Composite Aircraft Seat Back Torque Box for Weight and Bending Strength
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Solution Overview
Problem
Conventional aircraft passenger seats are heavy, consuming valuable cabin space and limiting legroom and personal space, while requiring bulky materials for structural support and cushioning, which hinders weight reduction and increased passenger capacity.
Innovation Solution
A lightweight composite construction for aircraft passenger seats, featuring a composite support leg structure with minimal metal parts, a composite seat pan assembly, and a composite seat back structure with a torque box to resist bending, allowing for a compact and lightweight design that meets structural requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal components and thick padding are used for structural support, then structural strength is improved, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by replacing conventional metal components with composite structures. Specifically, the seat back structure uses a composite frame with a torque box construction that combines multiple materials and structural elements to achieve both strength and weight reduction. The torque box incorporates a composite frame, foam core, and skin panels that work together to provide structural integrity while significantly reducing weight compared to traditional metal assemblies.
2Strength
If bulky materials and thick padding are used for structural support and comfort, then structural integrity is improved, but cabin space is consumed
Solution Approach 1:
The composite torque box structure enables a more compact design by integrating structural support functions into a smaller volume. The foam core provides both structural rigidity and cushioning in a single integrated element, eliminating the need for separate thick padding layers while maintaining both strength and comfort requirements.
Solution Approach 2:
The patent merges multiple functions into the torque box structure: the composite frame provides structural support, the foam core provides both structural rigidity and passenger comfort, and the skin panels provide additional structural integrity. This consolidation of functions into a single integrated assembly reduces the overall volume required compared to conventional designs that use separate metal frames and thick padding layers.
Data Source
AI summary
An aircraft passenger seat configured in accordance with an embodiment of the invention utilizes composite materials to achieve significant weight savings relative to conventional seat designs. The seat includes one or more lightweight composite support legs, a lightweight composite seat pan, and a lightweight composite seat back structure. The support legs are coupled to the seat pan, which is in turn coupled to the seat back structure. The support legs utilize composite frame elements that are formed as continuous compression molded composite extrusions. The seat pan includes composite fore and aft cross beams that are also formed as continuous compression molded composite extrusions. The aft cross beam includes a rear flange that serves as a flexible “hinge” for the seat back structure. The seat can leverage producible and relatively inexpensive composite manufacturing techniques such that the seat can be economically produced for use as an economy class seat.