Monocoque Seat Back Shroud Using Composite Structure for 16G and FST

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Solution Overview

Problem

Current passenger seat designs face challenges in achieving lightweight, simpler, and more compact structures while meeting 16G and FST regulations, and providing complex geometries and aesthetics, as traditional materials like metals are non-flammable but heavy, and plastics lack structural integrity and moldability.

Innovation Solution

A monocoque seat back design featuring a structural shroud with a mesh suspension system and cellular cushion, formed using composite materials like polyfuryl phenolic resin, which satisfies 16G and FST criteria, allows for complex geometries and improved ergonomics, and integrates features like stowage pockets and monitor surrounds without additional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional metal structural components are used, then structural integrity and flame resistance are achieved, but weight increases and complex geometries become difficult to manufacture

Engineering Contradiction:

Improvestructural integrityVSAvoidseat weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by integrating the structural component and shroud into a single molded piece made from flame-retardant composite materials. This composite structure provides both the structural integrity and flame resistance traditionally associated with metal, while simultaneously reducing weight and enabling complex geometries that would be difficult or impossible to achieve with traditional metal construction.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If traditional metal structural components are used, then flame resistance is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveflame resistanceVSAvoidmanufacturing simplicity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent merges the structural component and shroud into a single integrated piece, eliminating the need for separate manufacturing and assembly processes. This single-mold construction approach simplifies manufacturing while incorporating flame-retardant materials that meet regulatory requirements, thereby achieving both flame resistance and manufacturing simplicity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The use of flame-retardant composite materials allows the integrated structure to achieve flame resistance without requiring traditional metal components, thereby simplifying the manufacturing process and reducing production complexity while still meeting fire safety regulations.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If plastic shroud material is used, then lightweight construction and complex geometries are achieved, but structural integrity decreases

Engineering Contradiction:

Improveseat weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses flame-retardant composite materials that provide both the lightweight properties and moldability of plastic shroud materials while simultaneously achieving the structural integrity traditionally associated with metal components. The composite structure is engineered to meet 16G certification standards, proving that lightweight materials can provide sufficient structural strength when properly designed and formulated.

Inventive Principle:

Principle #40Composite materials

4Strength

If separate structural component and shroud are used, then structural integrity is maintained, but device complexity and assembly requirements increase

Engineering Contradiction:

Improvestructural integrityVSAvoidcomponent quantity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines the structural component and shroud into a single integrated molded piece, eliminating multiple components and their associated fasteners and assembly steps. This unified structure maintains structural integrity through its engineered composite construction while significantly reducing device complexity by removing the need for separate parts and assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated structure serves multiple functions simultaneously - it provides structural support, aesthetic appearance, and flame resistance all in one component. This multi-functionality reduces the overall number of parts needed in the seat assembly, thereby reducing device complexity while maintaining all necessary performance characteristics.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20230331128A1Structural seat back shroud

Publication Date: 2023.10.19 ZODIAC SEATS US LLC

AI summary

Described are monocoque seat backs having a structural shroud with a rear panel, a top lip and two side lips positioned along edges of the rear panel to form an interior volume. A mesh suspension system is coupled to the structural shroud and suspended over an opening of the interior volume. In certain embodiments, the structural shroud may be formed of one or more of a composite, a theroplastic resin, a thermoset resin, or a polyfuryl phenolic resin. The structural shroud is constructed to satisfy 16G criteria and FST criteria.