Foamless Tray Table Assembly with Protrusion Support Structure
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Solution Overview
Problem
Conventional tray table manufacturing processes face issues such as high scrap rates, extended manufacturing cycle times, increased infrastructure and labor costs, high inspection failure rates, health concerns, and certification challenges due to the use of injected polyurethane foam as filler material.
Innovation Solution
A tray table assembly design that replaces the foam filler material with a single support structure comprising upper and lower protrusions and a heat exchanger, which provides structural rigidity and dissipates heat, and a manufacturing method involving forming covers and punching a support structure to create protrusions and holes for reduced weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If injected polyurethane foam filler material is used in conventional tray tables, then structural filling and support are provided, but manufacturing scrap rates increase significantly and manufacturing cycle time is extended
Solution Approach 1:
The patent removes the foam filler material entirely from the tray table assembly, extracting only the necessary structural support function and implementing it through a rigid support structure with protrusions that contact the barrier layers, eliminating the need for foam injection, curing, and inspection processes
Solution Approach 2:
The invention changes the physical state and material properties from soft foam filler to rigid support structure with specific geometric features (protrusions), transforming the approach from volumetric filling to surface contact support, which eliminates manufacturing cycle time extensions associated with foam curing
2Quantity of substance
If injected polyurethane foam filler material is used in conventional tray tables, then structural filling is provided, but manufacturing infrastructure costs and labor costs increase
Solution Approach 1:
The patent extracts and eliminates the foam filler material and associated manufacturing infrastructure (foam machines, ovens, cleaning stations, spray booth stations, mold racks, and molds), replacing them with a simpler rigid support structure that requires no specialized equipment or extensive labor
Solution Approach 2:
The invention replaces expensive foam manufacturing infrastructure with a cost-effective rigid support structure made from readily available materials, significantly reducing both capital equipment costs and operational labor requirements
3Quantity of substance
If injected polyurethane foam filler material is used in conventional tray tables, then volume filling is achieved, but inspection failure rates increase due to delamination and warpage
Solution Approach 1:
The patent removes the foam filler material that causes delamination and warpage issues, replacing it with a rigid support structure that provides stable, predictable contact points with the barrier layers, eliminating the inspection failures associated with foam curing and adhesion
Solution Approach 2:
The invention creates a simplified model of structural support that copies only the essential function (providing rigidity and support) without the problematic foam material, using geometric protrusions that replicate the support function while eliminating the defects
4Quantity of substance
If foam filler material is used in conventional tray tables, then structural support is provided, but weight is increased
Solution Approach 1:
The patent extracts and removes the heavy foam filler material, replacing it with a lightweight rigid support structure that provides equivalent or superior structural support with significantly reduced weight, achieving both weight reduction and cost savings
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 results in a lightweight, durable tray table with a 20% reduction in weight and over $2 cost savings per assembly, while eliminating manufacturing inefficiencies and health concerns associated with foam use.
Implementation Method 1
a heat exchanger 405
Data Source
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AI summary
Described are tray table assemblies that include an upper cover, a lower cover, and a support structure disposed between the upper cover and the lower cover. The support structure may include a plurality of upper protrusions extending toward an inner surface of the upper cover and a plurality of lower protrusions extending toward an inner surface of the lower cover such that the support structure provides structural rigidity to the tray table assembly. The plurality of upper protrusions may contact the inner surface of the upper cover, the plurality of lower protrusions may contact the inner surface of the lower cover, and the support structure may dissipate heat.