Patent Description:
A headrest assembly is provided as claimed in claim <NUM>. The assembly includes a headrest support plate. The assembly includes a headrest slide sub-assembly configured to couple to one or more portions of the headrest support plate, the headrest slide sub-assembly configured to translate the headrest support plate between at least a first headrest position and a second headrest position. The assembly includes a base configured to couple the headrest assembly to a portion of a seatback of a seat, the base including a cavity defined by one or more walls of the base. The assembly includes a headrest removal sub-assembly. The headrest removal sub-assembly includes a plunger including a plunger shaft, the plunger shaft including a first end and a second end, the plunger including a lever portion positioned between the first end and the second end, the cavity configured to house at least a portion of the plunger shaft. The headrest removal sub-assembly includes a compressible spring coupled to the second end of the plunger and configured to surround at least a portion of the plunger shaft, the cavity configured to house at least a portion of the compressible spring. The headrest removal sub-assembly includes a stopper configured to couple to the first end of the plunger, the stopper configured to engage with a cavity within the headrest support plate. The plunger configured to translate the stopper between at least a first stopper position and a second stopper position when a force is applied to the lever portion of the plunger to cause the plunger to compress a portion of the compressible spring within the cavity of the base to cause the stopper to disengage from the cavity within the headrest support plate to cause the headrest removal sub-assembly to disengage from the headrest support plate.

In some embodiments, the headrest removal sub-assembly may further include a bearing positioned proximate to the first end of the plunger, at least a portion of the plunger shaft configured to translate within an opening in the bearing.

In some embodiments, the first stopper position of the stopper may include an engaged position and the second stopper position of the stopper may include a disengaged position.

In some embodiments, the assembly may further include a headrest cushion configured to at least substantially conform to the headrest support plate, the headrest cushion configured to attach to at least a portion of the headrest support plate and a headrest dress cover configured to fit over at least a portion of the headrest cushion.

In some embodiments, the first headrest position of the headrest support plate may include a stowed position.

In some embodiments, the second headrest position of the headrest support plate may include a deployed position.

In some embodiments, the headrest slide sub-assembly may include a rail and carriage sub-assembly.

In some embodiments, the rail and carriage sub-assembly may include one or more linear rails configured to couple to one or more portions of the headrest support plate and a carriage slider configured to be axially displaceable within a channel of the one or more linear rails.

In some embodiments, the base may further include a u-shaped slot positioned proximate to the cavity of the base, the u-shaped slot configured to at least partially surround a portion of the lever portion of the plunger.

A headrest removal assembly is provided as claimed in claim <NUM>. The assembly includes a plunger including a plunger shaft, the plunger shaft including a first end and a second end, the plunger including a lever portion positioned between the first end and the second end, the cavity configured to house at least a portion of the plunger shaft. The assembly includes a compressible spring coupled to the second end of the plunger and configured to surround at least a portion of the plunger shaft, a cavity within a base configured to house at least a portion of the compressible spring. The assembly includes a stopper configured to couple to the first end of the plunger, the stopper configured to engage with a cavity within a headrest support plate. The plunger configured to translate the stopper between at least a first stopper position and a second stopper position when a force is applied to the lever portion of the plunger to cause the plunger to compress a portion of the compressible spring within the cavity of the base to cause the stopper to disengage from the cavity within the headrest support plate to cause the headrest removal sub-assembly to disengage from the headrest support plate.

In some embodiments, the headrest support plate may be coupled to a portion of a headrest slide sub-assembly, the headrest slide sub-assembly configured to translate the headrest support plate between at least a first headrest position and a second headrest position.

In some embodiments, the cavity within the base may be defined by one or more walls of the base, the base configured to couple the headrest support plate to a portion of a seatback of a seat.

Before explaining one or more embodiments of the invention in detail, it is to be understood the embodiments are not limited in their application to the details of construction and the arrangement of the components or steps or methodologies set forth in the following description or illustrated in the drawings. In the following detailed description of embodiments, numerous specific details may be set forth in order to provide a more thorough understanding of the invention.

Such shorthand notations are used for purposes of convenience only and should not be construed to limit the invention in any way unless expressly stated to the contrary.

The appearances of the phrase "in some embodiments" in various places in the specification are not necessarily all referring to the same embodiment, and embodiments may include one or more of the features expressly described or inherently present herein, or any combination of or sub-combination of two or more such features, along with any other features which may not necessarily be expressly described or inherently present in the instant invention.

<FIG> in general illustrate a quick release headrest removal assembly for an aircraft seat, in accordance with one or more embodiments of the invention.

Seats may include headrest assemblies including one or more headrest components. The headrest assembly and/or one or more components of the headrest assembly may be subject to increased wear (e.g., stress, strain, for dirt or other mess such as airsickness, contraband, or the like resulting in damage of headrest assembly).

After a period of time and/or a particular type of wear factor occurring, headrest assembly and/or one or more components of the headrest assembly may need to be accessed and/or remove after the headrest assembly is installed for maintenance, cleaning, and/or replacement. For example, a headrest slide mechanism of the headrest assembly may need to be accessed after the headrest assembly has been installed to perform routine maintenance on the headrest slide mechanism or to repair one or more components of the headrest slide mechanism in the event one or more components are inoperable (or become damaged). By way of another example, the headrest dress cover and/or cushion may need to be accessed to perform routine maintenance (such as routine cleaning services) on such components. Removing and re-installing the headrest assembly (and/or one or more components of the assembly) may require a method that is quick, inexpensive, and low-labor. For example, the assembly should be quickly dismantled and put together without incurring considerable labor costs or without requiring tools.

In addition, in select industries the build of the seat (and any included components within the build) may be required to meet guidelines and/or standards. For example, aircraft seats may be required to meet aviation guidelines and/or standards. For instance, the select aircraft seats may need to be configured in accordance with aviation guidelines and/or standards put forth by, but not limited to, the Federal Aviation Administration (FAA), the European Aviation Safety Agency (EASA) or any other flight certification agency or organization; the American National Standards Institute (ANSI), Aeronautical Radio, Incorporated (ARINC), or any other standards setting organization or company; the Radio Technical Commission for Aeronautics (RTCA) or any other guidelines agency or organization; or the like.

As such, it would be desirable to provide a quick release headrest assembly. The quick release headrest assembly should allow for enhanced access to a headrest slide mechanism and maintenance thereof. The quick release headrest assembly should allow for maintenance of the headrest dress cover and/or headrest cushion. The quick release headrest assembly should allow the headrest to be quickly removed without tools to reduce associated maintenance times. The quick release headrest assembly should be configured in accordance with aviation guidelines and/or standards.

Referring in general to <FIG>, a quick release headrest assembly may be integrated within an aircraft seat <NUM> installed within an aircraft cabin. For example, the aircraft seat <NUM> may include, but is not limited to, a business class or first-class passenger seat, an economy-class passenger seat, a crew member seat, or the like. It is noted the terms "aircraft seats" and "passenger seats" may be considered equivalent, for purposes of the invention.

The aircraft seat <NUM> may be rotatable about an axis (e.g., swivelable). The aircraft seat <NUM> may be fully positionable between the outer limits of motion as defined by the moveable components of the aircraft seat <NUM>. Where the aircraft seat <NUM> is installed within a passenger compartment, the aircraft seat <NUM> may be fully positionable between the outer limits of motion as defined by one or more passenger compartment monuments of the passenger compartment. It is noted an upright or raised position may be considered a taxi, takeoff, or landing (TTL) position during select stages of flight (though the upright or raised position is not limited to use during the select stages of flight as the TTL position, but also may be used at any point during the flight), for purposes of the present invention. In addition, it is noted that any position that does not meet the above-defined requirements of the TTL position may be considered a non-TTL position, for purposes of the present invention. Further, it is noted the aircraft seat <NUM> may be actuatable (e.g., translatable and/or rotatable) from the TTL position to a non-TTL position, and/or vice versa. Further, it is noted the aircraft seat <NUM> may be capable of a fully upright or raised position, and that the TTL position may have a more reclined seatback cushion and a more angled upward seat pan cushion as compared to the fully upright or raised position. Therefore, the above description should not be interpreted as a limitation on the present invention but merely an illustration.

In general, an aircraft seat <NUM> may be translatable (e.g., trackable or slidable). The aircraft seat <NUM> may be rotatable about an axis cross-wise through the aircraft seat <NUM> into a position including, but not limited to, the upright or raised position, one or more lounge or reclined positions, and a lie-flat or bed position. For example, the aircraft seat <NUM> may transition directly between the upright or raised position and the lie-flat or bed position. By way of another example, it is noted the aircraft seat <NUM> may transition through one or more lounge or reclined positions between the upright or raised position and the lie-flat or bed position. By way of another example, the aircraft seat <NUM> may transition into one or more lounge or reclined positions in a motion separate from the transition between the upright or raised position and the lie-flat or bed position. Therefore, the above description should not be interpreted as a limitation on the scope of the invention but merely an illustration.

The aircraft seat <NUM> may include a seatback <NUM>, a seat pan <NUM>, and one or more arms <NUM>. The aircraft seat <NUM> may be coupled to a base <NUM> couplable to a floor of an aircraft cabin.

Referring generally to <FIG>, the seatback <NUM> may include a headrest assembly <NUM>. For example, the headrest assembly <NUM> may be a separate component coupled to (or inserted into) the seatback <NUM>. For instance, the headrest assembly <NUM> may be movable relative to the seatback frame of the aircraft seat <NUM> (e.g., adjustable, removable, or the like).

<FIG> illustrate the headrest assembly <NUM>, in accordance with one or more embodiments of the invention. In particular, <FIG> depicts an exploded view of the headrest assembly <NUM>, in accordance with one or more embodiments of the invention. In particular, <FIG> depicts a rear perspective view of the headrest assembly, in accordance with one or more embodiments of the invention. In particular, <FIG> depicts a top view of the headrest assembly, in accordance with one or more embodiments of the invention. In particular, <FIG> depict cross-sectional views of the headrest assembly, in accordance with one or more embodiments of the invention. In particular, <FIG> depicts a detailed cross-sectional view of the headrest assembly, in accordance with one or more embodiments of the invention. In particular, <FIG> depict detailed views of the headrest assembly, in accordance with one or more embodiments of the invention.

Referring to <FIG>, the headrest assembly <NUM> may include a headrest dress cover <NUM>. The headrest assembly <NUM> may include a headrest cushion <NUM> configured to conform or substantially conform to a headrest support plate <NUM>. The dress cover <NUM> may be configured to fit over at least a portion of the cushion <NUM>. For example, the dress cover <NUM> may be configured to wrap around or otherwise enclose exterior surfaces of the cushion <NUM>. The headrest cover <NUM> may be configured to attach to the support plate <NUM> and/or the cushion <NUM>. Although <FIG> depicts the dress cover <NUM> and the cushion <NUM> as separate components, it is noted that the dress cover <NUM> and the cushion <NUM> may be integrated to form a single component.

The headrest assembly <NUM> may include a headrest slide sub-assembly <NUM> couplable to one or more portions of the headrest support plate <NUM>. The headrest slide sub-assembly <NUM> may be configured to transition the support plate <NUM> (including the cushion and/or dress cover) between one or more positions. For example, the headrest slide sub-assembly <NUM> may be configured to linearly slide the support plate <NUM> relative to the seatback <NUM> of the aircraft seat <NUM> to transition the headrest assembly <NUM> between the one or more positions. In one instance, as shown in <FIG>, the headrest assembly <NUM> may be in a stowed position during TTL phases of flight. In another instance, as shown in <FIG>, the headrest assembly <NUM> may be in a deployed position during non-TTL phases of flight. It is noted the headrest assembly <NUM> may also be configured for one or more intermediate positions. For example, the headrest assembly <NUM> may be in a particular intermediate position during transition between the stowed position and the deployed position.

The headrest slide sub-assembly <NUM> may include a rail and carriage sub-assembly including one or more linear rails <NUM> and a carriage slider <NUM>. The rail and carriage sub-assembly may be couplable to one or more portions of the support plate <NUM>. For example, a first rail <NUM> may be couplable to a first portion of the support plate <NUM> and an additional rail <NUM> may be couplable to an additional portion of the support plate. For instance, a first portion of the carriage slider <NUM> may be couplable to the first rail <NUM> and an additional portion of the carriage may be couplable to the additional rail <NUM>.

The one or more linear rails <NUM> may include one or more surfaces that form a channel. For example, the channel may be configured to receive a portion of the carriage slider <NUM>. The carriage slider <NUM> may be configured to be axially displaceable with the channel of the one or more linear rails <NUM>. For example, the carriage slider <NUM> may be axially displaceable within the first rail <NUM> and the additional rail <NUM> when the carriage slider <NUM> is coupled to the one or more linear rails <NUM>.

The headrest assembly <NUM> may include a quick release headrest removal sub-assembly <NUM>. It is noted that the terms "quick release headrest removal sub-assembly", "headrest removal sub-assembly", "sub-assembly", and variants thereof may be considered equivalent unless otherwise noted herein. The quick release headrest removal sub-assembly <NUM> may include, but is not limited to, a retractable plunger <NUM>, a compressible spring <NUM>, a stopper <NUM>, and a bearing <NUM>.

The headrest assembly <NUM> may include a base <NUM> couplable to a portion of the seatback <NUM>. The base <NUM> may include a cavity <NUM> (e.g., bore housing) defined by one or more walls of the base <NUM>. The cavity <NUM> may be configured to house one or more components of the quick release headrest removal sub-assembly <NUM>. For example, the cavity <NUM> may be configured to house at least a portion of the plunger <NUM> and the compressible spring <NUM>. For instance, the cavity <NUM> may be configured to house a distal end of the plunger <NUM> including the compressible spring <NUM>.

The base <NUM> may include a slot <NUM> configured to at least partially surround a lever portion <NUM> (or tab portion <NUM>) of the plunger <NUM>, as discussed further herein. It is noted that the slot <NUM> may be shaped to complement the shape of lever <NUM>. For example, the slot <NUM> may include a U-shaped slot <NUM> to complement the shape of the lever <NUM> of the plunger <NUM>, such that the U-shaped slot <NUM> may prevent the lever <NUM> and/or the plunger <NUM> from rotating within the cavity <NUM>, such that a user may translate the plunger <NUM> within the cavity <NUM>.

The plunger <NUM> may be configured to couple to the stopper <NUM> via one or more fasteners <NUM>. For example, a proximal end of the plunger <NUM> may be configured to couple to the stopper <NUM>. The stopper <NUM> may be configured to stop travel and prevent the support plate <NUM> from detaching from the slide sub-assembly <NUM>. For example, the stopper <NUM> may be configured to translate within a cavity <NUM> within the support plate <NUM>.

The retractable plunger <NUM> may include a lever portion <NUM> (or tab portion <NUM>) configured to translate the retractable plunger <NUM> in a horizontal direction within the cavity <NUM> upon an application of force. For example, upon an application of force, the retractable plunger <NUM> may be configured to translate the stopper <NUM> in a horizontal direction to disengage the stopper <NUM> from the support plate <NUM>, such that the support plate <NUM> (including the cushion and/or dress cover) may be removed. In this regard, when the support plate <NUM> (including the cushion and/or dress cover) is disengaged, one or more components of the headrest assembly <NUM> may be cleaned/serviced. In one instance, the headrest dress cover <NUM> and/or headrest cushion <NUM> may be laundered once the support plate <NUM> is removed. It is noted that removal of the support plate <NUM> may be quick, inexpensive, low-labor and tool-less, such that associated maintenance times may be reduced.

Further, once the support plate <NUM> has been removed, as previously discussed herein, one or more components of the slide sub-assembly <NUM> may be serviceable. For example, the one or more linear rails <NUM> may be serviced once the support plate <NUM> has been removed. By way of another example, the carriage slider <NUM> may be serviced once the support plate <NUM> has been removed.

The bearing <NUM> may be configured to allow the plunger <NUM> to move freely within the assembly <NUM>. For example, the bearing <NUM> may be couplable to a portion of the base <NUM> and positioned adjacent to the shaft of the plunger <NUM>. Further, the bearing <NUM> may be configured to provide support for the plunger <NUM> when the plunger <NUM> is translating the horizontal direction. For example, the bearing <NUM> may be formed of a durable lubricated material (e.g., plastic, or the like) to allow the plunger to move freely and provide support during translation. It is noted that the bearing <NUM> may include any type of bearing including, but not limited to, a sleeve bearing.

Referring to <FIG>, the slide sub-assembly <NUM> may be un-coupled from the base <NUM>, and thereafter the bearing <NUM> may be un-coupled from the base <NUM>, such that one or more components of the removal sub-assembly <NUM> or the base <NUM> may be serviced. For example, the slide sub-assembly <NUM> may be un-coupled from the base <NUM> by removing one or more fasteners and thereafter the bearing <NUM> may be un-coupled from the base <NUM> by removing one or more fasteners coupled to the base <NUM>, such that the base <NUM>, the plunger <NUM> and compressible spring <NUM> positioned within the cavity <NUM> may be easily accessed. In this regard, the bearing <NUM> may be un-coupled from the base <NUM> to service (e.g., replace, repair, clean, or the like) the compressible spring <NUM>. Further, the bearing <NUM> may be un-coupled from the base <NUM> to service the bearing <NUM> (e.g., replace, repair, clean, or the like). As such, the one or more components of removal sub-assembly <NUM> may be serviceable components, such that the removal sub-assembly <NUM> may be a serviceable unit (e.g., the whole sub-assembly <NUM> does not need to be replaced).

Disassembling the headrest assembly <NUM> may include one or more of the following steps of the method or process <NUM>:.

In a step <NUM>, a force may be applied to disengage the stopper <NUM> from the support plate <NUM>. For example, the force may be applied through an application of force on the plunger <NUM> in a specific direction, the specific direction not being one accomplished when sitting in the aircraft seat <NUM>. For instance, the direction may be along the x-axis (e.g., horizontal axis) to cause the stopper <NUM> to move in the horizontal direction, which then causes the stopper <NUM> to disengage from the support plate <NUM>. In this regard, the force may cause the compressible spring <NUM> surrounding a distal end of the plunger <NUM> to compress within the cavity <NUM> to cause the stopper <NUM> to translate and disengage from the support plate <NUM>.

In a step <NUM>, the support plate <NUM> may be removed from the slide sub-assembly <NUM>. For example, on the stopper <NUM> has been disengaged from the support plate <NUM>, the support plate <NUM> may be removed from the slide sub-assembly <NUM>.

Once the support plate <NUM> has been removed from the slide sub-assembly, one or more components of the headrest assembly <NUM> may be serviced or maintained. For example, the headrest dress cover <NUM> and/or headrest cushion <NUM> may be laundered once the support plate <NUM> has been removed. By way of another example, the one or more linear rails <NUM> of the slide sub-assembly <NUM> may be serviced once the support plate <NUM> has been removed. By way of another example, the carriage slider <NUM> of the slide sub-assembly <NUM> may be serviced once the support plate <NUM> has been removed.

In an optional step <NUM>, the slide sub-assembly <NUM> may be removed from the base <NUM>. For example, the slide sub-assembly <NUM> may be un-coupled from the base <NUM> by removing one or more fasteners. For instance, the slide sub-assembly <NUM> may be un-coupled from the base <NUM> to service one or more components of the slide sub-assembly <NUM> and/or one or more components of the removal sub-assembly <NUM>.

In an optional step <NUM>, the bearing <NUM> may be removed from the base <NUM>. For example, the bearing <NUM> may be un-coupled from the base <NUM> by removing one or more fasteners coupled to the base <NUM>, such that the base <NUM>, the plunger <NUM> and compressible spring <NUM> positioned within the cavity <NUM> may be easily accessed. In this regard, the bearing <NUM> may be un-coupled from the base <NUM> to service (e.g., replace, repair, clean, or the like) the compressible spring <NUM>. Further, the bearing <NUM> may be un-coupled from the base <NUM> to service the bearing <NUM> (e.g., replace, repair, clean, or the like).

It is noted the method or process <NUM> is not limited to the steps and/or sub-steps provided. The method or process <NUM> may include more or fewer steps and/or sub-steps. In addition, the method or process <NUM> may perform the steps and/or sub-steps simultaneously. Further, the method or process <NUM> may perform the steps and/or sub-steps sequentially, including in the order provided or an order other than provided. Therefore, the above description should not be interpreted as a limitation on the scope of the invention but merely an illustration.

Although embodiments of the invention illustrate coupling or uncoupling various components of the headrest assembly <NUM> in a specific direction, it is noted various components of the headrest assembly <NUM> may be coupled or uncoupled from one or more additional directions with enough applied force. Therefore, the above description should not be interpreted as a limitation on the scope of the invention but merely an illustration.

It is noted the headrest assembly <NUM> (and/or one or more components of the headrest assembly <NUM>) may be configured to work with any aircraft seat <NUM> and/or any set of components in the aircraft seat <NUM>. For example, the headrest assembly <NUM> (and/or one or more components of the headrest assembly <NUM>) may be configured to take into account any changes in shape of the components of the aircraft seat <NUM> (e.g., within an x-y plane forming a seating surface for an occupant), where the changes in shape may be caused by or otherwise dependent on the location of the aircraft seat <NUM> within the aircraft cabin.

Although embodiments of the disclosure illustrate the headrest assembly <NUM> being integrated within the aircraft seat <NUM>, it is noted, however, that the headrest assembly <NUM> and/or components of the headrest assembly <NUM> are not limited to the aviation environment and/or the aircraft components within the aviation environment. For example, the headrest assembly <NUM> and/or components of the headrest assembly <NUM> may be configured for any type of vehicle known in the art. For instance, the vehicle may be any air, space, land, or water-based personal equipment or vehicle; any air, space, land, or water-based commercial equipment or vehicle; any air, space, land, or water-based military equipment or vehicle known in the art. By way of another example, the headrest assembly <NUM> and/or components of the headrest assembly <NUM> may be configured for commercial or industrial use in either a home or a business. Therefore, the above description should not be interpreted as a limitation on the present invention but merely an illustration.

Claim 1:
A headrest removal assembly (<NUM>), the headrest removal assembly comprising:
a plunger (<NUM>) including a plunger shaft, the plunger shaft including a first end and a second end, the plunger including a lever portion positioned between the first end and the second end of the plunger shaft, a cavity (<NUM>) within a base (<NUM>) configured to house at least a portion of the plunger shaft;
a compressible spring (<NUM>) coupled to the second end of the plunger shaft and configured to surround at least a portion of the plunger shaft, the cavity configured to house at least a portion of the compressible spring; and
a stopper (<NUM>) configured to couple to the first end of the plunger shaft, the stopper configured to engage with a cavity within a headrest support plate (<NUM>),
the plunger configured to translate the stopper between at least a first stopper position and a second stopper position when a force is applied to the lever portion of the plunger to cause the plunger to compress a portion of the compressible spring within the cavity of the base to cause the stopper to disengage from the cavity within the headrest support plate to cause the headrest removal assembly to disengage from the headrest support plate.