Thermoplastic composite components for commercial aircraft seats
Described are thermoplastic composite parts ( 30, 110 ) made up of resin-based fiber composites for use in aircraft furnishings. The thermoplastic composite parts ( 30, 110 ) can be formed into various shapes including bends so as to be suitable for replacing heavier sheet-metal components ( 100 ), particularly in aircraft furnishings.
1. A bent composite structural component for a passenger furnishing, the component comprising:
a thermoplastic composite sheet comprising a resin and a plurality of reinforcing fibers bent from a planar configuration to form a three-dimensional structure, the thermoplastic composite sheet having an angled cut in a side or corner of the thermoplastic composite sheet in the planar configuration that forms a corner joint in the three-dimensional structure;
one or more attachment features integrally formed in the thermoplastic composite sheet; and
two bends in the thermoplastic composite sheet that form the three-dimensional structure by intersecting with edges of the angled cut at the corner joint,
wherein the three-dimensional structure of the component comprises a structural component of an aircraft seat.
2. The component of claim 1 , further comprising:
one or more voids integrally formed in the thermoplastic composite sheet, the one or more voids being configured to reduce a weight of the component and facilitate circulation of air across the component.
3. The component of claim 1 , further comprising at least two angled cuts and corresponding bends in the thermoplastic composite sheet that form at least two corner joints in the three-dimensional structure of the component.
4. The component of claim 1 , wherein the thermoplastic composite sheet comprises a carbon fiber composite.
5. The component of claim 4 , wherein the thermoplastic composite sheet further comprises a composite with a resin comprising one or more of: polyphenylene sulfide (PPS), polyetheretherketone resin (PEEK), Polyetherimide resin (PEI), polycarbonate resin (PC), or combinations thereof.
6. The component of claim 1 , wherein the thermoplastic composite sheet further comprises a polyphenylene sulfide (PPS) resin.
7. The component of claim 1 , wherein the three-dimensional structure of the component comprises an in-flight electronics box.
8. The component of claim 1 , wherein the three-dimensional structure of the component comprises one or more of: a seat pan, a seat back, and a seatback shroud.
9. The component of claim 1 , wherein the bends are integrally formed in the thermoplastic composite sheet without forming a discontinuity or break in the plurality of reinforcing fibers.
10. The component of claim 1 , wherein the component comprises an aircraft seat component that has conventionally been formed of sheet metal.
11. The component of claim 1 , wherein the structural component comprises a container.
12. The component of claim 11 , wherein the container is configured to connect with an aircraft seat assembly.
13. The component of claim 11 , wherein the container further comprises attachment features, the attachment features being arranged to facilitate connection of the container to one or more rails of an aircraft seat assembly.
14. A bent composite structural component for a passenger furnishing, the component comprising:
a thermoplastic composite sheet comprising a resin and a plurality of reinforcing fibers bent from a planar configuration to form a three-dimensional structure, the thermoplastic composite sheet having an angled cut in a side or corner of the thermoplastic composite sheet in the planar configuration that forms a corner joint in the three-dimensional structure;
one or more attachment features integrally formed in the thermoplastic composite sheet; and
two bends in the thermoplastic composite sheet that form the three-dimensional structure by intersecting with edges of the angled cut at the corner joint,
wherein the three-dimensional structure of the component comprises a container configured to connect with an aircraft assembly.
15. The component of claim 14 , further comprising:
one or more voids integrally formed in the thermoplastic composite sheet, the one or more voids being configured to reduce a weight of the component and facilitate circulation of air across the component.
16. The component of claim 14 , further comprising at least two angled cuts and corresponding bends in the thermoplastic composite sheet that form at least two corner joints in the three-dimensional structure of the component.
17. The component of claim 14 , wherein the thermoplastic composite sheet comprises a carbon fiber composite.
18. The component of claim 17 , wherein the thermoplastic composite sheet further comprises a composite with a resin comprising one or more of: polyphenylene sulfide (PPS), polyetheretherketone resin (PEEK), Polyetherimide resin (PEI), polycarbonate resin (PC), or combinations thereof.
19. The component of claim 14 , wherein the thermoplastic composite sheet further comprises a polyphenylene sulfide (PPS) resin.
20. The component of claim 14 , wherein the container comprises a structural component of an aircraft seat.
21. The component of claim 20 , wherein the container comprises an in-flight electronics box.
22. The component of claim 14 , wherein the bends are integrally formed in the thermoplastic composite sheet without forming a discontinuity or break in the plurality of reinforcing fibers.
23. The component of claim 14 , wherein the component comprises an aircraft seat component conventionally formed of sheet metal.
24. The component of claim 14 , wherein the aircraft assembly comprises an aircraft seat assembly.
25. The component of claim 14 , wherein the container further comprises attachment features, the attachment features being arranged to facilitate connection of the container to one or more rails of an aircraft seat assembly.