Modular monocoque backrest
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Solution Overview
Problem
Traditional aircraft passenger seats use heavy metallic materials in backrest structures, making them heavy and costly while failing to efficiently distribute stress loads without additional reinforcement.
Innovation Solution
A modular monocoque backrest design utilizing carbon fiber composite materials for the front and back shrouds, coupled with aluminum back spars and integrated restraint systems, which eliminates the need for external metallic components and allows for lightweight, durable, and stylish seating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy metallic materials are used in backrest structure, then strength and load bearing capacity are improved, but weight increases
Solution Approach 1:
The patent applies composite materials by integrating aluminum back spars with carbon fiber reinforced plastic (CFRP) shrouds to create a hybrid structure. The aluminum spars provide rigid load-bearing support while the CFRP shrouds provide structural enclosure with reduced weight compared to all-metallic construction, achieving optimal strength-to-weight ratio
Solution Approach 2:
The backrest structure is segmented into distinct functional components: aluminum back spars for load bearing, CFRP front and back shrouds for structural enclosure, and integrated restraint systems. This segmentation allows each component to be optimized for its specific function while collectively achieving reduced overall weight
2Strength
If heavy metallic materials and additional reinforcement components are used, then load bearing capacity is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into integrated components. The shrouds are molded to include built-in restraint exits and mounting surfaces for restraint systems, eliminating the need for separate external hardware. The back spars are positioned to simultaneously provide structural support and serve as mounting points for restraint anchors, reducing overall component count and assembly complexity
Solution Approach 2:
The back spars serve multiple functions: providing rigid load-bearing support for crash loads, serving as structural anchors for restraint systems, and acting as mounting surfaces for various backrest components. This multi-functionality reduces the need for separate dedicated components for each function
3Reliability
If traditional metallic frame with shear panels and cross bars is used, then crash load resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces traditional all-metallic construction with a composite structure combining aluminum back spars and CFRP shrouds. This composite approach reduces material costs compared to heavy metallic construction while maintaining crash load resistance through the synergistic properties of both materials
Solution Approach 2:
The shrouds are molded as single integrated pieces that incorporate restraint exits, mounting surfaces, and structural features directly into the molded geometry. This integration eliminates the need for separate manufacturing and assembly of multiple discrete components, reducing manufacturing complexity and cost
Data Source
AI summary
A modular monocoque backrest is provided. The modular monocoque backrest may comprise a front shroud, a back shroud, and an at least one back spar. The front shroud may be coupled to the back shroud, and the back spar may be configured as a mounting point, enabling the modular monocoque backrest to mount to an aircraft floor. The front shroud and the back shroud may comprise a carbon fiber composite material, allowing the modular monocoque backrest to be modular in nature. The carbon fiber composite material may enable the modular monocoque backrest to have a lightweight design while also maintaining resistance to dynamic crash loads.