Integrally Molded Composite Aircraft Seat Back Diaphragm

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Solution Overview

Problem

Current aircraft seat back manufacturing techniques require a separate and precise application of a tensioned fabric diaphragm over a seat back frame, which is challenging to execute and can result in misfits or inadequate support, and involve multiple parts with potential mismatches.

Innovation Solution

Integrally molding a composite seat back diaphragm into the seat back frame during the manufacturing process, using composite materials like carbon fiber, to form a unitary structure that eliminates the need for separate assembly and allows for varied diaphragm positions and contours.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a fabric diaphragm is pulled over the seat back frame under tension, then the seat back provides comfortable support, but the manufacturing process becomes complex and prone to misfit

Engineering Contradiction:

Improveease of manufacturingVSAvoiddiaphragm fit precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent combines the diaphragm and seat back frame into a single integrated component manufactured via additive manufacturing. This eliminates the separate assembly step of pulling a fabric diaphragm over the frame, removing the complexity of tensioning and fitting while ensuring precise integration of the diaphragm with the frame structure.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If the diaphragm is sized to be under tension after installation, then the seat back provides proper support, but the diaphragm application becomes difficult and requires precise sizing

Engineering Contradiction:

Improveseat back support qualityVSAvoiddiaphragm installation difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent performs the diaphragm tensioning and positioning actions during the additive manufacturing process itself, before final assembly. The diaphragm is formed with the correct tension and positioning integrated into the frame structure during manufacturing, eliminating the difficult post-manufacturing adjustment and sizing operations.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If multiple separate parts are used for seat back frame and diaphragm, then manufacturing flexibility is maintained, but part mismatches can occur and assembly complexity increases

Engineering Contradiction:

Improvedesign flexibilityVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the diaphragm and seat back frame into a single integrated component manufactured via additive manufacturing. This reduces the number of parts from two separate components to one unified structure, eliminating part mismatches while maintaining design flexibility through the capabilities of additive manufacturing technology.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2825459B1Integral molded seat back for composite seat frame and method

Publication Date: 2016.10.26 BE AEROSPACE INC

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AI summary

An aircraft seat back including a composite material seat back frame (12) element and a composite seat back diaphragm (14) 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.