Compressible Multi-Density Foam Cushion for Extendable Aircraft Seats
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Solution Overview
Problem
Aircraft seat cushions that extend with the seat pan often require additional components like airbags or fire blocker layers, increasing complexity and discomfort, and fail to conform to the seat pan and occupant due to stiffness.
Innovation Solution
A compressible cushion with multiple foam layers of varying densities, cut in a specific pattern to prevent full collapse, allowing even compression and conformability without the need for additional layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fire blocker layer is added to meet flame requirements, then flame resistance is improved, but cushion stiffness increases reducing conformability
Solution Approach 1:
The patent changes the physical parameters of the foam material by introducing cuts that create compressible zones. These cuts allow the foam to deform and conform under pressure while the fire blocker layer maintains its flame resistance properties, resolving the contradiction between stiffness and conformability.
Solution Approach 2:
The introduction of cuts in the foam layers creates a porous structure that enhances compressibility and conformability. This porous design allows the cushion to adapt to seat pan contours and occupant body shapes while the fire blocker layer remains intact for flame resistance.
2Shape
If airbag or air bladder system is used to fill void between cushions, then gap filling is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the airbag or air bladder system from the cushion assembly. Instead of using a separate inflatable component to fill gaps, the design relies on the compressible foam structure itself to adapt and fill voids, significantly reducing system complexity.
Solution Approach 2:
The compressible foam layers with cuts are designed to automatically adjust and fill gaps through their inherent compression properties. This self-adjusting mechanism eliminates the need for external airbag systems, hooks, or control mechanisms, achieving gap filling through the material's own characteristics.
3Ease of operation
If multiple foam layers with varying densities are used, then conformability is improved, but manufacturing complexity increases
Solution Approach 1:
The cushion is segmented into multiple foam layers with different densities, where each layer serves a specific function. The lower density layers provide conformability and comfort, while higher density layers provide structural support. This segmentation allows for optimized performance while maintaining manageable manufacturing processes.
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 cushion that meets aviation flame requirements, conforms to the seat pan and occupant, and maintains consistent support regardless of seat position, enhancing comfort and appearance.
Implementation Method 1
The first foam layer and the at least a second foam layer are each configured to compress when the seat pan actuates between the extended position and a retracted position
Implementation Method 2
the plurality of cuts in the first foam layer and the plurality of cuts in the at least a second foam layer each have a width preventing the plurality of cuts in the first foam layer and the plurality of cuts in the at least a second foam layer from fully collapsing
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A compressible cushion may include a base structure (104) and a plurality of foam layers positioned on a seat pan of the aircraft seat. The plurality of foam layers may include a first foam layer stacked on the base structure (104), and at least a second foam layer stacked on the first foam layer. A density of the at least a second foam layer may be less than a density of the first foam layer. The first foam layer and the at least a second foam layer may be cut at a length corresponding to a length of the seat pan when in an extended position. The first foam layer and the at least a second foam layer each may include a plurality of cuts (200), which may be configured to compress when the seat pan actuates between the extended position and a retracted position.