Composite panels assembly, furniture comprising such assembly and aircraft comprising such assembly

Abstract

A composite panel assembly including a first panel with a first skin, a second skin, a core, and an assembly flange. A second panel includes a first skin, a second skin, a core, and an assembly flange. A fastening device is adapted to fasten the assembly flange of the first panel to the assembly flange of the second panel, wherein the core of one of the first panel or the second panel includes reinforcing pins and a high-density portion placed along the assembly flange.

Claims

1. A composite panel assembly comprising: a first panel comprising: a first layer forming a first skin; a second layer forming a second skin; a third layer forming a core, the core being between the first skin and the second skin; and wherein the first layer, the second layer, and the third layer are arranged to form a panel portion in which the first skin and the second skin are substantially parallel to each other with the core in between, an assembly flange in which the first skin and the second skin are directly against each other, and a bevel portion formed in a transition between the panel portion and the assembly flange; wherein an outer face of the first skin in the assembly flange forms an angle of between 145 degrees and 168 degrees with the outer face of the first skin in the bevel portion; and wherein the outer face of the first skin in the assembly flange forms an angle of between 120 degrees and 150 degrees with the outer face of the first skin in the panel portion; a second panel comprising: a first layer forming a first skin; a second layer forming a second skin; a third layer forming a core, the core being between the first skin and the second skin; and wherein the first layer, the second layer, and the third layer are arranged to form a panel portion in which the first skin and the second skin are substantially parallel to each other with the core in between, an assembly flange in which the first skin and the second skin are directly against each other, and a bevel portion formed in a transition between the panel portion and the assembly flange; wherein an outer face of the first skin in the assembly flange forms an angle of between 145 degrees and 168 degrees with the outer face of the first skin in the bevel portion; and wherein the outer face of the first skin in the assembly flange forms an angle of between 120 degrees and 150 degrees with the outer face of the first skin in the panel portion; at least a fastening device configured to fasten the assembly flange of the first panel to the assembly flange of the second panel; the core of at least one of the first panel or the second panel at least partly comprising reinforcing pins; the core comprising: a low-density portion with a first density; and a high-density portion with a second density, the second density being higher than the first density; and the high-density portion of the core forming a reinforcing edge of the core, the reinforcing edge being along the assembly flange.

2. The assembly according to claim 1, wherein at least some reinforcing pins are arranged to cross the core from the first skin to the second skin.

3. The assembly according to claim 1, wherein at least some pins are arranged at least partially in the first skin and/or in the second skin.

4. The assembly according to claim 1, wherein the high-density portion of the core is at least partially in the bevel portion formed by the first skin and the second skin.

5. The assembly according to claim 1, wherein the first skin and/or the second skin is reinforced in the bevel portion.

6. The assembly according to claim 1, wherein a density of the reinforcing pins varies.

7. The assembly according to claim 1, wherein a density of the reinforcing pins is higher in proximity to a reinforcing edge of the core.

8. The assembly according to claim 1, wherein the high-density portion of the core comprises reinforcing pins.

9. The assembly according to claim 1, wherein a density of the reinforcing pins varies within the low-density portion of the core.

10. The assembly according to claim 1, wherein a density of the reinforcing pins varies within the high-density portion of the core.

11. The assembly according to claim 1, comprising a cover element, configured to be mounted at least partially on at least part of the assembly flange of the first panel and/or at least part of the assembly flange of the second panel.

12. The assembly according to claim 11, wherein the cover element comprises an elastomer.

13. The assembly according to claim 1, wherein the fastening device comprises: an assembly piece configured to be fastened to the assembly flange of the first panel and to the assembly flange of the second panel; and at least one fastener adapted to fasten the assembly flange of the first panel and the assembly flange of the second panel to the assembly piece.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Some specific exemplary embodiments and aspects of the disclosure herein are described in the following description in reference to the accompanying, example figures.

(2) FIG. 1 is a representation of a cross-section of a portion of a composite panel of an assembly embodiment according to the disclosure herein.

(3) FIG. 2 is a representation of a cross-section of a portion of an assembly embodiment according to the disclosure herein.

(4) FIG. 3 is a representation of a cross-section of a portion of an assembly embodiment according to the disclosure herein.

(5) FIG. 4 is a representation of a cross-section of a portion of an assembly embodiment according to the disclosure herein.

(6) FIG. 5 is a representation of a cross-section of a portion of an assembly embodiment according to the disclosure herein.

DETAILED DESCRIPTION

(7) In FIG. 1 a portion of a composite panel 1 is represented. The panel comprises a first skin 3 (or outer skin), and a second skin 5 (or inner skin). In between the outer skin 3 and the inner skin 5, is a third layer or core 7.

(8) The outer skin 3 and the inner skin 5 may be made of composite material such as a fiber reinforced material. For example the skin 3, 5 may comprise carbon fiber textiles that are impregnated with a resin.

(9) The core 3 may comprise a lightweight foam including but not limited to PMI based closed cell foam materials.

(10) The core 7 comprises reinforcing pins 9. The reinforcing pins 9 may comprise fibers such as carbon fibers. The reinforcing pins 9 extend beneficially across the thickness of the core 7. In the examples represented in FIGS. 1-5, the reinforcing pins 9 extend into the outer skin 3 and into the inner skin 5, more particularly a first end of a reinforcing pin 9 extends into the outer skin 3 and a second end of the reinforcing pin 9 extend into the inner skin 5. The reinforcing pins 9 are thus anchored in the skins 3, 5. The reinforcing pins 9 reinforce the core of the panel 1, such that the mechanical resistance of the panel is improved.

(11) The panel 1 comprises a panel portion in which the outer skin 3 and the inner skin 5 are substantially parallel to each other, such that the panel forms a planar surface. Only part of the panel portion is represented in the figures.

(12) An edge of the panel 1 comprises an assembly flange 17. In the assembly flange 17 the outer skin 3 and the inner skin 5 are arranged directly against each other, forming one single layer. Such single layer in the assembly flange 17 is particularly robust and adapted for the fastening of the panel to another element, for example to another panel. Indeed the thickness of the outer skin 3 and of the inner skin 5 are here cumulated to form the assembly flange.

(13) The assembly flange 17 comprises a through-hole 15 adapted for the introduction of a fastening elements such as a screw, a bolt, a rivet, a pin, etc.

(14) The assembly flange 17 is angled to the panel portion of the panel 1 with an angle of about 45 degrees.

(15) The assembly flange 17 may be obtained by as integrally manufactured composite part in which plies are draped into with a mold with the required shape.

(16) The thickness of the core 7 diminishes in a bevel 11 of the panel in which the outer skin 3 and the inner skin 5 transition from the panel portion to the assembly flange 17. In the bevel 11, the outer skin 3 is angled compared to its orientation in the panel portion. In the example of FIG. 1, the outer skin 3 portion in the bevel 11 forms with the outer skin 3 portion in the panel portion an angle of about 12.5 degrees. The inner skin 5 on the contrary, keeps the same orientation in the bevel as in the panel portion, such that it is flat.

(17) An edge of the core 7 is situated in the bevel 11. The edge of the core 7 comprises a high-density portion 29 with a higher density than a low-density portion of the core 7 situated in the panel portion. The high-density portion 29 of the core placed in the bevel 11 ensures a high mechanical resistance of the panel, and in particular of the edge of the panel, including the panel portion's edge, the bevel 11, and the assembly flange 17. It also improves the transmission of load between the panel portion and the assembly flange 17. To form the high-density portion 29, a high-density foam may be used, while a low density foam may be used to form the low-density portion 7 of the core.

(18) In the bevel 11, the filler gusset 13 is between an end edge of the core (in particular of the high-density portion 29 of the core) and the joining of the first skin 3 with the second skin 5. The filler gusset 13 may be filled by the same material such as the core.

(19) Moreover, in some embodiments not represented here, the density of reinforcing pins 9 may be varied within the panel. For example, the reinforcing pins 9 density may be higher in proximity to an edge of the core 7 so as to progressively increase the mechanical resistance of the core and thus of the panel in proximity to its edge and in particular in proximity to the assembly flange 17. The presence of reinforcing pins 9 may replace the high-density portion 2 of the core or be used in combination with a core comprising multiple density portions. The reinforcing pins 9 density may also vary within the low-density portion 7 of the core and within the high-density portion 29 of the core so as to provide a smooth transition of mechanical properties between the low-density portion 7 and the high-density portion 29 and between the high-density portion 29 and the assembly flange 17. The panel may comprise at least one portion in the panel portion without reinforcing pins 9.

(20) The outer skin 3 and/or the inner skin 5 may be reinforced in the bevel 11 and/or the assembly flange 17 so as to provide a better mechanical resistance and durability. Indeed the angled portion of furniture is usually submitted to shear stress and therefore the mechanical resistance and load transmission in these angled portions of the panel can be improved by a local reinforcement of the outer skin 3 and the inner skin 5. The outer skin 3 and/or the inner skin 5 may for example be reinforced locally by additional layers of carbon fibers and/or of other types of fibers.

(21) In FIGS. 2, 3, 4 and 5, four different examples of embodiments of panel assembly according to the disclosure herein are represented. Each assembly comprises two panels 1, 2, each panel being similar to the panel described in relation to FIG. 1.

(22) In particular, the second panel 2 also comprises a first skin 4 (or outer skin), and a second skin 6 (or inner skin). In between the outer skin 4 and the inner skin 6 of the second panel 2, is a third layer or core. The core also comprises a low-density portion 8 and a high-density portion 28. The core of the second panel 2 is also reinforced with reinforcing pins 10. And the second panel 2 also comprises a filler gusset between the edge of the high-density portion 28 and the joining of the outer skin 4 and the inner skin 6.

(23) The second panel 2 comprises an assembly flange 18 with a through-hole 16. The assembly flange 18 is also angled at 45 degrees with the panel portion of the second panel 2, such that the assembly of the first panel 1 and the second panel 2 may be made so that an outer surface of the second panel 2 may form an angle of 90 degrees with an outer surface of the first panel 1. That way the disclosure herein provides an assembly at 90 degrees, which is very commonly sought for furniture, with particularly good mechanical characteristics.

(24) The second panel 2 also comprises a bevel 12 between its panel portion and its assembly flange 18. An outer surface of the bevel 12 forms an angle of about 12.5 degrees with the panel portion of the second panel 2 and an angle of about 12.5 degrees with the assembly flange 18.

(25) In the example of FIG. 2, the second panel 2 may be assembled to the first panel 1 by alignment of at least one of each of their through-holes 15, 16 and introduction of a piece of a fastening device in the through-holes 15, 16. An exemplary fastening device is represented which comprises a screw 30 and bolt 31, the screw 30 being adapted to be introduced in the respective through-holes 15, 16 of the assembly flange 17 of the first panel. The fastening device may however be of different types and comprise a bolt, a screw, a rivet, a pin, etc. (not represented) introduced in the respective through-holes 15, 16 of the assembly flange 17 of the first panel 1 and of the assembly flange 18 of the second panel 2. In this example, the assembly flange of one of the panels is at least partially placed over the assembly flange of the other panel.

(26) In the example of FIG. 3, the fastening device comprises an assembly piece 22. The second panel 2 may be assembled to the first panel 1 through the additional assembly piece 22. The assembly piece 22 is placed on the outer side of the assembly flanges 17, 18 of the first panel 1 and second panel 2. Such position of the assembly piece 22 facilitates the accessibility for assembly and disassembly of the panels. The assembly piece 22 comprises in this example at least two through-holes 21, 23. A first fastener (not represented) may be adapted to be arranged simultaneously in the through hole 15 of the first panel 1 and in a first through hole 21 of the assembly piece 22, and a second fastener (not represented) may be adapted to be arranged simultaneously in the through hole 16 of the second panel 2 and in a second through hole 23 of the assembly piece 22. The first panel 1 and the second panel 2 may thus be fastened to each other with their respective edges 19, 20 abutting to each other so as to ensure a good transmission of longitudinal loads between the two panels.

(27) The example of FIG. 4 is very similar to the example of FIG. 3, with the difference that the assembly piece 22 is placed on the inner side of the assembly flanges 17, 18. This arrangement may provide a better aesthetic from the outside of the assembly.

(28) In the example of FIG. 3, the first panel 1 is assembled directly to the second panel 2, as described in relation to FIG. 2. This presents the advantage of providing a lighter assembly, which is beneficial for aircraft applications. Moreover, in this embodiment the assembly further comprises a cover element 24.

(29) The cover element 24 permits to render the assembly of the two panel more aesthetic by hiding the assembly flanges 17, 18 and the fastening device. In particular the cover element 24 may have a shape and size adapted to have its edges 26, 27 along a first edge of the bevel 11 so that a smooth transition may be provided between the outer surface of the panel portion of the panels and the cover element 24.

(30) Moreover, the cover element 24 is beneficially elastic so that it may absorb shocks before they are transmitted to the panels 1, 2 and in particular to the assembly of the panels. The cover element 24 may therefore act as a bumper. The cover element 24 may comprise an elastomer.

(31) The cover element 24 may be mounted by elastic deformation onto the assembly. In particular a mounting portion 25 of the cover element 25 may be elastically deformed to be assembled to a fastener (not represented) such as a screw, a bolt, a rivet, a pin, etc. which is introduced in the through-holes 15, 16 of the first panel 1 and second panel 2.

(32) The disclosure herein is not limited to the specific embodiments herein disclosed as examples. The disclosure herein also encompasses other embodiments not herein explicitly described, which may comprise various combinations of the features herein described.

(33) While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a”, “an” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.