Acoustic cabin panel

Abstract

The present invention relates to acoustical panels. As to provide a cabin panel to be made as simple as possible and with optimized acoustical properties, an acoustical cabin panel (10) is provided that comprises a first (12) and a second layer (14) which are spaced apart from each other by an intermediate layer (16) and altogether with a plurality of reinforcement elements (22) form a core composite component (24). Furthermore, the panel comprises at least one intermediate layer (18) made of a core material (20) which is arranged in the intermediate layer. The reinforcement elements extend from the first to the second layer through the at least one intermediate film and are tension and pressure resilient in a finished state of the panel. The reinforcement elements can be at least partially infiltrated with a curable matrix material and at least one prepreg (26) soaked with matrix material is provided in the first and/or second layer. Thereby, the reinforcement elements to be infiltrated with matrix material are connected to the prepreg.

Claims

1. An acoustical cabin panel, comprising: a first and a second layer which are spaced apart from each other by an intermediate layer and altogether with a plurality of reinforcement elements form a core composite component; at least one intermediate sublayer made of a core material that is placed in the intermediate layer; wherein the reinforcement elements extend from the first to the second layer through the at least one intermediate sublayer and are tension and pressure resilient in a finished state of the panel; wherein the reinforcement elements can be at least partially infiltrated with a curable matrix material; wherein at least one prepreg soaked with matrix material is provided in the first and/or second layer; wherein the reinforcement elements to be infiltrated with matrix material are in connection with the prepreg; and wherein the core material is a silicone foam rubber.

2. The acoustical cabin panel according to claim 1, wherein the intermediate sublayer comprises a material which is elastically compressible and has a low rigidity.

3. The acoustical cabin panel according to claim 1, where the reinforcement elements are bend-proof; and wherein the reinforcement elements are connected to the first and second layer.

4. The acoustical cabin panel according to claim 1, wherein the reinforcement elements are formed as thread elements; and wherein the thread elements are infiltrated with the curable matrix material.

5. The acoustical cabin panel according to claim 1, wherein the reinforcement elements are inclined with respect to a layer direction, S.sub.R and layer thickness, S.sub.D.

6. The acoustical cabin panel according to claim 1, wherein the intermediate sublayer is provided with a blocking treatment at least in the area of reinforcement elements, wherein the blocking treatment prevents matrix material from entering when infiltrating the reinforcement elements.

7. The acoustical cabin panel according to claim 1, wherein the first and the second layer are made of fiber-reinforced plastic and/or of metal material.

8. An aircraft comprising at least one cabin section located in a fuselage construction, the cabin section comprising an interior trim having panels; wherein at least one of the panels is an acoustical cabin panel, the acoustical cabin panel comprising: a first and a second layer which are spaced apart from each other by an intermediate layer and altogether with a plurality of reinforcement elements form a core composite component; at least one intermediate sublayer made of a core material that is placed in the intermediate layer; wherein the reinforcement elements extend from the first to the second layer through the at least one intermediate sublayer and are tension and pressure resilient in a finished state of the panel; wherein the reinforcement elements can be at least partially infiltrated with a curable matrix material; wherein at least one prepreg soaked with matrix material is provided in the first and/or second layer; wherein the reinforcement elements to be infiltrated with matrix material are in connection with the prepreg; and wherein the core material is a silicone foam rubber.

9. A method for manufacturing an acoustical cabin panel, comprising the following steps: arranging an intermediate layer between a first and a second layer which are spaced apart by the intermediate layer; wherein the intermediate layer comprises at least one intermediate sublayer made of a core material that is arranged in the intermediate layer, wherein the core material is a silicone foam rubber; wherein a prepreg soaked with matrix material is provided in at least one of the first and second layer; arranging a plurality of reinforcement elements which extend from the first to the second layer through the at least one intermediate sublayer and which are tension and pressure resilient in the finished state of the panel; and infiltrating at least a part of the reinforcement elements with a curable matrix material; wherein the first layer, the intermediate layer and the second layer, together with the reinforcement elements form a core composite component.

10. The method according to claim 9, wherein the reinforcement elements are formed as thread elements; and wherein the method further comprises: curing of the matrix material.

11. The method according to claim 9, wherein prior to the curing of the matrix material provision is made for adjusting to a shape or a contour.

12. The method according to claim 9, where prior to the completed curing of the matrix material provision is made for curing the matrix material partly, so that the matrix material then is in a B-stage condition in which a part of the matrix material is cured and a part is not cured; and wherein provision is made for the adjusting to a shape or a contour afterwards.

13. The method according to claim 11, wherein the arranging of the reinforcement elements takes place prior to the shaping.

14. The method according to claim 9, wherein the prepreg soaked with matrix material is provided in one of the first and second layer; and wherein a shaping takes place prior to the application of a prepreg soaked with matrix material in the other one of the first and second layer and the prepreg soaked with matrix material is applied afterwards.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The various embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:

(2) FIG. 1 is a cross-section through an example of an acoustical cabin panel;

(3) FIG. 2A is another example of an acoustical cabin panel in the cross-section;

(4) FIG. 2B is a further example of an acoustical cabin panel with several intermediate layers;

(5) FIG. 2C is another example of an acoustical cabin panel with several core composite structures;

(6) FIG. 3 is a cross-section of a cabin panel in an example with inclined reinforcement elements;

(7) FIG. 4 is another example of an acoustical cabin panel with a reinforcement elements formed as sewing;

(8) FIG. 5 is an example of an aircraft with a cabin area with acoustical cabin panels as interior trim in a schematic cross-section;

(9) FIG. 6 is an example of a method for manufacturing an acoustical cabin panel; and

(10) FIG. 7 is another example of a manufacturing method.

DETAILED DESCRIPTION

(11) The following detailed description is merely exemplary in nature and is not intended to limit the disclosed embodiments or the application and uses thereof. Furthermore, there is no intention to be bound by any theory presented in the preceding background detailed description.

(12) FIG. 1 shows an acoustical cabin panel 10 which comprises a first layer 12 and a second layer 14, with an intermediate layer 16 provided in between 16, by which intermediate layer the first and the second layer 12, 14 are spaced apart from each other. At least one intermediate sublayer 18 made of core material 20 is provided in the intermediate layer 16.

(13) The first and the second layer 12, 14, form together with a plurality of reinforcement elements 22 a core composite component 24. The reinforcement elements 22 are tension resilient and pressure resilient and extend from the first layer 12 to the second layer 14 through the at least one intermediate sublayer 18. The reinforcement elements can be at least partially infiltrated with a curable matrix material (not shown). Therefore, at least one prepreg 26 soaked with matrix material (in FIG. 1 indicated by a hatching) is provided in the first and/or second layer. The reinforcement elements 22 to be infiltrated with matrix material are connected to the prepreg 26.

(14) The first layer 12 can also be referred to as the first top layer, while the second layer 14 can be referred to as a second top layer.

(15) In FIG. 1 the first layer 12 is shown as the prepreg 26 soaked with matrix material and the second layer 14 is shown as a different layer 28, which is indicated with a different cross sectional view is. In a further example which is not shown both the first and the second layer 12, 14 are formed as prepreg.

(16) In accordance with an example the intermediate sublayer 18 is made of a material which is elastically compressible and which is of a low rigidity. For example, the intermediate sublayer has a low E-module, for example to a value lower than 1 Giga Pascal, for example in a range of 0.1 to 0.01 Giga Pascal. For example, the intermediate sublayer 18 consists of a foam material 30, for example from a silicone foam rubber.

(17) FIG. 2A shows another example where the intermediate layer 16 is formed of two intermediate sublayers 18a, 18b. The two intermediate sublayers 18a, 18b both may be made of the same core material or with different core materials. For example, the reinforcement elements 22 extend through both intermediate sublayers 18a, 18b.

(18) For example, one of the two intermediate sublayers comprises the elastically compressible material having a low rigidity and the other of the two intermediate sublayers comprises a different material, such as a more rigid material.

(19) The reinforcement elements 22 are shown with a single line in the figures. The reinforcement elements 22 can be different, in particular having different cross-sections and diameters. For example, the reinforcement elements 22 have a diameter in the range of approx. 0.1 mm up to approx. 5 mm, e.g. a diameter of 0.5 mm to 1.5 mm.

(20) In FIG. 2B an embodiment is shown in which a first intermediate layer 18 is positioned between the first layer 12 and a further layer 32, which forms a second layer when referring to the intermediate sublayer 18 a forms a first layer when referring to a further intermediate sublayer 18. On the opposite side is yet another, outer layer arranged that acts as the second layer 14 for the further intermediate sublayer 18. The reinforcement elements 22 can be arranged continuously, i.e. from the one outer layer to the opposite second outer layer, or can be arranged offset, as indicated by reference signs 22.

(21) FIG. 2C shows a further embodiment in which a first core composite 24a and a second core composite 24b are provided together with the respective first and second layers 12, 14 and an intermediate layer 16 arranged in between. Between the two core components 24a, 24b a further layer 34 is provided, for example with a supporting structure or as further dampening structure depending on the requirement profile.

(22) In accordance with a further example it is provided that the reinforcement elements are bend-proof and connected to the first and the second layer.

(23) The reinforcement elements 22 can be perpendicular to the slice direction, i.e. parallel to the slice thickness as indicated in the FIGS. 1, 2A, 2B and 2C.

(24) In FIG. 3 is an embodiment is shown in which the reinforcement elements 22 are inclined, e.g. to a layer direction S.sub.R and a layer thickness S.sub.D.

(25) FIG. 4 shows an example in which the reinforcement elements 22 are formed as sewing and establish the connection between the reinforcement elements 22 and the first and second layer 12, 14 in a loop-like manner, as indicated by reference sign 36. The sewing can be provided for example as a diagonally extending zigzag pattern, or can be provided perpendicularly extending with the straps then being formed as a kind of bridging segments 38.

(26) In accordance with a further example shown as an option in FIG. 4, an additional layer can be provided on at least one of the two outer surfaces of the first or second layer 12, 14, the additional layer being for example a protective layer against UV radiation or other influences, or also as a further layer to influence the acoustical properties, e.g. as a diffuser. The additional layer 40 may also be the optical completion of a cabin panel facing the passenger cabin.

(27) As already mentioned, in accordance with a further example the reinforcement elements 22 can be formed as thread elements which can be infiltrated with the curable matrix material.

(28) In accordance with a (not further shown) embodiment a blocking treatment of the intermediate sublayer is provided at least in the area of the reinforcement elements as to prevent an intrusion of matrix material into the intermediate sublayer.

(29) FIG. 5 shows an aircraft 100 in a schematic cross-section. The aircraft 100 comprises a fuselage construction 102 and a cabin section 104 located therein. The cabin section 104 comprises an interior trim 106. To improve the acoustical properties at least a part of the interior trim is formed as acoustical cabin panels in accordance with one of the above mentioned embodiments. In the cabin area, which is separated from a cargo loading area 110 lying underneath for example by means of an intermediate floor construction 108, passenger seats 112 are schematically indicated. It should be noted that further installations, such as luggage compartments above the seats, are not shown as to simplify the drawings. The aircraft 100 is also shown equipped with wing constructions 114 on which engines 116 are arranged, for example. By providing at least a part of the interior trim panels 106 as acoustical cabin panels 10 the comfort of the passengers on board the aircraft is improved in terms of acoustics, for example by at least dampening a sound transmission from the turbines 116 arranged outside into the cabin area 104 through the panels.

(30) FIG. 6 shows an example of a method 200 for manufacturing an acoustical cabin panel. The method 200 comprises the following steps:

(31) In a first step 202 an intermediate layer is arranged between a first and a second layer, wherein the first and the second layer are spaced apart from each other through the intermediate layer. The intermediate layer comprises at least one intermediate sublayer made of a core material that is arranged in the intermediate layer. In accordance with the description a prepreg soaked with matrix material is provided in at least one of the first and second layers.

(32) In a second step 204 a plurality of reinforcement elements is arranged which extend from the first to the second layer through the at least one intermediate sublayer and which are tension and pressure resilient in the finished state of the panel.

(33) In a third step 206 at least a part of the reinforcement elements is infiltrated with a curable matrix material. The first layer, the intermediate layer and the second layer and the reinforcement elements altogether form a core composite component.

(34) In FIG. 6 it is also shown as an option that the reinforcement elements can be designed as thread elements wherein further a fourth step 208 is provided, in which the matrix material is cured.

(35) In a further example, the curing is also planned with reinforcement elements which are not provided as thread elements, but as pins or other applications, for example.

(36) The first step 202 is also referred to as step a), the second step 204 as step b), the third step 206 as step c), and the optionally shown fourth step 208 as step d).

(37) In FIG. 7 a further example is shown in which prior to the curing of the matrix material in the fourth step 208 a further step 210 is provided in which a customization to a shape or a contour takes place. For example, the arranging of the reinforcement elements in the second step 204 takes place prior to the shaping of the further step 210.

(38) In FIG. 7 it is shown, for example, that the shaping in the further step 210 takes place after the infiltration in the third step 206.

(39) In a further example it is provided that the shaping takes place before the infiltration of the reinforcement elements.

(40) The examples described above can be combined in different ways. In particular, aspects of the devices can be used for embodiments of the method and use of the devices and vice versa.

(41) Additionally, it is noted that comprising does not exclude other elements or steps and one or a does not exclude a plurality. It should also be noted that features or steps that are described with reference to one of the above embodiments can also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims are not to be construed as limitation.

(42) While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the embodiment in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the embodiment as set forth in the appended claims and their legal equivalents.