CA2537945C - A resin infused transparent skin panel and method of making same - Google Patents

A resin infused transparent skin panel and method of making same Download PDF

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Publication number
CA2537945C
CA2537945C CA2537945A CA2537945A CA2537945C CA 2537945 C CA2537945 C CA 2537945C CA 2537945 A CA2537945 A CA 2537945A CA 2537945 A CA2537945 A CA 2537945A CA 2537945 C CA2537945 C CA 2537945C
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CA
Canada
Prior art keywords
metal sheet
window
preform
fiber reinforced
skin panel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA2537945A
Other languages
French (fr)
Other versions
CA2537945A1 (en
Inventor
Robert G. Albers
Paul S. Nordman
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Boeing Co
Original Assignee
Boeing Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Boeing Co filed Critical Boeing Co
Publication of CA2537945A1 publication Critical patent/CA2537945A1/en
Application granted granted Critical
Publication of CA2537945C publication Critical patent/CA2537945C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B29C43/203—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
    • B29C70/885—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding with incorporated metallic wires, nets, films or plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
    • B64C1/12—Construction or attachment of skin panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/14—Windows; Doors; Hatch covers or access panels; Surrounding frame structures; Canopies; Windscreens accessories therefor, e.g. pressure sensors, water deflectors, hinges, seals, handles, latches, windscreen wipers
    • B64C1/1476—Canopies; Windscreens or similar transparent elements
    • B64C1/1492—Structure and mounting of the transparent elements in the window or windscreen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B29L2031/3082—Fuselages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/778—Windows
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/38—Meshes, lattices or nets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/18—Titanium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/40—Weight reduction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component
    • Y10T428/24339—Keyed
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component
    • Y10T428/24339—Keyed
    • Y10T428/24347—From both sides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24364—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.] with transparent or protective coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24777—Edge feature

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)

Abstract

A transparent skin panel for use in a mobile platform having a plurality of metal sheets (26). A fiber reinforced resin (36) at least partially surrounds the plurality of metal sheets (26). The fiber reinforced resin (36) is transparent. A cutout (32) is formed within each of the plurality of metal sheets (26), which is filled by the transparent resin (36) during the manufacturing process. The cutout (32) corresponds to a window (16) in the transparent skin panel (10). The transparent skin panel thus eliminates the need for a bulky and heavy frame structure that has traditionally been employed on aircraft, and which has heretofore limited the size of windows used on an aircraft. The present invention thus enables larger windows to be incorporated on aircraft without increasing the weight or cost associated with such windows.

Description

A RESIN INFUSED TRANSPARENT SKIN PANEL AND METHOD OF MAKING
SAME

FIELD OF THE INVENTION
[0001] The present invention relates to transparent aircraft skin panels and more particularly to a resin infused transparent skin panel and method of making same particularly well adapted for use in aircraft and aerospace applications.

BACKGROUND OF THE INVENTION
[0002] Passenger windows in most commercial aircraft are relatively small in size. This is due, in part, to the limited capabilities of current transparent window materials and also due to the heavy and complex support structure needed to support these windows within the frame of the aircraft.
[0003] Typically, these transparent window materials consist of a transparent polymer. While very successful and exhibiting such useful qualities as high durability and easy formation of complex shapes, these polymer windows do have a limited strength capability.
[0004] Windows require the heavy support structure in order to support the window within the structural skin of the aircraft. This support structure generally includes window forgings, and stringers. Each component is designed to strengthen the skin panel which surrounds and supports the window.
However, each component added in turn increases the cost and weight of the completed window assembly, thereby providing an incentive to keep passenger windows relatively small.
[0005] Accordingly, it would be highly desirable to either decrease the weight of current passenger window assemblies in modern aircraft and to alternatively provide larger passenger windows.
[0006] Accordingly, it is an object of the present invention to provide a method of making a transparent skin panel for use with an aircraft that provides an integrally formed transparent window panel that is both stronger and lighter than current passenger windows.

SUMMARY OF THE INVENTION
[0007] According to one aspect there is provided a transparent skin panel forming a single pane window assembly for use in a mobile platform, comprising: at least one metal sheet having a cutout portion and a perimeter portion having a plurality of spaced apart perforations; a fiber reinforced preform disposed against the at least one metal sheet, the fiber reinforced preform being transparent; and an optically transparent resin filling the cutout portion saturating the preform, and filling the perforations to form a single pane window assembly having a transparent skin panel portion.
[0007a] According to another aspect there is provided a method of forming a structural panel suitable for use as a single pane window, comprising: using at least one metal sheet to form a frame structure, wherein the frame structure defines an opening and has a perimeter portion having a plurality of spaced apart perforations; applying a generally transparent, fiber preform against the metal sheet to cover the metal sheet and fill the opening;
and infusing the metal sheet and fiber preform with a generally optically transparent resin to saturate the preform and the perforations in the metal sheet and fill the opening to form an integrally constructed, single pane window assembly.
[0007b] According to yet another aspect there is provided a single pane window panel sufficiently strong to be used in forming a structural portion of an aircraft fuselage, the window panel comprising: a single window pane having at least one layer of optically clear, fiber reinforced material for providing an optically transparent area of the window panel; and at least one layer of metallic material disposed against a peripheral portion of the window pane to further reinforce the peripheral portion of the window pane without occluding the optically transparent area, and enabling securing of the window panel within an opening in a portion of the aircraft fuselage to form an integral portion of the fuselage.
[0007c] According to still yet another aspect there is provided a transparent skin panel forming a window assembly for use in a mobile platform and having sufficient structural strength to form a structural portion of a fuselage of the mobile platform, comprising: at least one metal sheet having a cutout portion and a perimeter portion that bounds the cutout portion; and an optically transparent fiber preform disposed against the one metal sheet, the fiber preform having an optically transparent resin so that the fiber preform forms an optically transparent and structurally rigid portion of the transparent skin panel.
[0007d] According to still yet another aspect there is provided a light weight aircraft fuselage skin panel having an array of integrated optically clear single pane window assemblies, the skin panel comprising: one metal sheet having a central cutout portion and a perimeter portion having a plurality of spaced apart perforations; a fiber reinforced preform disposed against the one metal sheet, the fiber reinforced preform extending continuously across one dimension of the metal sheet such that fibers of the fiber reinforced preform reinforce the skin panel along a periphery of the central cutout portion; a portion of the metal sheet at least partially covering the preform and forming a portion of an outer surface of at least one of the window assemblies; and a resin filling the cutout portion saturating the preform and filling the perforations in the metal sheet to form an unitary optically clear fiber reinforced window assembly having an optically transparent skin panel portion exhibiting a resin bonded integrated structure that substantially reduces a weight of said optically clear, fiber reinforced window assembly.
10007e] According to still yet another aspect there is provided a light weight aircraft fuselage skin panel having an array of integrated, optically clear single pane window assemblies, the skin panel comprising: a first metal sheet having a plurality of central cutout portions, each said cutout portion having a perimeter portion; each said perimeter portion having a plurality of spaced apart perforations spaced circumferentially therearound; a fiber reinforced preform disposed against the first metal sheet, the fiber reinforced preform extending continuously across one dimension of the first metal sheet such that fibers of the fiber reinforced preform reinforce the skin panel along each said perimeter portion of each said central cutout portion; a portion of the first metal sheet at least partially covering the fiber reinforced preform and 2a forming a portion of an outer surface of each said window assembly; and an optically transparent resin filling each of the central cutout portions and saturating the fiber reinforced preform, and filling the perforations in each said perimeter portion of the first metal sheet, to form an integrated, unitary skin panel having a plurality of optically clear, fiber reinforced window assemblies longitudinally spaced apart from one another that substantially reduces a weight of said skin panel while providing a needed level of structural strength.
[0008] Further areas of applicability of the present Invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0010] Figure 1 is a partial view of a front of an aircraft having a transparent skin panel constructed according to the principles of the present invention;
[0011] Figure 2 is a side cross sectional view of the transparent skin panel taken in the direction of arrow 2-2 in Figure 1;
[0012] Figure 3 is an exploded perspective view of the materials used to construct the transparent skin panel of Figure 2; and 2b [0013] Figure 4 is a cross sectional view of a portion of the transparent skin panel of Figure 2 illustrating the layering and resin flow during the construction of the transparent skin panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0015] Referring to Figure 1, there is illustrated a transparent skin panel 10 constructed according to the principles of the present invention shown mounted to an aircraft 12. The transparent skin panel 10 includes a skin portion 14 and a window portion 16. While in the particular example provided the transparent skin panel 10 is illustrated as including a side window of the aircraft 12, it is to be understood that the transparent skin panel 10 may be used in any portion of the aircraft 12 and may include a cockpit window, a side window, a door, or an unbroken surface.
[0016] With reference to Figure 2, the transparent skin panel 10 is coupled to the structural frame component (not shown) of the aircraft 12. Skin portion 14 includes a plurality of metal sheets 20 and a fiber reinforced resin 22.
The metal sheets 20 are suspended within the fiber reinforced resin 22. In the particular example provided, three metal sheets 20 are illustrated. It is to be understood, however, that a greater or lesser number of metal sheets 20 may be used as are desired. Moreover, while the metal sheets 20 are illustrated as spaced on each side of the fiber reinforced resin 22 and within the fiber reinforced resin 22, the metal sheets 20 may be located anywhere within the fiber reinforced resin 22, as will be described in greater detail below.
[0017] The window portion 16 is preferably comprised solely of the fiber reinforced resin 22. The fiber reinforced resin 22 is transparent for allowing viewing therethrough as will be described in greater detail below.
[0018] Turning now to Figure 3, the method of constructing the transparent skin panel 10 will now be described. A mold 24 is provided, illustrated schematically in Figure 3, capable of receiving the components of the transparent skin panel 10. The mold 24 has a cavity (not shown) shaped to form the outer surface of the transparent skin panel 10. This shape, while illustrated as essentially rectangular and flat in Figures 1 and 2, may be any shape as required by the contour of the aircraft 12, for example round and curved.
[0019] A plurality of metal sheets 26 and a plurality of fiber preforms 28 are then provided. The metal sheets 26 include a plurality of perforations 30 formed therethrough. The perforations 30 are illustrated as circular although any size or shape may be employed. Each metal sheet 26 includes a cutout 32 in the center thereof. The cutout 32 in each metal sheet 26 corresponds to the window portion 16 of the assembled transparent skin panel 10. Again, while the cutout 32 is illustrated as circular, it may be of any shape including for example oval or rectangular. The metal sheets 26 are preferably made of aluminum due to its light weight and high strength, although various other metals may be employed including, for example, titanium.
[0020] The fiber preforms 28 each include a plurality of fibers 34 woven together to form a fiber mesh. The orientation of the plies is based on the desired directional strength of the resulting structure and may have unidirectional or bi-directional strength (e.g. the fibers 34 may run either in one direction (not shown) or two directions).
[0021] The metal sheets 26 and fiber preforms 28 are then inserted into the mold 24 in an order corresponding to the desired order of sheets in the transparent skin panel 10. In the particular example provided, the metal sheets 26 alternate with double layers of the fiber preforms 28.
[0022] The mold 24 is then either closed, or a vacuum bag is applied and a resin is infused into the mold using a process such as Controlled Atmospheric Pressure Resin Infusion (CAPRI), Seemann Composite Resin Infusion Molding Process (SCRIMPTM), Vacuum Assisted Resin Transfer Molding (VARTM), Resin Transfer Molding (RTM), or Resin Film Infusion (RFI). Other suitable methods of infusing resin into the mold 24 not listed herein may also be employed.
[0023] As best seen in Figure 4, the resin, indicated by reference numeral 36, flows in the direction of the arrows through the perforations 30.
The resin 36 moves through the fiber preforms 28, thereby fully wetting (e.g.
fully covering and saturating) the fibers 34. The transparent skin panel 10 is then cured over a period of time until the resin 36 hardens. The mold 24 is then opened and the transparent skin panel 10 removed. The metal sheets 26 correspond to the metal sheets 20 (Figure 2) and the resin 36 and fiber preforms 28 correspond to the fiber reinforced resin 22 (Figure 2).
[0024] Preferably the resin is an aliphatic epoxy which is resistant to ultraviolet degradation. However, other alternate resin materials may be employed. To impart transparency, the resin 36 is transparent and the fibers substantially transparent within the transparent skin panel 10. The index of refraction of the fibers 34 is matched to the index of refraction of the resin 36. In this way, the transparent skin panel 10 is fully transparent in the areas of the cutouts 32 in the metal sheets 26.
[0025] By integrally forming the transparent reinforced resin 22 with the metal sheets 20, a solid and high strength transparent skin panel 10 is provided.
Simultaneously, the heavy support structure typically used to frame aircraft windows is substantially eliminated, thus reducing the weight of the aircraft.
This in turn allows for larger windows to be employed, if desired, without increasing the cost and weight of the aircraft.
[0026] While the present invention has been described in connection with aircraft windows, it will be appreciated that the invention can be incorporated on other forms of mobile platforms such as buses, trains, ships, etc., where composite panels may be employed, or even on fixed structures where lightweight windows are needed.
[0027] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims (22)

1. A transparent skin panel forming a single pane window assembly for use in a mobile platform, comprising:
at least one metal sheet having a cutout portion and a perimeter portion having a plurality of spaced apart perforations;
a fiber reinforced preform disposed against the at least one metal sheet, the fiber reinforced preform being transparent; and an optically transparent resin filling the cutout portion saturating the preform, and filling the perforations to form a single pane window assembly having a transparent skin panel portion.
2. The transparent skin panel of claim 1, wherein the metal sheet is comprised of aluminum.
3. The transparent skin panel of claim 1, wherein the metal sheet is comprised of titanium.
4. The transparent skin panel of claim 1, wherein the fiber reinforced preform fully covers the at least one metal sheet.
5. The transparent skin panel of claim 1, wherein the fiber reinforced preform includes a plurality of fiber mesh sheets one atop the other.
6. A method of forming a structural panel suitable for use as a single pane window, comprising:
using at least one metal sheet to form a frame structure, wherein the frame structure defines an opening and has a perimeter portion having a plurality of spaced apart perforations;
applying a generally transparent, fiber preform against the metal sheet to cover the metal sheet and fill the opening; and infusing the metal sheet and fiber preform with a generally optically transparent resin to saturate the preform and the perforations in the metal sheet and fill the opening to form an integrally constructed, single pane window assembly.
7. The method of claim 6, wherein applying the generally transparent, fiber reinforced resin includes applying an aliphatic epoxy resin.
8. The method of claim 6, wherein using at least one metal sheet comprises using an aluminum sheet.
9. The method of claim 6, wherein applying a generally transparent, fiber reinforced resin comprises applying an aliphatic epoxy resin having a weave of fibers, wherein the fibers have an index of refraction matching an index of refraction of the resin.
10. The method of claim 6, wherein applying a generally transparent, fiber reinforced resin comprises applying an aliphatic epoxy resin.
11. A single pane window panel sufficiently strong to be used in forming a structural portion of an aircraft fuselage, the window panel comprising:
a single window pane having at least one layer of optically clear, fiber reinforced material for providing an optically transparent area of the window panel; and at least one layer of metallic material disposed against a peripheral portion of the window pane to further reinforce the peripheral portion of the window pane without occluding the optically transparent area, and enabling securing of the window panel within an opening in a portion of the aircraft fuselage to form an integral portion of the fuselage.
12. The window panel of claim 11, wherein the layer of fiber reinforced material and the layer of metallic material are integrally formed to form the single window pane.
13. The window panel of claim 11, wherein the window panel is structurally integrated with the fuselage to form an integral, load bearing portion of the fuselage.
14. The window panel of claim 11, wherein the window pane forms a high strength window pane.
15. The window panel of claim 11, the window pane having a first side and a second side, the first side being exposed to cabin air within a cabin of the aircraft, and the second side being exposed to ambient air outside the aircraft.
16. A transparent skin panel forming a window assembly for use in a mobile platform and having sufficient structural strength to form a structural portion of a fuselage of the mobile platform, comprising:
at least one metal sheet having a cutout portion and a perimeter portion that bounds the cutout portion; and an optically transparent fiber preform disposed against the one metal sheet, the fiber preform having an optically transparent resin so that the fiber preform forms an optically transparent and structurally rigid portion of the transparent skin panel.
17. The transparent skin panel of claim 16, the one metal sheet being integrally formed with the optically transparent fiber preform to form a single piece, integrated assembly.
18. A light weight aircraft fuselage skin panel having an array of integrated optically clear single pane window assemblies, the skin panel comprising:
one metal sheet having a central cutout portion and a perimeter portion having a plurality of spaced apart perforations;
a fiber reinforced preform disposed against the one metal sheet, the fiber reinforced preform extending continuously across one dimension of the metal sheet such that fibers of the fiber reinforced preform reinforce the skin panel along a periphery of the central cutout portion;
a portion of the metal sheet at least partially covering the preform and forming a portion of an outer surface of at least one of the window assemblies; and a resin filling the cutout portion saturating the preform and filling the perforations in the metal sheet to form an unitary optically clear fiber reinforced window assembly having an optically transparent skin panel portion exhibiting a resin bonded integrated structure that substantially reduces a weight of said optically clear, fiber reinforced window assembly.
19. The skin panel of claim 18, further comprising-a second metal sheet covering the opposite side of the preform forming a portion of the outer surface of the at least one window assembly having an integrated metalpreform-metal cross section construction.
20. The skin panel of claim 19, further comprising:
a second fiber reinforced preform disposed against a second metal sheet; and a third metal sheet disposed between the first and second metal sheets and forming a portion of the at least one window assembly having an integrated metal-preform-metal-preform-metal cross section.
21. The skin panel of claim 18, further comprising:
at least two window panes longitudinally spaced apart.
22. A light weight aircraft fuselage skin panel having an array of integrated, optically clear single pane window assemblies, the skin panel comprising:
a first metal sheet having a plurality of central cutout portions, each said cutout portion having a perimeter portion;
each said perimeter portion having a plurality of spaced apart perforations spaced circumferentially therearound;

a fiber reinforced preform disposed against the first metal sheet, the fiber reinforced preform extending continuously across one dimension of the first metal sheet such that fibers of the fiber reinforced preform reinforce the skin panel along each said perimeter portion of each said central cutout portion;
a portion of the first metal sheet at least partially covering the fiber reinforced preform and forming a portion of an outer surface of each said window assembly; and an optically transparent resin filling each of the central cutout portions and saturating the fiber reinforced preform, and filling the perforations in each said perimeter portion of the first metal sheet, to form an integrated, unitary skin panel having a plurality of optically clear, fiber reinforced window assemblies longitudinally spaced apart from one another that substantially reduces a weight of said skin panel while providing a needed level of structural strength.
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PCT/US2004/028549 WO2005056383A2 (en) 2003-09-04 2004-09-02 A resin infused transparent skin panel and method of making same

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EP1663776A2 (en) 2006-06-07
US7968170B2 (en) 2011-06-28
US7300693B2 (en) 2007-11-27
WO2005056383A2 (en) 2005-06-23
US20070034743A1 (en) 2007-02-15
EP1663776B1 (en) 2012-11-07
JP4638434B2 (en) 2011-02-23
US20050053765A1 (en) 2005-03-10
US20080131661A1 (en) 2008-06-05
US7651756B2 (en) 2010-01-26
CA2537945A1 (en) 2005-06-23
WO2005056383A3 (en) 2005-12-08
WO2005056383A9 (en) 2005-08-11

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