FIELD OF THE INVENTION

[001 ]. The present invention relates generally to visual display and control panels used in synthetic training devices. More particularly, the invention is directed to improvements in synthetic training device panels having illuminated features and methods of manufacture thereof.

BACKGROUND TO THE INVENTION

[002], Synthetic training devices are an indispensable tool in pilot education, allowing for a trainee to accumulate hours of experience without the cost of real aircraft operation. At the filing date of this application, such devices are typically accredited in Australia by the Civil Aviation Safety Authority (CASA) against the Civil Aviation Safety Regulations 1998 Manual of Standards (MOS) Part 60 Amendment 1 2008. Part 60 sets out the rules for flight simulation training devices (FSTDs), covering initial and recurrent qualification and use of such devices. The synthetic training device regulations are varied across both aeroplane and helicopter flight training devices standards.

[003], The term “FSTD” may be used to refer to a device that simulates an aircraft or part of an aircraft used to train personnel who interact with aircraft flight controls or power plant controls to manoeuvre the aircraft in flight and/or on the ground. Such devices typically have approved standards for the purpose of permitting experience acquired therein to be credited towards meeting requirements for operator qualification, categorisation or currency. Synthetic training device regulations are varied across both aeroplane and helicopter flight training devices standards.

[004], The term “flight training device” (FTD) may refer to a FSTD for a specific type (or a specific make, model and series) of aircraft. A FTD may refer to a device that simulates the subject aircraft in ground and flight operations to the extent of the systems installed in the device and comprises a full size replica of the instruments, equipment, panels and controls in an open flight deck area, or an enclosed flight deck of the aircraft, but does not, in every respect, simulate the aircraft in ground and flight operations. An FTD includes the necessary software and equipment, and the way that the equipment is interconnected.

[005], It is generally desirable for a synthetic training device to obtain an accreditation standard of MOS FTD level 5 in respect of a specific class of aircraft meeting a specific FTD design criteria.

[006], Apart from Australia, many other countries have regulatory regimes with regard to synthetic training devices in the aeronautical field. Furthermore, in some jurisdictions the regulation of synthetic training devices for military aircraft is overseen by a civil authority whilst in others, a separate authority is established. In some contexts, a synthetic training may not be subject to any regulatory regime whatsoever.

[007], Computer-based synthetic training devices became prevalent in the late 20 ^th century, revolutionising the field by allowing for accurate simulation of aircraft behaviour in response to pilot inputs and virtual weather conditions. Standard video display units of the type routinely used with personal computers were used to display a simulated view of the cockpit, including the external environment and also internal features such as control panels (such a radio communications panel, or an electrical panel) and display panels (such as a lighting panel or a smoke panel). Whilst serious attempts were made by developers to render the panels in a realistic manner, the result invariably lacked sufficient realism to provide the trainee with a faithful reproduction of the real-world cockpit panel involved.

[008], The trainee pilot would often use a computer mouse to virtually manipulate the panel controls. For example, where a toggle switch was involved the trainee would move a pointer on the screen to the switch and toggle by clicking the mouse button. Rotary controls could be moved by a “dragging” technique whereby the mouse was moved whilst depressing the mouse button. Alternatively, the mouse was moved to the desired circumferential point about the rotary control and the button clicked.

[009], The development of touch-sensitive displays allowed for the trainee pilot to manipulate on-screen panel controls without the need for a mouse in a more natural manner. Whilst this approach was generally workable, the trainee was again deprived of a sufficiently authentic experience.

[010], To improve realism, physical cockpit panels that act as inputs and outputs for a computer based synthetic training devices are now known and remain well-used in the art. While the windscreen view is displayed on one or more large screens, smaller physical panels are constructed having realistic face plates, indicator lights, hardware switches and hardware knobs. Such panels are typically arranged in the simulator cockpit so as to emulate that of the real aircraft. This approach provides a high level of realism in both a visual and tactile sense.

[Oi l], A number of problems arise in prior art physical synthetic training device panels. One problem is that the panels are difficult or expensive to manufacture and repair. A further problem is that indicator lighting has an unrealistic visual appearance. A further problem arises in the control of light emitted by indicator lighting in a panel so as to maintain visual realism in the panel and in the cockpit as a whole.

[012], These problem arise in seeking to faithfully re-create a representation of the cockpit for popular trainer aircraft such as the PC-21™ (Pilatus Aircraft Ltd, Sweden), amongst others.

[013], It is an aspect of the present invention to provide synthetic training device cockpit panels having improved visual realism. It is a further aspect of the present invention to provide synthetic training device cockpit panels that are simpler and/or less expensive to manufacture and/or repair. It is a further aspect of the present invention to provide a useful alternative to prior art synthetic training device cockpit panels. [014], The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.

SUMMARY OF THE INVENTION

[015], In a first aspect, but not necessarily the broadest aspect, the present invention provides a multi-layer synthetic training device cockpit panel configured to be viewable and manually actuatable by a user facing the panel, the panel comprising: a first portion comprising:

(i) first and second electrical contacts,

(ii) a light source in electrical connection with the first electrical contact, the light source configured to emit light generally toward the user, and

(iii) a user operable actuator in electrical connection with the second electrical contact, the actuator extending outwardly from the panel, and generally toward the user; a second portion configured to:

(i) transmit and diffuse light emitted by the light source, and

(ii) allow, or not prevent, the actuator to extend outwardly from the panel and generally toward the user; and a third portion configured to:

(i) allow a portion of the light diffused and transmitted by the second portion to be viewable by the user,

(ii) prevent a portion of the light diffused and transmitted by the second portion being viewable by the user, and

(iii) allow, or not prevent, the actuator to extend outwardly from the panel and generally the user. [016], In one embodiment of the first aspect, the second portion and/or the third portion(s) comprise(s) an aperture configured to allow the manual actuator to pass therethrough.

[017], In one embodiment of the first aspect, the second portion is fabricated from a manufactured polymeric material, a plastic material, an acrylic material or a vitreous material.

[018], In one embodiment of the first aspect, the third portion is configured to mask light diffused and transmitted by the second layer such that the light allowed through the mask provides the appearance of a regularly shaped indicator light or an illuminated alphanumeric character.

[019], In one embodiment of the first aspect, the third portion is fabricated from or coated with a material that is substantially impervious to light and an aperture is formed in the third portion to allow passage of light therethrough.

[020], In one embodiment of the first aspect, the third portion is fabricated from a metallic material

[021 ]. In one embodiment of the first aspect, the third potion has human-comprehensible indicium that is viewable by a user, the indicium being a synthetic training devices-related label.

[022], In one embodiment of the first aspect, the panel further comprises a fourth portion fabricated from or coated with a material that is substantially impervious to light, and configured to prevent lateral transmission of light from the second portion and laterally outwardly from the panel.

[023], In one embodiment of the first aspect, the fourth portion is disposed adjacent to one, two, three or four lateral side(s) or edge(s) of the second portion. [024], In one embodiment of the first aspect, the fourth portion is configured to maintain the second portion in spaced relationship to the first portion.

[025], In one embodiment of the first aspect, the fourth portion comprises a spacer portion configured to contact the first portion, and a light impervious portion extending from the spacer portion and configured prevent the lateral transmission of light from the second portion.

[026], In one embodiment of the first aspect, the spacer portion and the light impervious portion are each generally planar, and the light impervious portion extends at an angle of about 90 degrees from the spacer portion.

[027], In one embodiment of the first aspect, the fourth portion is a unitary structure which completely surrounds the second portion.

[028], In one embodiment of the first aspect, the first, and/or second, and/or third, portion(s) is/are of a generally planar and/or unitary construction.

[029], In one embodiment of the first aspect, the fourth portion is of a generally planar and/or unitary construction.

[030], In one embodiment of the first aspect, the first, second, third and fourth (where present) form discrete layers of the panel.

[031], In one embodiment of the first aspect, the discrete layers are ordered as follows: first portion, fourth portion (where present), second portion, third portion.

[032], In one embodiment of the first aspect, the discrete layers are ordered as follows: first portion forming a first layer, fourth portion and second portion forming a second layer, third portion forming a third layer. [033], In one embodiment of the first aspect, the first and/or second and/or third and/or fourth portion(s) comprise(s) one or more locating formations configured to correctly spatially locate one portion relative to another portion.

[034], In one embodiment of the first aspect, the actuator is not mounted on and/or fixed to the first portion.

[035], In one embodiment of the first aspect, the actuator is mounted on and/or fixed to the second portion

[036], In one embodiment of the first aspect, the actuator is electrically connected to the second electrical contact of the first portion by a discrete electrical conduit.

[037], In one embodiment of the first aspect, the light source is not mounted on and/or fixed to the first portion.

[038], In one embodiment of the first aspect, the light source is mounted on and/or fixed to the second portion.

[039], In one embodiment of the first aspect, the light source is electrically connected to the first electrical contact of the first portion by a discrete electrical conduit.

[040], In one embodiment of the first aspect, the first portion is a printed circuit board.

[041], In one embodiment of the first aspect, the actuator is a mechanical or semimechanical actuator selected from a switch, a toggle switch, a multi-position switch, a slider, a continuously variable slider, a multiple position slider, a button, a momentary button, a latching button, a rotary knob, a continuously variable rotary knob, or a multiple position rotary knob. [042], In one embodiment of the first aspect, any two or more portions are retained together by a fastener, a screw, a bolt, a rivet, a clamp or an adhesive.

[043 ]. In one embodiment of the first aspect, the panel is configured to have a visual and/or functional similarity to an aircraft communications panel, an aircraft orientation panel, an aircraft lighting panel, an aircraft oxygen panel, an aircraft smoke panel, an aircraft electrical panel, an aircraft weapon control panel, an aircraft caution panel, or an aircraft environment system panel.

[044], In a second aspect, the present invention provides a synthetic training devices cockpit comprising two or panels according to any embodiment of the first aspect, the two or more panels being arranged adjacent to each other.

[045], In one embodiment of the second aspect, each of the two more panels is disposed in a position of the cockpit consistent with their position in the real aircraft.

[046], In one embodiment of the second aspect, the cockpit has an entry/exit way for the user which is disposed more rearward than that in the real aircraft so as to facilitate user entry and exit therefrom.

[047], In one embodiment of the second aspect, the synthetic training devices cockpit is configured to have a visual and/or functional similarity to the cockpit of a trainer aircraft.

[048], In one embodiment of the second aspect, the trainer aircraft subject of the synthetic training device is a Pilatus™ PC-21™.

[049], In a third aspect, the present invention provides a flight simulation system comprising the panel of any embodiment of the first aspect, or the cockpit of any embodiment of the second aspect, the system further comprising a computer having access to program instructions for a computer-implemented synthetic training devices, wherein the computer is in direct or indirect electrical or data communication with the panel. [050], In a fourth aspect, the present invention provides a method of producing a multilayer synthetic training device aircraft cockpit panel configured to be viewable and manually actuatable by a user facing the panel, the method comprising the steps of: providing a first portion comprising:

(i) first and second electrical contacts,

(ii) a light source in electrical connection with the first electrical contact, the light source configured to emit light generally toward the user, and

(iii) a user operable actuator in electrical connection with the second electrical contact, the actuator extending outwardly from the panel, and generally toward the user; providing a second portion configured to:

(i) transmit and diffuse light emitted by the light source, and

(ii) allow, or not prevent, the actuator to extend outwardly from the panel and generally toward the user; and providing a third portion configured to:

(i) allow a portion of the light diffused and transmitted by the second portion to be viewable by the user,

(ii) prevent a portion of the light diffused and transmitted by the second portion being viewable by the user,

(iii) allow, or not prevent, the actuator to extend outwardly from the panel and generally the user, and bringing the first, second and third portions together such that the resultant portions are layered thus: first portion, second portion, third portion.

[051 ]. In one embodiment of the fourth aspect, the method comprises the further steps of: providing a fourth portion fabricated from or coated with a material that is substantially impervious to light, and configured to prevent lateral transmission of light from the second portion and laterally outwardly from the panel and further configured to maintain the second portion in spaced relationship to the first portion, and. bringing the first, second, third and fourth portions together such that the resultant portions are layered thus: first portion, fourth portion, second portion, third portion.

[052], In a fifth aspect, the present invention provides use of the method of any embodiment of the fourth aspect for the production of a multi-layer synthetic training device aircraft cockpit panel to produce the multi-layer synthetic training device aircraft cockpit panel of any embodiment of the first aspect.

BRIEF DESCRIPTION OF THE FIGURES

[053], FIG. 1 A illustrates in highly schematic form and in a lateral cross-sectional view a preferred panel of the present invention having first, second, third and fourth portions.

[054], FIG. IB illustrates an exploded view of the panel drawn in FIG. 1 A.

[055], FIG. 2 illustrates an exploded perspective view of first, second, third and fourth portions perspective view of a preferred panel of the invention having first, second, third and fourth portions. No actuator is shown in this drawing.

[056], FIG. 3 illustrates an exploded perspective view of first, second, third and fourth portions perspective view of a preferred panel of the invention having first, second, third and fourth portions. Indicium are shown on the face plate (upper most portion). No actuator is shown in this drawing.

[057], FIG. 4 shows highly schematically a plan view of four panels of the present invention disposed adjacent to one another. The double-ended arrows show the directions of potential light bleeding, the light bleeding being prevented by the flange of the panel fourth portion.

[058], Unless otherwise indicated herein, features of the drawings labelled with the same numeral are taken to be the same features, or at least functionally similar features, when used across different drawings. Particularly with reference to FIG. 1A and FIG. IB, the components are shown with exaggerated thicknesses so as to more clearly show the components and the mean by which the components fit together.

[059], The drawings are not prepared to any particular scale or dimension and are not presented as being a completely accurate presentation of the various embodiments.

DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS THEREOF

[060], After considering this description it will be apparent to one skilled in the art how the invention is implemented in various alternative embodiments and alternative applications. However, although various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of example only, and not limitation. As such, this description of various alternative embodiments should not be construed to limit the scope or breadth of the present invention. Furthermore, statements of advantages or other aspects apply to specific exemplary embodiments, and not necessarily to all embodiments, or indeed any embodiment covered by the claims.

[061 ]. Throughout the description and the claims of this specification the word "comprise" and variations of the word, such as "comprising" and "comprises" is not intended to exclude other additives, components, integers or steps.

[062], Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may.

[063], As used herein, positional terms such as “lateral”, “across”, “above”, “below”, “higher”, “lower”, upward, downward, “plan view” and the like are to be considered with reference to a flight simular panel as installed into a flight simulation cockpit, the cockpit being a true representation of a cockpit of the real aircraft.

[064], The present invention is predicated at least in part on the inventors’ discovery that the realism of a synthetic training devices panel (such as a communications panel, a smoke panel, or an oxygen panel) is improved where the panel is configured to be viewable and manually actuatable by a user facing the panel, and the panel comprises: a first portion comprising: (i) first and second electrical contacts, (ii) a light source in electrical connection with the first electrical contact, the light source configured to emit light generally toward the user, and (iii) a user operable actuator in electrical connection with the second electrical contact, the actuator extending outwardly from the panel, and generally toward the user; a second portion configured to: (i) transmit and diffuse light emitted by the light source, and (ii) allow, or not prevent, the actuator to extend outwardly from the panel and generally toward the user; and a third portion configured to: (i) allow a portion of the light diffused and transmitted by the second portion to be viewable by the user, (ii) prevent a portion of the light diffused and transmitted by the second portion being viewable by the user, and (iii) allow, or not prevent, the actuator to extend outwardly from the panel and generally the user.

[065], A panel in accordance with the description above provides an indicator light and/or a combination of actuator (such as a switch or a button) and indicator light which more closely resembles those of actual aircraft. The indicator light appears even across its dimensions and regularly shaped (such as a square, circle or a ring). Prior art panels typically use light emitting diodes as a source of light (as indeed does the present invention, in a preferred embodiment), and while effective as light emitters these devices fail to provide a light source that is similar to that emitted by indicator lights in the real aircraft.

[066], Some panel embodiments comprise a fourth portion fabricated from or coated with a material that is substantially impervious to light, and configured to prevent lateral transmission of light from the second portion and laterally outwardly from the panel. In such embodiments, light from a panel may bleed into an adjacent panel. One result of bleeding is that an unilluminated indicator light appears to be illuminated, thereby providing the user with erroneous information. Another result of bleeding is that the cockpit as whole takes on an unrealistic appearance. As will be appreciated, synthetic training devices are often operated under low light conditions, and bleeding of light from one panel to another can be very noticeable.

[067], In some embodiments, the light source and/or actuator is/are not PCB (printed circuit board)-mounted. Instead, one or both of these components may be mounted on the second portion (i.e. the light diffusing layer of the panel), and electrically connected to PCB by a jumper or other discrete electrical conduit. Thus, when a light or actuator requires replacement, the component can be accessed by simply removing the panel third portion (i.e. the panel face plate), physically unmounting the component (by removing a fastener, or breaking an adhesive bond, for example), electrically isolating the component from the panel (such as by desoldering the component and releasing it from the discrete electrical conduit), and replacing it by the reverse process.

[068], In prior art panels, it is necessary to remove the panel, fully disassemble it, remove the PCB, remove the defective component from the PCB by desoldering, replace the component and reassemble the panel. Quite apart from the time and labour involved, replacement of PCB-mounted components brings the risk of damage to circuits due flexion of the board, heat damage to sensitive components such as microprocessors by soldering and desoldering, and the possibility of static electricity damage due to handling of the board by the repair technician. In some approaches of the prior art, the PCB is never repaired and is instead replaced completely.

[069], LEDs are considerably less prone to failure than are actuators, and accordingly in some embodiments of the invention the light source is PCB-mounted, and the actuator is not PCB-mounted.

[070], A non-limiting embodiment of the invention will now be further described by reference to the accompanying drawings. [071 ]. Turning firstly to FIG. 1 A there is shown highly diagrammatic cross-sectional view of a preferred assembled panel (5) of the invention detailing the components which are assembled to produce a preferred embodiment of the present invention. The first panel portion is aPCB (10) ofthetype well known to the skilled artisan. ThePCB (10) comprises the components and electrical connection required for the panel to operate in the context of an overall Synthetic Training system. The panel comprises a plurality of surfacemounted LEDs (two marked 15) for the panel light source. Each LED (15) makes electrical connection with the PCB such that it may be switched on and off as required for illumination of the panel.

[072], The second panel portion is a sheet (20) having two functions in this embodiment. Firstly, the sheet (20) diffuses light being emitted by the underlying LEDs (15). In that regard plastic or vitreous materials are preferred. Where the sheet (20) is fabricated from a plastic material, an acrylic or a polycarbonate may be used. Acrylic materials are preferred given their superior optical properties, and still further preferred is polymethylmethacrylate. In some embodiments, the sheet (20) is fabricated from a material having a high optical transparency (i.e. a non-diffusing material) but having a film or other coating applied thereto so as to confer the ability to diffuse light.

[073], . The sheet (20) preferably provides an even diffused light output, with little or no discernible bright spots visible when the underlying LED’s (15) are active. Thus, diffusers having ribs or prismatic structures and the like are contraindicated, with very fine grain satin-like consistency being preferred. The sheet is typically white and thin (less than 5, 4, 3, or 2 mm depth).

[074], A second function of the sheet (20) is to act a structure upon which an actuator (such as a switch) can be mounted, as will be further detailed infra. In that regard, it is preferred that the sheet (20) is of solid construction so as to provide a sound substrate for mounting the actuator. Plastics (as discussed supra) are preferred over vitreous and other materials given the ability for many to take a screw or other fastener. [075], The sheet (20) of the second panel portion has an aperture (25) sized and positioned to allow a toggle switch (30) to pass through the sheet (20). In preferred embodiments, the toggle switch is physically fixed to the sheet (20) with the base of the switch snuggly fitting into the aperture. The switch wiring (35a, 35b) extends from the switch base and makes electrical connection with the PCB (10)

[076], The third panel portion is a face plate (40) being fabricated in anodised aluminium for provide a feel and appearance of the real aircraft panel. The face plate (30) has apertures (45, 50). The aperture (50) allows for the toggle switch (30) terminus to extend outside the panel and therefore be manually actuatable by a user (such as by pushing or turning). It will be noted that the aperture (50) is sized to expose a ring of the underlying sheet (20). Thus, when the underlying LEDs (15) are illuminated the exposed ring glows (and is visible to the user), thereby functioning as an indicator light. For example, the indicator light may illuminate when the switch is in the “on” state but does not illuminate when in the “off’ state. The threaded barrel of the toggle switch (30) may allow for a transparent bezel to be wound thereon thereby forming a flush finish on the face plate (40). In some embodiments, the actuator is transparent through a region (such as a knob on a rotary switch) to allow illumination of the actuator itself.

[077], A second type of aperture (45) is formed in the sheet (20). The aperture (20) is not required to accommodate an actuator, and instead functions only as an opening in a mask so as to allow light emitted by the underlying LEDs (15) and diffused by the sheet (20) to be visible to the user.

[078], The aperture (45) may have some regular shape such as a square or a circle so as to give the appearance of a realistic indicator light. Alternatively, the aperture (45) may be a cut-out (formed by laser cutting, for example) to form the shape of an alphanumeric character or graphic or other indicium. In this way, the face plate (40) may display illuminated text for viewing by the user as required. For example, the text may be a warning such as “smoke”, the warning illuminating only when the synthetic training devices triggers a virtual fire in the aircraft. The face plate (40) may be dark coloured such that when the warning text is not illuminated, the text is inconspicuous to the user.

[079], A fourth panel portion is provided in the form of a flanged spacer (50) which runs around the periphery of the PCB (10). The function of the spacer portion (50a) is to maintain the sheet (20) clear of the PCB (10) and any components mouthed thereon, such as LEDs (15). The function of the flange portion (50b) is to prevent that lateral escape of light (i.e. to the left or to the right, as drawn) from the panel. The sheet (20) functions to scatter light emitted by the LEDs (15) (scattering being a function of its diffusion role) and so inevitably light is scattered laterally, causing an undesired “bleeding” of light to an adjacent panel. The flange is therefore formed from a material that is substantially impervious to light. The entire flanged/spacer is typically formed from a lightweight plastic, however other materials such as metals, rubber, silicones and the like will be operable.

[080], The present invention is described mainly by reference to panels that are representations of those of a Pilatus™ PC-21™ seeking to obtain a FTD level 5 accreditation within the MOS 60 civil aviation standard. However, the invention is not to be considered restricted to any such aircraft or any such standard.

[081], Those skilled in the art will appreciate that the invention described herein is susceptible to further variations and modifications other than those specifically described. It is understood that the invention comprises all such variations and modifications which fall within the spirit and scope of the present invention.

[082], Accordingly, the spirit and scope of the present invention is not to be limited by the foregoing examples, however is to be understood in the broadest sense allowable by law.