Modular monocoque backrest
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Solution Overview
Problem
Traditional aircraft passenger seat backrests are heavy and costly due to the use of metallic materials, which do not efficiently distribute stress loads and require additional reinforcement for crash and torsional loads.
Innovation Solution
A modular monocoque backrest structure made from carbon fiber composite materials, incorporating a honeycomb structure and foam core for stress distribution, and integrated design features such as a restraint system and lumbar support, eliminating the need for external metallic components and additional hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy metallic materials are used in the backrest structure, then structural strength and load-bearing capacity are improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent applies composite materials by combining carbon fiber reinforced plastic (CFRP) with aluminum spars and honeycomb structures. The CFRP monocoque shell provides high strength-to-weight ratio, while the aluminum spars and honeycomb core provide additional structural support and energy absorption during crashes, achieving both weight reduction and maintained structural strength
Solution Approach 2:
The patent changes the material parameters from traditional heavy metals to lightweight composites with optimized mechanical properties. The CFRP material provides equivalent or superior strength to aluminum while reducing weight, and the modular design allows parameter optimization for different crash load scenarios
2Reliability
If additional metallic reinforcement components are added to endure crash and torsional loads, then structural reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple structural functions into integrated components. The aluminum spars are embedded within the CFRP monocoque structure, combining the shell and reinforcement into a unified load-bearing system. The honeycomb structure serves multiple functions: structural support, energy absorption, and weight reduction, eliminating the need for separate reinforcement components
Solution Approach 2:
The composite construction of CFRP monocoque with aluminum spar reinforcement creates a multi-material structure that achieves superior crash resistance through material synergy rather than through adding multiple separate metallic reinforcement components, thereby reducing overall structural complexity
3Strength
If traditional metallic frame structures with multiple components are used, then load-bearing capacity is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent segments the backrest into modular components: the CFRP monocoque shell, aluminum spars, honeycomb core, and integrated restraint system. This segmentation allows each component to be manufactured and tested separately, then assembled into the final structure, reducing overall manufacturing complexity and cost while maintaining load-bearing capacity
Solution Approach 2:
The use of composite materials enables more efficient load distribution throughout the structure, allowing for optimized material placement and reduced overall material usage compared to traditional all-metallic constructions, thereby reducing manufacturing cost
Data Source
Figure 1A
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Figure 1C
AI summary
A modular monocoque backrest (100) is provided. The modular monocoque backrest (100) comprises a front shroud (110), a back shroud (120), and an at least one back spar (130). The front shroud (110) is coupled to the back shroud (120), and the back spar (130) is configured as a mounting point, enabling the modular monocoque backrest (100) to mount to an aircraft floor. The front shroud (110) and the back shroud (120) may comprise a carbon fiber composite material, allowing the modular monocoque backrest (100) to be modular in nature. The carbon fiber composite material may enable the modular monocoque backrest (100) to have a lightweight design while also maintaining resistance to dynamic crash loads.