MODULAR MONOCOQUE BACKREST

• US 20170267146A1
• Filed: 03/18/2016
• Published: 09/21/2017
• Est. Priority Date: 03/18/2016
• Status: Active Grant

• Current Assignee: AMI Industries, Inc. (Rtx Corporation)
• Original Assignee: AMI Industries, Inc. (Rtx Corporation)
• Inventors: Ferguson, Keith M., Hoover, Douglas E.
• Granted Patent: US 9,868,374 B2
• Time in Patent Office: Days
• CPC Class Codes: A47C 5/12 of plastics, with or without reinforcement
• CPC Class Codes: B60N 2/66 Lumbar supports
• CPC Class Codes: B60N 2/667 having flexible support member bowed by applied forces
• CPC Class Codes: B60N 2/682 Joining means
• CPC Class Codes: B60N 2/686 Panel like structures
• CPC Class Codes: B60N 2/688 Particular seat belt attachment and guiding
• CPC Class Codes: B60R 22/36 self-locking in an emergency B60R22/3405 , B60R22/343 take precedence
• CPC Class Codes: B64D 11/062 Belts or other passenger restraint means for passenger seats
• 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

Abstract

A modular monocoque backrest is provided. The modular monocoque backrest may comprise a front shroud, a back shroud, and an at least one back spar. The front shroud may be coupled to the back shroud, and the back spar may be configured as a mounting point, enabling the modular monocoque backrest to mount to an aircraft floor. The front shroud and the back shroud may comprise a carbon fiber composite material, allowing the modular monocoque backrest to be modular in nature. The carbon fiber composite material may enable the modular monocoque backrest to have a lightweight design while also maintaining resistance to dynamic crash loads.

Claims

1. A seat backrest, comprising:

a front shroud formed from a first molded carbon fiber composite;

a back shroud coupled to the front shroud and formed from a second molded carbon fiber composite; and

an at least one back spar coupled between the front shroud and the back shroud, wherein the at least one back spar extends in a direction away from the front shroud and the back shroud.

2. The seat backrest of claim 1, further comprising a headrest bracket coupled at a first end to the back shroud and coupled at a second end to the front shroud.

3. The seat backrest of claim 1, further comprising a lumbar support mechanism coupled to the front shroud.

4. The seat backrest of claim 1, further comprising a restraint exit coupled to the back shroud, wherein the restraint exit defines a void on the back shroud, and wherein the void is configured to allow passage of a shoulder restraint belt.

5. The seat backrest of claim 4, further comprising a restraint inertia reel coupled to the back shroud, wherein the restraint inertia reel is configured to deploy and retract the shoulder restraint belt through the restraint exit.

6. The seat backrest of claim 4, wherein the restraint exit comprises a restraint support having a top surface opposite of a bottom surface, wherein the bottom surface is coupled to the back shroud, and wherein a restraint bezel is coupled to the top surface.

7. The seat backrest of claim 4, wherein the restraint exit comprises the second carbon fiber composite material, and wherein the restraint exit is molded with the back shroud such that the back shroud and the restraint exit comprise a single continuous part.

8. The seat backrest of claim 1, wherein the at least one back spar comprises an aluminum material.

9. The seat backrest of claim 8, wherein the at least one back spar comprises a plurality of cross bracings.

10. A modular monocoque backrest, comprising:

a front shroud having a cushion support surface opposite of a first connecting surface, wherein the front shroud comprises a first carbon fiber composite material;

a back shroud having a second connecting surface opposite of a back surface, wherein the back shroud comprises a second carbon fiber composite material, and wherein the second connecting surface of the back shroud is integrally coupled to the first connecting surface of the front shroud such that the front shroud and the back shroud form a single integrated object; and

an at least one back spar having a top end opposite of a bottom end, wherein the top end is coupled at a first edge to the first connecting surface of the front shroud and coupled at a second edge to the second connecting surface of the back shroud, and wherein the bottom end extends in a direction away from the front shroud and the back shroud.

11. The modular monocoque backrest of claim 10, further comprising a headrest bracket coupled at a first end to the second connecting surface of the back shroud and coupled at a second end to the first connecting surface of the front shroud.

12. The modular monocoque backrest of claim 10, further comprising a lumbar support mechanism coupled to the cushion support surface of the front shroud.

13. The modular monocoque backrest of claim 10, further comprising a restraint exit coupled to a top of the back shroud, wherein the restraint exit defines a void on the top of the back shroud, configured to allow passage of a shoulder restraint belt.

14. The modular monocoque backrest of claim 13, further comprising a restraint inertia reel coupled to the second connecting surface of the back shroud, wherein the restraint inertia reel is configured to deploy and retract the shoulder restraint belt through the restraint exit.

15. The modular monocoque backrest of claim 13, wherein the restraint exit comprises a restraint support coupled to the top of the back shroud, and a restraint bezel coupled to the top of the restraint support.

16. The modular monocoque backrest of claim 13, wherein the restraint exit comprises the second carbon fiber composite material, and wherein the restraint exit is molded with the back shroud such that the back shroud and the restraint exit comprise a single continuous part.

17. The modular monocoque backrest of claim 10, wherein the at least one back spar comprises an aluminum material.

18. The modular monocoque backrest of claim 17, wherein the at least one back spar comprises a plurality of cross bracings.

19. A method of manufacturing a modular monocoque backrest, comprising:

forming a front shroud having a cushion support surface opposite of a first connecting surface, wherein the front shroud comprises a first carbon fiber composite material;

forming a back shroud having a second connecting surface opposite of a back surface, wherein the back shroud comprises a second carbon fiber composite material;

coupling the first connecting surface of the front shroud to the second connecting surface of the back shroud; and

coupling an at least one back spar to the front shroud and the back shroud, wherein the back shroud comprise a top end opposite of a bottom end, wherein the top end is configured to couple at a first edge to the first connecting surface of the front shroud and couple at a second edge to the second connecting surface of the back shroud, and wherein the bottom end extends in a direction away from the front shroud and the back shroud.

20. The method of claim 19, wherein the front shroud is coupled to the back shroud via an epoxy adhesive.