Active composite panel assemblies, systems, and methods

An active composite panel assembly is configured to transfer electrical signals from a source to an electrical device. The active composite panel assembly includes a composite layer, and an active layer secured to the composite layer. The active layer is configured to receive and conduct the electrical signals.

FIELD OF THE DISCLOSURE

Embodiments of the present disclosure generally relate to composite panel assemblies, and more particularly, to active composite panel assemblies, systems, and methods that are configured to transfer electrical signals (such as power and/or data signals) to electrical devices.

BACKGROUND OF THE DISCLOSURE

In various applications, electrical signals (such as power and/or data signals) are transferred from a source to one or more electrical devices. For example, an interior cabin of an aircraft includes numerous signs, displays, and the like that receive power and/or data signals in order to operate.

Typically, an electrical device secured within an internal cabin of an aircraft is connected to surface mounted or embedded electrical wiring. In short, the electrical device is connected to a source of power or data through wiring, circuits, conduits, raceways, and/or the like. Wiring is typically routed from the electrical device to the source. In general, wiring is routed to and connected to each electrical device within an internal cabin. In some instances, portions of panels are removed to accommodate and route wiring to devices mounted on the panels.

As can be appreciated, in order to accommodate the various electrical devices onboard an aircraft, large amounts of electrical wiring may be used. During manufacture of the aircraft, the processes of connecting the electrical devices to the wiring, and routing the wiring through the aircraft are typically time and labor intensive. Moreover, the wiring, associated routing infrastructure, and attachment hardware add weight and complexity to the aircraft, which may decrease fuel efficiency during operation.

SUMMARY OF THE DISCLOSURE

A need exists for a system and method for efficiently connecting electrical devices to a source, such as a power and/or data source. A need exists for a system and method for reducing the amount of electrical wiring and/or circuit boards within a structure, device, component, vehicle, such as an aircraft, and/or the like.

With those needs in mind, certain embodiments of the present disclosure provide an active composite panel assembly that is configured to transfer electrical signals from a source to an electrical device. The active composite panel assembly includes a composite layer, and an active layer secured to the composite layer. The active layer is configured to receive and conduct the electrical signals.

The active layer may include one or more of a conductive nano-grid arranged in a pattern, conductive nano-wires, conductive nano-particles, conductive fibers, thin film transistors, switches, conductive films, conductive filaments, conductive strands, and/or the like.

A conductive substrate may be secured to the active layer opposite from the composite layer. A cover may be positioned over the active layer. The cover may be formed of one or more of laminate, plastic, or glass. In at least one embodiment, a channel is formed through the cover. The channel may be sized and shaped to receive at least a portion of the electrical device.

In at least one embodiment, the active composite panel assembly includes the electrical device, which is electrically coupled to the active layer. The electrical device may be embedded within the active composite panel assembly. In at least one other embodiment, the electrical device is mounted onto a portion of the active composite panel assembly.

The active composite panel assembly may also include a signal transfer medium that extends through a portion of the composite layer and couples the active layer to one or both of an electrical connector or an electrical source.

Certain embodiments of the present disclosure provide a method of forming an active composite panel assembly that is configured to transfer electrical signals from a source to an electrical device. The method includes providing a composite layer, and securing an active layer to the composite layer. The active layer is configured to receive and conduct the electrical signals.

The method may also include securing a conductive substrate to the active layer opposite from the composite layer. The method may also include positioning a cover over the active layer. In at least one embodiment, the method may include forming a channel through the cover.

The method may include positioning the electrical device on or in the active composite panel assembly, and electrically coupling the electrical device to the active layer. The positioning operation may include embedding the electrical device within the active composite panel assembly. In at least one other embodiment, the positioning operation includes mounting the electrical device onto a portion of the active composite panel assembly.

The method may include positioning a signal transfer medium through a portion of the composite layer, coupling the active layer to the signal transfer medium, and coupling the signal transfer medium to one or both of an electrical connector or an electrical source.

DETAILED DESCRIPTION OF THE DISCLOSURE

Certain embodiments of the present disclosure provide an active composite panel assembly that includes an active layer that is configured to conduct electrical signals, such as power and data signals. The active layer provides an actively charged or otherwise conductive layer within the active composite panel assembly, which allows for the placement of electrical devices to be connected to the panel and receive the electrical signals. In at least one embodiment, the active layer may include a matrix layer that may be mapped to detect resistances on the surface of the active composite panel assembly. The resistances may be controlled with a logic map to control transmission of the electrical signals to the electrical device. In at least one embodiment, the active layer may include an active matrix layer that may be mapped with an internal or external logic controller that determines, directs, and/or controls the electrical signals to a discrete location or electrical device.

Embodiments of the present disclosure provide systems, methods, and assemblies that eliminate, minimize, or otherwise reduce hidden wiring within composite panels. Embodiments of the present disclosure are configured to replace, eliminate, minimize, or otherwise reduce wiring that would otherwise be routed through a composite panel, for example.

Embodiments of the present disclosure provide systems, methods, and assemblies that may eliminate, minimize, or otherwise reduce hard wire, circuits, conduits, and/or the like within a composite panel. An electrical device may be connected to an active composite panel assembly such that electrical contacts of the device are coupled to an active layer, thereby allowing electrical signals to be transferred to the device.

The active layer of the active composite panel assembly is used to transport or otherwise transfer electrical signals, such as power and/or data signals, to an electrical device coupled to the active composite panel assembly. In at least one embodiment, the active composite panel assembly includes an active layer (such as an active matrix) that is configured to transport electrical signals. The active composite panel assembly may also include a connector (such as a power and/or data connector) and a signal transfer medium (such as a flat cable, wire, or the like) that couples the connector to the active layer. A cover (such as a laminate, glass layer, or the like) may be positioned over the active layer.

FIG. 1is a diagrammatic representation of a perspective exploded front view of an active composite panel assembly100, according to an embodiment of the present disclosure. The active composite panel assembly100includes a composite layer102and an active layer104. The active layer104may be positioned over (or under) the composite layer102. In at least one embodiment, the active layer104may cover an entire upper surface106of the composite layer102. Optionally, the active layer104may cover less than the entire upper surface106.

The active layer104may be secured to the composite layer102through a conductive adhesive, for example. In at least one other embodiment, the active layer104may be secured to the composite layer102through one or more conductive fasteners. In at least one other embodiment, the active layer104may be positioned over the composite layer102and encapsulated or otherwise covered with a securing film, wrap, adhesive, or the like having at least a portion that is conductive.

A signal transfer medium (not shown inFIG. 1) may extend through a portion of the composite layer102. For example, the signal transfer medium may be ribbon cable that linearly extends through the composite layer102from a bottom surface to a top surface (or vice-versa). The signal transfer medium couples the active layer104to a connector, such as a power and/or signal connector, which electrically connects the active composite panel assembly100to a source, such as a power source and/or data source. In at least one other embodiment, the signal transfer medium couples the active layer104directly to the source without a separate and distinct connector.

The composite layer102may include a core108sandwiched between opposed first and second skins110and112. The core108may include a plurality of interconnected honeycomb cells111. In at least one other embodiment, the core may be a solid layer or porous foam layer. The core108may be formed of aramid fibers, and/or polyamides, for example. The first and second skins110and112may be or include one or more pre-impregnated epoxy resin layers that include fibers, such as fiberglass, graphite, Kevlar, and/or the like. The first and second skins110and112may be identical to one another. In at least one other embodiment, the first and second skins110and112may include more or less layers than one another.

The active layer104may be or include one or more sheets of a conductive nano-grid arranged in a pattern, conductive nano-wires, conductive nano-particles, conductive fibers, thin film transistors, switches, conductive films, conductive filaments, conductive strands, and/or other types of substrates that are configured to allow electrical signals to be transferred therethrough. In at least one embodiment, the active layer104may be a sheet, panel, or other such substrate that includes silver nano-wires, conductive filaments, thin film transistors, and/or the like. When connected to a source of electrical power, the entire active layer104may be energized. The power signals may be transferred from a power source through the active layer104. In a similar manner, data signals may be transferred through the active layer104. In at least one embodiment, the active layer104may include defined areas, such as grids, cells, transistors, switches, and/or the like, in which electrical signals may be routed through a control unit. For example, electrical signals (such as power and/or data signals) may be controlled and delivered to various distinct locations of the active layer104.

As shown, the active layer104is positioned over the composite layer102. In at least one other embodiment, the active layer104may be positioned under or to a side of the composite layer102. That is, the orientation of the active composite panel assembly100shown inFIG. 1may be inverted, rotated, and/or the like.

A conductive substrate114may be positioned over the active layer104opposite from the composite layer102. The conductive substrate114may be or include one or more sheets of conductive material that allow electrical signals to pass therethrough. As shown, the active layer104may be sandwiched between the composite layer102and the conductive substrate114. In at least one other embodiment, the active composite panel assembly100may not include the conductive substrate114.

An electrical device116is positioned over the conductive substrate114. The electrical device116may include one or more conductive contacts118(such as conductive pins, tails, plugs, leads, or other such electrical contacts) that conductively connect to the conductive substrate114. Optionally, as noted above, the active composite panel assembly100may not include the conductive substrate114, in which case the contacts118may conductively and directly connect to the active layer104.

As shown, the electrical device116may be embedded within the active composite panel assembly100. In at least one other embodiment, the electrical device116may be mounted onto the active composite panel assembly100. In at least one other embodiment, the electrical device116may be coupled to the active composite panel assembly100, such as through a cable, for example.

The electrical device116may be or include one or more lights (such as light emitting diodes), a graphic or video display (such as an organic light emitting diode panel, sheet, screen or the like), an audio device (such as one or more speakers), an electrical connector (such as an outlet into which another electrical device may connect to, such as through a plug), a heater, a cooling unit, and/or the like.

The active composite panel assembly100may also include a cover120positioned over the electrical device116. The cover120may be a laminate sheet, for example. In at least one embodiment, the cover120may be a decorative laminate sheet that covers the electrical device. In at least one other embodiment, the cover120may be a sheet of plastic, glass, Plexiglas, and/or the like. Alternatively, the active composite panel assembly100may not include the cover120.

The active composite panel assembly100may be shaped as a flat, planar piece, as shown inFIG. 1. It is to be understood, however, that the active composite panel assembly100may be shaped as various other shapes, such as those having bends, cants, curves, and/or the like. For example, the active composite panel assembly100may be shaped as a tubular or semi-tubular structure. The active composite panel assembly100may be regularly or irregularly shaped.

The components of the active composite panel assembly100may be securely sandwiched together through one or more adhesives, fasteners, wraps, films, and/or the like.

In operation, electrical signals (such as power and/or data signals) are transferred to the active composite panel assembly100from a source. The electrical signals are transferred to the active layer104through the signal transfer medium (not shown inFIG. 1) that extends through a portion of the composite layer102. Optionally, the signal transfer medium may be positioned around a portion of the composite layer102(instead of passing therethrough). Because the active layer104is conductive, the active layer104allows the electrical signals to pass. When coupled to a source of electrical power, for example, the entire active layer104may be energized and conduct the electrical signals. The electrical signals are transferred to the electrical device116through the active layer104. In this manner, the electrical device116may be powered and/or data signals transferred therethrough without the use of a plurality of wires and conduits being routed through and/or secured on the composite layer102.

FIG. 2is a diagrammatic representation of a lateral exploded view of the active composite panel assembly100, according to an embodiment of the present disclosure. As shown, the signal transfer medium122may extend through the composite layer102and electrically couple the active layer104to a connector124. Optionally, the signal transfer medium122may extend around an outer portion (such as an edge) of the composite layer102. The signal transfer medium122may be or include a flat wire harness or flat cable (such as ribbon wire). In at least one other embodiment, the signal transfer medium122may be or include one or more wires, cables, or the like. The connector124may be a power or data connector that couples the active composite panel assembly100to a source126, such as a power source and/or a data source (for example, a computer, one or more processors, and/or the like). For example, the connector124may be an outlet or plug that removably couples to a reciprocal component that connects to the source126. In at least one other embodiment, the signal transfer medium122may directly connect to the source126without the separate and distinct connector124.

As shown, the electrical device116may be embedded within the active composite panel assembly100. The electrical device116may include more or less conductive contacts118than shown. The contacts118may be pins, plugs, and/or the like. In at least one other embodiment, the electrical device116may not include separate and distinct contacts, but may be configured to receive electrical signals from the active layer104by being in close proximity thereto, such as by abutting into a surface of the active layer104.

Optionally, the electrical device116may be mounted on the active composite panel assembly100, such as over the cover120. In at least one other embodiment, the electrical device116may be remotely located from the active composite panel assembly100, and connected thereto through a cable, for example.

FIG. 3is a diagrammatic representation of a perspective exploded front view of the active composite panel assembly100, according to an embodiment of the present disclosure. In this embodiment, a channel130is formed through the cover120to expose a portion of the active layer104. An electrical device (not shown inFIG. 1) may mount to the active composite panel assembly100such that contacts are coupled to the active layer104(and/or a conductive substrate) through the channel130.

The channel130may be sized and shaped to accommodate an electrical device of a specific size and shape. For example, the electrical device may be a light panel, and the channel130may be sized to allow the light panel to fit therein. The channel130may be formed of various shapes and sizes other than shown. Further, additional channels may be formed through the cover120.

The electrical device may be securely mounted to the active composite panel assembly100through adhesives, fasteners, and/or the like. Optionally, the electrical device may be securely mounted to the active composite panel assembly100by way of the contacts of the electrical device being retained within reciprocal members (such as plated conductive through-holes) formed through the conductive substrate114(shown inFIGS. 1 and 2) and/or the active layer104. In at least one other embodiment, a conductive adhesive may be applied between interfacing surfaces of the electrical device and the active layer104.

FIG. 4is a diagrammatic representation of a perspective exploded front view of the active composite panel assembly100, according to an embodiment of the present disclosure. In this embodiment, in addition to the channel130being formed through the cover130, a passage140may be formed through the active layer104and the composite layer102. The passage140is configured to accommodate a signal transfer medium, a connector, a structural portion of an electrical device, and/or the like. The composite panel assembly100may include additional passages formed therethrough. Further, the passage140may be smaller or larger than shown.

Referring toFIGS. 1-4, the active composite panel assembly100may be secured within or on various structures. For example, an internal cabin of a vehicle, such as a commercial aircraft, may include numerous active composite panel assemblies100, such as on walls, ceilings, floors, monuments, barriers, and/or the like. Further, the active composite panel assembly100may be used on exterior surfaces of a vehicle, such as on or within wings, outer surfaces of fuselages, cargo panels, engines, and/or the like. Further, the active composite panel assembly100may be used on or within fixed structures, such as buildings (residential and commercial), and/or the like. For example, a plurality of composite panel assemblies100may form walls, ceilings, floors, partitions, dividers, and the like within various structures. As such, the portions of the structures may be configured to transfer electrical signals to electrical devices coupled thereto.

FIG. 5is a diagrammatic representation of a front view of an aircraft210(or aircraft assembly), according to an embodiment of the present disclosure. The aircraft210includes a propulsion system212that may include two turbofan engines214, for example. Optionally, the propulsion system212may include more engines214than shown. The engines214are carried by wings216of the aircraft210. In other embodiments, the engines214may be carried by a fuselage218and/or an empennage220. The empennage220may also support horizontal stabilizers222and a vertical stabilizer224.

The fuselage218of the aircraft210defines an internal cabin, which may include a cockpit, one or more work sections (for example, galleys, personnel carry-on baggage areas, and the like), and one or more passenger sections (for example, first class, business class, and coach sections). Each of the sections may be separated by a cabin transition area, which may include one or more class divider assemblies. Overhead stowage bin assemblies may be positioned throughout the internal cabin. Various exterior portions of the aircraft210, such as exterior portions shown and/or interior portions within an internal cabin, may be formed of one or more active composite panel assemblies100(shown inFIGS. 1-4).

FIG. 6Ais a diagrammatic representation of a top plan view of an internal cabin230of an aircraft, according to an embodiment of the present disclosure. The internal cabin230may be within a fuselage232of the aircraft. For example, one or more fuselage walls may define the internal cabin230. The internal cabin230includes multiple sections, including a front section233, a first class section234(or first class suites, cabins, for example), a business class section236, a front galley station238, an expanded economy or coach section240, a standard economy or coach section242, and an aft section244, which may include multiple lavatories and galley stations. It is to be understood that the internal cabin230may include more or less sections than shown. For example, the internal cabin230may not include a first class section, and may include more or less galley stations than shown. Each of the sections may be separated by a cabin transition area246, which may include class divider assemblies between aisles248.

As shown inFIG. 6A, the internal cabin230includes two aisles250and252that lead to the aft section244. Optionally, the internal cabin230may have more or less aisles than shown. For example, the internal cabin230may include a single aisle that extends through the center of the internal cabin230that leads to the aft section244.

FIG. 6Bis a diagrammatic representation of a top plan view of an internal cabin280of an aircraft, according to an embodiment of the present disclosure. The internal cabin280may be within a fuselage281of the aircraft. For example, one or more fuselage walls may define the internal cabin280. The internal cabin280includes multiple sections, including a cockpit289, a main cabin282having passenger seats283, and an aft section285behind the main cabin282. It is to be understood that the internal cabin280may include more or less sections than shown.

The internal cabin280may include a single aisle284that leads to the aft section285. The single aisle284may extend through the center of the internal cabin280that leads to the aft section285. For example, the single aisle284may be coaxially aligned with a central longitudinal plane of the internal cabin280.

Referring toFIGS. 6A and 6B, various portions within an internal cabin of an aircraft may be formed of one or more active composite panel assemblies100(shown inFIGS. 1-4). For example, interior walls that define the internal cabin may be formed of one or more active composite panel assemblies100. Portions of seats within the internal cabin may be formed of one or more active composite panel assemblies100. Doors of the aircraft may be formed of one or more active composite panel assemblies. Portions of a floor within the internal cabin may be formed of one or more active composite panel assemblies100.

Alternatively, instead of an aircraft, embodiments of the present disclosure may be used with various other vehicles, such as automobiles, buses, locomotives and train cars, watercraft, spacecraft, and the like. Further, embodiments of the present disclosure may be used with various structures, devices, components, and the like other than vehicles. For example, embodiments of the present disclosure may be used to form walls, floors, ceilings, and/or the like within fixed structures, such as residential and commercial buildings.

FIG. 7is a diagrammatic representation of a passenger area300within an internal cabin302of an aircraft, according to an embodiment of the present disclosure. The passenger area300may include a plurality of seats304, walls306, monuments308, and the like. Overhead stowage bins310may be positioned over portions of the seats304. At least portions of each of the seats304, walls306, monuments308, stowage bins310, and the like may be formed of one or more active composite panel assemblies100(shown inFIGS. 1-4).

FIG. 8is a diagrammatic representation of an attendant seating area400within an internal cabin402of an aircraft, according to an embodiment of the present disclosure. An overhead exit sign404may be positioned above an aisle405. The overhead exit sign404may be formed of one or more active composite panel assemblies100(shown inFIGS. 1-4). The exit sign404may include a graphic cover406having exit indicia408. An electrical device in the form of one or more light emitting diodes may be positioned behind the graphic cover406. The light emitting diodes may be receive power signals through one or more active layers, as described with respect toFIG. 4.

FIG. 9is a diagrammatic representation of a door500within an internal cabin502of an aircraft, according to an embodiment of the present disclosure. An exit sign504may be formed of one or more active composite panel assemblies100(shown inFIG. 4).

FIG. 10is a diagrammatic representation of an overhead stowage bin600within an internal cabin602of an aircraft, according to an embodiment of the present disclosure. The stowage bin600may be formed of one or more active composite panel assemblies100(shown inFIGS. 1-4), such that an electronic latch604is the electrical device.

FIG. 11is a diagrammatic aft view of passenger seats700within an internal cabin702of an aircraft, according to an embodiment of the present disclosure. Aft supports704of the seats700may be formed of one or more active composite panel assemblies100(shown inFIGS. 1-4), such that a video monitor706is the electrical device.

FIG. 12illustrates a flow chart of a method of forming an active composite panel assembly, according to an embodiment of the present disclosure. The method begins at800, in which an active layer is positioned on a surface of a composite layer. At802, the active layer is secured to the composite layer, such as through adhesives, fasteners, and/or the like. At804, a conductive substrate is secured onto a surface of the active layer that is opposite from the composite layer. Optionally,804may be omitted. At806, an electrical device is coupled to the active layer. For example, the electrical device may be embedded within the active composite panel assembly, such as by being positioned between the active layer and a cover. In at least one other embodiment, the electrical device may be mounted onto the active composite panel assembly, or connected thereto with a cable, for example.

In at least one embodiment, the active composite panel assembly100may be integrally formed. For example, the components of the active composite panel assembly100are integrally formed together. As an example,800,802,804, and806may occur concurrently, or have portions that occur concurrently. In at least one other embodiment, the800,802,804, and806may occur sequentially, as shown. The active matrix layer104, the conductive substrate114, the laminate120, and the like may be secured to the composite layer102subsequently to the composite layer102first being produced.

As described above, embodiments of the present disclosure provide systems and methods that efficiently connect electrical devices to a source, such as a power and/or data source. Further, embodiments of the present disclosure provide systems and methods that reduce the amount of electrical wiring and/or circuit boards within a structure or vehicle, for example.