Patent Description:
A base assembly for an aircraft seat is disclosed, in accordance with one or more embodiments of the present invention. The base assembly includes one or more leg sub-assemblies. Each leg sub-assembly comprises a front leg. Each leg sub-assembly comprises a rear leg. Each leg sub-assembly comprises a link beam configured to couple the front leg to a portion of the rear leg. At least one of the front leg or the rear leg being at least partially formed of a hybrid composite structure, the link beam being at least partially formed of the hybrid composite structure. The hybrid composite structure formed of at least a first material and a second material, where the first material is different from the second material, the first material including a thermoplastic material configured to provide ductility for the base assembly, the second material including a composite material configured to provide strength for the base assembly. The hybrid composite structure including one or more first portions formed of the first material and one or more second portions of the second material, where the second material is over-molded by one or more portions of the first material to form one or more belts of the second material on the first material.

In some embodiments, the thermoplastic material may include polyether ether ketone (PEEK).

In some embodiments, the thermoplastic material may include a cycloaliphatic diamine dodecanedioic acid based thermoplastic material.

In some embodiments, the composite material may include a continuous fiber material.

In some embodiments, the continuous fiber material may be formed of carbon fibers.

In some embodiments, a first portion of the link beam may be integrated with the front leg and a second portion of the link beam may be integrated with the rear leg to form an integrated leg sub-assembly.

In some embodiments, the front leg may include a first connection portion of the one or more connection portions and the rear leg may include a second portion of the one or more connection portions, the link beam may be configured to couple the first connection portion of the front leg to the second connection portion of the rear leg.

In some embodiments, the first connection portion of the front leg may be formed of a thermoplastic material and the second connection portion of the rear leg may be formed of a thermoplastic material.

In some embodiments, the front leg may be formed of at least one of a metal alloy, a thermoplastic material, or a composite material.

In some embodiments, the rear leg may include an opening configured to couple to a rear structure beam of an aircraft seat, the opening may be formed of the first material.

In some embodiments, the front leg may include an opening configured to couple to a front structure beam of an aircraft seat, the opening may be formed of the first material.

In some embodiments, the base assembly may further include one or more track covers and one or more floor fittings.

In some embodiments, the rear leg may include one or more raised portions formed of the first material.

In some embodiments, the rear leg may include a raised portion where the rear leg couples to a floor fitting connection portion of the base assembly, the floor fitting connection portion may be configured to couple to a portion of a floor fitting of the one or more floor fittings to couple the base assembly to a floor of an aircraft cabin.

An aircraft seat is disclosed, in accordance with one or more embodiments of the present invention. The aircraft seat includes a seatback. The aircraft seat includes a seat pan. The aircraft seat includes a base assembly couplable to a floor of an aircraft cabin via one or more floor fittings, The base assembly includes one or more leg sub-assemblies. Each leg sub-assembly comprises a front leg. Each leg sub-assembly comprises a rear leg. Each leg sub-assembly comprises a link beam configured to couple the front leg to a portion of the rear leg. At least one of the front leg or the rear leg being at least partially formed of a hybrid composite structure, the link beam being at least partially formed of the hybrid composite structure. The hybrid composite structure formed of at least a first material and a second material, where the first material is different from the second material. The hybrid composite structure including one or more first portions formed of the first material and one or more second portions formed of the second material, where the second material is over-molded by one or more portions of the first material to form one or more belts of the second material on the first material. The first material including a thermoplastic material configured to provide ductility for the base assembly, the second material including a composite material configured to provide strength for the base assembly.

In the drawings:.

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.

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 disclosure.

Seats may include components such as, but not limited to, a seatback, a seat pan, and a base assembly (e.g., a primary structure). 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, the select aircraft seats must be formed of a material ductile enough to absorb energy. Further, 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), or any other standards setting organization or company; or any other guidelines agency or organization; or the like. The base assembly may present difficulties such as, but not limited to, failing to meet load requirements (e.g., abuse, reliability, and dynamic load requirements (e.g., <NUM> lateral and <NUM> FWD load requirements)), or the like as set forth by the FAA in <NUM> C. Part <NUM>, AIRWORTHINESS STANDARDS: TRANSPORT CATEGORY AIRPLANES)).

Continuous fibers, such as carbon, are occasionally used in the build of aircraft seats. Although continuous fibers (e.g., CFRP) may withstand the load requirements (e.g., abuse, reliability, and dynamic load requirements (e.g., <NUM> lateral and <NUM> FWD load requirements)), continuous fibers (e.g., carbon) cannot absorb enough energy (i.e., cannot deliver ductility) (as shown in <FIG>). Alternatively, thermoplastic injection molded materials are occasionally used in the build of aircraft seats. Although thermoplastic injection molded materials deliver ductility, the thermoplastic injection molded materials cannot withstand the load requirements (e.g., abuse, reliability, and dynamic load requirements (e.g., <NUM> lateral and <NUM> FWD load requirements)). Further, metal alloys (e.g., aluminum and mild steel, as shown in <FIG>) conventionally are used in the build of aircraft seats and delivery both strength and ductility, however, metal alloys increase the cost and weight of the aircraft seat and it is often desirable to reduce the cost and weight of the seat.

As such, it would be desirable to provide an aircraft seat base assembly configured to address one or more shortcomings of the previous approaches. The assembly should be configured in accordance with aviation guidelines and/or standards. For example, the assembly should meet load requirements (e.g., abuse, reliability, and dynamic load requirements (e.g., <NUM> lateral and <NUM> FWD load requirements)). Further, the assembly should have high energy absorption capabilities and meet ductility requirements. The assembly should reduce the cost and weight of the seat.

<FIG> in general illustrate an aircraft seat base assembly for an aircraft seat, in accordance with one or more embodiments of the invention.

Referring in general to <FIG>, a base assembly may be integrated within an aircraft seat <NUM> installed within an aircraft cabin. For example, as shown in <FIG>, the one or more base assemblies may be integrated within an individual aircraft seat <NUM> installed within an aircraft cabin. By way of another example, as shown in <FIG>, the one or more base assemblies may be integrated within a row of aircraft seats <NUM> installed within an aircraft cabin. It is noted that <FIG> are provided merely for illustrative purposes and shall not be construed as limiting the scope of the present invention.

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 disclosure.

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 disclosure 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 disclosure but merely an illustration.

The aircraft seat <NUM> may include a seatback <NUM>. The aircraft seat <NUM> may include a seat pan <NUM>. The aircraft seat <NUM> may include one or more arms <NUM>.

The seatback <NUM> may include a headrest <NUM>. For example, the headrest <NUM> may be integrated within the seatback <NUM>. By way of another example, the headrest <NUM> may be a separate component coupled to (or inserted into) the seatback <NUM>. For instance, the headrest <NUM> may be movable relative to the seatback frame of the aircraft seat <NUM> (e.g., adjustable, removable, or the like).

The aircraft seat <NUM> may be coupled to a base assembly <NUM> (such as the base assembly shown in <FIG>). For example, the seat frame of the aircraft seat <NUM> may be couplable to the base assembly <NUM>. The base assembly <NUM> may be couplable to a floor of an aircraft cabin. For example, the base assembly <NUM> may be couplable to a floor of an aircraft cabin via one or more tracks (not shown), one or more track covers <NUM>, and/or one or more floor fittings <NUM> (or track fasteners <NUM>).

The base assembly <NUM> may include one or more leg sub-assemblies <NUM>. Each leg sub-assembly <NUM> may include one or more legs. For example, each leg sub-assembly <NUM> may include a front leg <NUM> and a rear leg <NUM>.

Referring to <FIG>, the one or more legs may be couplable to one or more portions of the seat frame of the aircraft seat <NUM>. For example, the one or more front legs <NUM> may be couplable to a front portion of the seat frame of the aircraft seat <NUM>. By way of another example, the one or more rear legs <NUM> may be couplable to a rear portion of the seat frame of the aircraft seat <NUM>. Referring to <FIG>, the one or more legs may be couplable to one or more structural beams <NUM> and/or one or more spreaders <NUM>. For example, the one or more front legs <NUM> may be couplable to a front structural beam of the one or more structural beams <NUM> and a front portion of the one or more spreaders <NUM> (e.g., a front opening). By way of another example, the one or more rear legs <NUM> may be couplable to a rear structural beam of the one or more structural beams <NUM> and a rear portion of the one or more spreaders <NUM> (e.g., a rear opening). In this regard, the one or more legs <NUM>, <NUM> may be configured to attach to the one or more structural beams <NUM> and secure to the one or more tracks <NUM> located in the floor of the aircraft cabin via the one or more fittings <NUM>.

<FIG> illustrate a base assembly <NUM> including one or more leg sub-assemblies <NUM>, in accordance with one or more embodiments of the disclosure. In particular, <FIG> depicts a perspective view of a leg sub-assembly of the base assembly. In particular, <FIG> depicts a perspective view of a leg sub-assembly of the base assembly. In particular, <FIG> illustrates a side view of a leg sub-assembly of the base assembly. In particular, <FIG> depicts a side perspective view of a leg sub-assembly of the base assembly. In particular, <FIG> depicts a detailed view of a connection point of the leg sub-assembly. In particular, <FIG> illustrates a perspective view of a link beam of the leg sub-assembly. In particular, <FIG> depicts a perspective view of a link beam of the leg sub-assembly. In particular, <FIG> depicts a cross-sectional view of a link beam of the leg sub-assembly. In particular, <FIG> illustrates a side view of a leg sub-assembly of a base assembly. In particular, <FIG> depicts a side view of a leg sub-assembly of a base assembly.

Each leg sub-assembly <NUM> may include a link beam <NUM> configured to couple the front leg <NUM> to a portion of the rear leg <NUM>. For example, the front leg <NUM> may include a connection portion <NUM> configured to couple to a first end of the link beam <NUM> and the rear leg <NUM> may include a connection portion <NUM> configured to couple to a second end of the link beam <NUM>. In some embodiments, as shown in <FIG> , the leg sub-assembly <NUM> may be a single piece, such that the front leg <NUM>, the rear leg <NUM>, and the link beam <NUM> are directly coupled to form a single piece.

At least one of the one or more legs may be formed of a hybrid composite material formed of two or more materials. For example, the rear leg <NUM> may be formed of a hybrid composite material formed of two or more materials. For instance, the rear leg <NUM> may include one or more first portions <NUM> formed of a first material and one or more second portions <NUM> formed of a second material. In this regard, the rear leg <NUM> may be formed of the first material and may include one or more belts <NUM> formed of the second material, where the one or more belts <NUM> may surround one or more portions of the first material to form the one or more first portions <NUM>. By way of another example, the front leg <NUM> may be formed of a hybrid composite structure formed of two or more materials.

The link beam <NUM> may be formed of a hybrid composite structure formed of two or more materials. For example, the link beam <NUM> may include one or more first portions <NUM> formed of a first material and one or more second portions <NUM> formed of a second material. For instance, the link beam <NUM> may be formed of the first material and may include one or more belts <NUM> formed of the second material, where the one or more belts <NUM> may surround one or more portions of the first material to form the one or more first portions <NUM>.

The two or more materials of the at least one leg of the one or more legs and the link beam <NUM> may include at least the first material and the second material, where the first material is different from the second material. For example, the first material may include a thermoplastic material and the second material may include a composite material. In one instance, the rear leg <NUM> may include one or more first portions <NUM> formed of a thermoplastic material and one or more second portions <NUM> formed of a composite material. In this regard, the rear leg <NUM> may be formed of the thermoplastic material and may include one or more belts <NUM> of composite material, where the one or more belts <NUM> of composite material may surround the thermoplastic leg to form the one or more first portions <NUM> of thermoplastic material. In another instance, the link beam <NUM> may include one or more first portions <NUM> formed of a thermoplastic material and one or more second portions <NUM> formed of a composite material. In this regard, the link beam <NUM> may be formed of the thermoplastic material and may include one or more belts <NUM> of composite material, where the one or more belts <NUM> of composite material may surround the thermoplastic link beam to form the one or more first portions <NUM> of thermoplastic material.

It is noted the first material may include any type of thermoplastic material. For example, the thermoplastic material may include a cycloaliphatic diamine dodecanedioic acid based thermoplastic material. By way of another example, the thermoplastic may include polyether ether ketone (PEEK). Further, the second material may include any type of composite material. For example, the composite material may include a continuous fiber material, such as, but not limited to, carbon, or the like.

It is noted that two or more materials (e.g., thermoplastic and composite) may be configured to provide both ductility and strength for the base assembly of the aircraft seat. For example, the composite portions may be configured to provide strength to withstand the load requirements (e.g., abuse, reliability, and dynamic load requirements (e.g., <NUM> lateral and <NUM> FWD load requirements)), while the thermoplastic portions may be configured to provide ductility.

The second material of the two or more materials may be over-molded by the first material to form a thermoplastic over-molded composite structure. For example, the composite material (e.g., continuous fiber material) may be over-molded by the thermoplastic material to form a thermoplastic over-molded composite leg. For instance, the composite material (e.g., continuous fiber material) may be wrapped around one or more portions of an injection molded thermoplastic leg, such that the one or more legs include one or more belts of composite material around one or more portions of the thermoplastic injection molded thermoplastic legs. By way of another example, as shown in <FIG>, the composite material (e.g., continuous fiber material) may be over-molded by the thermoplastic material to form a thermoplastic over-molded composite link beam. For instance, the composite material (e.g., continuous fiber material) may be wrapped around one or more portions of an injection molded thermoplastic link beam, such that the link beam include one or more belts of composite material around one or more portions of the thermoplastic injection molded thermoplastic link beam.

The one or more legs may include one or more openings. For example, the rear leg <NUM> may include an opening <NUM>. For instance, as shown in <FIG>, the opening <NUM> may include a rear opening configured to couple to a rear structural beam <NUM>. By way of another example, the front leg <NUM> may include an opening <NUM>. For instance, as shown in <FIG>, the opening <NUM> may include a front opening configured to couple to a front structural beam <NUM>.

The one or more openings may be formed of the first material. For example, the opening <NUM> of the rear leg <NUM> may be formed of the first material. For instance, the opening <NUM> of the rear leg <NUM> may be formed of a thermoplastic material. In this regard, the thermoplastic opening <NUM> of the rear leg <NUM> may be configured to provide ductility for the leg sub-assembly of the base assembly.

The one or more connection portions may be formed of the first material. For example, the connection portion <NUM> of the front leg <NUM> may be formed of the first material. For instance, the connection portion <NUM> of the front leg <NUM> may be formed of a thermoplastic material. By way of another example, the connection portion <NUM> of the rear leg <NUM> may be formed of the first material. For example, the connection portion <NUM> of the rear leg <NUM> may be formed of a thermoplastic material. In this regard, the thermoplastic connection portions <NUM>, <NUM> of the front and rear legs, respectively may be configured to provide ductility for the leg sub-assembly of the base assembly.

The rear leg <NUM> may couple to a floor fitting connection portion <NUM> configured to couple the rear leg <NUM> to a portion of the floor fitting <NUM>. For example, the floor fitting connection portion <NUM> may be formed of the first material. For instance, the floor fitting connection portion <NUM> may be formed of the thermoplastic material. In this regard, the thermoplastic connection portion <NUM> coupled to the rear leg <NUM> may be configured to provide ductility for the leg sub-assembly of the base assembly.

One or more portions of the rear leg <NUM> may include one or more raised portions at one or more higher energy absorption zones. For example, the rear leg <NUM> may include one or more raised portions of thermoplastic material at one or more the connection portions. In one instance, as shown in <FIG>, the rear leg <NUM> may include a raised portion <NUM> where the rear leg <NUM> couples to the floor fitting connection portion <NUM>, such that the increased height of the raised portion <NUM> may be configured to provide high ductility at that particular high energy absorption zone. It is noted that the raised portion <NUM> may have an increased height relative to a height of a side wall <NUM> of the rear leg <NUM>. In a non-limiting example, the height of the side wall <NUM> may be <NUM> and the height of the raised portion <NUM> may be <NUM>.

The front leg <NUM> may be formed of any material suitable for providing strength for the leg sub-assembly of the base assembly. For example, the front leg <NUM> may be formed of a thermoplastic material. By way of another example, the front leg <NUM> may be formed of a metal alloy (e.g., aluminum alloy). By way of another example, the front leg <NUM> may be formed of a composite material (e.g., carbon fibers). It is noted that the leg sub-assembly be formed of a plurality of components or the leg sub-assembly may be formed of a single piece (such as the assembly <NUM> shown in <FIG>). In some embodiments, as shown in <FIG>, the front leg <NUM> may include a tubular structure <NUM>. For example, the tubular structure <NUM> may include a shaft formed of a metal alloy and one or more connection portions formed of thermoplastic material. For instance, the metal alloy and/or composite material may be configured to provide strength for the front leg <NUM> and the thermoplastic connection portions may be configured to provide ductility for the front leg <NUM> to absorb energy. As such, <FIG> are provided merely for illustrative purposes and shall not be construed as limiting the scope of the present invention.

It is noted the base assembly <NUM> and/or the leg sub-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 base assembly <NUM> and/or the leg sub-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 invention illustrate the base assembly <NUM> and/or the leg sub-assembly <NUM> being integrated within the aircraft seat <NUM>, it is noted, however, that the base assembly <NUM> and/or the leg sub-assembly <NUM> and/or components of the base assembly <NUM> and/or the leg sub-assembly <NUM> are not limited to the aviation environment and/or the aircraft components within the aviation environment. For example, the base assembly <NUM> and/or the leg sub-assembly <NUM> and/or components of the base assembly <NUM> and/or the leg sub-assembly <NUM> may be configured for any type of vehicle known in the art. By way of another example, the base assembly <NUM> and/or the leg sub-assembly <NUM> and/or components of the base assembly <NUM> and/or the leg sub-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 base assembly (<NUM>) for an aircraft seat (<NUM>), the base assembly comprising:
one or more leg sub-assemblies (<NUM>), each leg sub-assembly comprising:
a front leg (<NUM>);
a rear leg (<NUM>); and
a link beam (<NUM>) configured to couple the front leg to a portion of the rear leg,
at least one of the front leg or the rear leg at least partially formed of a hybrid composite structure, the link beam at least partially formed of the hybrid composite structure,
the hybrid composite structure formed of at least a first material and a second material, where the first material is different from the second material, the first material including a thermoplastic material configured to provide ductility for the base assembly, the second material including a composite material configured to provide strength for the base assembly,
the hybrid composite structure including one or more first portions (<NUM>) formed of the first material and one or more second portions (<NUM>) formed of the second material,
characterised in that the second material is over-molded by one or more portions of the first material to form one or more belts (<NUM>) of the second material on the first material.