Hybrid Composite Aircraft Seat Base for Strength and Energy Absorption
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Solution Overview
Problem
Aircraft seat base assemblies face challenges in meeting load requirements such as abuse, reliability, and dynamic loads while balancing the need for ductility, strength, cost, and weight, as current materials like continuous fibers and thermoplastic injection molded materials either fail to absorb enough energy or are insufficient in strength.
Innovation Solution
A hybrid composite structure is used for the base assembly, combining a thermoplastic material for ductility and a composite material like continuous carbon fibers for strength, with the composite material being over-molded onto the thermoplastic to form belts, providing a thermoplastic over-molded composite structure that integrates with the seat's legs and link beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber composite material is used, then strength is improved, but ductility and energy absorption deteriorate
Solution Approach 1:
The patent applies composite materials by combining thermoplastic material and composite material in a hybrid structure. The thermoplastic material provides ductility and energy absorption, while the composite material provides strength. This composite approach resolves the contradiction by integrating materials with complementary properties rather than relying on a single material type.
Solution Approach 2:
The patent applies local quality by using different materials in different regions of the leg sub-assembly. The thermoplastic material is used in portions requiring ductility and energy absorption, while the composite material is used in portions requiring strength. This localized material distribution optimizes performance for each specific functional requirement.
2Reliability
If thermoplastic injection molded material is used, then ductility is improved, but strength deteriorates
Solution Approach 1:
The patent uses composite materials to combine the advantages of thermoplastic material (ductility, energy absorption) with the advantages of composite material (strength). The hybrid composite structure allows both material types to coexist and contribute their respective strengths to the overall performance.
Solution Approach 2:
The patent implements local quality by strategically placing thermoplastic material in regions where ductility and energy absorption are critical, and composite material in regions where strength is paramount. This spatial differentiation of material properties resolves the strength-ductility contradiction.
3Strength
If hybrid composite structure is used, then strength and energy absorption are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by first forming the thermoplastic material component, then subsequently adding the composite material component in a staged manufacturing process. This sequential approach, rather than attempting to create the hybrid structure in a single step, reduces manufacturing complexity while achieving the desired hybrid composite structure.
4Reliability
If hybrid composite structure is used, then load requirements are met, but weight increases
Solution Approach 1:
The patent applies local quality by using composite material only in the specific portions where strength to meet load requirements is critical, rather than using it throughout the entire leg sub-assembly. The thermoplastic material is used in portions where full strength is less critical, reducing overall weight while still meeting load requirements.
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
This solution effectively meets aviation standards for load requirements, enhances energy absorption, reduces the weight and cost of the seat, and provides a durable structure that can withstand dynamic loads while maintaining ductility.
Implementation Method 1
the first material including a thermoplastic material configured to provide ductility for the base assembly
Implementation Method 2
the second material including a composite material configured to provide strength for the base assembly
Implementation Method 3
the second material is over-molded by one or more portions of the first material to form one or more belts of the second material on the first material
Data Source
AI summary
A base assembly for an aircraft seat is disclosed. The base assembly may include one or more leg sub-assemblies. Each leg sub-assembly may include a front leg, a rear leg, and a link beam configured to couple the front leg to a portion of the rear leg. At least one of the front leg or the rear leg being at least partially formed of a hybrid composite structure. The link beam being at least partially formed of the hybrid composite structure. The hybrid composite structure formed of at least a first material and a second material, where the first material is different from the second material, the first material including a thermoplastic material configured to provide ductility for the base assembly, the second material being a composite material configured to provide strength for the base assembly.