Aircraft flooring system
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Solution Overview
Problem
Airplane carpeting faces challenges such as weight constraints, spill containment issues due to bolts and electronics, and the undesirability of carpet tiles with seams, which increase the risk of liquid penetration.
Innovation Solution
A lightweight, dimensionally stable carpet tile system featuring a barrier backing with a polyester film membrane and a hook-and-loop system for secure adhesion to the aircraft floor, incorporating a reinforcing scrim layer and a polymer membrane to prevent deformation and enhance spill resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If carpet tiles are used for airplane carpeting, then installation flexibility is improved, but seam presence increases which provides pathways for liquid penetration
Solution Approach 1:
The carpeting system is divided into individual carpet tiles that can be independently installed and removed, providing installation flexibility while maintaining spill containment through the barrier backing membrane that prevents liquid penetration through seams
Solution Approach 2:
A barrier backing membrane is incorporated into the carpet tile construction to create a liquid barrier that prevents spills from penetrating through seams and reaching underlying components, while maintaining the flexibility needed for aircraft floor contours
2Reliability
If traditional carpet materials are used, then carpeting performance is adequate, but weight increases which is critical in aircraft applications
Solution Approach 1:
The carpet tile is constructed using composite materials including a lightweight polymer membrane for the barrier backing, synthetic fibers for the pile, and foam cushioning layers, achieving adequate performance while reducing overall weight compared to traditional carpet materials
3Object-affected harmful factors
If heavy-duty materials are used for spill containment, then spill resistance is improved, but weight increases and deformation resistance may worsen
Solution Approach 1:
A thin polymer membrane is used as the barrier backing to provide effective spill containment while minimizing weight addition, preventing liquid penetration through the carpet structure to protect underlying electronics and components
4Ease of operation
If carpet tiles with seams are used, then installation ease is improved, but cleaning difficulty increases due to liquid pathways through seams
Solution Approach 1:
The barrier backing membrane creates a continuous liquid barrier across carpet tile seams, preventing spills from penetrating through installation gaps and making cleaning easier by containing liquids on the carpet surface where they can be wiped away
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 carpet tile system achieves a low weight of less than 2034.6 grams per square meter while maintaining resistance to deformation and providing effective spill containment through a strong hook-and-loop system, ensuring safety and ease of cleaning.
Implementation Method 1
a loop part of a hook-and-loop system on the bottom surface of the barrier backing; a hook part of a hook-and-loop system configured to be adhered to an aircraft floor
Implementation Method 2
said top surface adhered to a polymer membrane, wherein in use of the carpet tile the barrier backing is coupled to the hook part of the hook-and-loop system
Data Source
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AI summary
An aircraft flooring system is provided, made up of a low-weight carpet tile (100) which functions both as a moisture barrier and as the loop part of a hook-and-loop system, for coupling to a hook part of a hook-and-loop system, which is bound to an aircraft floor. Specifically, a barrier backing (160) within the carpet tile, comprising a nonwoven fabric portion (140), is able to act as the moisture barrier (150) and the loop part (145), which allows for coupling of the carpet tile with the floor, without the need to add additional loops to the carpet tile, thereby realizing savings in material cost and weight.