Flexible Seat Shell Edge Lining for Lightweight 3D Coverage
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Solution Overview
Problem
Current techniques for lining aeronautical seat shells are either too costly, heavy, or aesthetically inadequate, failing to provide a lightweight, aesthetically pleasing, and cost-effective solution that covers the entire edge and boundaries of the shell simultaneously.
Innovation Solution
A flexible lining element composed of elongate, planar cut pieces secured together to match the three-dimensional shape of the seat shell edge, made from materials like leather or woven materials, which can be easily assembled and stored, and secured using methods like sewing or gluing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If metallic lining elements are obtained by machining in the mass, then a high-end appearance is achieved, but the weight and cost increase significantly
Solution Approach 1:
The patent uses thin flexible lining elements made from lightweight materials such as plastic, composite, or fabric instead of heavy metallic material. These thin films can be molded or formed to achieve the desired three-dimensional shape and aesthetic appearance while dramatically reducing weight compared to traditional machined metal lining elements.
Solution Approach 2:
The lining element is designed as a simplified copy or representation of the traditional metallic lining, achieving the aesthetic appearance through surface treatment, coloring, or texturing of lightweight materials rather than using the actual heavy material, thus replicating the visual effect without the weight penalty.
2Shape
If metallic lining elements are machined in the mass, then a high-end appearance is achieved, but the manufacturing cost increases
Solution Approach 1:
Instead of expensive machining operations on solid metal blocks, the patent employs cost-effective methods such as molding, forming, or assembling thin flexible materials. These processes require less material removal, lower energy consumption, and can be more easily automated, thereby reducing manufacturing costs while maintaining aesthetic appearance through surface treatments.
Solution Approach 2:
The patent adopts inexpensive lightweight materials that can be easily manufactured and replaced if necessary, rather than investing in expensive metallic materials and complex machining processes. The focus is on achieving the aesthetic effect through cheaper means that are sufficient for the application's lifespan.
3Ease of manufacture
If composite lining elements are obtained by molding, then production is simplified, but the mold cost increases
Solution Approach 1:
The patent uses thin flexible materials that can be formed using simpler, less expensive tooling compared to rigid composite molding. These materials can be thermally or mechanically formed using molds with lower complexity and cost, while still achieving the required three-dimensional shape and fit.
Solution Approach 2:
Instead of creating a single complex molded piece requiring an expensive multi-cavity or complex-constraint mold, the patent divides the lining into multiple simpler segments or sections. Each segment can be manufactured using simpler, cheaper molds, and then assembled together to form the complete lining element, reducing overall mold investment.
4Ease of manufacture
If extrusion techniques are used for lining elements, then cost is reduced, but aesthetic quality and coverage are limited
Solution Approach 1:
The patent employs thin flexible materials that can be formed into complex three-dimensional shapes through molding or forming processes, going beyond the limitations of simple extruded sections. These flexible films can be shaped to match complex seat geometries and provide full aesthetic coverage, unlike rigid extruded profiles.
Solution Approach 2:
The patent uses composite or multi-layer flexible materials that combine aesthetic surfaces with structural properties, allowing for better appearance quality than simple extruded plastic. These composite materials can be formed into complex shapes and provide both aesthetic and functional performance.
5Reliability
If lining elements cover the entire edge and boundaries, then protection and aesthetics are improved, but the complexity of the lining element increases
Solution Approach 1:
The patent uses a single continuous or seamlessly joined flexible lining element that can conform to complex edge geometries and cover both the edge and adjacent boundaries. The flexibility of the material allows it to wrap around contours without requiring multiple rigid components, joints, or fasteners, thereby providing comprehensive protection and aesthetics while maintaining simplicity.
Solution Approach 2:
The patent combines the edge covering and boundary covering functions into a single integrated lining element rather than using separate components. This merging of functions into one piece eliminates the need for junctions, fasteners, or alignment adjustments between multiple elements, reducing overall complexity while providing complete coverage.
Data Source
AI summary
A flexible element for lining an edge of an aeronautical seat shell, made up of an assembly of at least two elongate, flexible and planar cut pieces, secured together by respective longitudinal boundaries so that the assembly has a three-dimensional shape matching with an edge of an aeronautical seat shell.A method for manufacturing such a lining element, as well as a method for setting up such a lining element over an aeronautical seat shell.