contact with the electrically conductive pins of the second lining panel.
According to a fourth aspect of the disclosure herein, an aircraft or spacecraft comprises a lining panel according to the second aspect of the disclosure herein and/or a lining panel assembly according to the third aspect of the disclosure herein.
One idea of the present disclosure is to replace individual electric wires, cable routes or bundles, and, in particular, cable connectors and similar components of an electrical infrastructure of a passenger cabin by integrating electric connections directly into the lining panels of the cabin lining in a (multi-material) printing process. Using 3D printing processes even complexly structured electric connections, or even electric circuitry, may be manufactured directly on or in the panel bodies of the lining panels in cost and time efficient production manner. Due to this fact, lining panels according to the present disclosure can either replace and/or complement conventional lining panels of a passenger cabin. Various specific configurations of the thus implemented electrical connectors and electric lines may be advantageous depending on the application. For example, electrical connectors may be printed on a surface of a panel body, e.g. of a conventionally manufactured lining panel that may not require any particular preparation. These electrical connectors may then be connected with electrical lines installed at or on the panel body of the lining panel such that the lining panel may be electrically connected to other lining panels via the electrical connector. The electric lines may, for example, be provided in the form of flat flexible cables or the like and may be attached to a surface of the panel body, e.g. by bonding. However, the electric lines themselves may also be printed on or into the panel body by an AM or 3D printing technique. The electric lines may be partially or fully integrated into a panel body, e.g. such that the electric lines are placed flush with a surface of the panel body, which may be advantageous as the electric lines lie protected within the panel body. In addition, electric insulation of the electric connections may be provided, e.g. directly in the printing process.
The present disclosure offers a multitude of advantages for the passenger cabin environment. Due to the present disclosure, separately installed electrical connectors, electric wires and cable bundles may be avoided or at least significantly reduced in number. Holding components like brackets or similar may be reduced. In general, reductions in weight and space may be achieved. Furthermore, the present disclosure offers several advantages for the general safety and reliability of an electric infrastructure of a passenger cabin. Electrical connectors as well as electric lines may be integrated into the lining panels and hence there is less risk that cables or wires get torn apart or damaged during installation or maintenance. Inspection and maintenance efforts may be reduced on a general basis. Thus, not only weight, costs, installation and manufacturing efforts can be significantly lowered but also the general reliability of an electrical infrastructure of a passenger cabin can be improved.
In general, aspects of the disclosure herein offers great advantages for 3D printing or AM technology since 3D components may be printed without the additional need for subjecting the components or objects to further processing steps such as milling, cutting or drilling. This allows for a more efficient, material saving and time saving manufacturing process. Particularly advantageous in general is the reduction of costs, weight, lead time, part count and manufacturing complexity coming along with employing AM technology for printing electrical connectors, electric lines, electric circuits or other objects used for, employed in or being part of airborne vehicles. Moreover, the geometric and functional shape of the printed components or objects may be flexibly designed with regard to the intended technical purpose of parts or regions of the component/object.
Free form fabrication (FFF), direct manufacturing (DM), fused deposition modelling (FDM), powder bed printing (PBP), laminated object manufacturing (LOM), stereolithography (SL), selective laser sintering (SLS), selective laser melting (SLM), selective heat sintering (SHS), electron beam melting (EBM), direct ink writing (DIW), digital light processing (DLP) and additive layer manufacturing (ALM) belong to a general hierarchy of additive manufacturing (AM) methods, generally termed as 3D printing techniques. Those systems are used for generating three-dimensional objects based on digital model data by creating a cross-sectional pattern of the object to be formed and forming the three-dimensional solid object by sequentially building up layers of material. Any of such procedures will be referred to in the following description as AM or 3D printing without loss of generality. AM or 3D printing techniques usually include selectively depositing material layer by layer, selectively fusing or solidifying the material and removing excess material, if needed. 3D printing is currently used for prototyping and distributed manufacturing with multiple applications in engineering, construction, industrial design, automotive industries and aerospace industries.
According to an embodiment of the disclosure herein, the method may further comprise forming an insulation on the panel body of the lining panel around the electrically conductive pins. The insulation may include an insulating potting being selected from the group consisting of silicones, epoxies, polyesters, and urethanes, or similar materials can be used. Accordingly, in an embodiment of the lining panel, an insulation may be formed on the panel body of the lining panel around the electrically conductive pins. In one particular embodiment, the insulation may provide electrical insulation of the electric components. In another embodiment, in order to fulfill requirements with respect to moisture insulation, a groove may be printed surrounding the electrically conductive pins, which is then filled with an insulating potting. The insulating potting may for example be printed during a multi-material printing process. However, the insulation may be formed for more general protection of the components against vibration, moisture, thermal shock, chemicals and other contaminants.
According to an embodiment of the disclosure herein, the method may further comprise using an AM or 3D printing technique to form the electric lines on or into the panel body of the lining panel. Hence, not only the electrical connectors but also the electric lines may be formed in one single printing process on a panel body of a lining panel. Alternatively, the electrical connectors and the electric lines may be formed in consecutive printing steps.
According to a further embodiment of the disclosure herein, the method may further comprise using an AM or 3D printing technique to manufacture the panel body of the lining panel. Thus, the electrical connectors and/or the electric lines of the disclosure herein may either be printed by a separate 3D printer on a panel body prepared beforehand, e.g. a conventionally manufactured lining panel of a plastic or reinforced plastic material, or some or all of the electrical connectors and/or the electric lines may be printed together with the panel body itself in a multi-material printing process. For this, the AM or 3D printing technique may be optimized to employ different materials in a multiple material printing process. The respective 3D printer may be particularly configured to print electrically conductive circuits. In one exemplary embodiment, a powder bed or inkjet head 3D printer may be employed to place highly conductive particles, e.g. silver nanoparticles or other highly conductive metal or metal alloy materials, or highly conductive fibers or filaments on a substrate, e.g. a plastic material or fiber reinforced plastic material including fabric.
At least one of the electrically conductive pins and the electric lines may simultaneously be formed with the manufacturing of the panel body of the lining panel. In this embodiment, the lining panel may be manufactured as one single component in one continuous and rapid additive manufacturing process. Thus, the lining panel of this embodiment may be manufactured in a particularly cost- and time-efficient way.
According to an alternative embodiment of the disclosure herein, the method may further comprise using an automated tape placement technique to manufacture the panel body of the lining panel. In particular, fast manufacturing of the panel body may be achieved by combining rapid fiber- or tape-placement processes in a fast lay-up method. This permits to employ highly efficient pre-pregs with high fiber density, i.e. composite fibers pre-impregnated with a matrix material, such as epoxy, wherein the fibers may be provided in the form of fabric layers or the like. Hence, in a first method step of the disclosure herein, the panel body may be manufactured as a composite component by tape placement, e.g. by conventional tape placement methods such as laser assisted tape placement or variants thereof. In a next step of the method, electrical connectors and/or electric lines may then be printed onto or into the panel body to provide a lining panel with integrated electrical connectors and/or electric lines.
According to an embodiment of the disclosure herein, the method may further comprise forming connector ports within the panel body of the lining panel configured to take in the electrically conductive pins. The connector ports may be formed by at least one of laser ablation and an AM or 3D printing technique. Accordingly, in an embodiment of the lining panel, the electrically conductive pins may be formed within connector ports provided on the panel body of the lining panel. For example, a premanufactured panel body may be provided in a tape-placement process. In a next step, connector ports may be formed into the panel body by laser ablation in a precisely controlled way. In a further step, electrically conductive pins may then be printed into the thus formed connector ports. For example, depending on the desired geometry of the connector ports, material may be removed in a single pass of the laser, or, alternatively, in multiple passes in succession. A laser beam enables to form connector ports very precisely and rapidly. In one variant, the laser may be implemented into a print head of a 3D printer such that the electrically conductive pins may be formed into the connector ports in direct succession to the extraction of the connector ports with the laser. However, in other variants, the laser may be a standalone tool that is mechanically separated from the print head. In advantageous embodiments, some or all of the disclosed processes may be combined in various ways into one single continuous production process to increase efficiency. For example, the laser ablation process may be integrated into a tape placement process for manufacturing the panel body of the lining panel. To this end, a laser head may be adapted together with the corresponding optics to form one single system in conjunction with the tape placement head. Here, the laser could be guided by a suitable laser scanner optic or equivalent to achieve optimal geometrical freedom to produce the circuit channels. Another variant could be to integrate a laser head in front of a ink-jet or 3D-print head.
According to an embodiment of the disclosure herein, the method may further comprise forming circuit channels within the panel body of the lining panel configured to take in the electric lines. The circuit channels may be formed by at least one of laser ablation and an AM or 3D printing technique.
Accordingly, in an embodiment of the lining panel, the panel body may be interspersed by circuit channels, into which the electric lines are formed. For example, as in the above example, a premanufactured panel body may be provided in a tape-placement process. In a next step, a circuit channel may be formed into the panel body by laser ablation or a more conventional process like cutting, milling, drilling etc., where material can be removed from the panel body in a precisely controlled way. The panel body for example may be formed from plastic or reinforced plastic. In a further step, electric lines may then be printed into the thus formed circuit channels.
According to an embodiment of the lining panel, the electrically conductive pins may be formed in a generally planar configuration. Furthermore, the electric lines may be formed in a generally planar configuration. Hence, the electrical connectors as well as the electric lines may be implemented into a panel body with minimum space requirements and with minimum interference with the structural integrity of the panel body.
According to an embodiment of the lining panel, the electric lines may be configured as at least one of data lines and power lines. AM or 3D printing technologies generally allow to print electric lines, electrical connectors, electronic circuitry, circuit boards and other electronic structures by employing highly conductive 3D printing filaments or the like and combine them with known insulating materials. The circuits may be printed directly onto a range of common panel body materials: plastics, fiber reinforced plastic or similar. In principle, it is even possible to print circuits directly onto a fabric. Costs are much lower than in case of conventional cables or the like as the product is made in a single process, without the need for individual component assembly. By employing rapid 3D printing techniques electric lines may be configured for each individual use case. In one example, electric lines may be customized as power circuits to transmit electric energy through the lining panel for powering various electric cabin components, like for example cabin lights, displays, passenger service units, general passenger electronics, safety-related terminals, flight attendant panels or the like or other components of a typical cabin management system. In other variants, electric lines may be set up to transmit entertainment data, safety-related data, video data, audio data or the like, e.g. within a cabin management system and complying with the standards of a typical cabin intercommunication data system or similar. However, by virtue of the 3D printing process even very general electric lines may be printed that are used to transmit data and power.
According to an embodiment of the lining panel, the electrically conductive pins may be configured as at least one of data pins and power pins for connecting to the data lines and the power lines. As mentioned above, AM processes generally allow to print electric lines, electrical connectors, electronic circuitry, etc., by employing highly conductive 3D printing filaments or the like to print directly onto a range of common panel body materials: plastics, fiber reinforced plastic or similar. Like this, electrically conductive pins may be configured as power pins for connecting electric lines customized as power circuits to transmit electric energy through the lining panel for powering various electric cabin components. Alternatively, electrically conductive pins may be customized as data pins for transmitting entertainment data, safety-related data, video data, audio data or the like via electric lines set-up as data lines.
According to an embodiment of the lining panel assembly, the first lining panel may be fixed to the second lining panel by fastening elements integrated into the first lining panel and the second lining panel. The fastening elements of this embodiment may be used for installation purposes, for example. For the assembly of two adjacent lining panels, the first lining panel may be placed in the desired location. In a subsequent step, the second lining panel may be placed next to the first lining panel such that the electrical connectors establish electrical contacts between the electrically conductive pins of both lining panels. Finally, the fastening elements may fix the lining panels to each other such that their relative position is secured and thus the electrical contact between the electrically conductive pins will be maintained, e.g. in case of external mechanical influences or stress, e.g. due to vibrations, shaking or similar, or due to thermal expansion of the lining panels, etc. The fastening elements may also serve as a safeguard against minor tolerance and warping related geometry deviations of the components. Gaps between the lining panels may be prevented or minimized, so that for example moisture cannot enter between the lining panels. The person of skill will readily acknowledge that various different implementations of fastening elements may be provided with the disclosure herein. For example, one lining panel may be configured with an integrated fastening element that is formed as a male-ended member, e.g. a protruding plug, tenon, stud or similar, whereas the other lining panel may be customized with an integrated fastening element that is complementary formed to the male-ended member, e.g. a socket or similar. In one particular embodiment, the fastening elements in cooperation may provide a “snap & click” functionality, wherein one lining panel may be snapped in place after aligning it with the other lining panel. The fastening element may simply be printed together with the respective lining panel. However, in other embodiments, an external fastening element may be provided, e.g. a threaded screw or similar, that may be plugged into respective openings in the lining panels, e.g. threaded holes, thus coupling the lining panels to each other.
The disclosure herein will be explained in greater detail with reference to exemplary embodiments depicted in the drawings as appended.
The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate the embodiments of the present disclosure and together with the description serve to explain the principles of the disclosure herein. Other embodiments of the present disclosure and many of the intended advantages of the present disclosure will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. In the figures, like reference numerals denote like or functionally like components, unless indicated otherwise.
Although specific embodiments are illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.
Still referring to
The electrical connector 5 is configured to connect to the electric lines 2 of the lining panel 1 for electrically connecting this lining panel 1 to another similarly configured lining panel. Specifically, two lining panels may be formed to be joined to each other at their individual electrical connectors 5 in such a way that the electrically conductive pins 6 establish an electric contact between the electric lines 2 of both lining panels 1. This is explained in more detail with respect to
Again referring to
Still referring to
The lining panel 1 depicted in
Like this, cable connectors, electric wires and cable bundles and the like, as well as brackets and other holding components may be avoided or at least significantly reduced in number. In general, reductions in weight and space may be achieved. Electrical connectors 5 and electric lines 2 may be fully integrated into the lining panels 1 and hence the electric infrastructure is less vulnerable to mechanical or other influences or damage. Thus, not only weight, costs, installation and manufacturing efforts can be significantly lowered but also the general reliability of a lining 10 of a passenger cabin 11 can be improved.
With reference to
The method M comprises under M1′ using an automated tape placement technique to manufacture the panel body 3 of the lining panel 1. The tape placement technique may be, for example, a rapid fiber- or tape-placement process as it is known from the production of plastic components, composite preforms and/or the fabrication of fiber-reinforced composite components. The tape placement may comprise drawing tapes 14 from a tape spool 13 and placing the tapes 14 on a support surface or similar, where the tapes 14 are superimposed upon another to form a preform 15, i.e. a semi-finished component. The tapes 14 are laid down by a tape placement head 12 that presses each tape 14 onto the already placed tapes 14. The individual tapes 14 may consist of or comprise one or more layers of tape material, e.g. layers of a continuous web, such as strip or sheet material, or layers made of fabric impregnated with a curable material, like epoxy resin or the like. The individual layers of material may be essentially the same or may differ from one another depending on the specific requirements for the tape 14 and/or the lining panel 1. The person of skill will be aware that various manufacturing processes for the fabrication of plastic or composite panels may be used in the method of this embodiment of the disclosure herein. Hence, in a first method step of the embodiment, the panel body 3 may be particularly manufactured as a composite component by tape placement, e.g. by conventional tape placement methods such as laser assisted tape placement or variants thereof. The method step under M1′ may particularly comprise consolidating, curing or hardening the semi-finished component into a (fiber-reinforced) composite component to form the panel body 3.
With reference to
Referring now to
Referring now to
Hence, the embodiment of
Still referring to
In the foregoing detailed description, various features are grouped together in one or more examples or examples with the purpose of streamlining the disclosure. It is to be understood that the above description is intended to be illustrative, and not restrictive. It is intended to cover all alternatives, modifications and equivalents. Many other examples will be apparent to one skilled in the art upon reviewing the above specification.
The embodiments were chosen and described in order to best explain the principles of the disclosure herein and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure herein and various embodiments with various modifications as are suited to the particular use contemplated. Many other examples will be apparent to one skilled in the art upon reviewing the above specification.
While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a”, “an” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16 162 245.1 | Mar 2016 | EP | regional |
