Composite beam for aircraft seat frame

An aircraft seat, the aircraft seat comprising:

• a seatback;
• a seat pan;
• and
• a base assembly couplable to a floor of an aircraft cabin via one or more floor fittings, the base assembly comprising:
• one or more composite support beams, wherein the one or more composite support beams are hollow, wherein each of the hollow composite support beam comprises:
• an external fiber-reinforced polymer-matrix shell, wherein one or more walls of the external fiber-reinforced polymer-matrix shell define an internal cavity;
• one or more pultruded fiber-reinforced polymer-matrix composite parts, wherein the one or more pultruded fiber-reinforced polymer-matrix composite parts are arranged within the internal cavity defined by the one or more walls of the external fiber-reinforced polymer-matrix shell, wherein the one or more pultruded fiber-reinforced polymer-matrix composite parts are formed by a plurality of unidirectionally reinforced composites, wherein a fiber orientation of the one or more pultruded fiber-reinforced polymer-matrix composite parts positioned in an axial direction of a respective hollow composite support beam;
• and
• an internal fiber-reinforced polymer-matrix shell, wherein the one or more pultruded fiber-reinforced polymer-matrix composite parts are arranged between the one or more walls of the external fiber-reinforced polymer-matrix shell and one or more walls of the internal fiber-reinforced polymer-matrix shell, wherein the internal fiber-reinforced polymer-matrix shell is arranged within an internal cavity defined by one or more surfaces of the one or more pultruded fiber-reinforced polymer-matrix composite parts;
• one or more spreaders configured to receive the one or more composite beams;
• and
• one or more leg assemblies, wherein the one or more leg assemblies are configured to be coupled to the one or more composite beams.

A method of manufacturing a hollow composite support beam comprising:

• fabricating an internal fiber-reinforced polymer-matrix shell;
• fabricating one or more pultruded fiber-reinforced polymer-matrix composite parts, wherein the one or more pultruded fiber-reinforced polymer-matrix composite parts are formed by a plurality of unidirectionally reinforced composites, wherein a fiber orientation of the one or more pultruded fiber-reinforced polymer-matrix composite parts in an axial direction of a respective hollow composite support beam;
• assembling the fabricated internal fiber-reinforced polymer-matrix shell and the fabricated one or more pultruded fiber-reinforced polymer-matrix composite parts to form a first assembled part of the hollow composite support beam;
• fabricating an external fiber-reinforced polymer-matrix shell;
• and
• fabricating the hollow composite support beam by applying the external fiber-reinforced polymer-matrix on a top surface of the first assembled part.