Integrally formed tray table with flexural hinges
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Solution Overview
Problem
Conventional aircraft tray tables have multiple separate sub-assemblies, leading to increased components, weight, cost, and complexity, which complicates installation, removal, rework, and customer experience.
Innovation Solution
A tray table with flexural hinges formed as a single unitary structure using 3D printing, allowing for easier assembly and deployment, reducing parts and weight, and utilizing flexural members for pivoting surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional tray tables use multiple separate sub-assemblies, then structural stability is improved, but device complexity and weight increase
Solution Approach 1:
The patent merges multiple separate sub-assemblies (base portion, surface portions, hinges) into a single unitary structure formed by additive manufacturing. This integration eliminates the need for separate components while maintaining structural stability through the monolithic design, directly resolving the contradiction between stability and complexity.
Solution Approach 2:
The unitary structure serves multiple functions simultaneously: it provides structural support, acts as hinges through flexural members, and forms the tray surface. This multi-functionality consolidates what would traditionally require multiple separate components, reducing device complexity while maintaining stability.
2Stability of the object's composition
If conventional tray tables use multiple separate sub-assemblies, then structural stability is improved, but weight increases
Solution Approach 1:
By combining multiple sub-assemblies into one unitary structure, the patent eliminates redundant materials and connection components that would add weight. The single-piece construction reduces overall weight while maintaining structural integrity through the integrated design.
3Stability of the object's composition
If conventional tray tables use multiple separate sub-assemblies, then structural stability is improved, but manufacturing cost increases
Solution Approach 1:
The unitary structure manufactured via additive manufacturing consolidates multiple assembly steps into a single printing process. This eliminates the need for separate manufacturing, assembly, and quality inspection of multiple components, significantly reducing manufacturing cost while maintaining structural stability.
Solution Approach 2:
The patent changes the manufacturing parameter from traditional multi-step assembly processes to additive manufacturing. This parameter change enables the production of complex unitary structures that would be difficult or expensive to manufacture using conventional methods, reducing overall manufacturing cost.
4Stability of the object's composition
If conventional tray tables use multiple separate sub-assemblies, then structural stability is improved, but ease of installation and removal deteriorates
Solution Approach 1:
By integrating all components into a single unitary structure, the patent simplifies installation and removal to a single operation. The unitary tray table with integrated hinges can be installed or removed as one piece, eliminating the need to assemble or disassemble multiple sub-assemblies, thus improving ease of operation while maintaining stability.
5Ease of operation
If flexural hinges are used instead of conventional hinges, then ease of operation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical hinges with flexural hinges that utilize elastic deformation of the unitary structure. This substitution eliminates the need for separate hinge components and mechanical joints, simplifying the overall structure while maintaining ease of deployment and stowage through the flexibility of the printed material.
Solution Approach 2:
The patent changes the structural parameter from rigid mechanical connections to flexible elastic deformations. The flexural hinges rely on the elastic properties of the additive-manufactured material, allowing smooth deployment and stowage motions without complex mechanical mechanisms, thus improving ease of operation while reducing structural complexity.
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 single-structured tray table requires less force for deployment and stowage, reduces weight, and lowers manufacturing costs while maintaining stability and ease of use.
Implementation Method 1
The first flexural hinge comprises first flexural members. The first flexural members are pliable to enable the first flexural hinge to pivot.
Implementation Method 2
A method of 3D printing the tray table is also disclosed. The method may be performed by stereolithography (SLA).
Data Source
AI summary
A tray table for an aircraft and a method of manufacturing the same are disclosed. The tray table comprises a base portion, a first tray table portion, and a second tray table portion. A first flexural hinge pivots the first tray table portion relative to the base portion. A second flexural hinge pivots the second tray table portion relative to the first tray table portion. The first flexural hinge and the second flexural hinge comprise flexural members which are pliable to enable the respective flexural hinge to pivot. The base portion, the first surface portion, the first flexural hinge, the second surface portion, and the second flexural hinge are integrally formed to provide a unitary tray table construction.