Polymeric Tray Table Arm with U-Shaped Cross-Section
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Solution Overview
Problem
Current tray table support arms in vehicles are heavy due to metallic materials, leading to increased manufacturing costs and time, and do not efficiently accommodate all seat configurations, necessitating a lighter weight solution with improved structural integrity and manufacturing efficiency.
Innovation Solution
A retractable hinged arm made of filled thermoplastic material with a 'U' shaped cross-section, featuring a hinge and detent for deployment, and optionally a multiwall structure for enhanced strength, which can be used in tray table assemblies to provide structural integrity and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials such as aluminum are used for tray table support arms, then the arms achieve sufficient strength and structural integrity, but the weight increases leading to higher manufacturing costs and reduced fuel efficiency
Solution Approach 1:
The patent applies composite materials by combining thermoplastic polymer matrix with reinforcing fibers (glass, carbon, or other suitable fibers) to create a composite arm structure. This composite construction achieves the required strength and stiffness while significantly reducing weight compared to solid metallic arms, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent implements local quality by varying the fiber orientation, density, and distribution throughout the arm structure. Different regions of the arm have optimized fiber configurations tailored to local stress patterns, providing maximum strength where needed while minimizing material usage and weight in less critical areas.
2Reliability
If metallic materials are used for tray table support arms, then the arms provide adequate durability and reliability, but the manufacturing time and costs increase due to machining and secondary operations
Solution Approach 1:
The patent replaces the traditional mechanical machining process with a molding process for manufacturing the composite arms. The arms are formed by injecting thermoplastic material with embedded fibers into a mold, eliminating the need for subsequent machining, drilling, and finishing operations required for metallic arms, thereby significantly improving manufacturing efficiency.
Solution Approach 2:
The patent merges multiple manufacturing steps into a single molding operation. The arm structure, including complex geometries, reinforcement features, and surface finishes, are all created in one injection molding cycle, eliminating the need for separate machining and assembly operations that characterize traditional metallic arm manufacturing.
3Adaptability or versatility
If the tray table and support arm are positioned at the side of the seat, then the construction accommodates seats without front seats or in exit rows, but the mechanism for moving the tray table adds device complexity
Solution Approach 1:
The patent designs the support arm with universal adaptability to work with different seat configurations including standard seats, exit row seats, and seats without front neighbors. The arm's structural design and mounting system provide multi-functionality, allowing the same basic construction to serve various seating arrangements without requiring complex positioning mechanisms.
Solution Approach 2:
The patent extracts or removes the complex positioning mechanism from the design by utilizing the seatback structure itself as the mounting point. The support arm is directly attached to the seatback, eliminating the need for additional positioning mechanisms that would be required if the tray table were positioned at the side of the seat, thereby reducing device complexity while maintaining adaptability.
Data Source
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AI summary
A method of making a support arm includes heating a mold to a glass transition temperature of a thermoplastic material; injecting the thermoplastic material comprising a filler into the mold and allowing the thermoplastic material to conform to the mold; cooling the mold to an ejection temperature to form the support arm; and ejecting the support arm from the mold; wherein a cross-section of the support arm taken along a line from an inner edge to an outer edge of the support arm comprises a first "U" shaped portion and a second "U" shaped portion.