Patent Description:
Passenger vehicles, such as aircraft, buses, trains, ships, and automobiles, include passenger seats in which passengers can be seated and otherwise use during travel Existing passenger seats include a number of structural components at various locations on the passenger seats. For example, spreaders may serve as an interface at which various components of the passenger seat such as an armrest, seat back, table, leg assembly, etc. can be connected. This typical/traditional construction imposes limitations such as a higher part count, material waste, and compromises between optimization and manufacturability.

Document <CIT> describes a passenger seat assembly with a lower frame configured to support a seat bottom of the passenger seat and a backrest frame attached to the lower frame and configured to support a backrest assembly. Document <CIT> describes a seat with one or more lightweight composite support legs, a lightweight composite seat pan. and a lightweight composite seat back structure. The support legs are coupled to the seat pan. which is in turn coupled to the seat back structure. The support legs utilize composite frame elements that are formed as continuous compression molded composite extrusions. The seat pan includes composite fore and aft cross beams that are also formed as continuous compression molded composite extrusions.

The aft cross beam includes a rear flange that serves as a flexible "hinge" for the seat back structure. Document <CIT> describes a seating structure with a pair of spaced side supports, a seat pivotably mounted between the side supports, a back fixed to the side supports, an electrical outlet positioned on one of the side supports, and at least one data outlet positioned on one of the side supports. Each of the side supports includes an outlet housing affixed to the lower surface of an arm rest contained on the side support. The outlet housing extends inwardly toward the seat surface and provides the seat occupant with an electrical outlet and at least one data outlet. The electrical wiring and data line for each seat assembly pass through a wireway contained in the seat back. Document <CIT> describes a seat structure of the aircraft to store a source of pressurized gas or solid fuel necessary to expand the passive restraint is disclosed. The seat structure of the aircraft comprises multiple hollow tubes, and these hollow tubes can be utilized to either store pressurized gas or solid fuel directly, or to house a vessel that stores pressurized gas or solid fuel.

Document <CIT> describes an arm rest, a mounting bosshead defining a curved slot and comprising a curved boss, and a pin received by the curved slot and defining a groove, the pin configured for receipt by the curved slot in a selected first or second position, the first position having the curved boss aligned with the groove so as to permit travel of the pin within the curved slot and pivoting of the arm rest relative to the mounting bosshead and the second position having the curved boss misaligned with the groove so as to prevent pivoting of the arm rest relative to the mounting bosshead.

Document <CIT> discloses a seat back attachment post which is a carbon fibre/Kelvar shell structure mechanically interlocking with the back end of a seat support to which it is secured by a fixing bolt.

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, insofar as they fall within the scope of the appended claims.

A passenger seat assembly is provided, according to claim <NUM>.

Optional embodiments are defined by the dependent claims.

As illustrated in <FIG>, a passenger seat assembly <NUM> may include a seat base <NUM> and one or more seat backs <NUM> supported relative to the seat base <NUM>. The number of seat backs <NUM> should not be considered limiting on the disclosure. In various examples, the number of seat backs <NUM> correspond with the number of passengers that the passenger seat is capable of carrying, and each seat back <NUM> and the corresponding portion of the seat base <NUM> define a particular passenger seat <NUM>. In the example of <FIG>, the passenger seat assembly <NUM> is capable of carrying one passenger, and accordingly has one seat back <NUM> and one passenger seat <NUM>. However, in other examples, the passenger seat assembly <NUM> may be capable of carrying any desired number of passengers, such as one passenger, two passengers, three passengers, four passengers, or any other desired number of passengers. In these examples, the passenger seat assembly <NUM> can likewise have any desired number of corresponding seat backs <NUM>.

The seat base <NUM> of the passenger seat assembly <NUM> generally includes a leg assembly <NUM> and at least one base frame tube <NUM>. The seat base <NUM> may also include a support frame <NUM>, an armrest <NUM>, a spreader <NUM>, a luggage bar <NUM>, or other components. Cushioning (not illustrated) may be provided on any of the components of the seat base <NUM>.

The seat back <NUM> is connected to the seat base <NUM>, and is often pivotable relative to the seat base <NUM> such that the seat back <NUM> can be positioned in various positions such as a taxi-takeoff-landing (TTL) position, a reclined position, etc. In certain aspects, the seat back <NUM> is connected to the seat base <NUM> via the spreader <NUM>. The seat back <NUM> includes a frame component <NUM> having a forward side <NUM> and an aft side <NUM>. In some cases, other components of the passenger seat assembly <NUM> such as a tray table <NUM>, an in-flight entertainment monitor, or various other components may be supported on and/or relative to the seat back <NUM>. In certain cases, other components, such as the tray table <NUM> may be pivotably connected to the spreader <NUM>, and the tray table <NUM> may be movable relative to the aft side <NUM> of the seat back <NUM> between a stowed position and a deployed position. Cushioning (not illustrated) may be provided on any of the components of the seat back <NUM>.

Various structural assemblies of the seat base <NUM> and/or the seat back <NUM> may be subjected to different types of loads or forces when used. As one non-limiting example, with the spreader <NUM>, a lower portion of the spreader <NUM> (e.g., the portion that engages the base frame tube(s) <NUM>) may be subjected to pulling loads or forces during use, and an upper portion of the spreader <NUM> (e.g., the portion that connects with the seat back <NUM>) may be subjected to pushing loads during use. Other structural assemblies of the seat base <NUM> and/or the seat back <NUM> include, but are not limited to armrests and in-flight entertainment shrouds. In certain aspects, and as discussed in detail below, one or more of the structural assemblies may include a structural shroud.

<FIG> illustrate an example of a spreader assembly <NUM> having an upper spreader <NUM> and a lower spreader <NUM>. Similar to the spreader <NUM>, the spreader assembly <NUM> is configured to connect a seat back with the seat base as well as support various other components such as a tray table. In various embodiments, and as discussed below, the upper spreader <NUM> is configured to engage with and/or support a seat back of the passenger seat and/or other components such as a tray table and may be subject to pushing loads during use, and the lower spreader <NUM> is configured to engage with the base frame tube(s) <NUM> and may be subject to pulling loads during use.

The upper spreader <NUM> is a structural shroud <NUM> having a first end <NUM> and a second end <NUM> opposite from the first end <NUM>. The structural shroud <NUM> also has an inner surface <NUM> and an outer surface <NUM> extending from the first end <NUM> to the second end <NUM>. As illustrated in <FIG>, the inner surface <NUM> defines a central cavity <NUM> such that the structural shroud <NUM> is hollow along a length of the structural shroud <NUM>. In other words, a cross-sectional shape of the structural shroud <NUM> may have a hollow center due to the central cavity <NUM>. In various examples, at least one of the first end <NUM> or the second end <NUM> defines an opening providing access to the central cavity <NUM>. In the embodiment of <FIG>, the first end <NUM> includes a first opening <NUM> providing access to the central cavity <NUM> and the second end <NUM> includes a second opening <NUM> providing access to the central cavity <NUM>. Optionally, an intermediate opening <NUM> between the first end <NUM> and the second end <NUM> providing access to the central cavity <NUM>. In some non-limiting examples, a component of the passenger seat assembly, including but not limited to a power outlet, USB outlet, or other amenity or component of the passenger seat may be provided in the intermediate opening <NUM>. In certain aspects, the first end <NUM> may be a top-most portion of the assembled upper spreader <NUM> and lower spreader <NUM>. In some embodiments, a stiffener or reinforcing component <NUM> may optionally be provided on the structural shroud <NUM>. The stiffener or reinforcing component <NUM> may be provided on the inner surface <NUM> and/or the outer surface <NUM> as desired, and may stiffen the structural shroud <NUM>. In various embodiments, the stiffener or reinforcing component <NUM> may be a separate component attached to the structural shroud or may be integrally formed with the structural shroud.

In some embodiments, the structural shroud <NUM> includes a first shroud <NUM> and a second shroud <NUM> connected to the first shroud <NUM>. In various cases, the first shroud <NUM> may be connected to the second shroud <NUM> via various suitable devices or mechanisms as desired such that the second shroud <NUM> may be selectively removed from the first shroud <NUM> (e.g., to allow greater access to the central cavity <NUM>. As one non-limiting example, the second shroud <NUM> may be removably connected to the first shroud <NUM> via mechanical fasteners such that cabling or wiring or other features within the central cavity <NUM> may be accessed as desired. The structural shroud <NUM> may be constructed from various suitable materials, including but not limited to aluminum, stainless steel, aramid fibers, polycarbonate, polypropylene, other metallic materials, composite materials, or other similar materials. In one non-limiting example, the structural shroud <NUM> is constructed from a reinforced plastic such as a sheet molding compound.

As illustrated in <FIG>, the lower spreader <NUM> includes a forward end <NUM> and an aft end <NUM> opposite of the forward end <NUM>. Compared to the upper spreader <NUM>, the lower spreader <NUM> does not include an inner surface extending along a length of the lower spreader and/or a central cavity. In other words, a cross-sectional shape of the lower spreader <NUM> may be different from that of the upper spreader <NUM>. In some non-limiting embodiments, a center of the cross-sectional shape of the lower spreader <NUM> may be solid other than locations with apertures for the base frame tube(s) (discussed below). In certain aspects, the forward end <NUM> may be a forward-most portion of the spreader assembly <NUM>. In various aspects, the aft end <NUM> may be an aft-most portion and/or a lowermost portion of the spreader assembly <NUM>, although it need not be the aft-most and/or the lowermost portion. In the example of <FIG>, a portion of the upper spreader <NUM> extends aft of the aft end <NUM>. In other embodiments, the lower spreader <NUM> may be a structural shroud similar to the structural shroud <NUM> and may define a central cavity such that the lower spreader <NUM> is hollow. The lower spreader <NUM> is a separate component that is connected to the upper spreader <NUM> via various suitable connectors or connecting mechanisms as desired, or in an unclaimed example, the lower spreader <NUM> and the upper spreader <NUM> may be formed as a monolithic or integral component.

The lower spreader <NUM> includes one or more apertures <NUM> defined through a thickness of the lower spreader <NUM> between the forward end <NUM> and the aft end <NUM> that receive and engage base frame tube(s) of the passenger seat assembly. In the embodiment of <FIG>, the lower spreader <NUM> includes two apertures <NUM>. In other embodiments, or other suitable interfacing for the base frame tube(s) may be provided. The lower spreader <NUM> may also include interfacing for other components of the seat base of the passenger seat assembly as desired. The lower spreader <NUM> may be constructed from various materials as desired suitable for engaging the base frame tube(s) and the upper spreader <NUM>.

The upper spreader <NUM> may be connected to the lower spreader <NUM> proximate to the second end <NUM>. In various examples, the lower spreader <NUM> may include an interface <NUM> that may be used to connect the upper spreader <NUM> with the lower spreader <NUM>. As best illustrated in <FIG>, in the embodiment of <FIG>, the interface <NUM> includes a ridge <NUM> having a securing aperture <NUM>. Various other types of interfaces <NUM> may be utilized as desired, and the ridge <NUM> and/or securing aperture <NUM> need not be included. In some cases, the lower spreader <NUM> may be partially received within the central cavity <NUM>, although it need not in other examples (see, e.g., <FIG>). The upper spreader <NUM> may be connected to the lower spreader <NUM> via various suitable devices or mechanisms as desired, including but not limited to mechanical fasteners.

Connectors and/or other components that engage with features of the seat back are provided on the structural shroud <NUM> and extend outwards from the outer surface <NUM>. Such connectors and/or other components may be connected to the structural shroud <NUM> via various suitable mechanisms or devices as desired, or they may be integrally or monolithically formed with the structural shroud <NUM>. In the embodiment of <FIG>, the structural shroud <NUM> includes a table pivot <NUM> and a table stop <NUM> integrally formed with the structural shroud <NUM>.

Optionally, and as illustrated in <FIG>, the spreader assembly <NUM> includes an armrest pivot <NUM> supported proximate to the first end <NUM> of the upper spreader <NUM>. The armrest pivot <NUM> may connected to the upper spreader <NUM> via various suitable devices or mechanisms as desired. In certain aspects, the armrest pivot <NUM> includes one or more pivot grooves <NUM> that may interface with an armrest such that the armrest is pivotable relative to the spreader assembly <NUM>.

The spreader assembly <NUM>, which may be referred to as a "split" spreader assembly, may be advantageous over traditional spreaders. In one aspect, the split spreader assembly <NUM> may maximize the inertia of the upper spreader <NUM> and reduce the mass needed to achieve the required stiffness to withstand forces from the armrest, seat back, etc. The split spreader assembly <NUM> may also optionally reduce the number of parts required for a spreader by embedding one or more of the components (e.g., stiffener, table stops, pivots, etc.), into the structural shroud. In some cases, the split spreader assembly <NUM> may reduce the amount of material waste that is caused by the typical crescent shape of traditional spreaders. The split spreader assembly <NUM> may also optimize stiffness and strength requirements for portion that engages the armrest, seat back, etc. independently from the stiffness and strength requirements for the portion that engages the base frame tube(s) and needing to withstand <NUM> loads.

<FIG> illustrate an unclaimed example of a spreader assembly <NUM> that is substantially similar to the spreader assembly <NUM> and includes an upper spreader <NUM> and a lower spreader <NUM>. The upper spreader <NUM> is similar to the upper spreader <NUM> and includes a structural shroud <NUM>. Compared to the upper spreader <NUM>, the structural shroud <NUM> of the upper spreader <NUM> has a different shape than the structural shroud <NUM>, and the structural shroud <NUM> is a monolithic and does not include the first shroud <NUM> and the second shroud <NUM>. As illustrated in <FIG>, an interface component <NUM> may connect the armrest pivot <NUM> with the upper spreader <NUM>. The lower spreader <NUM> is substantially similar to the lower spreader <NUM> except that the interface <NUM> includes a ridge <NUM> having two securing apertures <NUM>.

<FIG> illustrate an unclaimed example of a spreader assembly <NUM> that is substantially similar to the spreader assembly <NUM> and includes an upper spreader <NUM> and a lower spreader <NUM>. The upper spreader <NUM> is similar to the upper spreader <NUM> and includes a structural shroud <NUM>. Compared to the upper spreader <NUM>, the structural shroud <NUM> of the upper spreader <NUM> has a different shape than the structural shroud <NUM>, and the structural shroud <NUM> is a monolithic and does not include the first shroud <NUM> and the second shroud <NUM>. The lower spreader <NUM> is substantially similar to the lower spreader <NUM> except that the interface <NUM> includes a ledge <NUM> that engages the upper spreader <NUM> and secures the lower spreader <NUM> to the upper spreader <NUM> without requiring separate fasteners or other joining devices. Compared to the spreader assembly <NUM>, a table pivot <NUM> and a table stop <NUM> are separate components from the structural shroud <NUM> that are supported on the structural shroud <NUM>.

<FIG> illustrates an example of an armrest <NUM> having a structural shroud <NUM>. Similar to the structural shroud <NUM>, the structural shroud <NUM> includes a first shroud <NUM> and a second shroud <NUM>. Compared to the structural shroud <NUM>, the second end <NUM> of the structural shroud <NUM> does not include second opening <NUM>. In the embodiment of <FIG>, the intermediate opening <NUM> is configured to receive an actuator <NUM> of the armrest <NUM>, and cabling <NUM> for the actuator <NUM> may be housed within the central cavity <NUM>.

Claim 1:
A passenger seat assembly (<NUM>) comprising a spreader assembly (<NUM>), the spreader assembly (<NUM>) comprising:
a lower spreader (<NUM>) extending in a forward direction and defining a forward-most portion of the spreader assembly (<NUM>); the lower spreader (<NUM>) including a forward end (<NUM>) and an aft end (<NUM>) opposite of the forward end (<NUM>), the lower spreader (<NUM>) including one or more apertures (<NUM>) defined through a thickness of the lower spreader (<NUM>) between the forward end (<NUM>) and the aft end (<NUM>) and configured to receive and engage base frame tube(s) of the passenger seat assembly (<NUM>), and
an upper spreader (<NUM>) attached to the lower spreader (<NUM>) and extending in a vertical direction relative to the lower spreader (<NUM>), wherein the upper spreader (<NUM>) is a structural shroud (<NUM>) having a first end (<NUM>) and a second end (<NUM>) opposite from the first end (<NUM>), wherein the upper spreader (<NUM>) defines a top-most portion of the spreader assembly (<NUM>), wherein the upper spreader (<NUM>) is configured to support a seat back of the passenger seat assembly, such that connectors and/or other components configured engage with features of the seat back are provided on the structural shroud (<NUM>) and extend outwards from an outer surface (<NUM>) of the structural shroud (<NUM>),
characterized in that the structural shroud (<NUM>) comprises a first shroud (<NUM>) and a second shroud (<NUM>) attached to the first shroud (<NUM>), and wherein the first shroud (<NUM>) and the second shroud (<NUM>) together define a central cavity such that the upper spreader (<NUM>) is hollow.