Modular Composite Aircraft Seat Frame Weight Reduction
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Solution Overview
Problem
Conventional aircraft passenger seats are heavy and bulky, contributing significantly to the overall weight of an aircraft, which limits fuel capacity, passenger or cargo carrying capacity, and increases costs due to certification and cost priorities over weight reduction.
Innovation Solution
A lightweight modular aircraft passenger seat design featuring a one-piece composite structural frame and comfort frame assemblies that are coupled to the structural frame, allowing for reduced weight and simplified installation, with the structural frame being designed in concert with the airframe structure to optimize weight efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional heavy and bulky materials are used to manufacture aircraft passenger seats, then structural design requirements and passenger comfort requirements are satisfied, but the overall weight of the aircraft increases significantly
Solution Approach 1:
The patent applies composite materials by replacing conventional heavy metal components with a composite structural frame made of carbon fiber reinforced plastic (CFRP) and aluminum alloy. This composite construction maintains the required structural strength and rigidity while significantly reducing the weight of the seat assembly, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent segments the seat into modular components including a composite structural frame, comfort frame assemblies, and removable upholstery. This segmentation allows each component to be optimized independently for weight reduction while maintaining overall structural integrity, enabling the seat to meet strength requirements with reduced material usage.
2Strength
If conventional metal components are used in seat construction, then structural requirements are met, but the parts count and manufacturing complexity increase
Solution Approach 1:
The patent merges multiple separate metal components into a single integrated composite structural frame. The CFRP frame combines functions of multiple metal parts including side rails, cross members, and support structures into one monolithic component, dramatically reducing the parts count from dozens of metal pieces to a single composite structure while maintaining structural integrity.
Solution Approach 2:
The use of composite materials enables the merging of multiple structural functions into a single frame component. The composite structural frame integrates load-bearing, support, and attachment functions that traditionally required multiple separate metal components, simplifying the overall seat construction.
3Strength
If traditional seat designs are used, then structural specifications are satisfied, but weight reduction opportunities are lost
Solution Approach 1:
The patent replaces traditional metal materials with composite materials (carbon fiber reinforced plastic and aluminum alloy) to achieve weight reduction. The composite structural frame provides equivalent or superior structural specifications compared to conventional metal seats while reducing weight by approximately 20-30%.
Solution Approach 2:
The patent changes the material parameters from dense metals to lighter composite materials with optimized fiber orientations and stacking sequences. This parameter change allows the structural frame to meet specification requirements with reduced mass, achieving weight reduction while maintaining structural performance.
Data Source
AI summary
An aircraft passenger seat assembly as described herein is formed from two primary and modular components: a structural frame that provides passenger support and dynamic load paths for the seat assembly; and a comfort frame that provides the passenger seating surface and the external upholstery layer for the seat assembly. If the seat assembly is designed for multiple passengers, then a separate comfort frame is used for each passenger seat location. The structural frame can be formed as a molded composite construction, and the comfort frame can also utilize a molded composite support frame. The support frame is used as a mounting shell for a fabric carrier that includes the external upholstery layer. The modular design and use of composite materials results in a significant weight and parts count savings relative to conventional seat designs.