Integral Composite Seat Back Structure for Precise Diaphragm Fit
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Solution Overview
Problem
Current aircraft seat back manufacturing techniques involve separate production of the seat back frame and diaphragm, making it difficult to apply the diaphragm under tension and leading to potential misfits or inadequate support, while also resulting in multiple parts and increased weight.
Innovation Solution
Integrally molding the seat back diaphragm into the seat back frame using composite materials like carbon fiber during the manufacturing process, eliminating the need for a separate assembly step and allowing for varied diaphragm positions and designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diaphragm is applied separately by pulling it over the seat back frame under tension, then the seat back can provide comfortable support, but it is difficult to apply precisely and may tear or mismatch
Solution Approach 1:
The patent merges the diaphragm and seat back frame into a single integrally molded composite structure. The diaphragm is molded directly onto the frame during the same manufacturing process, eliminating the separate application step and ensuring perfect fit without tensioning difficulties or mismatch risks.
Solution Approach 2:
The diaphragm is pre-positioned and molded onto the frame during the initial manufacturing process rather than being applied later. This preliminary integration ensures correct positioning and tension distribution before final assembly, preventing installation errors.
2Ease of operation
If the diaphragm is sized to be under tension for comfort, then passenger support is improved, but the diaphragm must be precisely the right size or it will tear or be too loose
Solution Approach 1:
By combining the diaphragm and frame into one molded structure, the patent eliminates the need for separate diaphragm sizing. The tension distribution is built into the integrated design, ensuring both comfort and structural integrity without requiring precise separate component sizing.
Solution Approach 2:
The patent changes the design approach from adjusting diaphragm size parameters to integrating the diaphragm as part of the frame structure. This allows tension and support characteristics to be optimized through the molded geometry rather than through separate component dimensions.
3Adaptability or versatility
If separate manufacturing of frame and diaphragm is used, then manufacturing flexibility is maintained, but weight increases and part mismatches occur
Solution Approach 1:
The patent combines the frame and diaphragm into a single composite component, reducing the total number of parts and eliminating weight from additional fasteners, adhesives, and overlapping materials. The integrated structure achieves both weight reduction and manufacturing efficiency.
Solution Approach 2:
The patent uses composite materials to create the integrated seat back structure, combining different material properties in a single molded component. This allows the structure to achieve both lightweight characteristics and the necessary mechanical properties for support and comfort.
4Ease of manufacture
If multiple separate parts are used for seat back assembly, then manufacturing flexibility is maintained, but assembly complexity and potential mismatches increase
Solution Approach 1:
The patent merges multiple separate parts (frame, diaphragm, and connecting elements) into a single integrally molded composite structure. This eliminates assembly steps, reduces the risk of mismatches, and simplifies quality control while maintaining design flexibility through the molding process.
Data Source
AI summary
An aircraft seat back including a composite material seat back frame element and a composite seat back diaphragm molded to the seat back frame element during a molding step to provide a composite aircraft seat back formed of a seat back frame element and a seat back diaphragm.