TFG by Martí Solà

TH Y T R E E CRISTAL CABIN AWARDS TREBALL DE FÍ DE GRAU Martí Solà Foix | Antoni Pérez Ínsa Bernat Costa | Giuseppe Busalacchi ELISAVA 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

0. ACKNOWLEDGEMENTS

On first instance we would like to thank our tutors Bernat Costa and Giuseppe Busalachi, who have shown us the door to the rabbit hole of the aircraft world; also for their constant tutorization and encouragement to continue stretching the thread. We also want to thank them for the opportunity they have given us to meet mister Michael Lau

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Michael Lau, and to him himself who listened to our projects and gave us his point of view. We also want to thank the esporadic tutorization of Iñaki Arbelaiz. One final mention to all of those who have deposited their own sand stone along the way of this project, and Joan, the cornerstone of my rationallity.

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

1. CRISTAL CABIN AWARDS

The Crystal Cabin Award is an international award for its excellence and innovation on aircraft interiors, It is granted by the Senate of Hamburg (Germany). This unique award for products and exceptional items for the passenger cabin was presented for the first time in 17 April 2007 during the Aircraft Interiors exhibition in Hamburg Participants compete in seven categories: _ Greener Cabin _ Safety and Environment _ Industrial Design | Visionary con cepts _ Materials and Components _ Health Products _ Passenger comfort systems for passenger comfort _ VIP & Premium _ Universities pag. 4

The purpose of the award is to motivate companies and research centers to develop new products and modern designs for aircraft cabin interiors. Development, manufacture and marketing of innovative products or services offer potential profit, both for the consumer, as well as for manufacturers. The main purpose of the Crystal Cabin Award is tp generate a significant improvement in passenger comfort . The Crystal Cabin Award is sponsored by Airbus, Aircraft Cabin Management, Aircraft Interiors Expo (Reed Exhibitions), Aircraft Interiors International Magazine, APEX, Bishop, Diehl Aerosystems Division Aviation FERCHAU, Jetliner Cabins, SILVER ATENA, SGS Germany and ZODIAC AEROSPACE.

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

AVANTPROJECT

2. INDEX

0. ACKNOWLEDGEMENTS

1. CRISTL CABIN AWARDS

3. INTRODUCTION 7 3.1 survey 9 3.2 surroundings 11 3.3 user 12 3.4 inflight sequence 14 4. RESEARCH 17 4.1 aircrafts 18 4.2 airlines 20 4.3 market competitors 23

CONCLUSION

CONCEPT

5. BRIEFING 29 6. FIRST DRAWINGS

7. REFINED SKETCHES 7.1 sleeping & privacy 7.2 shared armrest 7.3 new structure 7.4 use sequence 7.5 first 3D renderings 7.6 basic dimensioning

37 39 41 44 46 50 54

8. MATERIAL SELECTION 57 8.1 production processes 59 8.2 CAE analysis 64 8.3 cost by piece 71 8.4 suppliers 72 9. FINAL PRODUCT 9.1 real adaptation 9.2 general dimensions

73 94 102

10. CONCLUSIONS 105 10.1 results 106 10.2 personal conclsions 108 11. BIBLIOGRAPHY 111

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

INTRODUCTION

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

3. INTRODUCTION

The mission of our project is to obtein a New concept of seat for better comfort and experience on the “Economy Class”. To achieve this goal we have the propose to redesign the actual seats to get current users of short-range flights to have a better experience through an increased comfort. Once we find our possible changes we will have to adapt it to technical requirements and existing aviation regulations for our seat to enter the real market.

EXPERIENCE

LOW COST

ADAPTABILITY

COMPOUND MATERIALS

LIGHTNESS COMFORT

ERGONOMY

PERCEPCIÓ

SHARED ARMREST

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STRUCTURE SEAT

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

3.1 SURVEY In order to identify the real problems users have when traveling by plane, we made a joint survey to 96 people. The questions asked were the following: 1: What you find positive aspects when you travel by plane? 2: What aspects when you find negative travel. Of all the responses we had a graphic on ordering responses according to their relationship with low short or long, and its importance, either positive or negative. As conlcusions general, we can see that there are 5 major themes that users always indicated as negative.

1 Uncomfortable seats 2 Little room for luggage cabin 3 Mobility Seat restricted 4 Difficulty getting up during the flight 5 Sleeping problems

The results of the survey are posted on the next page. They have been classified in terms of positive or negative experiences, and relative to the distance of the flight.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

TFG CRYSTAL CABIN AWARDS INFOGRAFIA DE LES ENQUESTES

LLEGENDA

Sobre un total de 96 persones enquestades

Aspecte positiu - Vols llargs + vols curts

ELISAVA 2014

Aspecte positiu - Vols curts Aspecte positiu - Vols llargs Aspecte negatiu - Vols llargs + vols curts Aspecte negatiu - Vols curts Aspecte negatiu - Vols llargs

POSITIU Vistes Serveis durant el viatge Conéixer gent nova Taula plegable Reclinació del seient Comoditat dels seients Revistes Llum orientable per llegir Reposabraços Televisió en viatges llargs Transport ràpid

Conéixer gent nova Taula plegable Reclinació del seient Revistes

Transport ràpid Económic Espai per deixar les coses sota el seient

Sensació de seguretat Apte per a viatges curts

Disposició dels utensilis d’emergència

VOLS CURTS

Seients sortida d’emergències Bona senyalització dels seients Climatització perfecte Cinturó no aparatós La gràfica està molt bé No hi ha paperera als seients Mala insonorització Claustrofobia Males Olors Falta d’endolls a la corrent Teixit dels seients bruts No hi ha tantes finestres com files de seients

Nens petits

Pantalles allunyades Camp visual reduit

Espai per deixar les coses sota el seient Seients grans Comfort Sensació de seguretat Movilitat Kit de descans Configuració de l’entorn Disposició dels utensilis d’emergència Persiana a la finestra Auriculars per escoltar musica Llum dels passadissos per la nit es agradable Seients sortida d’emergències Passadís ample Cinturó no aparatós Lavabo suficient No WiFi Aire Acondicionat del veí Alçada compartiments maleta

VOLS LLARGS

No hi ha tantes finestres com files de seients Facturació Temperatura ambient Nens petits Taula inestable Color de les parets Poca varietat de càtering Poca mobilitat

Un reposabraços cada dos seients

Temps d’embarcament i desembarcament molt llarg Finestres petites

Seients restringeixen accessibilitat Seients restringeixen movilitat Seients incòmodes Espai compartiment maletes reduit

Higiene als banys Un reposabraços cada dos seients Poques distraccions Banys petits Temps d’embarcament i desembarcament molt llarg Finestres petites Poca intimitat Reclinació seient de davant Passadís estret Seients restringeixen accessibilitat Seients restringeixen movilitat Seients incòmodes Espai compartiment maletes reduit

NEGATIU pag. 10

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

3.2 SRROUNDINGS The AIRBUS A320 is the most widely used aircraft for low-cost carriers, along with the Boeing 737 for short range flights. Keeping in mind that the environment includes the airport, once the passanger is in the aircraft, the seat becomes the direct environment of the passenger. Our problems to solve are the comfort and the user experience.

Passangers cabin

The section of the airbus A320 shows us the basic measures, such as the 62 inches wide of the 3 seats row.

Cross section

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

3.3 USER

LOW COST

{ { - < 4000 km - Europa - USA

{

- < 2:00 Hours

BUSINESS

- > 2:00 Hours

VIP

HOLIDAYS

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{

- Comfort - Image - Segregation

{

- Entertainement - No troubles - Occasional

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

{

The type who’s looking for a low price and the business person share many characteristics: - Short trips - Little comfort - Reduced Services - Economy Class

+EXPERIENCE +COMFORT -PRICE +PERCEPTION

{

These are areas for improvement which the chosen category of users give us. To do so we couldnfluence: - Seat - Service - Entertainment

{

Keeping in mind that a disminution of the price would be beneficial for the company, such as a reduction in weight of the seat. If we want to improve the experience we have to justify every weight or price increase. pag. 13

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

It is important to define the users who will use our products so as we can see what are their needs are and how they use the seat. We define two types of “persona” which includes two large groups of passengers traveling in Economy Class.

Jordi, Young 24 years

Carles, Adult 39 years

_ Recent graduate _ Insatiable traveler _ Nature lover

_ Businessman _ Family guy _ Neat

Jordi is an ecological engineering student who likes to live by the unexpected. Currently he is fulfilling his dream to travel arround the world searching for a place to work where he can really generate a change. It is a cheerful and friendly person who is passionate about making friends wherever he goes.

Carles is dedicated to travel for establishing communication between companies. He spends his free time with his family and his hobbies; which are sports, fishing, and spending time with his lifetime friends. It is very insightful, organized and polite.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

3.4 USE SEQUENCE The sequence of use related to an aircraft begins to reach the airport, where passengers: - Board - Find Your Seat - Store suitcase - Seat - Attach seabelt - Takeoff - Use of seat (movies, recline, eat, get up, work, read ...) - Reattach seatbelt - Land - Grab the suitcase - Disembark In the process we can determine certain times where there are more problems than others.

It is during the flight that the user might get comfort improovements.

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If we change the seat we also have to think of all the crew procedures such as cleaning and security checks.

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

RESEARCH

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

4. RESEARCH

The first research that we did it was divided into 3 big categories: the first one beeing how aircrafts are made and how they work. The second category is how do airlines operate and how they organise their aircrafts. Finallly we did a research on which are the new generation aircraft seats and how do they solve the actual problems.

4.1 AIRCRAFTS We are interested on the fuselage which is the area where we develop our proposals for improvement. The fuselage is divided into several zones as seen in the cross section, from which we are interested in #7.

5 1 CABIN 2 FUSELAGE 3 WINGS 4 MOTORS

5 TAIL 6 TREN D’ATERRATGE 7 PASSANGER ZONE

8 LOAD ZONE pag. 18

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The choosen aircraft, the A320, is used for low-cost carriers on flights from short range or average price for companies medium-distance flights. There is a long list of similar aircraft that we could rely on, similar size and where the properties of the scene could be repeated or even mimic such Unidos Boeing 737, Boeing 757-200, Boeing 717, Bombardier CSeries, COMAC C919, Embraer 195 McDonnell Douglas MD-80 McDonnell Douglas MD-90, Tupolev Tu-204.

Flight range A320 (Airbus website)

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

4.2 AIRLINES As shown in the table, most budget airlines use planes but little importance, as the A320 family (A318, A319, A320 and A321), within which the A319 is a little below the A320 . Also keep in mind that the 4765 operating the A320 family, A320 3036 model are excluding orders for 3255 units (2011 data) Airline

Information table (obtained on Wikipedia | 2014)

China Eastern Airlines JetBlue Airwaya China Southern Airlines United Airlines TAM Airlines AirAsia IndiGo US Airways Delta Air Lines LAN Airlines Vueling EasyJet Lufthansa Shenzhen Airlines Jetstar Airways Aeroﬂot Air France British Airways Alitalia Virgin America Wizz Air Air Canada Interjet Air China

A318 1 18 2

A319 23 40 55 31 93 57 26 4 153 30 5 13 41 44 22 10 38 30

A320 147 130 103 97 96 73 72 72 69 66 66 64 60 60 59 52 52 50 47 43 42 41 41 38

A321 33 5 62 10 90 62 6 24 25 18 22 10 42

Total 203 135 205 152 137 73 72 255 126 93 70 217 152 65 65 89 136 114 91 53 42 89 41 110

As shown in the table, most budget airlines use planes but little importance, as the A320 family (A318, A319, A320 and A321), within which the A319 is a little below the A320 . We decide to pick some of the worldwide companies which are using a significant number of A320. From their seat organisation we will obtain the restricting space measures in which our seat must be adapted.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

AirAsia is one of the companies that we analise. They have a fleet of 73 A320, They offer a 29 inches pitch which is one of the smalles we can find in the market (apart from some companies that offer the minimum accepted of a 28 inches)

A320 AIRASIA

PITCH 29 inches WIDTH 18 inches SEATS 180

AIRASIA seat layout

EasyJet also offers a 29 inches pitch with a 18 inches width. A relevant information is that they offer the same space in the configuration of their A319. They have a fleet of 153 (A319), and 64 (A320).

A320 EASYJET

PITCH 29 inches WIDTH 18 inches SEATS 174

EASYJET seat layout

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Similar to the EasyJet fleet, the Vueling one has the same size offer on all his planes, which are A319 and A320.

A320 VUELING

PITCH 30 inches WIDTH 17 inches SEATS 174

VUELING seat layout

Finally we have the Jetstar fleet. They offer the narrowest sizes of the sector market that we are exploring, although they also have a minor number of A320, 59.

A320 JETSTAR

PITCH 29 inches WIDTH 17 inches SEATS 180

JETSTAR seat layout

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

4.3 MARKET Currently one of the most important sectors are the seats. It seeks to improve the facilities and provide more space for each passenger. Also very important factors come into play such as weight, since it depends directly on fuel consumption. Below are some examples of the most innovative seating acualment exist in the market, or implanted on the up coming months. You also need mecionar the final proposal can be chosen something they have not taken into account seats, or amillora qualities they already offer.

RECARO SL3510 Slim and trim for short-haul flights. Weights only 9.1kg, the SL3510 is one of the lightest economy class seats on the market, with approximately 40 percent less weight than conventional models of economy class seats. Instead of conventional foam a material used to form the groundbreaking network core support. This makes it possible to reduce the thickness of foam creating support and much lighter. Weight reduction was achieved without sacrificing the quality of the seat, design and passenger comfort. To achieve this, the engineers focused specifically on the qualities RECARO ergonomic seat. The backrest angle is pre- set at 15 degrees to a position you feel relaxed and network equipment conforms to the shape of the spine of the passenger. Even in high-density seating, passengers have more space thanks to the SL3510, and material support network makes much thinner, increasing the distance between rows of seats. An additional benefit is the simplification of maintenance, due to the reduction in the number of parts used in different seat.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

PARKER EC-00 The range of ECO-01 economy seats ZIM Flugsitz suitable for all path lengths and weighing 26.7kg certified through the use of composite materials. For airlines seeking a short version but lighter dedicated, the company has developed the EC-00, which has been specially sculpted to improve comfort in a pitch of 28 inches. You can enjoy the simplicity of the tablet remain on the table back. This small table implies that the passenger might be hands free while you entertain.

ZIODIAC Dragonfly This model, with a weight of 7.5 kg per square is suitable for all types of aircraft with different configurations available, such as for A320 / B737 / A330 / A380. The Dragonfly has a basic structure of aluminum and contains 85% recyclable components, according to REACH environmental legislation, and the height of the seat cushion in 16.2, reducing the risk of DVT. Two additional versions are available: 8.2 kg Dragonfly high comfort with long armrests and backrest. Recliner for medium-haul aircraft flying within four hours of flight, and 12.5kg Dragonfly & Comfort.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

EXPLISEAT Titanium This French brand seat tickets made a bold entrance with the debut of his seat titanium weighing 4 kg per square claimed to use 737 or A320 aircraft on routes short and medium radius . However , although you may not have heard of the company before , it’s worth knowing that Christian Streiff , the former CEO of Airbus , is one of its investors. The seat is designed for low weight , high strength and low maintenance , with its combination of a structure made of titanium and a set that includes only 30 pieces. Expliseat says that the seat is more durable on the market, capable of supporting up to 100,000 cycles of use , equivalent to 10 years of operation . Support 2 inches thick is highly adapted to the human back for comfort , while the technical textile absorbs impact and movement of the knees of the passengers in the back row .

GRENIER Access all areas Greiner Aerospace has developed in collaboration with industrial design studio and Ludekedesign Kobleder specialist fabric technology. What makes this different from other seats seat aircraft design point is that the tech is claimed to be about 1/3 of a combination of conventional shock absorber and cover. At the same time, improves comfort thanks to the ability of the seat to suit different body sizes, shapes and weights, supporting all positions, in addition to reducing pressure points. The structure also has good properties of woven microclimate due to its air permeability. pag. 25

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Optimal response to the need for solutions focused on economy class passengers with Sable, a seat back cover semi-fixed. The design, created in conjunction with Factorydesign based in London, combines the best of traditional seating space with the advantage of a fixed-back shell. Proposed with a pitch of 32 inches, Sabre allows passengers to stretch their legs completely under the structure of carbon fiber ultra- efficient front seat. While reclines, the seat bottom slides forward and slightly downward, supporting a unique cushioning system, providing lumbar support in all positions.

OPTIMARES Sabre

The top cover does not move, so the rear passenger space remains unchanged, allowing them to continue to eat, work or relax, while enjoying a space constant intrusion sen. The only perceptible movement of the passenger rear is smooth slide on the screen, it does not affect the visibility of the IFE. It also avoids the claustrophobic effect than previous generations of seats fixed backshell economy could be imposed on passengers. Luxury finishes, plastic materials do everything, and the solutions are only in luxury cars complete this settlement, which will soon be called optimal wheel with its launch customer .

GEVEN Piuma evo The latest in the range of Piuma, Piuma Evo is intended to be the lightest model in its class (actually ‘Piuma’ means feather), while offering a high level of reliability and low maintenance requirements comfort. GEVEN engineers have been studying each structural element for weight reduction potential and performance improvements, and explore the use of new materials. The project should be completed shortly. pag. 26

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Ultra Superlight is a lightweight seat for longer flight sectors. Skin contoured, composite seat, cushion foam base and location monospar the front seat are designed to provide space for the legs and convenience - up to 3 inches more space for the legs of the seats conventional in the same tone, according to the company. The seat can

XC & ACRO Superlight ultra

be used in applications for both single and dual corridor of the economy and the economy of high quality, and available in any combination of double, triple and quadruple that covers all possible configurations. Ultra fully dressed weighs around 11kg per person, and seating is currently flying with the airline First Air Recreational Danish in their 737NG fleet.

Aircraft Seating Systems show again lightweight economy seat. The seat is aimed at the British market retrofit of the A320 and B737 and weighs a sub -25kg called a triple standard. The low weight is possible thanks to an aluminum primary structure, along with a semi- recumbent fixed support customizable molded from

ASS Pitch pitching

lightweight composite materials, which can offer a fully integrated package IFE support iPad, or just a pocket high or low literature. The support modules are interchangeable, so that customers can choose to add IFE later. The family includes variants for seating rows behind the front fuselage section, and tapered output. To facilitate entry and exit, the front seat cushions and armrests are angled between ireclinar be back cushions.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

BRIEFING

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

5. BRIEFING

At the end of the research we already came up with a defined and closed briefing within which are summerized the improovements that we want to achieve through our project.

PROBLEMATIC We want a better “Economy Class” seat for aircrafts on short range flights. To do so the first step is to identify the problems. After the potential customer survey, we extracted insights, which we have distilled some problems to improve: - Little legroom - Privacy - Shared armrest - Lumbar pain - Discomfort in sleep

RESTRICTIONS We consider some restrictions given by the product environment -rules and regulations of products in an aircraft- and the same product, such as overall size (width 17“-18” | pitch 28“-30“).

BUDGET To try a product like the “Economy Class” seats we take into account that the cost can not be higher than competitors; to offer a competitive product in a market where every day new products are substantial improvements.

GANT plan of the project pag. 30

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

PORPOSAL You must develop a seat that improves previous constraints problematics. To do so we do a redesign to take into account aspects such as the use of an external structure to gain and lose weight space, change classical form to improve ergonomics, add a mechanism that allows movement the headrest, lumbar improve, improve the comfort of the legs in the limited space provided by the companies; and all this from a studio to stay within your budget, considering that we possess a knowledge of materials and extensive production techniques.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

FIRST DRAWINGS

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

REFINED SKETCHES

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

7. REFINED SKETCHES

From this point on, we will see the sketched solutions that we are already looking into in order to find viable solutions to the problems exposed previously and that can be seen on the infographic below:

SLEEPING PRIVACY SHEARING ARMREST

PITCH KNEE AREA

CERTIFICATION LIGHTNESS PRICE pag. 38

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

7.1 SLEEPING & PRIVACY One of the major problems is privacy and comfort during the sleep. A possible solution would be to take the idea of the actual foldable head cushins and take it to a different level, such as using the plastic structure to create a closed space, or even generating 2 diferent pieces.

Curver structure that enhaces the sleeping position, and the privacy.

Separated adjustable piece that allows any height user and more privacy

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Curved structure that enhaces the sleeping position, and the privacy.

On the front view we can apreciate how we should affect the shape of a real seat. Our idea is to modify The whole construction structure of the seat so we can obtain the improovements but we don’t increase the price of the seat. Nowadays almost every Economy Class seat is made with bent aluminium tubes, a plastic wall and foam cushins. If we want a diferent shape we might have to change the plastic wall, and for that we will need to change the full structure.

Separated adjustable piece that allows any height user and more privacy

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

7.2 SHARED ARMREST Even if it seems like a simple topic, the shared middle armrests are one of the main critiques made by the users. First of all because theyir comfort depends directly on another person’s choice. To avoid these problems and to improove the experience of the costumer we want to separate the two arms or maybe even generate enough space for the 2 people.

We could generate a 2 height space by curving the plastic cover of the armrest, although it might hurt the passenger.

To avoid the pointy end on the previous design we could generate a second height by creating a full second stage. But there would still be mobility problems when entering and leaving the seat.

Using the wave shape we avoid such mobility problems and we give a lot of space to both passengers. The problem then would be the obligation of one passenger always beeing on top.

Finally we could have an experience improovement, by adding new functions on the space generated, making up the mobility problem on #2. pag. 41

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Using the actual armrest aluminium core we can design another way to generate a larger surface. After trying diferent options such as articulations, drawers and guides, we decided to use a rotation axis. On the drawings below we can see the possible shape and sized that it would have.

The VUELING armrest has a width of 6 cm, with a theoretical width of 3 cm per person. Including the fact that usually one arm stays on th back and the other one on the front of the armrest, if it is shard. With our idea both arms could be spread wide and would have a width of 6.5 cm per person.

The general shape conserves a round end to make mobility easier. The measures are 6x5x35 cm, keeping the RYANAIR sizes, which are adapted to the Economy Class seat.

The blocking mechanism must be strong, easy to produce, and easily replaceable. We must block the rotation of the wing along with the axis one. pag. 42

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Nowadays entertainement is a very important sector of the aviation business. Nevertheless, the low cost companies usually don’t offer such entertainement becuse it increases the overall cost per passenger. In addition, pleople nbring their own entertainement on their computers, tablets or smartphones. Then a simple hook adaptable to any media player would be a good investment for the company. The seat could have such product integrated or it could be attached f the passenger requested it.

The idea is to use the new structure of our seat to adapt a clipping mechanism. Then every passenger could ask for the support for his own device. Using this system the company wouldn’t have to spend more. We may also consider the new technologies which will be abailable on the next year such as flexible screens. Theese kind of products could generate a new buissness model such as paying a little extra cost per passenger pag. 43

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

7.3 NEW STRUCTURE To preserve the weight restrictions imposed by the actual market range, we have to make a very slim seat. We purpose the use of a new structure. Almost every seat on the actual market uses a structure made of bent tubes. Then some other metal structures are attached to the tube structure in order to generate enough surface where the cushins will be put. Also they have plastic structures which are then adapted to the exterior of the seat, and united to the metal structure; making it very difficult to change the cushin foam. We want a different metal structure along with a single piece of plastic. The cushins can also be improoved with new materials that we will study later on.

We should not sacrifice the comfort in exchange of a benefit for the air company. Therefore, we must know that the lightest seat on the market weights arround 25 kg; and the heaviest one arround 50 kg.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The material used for the back spine will be aluminium; due to its mechanical properties and its light weight compared to other materials steel. We considered the use of a layer structure made of polymers and fiber such as glass, carbon or aramide, but we would have flexing problems and structural problems in case of impact. Below we can see some ideas of the shape the spine could have.

Due to production process we have to keep a simple shape in order to be able to make it, and keep a low price

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

7.4 USE SEQUENCE Once we have defined our formal proposition, we decided to study the user behaviour inside the plane, and how he would interact with the new improovements. From this sequence we might obtain more important intel about the critical areas of our seat.

The first thing we run across is the boarding time. The user finds it easier if the armrests can rotate, so he can enter the seat easier. From there we pick up the fact that the whole armrest must have a nice touch.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

While seated the first thing, after the take off, that the user might do is to increase the armrest space. To do so he only needs to push the button (#1), twhich unblocks the mechanism. Then he can rotate the wing (#3). Once the wing reaches the right position, the mechanism snaps pack into position, blocking the rotation and supporting the arm weight.

On the top view we can see that with the provided space both passengers to spread wide their arms, without bothering each other. Plus it’s shape makes it comfortable even for passengers with a big belly.

pag. 47

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The final formal proposition is based on a adjustable headrest. It might seem as the other products on the market, but we want to offer something new.

A higher evel of adaptability is achieved by using 5 separated pieces, wchich can be adjusted at the users choice. There can be many head sizes or preferences when it comes to sleep. Also it gives the passenger the possibility of hiding his face, and increasing his level of privacy as well.

pag. 48

We will use a mechanism that emulates the ones already exitents. The idea is to generate a hinge on every union bewteen pieces so the headrest remains on the position choosen by the passenger.

Final Project on Industrial Design Engineering THYTREE | Antoni PĂ¨rez, MartĂ SolĂ | June 2014

The last gadget available on our seat is the multimedia screen. It can be requested by any passenger, and it gets attached to the back of the front seat. We had a first idea of creating the support for the gadget, but maybe it would be better if we took advantgadge of the new technologies such as flexible screens in order to get a lighter object, and maybe, as metioned before, the airline company could charge an extra cost.

There are some companies that are already developping flexible OLED screens such as SAMSUNG or KYOCERA. The reality is that they might be flexible but they need a rigid support. We can use it as an advantage ang use the rigid part as support on the front seat.

pag. 49

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

7.5 FIRST RENDERS The first idea that we had was put into 3D modeling to see what results were obtained. On a very basic level, we achieved to generate each and every one of the improovements, and see how they would look and be at eye sight.

Only 4 out of 5 pieces are adjustable. The cushin must be a unique piece, in order to ensure te head comfort.

We need to generate a perfect protected structure. The passenger should not see or touch the metal parts.

The central piece of the headrest has a guide that allows the Z plane movement. It is attached to the central spine.

pag. 50

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Thanks to the first 3D we could find many defect of our initial idea. Also the help of mister Michael Lau and his advise helped us realise many of those errors. As it can be seen on the picture too, there are still many pieces to be done such as the plastic cover for the armrest structure. Also the legs of the full set must be changed to get past the crash tests.

The armrest aluminium core must be protected and unseen. It has to hold the weight of a human body.

The lateral pieces of the headrest must have round corners due to: the shape of the fuselage, the walking passengers, and finally for the shoulders of the very user across you.

pag. 61

The lateral armrests don’t need to hava a double extendable wing. This will increase the number of pieces and moulds needed for its production

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The back of the seat would look like this one. The bifide spine is theoretically supposed to divide the mechanical effort during the crash. As we will see on the final product, we had to change it in order to have a safety factor.

The spine is made of injected aluminium. It is also embraced by the plastic piece so it doesnt hurt at all the passenger.

The union between the pieces of the headrest should be hidden in order to be safer.

pag. 52

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The last piece we worked on was the extensible armrest. Many mistakes were highlighted after seein how the 3D was made. Things such as the zero need for the extreme armrests to have an extensible wing.

The articulation of the armres has to be very simple and it might include part of the mecanism used by the rotating wings. The shape must be round, and the button mechanism must be more simple. Also every piece must be covered by a soft rough TPU polymer.

pag. 53

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

7.6 BASIC DIMENSIONS The height of the headrest is adjustable on the Z plane. It has a 12 cm path that covers from the regular percentil to the highest one. Such feature must be available because there is a wide range of heights amongst passengers.

The second feature of our headrest is the adjustability on the XY plane. Every piece can rotate up to 45º relative to its predecessor. That makes it even possible to almost close the space in front of you. In the future that could be used to create an entertaining space, where nobody would see your scree,. Also it improoves privacy and comfort during sleep time.

pag. 54

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

We maintain the 28 inches pitch, to proove that on the smalest space we can generate more comfort. Actually, as we use an injected plastic piece for the backrest we win 6 cm for the knees, apart from the 30.1 cm space.

Most companies that offer economy seats, and usually low cost flights, don’t offera reclinable seat. We want to offer it. That will increase the cost, but will generate a big confort.

The angle of reclination s 15º. After the firs renders and technical drawings we observed that it was too much. We will reduce it to a maximum of 12º in order to keep confort for the passenger behind. The Sabre seat solves this problem by reclining frontwards. pag. 55

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

pag. 56

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

MATERIAL SELECTION

pag. 57

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

8. MATERIALS

The list of materials used is not very long. This makes it a better product when it comes to disassembly and recycling its parts. In our Thytree seat we can find:

ABS nonflamable

PC nonflamable

ALUMINIUM 6061-T6

TPU

FOAM

SYNTHETIC LEATHER

STAINLESS STEEL

A very important part of the product are the finishings. First the chemic threatements such as galvanized to protect the aluminium parts from corrosion. And then the visual finishings such as the following:

BLASTING ALUMINIUM

POLISHED ALUMINIUM

ROUGH ALUMINIUM

ROUGH STEEL

The material datasheets are located on the annex, along with all the mechanical properties.

pag. 58

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

8.1 PRODUCTION PROCESSES To produce all the pieces that we need we make use of many production processes:

INJECTION _ aluminuim _ abs _ pc

MATRIX _ aluminium

TORNING _ steel

EXTRUDE _ aluminium

As we will see on the costs, every process has a cost and a wide range of possibilities depending on the material used on each case. We have to take into account that some methods like the matrix need a worker. pag. 59

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Stage 1

8.1.2 MATERIAL SELECTION To choose the materials we runed some analysis on the CES Selector program which is an information database about materials. Here are some of the following studies we realized:

Aluminum, 7075, wrought, T651 1000

Yield strength (elastic limit) (MPa)

Aluminum, 7075, wrought, T6 Aluminum, 2024, wrought, T6 100

Aluminum, 6016, wrought, T6

0.1

0.01

0.001 1e-5

1e-4

0.001

0.01

0.1

Young's modulus (GPa)

100

1000

We need a material with high yeild strength that will not break into pieces. We can choose between the aluminium 7075, the 2024 and the 6061. Finally we choose the 6061 because it can be welded, not like the 7075, and is lighter than the 2024. Plus the 6061 wrough T6 has equal mechanical and chemical propierties than the 2024. It is also the less expensive of all 3 possibilities. (See next pages).

EduPack 2013 pag. CES 60

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Aluminum, 7075, wrought, T6

2800

Density (kg/m^3)

Aluminum, 2024, wrought, O

Aluminum, 7075, wrought, O

2750

Stage 1 2700

Aluminum, 6061, wrought, T6

Density chart

Wrought aluminum alloy, 2024

Wrought aluminum alloy, 6061

Aluminum, 2024, wrought, T3510/T3511 Aluminum, 2024, wrought, T8510/T8511

Wrought aluminum alloy, 7075

Aluminum, 7075, wrought, O

Aluminum, 2024, wrought, T361

Aluminum, 7075, wrought, T6

Young's modulus (GPa)

Aluminum, 6061, wrought, T6

CES EduPack 2013 (C) Granta Design Ltd 74

Aluminum, 2024, wrought, T4 70

Young’s modulus chart

Wrought aluminum alloy, 2024

pag. 61

Wrought aluminum alloy, 6061

Wrought aluminum alloy, 7075

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

500

Aluminum, 2024, wrought, T861

Flexural strength (modulus of rupture) (MPa)

Aluminum, 7075, wrought, T6510/1 400

Aluminum, 6061, wrought, T6 300

Aluminum, 7075, wrought, T6

uminum, 2024, wrought, T6 200

Aluminum, 2024, wrought, T42

Stage 1

100

Flexural strenght

Wrought aluminum alloy, 2024

Wrought aluminum alloy, 6061

Wrought aluminum alloy, 7075

2.3

2.2

Price (EUR/kg)

CES EduPack 2013 (C) Granta Design Ltd

2.1

1.9

Price €/kg

Wrought aluminum alloy, 2024

pag. 62

Wrought aluminum alloy, 6061

Wrought aluminum alloy, 7075

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Along with our research we found the materials used specifically on some airplane seats used nowadays. Every single piece could have a number of diferent aluminium series due to basic properties such as mechanical (elongation / fatigue), chemical (corrosion) and procedural (injectable / extrudable / weldable...). On our 3D simualtions we will only use the AL6061 T6 in order to get the structural results. Eventhough here is the list of pieces along with the criteria that used: Front legs: - good elongation (>7%) - good fatigue values - good corrosion properties - milled, forged or casted 6082/ 2017/2024 alloys Back legs - good elongation (>10%) - good fatigue values - good corrosion properties - milled or forged 7075 alloys Beams: - good elongation (>15%) - good fatigue values - good corrosion properties - extrusion - 2024 alloys Backrest & armrests: - good elongation (>15%) - good fatigue values - good corrosion properties - extrusion - “6000” alloys Seat spreaders: - good elongation (>13%) - good fatigue values

pag. 63

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

8.2 CAE ANALYSIS To ensure the safety of our product we must do the CAE structural analysis. We will begin by assigning the material that we want. Then the movement constraints, and finally the applied crash test force of 1800N (16 x 9.8m/s2 x 12kg) The density and mechanical properties are defined to assign the materiall to the piece studied.

We add the Von Misses criteria of fracture in order to obtain results that include if the piece breaks and the safety factor it has

We constrict the piece how it will be done on the seat, and we apply the force of the impact on the surface where the whole backrest will be attached.

On the images above we can see the material assignation (left), and the image of the spine with the force and the constraints already placed. Force (orange arrows), and constraints (blue triangles). The carts were they are difined are on the next page.

pag. 64

Final Project on Industrial Design Engineering THYTREE | Antoni PĂ¨rez, MartĂ SolĂ | June 2014

As said on the previous pagen below we have the force definition (left) and constraints (right) The force applyed (CARREGA) has a value defined of 1800 Newtons equivalent to the crash test adding extra weight on the backrest.

The movement restriction are also defined (CONSTRAIN). All axis are bloqued in order to see how the piece really works.

We can refine the mesh in order to obtain more precise results. We create 8707 tetrahedrons.

To obtain very precise results we refine the 3D mesh. This will allow the simulation to analyse more data nodes.

pag. 65

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

So we can begin with the analysis. We will launch for every case of study a Multipass of grade 9 and data convergence of 5%. When we run the last analysis we will use the convergence table to see the precision of the results. We will be studying the Failure Index which is the inverse of the safety factor. to get a positive result we need a number superior than 1. If we get 0.5 it means it has a SF of 2.

The maximum result is 3.4 x 10 -1. it is located on the most weak part of the piece

On the first attempt we got a positive result (0.3) which means it has a 3 SF, but the weight (7kg) is excessive.

The secon bifid spine has less material, but instead of dividing the force recieved it has a worst result (0.8). It is also still too heavy like its predecessor. The 2 cm thick piece is too much for the seat.

pag. 66

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

On a triple little ending we find very good mechanic properties, but it is not possible to produce it. Plus it still weights too much, actually it weights more than the second trial.

We finally reduce the section to a single spine with a constant profile of 100 mm width. we also give it a beam profile, reducing the weight to 3Kg. The problem now appears to be the piece breaking on the red area.

We solve the final problems having the beam I profile rounded. The adittion of material is minimum and we obtain a piece that doesn’t break, with a FS of 1.5.

pag. 67

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The final shape of the spine is tested. We obtain very good results. A 0.49 on the failure index test, and a resistence of 159 MPa (1), plus it has a SF of 2 (2). It is ready to be produced and installed on the seat. We had to reenforce the curved part at the bottom to make it stronger, it doesn’t add a lot of weight and it makes the weak part of the spine more than enough strong. 1

The area that suffers the most is reinforced by beeing filled with aluminium too. This suposes a minimum change on the mould that will give a great advantage.

Even if it might seem weird to use a single spine, it is the optimized version. We had to find a balance between price, wheigt and resistence, and the CAE analysis have shown that this might be perfect.

pag. 68

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

To see if the data obtained is accurate we can extract the divergence graph. If the information is correct after the first peak it should stabilize into a continuous curve. That prooves that we have the good information.

Finaly after assigning the material we can also acces the mass data, and know how much does every piece weights. The spine is shown below, and it weights 3.1 kg.

pag. 69

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

We simulated the wing on the armrest to make sure that if a human sat on it the mechanism would not break. We block the rotation axis movement in order to see what happens on the blocking area. Then we apply the force of 700N which is a human wheight. The reults were positive, it suffered 2.83 MPa, way under it’s limit

We also tested the index failure of the piece that holds the whole armrest, and it gave a Safety Factor of 5.

pag. 70

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

8.3 COSTS BY PIECE The cost has been calculated b the following premises: _ unit: 3 seats = 1 row _ selling ideal: 66 planes (VUELING A320) The table shown below is the template used for every piece (annex). The data obtained is compared with the website CUSTOMPARTNET. On this table we consider the 4 basic costs of every piece: the weight, the production process, the mould and the finish if there is one. NOM NUMERO # MASSA TOTAL (Kg) MATERIAL PREU MATERIAL PREU PEÇA (€) PROCESS PREU HORES/MAQUINA/PEÇA (€) PREU MOTLLE (€) / 20000 uds. ACABAT PREU ACABAT (€) OPERARIS PREU TOTAL

ARTICULACIÓ REPOSABRAÇ 4 0.4 Al6061 1.9 €/Kg 0.76 INJECCIÓ 1.8 1 GALVANITZAT 0.3 - 3.86

Then we have to add some other costs that are also explained on the annex such as transport, weldings and assembly. As an example we consider the assembly as: _ The job must be precise and perfectly done due to its safety regulations, so we consider it pays about 100 €/h. _ A single row takes about 8 hours to assemble _ Assembling price 1200 €/row The final price of the row is 5604.4€ The total weight of the 3 seat row is 41.14 Kg We also add a benefit of a 50%, that is traduced to a final price of 11208.8 €.

pag. 71

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

8.4 SUPPLIERS After looking for the prices of the materials and the production of the piece we have also searched for all the suppliers that we might need if we wanted to make the set real. So we have listed the names of the companies and the processes they would do for us: Aluminium tubes: IDEATUBO, Barcelona Plastic injected pieces: SP BERNER, València Moulded aluminium: RIO TINTO ALCAN, Molins de Rei HIinges: HÄFA Foams & leather: QP (Quality Foam Packaging), Califorinia Screws: ALABALL, Barcelona Piston: TAVIL, Olot Flexible screen: KYOCERA, California

pag. 72

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

FINAL PRODUCT

pag. 73

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

9. FINAL PRODUCT

The final product renders show us the result achieved through the whole project. From this point on we will walk trough every part of the seat, how it is assembled, what materials it is made of and how it works.The colour & trim choosed for the photorenders could be modified by the very sme VUELING, although our proposal is adapted to their company colours.

THYTREE TH Y T R E E TH Y T R E E TH Y T R E E

Detail render side-back view pag. 74

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The first thing we are going over is what we call the metallic structure. It is the first part to be assembled. It is made of multiple pieces most of which are made of injected aluminium. It also has 6 weldings that must be done during the assembly of the very same structure.Here we can see how it is once finished.

Detail render metal structure

Close up of the structure pag.75

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The first important part is the leg subassembly. All of theese pieces have a galvanization treatment, but they have a rough finish because anyone has to see them so they do not need an extra mould cost. the pieces are: 1.one leg structure 2. two joints 3. six screws M10xL50 4. three screws M6xL30 5. one front pin 6. one rear guide block 7. two double washers 8. one screw M6xL45 9. one security nut M5.

pag. 76

ALUMINIUM 6061-T6

STAINLESS STEEL

ROUGH ALUMINIUM

ROUGH STEEL

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

After we have the leg subassemblys we add the armrests and the structural bars. Along with this assembly we also have to put the spine through the structural bars, along with the pistons. Then we can weld the spine blockages on the structural bars and the piston to the spine. Finally we add the seat metal sheet which is rivetted to the leg structures. Then 2 velcros are glued to the metalic sheet in order to install the cushins later. When it is all assembled, we add the foot bar. 1.two leg structure 2. four arm structures 3. two structural bars 4. thirty M4xL5 rivets 5. three blockages 6. three spines (blasted) 7. one foot bar 8. three seat metal sheets 9. fourty M4xL5 screws

ALUMINIUM 6061-T6 The 7 pieces

STAINLESS STEEL

ROUGH ALUMINIUM

ROUGH STEEL

Screws Rivets

BLASTING ALUMINIUM

pag. 77

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

On this image we can clearly see the reclination system as well as the plastic protections and the structure system. The seat cushin is made of a unique piece too, and protects the passenger from touching any part of the structure.

Close up of the rivet frontal view.

Posterior view of the riveting between the seat metal cheet ant the posterior bar. pag. 78

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Exploded view of the rivets used per seat.

Close up of the screws that tie the metal sheet to the armrest structure. pag. 79

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The cushins are attached to the structure with the velcro strips glued to the seat metal sheet.

Detail of the top view of the metallic structure. Note the seat metal sheet’s holes for the piston and spine

Detail of an already assembled and welded piston that allows the reclination

pag. 80

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Once the metallic struture is prepeared we proceed to install the armrest structure plastic protections, the lateral and central armressts and the backrest. The pieces that are now installled are mostly made of aluminium, steel, PC, TPU and ABS. The armrest pieces will be explained on the following pages.

ABS nonflamable

PC nonflamable

TPU

On the image we can see that the spine and the blockage are not installed; this is only a photorender to show how the plastic covers are, and where they go. We made them in order to protect the metal parts. They are very simple injected pieces

pag. 81

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The backrest is made of injected PC, and it is tied to the spine with 26 rivets. It also has the velcros installed so the cushin can be mounted easily. The armrests are also mounted with a pin that allows the rotation movement. The mechanisms will be covered by the cushins and the plastic covers.

As we can see on the image the lateral armrests are different than the central. This has been explained before, and on the next pages we will see the real differences.

pag. 82

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Close up of the rivets of the backrest with the spine.

Armrest subassembly, with the right wing extended. pag. 83

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Now we will proceed to the explanation on how does the armrest works, with it’s mechanism and the pieces that conform it. We will also see the minimum differences between both lateral and central armrests. They are composed by the nucleous (AL 6061 T6), the wings (PC/TPU binjection), the posterior blocks (AL 6061 T6), the superior plastic cover (TPU), two blocking pins (SS), two springs (T STEEL) and two buttons (ABS).

Exploded view of the central armrest (right). Close up of the blocking pieces (up).

Exploded view of the lateral armrest (right). Close up of the plastic cover (up). pag. 84

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The blocking mechanis allows two positions for each wing. This allows the A MODIFICAT Nº FULLAfrom 3DATA the surface where his armPER will be placed cm MODIFICACIÓ to 6 cm. It works with A-A four easy steps:

11.

OBSERVACIONS user to increase

REVISIÓ

1. you push the button and unlock the wing from the nucleous. 2. The wing rotates with the blocking pin inside. 3. When the wing reaches the second position. 4. The spring forces the locking pin into the nucleous again, blocking the sistem

Key part of the nucleous that allows both positions (up). Opened wings (right). 1

1 PUSH

2 UNLOCKED

4 4 BLOCK ON POSITION 2

3 ROTATE

pag. 85 2:1

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The basic measures can be found on the technical drawings. But we must mention that the shape of the wings has been inspired on the armtable schooldesk, that allows the body on a comfortable position even for people with bigger bellys.

Detail of the armrest when it is folded

Top view detail of the armrest once it is unfolded pag. 86

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Now we will see how the headrest is made and how the mechanisms that it has to work. Basically to adjust the height we play with an interference fit of H8 h9, light forced slider without lubrication. To make the rotation pieces adaptable dor the head comfort we have hinges between the pieces ith an adjustment of H8 f7 which stands for swivel with little fitting interference. The materials used are:

ABS nonflamable

PC nonflamable

TPU

FOAM

We will not be showing the posterior pins that have the only use of blocking the maximum and minimum height that can be adjusted by the user. On this image we can also see the purpose of our flexible screen.

pag. 87

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Exploded view of the components (cushins, plastic plaques and hinges)

Detail of the hinge union. The blue nylon washer is the piece that allows the adjustment H8 f7 to last more cycles due to its preservnce of avoiding one metal piece from scrtching the other pag. 88

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

REVISIÓ

OBSERVACIONS

180

A 56.9

135

pag. 89

191.3

441.4

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014 8

VISAGRA

TAPA_CENTRAL

TFG_

PLACA_4

TFG_

The seat cushins are very important for the comfort of the passenger. The material choosed is ARANDIPUR. It is a material made of foam that has no need for leather covers, due to its finish obtained directly when the object exits the mould. It is very cheap and although it is not the best nonflammable foam, it reduces the costs a lot the final price and it could be treated to obtain the necessary properties.

Exploded view of the full assembly. we can see the three backrests and the seating cushins

The backrest cushins are essential for our design because they embrace the back part of the seat in order to offer a better comfort for the knees of th passenger seating behind, without a reduction of space. pag. 90

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Finally we have decided to adapt the new flexible screens to ous seat. The backrest has two cavities designed to plug the rollable screen. the screen by itself has no btterie, so we have to describe through where the cables will go,Now we will see how the product would look like.

Close up of the flexible screen

Posterior view of the seat with the cable location. (through the plastic backres, then down the spine section and from below the seat to the leg into the floor). pag. 91

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

On the image below we can see the final product assembled. We can appreciate the colours picked which are black for the cushins and white for the injected plastic pieces. Also we have the aluminium blasted on all the pieces that the user might touch. The sand blasting is the same finish you can touch on an Apple computer.

pag. 92

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

A good property about the foam used for the cushins is that the exterior finished can be soft touch, or it can have any texture desired. As a client you only need to specify what you want and it will be carved into the mould’s surfaces.

pag. 93

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

9.1 REAL ADAPTATION To be able to observe our THYTREE we must adapt it on photorender views ans see how it would look inside a real plane. In this section we will also review some important data of the project such as fitting the percentiles of the population in our seat.

pag. 94

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

It is a major concer to be careful with the sizes such as to keep the airlines preciated pitch. As we are looking at VUELING standards we are going to stick with their 30 inches pitch used on their fleet of A320. Another basic size to take into account are the percentiles of the population.

50%

95% 30”

pag. 95

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Here we have an integration of our seats inide an already existing A320. This exact model is a little bit older than the ones in which we think our seat would be installed, although if the company has to change all the seats this is an idea of how it would look.

pag. 96

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

The whole on the plastic backrest allows the screen which could display many different kinds of data such as inflight information or even internet browsing which is starting to be allowed on some flights. The rest of the whole can be used for magazines or it could even be dock for the passenger’s cellphon. And since the screen already uses the backrest as cable cnductor it should pose no problem.

pag. 97

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

pag. 98

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Here we see another possible integration on a classic A320 distribution of seats with 2 columns and 3 seats rows. The width of the aisle is 25”, adapted to the 17” of seat width offered by VUELING.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

A basic aspect of our seat is that it has an adjustable headrest. This feature enhaces the comfort of passengers of every height since it is tested on the limit percentiles of the 5% and 95% which are the extreme ones. As we can see on the three images of this page the height is adjustable. On the bottom right corner image we can see how the seats would look if they had another colour such as black.

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

9.2 GENERAL DIMENSIONS The height dimensions are shown below, along with de minimum and maximum height at which the headrest can be adjusted. 1

The space measures are taken from real seats. We obtain more knee space that is protected with the cushin too. The minimum sizes established by the N 64 study regulation are accomplished. (N64 on annex).

428.1 F

1510

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

REVISIÓ

OBSERVACIONS

MODIFICAT PER

Nº FULLA

DATA MODIFICACIÓ

11.6

104.9

284.9

10°

1219

398.5

Reclination has been modified since the latest version, now the maximum is up to 12º, and it coul be reduced even more. 7 8 The width of the seat for every passenger is the same 9that the actual seats10 offer, adapted to the N64 regulations.

482.8

Projectat:

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Data

Nom

14/07/2014

THY TREE

14/07/2014

Escala 6.3

ELISAVA

Just net

3.2

1.6

0.8

CONJUNT_SEIENT Acabat:

Sense mecanitzar

ProjectAcabat on bast Industrial Design Engineering THY TREE Final 1:5 Acabat fi THYTREE | Antoni Pèrez, Martí Solà | June 2014 Material Pes (Kg) 0.4

Rectificat bast

Rectificat fi

Format Nº Fulla

1 de 1

Nº Plànol

41.4

TFG_200_000

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

CONCLUSIONS

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

10.1 RESULTS We consider our project to this point as finished. The first observation that we want to make is that, as every other project we are leaving some details undone or unfinished. It is usual to find little things that could be imrooved but once we arrive at a certain point we must put ourselves a limit. This project is a huge piece of work, mainly due to the complexity and the multiple pieces that it has, and that is why we could spend months working on it trying to make it perfect. Many goals that were set on the initial briefing have been achieved, such improoving all the problems that we stated, from the sleeping comfort and privacy, through the shared armrest, to the enhacement of the knee area. Plus we managed to keep a low budget, the certifications and the necessary lightness. We would have enjoyed a lot more to be working on a conceptual design, but the real certifications are very strict and the implementation of new materials and extraordinari shapes is not yet to be implanted. Nevertheless we are very satisfied on the final project.

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Final Project on Industrial Design Engineering THYTREE | Antoni PĂ¨rez, MartĂ SolĂ | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

10.2 PERSONAL CONCLUSIONS

Antoni Pèrez Insa On the cusp of the project I realized to do the redesign of a complex object like an airplane seat requires a lot of knowledge and time. I also would say that is a work that can only be done by large groups of people, with a good group to work out a perfect seat. I would also say that 6 months for such a large project can become just as it is a project that if I end up not offer, there are always nuances. After these six months of the project even change things as you see imperfections in the end. I did not know much about the world of aircraft prior to this project, now I can say I learned a lot about the design of the seats, for which I have a special interest. pag. 108

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

Martí Solà Foix Since I was a little kid I have always been interested about aircrafts. Doing this project has made me realize that, as any other object, a plane seat can be studied and modified on every milimeter of its body. Personally I learnt a lot of information I would have never guessed and I had a great experience facing something new and unknown. Althoug I must say that the complexity of the object might be a bit over the attaints of two students; , but we put the best of ourselves on this project. We liked the evolution that we followed, and we are very thankful with the guidance of our tutors, and we are quiet surprised about how do some things work; things we never thought we would look into! pag. 109

Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

BIBLIOGRAPHY

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014

11. BIBLIOGRAPHY

WEB AIRBUS: http://www.airbus.com/aircraftfamilies/passen geraircraft/a330family/a330-200/cabin-layout/ WEB REGULACIONS: http://www.flightsimaviation.com/data/ FARS WEB LAYOUTS: http://www.airlinequality.com/Product/seat_ intro.htm WEB DISTRIBUCIÓ SEIENTS: http://www.seatguru.com WEB PRODUCTES: http://www.aircraftinteriorsinternational. com/ WEB ANTROPOMETRIA: http://msis.jsc.nasa.gov/sections/ section03.htm WEB PRESSUPOSTS: http://www.custompartnet.com WEB IMATGES: http://www.airliners.net WEB LLISTAT A320: http://en.wikipedia.org/wiki/List_of_Air

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Final Project on Industrial Design Engineering THYTREE | Antoni Pèrez, Martí Solà | June 2014