Modular Aircraft Crew Rest Module Design
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Solution Overview
Problem
Crew rest modules for mobile platforms, such as commercial aircraft, face challenges due to limited space, heavy weight, and complex installation requirements, particularly when space is extremely limited and installation must occur before final assembly of the fuselage.
Innovation Solution
A modular crew rest module design that includes an entrance module and a bunk module, both with peripheral walls sized to fit through a passenger door, allowing for installation after the aircraft is substantially assembled, featuring elevated seating and berths with staggered steps, and using tab and slot joints with adhesive for reduced weight and bracketry, enabling efficient use of space and easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-assembled crew rest monuments are used, then crew rest functionality is provided, but weight increases and installation becomes difficult
Solution Approach 1:
The crew rest module is divided into multiple separable components including peripheral walls, floor panels, and support structures that can be assembled in situ rather than pre-assembled as a heavy monument. This segmentation reduces the weight that needs to be handled during installation while maintaining the complete crew rest functionality.
2Area of stationary object
If large pre-assembled crew rest monuments are installed, then crew rest space is provided, but installation clearance requirements increase
Solution Approach 1:
The crew rest is constructed from modular components that can be assembled in the final configuration space without requiring large clearance areas during installation. The peripheral walls and floor panels can be installed sequentially as the aircraft structure is assembled, eliminating the need for large installation clearances.
Solution Approach 2:
The crew rest components are designed to be installed in conjunction with the final assembly of the aircraft fuselage rather than requiring pre-installation. This preliminary coordination with the assembly schedule allows the crew rest to be fitted into the final configuration space without requiring excessive clearance during installation.
3Weight of stationary object
If traditional crew rest systems are used, then crew rest functionality is provided, but weight reduction is limited
Solution Approach 1:
The crew rest employs thin-walled peripheral walls and floor panels that provide the necessary structural enclosure with minimal material usage. These thin-walled constructions reduce the overall weight while maintaining the structural integrity required for the crew rest module.
Solution Approach 2:
By segmenting the crew rest into separate peripheral walls, floor panels, and support elements, the design can optimize each component for minimal weight while maintaining structural requirements. This segmentation allows for more efficient material usage compared to monolithic pre-assembled structures.
Data Source
AI summary
The present disclosure relates to an aircraft having a fuselage. The fuselage may have a plurality of frame members, a cabin formed within the fuselage, a floor defining a portion of the cabin, a center section of seats disposed on the floor, a crown positioned above a center section of seats, and a crew rest module. The crew rest module may have an entrance module defined by at least two entrance module peripheral walls and having a seating area, and a bunk module being separate from the seating area and being defined by at least three bunk module peripheral walls. The entrance module peripheral walls and the bunk module peripheral walls may be sized to fit through a passenger door of a substantially assembled aircraft.