Monolithic Aircraft Floor with Integral Cross Strut and Flush Seat Rails
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional aircraft cabin floors consist of multiple components, leading to increased installation time, weight, and potential corrosion issues at seat rails, requiring replacement of entire floor panels or elements upon damage.
Innovation Solution
A monolithic floor assembly with an integral cross strut and support structures, made from materials like metal or composite plastic, which can be easily produced through punching or molding, and includes features like dome-shaped support structures for enhanced strength and flexibility, allowing seat rails to be mounted on a flush surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional cabin floor is made from multiple components (longitudinal beams and floor panels), then the structural strength is improved, but the installation time and overall weight increase
Solution Approach 1:
The patent combines multiple floor components (longitudinal beams and floor panels) into a single monolithic floor element formed from one piece of sheet material. This merging eliminates the need for separate assembly of multiple components, thereby reducing installation time while maintaining structural integrity through the integrated design
2Ease of manufacture
If the cabin floor is made from multiple components, then the manufacturing flexibility is improved, but the overall weight and complexity increase
Solution Approach 1:
The patent merges multiple floor components into a single monolithic element made from sheet material that can be punched or formed into the final shape. This approach reduces the total weight by eliminating redundant materials and connections, while maintaining manufacturing flexibility through standard sheet metal forming processes
Solution Approach 2:
The monolithic floor element is designed with integrated longitudinal beams and floor panels as distinct functional zones within a single piece. This segmentation of functions within a unified structure allows for optimized material distribution, reducing overall weight while maintaining the structural benefits of multiple components
3Manufacturing precision
If seat rails are mounted in dedicated recesses of the floor panel, then the mounting precision is improved, but the corrosion resistance deteriorates and repair complexity increases
Solution Approach 1:
The patent extracts the seat rail mounting function from dedicated recesses in the floor panel and relocates it to the upper surface of the monolithic floor element. This extraction eliminates the recess structure that trapped moisture and caused corrosion, while maintaining precise mounting capability through surface-level attachment points
Solution Approach 2:
Instead of mounting seat rails in recesses below the floor surface, the patent inverts the approach by providing mounting surfaces on the upper surface of the floor element. This inversion improves corrosion resistance by eliminating hidden recesses while maintaining mounting precision through designed attachment features
4Loss of time
If a monolithic floor element is used, then the installation time is reduced, but the handling difficulty increases due to bulkiness
Solution Approach 1:
The patent uses thin sheet material to form the monolithic floor element, which can be flexed and bent into the required shape during installation. This thin-film approach reduces the bulkiness and weight of the monolithic element, making it easier to handle and install while maintaining the structural benefits of a single-piece construction
Data Source
AI summary
A floor assembly for an aircraft which includes a monolithic floor element including an integral cross strut. The monolithic floor element has an upper surface, which includes a seat rail surface portion configured to mount a seat rail thereon. The floor assembly further includes at least one support structure arranged underneath the monolithic floor element and configured to support the monolithic floor element at least in an area of the seat rail surface portion.