Composite structural element and method

Abstract

A structural element that includes a central part formed of a fibrous material suspended in a thermoplastic matrix and at least one side part formed of a fibrous material suspended in a thermoplastic matrix and having at least one void therein. The central part and the at least one side part are bonded together while in a heated thermoplastic state to form a single, integral structure characterized by the absence of discontinuity across the bond plane of the structure.

Claims

1. An aircraft seat spreader beam corresponding to outer sides of a seat pan and seat back of an assembled aircraft seat, the aircraft seat spreader beam comprising: (a) a central part formed of a fibrous material suspended in a thermoplastic matrix, the central part having a continuous periphery forming a predetermined shape and internal portions separated by an array of weight-reducing interior voids, the internal portions are each diagonally oriented relative to the continuous periphery and directly connected to the continuous periphery thereby reinforcing the central part; (b) a first and second side part, each side part formed of woven materials embedded in a thermoplastic matrix; and (c) the central part positioned between the first and second side parts being directly bonded together while in a heated thermoplastic state to form a single, integral structure with the absence of discontinuity across the bond plane of the structure, wherein: the spreader beam includes a through hole adapted for attachment of the aircraft seat spreader beam to an aircraft seat.

2. The aircraft seat spreader beam according to claim 1, wherein the spreader beam consists of the first and second side parts and the central part.

3. The aircraft seat spreader beam according to claim 2, wherein the central part and the first and second side parts have the same peripheral shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the description of the invention proceeds when taken in conjunction with the following drawings, in which:

(2) FIG. 1 is an exploded view of an aircraft seat structural part, by way of example, a spreader beam, made according to the method according to the invention; and

(3) FIG. 2 is an aircraft seat that includes structural parts according to the invention, and made according to the method of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

(4) Referring now specifically to the drawings, a spreader beam 10 is shown in FIG. 1 and forms a structural element of an aircraft passenger seat “S” illustrated in FIG. 2. The beam 10 includes a central beam part 12 and a pair of side parts in the form of plates 14, 16 that are bonded to opposite sides of the central beam part 12. The central beam part 12 may be an extruded, molded or pultruded composite formed of a chopped or short fiber fill material molded with a composite matrix material. The fiber fill material may be selected from a wide variety of suitable fiber material, including carbon fiber and similar high-strength, low weight materials. The fibrous material is suspended in a thermoplastic material matrix rather than a thermoset material. The beam part 12 may be formed with through voids 13 in the structure, as shown. The use of a thermoplastic matrix material permits a wide variety of formation techniques to be used.

(5) Side plates 14, 16 are formed of woven, directional weave materials embedded in a thermoplastic resin similar to the material of the central beam part 12. The side plates 14, 16 can thus be heat formed or bonded in situ, or similarly welded by other means. Using thermoplastic composites permits 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. The result is a single, hollow, monocoque structure that is lighter than comparable aluminum structures yet with enhanced strength. There is no discontinuity across the bond plane of the beam 10 and the part is therefore stronger.

(6) The woven and molded strengthening materials can be fabricated from dissimilar processes and yet bonded into a single homogenous matrix. The techniques can thus be adapted for use with many types of parts and part components. In general, any loaded part that uses machined I-beam or C-sections can be replaced with a part fabricated in accordance with the disclosure of this application.

(7) A structural element formed of multiple layers of thermoplastic composite material is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.