Patent Description:
As an airplane is operated, condensation may occur during various phases of flight. In particular, surfaces of interiors aircraft components in spaces that are not climate controlled are frequently exposed to condensate. During aircraft design and manufacture, special consideration is given with respect to the potential of moisture within the airplane, so as to ensure that corrosion of various internal structures, short-circuiting, arcing, and/or degradation of electrical components, and the like, does not occur. In general, condensation is directly related to environmental conditions within an internal cabin of the airplane, and indirectly related to ambient conditions outside of the airplane when grounded. Passengers, crew, onboard meals, and onboard beverages may contribute to condensation within an airplane.

Water accumulation due to condensation occurs in both short and long range flights, but is generally more excessive in continuous long-range flights over six hours having quick turn-around departures. Accordingly, various systems and methods have been developed to control and manage condensation within an airplane.

Many airplanes include various moisture management devices to minimize or otherwise reduce moisture within an internal cabin. For example, drains, moisture impermeable insulation blankets, zonal air dryers (such as dehumidifiers), humidity control systems, and other such moisture management devices are used to capture and/or direct moisture away from an internal cabin interior and divert the moisture to a bilge, through which the moisture drains overboard via pressure valves.

As can be appreciated, however, the various moisture management devices add weight and cost to an airplane. Further, installing the various moisture management devices increases manufacturing time.

Also, during installation, absorbent moisture management devices may be compressively rolled or stacked in relation to other aircraft components. As the moisture management device is compressed, internal absorbing space within the moisture management device is also compressed, which may reduce the ability of the moisture management device to absorb and retain moisture. Therefore, as the moisture management device is compressed, its effectiveness may decrease.

<CIT>, in accordance with its abstract, states a folded core panel that includes a folded core having peaks and valleys characterized by a corrugated zigzag pattern. The folded core may include an airflow channel. The airflow channel may provide an egress to reduce the concentration of moisture in the folded core. The folded core may be formed from a single piece of material. The folded core may have varying face slopes depending on the force distribution requirements at the location of the peak. One or more folded cores may be stacked to form a stacked core.

<CIT>, in accordance with its abstract, states a method for producing, planar, simple or doubly folded core composites with at least one folded honeycomb core. A hardening and later removable core filler is introduced into the through drainage channels of the folded honeycomb core before application of the initially unhardened surface layers in order to prevent a penetration of the cover layers into the channels of the folded honeycomb core on the application and/or hardening of the surface layers and to achieve surfaces of the core composite without edges or polygons.

<CIT>, in accordance with its abstract, states an aircraft fuselage comprising a structure, a skin connected to the structure and forming a barrier between the interior and the exterior of the fuselage, an external coating being plated or placed against said skin, wherein the external coating comprises a thermal insulator that covers the fuselage at least in part and has at least one foam insulating layer. The external coating comprises a plurality of juxtaposed panels adhesively bonded to the fuselage and/or secured to the fuselage by mechanical fixings.

<CIT>, in accordance with its abstract, states a composite laminate comprising in order (a) a flame retardant polymeric moisture barrier (b) an inorganic platelet layer and (c) a flame retardant thermoplastic film layer; It is also directed to a thermal insulation and acoustic blanket comprising a core of fibrous material or foam surrounded by the above composite laminate wherein the thermoplastic film layer of the composite laminate contacts and encapsulates the core.

<CIT>, in accordance with its abstract, states that an aircraft body member has the space between the bulkheads on the interior of the aircraft filled with a polyisocyanurate solid closed cell foam material. The foam is applied so that it adheres to both the inside of the aluminum skin of the fuselage and the facing sides of the bulkheads. The foam may be applied by either spraying or by pouring the resin with appropriate catalyst materials to cause the resin to form the foam. The foam acts to significantly strengthen the aircraft structure and thereby increase the time of usage of aging aircraft before the catastrophic failure of the adherence of the skin to the bulkheads.

<CIT>, in accordance with its abstract, states an apparatus which includes a foam layer, a coating layer and an elastomer. The foam layer includes a first surface for coupling the apparatus to a surface exposed to weather, a second surface opposite the first surface and a plurality of pores within the foam layer. The coating layer is deposited on the second surface of the foam layer. The elastomer is deposited within the plurality of pores within the foam layer.

A need exists for efficient moisture management within an aircraft, for example. Further, a need exists for structures, such as panels, within vehicles that are configured to isolate an internal cabin from surrounding aircraft volumes and isolate moisture.

With those needs in mind, certain embodiments of the present disclosure provide moisture isolation and control systems and methods, with respect to a panel assembly as defined in appended claim <NUM>.

As an example, the panel assembly includes a first ply, and a second ply. One or both of the first ply or the second play includes the at least one surface. For example, the at least one surface may include an outer surface of the first ply. As another example, the at least one surface may include an inner surface of the second ply. The panel assembly may also include insulation secured to the second ply.

In at least one embodiment, the at least one liquid flow path includes a flow-directing network including a plurality of interconnected flow director elements. As an example, one or more of the plurality of interconnected flow director elements includes a central stem, a first lateral branch connected to the central stem, and a second lateral branch connected to the central stem. The first lateral branch may be a mirror image of the second lateral branch.

In at least one embodiment, the first lateral branch and the second lateral branch include an upper channel that angles towards the central stem, an inwardly-curved channel connected to the upper channel, and an outwardly-curved channel connected to the inwardly-curved channel and a lower portion of the central stem.

In at least one embodiment, the flow-directing network includes a first plurality of flow director elements within a first row, and a second plurality of flow director elements within a second row. In at least one embodiment, the plurality of flow director elements within the first row have a first height, and the plurality of flow director elements within the second row have a second height that is greater than the first height.

As but one example, the flow-directing network includes at least ten rows of the flow director elements. A height of flow director elements in lower rows is greater than a height of flow director elements in upper rows.

In at least one embodiment, the flow directing network also includes at least one flow transmission orifice area on the boundary of the outer surface. The area may be located and oriented such that liquid from the flow directing network is channeled to the orifice and thus to adjacent aircraft components. The adjacent components may also include flow direction features.

As an example, the flow direction features of the adjacent component may couple to a flow directing network of the first component. The flow directing network on the adjacent component may include a greater capacity such that liquid diverted by the at least one flow transmission orifice of the first component is accommodated along with moisture deposited on the outer surface of the second component from other sources. In at least one embodiment, at least two adjacent components with surfaces that include flow directing networks are present such that liquid flows continuously across the outer surfaces of the at least two components. The surface of the at least two components may include a moisture control network that directs moisture towards a designated aircraft bilge zone.

Certain embodiments of the present disclosure provide an aircraft including an internal cabin, and at least one component within the internal cabin. The at least one component includes a panel assembly, as described herein. For example, the at least one component comprises one or more of one or more ceiling panels, one or more stowage bin assemblies, one or more sidewall panels, one or more ceiling coves, one or more doorway arch panels, and/or one or more doorway side panels.

The foregoing summary, as well as the following detailed description of certain embodiments, will be better understood when read in conjunction with the appended drawings. Further, references to "one embodiment" are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments "comprising" or "having" an element or a plurality of elements having a particular property may include additional elements not having that property.

Embodiments of the present disclosure provide methods of forming liquid flow paths on a surface of a structure. The liquid flow paths divert liquid to designated locations, such as a drain, bilge, or the like. The structure having the liquid flow paths can be used in various settings, such as within a vehicle (such as an aircraft, automobile, train car, watercraft, or the like), a building (such as a residential or commercial property), and/or various articles of manufacture.

Certain embodiments of the present disclosure provide a method including providing a structure having an outer surface, and modifying the outer surface through surface treatment. In at least one embodiment, the modifying includes forming one or more liquid flow paths having a first wettability (or first surface flow resistance) that differs from other portions of the structure. For example, the liquid flow paths are between banks having a second wettability (or second flow resistance) that differs from the first wettability. The first wettability provides increased liquid flow in comparison to the second wettability. Accordingly, liquid flows over the liquid flow paths. In this manner, the structure is formed having liquid flow paths, such as through surface treatment. The liquid flow paths are configured to direct liquid towards a desired location, such as to a drain, bilge, or the like.

Embodiments of the present disclosure provide structures that are configured to control condensation, such as within an aircraft, vehicle, building, or the like. Further, embodiments of the present disclosure provide structures that route liquid to desired locations without increasing weight and cost (in contrast to separate and distinct moisture control devices) to a system.

Certain embodiments of the present disclosure provide a panel assembly, such as may be used within an aircraft. The panel assembly includes areas of different surface energy, which are configured to control moisture. Areas of first (or second) surface energy (associated with a first (or second) wettability) are hydrophobic and discourage moisture flow. Areas of second (or first) surface energy (associated with a second (or first) wettability) are non-hydrophobic and encourage moisture flow. In at least one embodiment, an outer surface of the panel assembly includes a liquid flow path including a flow-directing network having a plurality of interconnected flow director elements that collect and route moisture via gravitational force.

Certain embodiments of the present disclosure provide a panel assembly that includes a pattern of different surface energies over a surface. Such integral surface features route moisture from across an entire area of the surface of the panel assembly to designated drainage paths. The drainage paths may connect with other moisture routing features, or allow the moisture to freely flow into a bilge area, for example.

Certain embodiments of the present disclosure provide a panel assembly that includes an inner ply, a core, and an outer ply. The outer ply includes a surface treatment. The surface treatment includes at least one liquid flow path for diverting moisture. The outer ply may include an insulation layer for resisting sound and/or heat.

In at least one embodiment, the surface treatment includes a liquid flow path formed by branches and stems. The branches and stems are configured to channel liquid towards a union of the branches and stems. The flow direction is substantially aligned with a direction of gravitational or inertial force.

<FIG> illustrates a perspective front view of a structure <NUM>, according to an embodiment of the present disclosure. In at least one embodiment, the structure <NUM> is a panel, sheet, or the like. In at least one other embodiment, the structure <NUM> is a block, sphere, pyramid, irregularly-shaped structure, or the like.

As shown, the structure <NUM> can be a flat sheet of material. Optionally, the structure <NUM> can include one or more curved surfaces.

The structure <NUM> includes a first face <NUM> having an exposed surface <NUM>. The first face <NUM> is coupled to a second face <NUM> opposite from the first face <NUM>. The first face <NUM> can be a front, rear, top, bottom, lateral, or other such face. The surface <NUM> is an outer surface of the structure <NUM>.

The structure <NUM> is formed of a material, such as a plastic, metal, composite, and/or the like. For example, the structure <NUM> can be formed of a thermoplastic, such as nylon, polycarbonate (PC), polypheylsulfone (PPSU), polyetherimide (PEI), or the like. As another example, the structure <NUM> can be formed of epoxy, phenolic materials, and/or the like.

<FIG> illustrates a perspective front view of the structure <NUM> having liquid flow paths <NUM> formed through surface treatment, according to an embodiment of the present disclosure. The liquid flow paths <NUM> are formed on a main body <NUM>, such as between banks <NUM>. The liquid flow paths <NUM> have a first wettability <NUM> that differs from a second wettability <NUM> of the remainder of the main body <NUM>, such as the banks <NUM>. The first wettability <NUM> provides increased liquid flow rate as compared to the second wettability <NUM>. As such, the first wettability <NUM> of the liquid flow paths <NUM> allows for liquid to flow with increased ease as compared to the banks <NUM>. In this manner, the liquid flow paths <NUM> are configured to divert liquid, such as water, to a desired location, such as a bilge, drain, or the like, such as via gravity.

Liquid can flow on the banks <NUM>. However, the banks <NUM> resist liquid flow greater than the liquid flow paths <NUM>. During a flight of an aircraft, structures within an aircraft may vibrate. Due to gravity and vibration during a flight, liquid gathers and flows along the liquid flow paths <NUM>. In at least one embodiment, boundaries between treated and untreated areas provide the banks <NUM>.

It is to be understood that first and second in relation to wettability are merely terms used to differentiate. That is, the first wettability differs from the second wettability. The liquid flow paths <NUM> have increased wettability in comparison to the remainder of the main body <NUM> of the structure <NUM>, such as that of the banks <NUM>. It is to be understood that the first wettability is not necessarily one of increased wettability. For example, the liquid flow paths <NUM> may have a second wettability that is increased in relation to a first wettability of the banks <NUM>.

The structure <NUM> can include more or less liquid flow paths <NUM> than shown. Further, the liquid flow paths <NUM> can be sized and shaped differently than shown. For example, the liquid flow paths <NUM> can be horizontally or diagonally oriented, instead of vertically oriented. As another example, the liquid flow paths <NUM> can include one or more curved portions, instead of being linear.

The wettability of a surface relates to surface tension or surface energy of a liquid, such as water. Wettability relates to surface flow resistance. As an example, increasing wettability of a surface increases a likelihood that the liquid flows over the surface, in contrast to beading up on the surface. Conversely, decreasing wettability of a surface increases a likelihood that the liquid will bead on the surface, as opposed to flowing over the surface. As another example, increasing the surface flow resistance of a surface decreases a likelihood that liquid flows over the surface, in contrast to beading up on the surface. Conversely, decreasing the surface flow resistance of a surface decreases a likelihood that the liquid will bead on the surface, as opposed to flow over the surface. For example, a bank <NUM> has a higher surface flow resistance than a liquid flow path <NUM>.

<FIG> illustrates a flow chart of a method of forming one or more liquid flow paths on a surface of a structure, according to an embodiment of the present disclosure. Referring to Figures <NUM>, at <NUM>, the structure <NUM> having the surface <NUM> is provided. At <NUM>, the surface <NUM> is treated to provide at least one area having a different wettability than at least one area that is adjacent to the at least one area. The at least one area provides at least one liquid flow path <NUM>, while the at least one area that is adjacent to the at least one area can be or include one or more banks <NUM>. Accordingly, at <NUM>, the one or more liquid flow paths <NUM> are defined by the treatment of the surface <NUM>.

The surface treatment of <NUM> can be performed through a variety of surface treatment processes. For example, the structure <NUM> can be formed of a thermoplastic or thermoset, such as an epoxy or phenolic material. The treatment can be via an in-mold texturing, printing, bonding or cutting, chemical etching, painting using a blocking layer, and/or the like. As another example, the structure <NUM> can be nylon, PC, PPSU, PEI, or the like, and the treatment can be via superficial foaming, bonding, texturing, chemical etching, or the like. The treatment modifies at least a portion of the surface <NUM> to define one or more liquid flow paths <NUM> having a different wettability than a remainder of the main body <NUM>, such as the banks <NUM>.

Treating a portion of the surface <NUM> of the structure <NUM> to form one or more liquid flow paths <NUM> can include texturing the portion to modify a wettability of the portion. As another example, treating the portion can include printing on the portion, such through three-dimensional printing, ink printing, laser printing, and/or the like, to modify a wettability of the portion. As another example, the treating can include chemically etching the portion to modify a wettability of the portion. As another example, the treating can include superficial foaming the portion to modify a wettability of the portion. In at least one embodiment, the treating can include one or more of texturing the portion to modify a wettability of the portion, printing on the portion, chemically etching the portion to modify a wettability of the portion, and/or superficial foaming the portion to modify a wettability of the portion.

In at least one embodiment, the treatment of the surface <NUM> is via superficial foaming. For example, in the case of a thermoplastic surface, a physical foaming agent (such as high pressure carbon dioxide gas or supercritical carbon dioxide) can be applied to the localized area on surface <NUM>, such as at areas that are to be the liquid flow paths <NUM>. In the saturation process, the physical foaming agent can be allowed to remain on the surface <NUM> for a predetermined period of time to diffuse into the area for a certain depth, such as ten minutes (optionally, the time period can be more or less than ten minutes, such as twenty minutes, or five minutes). The physical foaming agent is then removed, and the structure <NUM> can then be heated leading to superficial foaming, which thereby modifies the areas to a certain depth. In this manner, superficial foaming modifies a wettability of areas of the structure. Further, during the saturation process, an area to be treated may be sealed locally to maintain a high pressure gas state or supercritical state for the physical foaming agent.

<FIG> illustrates a flow chart of a method of forming one or more liquid flow paths on a surface of a structure, according to an embodiment of the present disclosure. Referring to <FIG>, and <FIG>, at, the structure <NUM> having the surface <NUM> with <NUM> a first wettability is provided. As an example, the first wettability can be one in which water beads on the surface. As such, the first wettability can be a relatively low wettability in that water beads thereon, instead of flowing over the surface <NUM>. Next, at <NUM>, one or more areas are treated on the surface to alter the first wettability to a second wettability. The treatment can include superficial foaming, chemical etching, painting, printing, or the like. In at least one embodiment, the one or more areas are desired locations for the liquid flow paths <NUM>. As such, the second wettability is greater than the first wettability. That is, the second wettability allows for increased liquid flow, and decreased liquid beading.

As another example, the first wettability can be one in which water tends to flow over, as opposed to bead. As such, the first wettability can be a relatively high wettability. In this embodiment, areas on the surface <NUM> are treated to alter the first wettability to a second wettability that is less than the first wettability. As such, the areas that are formed through surface treatment can be those that are desired to be the banks <NUM>. The liquid flow paths <NUM> are formed between the banks <NUM>.

As described herein, embodiments of the present disclosure provide a method of forming one or more liquid flow paths on a surface of a structure. The method includes providing the structure, and treating at least a portion of the surface of the structure to alter or otherwise modify a wettability thereof. The treating defines the liquid flow paths. A first wettability of the portion of the surface differs from a second wettability of a remainder of the surface. In at least one embodiment, the first wettability allows for increased flow of liquid in comparison to the second wettability. In at least one other embodiment, the first wettability allows for decreased flow of liquid as compared to the second wettability.

In at least one embodiment, the treating increases the wettability, thereby providing the liquid flow paths at the locations of treatment (for example, at the portion(s) where treated). In at least one other embodiment, the treating decreases the wettability, thereby providing the liquid flow paths at locations other than the locations of the treatment (for example, at areas other than portion(s) where treated).

<FIG> illustrates a perspective front view of an aircraft <NUM>, according to an embodiment of the present disclosure. The aircraft <NUM> includes a propulsion system <NUM> that may include two turbofan engines <NUM>, for example. Optionally, the propulsion system <NUM> may include more engines <NUM> than shown. The engines <NUM> are carried by wings <NUM> of the aircraft <NUM>. In other embodiments, the engines <NUM> may be carried by a fuselage <NUM> and/or an empennage <NUM>. The empennage <NUM> may also support horizontal stabilizers <NUM> and a vertical stabilizer <NUM>.

The fuselage <NUM> of the aircraft <NUM> defines an internal cabin, which may be defined by interior sidewall panels that connect to a ceiling and a floor. The internal cabin may include a cockpit, one or more work sections (for example, galleys, personnel carry-on baggage areas, and the like), one or more passenger sections (for example, first class, business class, and coach sections), and an aft section. Portions of the aircraft <NUM>, such as panels within the internal cabin, can be formed by methods to form liquid flow paths, as described herein.

In examples not presently being claimed, instead of an aircraft, a panel assembly according to the present disclosure may be used with various other vehicles, such as automobiles, buses, locomotives and train cars, watercraft, spacecraft, and the like. As another example not presently being claimed, a panel assembly according to the present disclosure can be used to form structures having liquid flow paths for structures within buildings, articles of manufacture, or the like.

<FIG> illustrates a perspective view of a panel assembly <NUM> that forms a portion of wall <NUM> within an internal cabin of an aircraft, according to an embodiment of the present disclosure. The panel assembly <NUM> includes a plurality of window openings <NUM>. Optionally, the panel assembly <NUM> may not include window openings.

The panel assembly <NUM> includes a first or inner ply <NUM>, which faces the internal cabin. An outer surface <NUM> of the inner ply <NUM> facing away from the internal cabin may include a lining. For example, the lining may be secured to the outer surface <NUM>.

The panel assembly <NUM> also includes a second or outer ply <NUM>. In at least one embodiment, insulation <NUM> is secured to an inner surface <NUM> of the outer ply <NUM> facing toward the internal cabin. Optionally, the panel assembly <NUM> may not include the insulation <NUM>. An outer surface <NUM> of the outer ply <NUM> is opposite from the inner surface <NUM>.

An air gap <NUM> may be formed between the inner ply <NUM> and the outer ply <NUM>. The air gap <NUM> separates the inner ply <NUM> from the outer ply <NUM>. Optionally, the panel assembly <NUM> may not include the air gap. Instead, the inner ply <NUM> may be directly coupled to the outer ply <NUM>.

In at least one embodiment, one or more surfaces of the panel assembly <NUM> include liquid flow paths, as described herein. For example, the outer surface <NUM> of the inner ply <NUM> may include liquid flow paths, as described herein. As another example, the inner surface <NUM> of the outer ply <NUM> may include liquid flow paths. In at least one embodiment, both the outer surface <NUM> of the inner ply <NUM> and the inner surface <NUM> of the outer ply <NUM> may include liquid flow paths. In at least one embodiment, inner and outer surfaces of the inner ply <NUM> and inner and outer surfaces of the outer ply <NUM> may include liquid flow paths.

As shown in <FIG>, a wall of an internal cabin of an aircraft may include one or more panel assemblies <NUM>. Optionally, various other portions of the aircraft may be formed by one or more panel assemblies <NUM>. For example, interior monuments, such as lavatories, closets, cabinets, section dividers, and the like may include one or more panel assemblies <NUM>. As another example, portions of stowage bin assemblies may include one or more panel assemblies <NUM>. The panel assemblies <NUM> may be sized and shaped as desired.

<FIG> illustrates a front view of a surface <NUM> of a panel assembly <NUM>, according to an embodiment of the present disclosure. The panel assembly <NUM> shown in <FIG> is an example of the panel assembly <NUM>. The surface <NUM> has been treated to provide a liquid flow path <NUM>, as described herein. The surface <NUM> may be an outer and/or inner surface of an outer ply (such as the outer ply <NUM> shown in <FIG>), an outer and/or inner surface of an inner ply (such as the inner ply <NUM> shown in <FIG>), and/or the like.

The liquid flow path <NUM> includes a flow-directing network <NUM> that is configured to divert liquid to a desired location, such as toward a bottom <NUM> of the panel assembly <NUM>, via gravity or inertial force. The flow-directing network <NUM> includes a plurality of interconnected flow director elements <NUM> formed between banks <NUM>. The banks <NUM> provide barriers surrounding the flow-directing network <NUM>. The flow-director elements <NUM> have a first wettability that is configured to allow for fluid flow, while the banks <NUM> have a second wettability that resists fluid flow. The first wettability is associated with a first surface energy. The second wettability is associated with a second surface energy, which is lower than the first surface energy (conversely, the first surface energy is higher than the second surface energy). The first surface energy provides a smooth surface that allows for fluid flow. The second surface energy provides a rough surface (that is, rougher than the smooth surface provided by the first surface energy) that resists fluid flow. As such, liquid tends to bead on the banks <NUM>. The liquid beads on the banks <NUM> moves to the liquid flow paths <NUM>, via gravity, where the liquid then freely flows downwardly, via gravity, towards a desired location, such as towards the bottom <NUM>.

In at least one embodiment, one or more of the flow director elements <NUM> includes a central stem <NUM> connected to a first lateral branch <NUM> and a second lateral branch <NUM>. The central stem <NUM> provides a longitudinal channel that extends towards the bottom <NUM>. The central stem <NUM> may be a linear channel, formed as described herein. The first lateral branch <NUM> may be a mirror image of the second lateral branch <NUM>. The first lateral branch <NUM> and the second lateral branch <NUM> include an upper channel <NUM> that downwardly angles towards the central stem <NUM>. The upper channels <NUM> connect to an inwardly-curved channel <NUM> (which inwardly curve towards the central stem <NUM>). The inwardly-curved channel <NUM> connects to an outwardly-curved channel <NUM> that connects to a lower portion of the central stem <NUM>, thereby providing a union <NUM> between the central stem <NUM>, the first lateral branch <NUM>, and the second lateral branch <NUM>.

The flow director elements <NUM> may be sized and shaped differently than shown. In at least one embodiment, the flow director elements <NUM> include more or less branches. For example, the flow director elements <NUM> may include two lateral branches on either side of the central stem <NUM>. As another example, the flow director elements <NUM> may not include the central stem. As another example, the branches <NUM> and <NUM> may not be symmetrical about the central stem <NUM>.

As shown in <FIG>, the flow-directing network <NUM> includes a first row <NUM> of flow director elements <NUM> above a second row <NUM> of flow director elements <NUM>. The second row <NUM> may be above a third row of flow director elements, and so on. In at least one embodiment, the flow-directing network <NUM> may include only a single row of flow director elements <NUM>. In at least one embodiment, instead of a flow-director network <NUM>, the panel assembly <NUM> may include a single flow director element <NUM>. As shown in <FIG>, the union <NUM> of a flow director element <NUM> within the first row <NUM> connects to (for example, is in fluid communication with) a first lateral branch <NUM> of a first flow director element 508a of the second row <NUM> and a second lateral branch <NUM> of a second flow director element 508b of the second row <NUM>. As shown, the first lateral branch <NUM> of the first flow director element 508a is integrally formed and connected with the second lateral branch <NUM> of the second flow director element 508b. In this manner, flow director elements <NUM> within the first row <NUM> may interconnect and cascade with flow director elements <NUM> of the second row <NUM> (which may similarly interconnect and cascade with flow director elements <NUM> of a third row, and so on).

The flow director elements <NUM> within the first row <NUM> may be sized and shaped the same as the flow director elements <NUM> within the second row <NUM>. Optionally, the flow director elements <NUM> within the first row <NUM> may be sized and shaped differently than the flow director elements <NUM> within the second row <NUM>. For example, the central stems <NUM> and/or the first and second lateral branches <NUM> and <NUM> of the flow director elements <NUM> within the second row <NUM> may be larger (for example, have increased height and/or area) than those within first row <NUM>, or vice versa. The flow director elements <NUM> within each row may be sized and shaped the same or differently.

The flow director elements <NUM> provide a pattern formed by surface treatment, as described herein, that is configured to divert liquid toward a desired location, such as the bottom <NUM> of the panel assembly <NUM>. The sizes and shapes of the flow director elements <NUM> may vary depending on setting, application, part geometry, part orientation, and/or the like.

In operation, moisture that condenses on the rougher areas, defined by the banks <NUM>, forms beads. The external flow of liquid on the banks <NUM> flows in an uncontrolled manner until it intersects a portion of a flow director element <NUM>, which provides a relatively smooth area that promotes controlled flow of liquid. As liquid contacts a portion of the flow director element <NUM>, the liquid flows in a controlled manner within the flow director element <NUM>, via gravity, due to the relatively high surface energy of the flow director element <NUM>. Adhesion of the liquid to the higher surface energy of the flow director element <NUM> prevents, minimizes, or otherwise reduces the potential of the liquid flowing onto the banks <NUM>. The panel assembly <NUM> facilitates liquid flow by destabilizing droplet shapes on the roughened areas of the banks <NUM>, allowing inertial forces to dominate surface tension, and promote flow into and through the liquid flow path <NUM>, defined by the one or more flow director elements <NUM>.

<FIG> illustrates a perspective front view of a panel assembly <NUM>, according to an embodiment of the present disclosure. The panel assembly <NUM> shown in <FIG> and the panel assembly <NUM> shown in <FIG> are examples of and/or provide portions of the panel assembly <NUM> shown in <FIG>, or vice versa. As shown, the panel assembly <NUM> includes a liquid flow path <NUM> formed on a surface <NUM> thereof. The liquid flow path <NUM> includes a flow-directing network <NUM> of interconnected and cascading flow director elements <NUM>. For example, the flow-directing network <NUM> includes ten or more rows of interconnected flow director elements <NUM>. Optionally, the flow-directing network <NUM> may include less than ten rows of interconnected flow director elements <NUM>.

Liquid on the surface <NUM> beads on the banks <NUM> and moves, via gravity or inertial force, into the flow director elements <NUM>. The liquid flows downwardly in the direction of arrow A towards a lower drain channel <NUM> of the flow-directing network <NUM>. The lower drain channel <NUM> is formed in the same manner as the liquid flow directors <NUM>. That is, the lower drain channel <NUM> has a wettability that promotes liquid flow, in contrast to the banks <NUM>.

Lower drain channel <NUM> may include downwardly angled segments <NUM> that connect to the lowest row <NUM> of flow director elements <NUM>. The segments <NUM> may, in turn, connect to drain outlets <NUM>.

As shown, the height or area of the flow director elements <NUM> within higher rows may be less than the height or area of the flow director elements <NUM> within lower rows. That is, a height of flow director elements in lower rows is greater than a height of flow director elements in upper rows. The height of flow director elements may progressively increase as rows descend. For example, the height <NUM> of the flow director elements <NUM> within the highest row <NUM> may be less than the height <NUM> of the flow director elements <NUM> within the lowest row <NUM>. The increasing height progression from upper to lower rows accommodates and promotes increased flow rates.

As shown, the flow-directing network <NUM> is circuitous and tortuous, with numerous interconnected and cascading flow director elements <NUM>. The multiple potential paths for liquid flow defined by the numerous interconnected flow director elements <NUM> accommodate an increased volume of flow. That is, flow volume increases with the number of flow director elements <NUM>. Further, as shown, the interconnected flow director elements <NUM> define multiple directions for liquid flow, which ensures flow of liquid towards the bottom in the direction of arrow <NUM>, even during orientational changes (such as when an aircraft changes altitude or attitude). Moreover, the various directional changes defined by the numerous flow direction elements <NUM> within the flow-directing network <NUM> limit flow inertial velocity, which reduces a potential of a surge flow and/or liquid overflowing the banks <NUM>.

The panel assembly <NUM> may be formed of a composite thermoplastic or thermoset, for example. The pattern of flow director elements <NUM> within the flow-directing network <NUM> may be formed by surface treatment, as described herein. For example, the flow director elements <NUM> may be formed by texture pattern on a forming die, chemical etching on a metallic surface, and/or the like.

<FIG> illustrates a perspective internal view of an internal cabin <NUM> of a vehicle, (such as the aircraft <NUM> shown in <FIG>) according to an embodiment of the present disclosure. The internal cabin <NUM> includes numerous components that may be formed from and/or otherwise include panel assemblies, such as the panel assembly <NUM> (shown in <FIG>), the panel assembly <NUM> (shown in <FIG>), and the panel assembly <NUM> (shown in <FIG>). For example, ceiling panels <NUM>, stowage bin assemblies <NUM>, sidewall panels <NUM>, ceiling coves <NUM>, doorway arch panels <NUM>, doorway side panels <NUM>, partitions, closets, lavatory walls, light valences, and/or the like may include panel assemblies, as described herein.

<FIG> illustrates a liquid flow system <NUM>, according to an embodiment of the present disclosure. The liquid flow system <NUM> includes a first panel assembly <NUM> coupled to a second panel assembly <NUM>, which, in turn, is coupled to a bilge <NUM>, such as a bilge within an aircraft. The panel assemblies <NUM> and <NUM> are connected in series, with the first panel assembly <NUM> secured above the second panel assembly <NUM>. The first panel assembly <NUM> includes a flow channel <NUM> (for example, a liquid flow path) that leads into a flow channel <NUM> (for example, a liquid flow path) of the second panel assembly <NUM>. The flow channel <NUM> leads into the bilge <NUM>. The flow channels <NUM> and <NUM> are formed through surface treatment, as described herein. The flow channels <NUM> and <NUM> may be sized and shaped differently than shown. Further, the liquid flow system <NUM> may include more or less panel assemblies than shown.

The liquid flow system <NUM>, such as a flow directing network, may include includes at least one flow transmission orifice <NUM> on the boundary of the outer surface of the first panel assembly <NUM>. The area may be located and oriented such that liquid from the flow directing network is channeled to the orifice <NUM> and thus to adjacent aircraft components, such as to the second panel assembly <NUM>. The adjacent components may also include flow direction features.

As an example, the flow direction features of the adjacent component (for example, the second panel assembly <NUM>) may couple to a flow directing network of the first component (for example, the first panel assembly <NUM>). The flow directing network on the adjacent component may include a greater capacity such that liquid diverted by the at least one flow transmission orifice of the first component is accommodated along with moisture deposited on the outer surface of the second component from other sources.

In at least one embodiment, at least two adjacent components with surfaces that include flow directing networks are present such that liquid flows continuously across the outer surfaces of the at least two components. The surface of the at least two components may include a moisture control network that directs moisture towards a designated aircraft bilge zone, such as the bilge <NUM>.

As described herein, embodiments of the present disclosure provide panel assemblies and methods of forming panel assemblies that are configured to efficiently manage moisture, such as within an aircraft, for example. The structures include liquid flow paths that are formed through surface treatment. Embodiments of the present disclosure provide lightweight and cost-effective structures that are integrally formed with liquid flow paths. As such, weight for a system can be reduced as there is a reduced need for separate and distinct moisture management devices. Instead, the structures that form portions of a system, such as an aircraft, are integrally formed with their own liquid flow paths that divert moisture to desired locations.

Certain embodiments of the present disclosure provide a structure, such as a panel, sheet, or the like. The structure has a surface, such as an exposed outer surface. A portion of the surface is treated to modify a wettability of the portion of the structure. At least one liquid flow path is formed on the surface through the treated portion.

While various spatial and directional terms, such as top, bottom, lower, mid, lateral, horizontal, vertical, front and the like may be used to describe embodiments of the present disclosure, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. While the dimensions and types of materials described herein are intended to define the parameters of the various embodiments of the disclosure, the embodiments are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the various embodiments of the disclosure should, therefore, be determined with reference to the appended claims. In the appended claims, the terms "including" and "in which" are used as the plain-English equivalents of the respective terms "comprising" and "wherein. " Moreover, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

Claim 1:
A panel assembly (<NUM>, <NUM>, <NUM>) for moisture management within an aircraft, comprising:
at least one liquid flow path (<NUM>) formed on at least one surface (<NUM>, <NUM>, <NUM>) through surface (<NUM>, <NUM>, <NUM>) treatment,
wherein the at least one liquid flow path (<NUM>) is formed in relation to at least one bank (<NUM>) on the at least one surface (<NUM>, <NUM>, <NUM>), and
wherein the at least one liquid flow path (<NUM>) is configured to divert liquid to a desired location, wherein the at least one liquid flow path (<NUM>) has a first wettability (<NUM>) associated with a first surface energy of the liquid,
characterized in that the at least one bank (<NUM>) has a second wettability (<NUM>) which is lower than the first wettability (<NUM>) and which is associated with a second surface energy of the liquid lower than said first surface energy, wherein the first wettability (<NUM>) provides increased liquid flow compared to the second wettability (<NUM>).