Composite Aircraft Seat Back Structure with Torque Box
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Solution Overview
Problem
Conventional aircraft passenger seats are heavy, consuming valuable space and weight, which limits flight range, passenger capacity, and profitability due to the use of bulky metal components and thick padding necessary for structural support and comfort.
Innovation Solution
A lightweight composite construction for aircraft passenger seats, including 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 weight-reduced design that meets structural requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional heavy and bulky materials are used for structural support, then structural integrity is maintained, but weight increases significantly
Solution Approach 1:
The patent applies composite materials throughout the seat structure, including composite support legs, composite seat pan, and composite seat back. These composite structures provide the necessary structural integrity while significantly reducing weight compared to conventional metal materials. The composite torque box in the seat back structure specifically addresses strength requirements while maintaining weight reduction goals.
2Strength
If bulky materials and thick padding are used for structural support and cushioning, then structural requirements and passenger comfort are satisfied, but cabin space is consumed
Solution Approach 1:
The composite support structures enable a more compact design compared to conventional bulky metal frameworks. The composite torque box and composite support legs provide structural support in a more space-efficient manner, reducing the overall volume of the seat assembly while maintaining structural integrity.
3Productivity
If more seat rows are added to increase passenger capacity, then profitability increases, but available cabin space decreases
Solution Approach 1:
The seat is divided into distinct composite components (support legs, seat pan, seat back, torque box) that can be optimized independently. This segmentation allows for compact design of each component, reducing the overall space required per seat and enabling increased passenger capacity within the same cabin volume.
4Strength
If conventional metal components are used, then structural specifications are met, but weight reduction goals are hindered
Solution Approach 1:
The patent comprehensively applies composite materials to replace conventional metal components throughout the seat structure. The composite support legs, composite seat pan, composite seat back, and composite torque box collectively achieve significant weight reduction while meeting all structural specifications through the inherent strength-to-weight ratio of composite materials.
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.