Patent Description:
German patent application <CIT> discloses a backrest for a vehicle seat having the head support and/or at least a part of the back section fitted with a covering layer concealing a centre of compressible foam. The height of the head support can be adjusted relative to the height of the backrest section. The head support and the movable backrest section are adjusted by the raising or lowering of a bow-shaped bar running inside a guide tubes.

German utility model <CIT> discloses a seat device with backrest and headrest in motor vehicles, airplanes and ships. Between the backrest covering at the front and the backrest covering at the rear in the backrest interior there is a mechanical device in this a guide carriage. The headrest can be pushed into the backrest interior and is locked in the pushed-in headrest position of the headrest by the guide carriage lock. By a switching unit in the seat part, the headrest, which is located between the front backrest covering and the rear backrest covering in the backrest interior, is switched back on when the seat part is relieved transported from the backrest interior by means of a mechanical device in the headrest position.

United States patent application <CIT> discloses a vehicle seat construction with a rear impact energy absorbing damping system along with a fully adjustable, fitted, contoured seat back. The seat back is provided with a vertical telescoping and pivoting support frame arrangement for height and contour adjustment for the occupant, and air bags for adjusting the contour of the seat back to the back of the occupant. The seat back construction includes configurable and positionable components for the lower back, the middle back and the head/neck area of the occupant, each component including inflatable pockets for contouring of the front surface of the seat back.

However, as seat backrests become shorter, backrest or headrest extension assemblies become larger and heavier. Increasingly heavy backrest or headrest extension assemblies may be difficult for vehicle occupants to move and adjust, particularly from a seated position. Consequently, there is a need in the art for backrest and/or headrest assemblies that are easier to reposition.

To fulfill the identified need, the instant invention provides a multi-stage seatback extension system according to claim <NUM>. The links can rotate toward a center of the headrest assembly or away from the center of the headrest assembly to respectively retract or extend the headrest assembly.

Optionally, the extendable backrest assembly is moveably coupled to the backrest base assembly by a plurality of extension members coupled to the extendable backrest assembly and a plurality of ports on the backrest base assembly that are configured to receive the extension members. For example, respective ones of the extension members can be configured to slide within respective ones of the ports. The extension members may be infinitely positionable within the ports.

This Summary is provided solely as an introduction to subject matter that is fully described in the detailed description and drawings.

Implementations of the inventive concept disclosed herein may be better understood when consideration is given to the following detailed description thereof. In the drawings:.

Before explaining at least one embodiment of the instant invention in detail, it is to be understood that the instant invention may be practiced or carried out in various ways, as long as it remains within the scope of the appended claims.

As used herein a letter following a reference numeral is intended to reference a feature or element that may be similar, but not necessarily identical, to a previously described element or feature bearing the same reference numeral (e.g., <NUM>, 1a, 1b). Such shorthand notations are used for purposes of convenience only, and should not be construed to limit the instant invention in any way unless expressly stated to the contrary.

In addition, use of the "a" or "an" are employed to describe elements and components of embodiments of the instant invention. This is done merely for convenience and to give a general sense of the invention, and "a' and "an" are intended to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

Broadly, embodiments of the instant invention are directed to a multi-stage seatback extension system. Headrest or backrest extension assemblies may be required in some aircraft and other vehicles with shorter seat backrests in order to support the head, neck, and back of vehicle occupants. However, as headrest or backrest extension assemblies become larger, they often become heavier and increasingly difficult for vehicle occupants to move and adjust, particularly from a seated position. For instance, the force required to adjust heavy headrest or backrest extension assemblies may be awkward, difficult, or even impossible to achieve from a seated position. As such, embodiments of the instant invention may facilitate the movement of headrest and/or backrest extension assemblies for easier, smoother adjustment. In particular, a multi-stage seatback extension system that can be manipulated more easily than a single stage headrest or backrest extension assembly is disclosed.

In example implementations, the instant invention may be incorporated in the passenger chairs of an aircraft in order to facilitate the movement of the headrests and backrests of the passenger chairs. Using the instant invention, aircraft passengers may be able to quickly and easily adjust the headrests and backrests of their seats. Although example embodiments of the instant invention are shown and described in an aviation environment, the instant invention may be configured to operate in any type of chair and/or vehicle known in the art. For example, the embodiments of the instant invention may be incorporated into the driver/passenger chairs of any air, land, or water-based personal equipment or vehicle; any air, land, or water-based commercial equipment or vehicle; any air, land, or water-based military equipment or vehicle known in the art. In another example, embodiments of the instant invention may be incorporated into the driver/passenger chair of an automobile. In the interest of simplicity and to most clearly define the instant invention, embodiments may be described throughout the present disclosure in an aircraft environment. However, these references are not to be regarded as limiting. Thus, references to "aircraft," "airplanes," "aviation," and like terms should not be interpreted as a limitation on the instant invention, unless noted otherwise herein.

<FIG> illustrate example embodiments of a multi-stage seatback extension system <NUM>. For example, <FIG> and <FIG> illustrate example embodiments of a multi-stage seatback extension system <NUM> in an extended configuration for a wide passenger chair and a narrow passenger chair, respectively; and <FIG> and <FIG> illustrate example embodiments of the multi-stage seatback extension system <NUM> in a fully retracted/stowed configuration for a wide passenger chair and a narrow passenger chair, respectively.

Referring generally to <FIG>, the multi-stage seatback extension system <NUM> includes a backrest base assembly <NUM>, an extendable backrest assembly <NUM>, and an extendable headrest assembly <NUM>. The extendable backrest assembly <NUM> is moveably coupled to the backrest base assembly <NUM> such that it can be pulled away from the backrest base assembly <NUM> or pushed toward the backrest base assembly <NUM>. The extendable headrest assembly <NUM> is coupled to the extendable backrest assembly <NUM> so that the headrest assembly <NUM> can also be extended (or retracted). In this regard, the extendable backrest assembly <NUM> and the headrest assembly <NUM> implement a multi-stage (e.g., two stage) seatback extension system <NUM> that can be manipulated more easily than a single stage headrest or backrest extension assembly. For example, a user can raise the extendable backrest assembly <NUM> to a desired height and then raise the extendable headrest assembly <NUM> to a desired height, or only raise one of the extendable backrest assembly <NUM> or the extendable headrest assembly <NUM> to a desired height while keeping the other in a retracted/stowed configuration.

In some embodiments, the extendable backrest assembly <NUM> is moveably coupled to the backrest base assembly <NUM> by a plurality of extension members <NUM> coupled to the extendable backrest assembly <NUM> and a plurality of ports <NUM> on the backrest base assembly <NUM> that are configured to receive the extension members <NUM>. For example, respective ones of the extension members <NUM> can be configured to slide within respective ones of the ports <NUM>. The extension members <NUM> may be infinitely positionable within the ports <NUM>. For example, the extension members <NUM> can be slid up or down within the ports <NUM> to any desired position within the range of motion allowed by structural interface between the backrest base assembly <NUM> and extendable backrest assembly <NUM>. This may provide for greater flexibility in adjusting the position of the extendable backrest assembly <NUM>. In some embodiments, the ports <NUM> may include a gasket material and/or may be appropriately dimensioned so that the extension members <NUM> are tightly held within the ports <NUM> so that the position of the extendable backrest assembly <NUM> is maintained until a user force that exceeds a predetermined threshold is applied to raise or lower the extendable backrest assembly <NUM>.

While the extendable backrest assembly <NUM> is depicted as being movably coupled to the backrest base assembly <NUM> via one or more extension members <NUM> that are received in respective ports <NUM>, in other embodiments, the extendable backrest assembly <NUM> may be movably coupled to the backrest base assembly <NUM> via extension members <NUM> configured to ride on respective tracks, or any other manner that allows for linear movement of the extendable backrest assembly <NUM> relative to the backrest base assembly <NUM>.

As shown in <FIG>, in embodiments, the multi-stage seatback extension system <NUM> may further include an extension assist assembly <NUM> configured to apply an assistive force for raising the extendable backrest assembly <NUM>, which may be quite heavy in some embodiments. The one or more extension members <NUM> may be coupled to the extension assist assembly <NUM>. The extension assist assembly <NUM> can include any extension apparatus configured to assert an extension force (or a component of an extension force) in a direction for raising the extendable backrest assembly <NUM> (e.g., upward or substantially upward). For example, the extension assist assembly <NUM> may include a gas spring, a gas strut, or a mechanical strut. In some embodiments, the extension assist assembly <NUM> includes a damper configured to control the speed at which the extendable backrest assembly <NUM> is raised or lowered.

In some embodiments, the one or more extension members <NUM> may be coupled to the extension assist assembly <NUM> at an attachment point <NUM> by one or more fasteners. Similarly, the extension assist assembly <NUM> may be coupled to the backrest base assembly <NUM> at an attachment point <NUM> by one or more fasteners. The fasteners may include, but are not limited to, one or more rivets, one or more screws, one or more nuts/bolts, one or more pins (e.g., hitch and pin, cotter pin, split pin, locking pin), one or more clamps, one or more adhesives, one or more welded joints, one or more snaps, any combination thereof, or the like. In some embodiments, the extension assist assembly <NUM> is coupled to a mounting bracket affixed to the backrest base assembly <NUM> and/or a mounting bracket affixed to one or more extension members <NUM>.

Although the extension assist assembly <NUM> is illustrated as attaching to an attachment point <NUM> fixed to the backrest base assembly <NUM>, this is not to be regarded as a limitation of the instant invention. The extension assist assembly <NUM> may be coupled to an attachment point <NUM> which is stationary with respect to the extendable backrest assembly <NUM>. For example, the extension assist assembly <NUM> may be coupled to an attachment point <NUM> which is located on the floor upon which the seat and backrest base assembly <NUM> are situated. In another example, the extension assist assembly <NUM> may be coupled to an attachment point <NUM> which is located on a mounting bracket which extends from the floor. In this regard, the extension assist assembly <NUM> may be coupled to any fixed point relative to the extendable backrest assembly <NUM>.

The extension assist assembly <NUM> may be configured to exert an extension force (or a component of an extension force) upon the extendable backrest assembly <NUM>. The extension force exerted by the extension assist assembly <NUM> may offset, or partially offset, an extension resistance force which acts in an opposite direction to the extension force. For example, gravity may act as an extension resistance force, pulling the extendable backrest assembly <NUM> down. Conversely, the extension assist assembly <NUM> may exert an extension force upward such that it offsets, or partially offsets, the force of gravity acting upon the mass of the extendable backrest assembly <NUM>. Offsetting, or partially offsetting, the extension resistance force may allow a user to raise the extendable backrest assembly <NUM> with less force, thereby providing a smoother, more luxurious experience.

The extension force exerted by the extension assist assembly <NUM> may be based on a number of factors including, but not limited to, the force desired to extend the extendable backrest assembly <NUM>, and the magnitude of the extension resistance force, which may be affected by the mass of the extendable backrest assembly <NUM>, forces of friction, and the like. Accordingly, system <NUM> and extension assist assembly <NUM> may be tailored on a bespoke basis dependent on any number of factors including, but not limited to, the type of aircraft, particular passengers, desired flying experience, need for adjustability, frequency of adjustments, and the like. For example, the extension assist assembly <NUM> may be tailored such that the extension force is between <NUM> and <NUM> kilograms (two and five pounds) less than the extension resistance force, such that only <NUM> to <NUM> kilograms (two to five pounds) of force is required to extend the extendable backrest assembly <NUM> from a retracted position to an intermediate or extended position.

As noted previously herein, the extension assist assembly <NUM> may include a gas spring. In embodiments, the extension assist assembly <NUM> (e.g., gas spring) may be loaded in compression, or may be loaded in extension. In some embodiments, a first end of the extension assist assembly <NUM> may be coupled to an extension member <NUM>. A second end of the extension assist assembly <NUM> may be coupled to the backrest base assembly <NUM> at an attachment point <NUM> located on the backrest base assembly <NUM> substantially opposite the extendable backrest assembly <NUM>. In such embodiments, when the extension assist assembly <NUM> is in a contracted/retracted state, the extendable backrest assembly <NUM> may also be in a retracted position (e.g., stowed position), as shown in <FIG>. Conversely, as shown in <FIG>, when the extension assist assembly <NUM> is in an extended state, the extendable backrest assembly <NUM> may also be in an extended state (e.g., raised/pulled away from the backrest base assembly <NUM>). The extension assist assembly <NUM>, loaded in compression, may resist compression such that it exerts an extension force (upward) to assist with raising the extendable backrest assembly <NUM>.

In other embodiments, the extension assist assembly <NUM> (e.g., gas spring) may be loaded in extension. In such embodiments, a first end of the extension assist assembly <NUM> may be coupled to an extension member <NUM>, and a second end of the extension assist assembly <NUM> is coupled to the backrest base assembly <NUM> at attachment point which is located on the backrest base assembly <NUM> at a point which is proximate to the extendable backrest assembly <NUM> and/or one or more ports <NUM>. Consequently, when the extension assist assembly <NUM> is in an extended state, the extendable backrest assembly <NUM> may be in a retracted position (e.g., stowed position). Conversely, when the extension assist assembly <NUM> is in a retracted state, the extendable backrest assembly <NUM> may be in an extended state. The extension assist assembly <NUM>, loaded in extension, may resist extension such that it exerts an extension force (upward) to assist with raising the extendable backrest assembly <NUM>. Embodiments of the extension assist assembly <NUM>, which can be loaded in compression or extension, are further described in <CIT>, especially in paragraphs <NUM>-<NUM> of said U. Patent Application. The multi-stage seatback extension system <NUM> can include any such extension assist assembly; however, in other embodiments, the multi-stage seatback extension system <NUM> may be implemented without an extension assist assembly (e.g., as shown in <FIG>).

Referring again to <FIG> and <FIG>, the extendable headrest assembly <NUM> includes a stationary member <NUM> coupled to the extendable backrest assembly <NUM>, a moveable cross member <NUM>, at least two lower links <NUM>, and at least two upper links <NUM>. The lower links <NUM> are rotationally coupled to respective lower pivot joints <NUM> of the stationary member <NUM>, and the upper links <NUM> are rotationally coupled to respective upper pivot joints <NUM> of the moveable cross member <NUM>. Respective ones of the lower links <NUM> can be coupled to respective ones of the upper links <NUM> by respective link pivot joints <NUM>. The links <NUM> and <NUM> can rotate toward a center of the headrest assembly <NUM> or away from the center of the headrest assembly <NUM> to respectively retract or extend the headrest assembly <NUM>. For example, when the headrest assembly <NUM> is retracted by lowering the moveable cross member <NUM>, the links <NUM> and <NUM> rotate toward the center of the headrest assembly <NUM> such that the lower links <NUM> and the upper links <NUM> are brought closer to each other. Conversely, when the headrest assembly <NUM> is extended by raising the moveable cross member <NUM>, the links <NUM> and <NUM> rotate away from the center of the headrest assembly <NUM> links such that the lower links <NUM> and the upper links <NUM> are spread apart from each other.

In some embodiments, the headrest assembly <NUM> includes at least one motion restrictor <NUM> configured to limit a rotational movement of at least one of the links <NUM>/<NUM>. For example, in <FIG> and <FIG>, the headrest assembly <NUM> is shown to include motion restrictors <NUM> that limit the rotational movement of the lower links <NUM>. In other embodiments, one or more motion restrictors <NUM> can additionally or alternatively limit the rotational movement of at least one of the upper links <NUM>. In embodiments, a motion restrictor <NUM> can include an arc-shaped member with blocking elements on either end to limit the rotational movement of a respective link <NUM>/<NUM> to the arc-length defined by the motion restrictor <NUM>. Any number of motion-restrictors <NUM> may be employed, and the shape of the motion restrictors <NUM> may differ. For example, in another embodiment, a motion restrictor <NUM> may simply include one or more blocking elements that limit the rotation movement of a respective link <NUM>/<NUM>.

The headrest assembly <NUM> further includes one or more dampers <NUM> coupled to one or more of the lower links <NUM>, the upper links <NUM>, the lower pivot joints <NUM> of the stationary member <NUM>, the upper pivot joints <NUM> of the moveable cross member <NUM>, or the link pivot joints <NUM>. For example, in <FIG> and <FIG>, the headrest assembly <NUM> is shown to include rotary dampers <NUM> coupled to the lower pivot joints <NUM> of the stationary member <NUM>. In other embodiments, rotary dampers <NUM> can additionally or alternatively be coupled to one or more of the upper pivot joints <NUM> and/or the link pivot joints <NUM>. Furthermore, the one or more dampers <NUM> can include other types of dampers, such as, but not limited to, a gas spring damper, a mechanical spring damper, or the like. Examples of different types of dampers <NUM> and additional embodiments of the headrest assembly <NUM> (e.g., extension/retraction systems) are further described in <CIT>, especially in paragraphs <NUM> - <NUM> of said U. Patent Application. The multi-stage seatback extension system <NUM> can include any such dampers.

In embodiments, the multi-stage seatback extension system <NUM> includes both an extendable headrest assembly <NUM> and an extendable backrest assembly <NUM> that can be adjusted up or down with infinite position (i.e., to any position allowed by each component's range of motion). In some embodiments, the translation of any of the stages may be driven by a powered actuator to either extend the tubes/extension members <NUM> and/or links <NUM> and/or <NUM> (e.g. linear actuator or a rotary actuator with gears around the lower link pivot <NUM>).

The extendable backrest assembly <NUM> can be raised or lowered to any appropriate position for providing back and shoulder support for an occupant. In some embodiments, the extendable backrest assembly <NUM> can be extended up to <NUM> (four inches) from the backrest base assembly <NUM>. In other embodiments, the extendable backrest assembly <NUM> may have a greater or lesser range of motion. Similarly, the extendable headrest <NUM> can be raised or lowered to any appropriate position for providing neck and head support. In some embodiments, the extendable headrest assembly <NUM> can be extended up to <NUM> (four inches) from the extendable backrest assembly <NUM>. In other embodiments, the extendable headrest assembly <NUM> may have a greater or lesser range of motion. The multi-stage seatback extension system <NUM>, when fully extended, may achieve occupant support in the range of <NUM> to <NUM> (<NUM> to <NUM> inches) (e.g., <NUM> (<NUM> inches)). In other embodiments, the multi-stage seatback extension system <NUM> achieves occupant support in a greater or lesser range when fully extended.

The multi-stage seatback extension system <NUM> can be configured according to the occupant protection requirements of FAA Policy ANM-<NUM>-<NUM>-<NUM> for aft facing seats by limiting the vertical gap in the backrest support to less than <NUM> (<NUM> inches). The multi-stage seatback extension system <NUM> can also be configured according to the occupant protection requirements of FAA Policy ANM-<NUM>-<NUM>-<NUM> by limiting the fore/aft offset of the head, neck, and shoulders. The multi-stage seatback extension system <NUM> can also be configured according to the occupant protection requirements of FAA Policy ANM-<NUM>-<NUM>-<NUM> by limiting the dynamic deflection of the system to support the occupant under static and dynamic loading. The multi-stage seatback extension system <NUM> can also be configured according to the occupant support height requirements of SAE AS8049B for aft facing occupants to support a range of occupant heights with infinite adjustment. The multi-stage seatback extension system <NUM> may also limit injury potential in the thoracic and cervical spine regions by limiting deflection under dynamic (crash) loads as prescribed by <NUM> CFR <NUM>.

The multi-stage seatback extension system <NUM> provides a unique backrest extension feature to react the dynamic loading of the occupant's shoulders while simultaneously maintaining support of the occupant's head during the event. The multi-stage seatback extension system <NUM> also utilizes a space-saving extension mechanism that allows for dampened extension and retraction of the headrest support portion.

The various singular/plural permutations are not expressly set forth herein for sake of clarity.

Furthermore, it is to be understood that optional features of the invention are defined by the appended claims.

Claim 1:
A multi-stage seatback extension system (<NUM>), comprising:
a backrest base assembly (<NUM>);
an extendable backrest assembly (<NUM>) moveably coupled to the backrest base assembly (<NUM>); and
an extendable headrest assembly (<NUM>) coupled to the extendable backrest assembly (<NUM>),
characterized in that the extendable headrest assembly (<NUM>) comprises:
a stationary member (<NUM>) coupled to the extendable backrest assembly (<NUM>);
a movable cross member (<NUM>);
at least two lower links (<NUM>) rotationally coupled to respective lower pivot joints (<NUM>) of the stationary member (<NUM>); and
at least two upper links (<NUM>) rotationally coupled to respective upper pivot joints (<NUM>) of the moveable cross member (<NUM>), wherein respective ones of the at least two lower links (<NUM>) are coupled to respective ones of the at least two upper links (<NUM>) by respective link pivot joints (<NUM>).