Aircraft Floor Padding with Discontinuous Couplings

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Solution Overview

Problem

Existing aircraft carpet flooring assemblies lack sufficient noise attenuation, thermal protection, and comfort, as they rely on single-layer carpet pads that inadequately address vibrations and noise radiating from the structural floor.

Innovation Solution

A multi-layered carpet pad assembly with discrete couplings between layers, where each layer is secured at infrequent locations by discontinuous attachments, enhancing noise attenuation and thermal insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single-layer carpet pad is used, then the structure is simple and easy to manufacture, but noise attenuation and thermal protection are insufficient

Engineering Contradiction:

Improvestructure simplicityVSAvoidnoise attenuation

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The carpet pad is divided into multiple discrete layers (first pad layer, second pad layer, third pad layer) that are laterally separated by void portions. This segmentation allows each layer to independently attenuate vibrations and noise while maintaining structural simplicity through modular construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a single-layer two-dimensional structure to a multi-layer three-dimensional structure with vertical stacking of pad layers separated by voids. This dimensional change creates air gaps that enhance noise attenuation and thermal protection while preserving ease of manufacture through layer-by-layer assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Stability of the object's composition

If continuous coupling between pad layers is used, then structural stability is improved, but noise attenuation is reduced due to vibration transmission

Engineering Contradiction:

Improvestructural stabilityVSAvoidvibration transmission

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

Instead of uniform continuous coupling, the invention applies localized coupling only at perimeter regions and discrete interior points. This local quality approach provides sufficient structural stability at connection points while leaving the majority of the pad layers uncoupled to independently dampen vibrations and reduce noise transmission.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coupling between pad layers is applied partially rather than continuously - only at perimeter edges and selected discrete locations. This partial action maintains adequate structural stability for installation and use while allowing the majority of the pad structure to remain decoupled for optimal noise attenuation performance.

Inventive Principle:

Principle #16Partial or excessive action

3Object-affected harmful factors

If multiple pad layers are used, then noise attenuation and thermal protection are improved, but device complexity increases

Engineering Contradiction:

Improvenoise attenuationVSAvoidassembly complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The multi-layer pad assembly is segmented into discrete, independently installable layers with clear separation by void portions. This segmentation reduces assembly complexity by allowing each layer to be installed separately rather than requiring complex integration of a monolithic structure, while still achieving enhanced noise attenuation through multiple layers.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The multi-layered carpet pad assembly significantly improves sound transmission loss and thermal protection, reducing audible noise and enhancing comfort for aircraft occupants by strategically securing pad layers with minimal mechanical attachment area.

Implementation Method 1

The padding assembly attenuates the noise and includes a first pad layer, a second pad layer, and a plurality of discontinuous couplings

Methodology Applied

Scientific EffectVibration isolation: Vibration

Implementation Method 2

works with the carpet to help block underfloor noise and noise that is radiating off the vibrating structural floor

Methodology Applied

Scientific EffectAcoustic damping: Damping

Implementation Method 3

The second pad layer is adjacent to the first pad layer... providing thermal protection

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11685506B2Aircraft floor assemblies with discontinuous coupling between layers

Publication Date: 2023.06.27 GULFSTREAM AEROSPACE CORP

AI summary

A finished floor assembly covers a floor area of an aircraft and includes a subfloor, a padding assembly, and a finish flooring layer. Noise radiates from the subfloor due to vibrations transmitted by an aircraft structure. The padding assembly attenuates the noise and includes a first pad layer, a second pad layer, and a plurality of discontinuous couplings. The first pad layer abuts the subfloor. The second pad layer is adjacent to the first pad layer. The plurality of discontinuous couplings are laterally separated from each other along the floor area by void portions. The discontinuous couplings secure the first pad layer to the second pad layer and the first pad layer and the second pad layer are in contact at the void portions. The finish flooring layer disposed overtop the padding assembly.