Innovation in Aircraft Cabin Interior Panels. Part II: Technical Assessment on Replacing Glass Fiber with Thermoplastic Polymers and Panels Fabricated Using Vacuum Forming Process

Abstract

The manufacturing process of the aircraft cabin interior panels is expensive and time-consuming, and the resulting panel requires rework due to damages that occurred during their fabrication. The aircraft interior panels must meet structural requirements; hence sandwich composites of a honeycomb core covered with two layers of pre-impregnated fiberglass skin are used. Flat sandwich composites are transformed into panels with complex shapes or geometries using the compression molding process, leading to advanced manufacturing challenges. Some aircraft interior panels are required for non-structural applications; hence sandwich composites can be substituted by cheaper alternative materials and transformed using disruptive manufacturing techniques. This paper evaluates the feasibility of replacing the honeycomb and fiberglass skin layers core with rigid polyurethane foams and thermoplastic polymers. The results show that the structural composites have higher mechanical performances than the proposed sandwich composites, but they are compatible with non-structural applications. Sandwich composite fabrication using the vacuum forming process is feasible for developing non-structural panels. This manufacturing technique is fast, easy, economical, and ecological as it uses recyclable materials. The vacuum forming also covers the entire panel, thus eliminating tapestries, paints, or finishes to the aircraft interior panels. The conclusion of the article describes the focus of future research.

Vacuum formed bio‐based composite materials using polyolefin and thermally modified wood powder

“…Normally vacuum forming is performed on "single-component" polymers, although the technique has also been applied on sandwich structures. 43 Otherwise compression molding is the natural choice for thermoforming composites and other heterogeneous polymer-based systems. [44][45][46]…”

“…To summarize, it was shown here that it is possible to dilute the generally non‐biobased polyolefin with biobased wood powder without critically compromising the mechanical properties of vacuum formed products. Normally vacuum forming is performed on “single‐component” polymers, although the technique has also been applied on sandwich structures 43 . Otherwise compression molding is the natural choice for thermoforming composites and other heterogeneous polymer‐based systems 44–46 …”

Effect of SEBS Molecular Structure and Formula Composition on the Performance of SEBS/PP TPE for Automotive Interior Skin

“…Additionally, given that it covers the airbag area, the soft skin must also display excellent toughness to guarantee personal safety during airbag deployment. Traditional automotive interior skins mainly include polyvinyl chloride (PVC) slush skins and thermoplastic polyolefin (TPO) vacuum-molded skins [ 4 ]. However, PVC exhibits poor weatherable resistance, and environmentally unfriendly properties such as high odor, VOC emission, fogging, and difficulty to recycle and reuse.…”