WO2021111108A1 - Light-emitting structural panel - Google Patents

Light-emitting structural panel Download PDF

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Publication number
WO2021111108A1
WO2021111108A1 PCT/GB2020/053027 GB2020053027W WO2021111108A1 WO 2021111108 A1 WO2021111108 A1 WO 2021111108A1 GB 2020053027 W GB2020053027 W GB 2020053027W WO 2021111108 A1 WO2021111108 A1 WO 2021111108A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
structural panel
composite structural
quantum dots
composite
Prior art date
Application number
PCT/GB2020/053027
Other languages
French (fr)
Inventor
Ataollah YOOSEFINEJAD
Arno MYBURGH
Original Assignee
Safran Seats GB Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Safran Seats GB Limited filed Critical Safran Seats GB Limited
Publication of WO2021111108A1 publication Critical patent/WO2021111108A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/02—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies
    • H01L33/04—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies with a quantum effect structure or superlattice, e.g. tunnel junction
    • H01L33/06—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies with a quantum effect structure or superlattice, e.g. tunnel junction within the light emitting region, e.g. quantum confinement structure or tunnel barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/02—Layer formed of wires, e.g. mesh
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    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q3/00—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors
    • B60Q3/50—Mounting arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
    • B64D11/00—Passenger or crew accommodation; Flight-deck installations not otherwise provided for
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Definitions

  • the present invention concerns a structural panel. More particularly, but not exclusively, this invention concerns a structural panel with integrated illumination means. The invention also concerns a structural panel for an aircraft interior.
  • Structural panels with integrated illumination means may be provided in an aircraft interior. Such panels require various wiring looms to be installed in the panel, and may be time consuming and expensive to produce.
  • the present invention seeks to mitigate the above-mentioned problems. Alternatively or additionally, the present invention seeks to provide an improved structural panel.
  • the present invention provides, according to a first aspect, a composite structural panel comprising a structural layer, a layer of quantum dots, an electrically conducting layer associated with the layer of quantum dots, the electrically conducting layer configured to supply electrical power to the quantum dots, such that the quantum dots emit light.
  • quantum dots as part of a structural panel allows significant flexibility in the design of illumination patterns.
  • a further advantage is the low energy consumption of quantum dots as an illumination source.
  • the provision of an electrically conducting layer arranged to supply electrical power to the quantum dots may eliminate the need for wiring within the structural panel, thus reducing or simplifying the need for maintenance.
  • the composite structural panel may also be lighter than a panel comprising internal wiring and alternative light sources, for example light sources installed on the surface of the panel.
  • the layer of quantum dots may be directly adjacent to the electrically conducting layer.
  • the layer of quantum dots may be integrated with the electrically conducting layer.
  • the layer of quantum dots may comprise a web of fibrous material.
  • the web of fibrous material may comprise polyamide nanofibers.
  • the web of fibrous material may comprise poly(hexamethylene adipamide).
  • the web of fibrous material may be electrically conducting.
  • the web of fibrous material may comprise one or more of: silver particles, single wall carbon nanotubes, graphene, or a combination thereof.
  • the electrically conducting layer may comprise a web of fibrous material doped with a conducting material.
  • the web of fibrous material may comprise one or more of: silver particles, single wall carbon nanotubes, graphene, or a combination thereof.
  • the web of fibrous material may comprise polyamide nanofibers.
  • the polyamide nanofibers may comprise poly(hexamethylene adipamide).
  • the electrically conducting layer may comprise resin.
  • the layer of quantum dots may be sandwiched between two dielectric layers.
  • the layer of quantum dots may therefore be spaced apart from the electrically conducting layer.
  • a second electrically conductive layer may be provided, such that the quantum dot layer and the two dielectric layers are sandwiched between two conductive layers.
  • the second conductive layer which is preferably the top conductive layer, may be transparent or translucent.
  • Being the top conductive layer means that, where the structural panel has an externally facing surface, the top conductive layer is closer to the externally facing surface than the other conductive layer or layers.
  • the top conductive layer may comprise indium tin oxide, or poly(3,4 ethylenedioxythiophene) (PEDOT). At least one of, and preferably the top, dielectric layer may be transparent or translucent.
  • the electrically conducting layer may comprise a metallic mesh.
  • the metallic mesh may comprise copper mesh.
  • the electrically conducting layer may comprise a flexible printed circuit board (PCB).
  • PCB printed circuit board
  • the invention provides a composite structural panel comprising an electrically conducting fibrous web layer with quantum dots, and a structural layer.
  • the electrically conducting fibrous web layer with quantum dots may comprise polyamide nanofibers.
  • the polyamide nanofibers may comprise poly(hexamethylene adipamide).
  • the electrically conducting fibrous web layer with quantum dots may comprise one or more of: silver particles, single wall carbon nanotubes, graphene or combinations thereof.
  • the electrically conducting fibrous web layer with quantum dots may comprise a resin.
  • the structural layer may comprise a cellular structure, for example a honeycomb structure.
  • the cellular structure may comprise calendered aramide sheets, for example NOMEX ⁇ RTM>.
  • the calendered aramid sheets may be coated or saturated with a phenolic resin.
  • the cellular structure may comprise aluminium.
  • the cellular structure may be sandwiched between one or more resin impregnated layers.
  • the resin impregnated layers may comprise resin impregnated fibre reinforced layers.
  • the resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin.
  • the fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
  • the structural layer may comprise a plurality of resin impregnated fibre reinforced layers.
  • the resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin.
  • the fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
  • the structural layer may comprise a foam layer.
  • One or more resin layers may be located on one or both sides of the foam layer.
  • the resin layer may comprise a fibre reinforced layer.
  • the resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin.
  • the fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
  • the quantum dots may comprise one or more of: lead sulphide, lead selenide, cadmium selenide, cadmium sulphide, cadmium telluride, indium arsenide, indium phosphide, or cadmium selenide sulphide.
  • the quantum dots may comprise a particle diameter from 2 to 10 nm.
  • the composite structure may comprise an integrated connector arranged to connect the electrically conducting layer to an external power source.
  • the connector may be exposed at a surface of the panel for direction connection to an external power source.
  • the connector may be arranged such that it may electrically connect the composite structure to another composite structure with a suitable connector. Such an arrangement may allow for indirect connection to an external power source via the other composite structure.
  • the connector may comprise a plurality of output ports arranged to independently electrify different regions of the composite structure.
  • the composite structure may comprise a cavity for receiving a mating part that electrically connects to the electrical connector.
  • the electrical connector may be located within the cavity.
  • the composite structural panel and connector may be arranged such that the surface of the mating part does not extend beyond the surface of the composite structural panel when the mating part is electrically connected to the electrical connector.
  • the surface of the mating part may be flush with the surface of the composite structural panel.
  • the composite structural panel may comprise a plurality of connectors. The plurality of connectors may be electrically connected to each other, for example by a conductive layer in the composite structural panel, or by a wire embedded in the composite structural panel.
  • the composite structural panel may comprise a transparent or translucent top layer.
  • the top layer may act to protect and/or electrically insulate the layers below the top layer, whilst still allowing the quantum dots to provide illumination which may be seen by, for example, a passenger on an aircraft comprising the composite structural panel.
  • the transparent or translucent top layer may comprise a resin, a lacquer, or a varnish.
  • the structural panel may comprise an interior aircraft panel.
  • the structural panel may comprise any of the following aircraft elements: an aircraft seat unit, a class divider, a lavatory, an overhead bin, a galley kitchen, floor level illumination panels, or interior side panels.
  • the quantum dots may be arranged to provide illumination, for example for any of the following reasons: in-cabin mood lighting, seat numbers, emergency information, direction of emergency exits, no-smoking information, seat-belt information, airline branding, etc.
  • the quantum dots may be arranged in a homogenous or heterogeneous pattern, chosen in dependence on the intended purpose of the quantum dots.
  • the quantum dots may vary in size, in order to provide illumination of different colours.
  • a method of manufacturing a composite structural panel as described with reference to the first or second aspect of the invention comprising the steps of: arranging the layers of the composite structural panel in the prescribed order to create a lay-up, placing the lay-up into a mould, and applying a prescribed temperature and pressure to cure the lay up.
  • the method may comprise adding a top layer to the cured lay-up.
  • the top layer may, for example, be a transparent or translucent layer for protecting and/or electrically insulating the electrically conductive layer of the composite structural panel.
  • a method of manufacturing a composite structural panel as described with reference to the first or second aspect of the invention comprising the steps of: arranging the structural layer of the composite structural panel to create a lay-up, placing the lay-up into a mould, and applying a prescribed temperature and pressure to cure the lay-up with a first curing step.
  • the method may comprise the step of adding the electrically conducting layer to the lay-up prior to the first curing step.
  • the method may comprise the step of adding the electrically conducting layer to the lay-up after the first curing step, and applying a prescribed temperature and pressure in a second curing step.
  • the method may comprise the step of adding the quantum dot layer to the lay-up after the first curing step, and applying a prescribed temperature and pressure in a second curing step.
  • the method may comprise the step of adding the quantum dot layer to the lay-up after a second curing step, and applying a prescribed temperature and pressure in a third curing step.
  • the method may comprise adding a top layer to the composite structural panel.
  • the addition of the top layer may comprise a final curing step.
  • the addition of the top layer may be added without requiring a curing step, for example if the top layer is a lacquer.
  • the top layer may be sprayed onto the composite structural panel.
  • a composite structural panel comprising an electrically conducting layer, a structural layer, and an electrical connector, wherein the electrical connector is at least partially integrated into the structural layer, is electrically connected to the electrically conducting layer, and has an exposed connection at the surface of the panel.
  • the composite structural panel may comprise a consumer unit.
  • the electrical connector may be electrically connected to the consumer unit.
  • the consumer unit may comprise a light source, for example, one or more quantum dots, LEDs, OLEDs, or PLEDs.
  • the structural layer may comprise a cellular structure, for example a honeycomb structure.
  • the electrically conducting layer may comprise a web of fibrous material doped with a conducting material.
  • the web of fibrous material may comprise one or more of: silver particles, single wall carbon nanotubes, graphene, or a combination thereof.
  • the web of fibrous material may comprise polyamide nanofibers.
  • the polyamide nanofibers may comprise poly(hexamethylene adipamide).
  • the electrically conducting layer may comprise resin.
  • the electrically conducting layer may comprise a metallic mesh.
  • the metallic mesh may comprise copper mesh.
  • the electrically conductive layer may comprise a conductive web, foil, wire, or vapour deposited metal layer.
  • the electrically conducting layer may comprise a flexible printed circuit board (PCB).
  • PCB printed circuit board
  • the cellular structure may comprise calendered aramide sheets, for example NOMEX ⁇ RTM>.
  • the cellular structure may comprise aluminium.
  • the cellular structure may be sandwiched between one or more resin impregnated layers.
  • the resin impregnated layers may comprise resin impregnated fibre reinforced layers.
  • the resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin.
  • the fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
  • the structural layer may comprise a plurality of resin impregnated fibre reinforced layers.
  • the resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin.
  • the fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
  • the structural layer may comprise a foam layer.
  • One or more resin layers may be located on one or both sides of the foam layer.
  • the resin layer may comprise a fibre reinforced layer.
  • the resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin.
  • the fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
  • the composite structural panel may comprise an integrated connector arranged to connect the electrically conducting layer to an external power source.
  • the connector may be exposed at a surface of the panel for direction connection to an external power source.
  • the connector may be arranged such that it may electrically connect the composite structural panel to another composite structure with a suitable connector. Such an arrangement may allow for indirect connection to an external power source via the other composite structure.
  • the connector may comprise a plurality of output ports arranged to independently electrify different regions of the composite structural panel.
  • the composite structural panel may comprise a cavity for receiving a mating part that electrically connects to the electrical connector.
  • the composite structural panel and connector may be arranged such that the surface of the mating part does not extend beyond the surface of the composite structural panel when the mating part is electrically connected to the electrical connector.
  • the surface of the mating part may be flush with the surface of the composite structural panel.
  • the composite structural panel may comprise a plurality of connectors.
  • the plurality of connectors may be electrically connected to each other, for example by a conductive layer in the composite structural panel, or by a wire embedded in the composite structural panel.
  • the structural panel may form at least part of an interior aircraft panel.
  • the structural panel may form at least part of any of the following aircraft elements: an aircraft seat unit, a class divider, a lavatory, an overhead bin, a galley kitchen, floor level illumination panels, or interior side panels.
  • a method of manufacturing a composite structural panel according to the fifth aspect of the invention comprising the steps of: arranging the layers in the prescribed order, removing a prescribed amount of the layers to create a cavity, inserting the electrical connector into the cavity, and applying a sacrificial layer to the exposed connection, placing the lay-up including the electrical connector into a mould, applying a prescribed temperature and pressure to cure the lay-up, and removing the sacrificial layer from the exposed connection.
  • Figures 1 to 22 show cross-sectional views of various layer structures of composite structural panels according to embodiments of the invention.
  • Figures 23 and 24 show perspective views of composite structural panels with different coloured lighting patterns
  • Figures 25 to 31 show perspective views of various connection arrangements according to embodiments of the invention.
  • Figures 32 to 57 detail various methods of manufacturing composite structural panels according to embodiments of the invention.
  • a composite laminate comprises a structural layer, a layer comprising quantum dots, and an electrically conducting layer configured to power the quantum dots.
  • Methods of manufacturing the laminates are also described.
  • the layers shown in the figures are schematic only, and illustrative of the structure of the various composite structural panels. The layers do not accurately represent the relative thicknesses of the various layers.
  • FIG. 1 shows a schematic cross sectional view of a composite structural panel 100 according to an embodiment of the invention.
  • the composite structural panel 100 comprises one or more bottom layers 102 comprising fibre-reinforced plastic, a honeycomb core layer 104 comprising Nomex ⁇ RTM> or aluminium, one or more layers 106 of fibre reinforced plastic on top of the honeycomb core layer 104, an electrically conducting layer 108 of quantum dots and silver nanoparticles in a fibrous web, and a transparent insulating layer 110 comprising a varnish or lacquer.
  • FIG. 2 shows a schematic cross sectional view of a composite structural panel 200 according to an alternative embodiment of the invention.
  • the composite structural panel 200 comprises one or more bottom layers 202 comprising fibre- reinforced plastic, a honeycomb core layer 204 comprising Nomex ⁇ RTM> or aluminium, one or more layers 206 of fibre reinforced plastic on top of the honeycomb core layer 204, an electrically conducting layer 208 of silver nanoparticles in a fibrous web, a layer of quantum dots 210 in a fibrous web, and a transparent insulating layer 212 comprising a varnish or lacquer.
  • FIG 3 shows a schematic cross sectional view of a composite structural panel 300 according to an alternative embodiment of the invention.
  • the composite structural panel 300 comprises one or more bottom layers 302 comprising fibre- reinforced plastic, a honeycomb core layer 304 comprising Nomex ⁇ RTM> or aluminium, one or more layers 306 of fibre reinforced plastic on top of the honeycomb core layer 304, an electrically conducting layer 308 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 310 in a fibrous web, and a transparent insulating layer 312 comprising a varnish or lacquer.
  • Figure 4 shows a schematic cross sectional view of a composite structural panel 400 according to an alternative embodiment of the invention.
  • the composite structural panel 400 comprises one or more bottom layers 402 comprising fibre- reinforced plastic, a honeycomb core layer 404 comprising Nomex ⁇ RTM> or aluminium, one or more layers 406 of fibre reinforced plastic on top of the honeycomb core layer 404, an electrically conducting layer 408 of copper mesh, a layer of quantum dots 410 in a fibrous web, and a transparent insulating layer 412 comprising a varnish or lacquer.
  • FIG. 5 shows a schematic cross sectional view of a composite structural panel 500 according to an alternative embodiment of the invention.
  • the composite structural panel 500 comprises one or more bottom layers 502 comprising fibre- reinforced plastic, a honeycomb core layer 504 comprising Nomex ⁇ RTM> or aluminium, one or more layers 506 of fibre reinforced plastic on top of the honeycomb core layer 504, an electrically conducting layer 508 of copper mesh, a layer of silver nanoparticles and quantum dots 510 in a fibrous web, and a transparent insulating layer 512 comprising a varnish or lacquer.
  • FIG. 6 shows a schematic cross sectional view of a composite structural panel 600 according to an alternative embodiment of the invention.
  • the composite structural panel 600 comprises one or more bottom layers 602 comprising fibre- reinforced plastic, a layer of silver nanoparticles and quantum dots 604 in a fibrous web, and a transparent insulating layer 606 comprising a varnish or lacquer.
  • FIG. 7 shows a schematic cross sectional view of a composite structural panel 700 according to an alternative embodiment of the invention.
  • the composite structural panel 700 comprises one or more bottom layers 702 comprising fibre- reinforced plastic, a layer of silver nanoparticles in a fibrous web 704, a layer of quantum dots 706 in a fibrous web, and a transparent insulating layer 708 comprising a varnish or lacquer.
  • FIG. 8 shows a schematic cross sectional view of a composite structural panel 800 according to an alternative embodiment of the invention.
  • the composite structural panel 800 comprises one or more bottom layers 802 comprising fibre- reinforced plastic, a layer of silver nanoparticles in a fibrous web 804, a layer of silver nanoparticles and quantum dots 806 in a fibrous web, and a transparent insulating layer 808 comprising a varnish or lacquer.
  • Figure 9 shows a schematic cross sectional view of a composite structural panel 900 according to an embodiment of the invention.
  • the composite structural panel 900 comprises one or more bottom layers 902 comprising fibre-reinforced plastic, a foam core layer 904, one or more layers 906 of fibre reinforced plastic on top of the foam core layer 904, an electrically conducting layer 908 of quantum dots and silver nanoparticles in a fibrous web, and a transparent insulating layer 910 comprising a varnish or lacquer.
  • Figure 10 shows a schematic cross sectional view of a composite structural panel 1000 according to an alternative embodiment of the invention.
  • the composite structural panel 1000 comprises one or more bottom layers 1002 comprising fibre- reinforced plastic, a foam core layer 1004, one or more layers 1006 of fibre reinforced plastic on top of the foam core layer 1004, an electrically conducting layer 1008 of silver nanoparticles in a fibrous web, a layer of quantum dots 1010 in a fibrous web, and a transparent insulating layer 1012 comprising a varnish or lacquer.
  • FIG 11 shows a schematic cross sectional view of a composite structural panel 1100 according to an alternative embodiment of the invention.
  • the composite structural panel 1100 comprises one or more bottom layers 1102 comprising fibre- reinforced plastic, a foam core layer 1104, one or more layers 1106 of fibre reinforced plastic on top of the foam core layer 1104, an electrically conducting layer 1108 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 1110 in a fibrous web, and a transparent insulating layer 1112 comprising a varnish or lacquer.
  • Figure 12 shows a schematic cross sectional view of a composite structural panel 1200 according to an alternative embodiment of the invention.
  • the composite structural panel 1200 comprises one or more bottom layers 1202 comprising fibre- reinforced plastic, a honeycomb core layer 1204 of Nomex ⁇ RTM> or aluminium, one of more layers of fibre-reinforced plastic 1206 on top of the honeycomb core layer 1204, an electrically conductive layer 1208 of silver nanoparticles in a fibrous web, a dielectric resin layer 1210, a layer 1212 of quantum dots in a fibrous web, a transparent dielectric resin layer 1214, a transparent conductive layer 1216 of PEDOT, and a transparent insulating layer 1218 of resin or lacquer.
  • FIG. 13 shows a schematic cross sectional view of a composite structural panel 1300 according to an alternative embodiment of the invention.
  • the composite structural panel 1300 comprises one or more bottom layers 1302 comprising fibre- reinforced plastic, a honeycomb core layer 1304 of Nomex ⁇ RTM> or aluminium, one or more layers of fibre-reinforced plastic 1306 on top of the honeycomb core layer 1304, an electrically conductive layer 1308 of silver nanoparticles in a fibrous web, a dielectric resin layer 1310, a layer 1312 of quantum dots in a fibrous web, a transparent dielectric resin layer 1314, a partially transparent conductive layer 1316 of PEDOT and silver nanoparticles in a fibrous web, and a transparent insulating layer 1318 of resin or lacquer.
  • FIG 14 shows a schematic cross sectional view of a composite structural panel 1400 according to an alternative embodiment of the invention.
  • the composite structural panel 1400 comprises one or more bottom layers 1402 comprising fibre- reinforced plastic, a honeycomb core layer 1404 of Nomex ⁇ RTM> or aluminium, one of more layers of fibre-reinforced plastic 1406 on top of the honeycomb core layer 1404, an electrically conductive layer 1408 of silver nanoparticles in a fibrous web, a layer 1410 of different sized quantum dots and silver nanoparticles in a fibrous web, and a transparent insulating layer 1412 of resin or lacquer.
  • FIG. 15 shows a schematic cross sectional view of a composite structural panel 1500 according to an alternative embodiment of the invention.
  • the composite structural panel 1500 comprises one or more bottom layers 1502 comprising fibre- reinforced plastic, a honeycomb core layer 1504 of Nomex ⁇ RTM> or aluminium, one or more layers of fibre-reinforced plastic 1506 on top of the honeycomb core layer 1504, an electrically conductive layer 1508 of silver nanoparticles in a fibrous web, a dielectric resin layer 1510, a layer 1512 of different sized quantum dots in a fibrous web, a transparent dielectric resin layer 1514, a transparent conductive layer 1516 of PEDOT, and a transparent insulating layer 1518 of resin or lacquer.
  • FIG. 16 shows a schematic cross sectional view of a composite structural panel 1600 according to an alternative embodiment of the invention.
  • the composite structural panel 1600 comprises one or more bottom layers 1602 comprising fibre- reinforced plastic, a honeycomb core layer 1604 comprising Nomex ⁇ RTM> or aluminium, one or more layers 1606 of fibre reinforced plastic on top of the honeycomb core layer 1604, an electrically conducting layer 1608 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 1610 in a fibrous web, and a transparent insulating layer 1612 comprising a varnish or lacquer.
  • the layer 1610 of silver nanoparticles and quantum dots comprises two individual sets of quantum dots 1614 and 1616, each set comprising quantum dots of different sizes.
  • the individual sets of quantum dots 1614 and 1616 are connected to independent conductors in the conductive layer 1608, allowing each individual set 1614 and 1616 to be independently illuminated.
  • FIG. 17 shows a schematic cross sectional view of a composite structural panel 1700 according to an alternative embodiment of the invention.
  • the composite structural panel 1700 comprises one or more bottom layers 1702 comprising fibre- reinforced plastic, a honeycomb core layer 1704 comprising Nomex ⁇ RTM> or aluminium, one or more layers 1706 of fibre reinforced plastic on top of the honeycomb core layer 1704, an electrically conducting layer 1708 of silver nanoparticles in a fibrous web, a non-continuous dielectric resin layer 1710, a layer of quantum dots 1712 in a fibrous web, a transparent, non-continuous dielectric resin layer 1714, a transparent electrically conducting PEDOT layer 1716, and a transparent insulating layer 1718 comprising a varnish or lacquer.
  • the layer 1712 of quantum dots comprises two individual sets of quantum dots 1720 and 1722, each set comprising quantum dots of different sizes.
  • the quantum dots 1722 are electrically connected to the electrically conducting layer 1708, and the quantum dots 1720 are electrically connected to the PEDOT layer 1716. This allows each set of quantum dots to be controlled independently.
  • Figure 18 shows a schematic cross sectional view of a composite structural panel 1800 according to an alternative embodiment of the invention.
  • the composite structural panel 1800 comprises one or more bottom layers 1802 comprising fibre- reinforced plastic, a honeycomb core layer 1804 comprising Nomex ⁇ RTM> or aluminium, one or more layers 1806 of fibre reinforced plastic on top of the honeycomb core layer 1804, an electrically conducting layer 1808 of silver nanoparticles in a fibrous web, a non-continuous dielectric resin layer 1810, a layer of silver nanoparticles and quantum dots 1812 in a fibrous web, a transparent, non-continuous dielectric resin layer 1814, a transparent electrically conducting PEDOT layer 1816, and a transparent insulating layer 1818 comprising a varnish or lacquer.
  • the layer 1812 of silver nanoparticles and quantum dots comprises two individual sets of quantum dots 1820 and 1822, each set comprising quantum dots of different sizes.
  • the quantum dots 1822 are electrically connected to the electrically conducting layer 1808, and the quantum dots 1820 are electrically connected to the PEDOT layer 1816. This allows each set of quantum dots to be controlled independently.
  • FIG 19 shows a schematic cross sectional view of a composite structural panel 1900 according to an alternative embodiment of the invention.
  • the composite structural panel 1900 comprises one or more bottom layers 1902 comprising fibre- reinforced plastic, a honeycomb core layer 1904 comprising Nomex ⁇ RTM> or aluminium, one or more layers 1906 of fibre reinforced plastic on top of the honeycomb core layer 1904, an electrically conducting layer 1908 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 1910 in a fibrous web, and a transparent insulating layer 1912 comprising a varnish or lacquer.
  • An electrical connector 1914 is attached to the electrically conducting layer 1908 and extends down to the honeycomb core layer 1904. The electrical connector 1914 may be used to connect to an external power source, or electrically connect the composite structural panel 1900 to another suitably configured panel.
  • FIG 20 shows a schematic cross sectional view of a composite structural panel 2000 according to an alternative embodiment of the invention.
  • the composite structural panel 2000 comprises one or more bottom layers 2002 comprising fibre- reinforced plastic, a honeycomb core layer 2004 comprising Nomex ⁇ RTM> or aluminium, one or more layers 2006 of fibre reinforced plastic on top of the honeycomb core layer 2004, an electrically conducting layer 2008 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 2010 in a fibrous web, and a transparent insulating layer 2012 comprising a varnish or lacquer.
  • An electrical connector 2014 is attached to the electrically conducting layer 2008 and extends down to the honeycomb core layer 2004.
  • a mating part 2016 is attached to and extends from the electrical connector 2014.
  • the electrical connector 2014 and mating part 2016 may be used to electrically connect the composite structural panel 2000 to another suitably configured panel.
  • FIG. 21 shows a schematic cross sectional view of a composite structural panel 2100 according to an alternative embodiment of the invention.
  • the composite structural panel 2100 comprises one or more bottom layers 2102 comprising fibre- reinforced plastic, a honeycomb core layer 2104 comprising Nomex ⁇ RTM> or aluminium, one or more layers 2106 of fibre reinforced plastic on top of the honeycomb core layer 2104, an electrically conducting layer 2108 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 2110 in a fibrous web, and a transparent insulating layer 2112 comprising a varnish or lacquer.
  • First and second electrical connectors 2114 are attached to the electrically conducting layer 2108 and extend down to the honeycomb core layer 2104. The first and second electrical connectors 2114 may be used to connect to an external power source, or electrically connect the composite structural panel 2100 to another suitably configured panel.
  • FIG 22 shows a schematic cross sectional view of a composite structural panel 2200 according to an alternative embodiment of the invention.
  • the composite structural panel 2200 comprises one or more bottom layers 2202 comprising fibre- reinforced plastic, a honeycomb core layer 2204 comprising Nomex ⁇ RTM> or aluminium, one or more layers 2206 of fibre reinforced plastic on top of the honeycomb core layer 2204, an electrically conducting layer 2208 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and different sized quantum dots 2210 in a fibrous web, and a transparent insulating layer 2212 comprising a varnish or lacquer.
  • First and second electrical connectors 2214 are attached to the electrically conducting layer 2208 and extend down to the honeycomb core layer 2204.
  • the electrically conducting layer 2208 is arranged so that a first group of quantum dots 2216 and second set of quantum dots 2218 may be individually powered.
  • the first electrical connector 2214 connects to the first set of quantum dots 2216 and the second electrical connector 2214 connects to the second set of quantum dots 2218.
  • the electrical connectors 2214 may be used to connect to an external power source, or electrically connect the composite structural panel 2200 to another suitably configured panel.
  • Figure 23 shows a perspective view of a composite structural panel 2300 according to an embodiment of the invention.
  • a connector 2302 is arranged to connect to an electrical power source.
  • An electrically conducting layer of silver nanoparticles in a silver web 2304 extends from the connector 2302.
  • a layer of first quantum dots, specifically blue quantum dots 2306 is arranged in a “S” pattern.
  • a layer of second quantum dots, specifically white quantum dots 2308, is arranged to make the “Safran” logo.
  • a transparent insulating layer 2310 is layered on top of the layer or layers of quantum dots.
  • the composite structure 2300 may comprise various layers as identified in other embodiments of the invention described above.
  • the electrical arrangement shown in figure 23 allows for simultaneous illumination of the “S” pattern and “Safran” logo with a single power supply.
  • Figure 24 shows a panel 2400 similar to that shown in figure 23. However, two separate connectors 2402 are provided such that the “S” pattern and the “Safran” logo can be illuminated independently and by separate power sources.
  • FIG. 25 shows a perspective view of a composite structural panel 2500.
  • the composite structural panel 2500 comprises one or more bottom layers 2502 comprising fibre-reinforced plastic, a honeycomb core layer 2504 comprising Nomex ⁇ RTM> or aluminium, one or more layers 2506 of fibre reinforced plastic on top of the honeycomb core layer 2504, an electrically conducting layer 2508 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 2510 in a fibrous web, and a transparent insulating layer 2512 comprising a varnish or lacquer.
  • a connector 2514 is arranged in a cavity within the composite structural panel 2500, with four electrical lines running down from the electrically conducting layer 2508 of silver nanoparticles.
  • the connector is located in a middle portion of the panel 2500 so that the electrical connector 2514 may be arranged to supply power to either side of the panel 2500.
  • Figure 26 shows the composite structural panel 2500 and a connector 2600 for connecting a power source to the connector 2514.
  • Figure 27 shows a composite structural panel 2700, similar to that described with reference to figure 25. However, the connector 2702 is located to the side of the composite structural panel 2700, thereby allowing the panel to be electrically connected to a suitable connector on an adjacent panel.
  • Figure 28 shows the panel 2700 and connector 2702 and a corresponding panel 2800 and connector 2802 located adjacent to each other.
  • a mating part 2804 includes an electrical connection which electrically connects the two connectors 2702 and 2802, and therefore the two panels 2700 and 2800.
  • Such an arrangement allows a single external power source, connected to one of the panels 2700, 2800, to supply power to both panels.
  • Figure 29 shows a perspective view of a composite structural panel 2900 with a capacitor type arrangement, as described with reference to figure 12.
  • a connector 2902 provides an electrical connection to the electrically conducting layer of silver nanoparticles 1208 and the transparent conductive PEDOT layer 1216.
  • Figure 30 shows a perspective view of a composite structural panel 3000, with layers as described with reference to figure 17.
  • a connector 3002 allows individual connection of the quantum dots 1720 and quantum dots 1722 to individual power supplies as can be seen in the figure. Only a single connection is shown running to the electrically conducting layer 1708 of silver nanoparticles, though two connections may be present. The same is true of the connection which runs to the transparent conductive PEDOT layer 1716.
  • Figure 31 shows a connector arrangement comprising a male connector 3100 and female connector 3102.
  • the female connector 3102 may be located within any of the composite structural panels as described above.
  • the female connector 3102 comprises a bottom face with fixed flat contact points 3104, an internal conductive path 3106 running from each of the fixed contact points 3104, to a further set of fixed flat contact points 3108.
  • the male connector 3100 comprises spring loaded dome connector points 3110, an internal wire/conductor connecting each of the spring loaded dome connector points 3110 to a harness, and a wire harness 3114 leading to a loom/ECU.
  • the spring loaded dome connector points 3110 align with and electrically connect with the fixed flat contact points 3104 when the male connector 3100 is inserted into the female connector 3102.
  • Figures 32 and 33 show a method of preparing a homogenous silver nanoparticle web for use in a composite structural panel. Initially, a fibrous web is immersed in a suspension of silver nanoparticles 3200. Then the fibrous web with adsorbed silver nanoparticles is dried 3202.
  • Figure 33 shows an apparatus for use in the method of figure 32, with a backing paper including a fibrous web 3300 being run past a hopper 3302 containing silver nanoparticles, the silver nanoparticles are disposed onto the fibrous web 3304, a top backing paper 3306 is applied, and the various layers run through pinching rollers 3308, in order to output the fibrous web comprising silver nanoparticles 3310.
  • Figure 34 shows an alternative arrangement to that described with relation to figure 33.
  • the hopper 3302 of figure 33 is replaced with a spool of nanofiber doped with silver 3402.
  • the backing substrate 3400 and nanofiber 3402 are layered together, and a fibrous web comprising silver nanoparticles 3410 are output in a similar manner to that described for figure 33.
  • Figure 35 shows an alternative arrangement for preparing a web of silver nanoparticles.
  • Hoppers containing polymer granules/power 3500, a reagent 3502, and conductive particles 3504 feed into a mixing vessel 3506.
  • the resultant mixture is pumped 3508 into a manifold 3510 and passes through a nozzle 3512.
  • the arrangement is connected to a high voltage power supply 3520, wherein a jet of fibres 3514 results.
  • the jet of fibres 3514 are emitted onto a substrate, resulting in a conductive nanofiber coated substrate 3516.
  • a metallic collector terminal 3518 attracts the jet of fibres, assuring a good coverage of the substrate.
  • Figures 36 and 37 demonstrate a method of preparing a web of quantum dots in a homogeneous pattern.
  • a suspension of quantum dots is sprayed onto a fibrous web 3600.
  • the web is dried, resulting in a web with adsorbed quantum dots 3602.
  • Figure 37 shows the backing paper 3700, the spraying of quantum dots onto the backing paper 3702, drying of the layer of sprayed quantum dots 3704, and the resultant combination of a web with adsorbed quantum dots 3706.
  • Figure 38 shows an alternative system and method for creating a web of quantum dots in a homogenous pattern. The method is similar to that described with reference to figure 35, other than the hopper of conductive particles 3504 being replaced with a hopper of quantum dots 3800. The other elements and method remain the same as for figure 35.
  • Figure 39 and 40 demonstrate a method preparing a web of quantum dots and silver nanoparticles in a homogenous pattern. The method is the same as that described with reference to figure 36 and 37, with the replacement of the suspension of quantum dots being replaced with a suspension of quantum dots and silver nanoparticles 4000.
  • Figures 41 and 42 demonstrate a method of preparing a web of quantum dots in a heterogeneous pattern. A web of fibrous material is laid out 4100, 4200. The web is partially covered with a negative template of the desired pattern 4102, 4202, in this case, a company logo. A suspension of quantum dots is sprayed onto the fibrous web 4104. The web is allowed to dry and the template removed 4106, 4204. This results in a web with adsorbed quantum dots in the chosen pattern.
  • Figures 43, 44, and 45 demonstrate a method of preparing a web of silver nanoparticles and quantum dots in a heterogeneous pattern. The method corresponds to that described with reference to figures 41 and 42, with the additional steps of spraying a silver nanoparticle suspension in a chosen pattern to create electrically conducting tracks prior to spraying the quantum dots in the chosen pattern.
  • Figure 46 details a method of producing a fibrous web of quantum dots and silver nanoparticles, the silver particles in a homogenous pattern and the quantum dots in a heterogeneous pattern.
  • a fibrous web is immersed in a suspension of silver nanoparticles 4600.
  • the web is then dried to result in a web with adsorbed nanoparticles 4604.
  • the web is laid on a flat surface 4604.
  • a suspension of quantum dots is printed onto the fibrous web 4606, for example in the shape of a company logo.
  • the web is the dried, resulting in a web with adsorbed quantum dots and silver nanoparticles 4608.
  • Figure 47 details a method of producing a fibrous web with a combination of different sized quantum dots, and silver nanoparticles, in a heterogeneous pattern.
  • a fibrous web is laid out 4700.
  • Multichannel inkjet printing is used to print a multicolour company logo, with conductive tracks printed between the logo and connector positions 4702.
  • the multichannel printing includes a channel for quantum dots of a first size, quantum dots of a second size, and silver nanoparticles.
  • the web is then dried 4704.
  • Curing times may vary from one minute to two hours. The curing time may depend on several factors, including the panel dimension, geometry, and resin system. Curing of a lay-up may occur without applying pressure. Curing of a lay up may occur in an oven with a vacuum bag, or a hot press.
  • the curing process may take place as a single step, with the quantum dots and all other layers of the composite panel structure being cured at the same time.
  • the curing process may take place in two or more steps.
  • the structural layers of the composite structural panel may be cured in a first step, then the electrically conducting layers and quantum dot containing layers added, and a second curing step takes place.
  • a multi-stage curing process whilst potentially being more time consuming, may provide better control over the migration of the resin.
  • a multi-stage process may also reduce the risk of failure of a non-homogenous quantum dot distribution which could result due to distortion in the curing process.
  • Figure 48 demonstrates a method of producing a composite structural panel in a single curing step.
  • a lay-up comprising a sandwich of a fibre-reinforced plastic, core, fibre reinforced plastic, and layers of a conducting web and quantum dot web is provided 4800.
  • the lay-up is then cured in a mould 4802.
  • Figure 49 illustrates the lay-up comprising a lay-up of fibre-reinforced plastic 4900, a core 4902, fibre-reinforced plastic 4904, silver nanoparticles in a fibrous web 4906, and quantum dots and silver nanoparticles in a fibrous web 4908.
  • the lay-up is placed in a mould 4910 and heat and pressure are applied 4912 to cure the lay-up.
  • Figures 50 and 51 demonstrate a method of producing a composite structural panel in a two stage process, with a first, pre-curing step, and a second curing step.
  • a lay-up of the structural panel comprises a core sandwiched between fibre- reinforced plastic layers 5000. This initial lay-up is cured in a mould 5002. Layers comprising a web of silver nanoparticles, and a web of quantum dots and silver nanoparticles are added to the pre-cured panel 5004. A final curing step 5006 then takes place.
  • Figure 51 shows the sandwich of the core 5102, the fibre reinforced plastic 5100 and the press 5104 used in the pre-curing step to produce a standard panel 5106.
  • Figure 51 also shows the standard panel 5106, a resin layer 5108, a conductive nanofibers coated substrate 5110, a quantum dot web 5112, and a finishing lacquer 5114, which are laid up and cured using pressure and temperature in the second curing step.
  • Figures 52 and 53 demonstrate a method of producing a composite structural panel.
  • a standard panel arrangement is first produced by laying-up a core sandwiched by fibre-reinforced plastic 5200. The lay-up is cured in a mould 5202. Layer of web comprising silver nanoparticles, and quantum dots and silver nanoparticles are added to the standard panel arrangement 5204. The added layers are cured without needing the use of a mould 5206, possibly by applying heat, or simply waiting for the curing to take place overtime.
  • Figure 53 shows the core material 5304 sandwiched by fibre-reinforced plastic layers 5302, and a heated, vacuum assisted, press 5306.
  • the cured laminate 5308 has a resin layer 5310 added, a layer of conductive nanoparticles 5312 added, a web of quantum dots 5314 added, and a finishing lacquer added. Those additional layers are cured using the application of heat, without requiring further use of a press. As the layers added after the first curing step are not structural, the bonding strength required may be lower than for the structural layers.
  • Figures 54 to 57 demonstrate a method of inserting an electrical harness in a composite structural panel prior to curing of the panel. Initially a core is sandwiched between layers of fibre-reinforced plastic 5400. That lay up is machined to create a cavity 5402. Further lay-up steps include adding layers of a conducting web and a web containing quantum dots corresponding to the shape of the machined panel 5404. A connector plus sacrificial layer is inserted into the panel, along with linking of the conducting layer to the port of the connector 5406. Heat and pressure are applied in a mould 5408. Post-cure, the sacrificial layer is removed 5410. Figure 55 shows the panel lay-up prior to machining 5500.
  • a cavity is machined in the panel such that a panel with a machined cavity for an electrical connector 5502 results.
  • Figure 56 shows how conductive layers and a quantum dot containing layer is added to the panel 5502, with the conducting layer overlapping into the machined cavity 5600.
  • a connecter part 5604 and a sacrificial part 5606 are added to the machined cavity to provide a panel 5602 ready for curing.
  • Figure 57 shows heat and pressure being applied to the panel 5700. The mould is released and the sacrificial part removed, resulting in the final panel 5702 including exposed connectors, ready for connection to another panel, mating element, or power source.
  • fibre-reinforced resin or fibre-reinforced plastic, may be phenolic resin with glass fibres.
  • the fibre-reinforced resin may be used in the form of a so-called pre-preg.
  • Alternative resins include polyester, vinylester, bioresins (e.g. poly(furfuryl alcohol) (PFA)) or epoxy resins.
  • Alternatives to the glass fibres include carbon fibres, aramid fibres, or ultra-high molecular weight polyethylene.
  • the quantum dots may be standard quantum dots of 2 to lOnm, made of binary or ternary compounds such as lead sulphide, lead selenide, cadmium selenide, cadmium sulphide, cadmium telluride, indium arsenide, indium phosphide, or cadmium selenide sulphide.
  • the size of the quantum dot determines the wavelength of the emitted light, small diameter quantum dots emitting a bluish light, and larger diameter quantum dots emitting a reddish light. The skilled person will know how to select the dots required to emit a desired colour of light.
  • the quantum dots may be of single kind and of a uniform size or the quantum dots may contain a mixture of different kinds and/or different sizes.
  • the web/fibres described above may comprise any of: nano and submicron fibres made of nylon-6 ⁇ RTM>, nylon- 66 ⁇ RTM>, styrene based polymers such as polystyrene and its derivatives and blends, polycarbonate, polyacronitrile, and conductive polymers such as polyaniline.
  • the fibrous web may contain fibres with a diameter of 60 - 100 nm.
  • conductive materials to supply power to the quantum dots may be added and they may be any of: silver, single wall carbon nanotubes, multi-wall carbon nanotubes, graphene, graphite powder, carbon black, copper nano-particles and combinations thereof.
  • Silver may be in the form of silver nanoparticles.
  • the silver nanoparticles may have a particle diameter of less than 50 nm.
  • Such materials may form part of the electrically conducting fibrous layer or layers of a composite structural panel according to the invention.
  • Transparent conductive materials may include indium tin oxide, or polymers such as poly(3,4-ethylenedioxythiophene) (PEDOT).

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Abstract

Abstract Light-emitting Structural Panel The present invention concerns a composite structural panel with integrated illumination suitable for use within an aircraft interior. The composite structural panel comprises a structural layer of quantum dots, and an electrically conducting layer. The electrically conducting layer is configured to supply electrical power to the quantum dots, such that the quantum dots emit light. The use of quantum dots as part of a structural panel, allows significant flexibility in the design of the illumination patterns. There may be additional benefits, including reduced energy consumption compared to other light sources, and/or eliminating the need for wiring within the structural panel, thus reducing or simplifying the need for maintenance. Figure 1

Description

LIGHT-EMITTING STRUCTURAL PANEL
BACKGROUND OF THE INVENTION
[0001] The present invention concerns a structural panel. More particularly, but not exclusively, this invention concerns a structural panel with integrated illumination means. The invention also concerns a structural panel for an aircraft interior.
[0002] Structural panels with integrated illumination means, for example LEDs, may be provided in an aircraft interior. Such panels require various wiring looms to be installed in the panel, and may be time consuming and expensive to produce.
[0003] The present invention seeks to mitigate the above-mentioned problems. Alternatively or additionally, the present invention seeks to provide an improved structural panel.
SUMMARY OF THE INVENTION
[0004] The present invention provides, according to a first aspect, a composite structural panel comprising a structural layer, a layer of quantum dots, an electrically conducting layer associated with the layer of quantum dots, the electrically conducting layer configured to supply electrical power to the quantum dots, such that the quantum dots emit light.
[0005] The use of quantum dots as part of a structural panel allows significant flexibility in the design of illumination patterns. A further advantage is the low energy consumption of quantum dots as an illumination source. The provision of an electrically conducting layer arranged to supply electrical power to the quantum dots may eliminate the need for wiring within the structural panel, thus reducing or simplifying the need for maintenance. The composite structural panel may also be lighter than a panel comprising internal wiring and alternative light sources, for example light sources installed on the surface of the panel.
[0006] The layer of quantum dots may be directly adjacent to the electrically conducting layer. The layer of quantum dots may be integrated with the electrically conducting layer. The layer of quantum dots may comprise a web of fibrous material. The web of fibrous material may comprise polyamide nanofibers. The web of fibrous material may comprise poly(hexamethylene adipamide). The web of fibrous material may be electrically conducting. The web of fibrous material may comprise one or more of: silver particles, single wall carbon nanotubes, graphene, or a combination thereof. [0007] The electrically conducting layer may comprise a web of fibrous material doped with a conducting material. The web of fibrous material may comprise one or more of: silver particles, single wall carbon nanotubes, graphene, or a combination thereof. The web of fibrous material may comprise polyamide nanofibers. The polyamide nanofibers may comprise poly(hexamethylene adipamide). The electrically conducting layer may comprise resin.
[0008] The layer of quantum dots may be sandwiched between two dielectric layers. The layer of quantum dots may therefore be spaced apart from the electrically conducting layer. A second electrically conductive layer may be provided, such that the quantum dot layer and the two dielectric layers are sandwiched between two conductive layers. The second conductive layer, which is preferably the top conductive layer, may be transparent or translucent. Being the top conductive layer means that, where the structural panel has an externally facing surface, the top conductive layer is closer to the externally facing surface than the other conductive layer or layers. The top conductive layer may comprise indium tin oxide, or poly(3,4 ethylenedioxythiophene) (PEDOT). At least one of, and preferably the top, dielectric layer may be transparent or translucent.
[0009] The electrically conducting layer may comprise a metallic mesh. The metallic mesh may comprise copper mesh.
[0010] The electrically conducting layer may comprise a flexible printed circuit board (PCB).
[0011] According to a second aspect, the invention provides a composite structural panel comprising an electrically conducting fibrous web layer with quantum dots, and a structural layer.
[0012] The electrically conducting fibrous web layer with quantum dots may comprise polyamide nanofibers. The polyamide nanofibers may comprise poly(hexamethylene adipamide). The electrically conducting fibrous web layer with quantum dots may comprise one or more of: silver particles, single wall carbon nanotubes, graphene or combinations thereof. The electrically conducting fibrous web layer with quantum dots may comprise a resin.
[0013] The following features may be equally applied to either the first aspect or second aspect of the invention.
[0014] The structural layer may comprise a cellular structure, for example a honeycomb structure. The cellular structure may comprise calendered aramide sheets, for example NOMEX <RTM>. The calendered aramid sheets may be coated or saturated with a phenolic resin. The cellular structure may comprise aluminium. The cellular structure may be sandwiched between one or more resin impregnated layers. The resin impregnated layers may comprise resin impregnated fibre reinforced layers. The resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin. The fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
[0015] The structural layer may comprise a plurality of resin impregnated fibre reinforced layers. The resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin. The fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
[0016] The structural layer may comprise a foam layer. One or more resin layers may be located on one or both sides of the foam layer. The resin layer may comprise a fibre reinforced layer. The resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin. The fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
[0017] The quantum dots may comprise one or more of: lead sulphide, lead selenide, cadmium selenide, cadmium sulphide, cadmium telluride, indium arsenide, indium phosphide, or cadmium selenide sulphide. The quantum dots may comprise a particle diameter from 2 to 10 nm.
[0018] The composite structure may comprise an integrated connector arranged to connect the electrically conducting layer to an external power source. The connector may be exposed at a surface of the panel for direction connection to an external power source. The connector may be arranged such that it may electrically connect the composite structure to another composite structure with a suitable connector. Such an arrangement may allow for indirect connection to an external power source via the other composite structure. The connector may comprise a plurality of output ports arranged to independently electrify different regions of the composite structure. The composite structure may comprise a cavity for receiving a mating part that electrically connects to the electrical connector. The electrical connector may be located within the cavity. The composite structural panel and connector may be arranged such that the surface of the mating part does not extend beyond the surface of the composite structural panel when the mating part is electrically connected to the electrical connector. For example, the surface of the mating part may be flush with the surface of the composite structural panel. The composite structural panel may comprise a plurality of connectors. The plurality of connectors may be electrically connected to each other, for example by a conductive layer in the composite structural panel, or by a wire embedded in the composite structural panel.
[0019] The composite structural panel may comprise a transparent or translucent top layer. The top layer may act to protect and/or electrically insulate the layers below the top layer, whilst still allowing the quantum dots to provide illumination which may be seen by, for example, a passenger on an aircraft comprising the composite structural panel. The transparent or translucent top layer may comprise a resin, a lacquer, or a varnish.
[0020] The structural panel may comprise an interior aircraft panel. The structural panel may comprise any of the following aircraft elements: an aircraft seat unit, a class divider, a lavatory, an overhead bin, a galley kitchen, floor level illumination panels, or interior side panels.
[0021] The quantum dots may be arranged to provide illumination, for example for any of the following reasons: in-cabin mood lighting, seat numbers, emergency information, direction of emergency exits, no-smoking information, seat-belt information, airline branding, etc. The quantum dots may be arranged in a homogenous or heterogeneous pattern, chosen in dependence on the intended purpose of the quantum dots. The quantum dots may vary in size, in order to provide illumination of different colours.
[0022] According to a third aspect of the invention, there is provided a method of manufacturing a composite structural panel as described with reference to the first or second aspect of the invention, the method comprising the steps of: arranging the layers of the composite structural panel in the prescribed order to create a lay-up, placing the lay-up into a mould, and applying a prescribed temperature and pressure to cure the lay up.
[0023] The method may comprise adding a top layer to the cured lay-up. The top layer may, for example, be a transparent or translucent layer for protecting and/or electrically insulating the electrically conductive layer of the composite structural panel. [0024] According to a fourth aspect, there is provided a method of manufacturing a composite structural panel as described with reference to the first or second aspect of the invention, the method comprising the steps of: arranging the structural layer of the composite structural panel to create a lay-up, placing the lay-up into a mould, and applying a prescribed temperature and pressure to cure the lay-up with a first curing step. [0025] The method may comprise the step of adding the electrically conducting layer to the lay-up prior to the first curing step. The method may comprise the step of adding the electrically conducting layer to the lay-up after the first curing step, and applying a prescribed temperature and pressure in a second curing step.
[0026] The method may comprise the step of adding the quantum dot layer to the lay-up after the first curing step, and applying a prescribed temperature and pressure in a second curing step. The method may comprise the step of adding the quantum dot layer to the lay-up after a second curing step, and applying a prescribed temperature and pressure in a third curing step.
[0027] The method may comprise adding a top layer to the composite structural panel. The addition of the top layer may comprise a final curing step. Alternatively, the addition of the top layer may be added without requiring a curing step, for example if the top layer is a lacquer. In such an arrangement, the top layer may be sprayed onto the composite structural panel.
[0028] According to a fifth aspect, there is provided a composite structural panel comprising an electrically conducting layer, a structural layer, and an electrical connector, wherein the electrical connector is at least partially integrated into the structural layer, is electrically connected to the electrically conducting layer, and has an exposed connection at the surface of the panel.
[0029] The composite structural panel may comprise a consumer unit. The electrical connector may be electrically connected to the consumer unit. The consumer unit may comprise a light source, for example, one or more quantum dots, LEDs, OLEDs, or PLEDs. The structural layer may comprise a cellular structure, for example a honeycomb structure.
[0030] The electrically conducting layer may comprise a web of fibrous material doped with a conducting material. The web of fibrous material may comprise one or more of: silver particles, single wall carbon nanotubes, graphene, or a combination thereof. The web of fibrous material may comprise polyamide nanofibers. The polyamide nanofibers may comprise poly(hexamethylene adipamide). The electrically conducting layer may comprise resin.
[0031] The electrically conducting layer may comprise a metallic mesh. The metallic mesh may comprise copper mesh. The electrically conductive layer may comprise a conductive web, foil, wire, or vapour deposited metal layer.
[0032] The electrically conducting layer may comprise a flexible printed circuit board (PCB).
[0033] The cellular structure may comprise calendered aramide sheets, for example NOMEX <RTM>. The cellular structure may comprise aluminium. The cellular structure may be sandwiched between one or more resin impregnated layers. The resin impregnated layers may comprise resin impregnated fibre reinforced layers. The resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin. The fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres. [0034] The structural layer may comprise a plurality of resin impregnated fibre reinforced layers. The resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin. The fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
[0035] The structural layer may comprise a foam layer. One or more resin layers may be located on one or both sides of the foam layer. The resin layer may comprise a fibre reinforced layer. The resin may comprise one or more of: a phenolic resin, a bioresin, an epoxy resin, or a polyester resin. The fibres may comprise one or more of: glass fibres, carbon fibres, or aramid fibres.
[0036] The composite structural panel may comprise an integrated connector arranged to connect the electrically conducting layer to an external power source. The connector may be exposed at a surface of the panel for direction connection to an external power source. The connector may be arranged such that it may electrically connect the composite structural panel to another composite structure with a suitable connector. Such an arrangement may allow for indirect connection to an external power source via the other composite structure. The connector may comprise a plurality of output ports arranged to independently electrify different regions of the composite structural panel. The composite structural panel may comprise a cavity for receiving a mating part that electrically connects to the electrical connector. The composite structural panel and connector may be arranged such that the surface of the mating part does not extend beyond the surface of the composite structural panel when the mating part is electrically connected to the electrical connector. For example, the surface of the mating part may be flush with the surface of the composite structural panel. The composite structural panel may comprise a plurality of connectors. The plurality of connectors may be electrically connected to each other, for example by a conductive layer in the composite structural panel, or by a wire embedded in the composite structural panel.
[0037] The structural panel may form at least part of an interior aircraft panel. The structural panel may form at least part of any of the following aircraft elements: an aircraft seat unit, a class divider, a lavatory, an overhead bin, a galley kitchen, floor level illumination panels, or interior side panels. [0038] According to a sixth aspect, there is provide a method of manufacturing a composite structural panel according to the fifth aspect of the invention, the method comprising the steps of: arranging the layers in the prescribed order, removing a prescribed amount of the layers to create a cavity, inserting the electrical connector into the cavity, and applying a sacrificial layer to the exposed connection, placing the lay-up including the electrical connector into a mould, applying a prescribed temperature and pressure to cure the lay-up, and removing the sacrificial layer from the exposed connection.
[0039] It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the invention may incorporate any of the features described with reference to the apparatus of the invention and vice versa.
DESCRIPTION OF THE DRAWINGS
[0040] Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which:
[0041] Figures 1 to 22 show cross-sectional views of various layer structures of composite structural panels according to embodiments of the invention;
[0042] Figures 23 and 24 show perspective views of composite structural panels with different coloured lighting patterns; and
[0043] Figures 25 to 31 show perspective views of various connection arrangements according to embodiments of the invention;
[0044] Figures 32 to 57 detail various methods of manufacturing composite structural panels according to embodiments of the invention.
DETAILED DESCRIPTION [0045] The following description relates to various embodiments of the invention in which a composite laminate comprises a structural layer, a layer comprising quantum dots, and an electrically conducting layer configured to power the quantum dots. Methods of manufacturing the laminates are also described. The layers shown in the figures are schematic only, and illustrative of the structure of the various composite structural panels. The layers do not accurately represent the relative thicknesses of the various layers.
[0046] Figure 1 shows a schematic cross sectional view of a composite structural panel 100 according to an embodiment of the invention. The composite structural panel 100 comprises one or more bottom layers 102 comprising fibre-reinforced plastic, a honeycomb core layer 104 comprising Nomex <RTM> or aluminium, one or more layers 106 of fibre reinforced plastic on top of the honeycomb core layer 104, an electrically conducting layer 108 of quantum dots and silver nanoparticles in a fibrous web, and a transparent insulating layer 110 comprising a varnish or lacquer.
[0047] Figure 2 shows a schematic cross sectional view of a composite structural panel 200 according to an alternative embodiment of the invention. The composite structural panel 200 comprises one or more bottom layers 202 comprising fibre- reinforced plastic, a honeycomb core layer 204 comprising Nomex <RTM> or aluminium, one or more layers 206 of fibre reinforced plastic on top of the honeycomb core layer 204, an electrically conducting layer 208 of silver nanoparticles in a fibrous web, a layer of quantum dots 210 in a fibrous web, and a transparent insulating layer 212 comprising a varnish or lacquer.
[0048] Figure 3 shows a schematic cross sectional view of a composite structural panel 300 according to an alternative embodiment of the invention. The composite structural panel 300 comprises one or more bottom layers 302 comprising fibre- reinforced plastic, a honeycomb core layer 304 comprising Nomex <RTM> or aluminium, one or more layers 306 of fibre reinforced plastic on top of the honeycomb core layer 304, an electrically conducting layer 308 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 310 in a fibrous web, and a transparent insulating layer 312 comprising a varnish or lacquer. [0049] Figure 4 shows a schematic cross sectional view of a composite structural panel 400 according to an alternative embodiment of the invention. The composite structural panel 400 comprises one or more bottom layers 402 comprising fibre- reinforced plastic, a honeycomb core layer 404 comprising Nomex <RTM> or aluminium, one or more layers 406 of fibre reinforced plastic on top of the honeycomb core layer 404, an electrically conducting layer 408 of copper mesh, a layer of quantum dots 410 in a fibrous web, and a transparent insulating layer 412 comprising a varnish or lacquer.
[0050] Figure 5 shows a schematic cross sectional view of a composite structural panel 500 according to an alternative embodiment of the invention. The composite structural panel 500 comprises one or more bottom layers 502 comprising fibre- reinforced plastic, a honeycomb core layer 504 comprising Nomex <RTM> or aluminium, one or more layers 506 of fibre reinforced plastic on top of the honeycomb core layer 504, an electrically conducting layer 508 of copper mesh, a layer of silver nanoparticles and quantum dots 510 in a fibrous web, and a transparent insulating layer 512 comprising a varnish or lacquer.
[0051] Figure 6 shows a schematic cross sectional view of a composite structural panel 600 according to an alternative embodiment of the invention. The composite structural panel 600 comprises one or more bottom layers 602 comprising fibre- reinforced plastic, a layer of silver nanoparticles and quantum dots 604 in a fibrous web, and a transparent insulating layer 606 comprising a varnish or lacquer.
[0052] Figure 7 shows a schematic cross sectional view of a composite structural panel 700 according to an alternative embodiment of the invention. The composite structural panel 700 comprises one or more bottom layers 702 comprising fibre- reinforced plastic, a layer of silver nanoparticles in a fibrous web 704, a layer of quantum dots 706 in a fibrous web, and a transparent insulating layer 708 comprising a varnish or lacquer.
[0053] Figure 8 shows a schematic cross sectional view of a composite structural panel 800 according to an alternative embodiment of the invention. The composite structural panel 800 comprises one or more bottom layers 802 comprising fibre- reinforced plastic, a layer of silver nanoparticles in a fibrous web 804, a layer of silver nanoparticles and quantum dots 806 in a fibrous web, and a transparent insulating layer 808 comprising a varnish or lacquer.
[0054] Figure 9 shows a schematic cross sectional view of a composite structural panel 900 according to an embodiment of the invention. The composite structural panel 900 comprises one or more bottom layers 902 comprising fibre-reinforced plastic, a foam core layer 904, one or more layers 906 of fibre reinforced plastic on top of the foam core layer 904, an electrically conducting layer 908 of quantum dots and silver nanoparticles in a fibrous web, and a transparent insulating layer 910 comprising a varnish or lacquer. [0055] Figure 10 shows a schematic cross sectional view of a composite structural panel 1000 according to an alternative embodiment of the invention. The composite structural panel 1000 comprises one or more bottom layers 1002 comprising fibre- reinforced plastic, a foam core layer 1004, one or more layers 1006 of fibre reinforced plastic on top of the foam core layer 1004, an electrically conducting layer 1008 of silver nanoparticles in a fibrous web, a layer of quantum dots 1010 in a fibrous web, and a transparent insulating layer 1012 comprising a varnish or lacquer.
[0056] Figure 11 shows a schematic cross sectional view of a composite structural panel 1100 according to an alternative embodiment of the invention. The composite structural panel 1100 comprises one or more bottom layers 1102 comprising fibre- reinforced plastic, a foam core layer 1104, one or more layers 1106 of fibre reinforced plastic on top of the foam core layer 1104, an electrically conducting layer 1108 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 1110 in a fibrous web, and a transparent insulating layer 1112 comprising a varnish or lacquer. [0057] Figure 12 shows a schematic cross sectional view of a composite structural panel 1200 according to an alternative embodiment of the invention. The composite structural panel 1200 comprises one or more bottom layers 1202 comprising fibre- reinforced plastic, a honeycomb core layer 1204 of Nomex <RTM> or aluminium, one of more layers of fibre-reinforced plastic 1206 on top of the honeycomb core layer 1204, an electrically conductive layer 1208 of silver nanoparticles in a fibrous web, a dielectric resin layer 1210, a layer 1212 of quantum dots in a fibrous web, a transparent dielectric resin layer 1214, a transparent conductive layer 1216 of PEDOT, and a transparent insulating layer 1218 of resin or lacquer.
[0058] Figure 13 shows a schematic cross sectional view of a composite structural panel 1300 according to an alternative embodiment of the invention. The composite structural panel 1300 comprises one or more bottom layers 1302 comprising fibre- reinforced plastic, a honeycomb core layer 1304 of Nomex <RTM> or aluminium, one or more layers of fibre-reinforced plastic 1306 on top of the honeycomb core layer 1304, an electrically conductive layer 1308 of silver nanoparticles in a fibrous web, a dielectric resin layer 1310, a layer 1312 of quantum dots in a fibrous web, a transparent dielectric resin layer 1314, a partially transparent conductive layer 1316 of PEDOT and silver nanoparticles in a fibrous web, and a transparent insulating layer 1318 of resin or lacquer. [0059] Figure 14 shows a schematic cross sectional view of a composite structural panel 1400 according to an alternative embodiment of the invention. The composite structural panel 1400 comprises one or more bottom layers 1402 comprising fibre- reinforced plastic, a honeycomb core layer 1404 of Nomex <RTM> or aluminium, one of more layers of fibre-reinforced plastic 1406 on top of the honeycomb core layer 1404, an electrically conductive layer 1408 of silver nanoparticles in a fibrous web, a layer 1410 of different sized quantum dots and silver nanoparticles in a fibrous web, and a transparent insulating layer 1412 of resin or lacquer.
[0060] Figure 15 shows a schematic cross sectional view of a composite structural panel 1500 according to an alternative embodiment of the invention. The composite structural panel 1500 comprises one or more bottom layers 1502 comprising fibre- reinforced plastic, a honeycomb core layer 1504 of Nomex <RTM> or aluminium, one or more layers of fibre-reinforced plastic 1506 on top of the honeycomb core layer 1504, an electrically conductive layer 1508 of silver nanoparticles in a fibrous web, a dielectric resin layer 1510, a layer 1512 of different sized quantum dots in a fibrous web, a transparent dielectric resin layer 1514, a transparent conductive layer 1516 of PEDOT, and a transparent insulating layer 1518 of resin or lacquer.
[0061] Figure 16 shows a schematic cross sectional view of a composite structural panel 1600 according to an alternative embodiment of the invention. The composite structural panel 1600 comprises one or more bottom layers 1602 comprising fibre- reinforced plastic, a honeycomb core layer 1604 comprising Nomex <RTM> or aluminium, one or more layers 1606 of fibre reinforced plastic on top of the honeycomb core layer 1604, an electrically conducting layer 1608 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 1610 in a fibrous web, and a transparent insulating layer 1612 comprising a varnish or lacquer. The layer 1610 of silver nanoparticles and quantum dots comprises two individual sets of quantum dots 1614 and 1616, each set comprising quantum dots of different sizes. The individual sets of quantum dots 1614 and 1616 are connected to independent conductors in the conductive layer 1608, allowing each individual set 1614 and 1616 to be independently illuminated.
[0062] Figure 17 shows a schematic cross sectional view of a composite structural panel 1700 according to an alternative embodiment of the invention. The composite structural panel 1700 comprises one or more bottom layers 1702 comprising fibre- reinforced plastic, a honeycomb core layer 1704 comprising Nomex <RTM> or aluminium, one or more layers 1706 of fibre reinforced plastic on top of the honeycomb core layer 1704, an electrically conducting layer 1708 of silver nanoparticles in a fibrous web, a non-continuous dielectric resin layer 1710, a layer of quantum dots 1712 in a fibrous web, a transparent, non-continuous dielectric resin layer 1714, a transparent electrically conducting PEDOT layer 1716, and a transparent insulating layer 1718 comprising a varnish or lacquer. The layer 1712 of quantum dots comprises two individual sets of quantum dots 1720 and 1722, each set comprising quantum dots of different sizes. The quantum dots 1722 are electrically connected to the electrically conducting layer 1708, and the quantum dots 1720 are electrically connected to the PEDOT layer 1716. This allows each set of quantum dots to be controlled independently. [0063] Figure 18 shows a schematic cross sectional view of a composite structural panel 1800 according to an alternative embodiment of the invention. The composite structural panel 1800 comprises one or more bottom layers 1802 comprising fibre- reinforced plastic, a honeycomb core layer 1804 comprising Nomex <RTM> or aluminium, one or more layers 1806 of fibre reinforced plastic on top of the honeycomb core layer 1804, an electrically conducting layer 1808 of silver nanoparticles in a fibrous web, a non-continuous dielectric resin layer 1810, a layer of silver nanoparticles and quantum dots 1812 in a fibrous web, a transparent, non-continuous dielectric resin layer 1814, a transparent electrically conducting PEDOT layer 1816, and a transparent insulating layer 1818 comprising a varnish or lacquer. The layer 1812 of silver nanoparticles and quantum dots comprises two individual sets of quantum dots 1820 and 1822, each set comprising quantum dots of different sizes. The quantum dots 1822 are electrically connected to the electrically conducting layer 1808, and the quantum dots 1820 are electrically connected to the PEDOT layer 1816. This allows each set of quantum dots to be controlled independently.
[0064] Figure 19 shows a schematic cross sectional view of a composite structural panel 1900 according to an alternative embodiment of the invention. The composite structural panel 1900 comprises one or more bottom layers 1902 comprising fibre- reinforced plastic, a honeycomb core layer 1904 comprising Nomex <RTM> or aluminium, one or more layers 1906 of fibre reinforced plastic on top of the honeycomb core layer 1904, an electrically conducting layer 1908 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 1910 in a fibrous web, and a transparent insulating layer 1912 comprising a varnish or lacquer. An electrical connector 1914 is attached to the electrically conducting layer 1908 and extends down to the honeycomb core layer 1904. The electrical connector 1914 may be used to connect to an external power source, or electrically connect the composite structural panel 1900 to another suitably configured panel.
[0065] Figure 20 shows a schematic cross sectional view of a composite structural panel 2000 according to an alternative embodiment of the invention. The composite structural panel 2000 comprises one or more bottom layers 2002 comprising fibre- reinforced plastic, a honeycomb core layer 2004 comprising Nomex <RTM> or aluminium, one or more layers 2006 of fibre reinforced plastic on top of the honeycomb core layer 2004, an electrically conducting layer 2008 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 2010 in a fibrous web, and a transparent insulating layer 2012 comprising a varnish or lacquer. An electrical connector 2014 is attached to the electrically conducting layer 2008 and extends down to the honeycomb core layer 2004. A mating part 2016 is attached to and extends from the electrical connector 2014. The electrical connector 2014 and mating part 2016 may be used to electrically connect the composite structural panel 2000 to another suitably configured panel.
[0066] Figure 21 shows a schematic cross sectional view of a composite structural panel 2100 according to an alternative embodiment of the invention. The composite structural panel 2100 comprises one or more bottom layers 2102 comprising fibre- reinforced plastic, a honeycomb core layer 2104 comprising Nomex <RTM> or aluminium, one or more layers 2106 of fibre reinforced plastic on top of the honeycomb core layer 2104, an electrically conducting layer 2108 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 2110 in a fibrous web, and a transparent insulating layer 2112 comprising a varnish or lacquer. First and second electrical connectors 2114 are attached to the electrically conducting layer 2108 and extend down to the honeycomb core layer 2104. The first and second electrical connectors 2114 may be used to connect to an external power source, or electrically connect the composite structural panel 2100 to another suitably configured panel.
[0067] Figure 22 shows a schematic cross sectional view of a composite structural panel 2200 according to an alternative embodiment of the invention. The composite structural panel 2200 comprises one or more bottom layers 2202 comprising fibre- reinforced plastic, a honeycomb core layer 2204 comprising Nomex <RTM> or aluminium, one or more layers 2206 of fibre reinforced plastic on top of the honeycomb core layer 2204, an electrically conducting layer 2208 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and different sized quantum dots 2210 in a fibrous web, and a transparent insulating layer 2212 comprising a varnish or lacquer. First and second electrical connectors 2214 are attached to the electrically conducting layer 2208 and extend down to the honeycomb core layer 2204. The electrically conducting layer 2208 is arranged so that a first group of quantum dots 2216 and second set of quantum dots 2218 may be individually powered. The first electrical connector 2214 connects to the first set of quantum dots 2216 and the second electrical connector 2214 connects to the second set of quantum dots 2218. The electrical connectors 2214 may be used to connect to an external power source, or electrically connect the composite structural panel 2200 to another suitably configured panel.
[0068] Figure 23 shows a perspective view of a composite structural panel 2300 according to an embodiment of the invention. A connector 2302 is arranged to connect to an electrical power source. An electrically conducting layer of silver nanoparticles in a silver web 2304 extends from the connector 2302. A layer of first quantum dots, specifically blue quantum dots 2306 is arranged in a “S” pattern. A layer of second quantum dots, specifically white quantum dots 2308, is arranged to make the “Safran” logo. A transparent insulating layer 2310 is layered on top of the layer or layers of quantum dots. The composite structure 2300 may comprise various layers as identified in other embodiments of the invention described above. The electrical arrangement shown in figure 23 allows for simultaneous illumination of the “S” pattern and “Safran” logo with a single power supply.
[0069] Figure 24 shows a panel 2400 similar to that shown in figure 23. However, two separate connectors 2402 are provided such that the “S” pattern and the “Safran” logo can be illuminated independently and by separate power sources.
[0070] Figure 25 shows a perspective view of a composite structural panel 2500. The composite structural panel 2500 comprises one or more bottom layers 2502 comprising fibre-reinforced plastic, a honeycomb core layer 2504 comprising Nomex <RTM> or aluminium, one or more layers 2506 of fibre reinforced plastic on top of the honeycomb core layer 2504, an electrically conducting layer 2508 of silver nanoparticles in a fibrous web, a layer of silver nanoparticles and quantum dots 2510 in a fibrous web, and a transparent insulating layer 2512 comprising a varnish or lacquer. A connector 2514 is arranged in a cavity within the composite structural panel 2500, with four electrical lines running down from the electrically conducting layer 2508 of silver nanoparticles. The connector is located in a middle portion of the panel 2500 so that the electrical connector 2514 may be arranged to supply power to either side of the panel 2500. As can be seen, there are individual conductive pathways 2516 and 2518 running from the electrical connector 2514 to the layer 2510 of silver nanoparticles and quantum dots.
[0071] Figure 26 shows the composite structural panel 2500 and a connector 2600 for connecting a power source to the connector 2514.
[0072] Figure 27 shows a composite structural panel 2700, similar to that described with reference to figure 25. However, the connector 2702 is located to the side of the composite structural panel 2700, thereby allowing the panel to be electrically connected to a suitable connector on an adjacent panel.
[0073] Figure 28 shows the panel 2700 and connector 2702 and a corresponding panel 2800 and connector 2802 located adjacent to each other. A mating part 2804 includes an electrical connection which electrically connects the two connectors 2702 and 2802, and therefore the two panels 2700 and 2800. Such an arrangement allows a single external power source, connected to one of the panels 2700, 2800, to supply power to both panels.
[0074] Figure 29 shows a perspective view of a composite structural panel 2900 with a capacitor type arrangement, as described with reference to figure 12. A connector 2902 provides an electrical connection to the electrically conducting layer of silver nanoparticles 1208 and the transparent conductive PEDOT layer 1216.
[0075] Figure 30 shows a perspective view of a composite structural panel 3000, with layers as described with reference to figure 17. A connector 3002 allows individual connection of the quantum dots 1720 and quantum dots 1722 to individual power supplies as can be seen in the figure. Only a single connection is shown running to the electrically conducting layer 1708 of silver nanoparticles, though two connections may be present. The same is true of the connection which runs to the transparent conductive PEDOT layer 1716.
[0076] Figure 31 shows a connector arrangement comprising a male connector 3100 and female connector 3102. The female connector 3102 may be located within any of the composite structural panels as described above. The female connector 3102 comprises a bottom face with fixed flat contact points 3104, an internal conductive path 3106 running from each of the fixed contact points 3104, to a further set of fixed flat contact points 3108. The male connector 3100 comprises spring loaded dome connector points 3110, an internal wire/conductor connecting each of the spring loaded dome connector points 3110 to a harness, and a wire harness 3114 leading to a loom/ECU. The spring loaded dome connector points 3110 align with and electrically connect with the fixed flat contact points 3104 when the male connector 3100 is inserted into the female connector 3102. [0077] Various methods of producing the composite structural panels as described above will now be detailed.
[0078] Figures 32 and 33 show a method of preparing a homogenous silver nanoparticle web for use in a composite structural panel. Initially, a fibrous web is immersed in a suspension of silver nanoparticles 3200. Then the fibrous web with adsorbed silver nanoparticles is dried 3202. Figure 33 shows an apparatus for use in the method of figure 32, with a backing paper including a fibrous web 3300 being run past a hopper 3302 containing silver nanoparticles, the silver nanoparticles are disposed onto the fibrous web 3304, a top backing paper 3306 is applied, and the various layers run through pinching rollers 3308, in order to output the fibrous web comprising silver nanoparticles 3310.
[0079] Figure 34 shows an alternative arrangement to that described with relation to figure 33. In this arrangement, the hopper 3302 of figure 33 is replaced with a spool of nanofiber doped with silver 3402. The backing substrate 3400 and nanofiber 3402 are layered together, and a fibrous web comprising silver nanoparticles 3410 are output in a similar manner to that described for figure 33.
[0080] Figure 35 shows an alternative arrangement for preparing a web of silver nanoparticles. Hoppers containing polymer granules/power 3500, a reagent 3502, and conductive particles 3504 feed into a mixing vessel 3506. The resultant mixture is pumped 3508 into a manifold 3510 and passes through a nozzle 3512. The arrangement is connected to a high voltage power supply 3520, wherein a jet of fibres 3514 results. The jet of fibres 3514 are emitted onto a substrate, resulting in a conductive nanofiber coated substrate 3516. A metallic collector terminal 3518 attracts the jet of fibres, assuring a good coverage of the substrate. [0081] Figures 36 and 37 demonstrate a method of preparing a web of quantum dots in a homogeneous pattern. A suspension of quantum dots is sprayed onto a fibrous web 3600. The web is dried, resulting in a web with adsorbed quantum dots 3602. Figure 37 shows the backing paper 3700, the spraying of quantum dots onto the backing paper 3702, drying of the layer of sprayed quantum dots 3704, and the resultant combination of a web with adsorbed quantum dots 3706.
[0082] Figure 38 shows an alternative system and method for creating a web of quantum dots in a homogenous pattern. The method is similar to that described with reference to figure 35, other than the hopper of conductive particles 3504 being replaced with a hopper of quantum dots 3800. The other elements and method remain the same as for figure 35.
[0083] Figure 39 and 40 demonstrate a method preparing a web of quantum dots and silver nanoparticles in a homogenous pattern. The method is the same as that described with reference to figure 36 and 37, with the replacement of the suspension of quantum dots being replaced with a suspension of quantum dots and silver nanoparticles 4000. [0084] Figures 41 and 42 demonstrate a method of preparing a web of quantum dots in a heterogeneous pattern. A web of fibrous material is laid out 4100, 4200. The web is partially covered with a negative template of the desired pattern 4102, 4202, in this case, a company logo. A suspension of quantum dots is sprayed onto the fibrous web 4104. The web is allowed to dry and the template removed 4106, 4204. This results in a web with adsorbed quantum dots in the chosen pattern.
[0085] Figures 43, 44, and 45, demonstrate a method of preparing a web of silver nanoparticles and quantum dots in a heterogeneous pattern. The method corresponds to that described with reference to figures 41 and 42, with the additional steps of spraying a silver nanoparticle suspension in a chosen pattern to create electrically conducting tracks prior to spraying the quantum dots in the chosen pattern.
[0086] Figure 46 details a method of producing a fibrous web of quantum dots and silver nanoparticles, the silver particles in a homogenous pattern and the quantum dots in a heterogeneous pattern. A fibrous web is immersed in a suspension of silver nanoparticles 4600. The web is then dried to result in a web with adsorbed nanoparticles 4604. The web is laid on a flat surface 4604. Using an inkjet printing process, a suspension of quantum dots is printed onto the fibrous web 4606, for example in the shape of a company logo. The web is the dried, resulting in a web with adsorbed quantum dots and silver nanoparticles 4608.
[0087] Figure 47 details a method of producing a fibrous web with a combination of different sized quantum dots, and silver nanoparticles, in a heterogeneous pattern. Initially, a fibrous web is laid out 4700. Multichannel inkjet printing is used to print a multicolour company logo, with conductive tracks printed between the logo and connector positions 4702. The multichannel printing includes a channel for quantum dots of a first size, quantum dots of a second size, and silver nanoparticles. The web is then dried 4704.
[0088] The skilled person will be aware of conventional techniques for making layered composite structures. Typically, various layers are laid-up, either pre impregnated with a resin, or impregnated with a resin post layup. The lay-up may be cured in an autoclave with a minimum vacuum of 20 inHg (0.677 bar). Pressure may be varied on different types of panels, for example with a 6 bar pressure being introduced on monolithic panels with no core, and 3 bar pressure being introduced to sandwich panels which include a core, either foam or honeycomb. During the application of pressure and temperature, a tool may be used to compress the materials, and volatile material may escape through the vacuum line. The temperature during the curing process may range from 120 degrees Celsius to 230 degrees Celsius. The temperature chosen may be dependent on the resin used. Curing times may vary from one minute to two hours. The curing time may depend on several factors, including the panel dimension, geometry, and resin system. Curing of a lay-up may occur without applying pressure. Curing of a lay up may occur in an oven with a vacuum bag, or a hot press.
[0089] The curing process may take place as a single step, with the quantum dots and all other layers of the composite panel structure being cured at the same time. Alternatively, the curing process may take place in two or more steps. For example, the structural layers of the composite structural panel may be cured in a first step, then the electrically conducting layers and quantum dot containing layers added, and a second curing step takes place. A multi-stage curing process, whilst potentially being more time consuming, may provide better control over the migration of the resin. A multi-stage process may also reduce the risk of failure of a non-homogenous quantum dot distribution which could result due to distortion in the curing process.
[0090] Figure 48 demonstrates a method of producing a composite structural panel in a single curing step. A lay-up comprising a sandwich of a fibre-reinforced plastic, core, fibre reinforced plastic, and layers of a conducting web and quantum dot web is provided 4800. The lay-up is then cured in a mould 4802. Figure 49 illustrates the lay-up comprising a lay-up of fibre-reinforced plastic 4900, a core 4902, fibre-reinforced plastic 4904, silver nanoparticles in a fibrous web 4906, and quantum dots and silver nanoparticles in a fibrous web 4908. The lay-up is placed in a mould 4910 and heat and pressure are applied 4912 to cure the lay-up.
[0091] Figures 50 and 51 demonstrate a method of producing a composite structural panel in a two stage process, with a first, pre-curing step, and a second curing step. Initially, a lay-up of the structural panel comprises a core sandwiched between fibre- reinforced plastic layers 5000. This initial lay-up is cured in a mould 5002. Layers comprising a web of silver nanoparticles, and a web of quantum dots and silver nanoparticles are added to the pre-cured panel 5004. A final curing step 5006 then takes place. Figure 51 shows the sandwich of the core 5102, the fibre reinforced plastic 5100 and the press 5104 used in the pre-curing step to produce a standard panel 5106. Figure 51 also shows the standard panel 5106, a resin layer 5108, a conductive nanofibers coated substrate 5110, a quantum dot web 5112, and a finishing lacquer 5114, which are laid up and cured using pressure and temperature in the second curing step.
[0092] Figures 52 and 53 demonstrate a method of producing a composite structural panel. A standard panel arrangement is first produced by laying-up a core sandwiched by fibre-reinforced plastic 5200. The lay-up is cured in a mould 5202. Layer of web comprising silver nanoparticles, and quantum dots and silver nanoparticles are added to the standard panel arrangement 5204. The added layers are cured without needing the use of a mould 5206, possibly by applying heat, or simply waiting for the curing to take place overtime. Figure 53 shows the core material 5304 sandwiched by fibre-reinforced plastic layers 5302, and a heated, vacuum assisted, press 5306. After a first curing step, the cured laminate 5308 has a resin layer 5310 added, a layer of conductive nanoparticles 5312 added, a web of quantum dots 5314 added, and a finishing lacquer added. Those additional layers are cured using the application of heat, without requiring further use of a press. As the layers added after the first curing step are not structural, the bonding strength required may be lower than for the structural layers.
[0093] Figures 54 to 57 demonstrate a method of inserting an electrical harness in a composite structural panel prior to curing of the panel. Initially a core is sandwiched between layers of fibre-reinforced plastic 5400. That lay up is machined to create a cavity 5402. Further lay-up steps include adding layers of a conducting web and a web containing quantum dots corresponding to the shape of the machined panel 5404. A connector plus sacrificial layer is inserted into the panel, along with linking of the conducting layer to the port of the connector 5406. Heat and pressure are applied in a mould 5408. Post-cure, the sacrificial layer is removed 5410. Figure 55 shows the panel lay-up prior to machining 5500. A cavity is machined in the panel such that a panel with a machined cavity for an electrical connector 5502 results. Figure 56 shows how conductive layers and a quantum dot containing layer is added to the panel 5502, with the conducting layer overlapping into the machined cavity 5600. A connecter part 5604 and a sacrificial part 5606 are added to the machined cavity to provide a panel 5602 ready for curing. Figure 57 shows heat and pressure being applied to the panel 5700. The mould is released and the sacrificial part removed, resulting in the final panel 5702 including exposed connectors, ready for connection to another panel, mating element, or power source.
[0094] Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein. For example, and alternative method of creating a heterogeneous web pattern may be to immerse a web in a solution containing silver nanoparticles or silver nanoparticles and quantum dots, to dry the web, and then cut the web into the desired shape. This may then be added to a lay-up in a simple manner. Where various materials have been specified, there are alternatives as would be well known to a skilled person. These include the following. Nomex <RTM> is a calendered sheet of a meta-polyaramid, e.g. a condensation product of isophthaloylchloride and 1,3 -diamino-benzene. Alternative core materials may be cellular cores with paper-like materials, foam cores, or no core materials provided at all, instead provision multiple layers of reinforced polymer. The fibre-reinforced resin, or fibre-reinforced plastic, may be phenolic resin with glass fibres. The fibre-reinforced resin may be used in the form of a so-called pre-preg. Alternative resins include polyester, vinylester, bioresins (e.g. poly(furfuryl alcohol) (PFA)) or epoxy resins. Alternatives to the glass fibres include carbon fibres, aramid fibres, or ultra-high molecular weight polyethylene. The quantum dots may be standard quantum dots of 2 to lOnm, made of binary or ternary compounds such as lead sulphide, lead selenide, cadmium selenide, cadmium sulphide, cadmium telluride, indium arsenide, indium phosphide, or cadmium selenide sulphide. As the skilled person will know, the size of the quantum dot determines the wavelength of the emitted light, small diameter quantum dots emitting a bluish light, and larger diameter quantum dots emitting a reddish light. The skilled person will know how to select the dots required to emit a desired colour of light. The quantum dots may be of single kind and of a uniform size or the quantum dots may contain a mixture of different kinds and/or different sizes. The web/fibres described above may comprise any of: nano and submicron fibres made of nylon-6 <RTM>, nylon- 66 <RTM>, styrene based polymers such as polystyrene and its derivatives and blends, polycarbonate, polyacronitrile, and conductive polymers such as polyaniline. The fibrous web may contain fibres with a diameter of 60 - 100 nm. For a fibrous web made of a non-conducting polymer, conductive materials to supply power to the quantum dots may be added and they may be any of: silver, single wall carbon nanotubes, multi-wall carbon nanotubes, graphene, graphite powder, carbon black, copper nano-particles and combinations thereof. Silver may be in the form of silver nanoparticles. The silver nanoparticles may have a particle diameter of less than 50 nm. Such materials may form part of the electrically conducting fibrous layer or layers of a composite structural panel according to the invention. Transparent conductive materials may include indium tin oxide, or polymers such as poly(3,4-ethylenedioxythiophene) (PEDOT). [0095] Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.
[0096] It should be noted that throughout this specification, “or” should be interpreted as “and/or”.

Claims

1. A composite structural panel comprising structural layer, a layer of quantum dots, an electrically conducting layer associated with the layer of quantum dots, the electrically conducting layer configured to supply electrical power to the quantum dots, such that the quantum dots emit light.
2. A composite structural panel as claimed in claim 1, wherein the layer of quantum dots comprises a web of fibrous material.
3. A composite structural panel as claimed in claim 2, wherein the layer of quantum dots comprises a web of electrically conducting fibrous material.
4. A composite structural panel as claimed in any preceding claim, wherein the electrically conducting layer comprises a web of fibrous material doped with a conducting material.
5. A composite structural panel as claimed in any preceding claim, wherein the layer of quantum dots is sandwiched between two dielectric layers.
6. A composite structural panel as claimed in claim 5, further comprising a second electrically conductive layer, wherein the quantum dot layer and the two dielectric layers are sandwiched between two conductive layers.
7. A composite structural panel as claimed in claim 6, wherein the second conductive layer is transparent or translucent.
8. A composite structural panel as claimed in any of claims 5 to 7, wherein the top dielectric layer is transparent or translucent.
9. A composite structural panel as claimed in any preceding claim, wherein the electrically conducting layer comprises a metallic mesh.
10. A composite structural panel comprising an electrically conducting fibrous web layer with quantum dots, and a structural layer.
11. A composite structural panel according to any preceding claim, wherein the structural layers comprise a cellular structure.
12. A composite structural panel according to any preceding claim, wherein the cellular structure is sandwiched between one or more resin impregnated layers.
13. A composite structural panel according to claim 12, wherein the resin impregnated layers comprise resin impregnated fibre reinforced layers.
14. A composite structural panel according to any of claims 1 to 12, wherein the structural layer comprises a plurality of resin impregnated fibre reinforced layers.
15. A composite structural panel according to any of claims 1 to 12, wherein the structural layer comprises a foam layer.
16. A composite structural panel according to claim 15, wherein one or more resin layers are located on one or both sides of the foam layer.
17. A composite structural panel according to any preceding claim, further comprising an integrated connector arranged to connect the electrically conducting layer to an external power source.
18. A composite structural panel according to claim 17, wherein the connector is exposed at a surface of the panel for direct connection to an external power source.
19. A composite structural panel according to claim 17, wherein the connector is arranged such that it can electrically connect the composite structure to another composite structure with a suitable connector.
20. A composite structural panel as claimed in any of claims 17 to 19, wherein the connector comprises a plurality of output ports arranged to independently electrify different regions of the composite structure.
21. A composite structural panel as claimed in any of claims 17 to 20, further comprising a second connector electrically connected to the other connector.
22. A composite structural panel as claimed in any preceding claim, further comprising a transparent or translucent top layer.
23. A composite structural panel as claimed in preceding claim, wherein the structural panel is an interior aircraft panel.
24. A composite structural panel as claimed in claim 23, wherein the structural panel is an interior aircraft panel comprising all or part of any one of: an aircraft seat unit, a class divider, a lavatory, an overhead bin, a galley kitchen, floor level illumination panels, or interior side panels.
25. A composite structural panel as claimed in any preceding claim, wherein the quantum dots are arranged in a homogenous pattern.
26. A composite structural panel as claimed in any of claims 1 to 24, wherein the quantum dots are arranged in a heterogeneous pattern.
27. A composite structural panel as claimed in any preceding claim, wherein the quantum dots vary in size, in order to provide illumination of different colours.
28. A method of manufacturing a composite structural panel as claimed in any of claims 1 to 27, the method comprising the steps of: arranging the layers of the composite structure in the prescribed order to create a lay-up, placing the lay-up into a mould, and applying a prescribed temperature and pressure to cure the lay-up.
29. A method of manufacturing a composite structural panel as claimed in any of claims 1 to 27, the method comprising the steps of: arranging the structural layer of the composite structure to create a lay-up, placing the lay-up into a mould, and applying a prescribed temperature and pressure to cure the lay-up with a first curing step.
30. A method as claimed in claim 29, further comprising the step of adding the electrically conducting layer to the lay-up after the first curing step, and applying a prescribed temperature and pressure in a second curing step.
31. A method as claimed in any of claims 28 to 30, further comprising the step of adding the quantum dot layer to the lay-up after the first curing step, and applying a prescribed temperature and pressure in a second or third curing step.
PCT/GB2020/053027 2019-12-04 2020-11-27 Light-emitting structural panel WO2021111108A1 (en)

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