Modular Seat Upholstery Assembly for Fast Maintenance Access
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Solution Overview
Problem
Existing upholstery modules for vehicle seats, particularly aircraft seats, are difficult to assemble and disassemble efficiently, which complicates maintenance and reduces the effectiveness of out-of-operation time due to complex accessibility to functional components and comfort layers.
Innovation Solution
A modular upholstery system with detachable comfort layers and a support shell that uses various fixing elements such as clips, mechanical fasteners, and snap-in elements, allowing for easy assembly and disassembly, and featuring a design that keeps the support shell hidden from the passenger for comfort and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the upholstery module uses a fixed integrated design, then the structural stability is improved, but the assembly and disassembly time increases significantly
Solution Approach 1:
The upholstery module is divided into separate functional components: support shell, comfort layers, and functional elements. These segments are designed to be detachably coupled through fixing elements, allowing rapid assembly and disassembly while maintaining structural integrity during use. The support shell itself is segmented into backrest and seat pan portions that can be independently mounted.
Solution Approach 2:
The upholstery module employs dynamic coupling mechanisms that transition between locked and unlocked states. Detachable fixing elements engage securely during normal operation to provide structural stability, but can be quickly released for maintenance. The modular design allows the system to adapt between stable operation mode and rapid disassembly mode.
2Reliability
If the upholstery module uses complex fastening mechanisms, then the reliability of connection is improved, but the ease of assembly and disassembly deteriorates
Solution Approach 1:
The detachable fixing elements are designed to be self-aligning and self-latching during assembly. The fixing elements automatically engage with corresponding receptacles on the support shell and seat support structure, providing reliable connection without requiring complex alignment procedures or specialized tools. The design allows maintenance personnel to perform assembly and disassembly independently.
3Strength
If the support shell is made thick and rigid for stability, then the structural strength is improved, but the passenger comfort deteriorates due to reduced flexibility
Solution Approach 1:
The support shell exhibits varying thickness and rigidity in different regions. Thinner, more flexible sections are positioned in areas that contact the passenger directly, while thicker, stronger sections are located in structural load-bearing areas. This local variation in properties allows the shell to provide both structural strength and passenger comfort simultaneously.
Solution Approach 2:
The support shell is constructed from composite materials that combine rigidity and flexibility. The shell may incorporate layers of different materials with complementary properties, creating a structure that is strong where needed and compliant where it contacts the passenger. This composite construction resolves the contradiction between structural strength and comfort.
4Ease of manufacture
If the upholstery module is designed as a single integrated unit, then the manufacturing simplicity is improved, but the ease of repair and maintenance deteriorates
Solution Approach 1:
The upholstery module is segmented into standardized components that can be manufactured independently and then assembled. The support shell, comfort layers, and functional elements are separate modules that can be produced through simplified manufacturing processes. This segmentation enables easy replacement of defective components during maintenance without requiring complete disassembly or complex repair procedures.
Data Source
Figure 1
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Figure 3A
AI summary
The invention relates to an upholstery module (UM) for a seat (1), in particular a vehicle seat, such as an aircraft seat, comprising at least an upholstery part (9) forming at least one of a backrest upholstery part (9") and a seat pan upholstery part (9'), the upholstery part (9) comprises a number of stacked comfort layers (9.4 to 9.7) and a number of functional elements (9.8, 9.9, 9.17), wherein the upholstery part (9) is detachably coupled to at least one support shell (11), and the support shell (11) is detachably mounted to a seat support structure (5) of the vehicle seat (1). Further, the invention relates to a seat (1).