Elastomeric Lattices for Aircraft Seat Cushions
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Solution Overview
Problem
Current aircraft seat foams require intricate stacking and adherence, leading to increased time, expense, and weight, with poor breathability and heat transfer, resulting in passenger discomfort.
Innovation Solution
Three-dimensionally printed elastomeric lattices with open-celled, breathable structures mimicking foam compression profiles, offering lighter weight, improved ventilation, and enhanced heat transfer, formed from interconnected cuboid structures like body-centered cubes, face-centered cubes, and kagome structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple foam layers are stacked and adhered together to achieve desired compression profiles, then the compression profile is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The patent combines multiple foam layers into a single monolithic foam structure with internally defined zones of varying density and compressibility. This eliminates the need to stack and adhere separate foam layers while maintaining the desired compression profile through controlled material distribution within the single structure.
Solution Approach 2:
The single monolithic foam is segmented into multiple zones with different material properties (density, compressibility, cell structure) to achieve the desired compression profile. This internal segmentation replaces the external segmentation of stacking multiple foam layers, simplifying manufacturing while maintaining functional complexity.
2Manufacturing precision
If multiple foam layers are stacked and adhered together to achieve desired compression profiles, then the compression profile is improved, but the weight increases
Solution Approach 1:
The patent combines multiple foam layers into a single monolithic foam structure, eliminating the weight of adhesives and the cumulative weight of multiple separate layers while maintaining the desired compression profile through controlled material distribution within the single structure.
Solution Approach 2:
The monolithic foam incorporates local variations in density and material properties at different zones to achieve the desired compression profile. This allows optimized material distribution that reduces overall weight compared to uniform multi-layer foam stacks while maintaining required performance characteristics.
3Manufacturing precision
If conventional foams are used in aircraft seat assemblies, then the compression profile is achieved, but the breathability and heat transfer capacity are poor
Solution Approach 1:
The patent utilizes foam structures with controlled porosity and cell architecture that enhance breathability and heat transfer capacity. The open-cell structure and interconnected void spaces allow improved air circulation and thermal exchange while maintaining the desired compression and support characteristics.
Solution Approach 2:
The patent employs composite foam structures combining different material phases, densities, and cell structures within the monolithic foam to simultaneously achieve compression profile requirements and improved breathability and heat transfer properties.
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 lattices provide easier handling and installation, improved passenger comfort by reducing weight and enhancing breathability and heat transfer, while maintaining similar compression profiles to conventional foams.
Implementation Method 1
a resiliently deformable elastomeric lattice having a compressibility profile including a modulus of elasticity ranging from 0.1 to 0.8 and a compressive yield strength ranging from 0.35 kilograms (0.75 lbs) to 1.8 kilograms (4.0 lbs) that mimics foam
Data Source
AI summary
Cushion components for use in an aircraft and methods of making thereof. The cushion components having a lattice that is open celled, breathable, and has a compressibility profile that mimics an indentation load deflection (ILD) and spring rate of foam. In certain aspects, the elastomeric lattice is formed of interconnected cuboid structures that include, for example, interconnected face-centered cube (FCC) structures, interconnected body-centered cube (BCC) structures, or interconnected kagome structures.