Composite Tray Table Structure for Lightweight Aircraft Interiors
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Solution Overview
Problem
Commercial aircraft tray tables require weight reduction for fuel savings while maintaining strength and durability, and existing manufacturing methods are costly and time-consuming for replacement.
Innovation Solution
A thermoplastic tray assembly with an integral formed carbon or glass reinforced composite element integrated into an injection molded thermoplastic frame structure, featuring snap-fit linear bearing support components for easy removal and replacement, and a corrugated composite structure for enhanced strength and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional manufacturing methods are used for tray tables, then strength and durability requirements are met, but weight is excessive and manufacturing cost is high
Solution Approach 1:
The patent employs composite materials consisting of thermoplastic matrix combined with reinforcing fibers (such as carbon fiber or glass fiber) to create a structure that achieves high strength-to-weight ratio. The composite material provides both the necessary structural strength and significant weight reduction compared to traditional solid thermoplastic or metal constructions.
Solution Approach 2:
The patent implements varying fiber orientation and density in different regions of the tray table based on local stress requirements. Areas experiencing higher loads have enhanced fiber reinforcement, while lower-stress areas use reduced material density, optimizing both strength and weight characteristics across the entire structure.
2Ease of manufacture
If traditional manufacturing methods are used for tray tables, then structural integrity is maintained, but manufacturing cost and replacement time are excessive
Solution Approach 1:
The tray table is designed as a modular composite structure where the reinforcement fibers are separately embedded into the thermoplastic matrix through a staged manufacturing process. This segmentation allows for optimized production workflows and facilitates partial replacement or repair of specific components without replacing the entire assembly.
Solution Approach 2:
The patent utilizes thermoplastic material properties that allow for heating and reshaping during manufacturing and potential repair processes. By controlling temperature and pressure parameters, the material can be molded into precise shapes and then set, enabling cost-effective manufacturing and potential field repairs while maintaining structural integrity.
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 lightweight, durable, and cost-effective tray table assembly that meets regulatory standards, reduces manufacturing costs, and simplifies replacement processes, thereby saving time and labor.
Implementation Method 1
an integral formed carbon or glass reinforced composite element integrated into an injection molded thermoplastic frame structure
Data Source
AI summary
Disclosed embodiments relate to trays typically comprising a composite internal structure, a thermoplastic frame typically located about the composite internal structure, and two cover sheets forming the upper and lower tray surfaces. The composite internal structure may be a corrugated composite structure in some embodiments. In other embodiments, the composite internal structure may comprise a series of composite elements (which might act a beams or struts). The cover sheets may comprise thermoplastic material, and in some embodiments, the cover sheets may comprise composite material (for example the same as for the corrugated composite structure). In some exemplary embodiments, the thermoplastic frame and the composite internal structure may have the same thermoplastic material, and they may be joined together to have a plurality of homogeneous connective attachments.