Monolithic Aircraft Tray Table With 3D-Printed Flexural Hinges
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Solution Overview
Problem
Conventional aircraft tray tables are composed of multiple separate sub-assemblies, which increase complexity, weight, cost, and difficulty in installation and maintenance, while also compromising customer experience.
Innovation Solution
A single-structured tray table utilizing flexural hinges, manufactured through 3D printing, which integrates all components into a unitary structure, reducing parts and weight, and simplifying manufacturing and deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tray tables use multiple separate sub-assemblies, then structural strength and reliability are improved, but device complexity, weight, and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate sub-assemblies (tray table body, hinges, connectors, reinforcement elements) into a single monolithic component manufactured via 3D printing. This integration eliminates the need for separate parts while maintaining structural integrity through the flexural hinge design that provides necessary flexibility and strength within the unified structure.
Solution Approach 2:
The single monolithic tray table component performs multiple functions that previously required separate parts: structural support, hinge functionality, connector elements, and reinforcement are all integrated into one component. The flexural hinges provide both structural connection and rotational movement capability within the same piece.
2Ease of repair
If conventional tray tables use multiple separate sub-assemblies, then ease of repair is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines all tray table components into one manufacturable unit, reducing the number of parts that need to be inventoried, assembled, and maintained. While individual repairability of specific features is reduced, the overall maintenance complexity decreases due to fewer connection points and interfaces that can fail.
Solution Approach 2:
The patent changes the manufacturing parameter from traditional subtractive or assembly-based production to additive manufacturing (3D printing). This enables cost-effective production of complex monolithic structures with integrated features that would be expensive or impossible to manufacture using conventional methods.
3Device complexity
If flexural hinges are used instead of conventional hinges, then device complexity and weight are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces traditional mechanical hinge systems (with separate pins, leaves, and connectors) with flexural hinges that use elastic deformation of the monolithic structure to achieve rotational movement. This substitution eliminates complex mechanical assemblies in favor of a simplified elastic mechanism enabled by 3D printing precision.
Solution Approach 2:
The patent changes the manufacturing process to 3D printing, which provides the necessary precision for creating the complex flexural hinge geometries. The additive manufacturing process can accurately produce the curved, varying-thickness cross-sections of the flexural hinges that are difficult or impossible to achieve with conventional manufacturing methods.
4Productivity
If 3D printing is used to manufacture the tray table, then productivity and manufacturing efficiency are improved, but equipment investment and initial cost increase
Solution Approach 1:
The patent employs 3D printing to create a complete, pre-assembled monolithic tray table component in a single manufacturing operation. This preliminary formation of the entire structure with all features integrated eliminates subsequent assembly operations, reducing overall manufacturing time and increasing productivity despite the higher initial equipment investment.
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 tray table requires less resultant force for deployment and stowage, reduces weight and manufacturing costs, and enhances ease of installation and customer experience, while also enabling precise and efficient production through 3D printing.
Implementation Method 1
The flexural hinges are configured to provide motion (e.g., a pivot) between two adjacent portions/members by elastic deformation
Implementation Method 2
A method of 3D printing the tray table is also disclosed in accordance with claim 9. The method may be performed by stereolithography (SLA)
Data Source
Figure 1~2
Figure 3~4B
Figure 5~6B
AI summary
A tray table (200) for an aircraft and a method of manufacturing the same are disclosed. The tray table (200) comprises a base portion (210), a first tray table portion, and a second tray table portion. A first flexural hinge (240) pivots the first tray table portion relative to the base portion (210). A second flexural hinge (250) pivots the second tray table portion relative to the first tray table portion. The first flexural hinge (240) and the second flexural hinge (250) comprise flexural members (245a-c, 255a-c) which are pliable to enable the respective flexural hinge to pivot. The base portion (210), the first surface portion, the first flexural hinge (240), the second surface portion, and the second flexural hinge (250) are integrally formed to provide a unitary tray table (200) construction.