Foamless Tray Table Structure for Faster, Lighter Assembly
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Solution Overview
Problem
Conventional tray tables in passenger seats face manufacturing challenges due to the use of foam filler materials, including high scrap rates, extended manufacturing cycles, increased infrastructure and labor costs, high inspection failure rates, and health concerns, which result in increased costs and reduced efficiency.
Innovation Solution
A tray table assembly comprising an upper cover, a lower cover, and a support structure with upper and lower protrusions that provide structural rigidity and heat dissipation, replacing the need for foam filler materials, and a method of manufacturing involving forming and mounting these components to reduce weight and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foam filler material is used in tray tables, then structural support and cushioning are provided, but manufacturing scrap rates increase and manufacturing cycle time extends
Solution Approach 1:
The patent removes the foam filler material from the tray table assembly, extracting the problematic component that caused high scrap rates and extended manufacturing cycles. The support structure is redesigned to provide necessary structural support without relying on foam, thereby eliminating the manufacturing issues associated with foam processing while maintaining structural integrity.
Solution Approach 2:
The support structure is divided into multiple components including a frame structure, barrier layers, and discrete support elements. This segmentation allows for modular manufacturing where each component can be produced separately with optimized processes, avoiding the need for complex foam injection and curing cycles, thus reducing overall manufacturing time while maintaining structural support functionality.
2Strength
If foam filler material is used in tray tables, then cushioning and support are achieved, but manufacturing infrastructure costs and labor costs increase
Solution Approach 1:
The foam filler material is completely removed from the assembly, eliminating the need for specialized foam injection equipment, curing ovens, and associated infrastructure. The support function is achieved through the frame structure and barrier layers which can be manufactured using standard metal forming and assembly processes, significantly reducing infrastructure and labor costs.
Solution Approach 2:
The design employs simple, easily manufactured components such as metal frames and plastic barrier layers that can be produced using cost-effective, high-volume processes. These components replace expensive foam materials and the specialized infrastructure required to process them, achieving the same support function at lower cost.
3Quantity of substance
If foam filler material is used in tray tables, then filling and insulation are provided, but inspection failure rates due to delamination and warpage increase
Solution Approach 1:
The foam filler material is removed from the assembly, eliminating the source of delamination and warpage issues that plagued foam-based tray tables. The support structure relies on the rigid frame and layered barrier construction which are resistant to these defects, thereby dramatically reducing inspection failure rates and improving product reliability.
Solution Approach 2:
The tray table employs a composite construction of metal frame structures and plastic barrier layers that are inherently more stable and resistant to delamination and warpage compared to foam materials. This composite approach provides the necessary support and insulation functions without the reliability issues associated with foam filler.
4Strength
If foam filler material is used in tray tables, then insulation and support are achieved, but weight and material costs increase
Solution Approach 1:
The heavy foam filler material is removed from the tray table assembly, directly reducing the overall weight. The structural support function is maintained through the optimized metal frame structure and barrier layer configuration, achieving weight reduction while preserving the necessary support and insulation properties.
Solution Approach 2:
The support structure is segmented into a lightweight frame configuration with strategically placed support elements rather than solid foam filling. This segmentation provides the necessary structural support with minimal material usage, significantly reducing weight while maintaining strength and insulation 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 solution results in a lightweight, durable tray table with a raw material cost savings of over $2 per assembly and a 20% reduction in weight, improving manufacturing efficiency and reducing costs while eliminating foam-related issues.
Implementation Method 1
the support structure dissipates heat
Data Source
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.