Injection Molded Composite Blank and Guide for Lightweight Seat Frames
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Solution Overview
Problem
Current methods for manufacturing lightweight yet high-strength plastic parts, such as aircraft seat frames, are inefficient due to the use of thermoset composites which are time-consuming and costly, often resulting in increased weight and overdesigned strength where it is not needed.
Innovation Solution
A structural blank with oriented fiber plies in a thermoplastic matrix, combined with a guide of randomly dispersed fibers in a thermoplastic matrix, is used, where the guide is affixed to the structural blank through injection molding or overmolding, eliminating the need for adhesive layers and allowing for efficient production of lightweight, high-strength components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset composites reinforced with fibers are used to manufacture seat frames, then high strength is achieved, but production time increases and weight increases
Solution Approach 1:
The patent changes the material state from thermoset to thermoplastic, enabling injection molding processing. This parameter change allows the structural blank to be manufactured quickly through injection molding while maintaining high strength through oriented fiber plies, resolving the contradiction between strength and production time
Solution Approach 2:
The patent uses composite materials consisting of oriented fiber plies embedded in a thermoplastic matrix. The oriented fibers provide high strength in specific directions where stress occurs, while the thermoplastic matrix binds the fibers and allows for efficient injection molding processing, achieving both strength and fast production
2Strength
If thermoset composites reinforced with fibers are used to manufacture seat frames, then high strength is achieved, but weight increases
Solution Approach 1:
The patent changes from thermoset to thermoplastic materials, which generally have lower density and can be processed more efficiently. The oriented fiber reinforcement provides high strength-to-weight ratio, achieving the required strength with reduced weight compared to traditional thermoset composites
Solution Approach 2:
The patent applies oriented fiber plies only in areas where high strength is needed, rather than uniformly reinforcing the entire structure. This local reinforcement strategy reduces overall material usage and weight while maintaining strength in critical areas prone to failure under stress
3Strength
If oriented fiber plies are used in structural blank, then high strength is achieved in stress-prone areas, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates oriented fiber plies into the structural blank during the injection molding process itself, rather than requiring separate assembly steps. The fibers are placed in the mold in the desired orientation before the thermoplastic material is injected, achieving high strength in stress-prone areas while keeping the manufacturing process integrated and relatively simple
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 approach enables the production of lightweight, high-strength articles with reduced production time and cost, suitable for applications like aircraft interiors by distributing stress effectively and maintaining structural integrity under load.
Implementation Method 1
a structural blank... comprised of a plurality of oriented fiber plies in a structural blank thermoplastic matrix
Implementation Method 2
the guide is affixed to at least a portion of the structural blank top side with the guide thermoplastic matrix surrounding the structural blank guide hole
Data Source
AI summary
This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.