MODULAR PASSENGER SEAT FOR AN AIRCRAFT

• US 20080290715A1
• Filed: 08/16/2007
• Published: 11/27/2008
• Est. Priority Date: 05/22/2007
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Emery, Blake, Chadwick, Don, Petry, Sebastian, Wykes, David, Coburn, Scott E., Fullerton, James A., Bernett, Jeffrey, Brauer, R. Klaus
• Granted Patent: US 7,871,039 B2
• Time in Patent Office: Days
• US Class Current: 297/452.18
• CPC Class Codes: B60N 2/7011 of substantially two-dimensional shape, e.g. hammock-like, plastic shells, fabrics
• 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 11/0647 Seats characterised by special upholstery or cushioning features
• CPC Class Codes: B64D 11/0649 Seats characterised by special features for reducing weight
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 29/48 Upholstered article making
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

An aircraft passenger seat assembly as described herein is formed from two primary and modular components: a structural frame that provides passenger support and dynamic load paths for the seat assembly; and a comfort frame that provides the passenger seating surface and the external upholstery layer for the seat assembly. If the seat assembly is designed for multiple passengers, then a separate comfort frame is used for each passenger seat location. The structural frame can be formed as a molded composite construction, and the comfort frame can also utilize a molded composite support frame. The support frame is used as a mounting shell for a fabric carrier that includes the external upholstery layer. The modular design and use of composite materials results in a significant weight and parts count savings relative to conventional seat designs.

Claims

1. A passenger seat assembly for an aircraft, the passenger seat assembly comprising:

a one-piece structural frame configured to support at least one passenger and to transfer dynamic loads associated with the at least one passenger to an airframe structure of the aircraft; and

a comfort frame assembly coupled to the one-piece structural frame, the comfort frame assembly being configured to cooperate with the one-piece structural frame to accommodate movement of the comfort frame assembly relative to the one-piece structural frame.

2. The passenger seat assembly of claim 1, wherein the one-piece structural frame comprises a monocoque composite construction.

3. The passenger seat assembly of claim 1, the one-piece structural frame further comprising an aircraft mounting structure formed therein, the aircraft mounting structure being configured for coupling to the airframe structure of the aircraft.

4. The passenger seat assembly of claim 1, the one-piece structural frame further comprising seat belt coupling features for a passenger seat belt.

5. The passenger seat assembly of claim 1, the comfort frame assembly comprising:

a one-piece support frame; and

a fabric carrier coupled to the one-piece support frame, the fabric carrier defining a seating surface of the comfort frame assembly.

6. The passenger seat assembly of claim 5, the fabric carrier comprising:

a fabric carrier ring; and

at least one layer of material coupled to the fabric carrier ring.

7. The passenger seat assembly of claim 6, the at least one layer of material comprising:

a flexible diaphragm layer configured to support a passenger; and

a three-dimensional mesh layer over the flexible diaphragm layer.

8. The passenger seat assembly of claim 7, the at least one layer of material further comprising an upholstery layer over the three-dimensional mesh layer.

9. The passenger seat assembly of claim 5, wherein the one-piece support frame comprises a composite construction.

10. The passenger seat assembly of claim 1, further comprising a pivot mechanism configured to accommodate pivoting of the comfort frame assembly relative to the one-piece structural frame.

11. The passenger seat assembly of claim 10, wherein:

the comfort frame assembly comprises a lower end that corresponds to a passenger ankle location; and

the pivot mechanism is configured to accommodate pivoting of the comfort frame assembly about an axis that is located near the lower end.

12. A method of manufacturing a passenger seat assembly for an aircraft, the method comprising:

designing a one-piece composite structural frame in concert with an airframe structure of the aircraft;

forming the one-piece composite structural frame such that it comprises N seat subframes corresponding to N passenger seat locations;

fabricating N comfort frame assemblies for the passenger seat assembly, each of the N comfort frame assemblies comprising a respective support frame and a respective fabric carrier, which defines a seating surface, coupled to the respective support frame; and

coupling the N comfort frame assemblies to the one-piece composite structural frame.

13. The method of claim 12, wherein coupling the N comfort frame assemblies to the one-piece composite structural frame comprises pivotally coupling each of the N comfort frame assemblies to a respective one of the N seat subframes to accommodate pivoting of the N comfort frame assemblies relative to the one-piece composite structural frame.

14. The method of claim 12, wherein designing the one-piece composite structural frame comprises designing the one-piece composite structural frame as a structural member of the airframe structure of the aircraft.

15. The method of claim 12, further comprising fabricating N fabric carriers for the N comfort frame assemblies, wherein fabricating each of the N fabric carriers comprises encapsulating a portion of a layer of material in a respective fabric carrier ring.

16. The method of claim 12, further comprising coupling a respective seat belt to each of the N seat subframes.

17. A passenger seat assembly for an aircraft, the passenger seat assembly comprising:

a one-piece structural frame configured to support at least one passenger, the one-piece structural frame comprising a first seat subframe, a second seat subframe, and an aircraft mounting structure integrally formed therein;

a first comfort frame assembly coupled to the first seat subframe, the first comfort frame assembly comprising a first one-piece support frame and a first fabric crier coupled to the first one-piece support frame; and

a second comfort frame assembly coupled to the second seat subframe, the second comfort frame assembly comprising a second one-piece support frame and a second fabric carrier coupled to the second one-piece support frame.

18. A method of installing a passenger seat assembly on an aircraft, the method comprising:

coupling a structural frame to an airframe structure of the aircraft, the structural frame comprising a seat subframe corresponding to a passenger seat location; and

thereafter coupling a comfort frame assembly to the structural frame, the comfort frame assembly comprising a support frame and a fabric carrier that defines a seating surface.

19. The method of claim 18, further comprising coupling a seat belt to the seat subframe.

20. The method of claim 18, further comprising coupling an armrest to the seat subframe.

21. The method of claim 18, wherein coupling the comfort frame assembly to the structural frame comprises pivotally coupling the comfort frame assembly to the seat subframe to accommodate pivoting of the comfort frame assembly relative to the structural frame.