Thermoplastic Composite Structural Element for Aircraft Seating
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Solution Overview
Problem
Existing aircraft structural seating elements, such as spreader beams, are often made from heavy metals like aluminum, and closed section structures with welds or adhesives result in parts with varying mechanical properties, limiting weight reduction and strength enhancement.
Innovation Solution
The use of lightweight, high-strength composite materials with a thermoplastic matrix and chopped fibers, forming a single, hollow, monocoque structure through extrusion or pultrusion, eliminating discontinuities and enhancing strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If metal materials like aluminum are used for structural elements, then strength is maintained, but weight is increased
Solution Approach 1:
The patent applies composite materials consisting of thermoplastic matrix material and reinforcing fibers (such as carbon fiber, glass fiber, or aramid fiber) to replace traditional metal materials. This composite structure provides both weight reduction and maintained or enhanced strength characteristics, directly resolving the contradiction between weight and strength requirements for aircraft seating structural elements.
2Strength
If closed section structures with welds or adhesives are used, then structural integrity is improved, but mechanical property uniformity deteriorates
Solution Approach 1:
The patent merges multiple structural components into a single monolithic composite structure formed by co-curing thermoplastic matrix material with reinforcing fibers. This integration eliminates welds, adhesives, and other joining methods that create discontinuities, resulting in uniform mechanical properties throughout the entire structural element while maintaining structural integrity.
Solution Approach 2:
The use of thermoplastic matrix material that can be co-cured with reinforcing fibers creates a homogeneous composite structure. The matrix material uniformly distributes stress and binds the reinforcing fibers into a consistent monolithic structure, ensuring uniform mechanical properties across the entire component without the heterogeneity introduced by traditional joining methods.
3Weight of moving object
If traditional metal fabrication methods are used, then manufacturing reliability is maintained, but weight reduction opportunities are lost
Solution Approach 1:
The patent changes the material parameter from metal to thermoplastic composite materials, enabling new manufacturing approaches such as co-curing and monolithic forming. These parameter changes allow for weight reduction while maintaining manufacturing reliability through repeatable processes that produce consistent, high-quality composite structures with controlled fiber orientation and matrix distribution.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in aircraft seating components that are both lighter and stronger than traditional aluminum structures, offering a cost-effective and repeatable method for fabricating structural elements with uniform mechanical properties.
Implementation Method 1
The use of a thermoplastic matrix material permits a wide variety of formation techniques to be used... the base matrix that holds the fibers to be pressed together to form a single continuous section while the structural elements are remelted to form a single continuous section once the thermoplastic re-solidifies
Data Source
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AI summary
A structural element (10) that includes a central part (12,13) formed of a fibrous material suspended in a thermoplastic matrix and at least one side part (14 or 16) formed of a fibrous material suspended in a thermoplastic matrix and having at least one void therein. The central part (12,13) and the at least one side part (14 or 16) are bonded together while in a heated thermoplastic state to form a single, integral structure (10) characterized by the absence of discontinuity across the bond plane of the structure.