Patent Description:
Commercial airlines typically provide in-flight entertainment, safety notices, and other valuable information in the passenger cabin using static or programmable displays. Conventional static and programmable displays may include retractable display screens, passenger service units, display screens mounted in seat backs, or permanent placards. Static displays may only display a single image. As an example, a conventional backlit fasten seat belt sign in a commercial aircraft may be considered a static display. Programmable displays may be used to display a variety of images. For example, a retractable display screen in an aircraft that displays safety videos and in-flight entertainment may be considered a programmable display.

Conventional static and programmable displays on commercial aircraft may be undesirable in at least one of weight, bulk, number, efficiency, or connection complexity. For example, connecting a fasten seat belt sign may add manufacturing steps and time. Also, the fasten seat belt sign assembly may add weight to the aircraft. Connections and wiring for the fasten seat belt sign may also be more complex or heavier than desired. The bulk of a fasten seat belt sign assembly may be undesirable and may use additional fastening means for securing the fasten seat belt sign assembly.

Seat labeling and other location-flexible placards are currently not illuminated. It may be difficult to view the content of the placards under some lighting conditions or for some passengers.

One issue may be to reduce the bulk or weight of a display. Another issue may be to reduce or eliminate additional manufacturing steps for installing displays. A further issue may be to provide a cost efficient and weight efficient method of providing illuminated placards for conventionally non-illuminated placards.

<CIT> states, according to its abstract, a composite structural member with an integrated electrical circuit is provided. The structural member includes a plurality of layers of structural reinforcement material, and two or more electrical devices are disposed at least partially between the layers with an intermediate layer of the structural reinforcement material disposed between the electrical devices. At least one electrical bus is disposed in the structural member, and each electrical device is connected to the bus by a conductive electrode. Thus, the electrodes can extend through the intermediate layer of the structural reinforcement material to connect each of the electrical devices to one or more of the buses.

<CIT> states, according to its abstract, a carbon fiber shell is used to change the appearance or look of a vehicle, such as a motorcycle, and is formed to be non-permanently installed over an existing vehicle component to customize the appearance of a vehicle while still being removable. The carbon fiber shell is molded to match the contours or the shape of the original vehicle component so that, when installed, the shell has the same contours and thus the same physical shape as the original vehicle component. Moreover, the carbon fiber shell is configured to be mounted onto the vehicle using existing mounting brackets, holes or other structure on the vehicle that is provided to mount or secure the original vehicle component, thereby eliminating the need to drill holes into, or apply glue or other adhesives to the original vehicle component. This feature additionally allows the carbon fiber shell to be removed in the same manner as the original vehicle component. The carbon fiber shell may also incorporate lighting effects and may be ordered via a system for customizing the vehicle.

According to an aspect, there is provided a multilayer panel with an embedded light source according to claim <NUM>.

An illustrative example of the present disclosure provides a method. A first electrode and a second electrode are associated with a first layer of material. A light source is positioned in electrical communication with the first electrode and the second electrode. An assembly comprising the first layer of material, the first electrode, the second electrode, and the light source is processed to form a multilayer panel with an embedded light source.

Another illustrative example of the present disclosure provides a multilayer panel with an embedded light source. The multilayer panel comprises a first electrode, a second electrode, a light source, and a second layer of material. The first electrode is associated with a first layer of material. The second electrode is associated with the first layer of material. The light source is in electrical communication with the first electrode and the second electrode. The second layer of material is overlying the first layer of material and the light source.

A further illustrative example of the present disclosure provides an aircraft. The aircraft comprises a multilayer panel with an embedded light source and a controller. The multilayer panel comprises a first electrode associated with a first layer of material, a second electrode associated with the first layer of material, a light source in electrical communication with the first electrode and the second electrode, and a second layer of material overlying the first layer of material and the light source. The controller is in communication with the light source.

A yet further illustrative example of the present disclosure provides a multilayer panel with an embedded light source. The multilayer panel with the embedded light source comprises a first layer of composite material, a light source, and a second layer of composite material. The light source is positioned relative to the first layer of composite material. The second layer of composite material overlies the first layer of composite material and the light source.

The features and functions can be achieved independently in various examples of the present disclosure or may be combined in yet other examples in which further details can be seen with reference to the following description and drawings.

The novel features believed characteristic of the illustrative examples are set forth in the appended claims. The illustrative examples, however, as well as a preferred mode of use, further objectives and features thereof, will best be understood by reference to the following detailed description of an illustrative example of the present disclosure when read in conjunction with the accompanying drawings, wherein:.

With reference now to the figures, and in particular, with reference to <FIG>, an illustration of an aircraft is depicted in accordance with an illustrative example. In this illustrative example, aircraft <NUM> has wing <NUM> and wing <NUM> attached to body <NUM>. Body <NUM> may also be referred to as a fuselage. Aircraft <NUM> includes engine <NUM> attached to wing <NUM> and engine <NUM> attached to wing <NUM>.

Body <NUM> has tail section <NUM>. Horizontal stabilizer <NUM>, horizontal stabilizer <NUM>, and vertical stabilizer <NUM> are attached to tail section <NUM> of body <NUM>. Body <NUM> also has cockpit <NUM> and passenger cabin <NUM>. In this example, passenger cabin <NUM> may include passenger seating in seating area <NUM>. Passenger seating may include a number of aircraft seats. As used herein, a "number of" items means one or more items. For example, a number of aircraft seats means one or more aircraft seats.

Further, seating area <NUM> in passenger cabin <NUM> may also include storage areas, such as a number of overhead stowage bins. Passenger cabin <NUM> also may include lavatory <NUM> and galley area <NUM>. These two areas may be partitioned or separated from seating area <NUM> by a partitioning structure such as, for example, without limitation, a wall, a partition, a class divider, a lavatory, a galley, a curtain, a stair enclosure, or a bar unit.

Also, other areas may be present in addition to seating area <NUM>, lavatory <NUM>, and galley area <NUM>. Other areas may include, for example, without limitation, closets, storage areas, lounges, and other suitable areas for passenger seating. As another example, airplane seats within seating area <NUM> may be arranged differently from the depicted example. In other illustrative examples, some seats may be grouped into sets of single seats instead of three seats or pairs of seats as is illustrated in seating area <NUM>.

Aircraft <NUM> is an example of an aircraft having components which may be manufactured in accordance with an illustrative example. For example, passenger cabin <NUM> of body <NUM> of aircraft <NUM> may include embedded light sources in composite panels. As one example, an embedded light source in a composite panel inside body <NUM> of aircraft <NUM> may include at least one of cabin lighting, décor, advertising, emergency signage, emergency lighting, entertainment displays, seat placards, safety signage, or another desirable type of display. As used herein, the phrase "at least one of," when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, "at least one of item A, item B, or item C" may include, without limitation, item A, item A and item B, or item B. Of course, any combinations of these items may be present. In other examples, "at least one of" may be, for example, without limitation, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations. The item may be a particular object, thing, or a category. In other words, at least one of means any combination items and number of items may be used from the list but not all of the items in the list are required.

This illustration of aircraft <NUM> is provided for purposes of illustrating one environment in which the different illustrative examples may be implemented. The illustration of aircraft <NUM> in <FIG> is not meant to imply architectural limitations as to the manner in which different illustrative examples may be implemented. For example, aircraft <NUM> is shown as a commercial passenger aircraft. The different illustrative examples may be applied to other types of aircraft, such as a private passenger aircraft, a military aircraft, a rotorcraft, and other suitable types of aircraft. For example, an illustration of a block diagram of aircraft <NUM> is depicted in <FIG>.

Although the illustrative examples for an illustrative example are described with respect to an aircraft, the illustrative example may be applied to other types of platforms. The platform may be, for example, a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, and a space-based structure. More specifically, the platform may be a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, and other suitable platforms.

In some illustrative examples, stationary platform may include any type of desirable building. For example, a stationary platform may take the form of a school, a hospital, a museum, an exhibition hall, or any other desirable type of building. For example, an embedded light source in a composite panel may be used for a display or lighting. When not in use, the embedded light source may not be detectable. As a result, an embedded light source in a composite panel may be used to form walls, ceilings, partitions, or any desirable portion of a building.

The embedded light source in a composite panel may be manufactured as an original component of a platform. In some illustrative examples, the composite panel may be a replacement or retrofitted component of a platform. For example, a composite panel in aircraft <NUM> without an embedded light source may be replaced with an embedded light source in a composite panel. In some illustrative examples, all or a portion of a wall of a building may be replaced with an embedded light source in a composite panel.

Although the illustrative examples are described with respect to a platform, the embedded light source in a composite panel need not be physically attached to a platform. In some illustrative examples, an embedded light source in a composite panel may be used as a portable display or portable lighting. As a result, a user may bring an embedded light source in a composite panel from platform to platform. In some illustrative examples, the embedded light source in the composite panel may be used as a display board, an easel, or other type of display. In some illustrative examples, the embedded light source in a composite panel may be used to form furniture, free-standing lighting fixtures, wired lighting fixtures, or other desirable movable components in a platform.

Turning now to <FIG>, an illustration of a block diagram of a manufacturing environment is depicted in accordance with an illustrative example. Manufacturing environment <NUM> may be used to manufacture multilayer panel <NUM> of aircraft <NUM>. Aircraft <NUM> of <FIG> may be a physical implementation of aircraft <NUM> of <FIG>.

Multilayer panel <NUM> includes number of layers <NUM>. In some illustrative examples, number of layers <NUM> includes number of composite layers <NUM>. Number of composite layers <NUM> is formed of a number of composite materials.

In these illustrative examples, multilayer panel <NUM> may also be called a composite panel. Composite materials may be tough, light-weight materials created by combining two or more functional components. For example, a composite material may include reinforcing fibers bound in a polymer resin matrix. Resins used in composite materials may include thermoplastic or thermoset resins. A thermoplastic material may become soft upon heating and may harden upon cooling. A thermoplastic material may be able to be repeatedly heated and cooled. A thermoset material may become hard when heated. The fibers may be unidirectional or may take the form of a woven cloth or fabric.

Multilayer panel <NUM> may have any desirable characteristic such as size, shape, flexibility, or other characteristics. Multilayer panel <NUM> may have any desirable shape. For example, multilayer panel <NUM> may be portions of aircraft <NUM> that are substantially planar or have a number of curves or contours. In some illustrative examples, multilayer panel <NUM> may have a non-planar curvature. Multilayer panel <NUM> may be rigid or flexible.

Multilayer panel <NUM> includes embedded light source <NUM>. Multilayer panel <NUM> with embedded light source <NUM> may be formed by processing assembly <NUM>. Embedded light source <NUM> is a structure that emits light. Embedded light source <NUM> may be any desirable type of light emissive structure. In some illustrative examples, embedded light source <NUM> may have a number of pixels. Embedded light source <NUM> may be formed by embedding light source <NUM> within number of layers <NUM>. Embedded light source <NUM> may be used for at least one of cabin lighting <NUM>, décor <NUM>, advertising <NUM>, emergency signage <NUM>, emergency lighting <NUM>, entertainment display <NUM>, seat placards <NUM>, safety signage <NUM>, or other desirable types of displays or lighting in aircraft <NUM>.

In illustrative examples in which embedded light source <NUM> in multilayer panel <NUM> is used for at least one of cabin lighting <NUM>, emergency lighting <NUM>, or other types of lighting, multilayer panel <NUM> may be referred to as an embedded lighting panel. In illustrative examples in which embedded light source <NUM> in multilayer panel <NUM> is used for at least one of décor <NUM>, advertising <NUM>, emergency signage <NUM>, entertainment display <NUM>, seat placards <NUM>, safety signage <NUM>, or other desirable types of displays multilayer panel <NUM> may be referred to as an embedded display panel.

Embedded light source <NUM> may be positioned between first layer of material <NUM> and second layer of material <NUM>. In some illustrative examples, first layer of material <NUM> and second layer of material <NUM> are processed together to form multilayer panel <NUM>. The embedded light source <NUM> is positioned in depression <NUM> within number of layers <NUM> and may be covered with laminate <NUM>. In this illustrative example, second layer of material <NUM> takes the form of laminate <NUM> and is adhered to first layer of material <NUM>. In this illustrative example, second layer of material <NUM> is a laminate layer. In this illustrative example, laminate <NUM> may not receive the same processing as first layer of material <NUM>.

Laminate <NUM> may provide desired functionality to multilayer panel <NUM>. For example, laminate <NUM> may provide a desired aesthetic appearance, UV resistance, fire-worthiness, protection from mechanical damages, chemical protection from chemicals, or other desirable functions to multilayer panel <NUM>. In some illustrative examples, laminate <NUM> may be a decorative laminate.

In this illustrative example, embedded light source <NUM> may be described as an inlay. However, embedded light source <NUM> may not necessarily be completely flush with first layer of material <NUM>.

Embedded light source <NUM> may take the form of any desired embedded light source. In some illustrative examples, embedded light source <NUM> may take the form of organic light emitting diode <NUM>. Organic light emitting diode <NUM> may be at least one of more energy efficient, lighter, or thinner than conventional display assemblies. Further, organic light emitting diode <NUM> may emit light across substantially the whole surface of organic light emitting diode <NUM>. In other illustrative examples, embedded light source <NUM> may take the form of electroluminescent (EL) structures, flexible light emitting diodes (LED), or other desirable emissive structures.

Light source <NUM> may be flexible <NUM>. By being flexible <NUM>, light source <NUM> may bend and flex with multilayer panel <NUM>. Further, light source <NUM> may be processed to form multilayer panel <NUM>. In some illustrative examples, light source <NUM> may be programmable <NUM>. The light source <NUM> may be used for multiple purposes. The light source <NUM> may display different images for a single purpose. In some illustrative examples, light source <NUM> may be static image <NUM>. The light source <NUM> may be used for a single purpose and may only show a single image.

When light source <NUM> takes the form of organic light emitting diode <NUM> and is flexible <NUM> and programmable <NUM>, it may be referred to as a programmable flexible organic light emitting diode. When light source <NUM> takes the form of organic light emitting diode <NUM> and is flexible <NUM> with static image <NUM> it may be referred to as a static image flexible organic light emitting diode.

To form multilayer panel <NUM>, number of electrodes <NUM> may be associated with first layer of material <NUM>. In some illustrative examples, number of electrodes <NUM> may be associated with first layer of material <NUM> by positioning number of electrodes <NUM> relative to first layer of material <NUM>. First electrode <NUM> may first be associated with first layer of material <NUM>. Second electrode <NUM> may also be associated with first layer of material <NUM>. At least one of first electrode <NUM> and second electrode <NUM> may be adhered to first layer of material <NUM>. In some illustrative examples, at least one of first electrode <NUM> and second electrode <NUM> is free to move relative to first layer of material <NUM>. In some illustrative examples, only one of first electrode <NUM> and second electrode <NUM> is affixed to first layer of material <NUM>.

By having at least one of first electrode <NUM> and second electrode <NUM> free to move relative to first layer of material <NUM>, inconsistencies may be reduced in the resulting multilayer panel <NUM>. For example, by having at least one of first electrode <NUM> and second electrode <NUM> free to move relative to first layer of material <NUM>, delamination in multilayer panel <NUM> may be reduced or prevented.

Number of electrodes <NUM> may take the form of at least one of conductive tape <NUM>, printed <NUM>, integrated <NUM>, direct write <NUM>, or any other desirable type of electrodes. Conductive tape <NUM> may be formed of copper <NUM>. When an electrode in number of electrodes <NUM> is printed <NUM>, it may be formed using a three-dimensional printer or other desirable type of printer. When an electrode in number of electrodes <NUM> is integrated <NUM>, the electrode may comprise conductive material within a layer of number of layers <NUM>. When an electrode in number of electrodes <NUM> is conductive tape <NUM>, conductive tape <NUM> may be associated with first layer of material <NUM> by conductive adhesive <NUM> of number of adhesives <NUM>.

Light source <NUM> is positioned in electrical communication with first electrode <NUM> and second electrode <NUM>. When light source <NUM> is in electrical communication with first electrode <NUM> and second electrode <NUM>, light source <NUM> is capable of receiving or transmitting electrical signals via at least one of first electrode <NUM> or second electrode <NUM>. In some illustrative examples, embedded light source <NUM> may be connected to at least one of first electrode <NUM> and second electrode <NUM> by bond <NUM>. Bond <NUM> may be formed using at least one of solder <NUM>, conductive paste <NUM>, or some other desirable bond.

The first layer of material <NUM> may be first composite layer <NUM>. In some illustrative examples, when first layer of material <NUM> is first composite layer <NUM>, light source <NUM> may be positioned in electrical communication with first electrode <NUM> and second electrode <NUM> prior to curing first composite layer <NUM>. In these illustrative examples, second layer of material <NUM> may be second composite layer <NUM>. Second composite layer <NUM> may be placed over light source <NUM>, first electrode <NUM>, second electrode <NUM>, and first composite layer <NUM>.

Layup <NUM> may be processed to form all, or part, of multilayer panel <NUM>. Layup <NUM> may be a stack of an unprocessed number of materials. For example, layup <NUM> may include number of electrodes <NUM> and first composite layer <NUM>. As another example, layup <NUM> may include number of layers <NUM>. Layup <NUM> may include number of layers <NUM> and embedded light source <NUM>. Portions of layup <NUM> may also receive surface treatment <NUM>. Surface treatment <NUM> may aid in adhering materials. For example, surface treatment <NUM> may aid in adhering thermoplastics, thermosets, metals, or other types of materials. Surface treatment <NUM> may reduce or prevent inconsistencies in the resulting multilayer panel <NUM>. For example, by having surface treatment <NUM>, delamination in multilayer panel <NUM> may be reduced or prevented. Surface treatment <NUM> may include at least one of chemical treatment, thermal treatment, mechanical treatment, or any other desirable type of treatment. Surface treatment <NUM> may include at least one of corona treatment, plasma treatment, or flame treatment.

In the above illustrative example, placing second composite layer <NUM> over light source <NUM>, first electrode <NUM>, second electrode <NUM>, and first composite layer <NUM> forms layup <NUM>. Afterwards, layup <NUM> including embedded light source <NUM>, first composite layer <NUM>, and second composite layer <NUM> are processed to cure first composite layer <NUM> and second composite layer <NUM>.

Layup <NUM> may be processed using at least one of curing equipment <NUM> or processing materials <NUM>. Processing materials <NUM> may include number of caul sheets <NUM>, release material <NUM>, texture <NUM>, or number of shims <NUM>. Layup <NUM> may be placed between number of caul sheets <NUM> and layup <NUM> may be placed into curing equipment <NUM>. Release material <NUM> may be positioned between number of caul sheets <NUM> and layup <NUM>. In some illustrative examples, texture <NUM> may be positioned between a layer of release material <NUM> and layup <NUM>. Texture <NUM> may change the exterior texture of layup <NUM>. In some illustrative examples, release material <NUM> may be parchment <NUM>. In some illustrative examples, curing equipment <NUM> may take the form of one of multiple opening press <NUM>, autoclave <NUM>, press <NUM>, or other desirable form of equipment.

A number of shims <NUM> may be positioned within layup <NUM> prior to curing number of composite layers <NUM>. In some illustrative examples, number of shims <NUM> may be positioned within processing materials <NUM> relative to layup <NUM> prior to curing number of composite layers <NUM>. For example, number of shims <NUM> may be positioned adjacent to layup <NUM> within release material <NUM>.

In illustrative examples in which second composite layer <NUM> is within layup <NUM>, when embedded light source <NUM> is illuminated, the light travels through second composite layer <NUM>. The light also travels through any additional layers positioned over second composite layer <NUM>. In these illustrative examples, second composite layer <NUM> has desirable transmission properties such that embedded light source <NUM> is visible through second composite layer <NUM> when illuminated.

When embedded light source <NUM> is processed with number of layers <NUM>, multilayer panel <NUM> may have a substantially consistent surface. As a result of the substantially consistent surface, embedded light source <NUM> may not be detected within multilayer panel when embedded light source <NUM> is not illuminated.

When layup <NUM> includes embedded light source <NUM>, embedded light source <NUM> will experience temperatures and pressures applied to number of layers <NUM> to cure number of composite layers <NUM>. The materials of number of layers <NUM> may be selected such that processing does not damage embedded light source <NUM>. In some illustrative examples, multilayer panel <NUM> may be a pre-existing product layup. Multilayer panel <NUM> may be selected to include embedded light source <NUM> based on pre-existing processing parameters for the materials of multilayer panel <NUM>.

In some illustrative examples, embedded light source <NUM> may not be exposed to processing temperatures or pressures. In these illustrative examples, first layer of material <NUM> of number of layers <NUM> may be processed prior to incorporating embedded light source <NUM>. For example, number of shims <NUM> may be placed relative to first composite layer <NUM> to form layup <NUM>. Afterwards, layup <NUM> including first composite layer <NUM> and number of shims <NUM> is processed to cure first composite layer <NUM>. Curing layup <NUM> forms cured panel <NUM>. Cured panel <NUM> has depression <NUM> formed by number of shims <NUM>.

Light source <NUM> may then be electrically associated with first electrode <NUM> and second electrode <NUM> on cured panel <NUM>. After placing light source <NUM> in depression <NUM> in first layer of material <NUM> and associating light source <NUM> with first electrode <NUM> and second electrode <NUM>, laminate <NUM> may be placed over light source <NUM> and cured panel <NUM>. Laminate <NUM> may take the form of second layer of material <NUM> in this illustrative example. Laminate <NUM> has light transmission properties <NUM>. When embedded light source <NUM> is illuminated, the light must travel through laminate <NUM>. In some illustrative examples, laminate <NUM> may take the form of either a thermoset laminate or a thermoplastic laminate. Laminate <NUM> may at least one of a resin, reinforcement, or additives. Additives may change at least one of a physical property, an electrical property, a thermal property, or some other desirable property. In some illustrative examples, laminate <NUM> may include at least one of an epoxy, a phenolic, a polyurethane, a cyanate ester, a melamine, or other desirable type of resin. In some illustrative examples, laminate <NUM> may take the form of polyvinyl fluoride <NUM>. Laminate <NUM> may be adhered over embedded light source <NUM> and cured first composite layer <NUM> using pressure sensitive adhesive <NUM> of number of adhesives <NUM>.

In some illustrative examples, number of composite layers <NUM> may include more than just first composite layer <NUM> and second composite layer <NUM>. In some illustrative examples, number of composite layers <NUM> may include three composite layers. In other illustrative examples, number of composite layers <NUM> may include more than three composite layers.

The multilayer panel <NUM> may also include core <NUM>. Core <NUM> may be referred to as a layer of core material. The number of layers <NUM> may include core <NUM>. Core <NUM> may be formed of metal, composite, polymer, or any other desirable material.

In other illustrative examples, multilayer panel <NUM> may not include core <NUM>. In these illustrative examples, multilayer panel <NUM> may not be substantially thicker than embedded light source <NUM> itself. In illustrative examples in which multilayer panel <NUM> does not contain core <NUM>, multilayer panel <NUM> may be referred to as a laminate. When multilayer panel <NUM> does not include core <NUM>, multilayer panel <NUM> may be adhered to another multilayer panel which does contain a core. For example, multilayer panel <NUM> with embedded light source <NUM> may be applied as a laminate over another composite panel.

Multilayer panel <NUM> may be interior panel <NUM> of aircraft <NUM>. Interior panel <NUM> may be any desirable type of panel in the interior of aircraft <NUM>. Interior panel <NUM> may be part of ceiling <NUM>, bulkhead <NUM>, trim <NUM>, wall <NUM>, or other desirable panels of the interior of aircraft <NUM>.

Multilayer panel <NUM> may be formed by processing assembly <NUM>. Assembly <NUM> includes first layer of material <NUM>, first electrode <NUM>, second electrode <NUM>, and embedded light source <NUM>. In some illustrative examples, first layer of material <NUM> in assembly <NUM> is cured. In these illustrative examples, assembly <NUM> may include layup <NUM> after curing. Assembly <NUM> may also include other components that were not part of layup <NUM>. In one example, processing assembly <NUM> may include adhering second layer of material <NUM> over first layer of material <NUM>. In this example, second layer of material <NUM> may take the form of laminate <NUM>. In another example, processing assembly <NUM> may include adhering laminate <NUM> to assembly <NUM>. In this example, laminate <NUM> may be adhered over both first layer of material <NUM> and second layer of material <NUM>, which are already cured.

In other illustrative examples, first layer of material <NUM> in assembly <NUM> is uncured. In these illustrative examples, assembly <NUM> may take the form of layup <NUM> prior to curing. In these illustrative examples, processing assembly <NUM> may include curing first layer of material <NUM> of assembly <NUM>.

Controller <NUM> may be in communication with light source <NUM>. Controller <NUM> may control the operation of light source <NUM>. Controller <NUM> may be implemented in software, hardware, firmware or a combination thereof. When software is used, the operations performed by controller <NUM> may be implemented in program code configured to run on hardware, such as a processor unit. When firmware is used, the operations performed by controller <NUM> may be implemented in program code and data and stored in persistent memory to run on a processor unit. When hardware is employed, the hardware may include circuits that operate to perform the operations in controller <NUM>.

The hardware may take the form of a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware configured to perform a number of operations. With a programmable logic device, the device may be configured to perform the number of operations. The device may be reconfigured at a later time or may be permanently configured to perform the number of operations. Examples of programmable logic devices include, for example, a programmable logic array, a programmable array logic, a field programmable logic array, a field programmable gate array, and other suitable hardware devices. Additionally, the processes may be implemented in organic components integrated with inorganic components and may be comprised entirely of organic components excluding a human being. For example, the processes may be implemented as circuits in organic semiconductors.

The controller <NUM> may be located in a computer system. The computer system includes one or more data processing systems. When more than one data processing system is present, those data processing systems may be in communication with each other using a communications medium such as a network. The data processing systems may be selected from at least one of a computer, a server computer, a tablet, a mobile phone, or some other suitable data processing system.

Turning now to <FIG>, an illustration of an exploded view of an embedded light source is depicted in accordance with an illustrative example. In this illustrative example, multilayer panel <NUM> includes number of layers <NUM>, embedded light source <NUM>, and number of electrodes <NUM>. Multilayer panel <NUM> may be one physical example of multilayer panel <NUM> shown in block form in <FIG>.

Number of layers <NUM> includes first layer of material <NUM> and second layer of material <NUM>. In some illustrative examples, first layer of material <NUM> may be first composite layer <NUM>. In some illustrative examples, second layer of material <NUM> may be second composite layer <NUM>. When at least one of first layer of material <NUM> or second layer of material <NUM> is made of composite, multilayer panel <NUM> may be referred to as a composite panel.

The second layer of material <NUM> may be a laminate. In these illustrative examples, second layer of material <NUM> may be adhered over embedded light source <NUM> using a number of adhesives.

Although, number of layers <NUM> is shown as only including two layers of material, any additional desirable number of layers may also be in multilayer panel <NUM>. For example, a number of additional layers may be positioned adjacent to first layer of material <NUM>. These additional layers may be integrated into multilayer panel <NUM> by at least one of co-curing or adhesives. For example, in co-curing, first layer of material <NUM> and the additional layers may be cured together. In one illustrative example, multilayer panel <NUM> may be adhered as a decorative laminate over a separate multilayer panel. In another example, a number of additional layers may be positioned adjacent to second layer of material <NUM>. These additional layers may be integrated into multilayer panel <NUM> by at least one of co-curing or adhesives.

A core may be positioned relative to first layer of material <NUM>. This core may be integrated into multilayer panel <NUM> or may be a component of another multilayer panel.

Number of electrodes <NUM> is associated with first layer of material <NUM>. In this illustrative example, number of electrodes <NUM> is formed of conductive tape <NUM>. At least one of first electrode <NUM> or second electrode <NUM> may be affixed to first layer of material <NUM>. At least one of first electrode <NUM> or second electrode <NUM> is free to move relative to first layer of material <NUM>.

Embedded light source <NUM> is in electrical communication with first electrode <NUM> and second electrode <NUM>. In some illustrative examples, embedded light source <NUM> may be adhered to at least one of first electrode <NUM> and second electrode <NUM>. In some illustrative examples, embedded light source <NUM> may be adhered to at least one of first electrode <NUM> and second electrode <NUM> using at least one of solder, conductive paste, or other desirable bonds.

Turning now to <FIG>, an illustration of a shim and a first layer of material is depicted in accordance with an illustrative example. <FIG> may be a top view of a layup during forming of a multilayer panel. Layup <NUM> includes number of electrodes <NUM>. As depicted, number of electrodes <NUM> is associated with first layer of material <NUM>. In this illustrative example, number of electrodes <NUM> includes first electrode <NUM> and second electrode <NUM>. Shim <NUM> is positioned relative to, and over, first electrode <NUM> and second electrode <NUM>. After shim <NUM> is positioned relative to, and over, first electrode <NUM> and second electrode <NUM>, layup <NUM> may be processed. For example, when first layer of material <NUM> is a composite material, layup <NUM> may be processed such that first layer of material <NUM> is cured. During processing, shim <NUM> may form a depression in layup <NUM>. The size and shape of shim <NUM> may be selected to form a depression having a desirable size, shape, and depth. Shim <NUM> may have the approximate thickness of a display to be associated with layup <NUM> after processing.

Turning now to <FIG>, an illustration of a layup including a shim being inserted into a press is depicted in accordance with an illustrative example. Layup <NUM> may be layup <NUM> of <FIG>. In some illustrative examples, layup <NUM> may be a different layup, such as a layup having a number of integrated electrodes. Layup <NUM> includes a shim (not depicted). In some illustrative examples, layup <NUM> may include processing caul sheets surrounding the number of layers of material to be processed.

Layup <NUM> may be inserted into press <NUM>. Press <NUM> may apply a desired pressure and desired temperature to layup <NUM> to process layup <NUM>. In some illustrative examples, press <NUM> may apply a desired pressure and desired temperature to cure composite layers in layup <NUM>.

Turning now to <FIG>, an illustration of a cured composite panel with a depression is depicted in accordance with an illustrative example. Cured composite panel <NUM> may be a depiction of layup <NUM> of <FIG> following curing. First layer of material <NUM> of cured composite panel <NUM> may be a cured composite material. Number of electrodes <NUM> of cured composite panel <NUM> includes first electrode <NUM> and second electrode <NUM>.

Cured composite panel <NUM> has depression <NUM>. Depression <NUM> may be a recessed area of cured composite panel <NUM>. Portion <NUM> of first electrode <NUM> may have a lower elevation than the remainder of first electrode <NUM> outside of depression <NUM>. Portion <NUM> of second electrode <NUM> may have a lower elevation than the remainder of second electrode <NUM> outside of depression <NUM>.

Depression <NUM> may be formed by placing a shim relative to first layer of material <NUM> prior to curing cured composite panel <NUM>. After curing, the shim may be removed from cured composite panel <NUM> to form depression <NUM>. A shim may be selected to form a desirable shape, size, and depth of depression <NUM>. Depression <NUM> may have a desirable shape, size, and depth for associating a light source with cured composite panel <NUM> such that the light source is nearly flush or substantially flush with the surface of cured composite panel <NUM> outside of depression <NUM>.

Turning now to <FIG>, an illustration of a light source inserted into a depression in a cured composite panel is depicted in accordance with an illustrative example. As depicted, light source <NUM> has been inserted in depression <NUM> of cured composite panel <NUM> of <FIG>. Light source <NUM> is placed in electrical connection with first electrode <NUM> and second electrode <NUM>. In some illustrative examples, light source <NUM> may be connected to first electrode <NUM> and second electrode <NUM> using a bond such as solder, conductive paste, or any other desirable type of bond.

After associating light source <NUM> with first electrode <NUM> and second electrode <NUM>, second layer of material <NUM> is adhered to first layer of material <NUM> and light source <NUM>. In some illustrative examples, second layer of material <NUM> may be laminate <NUM>. Laminate <NUM> may be adhered to first layer of material <NUM> and light source <NUM> using a number of adhesives (not depicted). In some illustrative examples, the number of adhesives (not depicted) may include a pressure sensitive adhesive. By placing laminate <NUM> over first layer of material <NUM> and light source <NUM>, cured composite panel <NUM>, light source <NUM>, and laminate <NUM> form multilayer panel <NUM>.

Turning now to <FIG>, an illustration of an exploded view of one implementation of a layup with a light source is depicted in accordance with an illustrative example. Layup <NUM> may be a physical implementation of layup <NUM> shown in block form in <FIG>. After processing, layup <NUM> will become a multilayer panel, such as multilayer panel <NUM> of <FIG>. Layup <NUM> includes number of layers <NUM>, number of processing materials <NUM>, number of electrodes <NUM>, and light source <NUM>. In this example, number of layers <NUM> includes core <NUM>. Each of number of layers <NUM> may be an adhesion promoter, a composite material, a resin, a polymer, a metal, a ceramic, a glass, or other desirable material. In this illustrative example, number of processing materials <NUM> includes caul sheet <NUM>, caul sheet <NUM>, release material <NUM>, release material <NUM>, texture <NUM>, and texture <NUM>.

Texture <NUM> and texture <NUM> may apply a surface finish to layer <NUM> and layer <NUM> of number of layers <NUM>. In some illustrative examples, texture <NUM> and texture <NUM> may bond to layer <NUM> and layer <NUM> to become a portion of the final multilayer panel. Number of layers <NUM> may also include layer <NUM>, first layer <NUM>, second layer <NUM>, and layer <NUM>. In some illustrative examples, first layer <NUM> and second layer <NUM> may each be a composite material. First electrode <NUM> and second electrode <NUM> are associated with first layer <NUM>. Light source <NUM> is in electrical communication with first electrode <NUM> and second electrode <NUM>.

Turning now to <FIG>, an illustration of an exploded view of one implementation of a layup with a light source is depicted in accordance with an illustrative example. Layup <NUM> may be a physical implementation of layup <NUM> shown in block form in <FIG>. After processing, layup <NUM> will become a multilayer panel, such as multilayer panel <NUM> of <FIG>. Layup <NUM> includes number of layers <NUM>, number of processing materials <NUM>, number of electrodes <NUM>, light source <NUM>, and core <NUM>. Each of number of layers <NUM> may be a composite material, a resin, a polymer, or other desirable material. In this illustrative example, number of processing materials <NUM> includes caul sheet <NUM>, caul sheet <NUM>, release material <NUM>, release material <NUM>, number of shims <NUM>, and texture <NUM>. Number of shims <NUM> may be positioned between release material <NUM> and release material <NUM>. Number of shims <NUM> may control a thickness of the resulting multilayer panel following processing of layup <NUM>.

Texture <NUM> may apply a surface finish to layer <NUM> of number of layers <NUM>. In some illustrative examples, texture <NUM> may bond to layer <NUM> to become a portion of the final multilayer panel. Number of layers <NUM> may also include layer <NUM>, first layer <NUM>, and second layer <NUM>. In some illustrative examples, first layer <NUM> and second layer <NUM> may each be a composite material. First electrode <NUM> and second electrode <NUM> are associated with first layer <NUM>. Light source <NUM> is in electrical communication with first electrode <NUM> and second electrode <NUM>.

Turning now to <FIG>, an illustration of an embedded light source in a multilayer panel is depicted in accordance with an illustrative example. Multilayer panel <NUM> may be a physical implementation of multilayer panel <NUM> shown in block form in <FIG>. Multilayer panel <NUM> may be one of layup <NUM> or layup <NUM> after processing.

Multilayer panel <NUM> has surface <NUM>. In this illustrative example, surface <NUM> is substantially uniform. As illustrated, the embedded light source (not depicted) is not visible when the embedded light source is not illuminated. As depicted, there is substantially no markoff on surface <NUM> from the embedded light source.

In some illustrative examples, multilayer panel <NUM> may be an example of multilayer panel <NUM> after adhering second layer of material <NUM>. In these illustrative examples, surface <NUM> may have some amount of markoff. In these illustrative examples, the embedded light source may be identified as a result of this markoff.

Turning now to <FIG>, an illustration of an illuminated embedded light source in a multilayer panel is depicted in accordance with an illustrative example. View <NUM> may be a view of multilayer panel <NUM> of <FIG> when the embedded light source is illuminated. As can be seen in view <NUM>, light from the embedded light source shines through surface <NUM>. In some illustrative examples, the embedded light source may be a dynamic display. In these illustrative examples, image <NUM> may change as desired. In other illustrative examples, the embedded light source may be a static display. In these illustrative examples, image <NUM> may be the same each time the embedded light source is illuminated.

Although image <NUM> is depicted as a fasten seat belt image, image <NUM> may take any desirable form. Further, image <NUM> as depicted does not limit the use of multilayer panel <NUM> to implementations in an aircraft. Multilayer panel <NUM> need not be present in an aircraft. Multilayer panel <NUM> may be present in any desirable type of platform such as a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, and a space-based structure. More specifically, the platform may be a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, and other suitable platforms.

The multilayer panel <NUM> may be a standalone product. Multilayer panel <NUM> may be a display panel which may be transported from location to location by an operator. Multilayer panel <NUM> may be a component of any desirable mobile platform, stationary platform, or any desirable type of structure. For example, multilayer panel <NUM> may be a component of a display board, an easel, or other type of display. In some illustrative examples, multilayer panel <NUM> may be used to form furniture, free-standing lighting fixtures, wired lighting fixtures, or other desirable movable components.

The multilayer panel <NUM> may be a component of a school, a hospital, a museum, an exhibition hall, or any other desirable type of building. For example, multilayer panel <NUM> may be used for a display or lighting. When not in use, the embedded light source may not be detectable. As a result, multilayer panel <NUM> may be used to form walls, ceilings, partitions, or any desirable portion of a building.

Multilayer panel <NUM> may be manufactured as an original component of a platform. In some illustrative examples, multilayer panel <NUM> may be a replacement or retrofitted component of a platform. For example, a composite panel in aircraft <NUM> without an embedded light source may be replaced with multilayer panel <NUM>. In some illustrative examples, all or a portion of a wall of a building may be replaced with multilayer panel <NUM>.

Yet further, multilayer panel <NUM> does not limit the size or shape of potential implementations of multilayer panel <NUM>. Multilayer panel <NUM> may be created in any desirable size or shape.

Turning now to <FIG>, an illustration of a flowchart of a process for forming a multilayer panel with an embedded light source is depicted in accordance with an illustrative example. Process <NUM> may be used in manufacturing environment <NUM> of <FIG> to form a multilayer panel with an embedded light source such as multilayer panel <NUM> with embedded light source <NUM> of <FIG>.

The process begins by associating a first electrode and a second electrode with a first layer of material (operation <NUM>). Associating the first electrode and the second electrode with the first layer of material includes affixing only one of the first electrode or the second electrode to the first layer of material. Affixing only one of the first electrode or the second electrode to the first layer of the material comprises at least one of adhering the only one of the first electrode or the second electrode to the first layer of material, printing the only one of the first electrode or the second electrode onto the first layer of material, or integrating conductive fibers into the first layer of material at selective locations to form the only one of the first electrode or the second electrode.

By affixing only one of the first electrode or the second electrode, inconsistencies may be reduced in the resulting multilayer panel. For example, by having only one of the first electrode and the second electrode affixed to the first layer of material, delamination in the multilayer panel may be reduced or prevented. In some illustrative examples, associating also includes positioning the other of the first electrode or the second electrode such that the other of the first electrode or the second electrode is free to move relative to the first layer of material.

The process then positions a light source in electrical communication with the first electrode and the second electrode (operation <NUM>). In some illustrative examples, positioning the light source in electrical communication with the first electrode and the second electrode includes bonding the light source to at least one of the first electrode or the second electrode. Bonding may include at least one of solder or conductive paste.

The process may then process an assembly comprising the first layer of material, the first electrode, the second electrode, and the light source to form a multilayer panel with an embedded light source (operation <NUM>). Afterwards the process terminates.

processing the assembly may include curing the first layer of material. In some illustrative examples, processing the assembly may include applying a laminate over the first layer of material and the light source. In some illustrative examples, the multilayer panel with embedded light source formed comprises at least one of cabin lighting, décor, advertising, emergency signage, emergency lighting, entertainment display, seat placards, or safety signage in an aircraft.

The flowcharts and block diagrams in the different depicted examples illustrate the architecture, functionality, and operation of some possible implementations of apparatuses and methods in an illustrative example. In this regard, each block in the flowcharts or block diagrams may represent a module, a segment, a function, and/or a portion of an operation or step.

The function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram.

For example, the process may further include applying a surface treatment to at least one of the light source or the first layer prior to processing the assembly panel. As another example, the process may further include placing a second layer of material over the light source and the first layer of material. In some illustrative examples, the first layer of material and the second layer of material are pre-impregnated composite materials, and processing the assembly comprises curing the assembly with at least one of applied heat or applied pressure to form a cured panel.

In some illustrative examples, the second layer of material comprises a material that allows at least some light from the light source to travel through the second layer of material. In some illustrative examples, processing the assembly further comprises applying a laminate over the cured panel.

The process may further include curing the first layer of material to form a cured panel after associating the first electrode and the second electrode with the first layer of material, wherein the light source is positioned in electrical communication with the first electrode and the second electrode on the cured panel, and wherein processing the multilayer panel comprises applying a laminate over the light source and the cured panel to form the multilayer panel with the embedded light source.

In one example, the process further includes associating a shim having the approximate thickness of the light source with the first layer of material. The shim may be used to form a depression during processing of the multilayer panel.

The illustrative examples of the disclosure may be described in the context of aircraft manufacturing and service method <NUM> as shown in <FIG> and aircraft <NUM> as shown in <FIG>. Turning first to <FIG>, a block diagram of an aircraft manufacturing and service method is depicted in accordance with an illustrative example. During pre-production, aircraft manufacturing and service method <NUM> may include specification and design <NUM> of aircraft <NUM> of <FIG> and material procurement <NUM>.

During production, component and subassembly manufacturing <NUM> and system integration <NUM> of aircraft <NUM> of <FIG> takes place. Thereafter, aircraft <NUM> of <FIG> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service <NUM> by a customer, aircraft <NUM> of <FIG> is scheduled for routine maintenance and service <NUM>, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

With reference now to <FIG>, a block diagram of an aircraft is depicted in which an illustrative example may be implemented. In this example, aircraft <NUM> is produced by aircraft manufacturing and service method <NUM> of <FIG> and may include airframe <NUM> with plurality of systems <NUM> and interior <NUM>. Examples of systems <NUM> include one or more of propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, different illustrative examples may be applied to other industries, such as the automotive industry. Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method <NUM> of <FIG>.

The examples may be used during manufacturing and service method <NUM> of <FIG>. For example, multilayer panel <NUM> having embedded light source <NUM> of <FIG> may be formed during component and subassembly manufacturing <NUM>. Further, multilayer panel <NUM> having embedded light source <NUM> of <FIG> may be inserted to replace a display in an aircraft during maintenance and service <NUM>.

The illustrative examples present methods of forming embedded light sources in multilayer panels. By embedding a light source, such as an organic light emitting diode, in a composite panel, at least one of weight, bulk, or connection complexity may be decreased for pre-existing display locations. For example, brackets and mounting equipment may not be used with embedded light sources in multilayer panels. By eliminating brackets and mounting equipment in select locations, the weight of an aircraft may be reduced. Reduction in aircraft weight may contribute to a reduction in costs.

Further, embedded light sources in multilayer panels may be used instead of conventionally unilluminated displays in some areas. Yet further, the number of displays in an aircraft may be reduced if embedded light sources are programmable displays. For example, the number of displays in an aircraft may be reduced if embedded light sources are capable of displaying multiple images in individual conventional displays.

By embedding light sources into multilayer panels, the number of manufacturing steps in an aircraft may be reduced. For example, holes to install brackets and mounting equipment for displays may not be used. As a result, these manufacturing steps may be eliminated. By eliminating or reducing steps of manufacturing, at least one of manufacturing time or manufacturing cost may also be reduced.

According to another aspect unclaimed by the present European patent, there is provided a method comprising: associating a first electrode and a second electrode with a first layer of material; positioning a light source in electrical communication with the first electrode and the second electrode; and processing an assembly comprising the first layer of material, the first electrode, the second electrode, and the light source to form a multilayer panel with an embedded light source.

Optionally, the method comprises: applying a surface treatment to at least one of the light source or the first layer of material prior to processing the assembly.

Optionally, associating the first electrode and the second electrode with the first layer of material comprises affixing only one of the first electrode or the second electrode to the first layer of material.

Optionally, associating the first electrode and the second electrode with the first layer of material further comprises: positioning an other of the first electrode or the second electrode such that the other of the first electrode or the second electrode is free to move relative to the first layer of material.

Optionally, affixing only one of the first electrode or the second electrode to the first layer of material comprises at least one of adhering the only one of the first electrode or the second electrode to the first layer of material, printing the only one of the first electrode or the second electrode onto the first layer of material, or integrating conductive fibers into the first layer of material at selective locations to form the only one of the first electrode or the second electrode.

Optionally, the method comprises: placing a second layer of material over the light source and the first layer of material.

Optionally, the second layer of material comprises a material that allows at least some light from the light source to travel through the second layer of material.

Optionally, the first layer of material and the second layer of material are pre-impregnated composite material, and wherein processing the assembly comprises: curing the assembly with at least one of applied heat or applied pressure to form a cured panel.

Optionally, processing the assembly further comprises: applying a laminate over the cured panel.

Optionally, the method comprises: curing the first layer of material to form a cured panel after associating the first electrode and the second electrode with the first layer of material, wherein the light source is positioned in electrical communication with the first electrode and the second electrode on the cured panel, and wherein processing the assembly comprises: applying a laminate over the light source and the cured panel to form the multilayer panel with the embedded light source.

Optionally, the method comprises: associating a shim having an approximate thickness of the light source with the first layer of material.

Optionally, the multilayer panel with the embedded light source comprises at least one of cabin lighting, décor, advertising, emergency signage, emergency lighting, entertainment display, seat placards, or safety signage.

According to another aspect, there is provided a multilayer panel with an embedded light source comprising: a first electrode associated with a first layer of material; a second electrode associated with the first layer of material; a light source in electrical communication with the first electrode and the second electrode; and a second layer of material overlying the first layer of material and the light source. The light source rests substantially within a depression in the first layer of material.

Optionally, the second layer of material is a laminate layer.

Optionally, the multilayer panel comprises: a conductive adhesive positioned between at least one of the first electrode or the second electrode and the light source.

Optionally, the multilayer panel comprises: a layer of core material.

Optionally, the second layer is a pre-impregnated composite material.

Optionally, the multilayer panel has a non-planar curvature.

Optionally, the light source is a static image flexible organic light emitting diode.

Optionally, the light source is a programmable flexible organic light emitting diode.

According to another aspect, there is provided an aircraft comprising: a multilayer panel with an embedded light source comprising a first electrode associated with a first layer of material, a second electrode associated with the first layer of material, a light source in electrical communication with the first electrode and the second electrode, and a second layer of material overlying the first layer of material and the light source. The light source rests substantially within a depression in the first layer of material.

Optionally, the multilayer panel comprises at least one of cabin lighting, décor, advertising, emergency signage, emergency lighting, entertainment display, seat placards, or safety signage.

According to another aspect unclaimed by the present European patent, there is provided a multilayer panel with an embedded light source comprising: a first layer of composite material; a light source positioned relative to the first layer of composite material; and a second layer of composite material overlying the first layer of composite material and the light source.

Optionally, the light source rests substantially within a depression in the first layer of composite material.

Claim 1:
A multilayer panel (<NUM>) with an embedded light source (<NUM>) comprising:
a first electrode (<NUM>) associated with a first layer of material (<NUM>);
a second electrode (<NUM>) associated with the first layer of material (<NUM>);
a light source (<NUM>) in electrical communication with the first electrode (<NUM>) and the second electrode (<NUM>); and
a second layer of material (<NUM>) overlying the first layer of material (<NUM>) and the light source (<NUM>),
characterized in that the light source (<NUM>) rests substantially within a depression (<NUM>) in the first layer of material (<NUM>) .