Flat-Woven Aircraft Carpet for Flame Resistance and Low Weight
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Aircraft interior carpets face challenges in meeting high flame resistance and smoke/toxic gas development standards while minimizing weight to reduce fuel consumption and maintenance costs, and require easy and quick installation and replacement.
Innovation Solution
A machine-woven flat carpet with a low basis weight, comprising a flame-retardant thermoplastic synthetic fiber material for both the base and active yarns, combined with a fleece and an adhesive-containing intermediate layer, which is easily attachable using Velcro strips, achieving mechanical strength, flame resistance, and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pile carpets made from wool or synthetic fibers are used, then flame resistance and mechanical durability are improved, but weight per unit area increases significantly
Solution Approach 1:
The patent changes the fundamental structure parameter from pile carpet to flat-woven carpet, and modifies material parameters by using flame-retardant treated yarns (both natural and synthetic fibers) to achieve the required flame resistance at reduced weight. The flame retardant treatment allows the use of lighter materials while meeting safety standards.
Solution Approach 2:
The invention uses composite construction combining different fiber materials (natural fibers like wool/cotton with synthetic fibers like polyester/nylon) in the warp and weft directions, creating a flat-woven structure that achieves both flame resistance and low weight. The combination of different materials with complementary properties resolves the contradiction between safety and weight.
2Strength
If heavy-duty materials are used to ensure mechanical strength and durability, then carpet longevity is improved, but installation and replacement complexity increases
Solution Approach 1:
The carpet is designed as a flat-woven structure without pile, creating a thinner, more flexible segment that can be easily handled, installed, and replaced. The segmentation of the carpet into manageable sections with standardized dimensions facilitates quick installation and replacement while maintaining mechanical strength through the flat-woven construction.
3Object-affected harmful factors
If flame-retardant treatments are applied to achieve safety standards, then fire safety is improved, but carpet weight and complexity increase
Solution Approach 1:
The patent applies flame-retardant treatments to modify the chemical parameters of the yarn materials, enabling both natural and synthetic fibers to meet flame resistance standards. This parameter change allows the use of simpler construction methods and lighter materials while achieving the required fire safety performance.
Data Source
AI summary
The carpet comprises a machine-woven material which forms a working surface. A non-woven material preferably a needled non-woven material, is made from a fire-resistant thermoplastic synthetic fiber material and an intermediate layer contains adhesive between the non-woven material and the flat material. An independent claim is also included for a method for laying fire resistant carpets.