Patent Publication Number: US-10329020-B2

Title: Integrated deployable leg rest for reclining passenger seats

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is the U.S. national phase entry of International Patent Application Serial No. PCT/US2015/024123 (“the &#39;123 application”), filed on Apr. 2, 2015, which application is related to and claims priority benefits from U.S. Provisional Application Ser. No. 61/974,492 (“the &#39;492 application”), filed on Apr. 3, 2014, entitled “Deployable Legrest that Moves with the Seat Pan”. The &#39;123 and &#39;492 applications are hereby incorporated in their entireties by this reference. 
    
    
     FIELD OF THE INVENTION 
     The field of the invention relates to passenger seats or the like, and more particularly to deployable leg rests for use with passenger seats. 
     BACKGROUND 
     Many passenger seats such as those on passenger aircraft, busses, trains, and the like are designed with a recline function to allow for greater comfort to passengers, particularly on longer journeys. To increase passenger comfort, seats may be designed with complex articulations, including different motions for the seat back and seat bottom or pan. 
     In some instances, a passenger seat may include a leg rest to support the passenger&#39;s calves, feet, or thighs when they are in a reclined position. These leg rests are typically mounted to a solid part of the passenger seat structure. For example, a leg rest may be mounted directly to a stationary part of the seat frame or to a seat tube. It is desirable to include a leg rest on a reclining seat to increase passenger comfort. The conventional method of mounting a leg rest to a reclining passenger seat has a number of disadvantages. The addition of a leg rest mounted to the seat tube or other stationary part of the passenger seat adds additional mounting hardware and linkages that may encroach on the mounting hardware and linkages for the seat back and seat bottom. Additional hardware may also be necessary to coordinate the motion of the seat back, seat bottom, and leg rest during seat recline. 
     Because of the additional hardware, the addition of more moving parts to a reclining seat, like a leg rest, often times leads to compromises in the range and type of motion available to each individual seat component. Not only do the additional mechanical parts restrict motion, but allowances for complementary ranges of motion for different portions of the passenger seat further diminishes available motion to avoid impingement of the portions of the passenger seat on one another. 
     In certain cases, it may be desirable to provide a passenger seat with a deployable leg rest that is coupled directly to the seat bottom. This arrangement may allow the leg rest to move and articulate with the seat and pivot and/or extend away from the seat bottom during deployment. The resulting mechanism, including an actuator to initiate and deploy the leg rest, is often simpler, lighter, and more compact than existing leg rest mechanisms. Such an integrated leg rest may allow for a greater range of movement for the seat back and seat bottom by reducing the amount of hardware contained under and within the seat and moving with the seat bottom to avoid interference with other reclining mechanisms and hardware. 
     SUMMARY 
     The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim. 
     According to certain embodiments of the present invention, a passenger seat may comprise a deployable leg rest coupled to a seat bottom and an actuator coupled to the deployable leg rest and the seat bottom. The actuator may induce deployment of the deployable leg rest. 
     In some embodiments, the seat bottom is moveable during the reclining of the passenger seat. 
     In some embodiments, the actuator may comprise a gas-charged cylinder. 
     In certain embodiments, the actuator may comprise a spring. 
     In some embodiments, the spring may comprise a coil spring. 
     In certain embodiments, the spring may comprise a torsion spring. 
     In some embodiments, the actuator may comprise a spring in combination with a gas-charged cylinder. 
     In some embodiments, the passenger seat further comprises a control button to initiate deployment of the deployable leg rest. 
     In certain embodiments, the passenger seat further comprises a locking mechanism to maintain the position of the deployable leg rest in a deployed position, a stowed position, or any intermediate position. 
     In some embodiments, the locking mechanism may comprise a ratchet. 
     In certain embodiments, the locking mechanism may comprise a clutch. 
     In some embodiments, the clutch may comprise a force-limiting clutch. 
     In some embodiments, the clutch may comprise a one-way clutch. 
     In certain embodiments, the actuator may comprise an electrically powered actuator. 
     In some embodiments, the electrically powered actuator may comprise an electric motor and gearing system to provide a torque to the deployable leg rest. 
     In certain embodiments, the electrically powered actuator may comprise an electric motor and lead screw. 
     In certain embodiments, the actuator may provide a deploying force to deploy the deployable leg rest. 
     In some embodiments, the actuator may provide a retracting force to retract the deployable leg rest. 
     In some embodiments, the deployable leg rest may rotate and extend between a stowed position and a deployed position. 
     According to certain embodiments of the present invention, a passenger seat may comprise a deployable leg rest coupled to a seat bottom, a gas-charged cylinder providing a motive force, a locking mechanism, and a control button in communication with the locking mechanism. The gas-charged cylinder may be coupled to the deployable leg rest and the seat bottom and the locking mechanism may lock the deployable leg rest in a stowed position. The control button may release the locking mechanism and allow the motive force of the gas-charged cylinder to deploy the deployable leg rest. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevation view of an integrated deployable leg rest in a stowed position, according to certain embodiments of the present invention. 
         FIG. 2  is a side elevation view of an integrated deployable leg rest in a deployed position, according to certain embodiments of the present invention. 
         FIG. 3  is a perspective view of an integrated deployable leg rest in a deployed position, according to certain embodiments of the present invention. 
         FIG. 4  is a perspective view of an integrated deployable leg rest shown in relation to a passenger seat in a deployed position, according to certain embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. 
     The described embodiments of the invention provide a deployable leg rest for reclining passenger seats. While the leg rests are discussed for use with aircraft seats, they are by no means so limited. Rather, embodiments of the leg rest may be used in passenger seats or other seats of any type or otherwise as desired. 
     In some embodiments of the present invention, as shown in  FIGS. 1 and 2 , a passenger seat bottom with an integrated deployable leg rest  1  comprises a deployable leg rest  10  coupled to a seat bottom  30  through a leg rest hinge  15 . In  FIG. 1 , the deployable leg rest  10  is shown in a stowed position.  FIG. 2  shows the deployable leg rest  10  in a deployed position. The leg rest hinge  15  is comprised of a leg rest bracket  11  and a seat bottom bracket  31  coupled to one another by a pin, bolt, screw, rivet, or other suitable component to serve as the axle or pivot of the leg rest hinge  15 . The deployable leg rest  10  may then pivot around the leg rest hinge  15 . 
     Still referring to  FIGS. 1 and 2 , an actuator  20  is mounted between the seat bottom  30  and the deployable leg rest  10 . In certain embodiments, the actuator  20  may be coupled at one end to the seat bottom  30 , which may be stationary or moveable as the passenger seat reclines, through a rear actuator bracket  24 . The rear actuator bracket  24  connects to the actuator  20  at a rear actuator pivot  25 . As the actuator  20  moves through its range of motion, it may pivot around the rear actuator pivot  25  and the rear actuator bracket  24 . Similarly, the actuator  20  is coupled to the deployable leg rest  10  through a front actuator bracket (not shown) that provides a front actuator pivot  23 . As the actuator  20 , here shown as a gas-charged cylinder, expands and contracts through its range of motion, it will pivot around the front actuator pivot  23  and rear actuator pivot  25 . In certain embodiments, the actuator  20  may also include an actuator release  21 . The actuator release  21  may be manipulated by a wire, lever, or other mechanism (not shown) to allow the actuator  20  to move through its range of motion. When the actuator release  21  is not engaged, the actuator  20  may provide a self-locking function to hold the deployable leg rest  10  steady at any point between a deployed position and a stowed position. 
       FIG. 3  is a bottom perspective view of an embodiment of the integrated deployable leg rest  1 . In certain embodiments, the deployable leg rest  10  is coupled to the seat bottom  30  through a pair of leg rest hinges  15 . The leg rest hinges  15  may be composed of a leg rest bracket  11  pivotally coupled to a seat bottom bracket  31  with a pin, rivet, bolt, screw, or other suitable component to serve as the axle or pivot point of the leg rest hinges  15 . The integrated deployable leg rest  1  also includes an actuator  20  coupled to both the deployable leg rest  10  and the seat bottom  30 . The actuator  20  is disposed between the deployable leg rest  10  and the seat bottom  30  so that as the actuator  20  moves through its range of motion, the deployable leg rest  10  will move between a stowed position and a deployed position. The actuator  20  is coupled to the deployable leg rest  10  with a front actuator bracket  22 . The front actuator bracket  22  is coupled to the deployable leg rest  10  and the actuator  20  such that the actuator  20  may pivot around the front actuator pivot  23 . The pivoting movement of the actuator  20  around the front actuator pivot  23  allows the actuator  20  to move the deployable leg rest  10  freely through its range of motion without binding. Similarly, the actuator  20  is coupled to the seat bottom  30  through a rear actuator bracket  24  that provides a rear actuator pivot  25 . If the actuator  20  is a linear actuator as shown in  FIG. 3  (here, a gas-charged cylinder), the use of a front actuator pivot  23  and a rear actuator pivot  25  allows the actuator  20  to move through its range of motion without having to support any twisting or moment loads about the front actuator bracket  22  or rear actuator bracket  24 . The actuator  20  will only support a linear force as it moves the deployable leg rest  10 , as it will pivot about the front actuator pivot  23  and rear actuator pivot  25 . This type of motion, where the actuator  20  need not support any twisting or moment forces, allows for the use of a smaller, lighter actuator  20 . Furthermore, in the case of a gas-charged cylinder serving as the actuator  20 , the lack of twisting or moment forces about the front actuator pivot  23  and rear actuator pivot  25  will reduce strain on the cylinder seals, helping to prevent leakage and allow for a longer service life with reduced maintenance costs. The actuator  20  also may include an actuator release  21 . The actuator release  21 , which may be activated by a cable, lever, or other means of articulation, can be controlled through a button or lever mounted on the console or armrest of the passenger chair (not shown). The passenger may then use the button or lever to activate the actuator release  21  to allow the deployable leg rest  10  to move between the stowed and deployed positions. 
       FIG. 4  is a perspective view of an embodiment of the integrated deployable leg rest  1  shown in relation to a passenger seat. The deployable leg rest  10 , shown here in a deployed position, is coupled to a seat bottom  30 . The seat back  40 , seat console  41 , and seat tubes  42  are also shown for context. The deployable leg rest  10  is coupled to the seat bottom  30  through leg rest hinges  15 , which are comprised of leg rest brackets  11  and seat bottom brackets  31  (not shown,  FIG. 3 ). The deployable leg rest  10  may pivot around the leg rest hinges  15  to move between a stowed and deployed position. 
     Still referring to  FIG. 4 , the integrated deployable leg rest  1  also includes an actuator  20  which is coupled to the deployable leg rest  10  with a front actuator bracket  22 . The front actuator bracket  22  provides a front actuator pivot  23  that allows the actuator  20  to rotate around the front actuator pivot  23  as it moves the deployable leg rest  10  between stowed and deployed positions. Similarly, the actuator  20  may be coupled to the seat bottom  30  through a rear actuator bracket  24  that provides a rear actuator pivot  25 . The actuator  20  may also have an actuator release  21 . The actuator  20  may have an internal locking mechanism that prevents the actuator  20 , and subsequently the deployable leg rest  10 , from moving when the actuator release  21  is not engaged. The actuator release  21  may be controlled by a cable, lever, or other suitable mechanism that may be connected to a control button or lever mounted on the passenger seat console or arm rest. A passenger may then use the control button or lever to activate the actuator release  21  to allow the movement of the actuator  20  and deployable leg rest  10 . 
       FIGS. 1-4  illustrate the integrated deployable leg rest  1  according to certain embodiments of the present invention. However, a number of alterations, modifications, or adaptations may be made to suit particular applications or design requirements. For example, in  FIGS. 1-4  above, the actuator  20  is generally shown as a gas-charged cylinder. In certain embodiments, the gas-charged cylinder would exert a linear force through expansion to move the deployable leg rest  10  from a stowed position to a deployed position. Normally, the actuator release  21  may serve a locking function to hold the actuator  20 , such as a gas-charged cylinder, in place. A passenger may then engage the actuator release  21  to allow movement of the actuator  20  and the deployable leg rest  10 . The passenger can then control the movement of the deployable leg rest  10  by either allowing the deployable leg rest  10  to be extended into a deployed position by the actuator  20 , or by pressing down on the deployable leg rest  10  to overcome the force of the actuator  20  and return the deployable leg rest  10  to a stowed position. The passenger may then disengage the actuator release  21  to lock the deployable leg rest  10  in the desired position. 
     In certain embodiments, the actuator  20  may take on any number of different mechanisms or configurations. For example, the actuator  20  may be a spring mechanism. The actuator  20  may comprise a linear spring, such as a coil spring, that is mounted or attached to the deployable leg rest  10  and seat bottom  30  in a similar manner as that shown in  FIGS. 1-4 . In other embodiments, the actuator  20  may comprise a torsion spring that provides a torque to rotate the deployable leg rest  10  about the leg rest hinge  15 . In certain embodiments, a torsion spring actuator may be mounted directly to one or more leg rest hinges  15 , or another point of rotation, to provide the force to deploy or stow the deployable leg rest  10 . In other embodiments, the actuator  20  may comprise a gas-charged cylinder and a spring, either linear or torsion, working in combination to provide the motive force to deploy or stow the deployable leg rest  10 . 
     In some embodiments, the actuator  20  may comprise an electrically powered actuator. Electric actuators may either provide a rotational or linear force to the deployable leg rest  10 . In certain embodiments, the electric actuator may comprise an electric motor coupled to the leg rest hinge  15  either directly or through a gearing system. In other embodiments, the actuator  20  may be an electrically powered linear actuator. For example, an electric motor may be coupled to a lead screw or lead screw collar. An electric motor may then rotate either the lead screw or the lead screw collar to cause an extension or retraction of the lead screw. The extension or retraction of the lead screw may provide a linear motion that deploys or stows the deployable leg rest  10 . Electrically powered actuators may offer a number of advantages over other mechanical actuator systems. In some embodiments, the electrically powered actuators may not require the use of a locking mechanism or actuator release  21  because the electric motor or gearing system provides a locking function without the use of an extra component. Also, in certain embodiments, the electrically powered actuator may provide both deploying and stowing forces to move the deployable leg rest  10  in both directions without the need for a passenger to exert any pressure on the deployable leg rest  10  or overcome the force of a purely mechanical actuator  20 . 
     In certain embodiments, the integrated deployable leg rest  1  may include a number of different locking and release mechanisms to selectively hold or allow for the movement of the deployable leg rest  10 . As shown in  FIGS. 1-4 , a gas-charged cylinder may have an integrated locking function that is released with an actuator release  21 . In some embodiments, regardless of the type of actuator  20  used, a separate locking mechanism may be used to stabilize the deployable leg rest  10 . In some embodiments, a ratcheting mechanism may be used to prevent the deployable leg rest  10  from moving in one direction while allowing it to move freely in another direction. The locking mechanism, or ratchet, may be connected to a control button allowing the passenger to release the locking mechanism or ratchet so that the deployable leg rest  10  may move in either direction. For example, a ratcheting mechanism may be used to oppose the deployment force of an actuator  20 . A passenger may press a control button mounted on the arm rest or seat console to release the ratcheting mechanism allowing the actuator  20  to deploy the deployable leg rest  10 . When the deployable leg rest  10  is at a desired height, the passenger may release the control button engaging the ratchet or locking mechanism to prevent further deployment of the deployable leg rest  10 . In this intermediate or deployed position, the ratchet will prevent further deployment of the deployable leg rest  10 , and the actuator  20  will prevent retraction of the deployable leg rest  10  providing a stable platform for the passenger. In certain embodiments, the force of the actuator  20  may be enough to stabilize the deployable leg rest  10  and support the weight of the passenger&#39;s lower legs, but is still low enough that the passenger may press down on the deployable leg rest  10  to return it to a stowed position. The passenger would not need to use the control button to stow the deployable leg rest  10  because the ratchet or locking mechanism would not oppose movement in that direction. 
     Additional locking mechanisms may be useful or preferable in other embodiments of the present invention. For example, a one-way clutch may be used in a similar manner as the ratchet locking mechanism described above. In some embodiments, a force-limiting clutch may provide certain advantages and additional functionality. Force-limiting clutches provide a certain degree of locking force that, once exceeded, will release the clutch or allow for slippage between clutch elements. A force-limiting clutch may be used to stabilize the deployable leg rest  10  up to a certain amount of force or pressure, but break away and allow movement if that amount of force or pressure is exceeded. In the case of a deployable leg rest  10 , a force-limiting clutch may be used to lock the deployable leg rest  10  into a desired position under normal circumstances and use. However, if the amount of locking force provided by the force-limiting clutch is exceeded, like when a passenger may attempt to stand on the deployable leg rest  10 , the force-limiting clutch will slip or release and allow the deployable leg rest  10  to move and prevent damage to the deployable leg rest  10 , actuator  20 , or other parts of the passenger seat. 
     In certain embodiments, the motion of the deployable leg rest  10  may not be exclusively rotational about an axis. The deployable leg rest  10  may rotate, translate, or both rotate and translate through a range of motion between a stowed and deployed position. In some embodiments, the connection between the deployable leg rest  10  and the seat bottom  30  may include a rotating element, such as a hinge, and a translating element like a carriage and track. 
     Any of the above described components, parts, or embodiments may take on a range of shapes, sizes, or materials as necessary for a particular application of the described invention. The components, parts, or mechanisms of the described invention may be made of any materials selected for the suitability in use, cost, or ease of manufacturing. Materials including, but not limited to aluminum, stainless steel, fiber reinforced plastics, composites, polycarbonate, polypropylene, other metallic materials, or other polymers may be used to form any of the above described components. 
     Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.