One of the first interiors I worked in was a GII completed at Atlantic Aviation in the mid-seventies. The cabinet sub-structure was made of marine plywood, wood screws and aluminum angles. At the same time, DuPont was further developing the woven fire proof fabric known as Nomex into structural material. It did not have the integrity that DuPont was seeking, but when the panel was combined with a honey comb interior and impregnated with Phenolic resin, it became rigid and very light weight. In the early eighties, Nomex panel became the aviation industry standard for sub-structure that could be manufactured into cabinets and formed into headliners and the like.
Parallel to the development of the Nomex panel was the enhanced development of aluminum honeycomb panels. Both of these types of panels at that time were very costly, but the benefit of weight savings could not be ignored by cabinet shops and completion centers. DuPont went even further than Nomex as a fire proof material with the development of Kevlar. This petroleum based fiber was then developed for the military in the eighties when the matrix woven fabric was then impregnated with low viscosity resin it was found to be bullet proof. This material it was so low in weight and high in tensile strength, that it could not be ignored for numerous uses that include body amour, building construction and aircraft airframe manufacturing as well.
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| Nomex Burn Samples |
Today all three of these panel materials are commonly used in the manufacture of business jet interiors. Depending on the location of application they can be used alone or combined to create complex components. Panels are now cut on Computer Numeric Controlled (CNC) Routers that allow one skin to remain intact so a five sectioned panel can be bent into a single drawer without being cut. Panels are glued together with pins, injected with epoxy and the edges are filled with structural putty.
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| Delrons |
Once formed or built, these panels can be secured to the aircraft structure with shock mounted brackets known as isolators. These attachments are fastened to the Nomex components with inserts called Delron’s that can be secured with screws that won’t crush the composite panel.
It is good to be able to inspect cabinets and components in rough form before they are covered in wood veneer or fabric. Edges of wet units like galleys and vanities need to have the composite edge filled and sealed so water cannot penetrate the panel. Corners and edges that have been filled with putty should be inspected to insure that the fill is adequate and won’t crack loose. By giving components the once over, it will guarantee that the finish material adheres properly especially wood veneer that can delaminate once that cabin pressurizes in operation.
Aircraft interiors are designed to be comfortable and functional. The seats are typically made from leather or other durable materials. They are also adjustable so that passengers can find a comfortable position. The aisle between the seats is wide enough for passengers to walk through easily. The overhead bins are large enough to store carry-on luggage.
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