Patent Description:
Today, cabinetry inside aircraft lavatories is typically formed of either injection-molded or thermoformed plastics. These injection-molded or thermoformed plastics are usually painted in solid colors. Cabinetry inside aircraft lavatories is visible and accessible to passengers within the aircraft.

Cabinetry in aircraft lavatories is desirably accessed only by aircraft personnel. Cabinetry in aircraft lavatories desirably contains consistent, tight gaps between cabinetry panels. Consistent, tight gaps between cabinetry panels create a desirable decorative appearance. Consistent, tight gaps between cabinetry panels may reduce visibility of doors in cabinetry to passengers.

Commercial aircraft are in service for decades. During the course of an aircraft's lifetime, components are replaced during maintenance due to wear or replacement schedules.

It would be desirable to have an improved ability to customize the decorative face of aircraft lavatory cabinets. It would also be desirable to reduce frequency of replacement of components of aircraft lavatory cabinetry.

The abstract of <CIT> reads 'An aircraft door includes a seal that integrates a flexible silicone seal portion and a rigid blade seal portion into a single continuous seal around the mold line gap between the door and frame. The arrangement allows for the use of space saving piano hinges to mount the door. The seal includes a rigid blade seal around three edges of the door and a flexible hinge cover seal adjacent to the hinge edge of the door. The flexible hinge cover seal is bonded to terminal blocks which in turn can be mounted to the door edge and to the door frame such that the flexible hinge cover seal covers the mold line gap adjacent to the hinge. ' Further prior art doors are disclosed in <CIT> and <CIT>.

The present disclosure provides an apparatus according to claim <NUM>.

The present disclosure recognizes and take into account one or more different considerations. For example, the present disclosure recognizes and takes into account that it is desirable to create cabinetry doors with greater durability to decrease replacement frequency. The present disclosure recognizes and takes into account that it is desirable to increase the strength of the doors of aircraft lavatory cabinetry. The present disclosure recognizes and takes into account that it is desirable to decrease the weight of aircraft components. The present disclosure recognizes and takes into account that it is desirable to maintain straight, tight gaps between door panels in lavatory cabinetry. The present disclosure recognizes and takes into account that it is desirable to prevent sagging doors in order to maintain straight, tight gaps between door panels in lavatory cabinetry.

The present disclosure recognizea and takes into account that composite sandwich panels have a high strength to weight ratio. The present disclosure recognizes and takes into account that to form composite sandwich panels, composite skins are compressed against a hollow cell core. The present disclosure recognizes and takes into account that conventionally, it is desirable to prevent over-crush of the hollow cell core.

The present disclosure s recognizes and takes into account that cut edges of composite sandwich panels have visible core cells. The present disclosure recognizes and takes into account that edge trim may be applied to cut edges of composite sandwich panels to cover the visible core cells. The present disclosure recognizes and takes into account that the edge trim is not considered desirably decorative or desirably durable by aircraft customers. The present disclosure recognizes and takes into account that the edge trim may cause doors in lavatory cabinetry to be undesirably visible to passengers. The present disclosure recognizes and takes into account that the presence of edge trims may call a passenger's attention to the fact that there is a door present. The present disclosure recognizes and takes into account that it is desirable for doors to remain effectively disguised from passengers.

The present disclosure recognizes and takes into account that the thickness of an edge of a composite sandwich panel affects the size of gaps in lavatory cabinetry. The present disclosure recognizes and takes into account that increasing the thickness of an edge of a composite sandwich panel increases the size of the gaps in the lavatory cabinetry.

The present disclosure presents an apparatus and method for forming a door comprising a composite sandwich panel. The present disclosure presents an apparatus comprising a composite sandwich panel, a seal, and a hinge. The composite sandwich panel has a first edge in a first over-crush edge region, wherein a thickness of the composite sandwich panel decreases within the first over-crush edge region in a direction towards the first edge. The seal is bonded to the first over-crush edge region of the composite sandwich panel and extending past the first edge. The hinge is connected to the composite sandwich panel such that an axis of rotation of the hinge is positioned over the first over-crush edge region of the composite sandwich panel.

Referring now to the figures and, in particular, with reference to <FIG>, an illustration of a block diagram of a manufacturing environment in which composite sandwich panels are used to form a door is depicted in accordance with the present disclosure. Composite sandwich panel <NUM> in manufacturing environment <NUM> has first edge <NUM> in first over-crush edge region <NUM>. Thickness <NUM> of composite sandwich panel <NUM> decreases within first over-crush edge region <NUM> in a direction towards first edge <NUM>.

Seal <NUM> is bonded to first over-crush edge region <NUM> of composite sandwich panel <NUM>. Seal <NUM> extends past first edge <NUM>.

Hinge <NUM> is connected to composite sandwich panel <NUM> such that axis of rotation <NUM> of hinge <NUM> is positioned over first over-crush edge region <NUM> of composite sandwich panel <NUM>.

In some illustrative examples, seal <NUM> ends before reaching hinge <NUM>. In some illustrative examples, a portion of seal <NUM> is sandwiched between hinge <NUM> and composite sandwich panel <NUM>.

Hinge <NUM> is a continuous hinge <NUM>. Continuous hinge <NUM> may also be referred to as a "piano hinge. " In some illustrative examples, continuous hinge <NUM> has length <NUM> equivalent to length <NUM> of first edge <NUM>. In some illustrative examples, hinge <NUM> is gooseneck hinge <NUM>.

Composite sandwich panel <NUM> comprises first composite skin <NUM>, second composite skin <NUM>, and hollow cell core <NUM> between first composite skin <NUM> and second composite skin <NUM>. First composite skin <NUM> and second composite skin <NUM> are compressed against hollow cell core <NUM> to form composite sandwich panel <NUM>. In some illustrative examples, hollow cell core <NUM> takes the form of honeycomb core <NUM>. In some illustrative examples, hollow cell core <NUM> is corrugated as shown in <FIG>.

Composite sandwich panel <NUM> has first face <NUM> and second face <NUM> opposite first face <NUM>. First face <NUM> is part of first composite skin <NUM>. Second face <NUM> is part of second composite skin <NUM>.

Second face <NUM> has concave surface <NUM> within first over-crush edge region <NUM>. Concave surface <NUM> may have any desirable shape. In some illustrative examples, concave surface <NUM> is curved. In some illustrative examples, concave surface <NUM> is a ramp. In some illustrative examples, concave surface <NUM> is a combination of straight and curved sections.

First edge <NUM> of first over-crush edge region <NUM> has first thickness <NUM>. First thickness <NUM> is less than nominal thickness <NUM> of composite sandwich panel <NUM>. Nominal thickness <NUM> is thickness <NUM> of composite sandwich panel <NUM> after consolidation of first composite skin <NUM>, hollow cell core <NUM>, and second composite skin <NUM> to form composite sandwich panel <NUM>. First thickness <NUM> is in the range of <NUM>%-<NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>. In some illustrative examples, first thickness <NUM> is in the range of <NUM>%-<NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>. In some illustrative examples, first thickness <NUM> has an <NUM>% over-crush. In these illustrative examples, first thickness <NUM> is approximately <NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>. In some illustrative examples, nominal thickness <NUM> may be referred to as an "uncrushed thickness.

First edge <NUM> is cut <NUM>. Portions of first composite skin <NUM>, hollow cell core <NUM>, and second composite skin <NUM> are visible at first edge <NUM>. First edge <NUM> has flat appearance <NUM> without visible core cells <NUM>.

In some illustrative examples, composite sandwich panel <NUM> further comprises second over-crush edge region <NUM>. Second over-crush edge region <NUM> comprises second edge <NUM> with second thickness <NUM>. Second thickness <NUM> is less than nominal thickness <NUM> of composite sandwich panel <NUM>. Second thickness <NUM> is in the range of <NUM>%-<NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>. In some illustrative examples, second thickness <NUM> is in the range of <NUM>%-<NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>. In some illustrative examples, second thickness <NUM> has an <NUM>% over-crush. In these illustrative examples, second thickness <NUM> is approximately <NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>.

Second edge <NUM> is cut <NUM>. Portions of first composite skin <NUM>, hollow cell core <NUM>, and second composite skin <NUM> are visible at second edge <NUM>. Second edge <NUM> has flat appearance <NUM> without visible core cells <NUM>.

In some illustrative examples, second face <NUM> has concave surface <NUM> within second over-crush edge region <NUM>. Concave surface <NUM> may have any desirable shape. In some illustrative examples, concave surface <NUM> is curved. In some illustrative examples, concave surface <NUM> is a ramp. In some illustrative examples, concave surface <NUM> is a combination of straight and curved sections.

In some illustrative examples, composite sandwich panel <NUM> further comprises third over-crush edge region <NUM>. Third over-crush edge region <NUM> comprises third edge <NUM> with third thickness <NUM>. Third thickness <NUM> is less than nominal thickness <NUM> of composite sandwich panel <NUM>. Third thickness <NUM> is in the range of <NUM>%-<NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>. In some illustrative examples, third thickness <NUM> is in the range of <NUM>%-<NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>. In some illustrative examples, third thickness <NUM> has an <NUM>% over-crush. In these illustrative examples, third thickness <NUM> is approximately <NUM>% of nominal thickness <NUM> of composite sandwich panel <NUM>.

Third edge <NUM> is cut <NUM>. Portions of first composite skin <NUM>, hollow cell core <NUM>, and second composite skin <NUM> are visible at third edge <NUM>. Third edge <NUM> has flat appearance <NUM> without visible core cells <NUM>.

In some illustrative examples, second face <NUM> has concave surface <NUM> within third over-crush edge region <NUM>. Concave surface <NUM> may have any desirable shape. In some illustrative examples, concave surface <NUM> is curved. In some illustrative examples, concave surface <NUM> is a ramp. In some illustrative examples, concave surface <NUM> is a combination of straight and curved sections.

Composite sandwich panel <NUM> comprises fourth edge <NUM>. Fourth edge <NUM> has fourth thickness <NUM>. Fourth thickness <NUM> is substantially the same as nominal thickness <NUM>. Fourth edge <NUM> has visible core cells <NUM>. In some illustrative examples, edge trim <NUM> is applied to fourth edge <NUM> to cover visible core cells <NUM>.

In some illustrative examples, portions of composite sandwich panel <NUM> are painted. In some illustrative examples, at least one of first face <NUM>, first edge <NUM>, second edge <NUM>, or third edge <NUM> is painted. In some illustrative examples, composite sandwich panel <NUM> further comprises decorative laminate <NUM>. In some illustrative examples, decorative laminate <NUM> covers first face <NUM> and first edge <NUM>. In some illustrative examples, decorative laminate <NUM> covers first face <NUM>, first edge <NUM>, second edge <NUM>, and third edge <NUM>.

By forming composite sandwich panel <NUM> in a crush core press, at least one edge is "over-crushed" to the point that the at least one edge behaves like solid fiberglass. In this illustrative example, each of first edge <NUM>, second edge <NUM>, and third edge <NUM> is produced using an "over-crush" process. The "over-crush" process uses heat and pressure to compress hollow cell core <NUM>, first composite skin <NUM>, and second composite skin <NUM> into a solid substrate along each of first edge <NUM>, second edge <NUM>, and third edge <NUM> of composite sandwich panel <NUM>.

By using this "over-crush" process on first edge <NUM>, second edge <NUM>, and third edge <NUM>, durable edges are created that do not use edge trims. By using this "over-crush" process, door <NUM> takes advantage of the benefits of a composite sandwich panel having a hollow cell core. In particular, a strength and a stiffness of composite sandwich panel <NUM> is maintained. Increasing a strength and a stiffness of door <NUM> results in a more durable product.

Fourth edge <NUM> of composite sandwich panel <NUM>, which is not over-crushed, allows volatile compounds to escape during the molding process. An injection-molded edge trim, such as edge trim <NUM>, can be applied to fourth edge <NUM>. In some illustrative examples, fourth edge <NUM> is hidden beneath a countertop where edge trim <NUM> does not create a decorative concern.

To form composite sandwich panel <NUM>, hollow cell core <NUM>, first composite skin <NUM>, and second composite skin <NUM> are placed into tool <NUM> with dies <NUM>. When closed, dies <NUM> of tool <NUM> form interior shape <NUM>. Interior shape <NUM> applies "over-crush" pressure to portions of composite sandwich panel <NUM> to form first over-crush edge region <NUM>, second over-crush edge region <NUM>, and third over-crush edge region <NUM>.

After performing an "over-crush" process to form composite sandwich panel <NUM>, composite sandwich panel <NUM> is cut using numerically controlled machinery <NUM>. Numerically controlled machinery <NUM> is used to form cut <NUM> first edge <NUM>, cut <NUM> second edge <NUM>, and cut <NUM> third edge <NUM>.

In some illustrative examples, composite sandwich panel <NUM>, seal <NUM>, and hinge <NUM> form door assembly <NUM>. Door assembly <NUM> is installed into cabinetry to form a door, such as door <NUM> of cabinetry <NUM>.

Seal <NUM> is configured to perform desired functions in door assembly <NUM>. Seal <NUM> is configured to close a gap of door assembly <NUM> in cabinetry, such as cabinetry <NUM>. In some illustrative examples, seal <NUM> is formed of polymeric material <NUM>. In some illustrative examples, seal <NUM> is formed of silicone <NUM>. In some illustrative examples, polymeric material <NUM> is reinforced <NUM>. Seal <NUM> is bonded to first over-crush edge region <NUM> after using numerically controlled machinery <NUM> used to form cut <NUM> first edge <NUM>.

After bonding seal <NUM> to first over-crush edge region <NUM>, hinge <NUM> is connected to composite sandwich panel <NUM>. In some illustrative examples, hinge <NUM> is also connected to cabinetry <NUM> in lavatory <NUM> of aircraft <NUM>. In some illustrative examples, hinge <NUM> is connected to composite sandwich panel <NUM> prior to connecting hinge <NUM> to cabinetry <NUM>. In some illustrative examples, hinge <NUM> is connected to cabinetry <NUM> prior to connecting hinge <NUM> to composite sandwich panel <NUM>.

Hinge <NUM> is connected to composite sandwich panel <NUM> using fasteners <NUM>. In some illustrative examples, prior to connecting hinge <NUM> to composite sandwich panel <NUM>, drilling and potting steps are performed on composite sandwich panel <NUM>. In these illustrative examples, the drilling and potting steps position fastener receivers. In these illustrative examples, fasteners <NUM> are connected to fastener receivers in composite sandwich panel <NUM>.

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. In other words, "at least one of" means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item may be a particular object, a thing, or a category.

This example also may include item A, item B, and item C, or item B and item C. Of course, any combination 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 illustration of manufacturing environment <NUM> in <FIG> is not meant to imply physical or architectural limitations to the manner in which the present disclosure may be implemented. Other components in addition to or in place of the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in the present disclosure.

Turning now to <FIG>, an illustration of a front view of a lavatory cabinetry with a door formed of a composite sandwich panel is depicted in accordance with the present disclosure. Cabinetry <NUM> is a physical implementation of cabinetry <NUM> of <FIG>.

Cabinetry <NUM> has door <NUM> and door <NUM>. Door <NUM> may be a physical implementation of door <NUM> of <FIG>. Door <NUM> may be a physical implementation of door <NUM> of <FIG>.

In some illustrative examples, cabinetry <NUM> is positioned in lavatory <NUM> of <FIG>. In some illustrative examples, cabinetry <NUM> may be positioned beneath a countertop.

Cabinetry <NUM> is configured to have desirable durability. Further, cabinetry <NUM> is designed such that door <NUM> and door <NUM> are not obviously doors. Cabinetry <NUM> is designed such that passengers in an aircraft do not probe door <NUM> and door <NUM>.

Turning now to <FIG>, an illustration of a back view of a lavatory cabinetry with a door formed of a composite sandwich panel is depicted in accordance with the present disclosure. View <NUM> is a back view of cabinetry <NUM>. As depicted, door <NUM> is connected to hinge <NUM>. As depicted, door <NUM> is connected to hinge <NUM>.

Using hinge <NUM>, door <NUM> opens in direction <NUM>. Using hinge <NUM>, door <NUM> opens in direction <NUM>.

Turning now to <FIG>, an illustration of a front isometric view of a composite sandwich panel is depicted in accordance with the present disclosure. Composite sandwich panel <NUM> is a physical implementation of composite sandwich panel <NUM> of <FIG>. In some illustrative examples, composite sandwich panel <NUM> is a component of door <NUM> of <FIG>.

As depicted, composite sandwich panel <NUM> has first edge <NUM>, second edge <NUM>, third edge <NUM>, and fourth edge <NUM>. Each of first edge <NUM>, second edge <NUM>, and third edge <NUM> has a flat appearance without visible core cells. First edge <NUM> is in first over-crush edge region <NUM>. First over-crush edge region <NUM> has concave surface <NUM>.

Second edge <NUM> is in second over-crush edge region <NUM>. Second over-crush edge region <NUM> has concave surface <NUM>. Third edge <NUM> is in third over-crush edge region <NUM>. Third over-crush edge region <NUM> has concave surface <NUM>.

Turning now to <FIG>, an illustration of a back isometric view of a composite sandwich panel is depicted in accordance with the present disclosure. View <NUM> is a back isometric view of composite sandwich panel <NUM> from fourth edge <NUM>.

As depicted, fourth edge <NUM> has visible core cells <NUM>. In some illustrative examples, prior to being placed into service, an edge treatment will be applied to fourth edge <NUM>. In some illustrative examples, prior to being placed into service, an edge trim is adhered to fourth edge <NUM>.

Turning now to <FIG>, an illustration of a front isometric view of a composite sandwich panel with a seal is depicted in accordance with the present disclosure. In view <NUM>, seal <NUM> has been bonded to first over-crush edge region <NUM>. Seal <NUM> extends past first edge <NUM>. Seal <NUM> is a physical implementation of seal <NUM> of <FIG>.

Seal <NUM> is formed of any desirable material. In some illustrative examples, seal <NUM> is formed of a polymeric material. In some illustrative examples, seal <NUM> is formed of a reinforced material.

Turning now to <FIG>, an illustration of a front isometric view of a composite sandwich panel with a seal and a hinge is depicted in accordance with the present disclosure. In view <NUM>, hinge <NUM> has been connected to composite sandwich panel <NUM> such that axis of rotation <NUM> of hinge <NUM> is positioned over first over-crush edge region <NUM> of composite sandwich panel <NUM>. As depicted, hinge <NUM> is continuous hinge <NUM>. As depicted, hinge <NUM> is gooseneck hinge <NUM>.

In some illustrative examples, composite sandwich panel <NUM>, seal <NUM>, and hinge <NUM> are referred to as door assembly <NUM>. Composite sandwich panel <NUM> has cut first edge <NUM>, cut second edge <NUM>, and cut third edge <NUM> each with a flat appearance without visible core cells. As depicted, seal <NUM> is bonded to composite sandwich panel <NUM> adjacent cut first edge <NUM>. Hinge <NUM> is connected to composite sandwich panel <NUM> adjacent cut first edge <NUM>.

As depicted, cut first edge <NUM> is within first over-crush edge region <NUM> of composite sandwich panel <NUM>, wherein seal <NUM> is bonded to first over-crush edge region <NUM>. As depicted, hinge <NUM> is connected to composite sandwich panel <NUM> such that an axis of rotation of hinge <NUM> is positioned over first over-crush edge region <NUM>.

Turning now to <FIG>, an illustration of a side view of a composite sandwich panel is depicted in accordance with the present disclosure. View <NUM> is a side view of first over-crush edge region <NUM> of composite sandwich panel <NUM>.

As depicted, concave surface <NUM> of first over-crush edge region <NUM> is curved <NUM>. As depicted, first edge <NUM> is cut <NUM>. Thickness <NUM> of first edge <NUM> is considerably less than nominal thickness <NUM> of composite sandwich panel <NUM>.

Turning now to <FIG>, an illustration of a side view of a composite sandwich panel with a seal is depicted in accordance with the present disclosure. View <NUM> is a side view of first over-crush edge region <NUM> of composite sandwich panel <NUM> with seal <NUM>. As depicted, seal <NUM> extends over first edge <NUM>. As depicted, seal <NUM> stops within first over-crush edge region <NUM>.

Turning now to <FIG>, an illustration of a side view of a composite sandwich panel with a seal and a hinge is depicted in accordance with the present disclosure. View <NUM> is a side view of first over-crush edge region <NUM> of composite sandwich panel <NUM> with seal <NUM> and hinge <NUM>. Hinge <NUM> has been connected to composite sandwich panel <NUM> such that axis of rotation <NUM> of hinge <NUM> is positioned over first over-crush edge region <NUM> of composite sandwich panel <NUM>. As depicted, hinge <NUM> is gooseneck hinge <NUM>. As depicted, seal <NUM> ends prior to hinge <NUM>.

Turning now to <FIG>, another illustration of a side view of a composite sandwich panel with a seal and a hinge is depicted in accordance with the present disclosure. View <NUM> is a side view of first over-crush edge region <NUM> of composite sandwich panel <NUM> with seal <NUM> and hinge <NUM>. Hinge <NUM> has been connected to composite sandwich panel <NUM> such that axis of rotation <NUM> of hinge <NUM> is positioned over first over-crush edge region <NUM> of composite sandwich panel <NUM>. As depicted, hinge <NUM> is gooseneck hinge <NUM>. As depicted, a portion of seal <NUM> is sandwiched between hinge <NUM> and composite sandwich panel <NUM>.

Turning now to <FIG>, an illustration of a side view of a composite sandwich panel with a seal and a hinge installed in cabinetry and in a closed position is depicted in accordance with the present disclosure. View <NUM> is a side view of composite sandwich panel <NUM>. Composite sandwich panel <NUM> is a physical implementation of composite sandwich panel <NUM> of <FIG>. Composite sandwich panel <NUM> may be composite sandwich panel <NUM> of <FIG>. In some illustrative examples, composite sandwich panel <NUM> is a component of one of door <NUM> or door <NUM>.

As depicted, composite sandwich panel <NUM> has first over-crush edge region <NUM> with first edge <NUM>. Seal <NUM> is bonded to first over-crush edge region <NUM>. Hinge <NUM> is connected to composite sandwich panel <NUM> such that axis of rotation <NUM> is positioned over first over-crush edge region <NUM>.

Hinge <NUM> is also connected to supporting structure <NUM> of cabinetry <NUM>. Door assembly <NUM> including composite sandwich panel <NUM>, seal <NUM>, and hinge <NUM> is in closed position <NUM>. Connecting hinge <NUM> to cabinetry <NUM> forms a composite door, such as door <NUM> or door <NUM> of <FIG>. In closed position <NUM>, seal <NUM> contacts facing <NUM>. In closed position <NUM>, first face <NUM> is substantially flush with facing <NUM>. Seal <NUM> seals gap <NUM> between composite sandwich panel <NUM> and facing <NUM>. Seal <NUM> deters entry of water or other contaminates to interior <NUM> of cabinetry <NUM>.

For an acceptable appearance, consistent, tight gaps are desirable between panels. Gaps are desirably closed out while not sacrificing a decorative appearance. When a decorative laminate is applied to composite sandwich panel <NUM>, seal <NUM> can be colored to match the decorative laminate. Seal <NUM> is configured to close out any gaps with a consistent appearance.

Turning now to <FIG>, an illustration of a side view of a composite sandwich panel with a seal and a hinge installed in cabinetry and in an open position is depicted in accordance with the present disclosure. View <NUM> is a side view of composite sandwich panel <NUM>. In view <NUM>, door assembly <NUM> is in open position <NUM>.

Turning now to <FIG>, an illustration of a flowchart of a method for forming and using a composite sandwich panel is depicted in accordance with the present disclosure. Method <NUM> may be used to form door assembly <NUM> of <FIG> or door assembly <NUM> of <FIG>. Method <NUM> may be used to form any of composite sandwich panel <NUM> of <FIG>, composite sandwich panel <NUM> of <FIG>, or composite sandwich panel <NUM> of <FIG>.

Method <NUM> bonds a seal to a first over-crush edge region of a composite sandwich panel, wherein a thickness of the composite sandwich panel decreases within the first over-crush edge region in a direction towards a first edge of the composite sandwich panel within the first over-crush edge region (operation <NUM>). Method <NUM> connects a hinge to the first over-crush edge region of the composite sandwich panel (operation <NUM>). Afterwards, the method terminates.

In some illustrative examples, method <NUM> also connects the hinge to cabinetry to form a composite door (operation <NUM>). In some illustrative examples, the cabinetry is within a lavatory of an aircraft (operation <NUM>).

In some illustrative examples, method <NUM> applies heat and a compressive force to the composite sandwich panel to form the first over-crush edge region (operation <NUM>). In some illustrative examples, method <NUM> applies a decorative laminate over a first face and the first edge of the composite sandwich panel (operation <NUM>).

The first face is opposite to a second face having a concave surface in the first over-crush edge region (operation <NUM>). In some illustrative examples, method <NUM> applies heat and a compressive force to the composite sandwich panel to form a second over-crush edge region and a third over-crush edge region (operation <NUM>).

In some illustrative examples, method <NUM> allows volatiles to escape through a fourth edge of the composite sandwich panel while forming the second over-crush edge region and the third over-crush edge region of the composite sandwich panel (operation <NUM>). In some illustrative examples, method <NUM> applies a decorative laminate over the first edge, a second edge within the second over-crush edge region, and a third edge within the third over-crush edge region (operation <NUM>). In some illustrative examples, method <NUM> applies an edge trim to the fourth edge (operation <NUM>).

The flowcharts and block diagrams illustrate the architecture, functionality, and operation of some possible implementations of apparatus and methods in the present disclosure. 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.

In some alternative implementations of, 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.

In some illustrative examples, not all blocks of method <NUM> are performed. For example, operations <NUM> through <NUM> are optional.

The present 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>, an illustration of an aircraft manufacturing and service method is depicted in accordance with the present disclosure. During pre-production, aircraft manufacturing and service method <NUM> may include specification and design <NUM> of aircraft <NUM> in <FIG> and material procurement <NUM>.

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

For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers or major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, or suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, and so on.

With reference now to <FIG>, an illustration of an aircraft is depicted in which the present disclosure may be implemented. In this example, aircraft <NUM> is produced by aircraft manufacturing and service method <NUM> in <FIG> and may include airframe <NUM> with a 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, the present disclosure 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>. The present disclosure may be used during component and subassembly manufacturing <NUM>, system integration <NUM>, or maintenance and service <NUM> of <FIG>. For example, door assembly <NUM> including composite sandwich panel <NUM> may assembled during component and subassembly manufacturing <NUM>. As another example, door assembly <NUM> including composite sandwich panel <NUM> may be a replacement part during maintenance and service <NUM> of <FIG>.

Apparatuses and methods embodied herein may be employed in manufacturing at least one component of aircraft <NUM>. For example, composite sandwich panel <NUM> of <FIG> may be manufactured to form a portion of interior <NUM>.

The illustrative examples present methods and apparatuses to use composite sandwich panels, including fiberglass panels, in lieu of standard thermoplastic doors. The illustrative examples present crushed core fiberglass door panels to be used in cabinetry. In some illustrative examples, the cabinetry may be present in the lavatory of an aircraft.

As presented, the over-crushed door panels can be painted. It is also possible to apply decorative laminates to the decorative surfaces of the over-crushed door panels. The decorative laminate can be wrapped around the three crushed edges for a seamless appearance.

The use of these over-crushed door panels may increase durability and aesthetics. It is desirable to maintain consistent, tight gaps between panels. It is also desirable to close out gaps while not sacrificing a decorative appearance.

By bonding a flap seal to the over-crushed edges of the panel, the gaps are closed out. The seal can be colored to match the decorative laminate applied to the panel, and the seal closes out any gaps with a consistent appearance.

Claim 1:
An apparatus comprising:
a composite sandwich panel (<NUM>) having a first edge (<NUM>) in a first over-crush edge region (<NUM>), wherein a thickness (<NUM>) of the composite sandwich panel (<NUM>) decreases within the first over-crush edge region (<NUM>) in a direction towards the first edge (<NUM>);
a seal (<NUM>) bonded to the first over-crush edge region (<NUM>) of the composite sandwich panel (<NUM>) and extending past the first edge (<NUM>); and
a hinge (<NUM>) connected to the composite sandwich panel (<NUM>) such that an axis of rotation (<NUM>) of the hinge (<NUM>) is positioned over the first over-crush edge region (<NUM>) of the composite sandwich panel (<NUM>), wherein the hinge (<NUM>) is a continuous hinge (<NUM>),
wherein the composite sandwich panel (<NUM>) has a first face (<NUM>) and a second face (<NUM>) opposite the first face (<NUM>), and wherein the second face (<NUM>) has a concave surface (<NUM>) within the first over-crush edge region (<NUM>), and wherein the seal (<NUM>) is bonded to the concave surface (<NUM>) of the second face (<NUM>).