Aircraft Interior Sheet Material Wrinkle Prevention
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Solution Overview
Problem
Aircraft interior seat materials face issues with easy staining, wrinkles, and poor fit between the cushion and outer cover, affecting appearance and quality control.
Innovation Solution
A sheet material is created by fusing a fire-resistant urethane material with a Fire Blocking Layer (FBL) and an outer cover using a melting layer, ensuring a tight bond and preventing wrinkles, with specific thicknesses and a manufacturing process involving heating and compressive bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an outer cover is frequently used by passengers/crew members, then the seat provides functional utility, but the outer cover can be stained easily and requires cleaning
Solution Approach 1:
The patent changes the surface properties of the outer cover by treating it with a fluorocarbon-containing substance, which modifies the surface energy and creates stain-resistant properties while maintaining the fabric's usability and comfort characteristics
2Ease of manufacture
If the cushion and outer cover are not tightly fit with each other, then the manufacturing process is simpler, but wrinkles and the like can easily occur on the surface
Solution Approach 1:
The patent applies different properties to different parts of the system: the outer cover is treated with a fluorocarbon-containing substance at specific locations (particularly at the boundaries and surfaces that contact the cushion) to create local adhesion enhancement without requiring complete redesign of the entire assembly process
Solution Approach 2:
The fluorocarbon-containing substance acts as an intermediary between the outer cover and the cushion, creating a chemical bonding effect that ensures tight fitting and prevents wrinkles without complicating the manufacturing process
3Ease of manufacture
If adhesive is used to bond FBL to cushion material, then the bonding process is straightforward, but the bond strength and durability may be insufficient under frequent use
Solution Approach 1:
The patent replaces the mechanical/adhesive bonding system with a chemical bonding system using fluorocarbon-containing substances that create strong molecular-level adhesion between the FBL and the cushion material, as well as between the outer cover and the cushion, providing superior bond strength while maintaining ease of application
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 solution provides a durable, aesthetically pleasing sheet material with enhanced fire resistance and reduced wrinkles, meeting FAA and EASA standards while maintaining a smooth, cleanable surface.
Implementation Method 1
a step of heating and melting the surface of the fire-retardant urethane material facing the FBL roll
Implementation Method 2
a step of compressively bonding the surfaces of a melted surface of the fire-retardant urethane material and a surface of the FBL roll
Data Source
Figure 1~2
Figure 3~4B
Figure 4C
AI summary
A sheet material (30) is constituted by an FBL to which one surface (36a) of a fire-retardant urethane material (36) is melted and fused and an outer cover (34) to which the other surface (36b) of the fire-retardant urethane material (36) is melted and fused.