Patent ID: 7716797

Claim:
A method of manufacturing a composite seat pan for a lightweight aircraft passenger seat, the method comprising: forming a fore cross beam from a first composite extrusion using a continuous compression molding process; forming an aft cross beam from a second composite extrusion using the continuous compression molding process; structurally joining the fore cross beam to the aft cross beam with a plurality of spreader bars; and structurally coupling a composite skin to the fore cross beam, the aft cross beam, and the spreader bars; wherein forming the fore cross beam comprises forming, in a first layup, the first composite extrusion from material having directional fibers, where at least thirty percent of the fibers in the first composite extrusion are oriented within the range of ±30 degrees relative to the major longitudinal axis of the first composite extrusion; and wherein forming the aft cross beam comprises forming, in a second layup, the second composite extrusion from material having directional fibers, where at least thirty percent of the fibers in the second composite extrusion are oriented within the range of ±30 degrees relative to the major longitudinal axis of the second composite extrusion.