LIGHTWEIGHT AIRCRAFT PASSENGER SEAT WITH COMPOSITE CONSTRUCTION

• US 20070267543A1
• Filed: 05/17/2006
• Published: 11/22/2007
• Est. Priority Date: 05/17/2006
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Boren, Kelly L., Kismarton, Max U., Retz, Kevin M.
• Granted Patent: US 7,954,762 B2
• Time in Patent Office: Days
• US Class Current: 244/118.500
• CPC Class Codes: B60N 2/682 Joining means
• CPC Class Codes: B60N 2/686 Panel like structures
• CPC Class Codes: B60N 2/914 Hydro-pneumatic adjustments of the shape
• CPC Class Codes: B60N 2/995 Lower-leg-rests, e.g. calf-rests
• CPC Class Codes: B64D 11/06 Arrangements of seats, or adaptations or details specially adapted for aircraft seats crew seat constructions for emergency purposes B64D25/04
• CPC Class Codes: B64D 11/0649 Seats characterised by special features for reducing weight
• CPC Class Codes: Y02T 50/40 Weight reduction

Abstract

An aircraft seat assembly configured in accordance with an example embodiment of the invention utilizes composite materials to achieve significant weight savings relative to conventional seat designs. The seat assembly includes a lightweight composite support structure, a lightweight composite seat base, and a seat back assembly that employs a lightweight inner frame. The seat cushion and the seat back cushion may utilize a sealed pneumatic element that self-inflates to provide increased air cushioning during flight. The seat assembly can leverage inexpensive manufacturing techniques such that the seat assembly can be economically produced for use as an economy class seat.

Claims

1. An aircraft seat assembly comprising:

a lightweight composite support structure having an upper end;

a lightweight composite seat base having an upper side, a lower side, and a rear section, the lower side being coupled to the upper end of the lightweight composite support structure;

a seat cushion positioned on the upper side of the lightweight composite seat base;

a seat back frame coupled to the rear section of the lightweight composite seat base; and

a seat back cushion coupled to the seat back frame.

2. An aircraft seat assembly according to claim 1, further comprising an attachment architecture coupled between the lightweight composite seat base and the seat back frame.

3. An aircraft seat assembly according to claim 2, the attachment architecture being configured to enable the seat back frame to pivot relative to the rear section of the lightweight composite seat base.

4. An aircraft seat assembly according to claim 2, the attachment architecture comprising seat belt anchoring features.

5. An aircraft seat assembly according to claim 2, the attachment architecture comprising armrest anchoring features.

6. An aircraft seat assembly according to claim 1, the lightweight composite support structure comprising a plurality of legs.

7. An aircraft seat assembly according to claim 6, each of the plurality of legs comprising:

a first side panel;

a second side panel;

a core material between the first side panel and the second side panel; and

at least one rigid reinforcement member between the first side panel and the second side panel.

8. An aircraft seat assembly according to claim 7, wherein:

the first side panel comprises a first carbon fiber sheet;

the second side panel comprises a second carbon fiber sheet;

the core material comprises a honeycomb material; and

the at least one rigid reinforcement member comprises a lightweight tube.

9. An aircraft seat assembly according to claim 1, the lightweight composite support structure being tuned according to a seating capacity of the aircraft seat assembly.

10. An aircraft seat assembly according to claim 1, the lightweight composite seat base comprising:

an upper panel;

a lower panel; and

a core material between the upper panel and the lower panel.

11. An aircraft seat assembly according to claim 10, wherein:

the upper panel comprises a first carbon fiber sheet;

the lower panel comprises a second carbon fiber sheet; and

the core material comprises a honeycomb material.

12. An aircraft seat assembly according to claim 1, the seat cushion comprising a sealed pneumatic element.

13. An aircraft seat assembly according to claim 12, the sealed pneumatic element comprising:

a sealed outer bag;

a cushioning material enclosed within the sealed outer bag; and

a gas enclosed within the sealed outer bag;

wherein

the gas and the sealed outer bag react to external air pressure conditions to provide increased air cushioning for aircraft cabin pressurization conditions.

14. An aircraft seat assembly according to claim 1, the seat back cushion comprising a sealed pneumatic element.

15. An aircraft seat assembly according to claim 14, the sealed pneumatic element comprising:

a sealed outer bag;

a cushioning material enclosed within the sealed outer bag; and

a gas enclosed within the sealed outer bag;

wherein

the gas and the sealed outer bag react to external air pressure conditions to provide increased air cushioning for aircraft cabin pressurization conditions.

16. An aircraft seat assembly comprising:

a plurality of lightweight composite support legs;

a one-piece lightweight composite seat base having an upper side and a lower side, the lower side being coupled to each of the lightweight composite support legs; and

a sealed pneumatic seat cushion positioned on the upper side of the lightweight composite seat base.

17. An aircraft seat assembly according to claim 16, each of the lightweight composite support legs comprising:

a first carbon fiber side panel;

a second carbon fiber side panel;

a honeycomb core material sandwiched between and coupled to the first carbon fiber side panel and the second carbon fiber side panel; and

at least one carbon fiber reinforcement member sandwiched between the first carbon fiber side panel and the second carbon fiber side panel.

18. An aircraft seat assembly according to claim 16, the one-piece lightweight composite seat base comprising:

a carbon fiber upper panel;

a carbon fiber lower panel; and

a honeycomb core material sandwiched between and coupled to the carbon fiber upper panel and the carbon fiber lower panel.

19. An aircraft seat assembly according to claim 16, the sealed pneumatic seat cushion comprising:

a sealed polyurethane outer bag;

a foam material enclosed within the sealed polyurethane outer bag; and

a gas enclosed within the sealed polyurethane outer bag;

wherein

the gas and the sealed polyurethane outer bag react to external air pressure conditions to provide increased air cushioning for aircraft cabin pressurization conditions.

20. An aircraft seat assembly according to claim 16, further comprising:

an attachment architecture coupled to the one-piece lightweight composite seat base;

a seat back frame coupled to the attachment architecture; and

a seat back cushion coupled to the seat back frame;

wherein

the attachment architecture is configured to enable the seat back frame to pivot relative to the one-piece lightweight composite seat base.