Structural assembly for a passenger seat and related method

Abstract

A structural cover for a passenger seat assembly includes a hollow body having a first end, a second end opposite the first end, and a central cavity located between the first end and the second end. In some embodiments, the structural cover may comprise a magnesium alloy and / or an aluminum alloy, and may be formed, particularly by casting, forging, and / or additive manufacturing. In some embodiments, the base frame assembly for the passenger seat assembly includes an integral base frame having a first leg and a first tube integrally formed therewith.

Description

[0001] Citation of relevant applications

[0002] This application is a continuation-in-part of International Application No. PCT / US2020 / 047006, filed on August 19, 2020, entitled “Structural Shield Assembly for Passenger Seats,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to seats for passenger vehicles, and more particularly to structural assemblies for various components of such seats. Background Technology

[0004] Passenger transport vehicles, such as airplanes, buses, trains, ships, and automobiles, include passenger seats in which passengers can sit and use during travel. Existing passenger seats comprise multiple structural components located at different positions within the seat. For example, spreaders can serve as interfaces connecting various components of the passenger seat, such as armrests, seat backs, tables, leg assemblies, etc. This typical / traditional construction imposes limitations, such as a higher number of parts, material waste, and trade-offs between optimization and manufacturability. Summary of the Invention

[0005] The terms “invention,” “the invention,” “this invention,” and “this invention” as used in this patent are intended to broadly refer to all the subject matter of this patent and the following patent claims. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the following patent claims. Embodiments of the invention covered by this patent are defined by the following claims rather than the summary of the invention. This summary is a high-level overview of various aspects of the invention and introduces some concepts further described in the following detailed description section. The summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to define the scope of the claimed subject matter. The subject matter should be understood by referring to the appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0006] According to certain embodiments of the present invention, a method of manufacturing a support assembly for a passenger seat assembly includes forming an upper support by forging or casting at least one of an aluminum alloy or a magnesium alloy, the upper support having a central cavity extending through the upper support. The method includes connecting the upper support to a lower support. In some embodiments, the lower support is configured to receive at least one seat crossbeam tube, and the upper support extends away from the lower support such that one end of the upper support is spaced apart from the lower support.

[0007] In some embodiments, the forming includes a forged or cast aluminum alloy. In various embodiments, the forming includes a forged or cast magnesium alloy. In some embodiments, forming the upper support includes forming at least one of a table stop or a table pivot together with the upper support.

[0008] In various embodiments, connecting the upper support to the lower support includes attaching the upper support to an interface of the lower support. In some aspects, forming the upper support includes forging or casting a first shield, forging or casting a second shield separate from the first shield, and connecting the first shield to the second shield. In some cases, forming the upper support includes forming an upper support with a wall thickness of 0.40 inches. Forming the upper support may also include forming auxiliary components together with the upper support by additive manufacturing, and in some cases, the auxiliary components include at least one of a table stop or a table pivot. In some aspects, the lower support is made of an aluminum alloy.

[0009] According to certain embodiments of the present invention, a method of manufacturing a passenger seat assembly includes forming a structural cover, wherein a first portion of the structural cover is cast or forged from an aluminum or magnesium alloy, and a second portion of the structural cover is formed by additive manufacturing. In some cases, the second portion includes a mesh structure. The method also includes connecting the structural cover to auxiliary components of the passenger seat assembly.

[0010] In some embodiments, the structural cover is an upper support, and the auxiliary component is a lower support configured to receive at least one seat crossbeam tube. Connecting the structural cover to the auxiliary component may include attaching the structural cover to the lower support such that the structural cover extends away from the lower support, spaced apart from one end of the upper support. In some cases, forming the structural cover includes forming a structural cover having a central cavity extending through it. In different embodiments, the structural cover is an armrest, and the auxiliary component is a support.

[0011] According to certain embodiments of the present invention, a structural cover for a passenger seat assembly includes a hollow body having a first end, a second end opposite to the first end, and a central cavity located between the first end and the second end. The wall thickness of the structural cover may be less than 0.08 inches, and the structural cover may comprise a magnesium alloy.

[0012] In some embodiments, at least a portion of the structural cover includes a mesh structure. In several aspects, the structural cover is an upper support connected to a lower support configured to receive at least one seat crossbeam tube. In some cases, the wall thickness is 0.04 inches. In various embodiments, the structural cover is an armrest. In some cases, an auxiliary component is integral with the structural cover, and the auxiliary component includes at least one of a table pivot or a table stop.

[0013] According to certain embodiments of the present invention, a method of forming a passenger seat includes integrally forming a first base frame including a first leg and a first tube. The method further includes integrally forming a second base frame having a second leg and a second tube. The method may include connecting the first base frame to the second base frame, and connecting the first base frame to the second base frame to form a base frame assembly for the passenger seat.

[0014] In some embodiments, integrally forming the first base frame includes casting a magnesium alloy into the first base frame, and integrally forming the second base frame includes casting a magnesium alloy into the second base frame. In various cases, a first leg extends vertically from a first tube portion, the first tube portion being elongated in a horizontal direction, a second leg extends vertically from a second tube portion, and the second tube portion being elongated in a horizontal direction.

[0015] In various embodiments, connecting the first tube portion of the first base frame to the second tube portion of the second base frame includes connecting the first tube portion to the second tube portion. Integrating the first base frame integrally may include integrally forming a first integral base frame having a third tube portion, such that the support legs extend vertically from the first tube portion and the third tube portion, and such that the third tube portion is offset from the first tube portion in a rearward direction.

[0016] In some embodiments, integrally forming the first base frame includes integrally forming a support portion having a first tube portion and a third tube portion. The support portion may extend from the first tube portion and the third tube portion at a location offset from the first support leg portion. In some embodiments, integrally forming the first base frame includes integrally forming at least one of a base support leg portion, a support leg portion, a support roller, a support partition, or a support inflator with the first tube portion and the first support leg portion.

[0017] According to certain embodiments of the present invention, an integral base frame for a passenger seat includes a leg portion and a tube portion integrally formed with said leg portion. The leg portion extends vertically from said tube portion, and said tube portion extends horizontally.

[0018] In some embodiments, the tube section is a first tube section, and the base frame also includes a second tube section integrally formed with the outrigger section. The second tube section may be offset from the first tube section in a rearward direction. In some aspects, at least one support section is integrally formed with the first and second tube sections, and the at least one support section may be offset from the outrigger section.

[0019] In various embodiments, the at least one support portion includes a first support portion and a second support portion integrally formed with the first tube portion and the second tube portion, and the support leg portion may be located between the first support portion and the second support portion. The integral base frame may also include at least one of a support inflator, a support partition, or a support roller integrally formed with the tube portion. In some cases, the support leg portion includes a first support leg, a second support leg, and a base support leg extending between the first support leg and the second support leg, and the base support leg is integrally formed with the first support leg and the second support leg.

[0020] According to certain embodiments of the present invention, a passenger seat includes a frame assembly having a first integral base frame and a second integral base frame. The first integral base frame includes a first leg and a first tube integrally formed therefrom. The first leg extends vertically from the first tube, and the first tube extends horizontally. The integral second base frame includes a second leg and a second tube integrally formed therefrom. The second leg extends vertically from the second tube, and the second tube extends horizontally. In various embodiments, the first integral base frame is connected to the integral second base frame to form a frame assembly. The frame assembly is configured to support the seat back of the passenger seat.

[0021] In some embodiments, the passenger seat also includes a seat back, and the seat back is pivotally connected to the base frame assembly, allowing the seat back to pivot relative to the base frame assembly. In some cases, a first integral base frame is attached to an integral second base frame, such that a first tube is connected to a second tube. In various embodiments, the first integral base frame is attached to the integral second base frame such that the second tube is offset rearwardly from the first tube.

[0022] In some embodiments, the first integral base frame includes a third tube integrally formed with the first leg portion, the third tube portion being offset rearwardly from the first tube portion. The integral base frame tube may also include at least one support portion integrally formed with the first tube portion and the third tube portion, and the at least one support portion may be offset from the leg portion.

[0023] In various aspects, the first integral base frame includes at least one of a support inflator, a support partition, or a support roller integrally formed with the tube portion. In some cases, the first leg portion includes a first leg, a second leg, and a base leg extending between the first leg and the second leg, and the base leg is integrally formed with the first leg and the second leg. Attached Figure Description

[0024] Figure 1 This is a side view of a passenger seat according to certain embodiments of the present invention.

[0025] Figure 2This is an exploded view of a support assembly according to certain embodiments of the present invention.

[0026] Figure 3 yes Figure 2 A three-dimensional view of the support components.

[0027] Figure 4 This is a side view of a support assembly according to certain embodiments of the present invention.

[0028] Figure 5 yes Figure 4 Side view of the lower support of the support assembly.

[0029] Figure 6 This is a side view of a support assembly according to certain embodiments of the present invention.

[0030] Figure 7 yes Figure 6 Rear view of the support components.

[0031] Figure 8 This is an exploded view of a handrail assembly according to certain embodiments of the present invention.

[0032] Figure 9 This is a perspective view of another support according to certain embodiments of the present invention.

[0033] Figure 10 yes Figure 9 Another perspective view of the support.

[0034] Figure 11 This is a perspective view of another support according to certain embodiments of the present invention.

[0035] Figure 12 yes Figure 11 Another perspective view of the support.

[0036] Figure 13 A base frame assembly according to certain embodiments of the present invention is shown.

[0037] Figure 14 This is a side view of a base frame assembly according to certain embodiments of the present invention. Detailed Implementation

[0038] The subject matter of this invention, specifically described herein, is intended to satisfy legal requirements, but is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future techniques. This description should not be construed as implying any particular order or arrangement of the steps or elements, unless the order of the steps or the arrangement of the elements is explicitly described.

[0039] Embodiments of the present invention provide structural components having structural covers for passenger seats. These structural components include, but are not limited to, spreaders, armrests, and in-flight entertainment covers. While the structural components discussed are used with aircraft seats, they are by no means limited thereto. Rather, embodiments of the structural components can be used with passenger seats or any other type of seat or other desired seating.

[0040] like Figure 1 As shown, the passenger seat assembly 100 may include a seat base assembly 102 and one or more seat backs 104 supported relative to the seat base assembly 102. The number of seat backs 104 should not be considered a limitation of the invention. In various examples, the number of seat backs 104 corresponds to the number of passengers the passenger seat can accommodate, and each seat back 104 and the corresponding portion of the seat base assembly 102 defines a particular passenger seat 126. Figure 1 In one example, passenger seat assembly 100 is capable of accommodating one passenger and therefore has a seat back 104 and a passenger seat 126. However, in other examples, passenger seat assembly 100 is capable of accommodating 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, passenger seat assembly 100 may also have any desired number of corresponding seat backs 104.

[0041] The seat base assembly 102 of the passenger seat assembly 100 typically includes a leg assembly 108 and at least one base tube 110. The seat base assembly 102 may also include a support frame 106, armrests 112, braces 114, luggage bars 116, or other components. A cushioning pad (not shown) may be provided on any component of the seat base assembly 102.

[0042] The seat back 104 is connected to the seat frame assembly 102 and is generally pivotable relative to the seat frame assembly 102, allowing the seat back 104 to be positioned in various positions, such as a taxi-takeoff-landing (TTL) position, a reclined position, etc. In some aspects, the seat back 104 is connected to the seat frame assembly 102 via a support 114. The seat back 104 includes a frame member 118 having a front side 120 and a rear side 122. In some cases, other components of the passenger seat assembly 100, such as a tray table 124, an in-flight entertainment display, or various other components, may be supported on and / or relative to the seat back 104. In some cases, other components, such as the tray table 124, may be pivotally connected to the support 114, and the tray table 124 may be movable relative to the rear side 122 of the seat back 104 between a stowed position and an extended position. A cushioning pad (not shown) may be provided on any component of the seat back 104.

[0043] Various structural components of the seat frame assembly 102 and / or seat back 104 may be subjected to different types of loads or forces during use. As a non-limiting example, for the support 114, the lower portion of the support 114 (e.g., the portion engaging one or more frame tubes 110) may be subjected to tensile loads or forces during use, and the upper portion of the support 114 (e.g., the portion connected to the seat back 104) may be subjected to lateral loads during use. Other structural components of the seat frame assembly 102 and / or seat back 104 include, but are not limited to, armrests and in-flight entertainment covers. In some aspects, and as discussed in detail below, one or more structural components may include structural covers.

[0044] Figure 2 and 3 An example of a support assembly 214 with an upper support 226 and a lower support 228 is shown. Similar to support 114, support assembly 214 is configured to connect a seat back to a seat frame assembly and support various other components such as a tray table. In various embodiments, and as described below, the upper support 226 is configured to engage and / or support the seat back of the passenger seat and / or other components such as a tray table, and to withstand push loads during use, and the lower support 228 is configured to engage with one or more frame tubes 110 and to withstand tensile loads during use.

[0045] In various embodiments, the upper support 226 is a structural cover 230 having a first end 232 and a second end 234 opposite to the first end 232. The specific shape of the structural cover 230 should not be considered a limitation of the invention. The structural cover 230 also has an inner surface 246 and an outer surface 248 extending from the first end 232 to the second end 234. Figure 2 and 3 As shown, the inner surface 246 defines a central cavity 236, such that the structural shield 230 is hollow along its length. In other words, due to the central cavity 236, the cross-sectional shape of the structural shield 230 can have a hollow center. In various examples, at least one of the first end 232 or the second end 234 defines an opening providing access to the central cavity 236. Figure 2 and 3In some embodiments, the first end 232 includes a first opening 238 providing an entrance to the central cavity 236, and the second end 234 includes a second opening 240 providing an entrance to the central cavity 236. Optionally, an intermediate opening 278 between the first end 232 and the second end 234 provides an entrance to the central cavity 236. In some non-limiting examples, components of the passenger seat assembly (including, but not limited to, power outlets, USB outlets, or other conveniences or components of the passenger seat) may be disposed in the intermediate opening 278. In some aspects, the first end 232 may be the topmost part of the assembled upper support 226 and lower support 228. In some embodiments, a reinforcement or reinforcing member 251 may optionally be provided on the structural cover 230. The reinforcement or reinforcing member 251 may be disposed on the inner surface 246 and / or the outer surface 248 as needed, and may reinforce the structural cover 230. In various embodiments, the reinforcement or reinforcing member 251 may be a separate component attached to the structural cover or may be integrally formed with the structural cover.

[0046] In some embodiments, the structural shield 230 includes a first shield 242 and a second shield 244 connected to the first shield 242. In various cases, the first shield 242 may be connected to the second shield 244 via various suitable means or mechanisms as needed, such that the second shield 244 can be selectively removed from the first shield 242 (e.g., to allow a larger entrance to the central cavity 236). As a non-limiting example, the second shield 244 may be detachably connected to the first shield 242 by mechanical fasteners, allowing access to cables or wiring or other features within the central cavity 236 as needed. The structural shield 230 may be constructed from a variety of suitable materials, including but not limited to aluminum, aluminum alloys, magnesium, magnesium alloys, stainless steel, aramid fibers, polycarbonate, polypropylene, other metallic materials including alloys, composite materials, or other similar materials. In one non-limiting example, the structural shield 230 is constructed from a reinforced plastic such as sheet molding compound. In another non-limiting example, the structural shield 230 is formed of aluminum or an aluminum alloy. In one non-limiting example, the structural shield 230 may be a 7xx.x series cast aluminum alloy, but in other embodiments, other aluminum alloys may be used as needed (e.g., 1xx.x series cast aluminum alloys, 2xx.x series cast aluminum alloys, 3xx.x series cast aluminum alloys, 4xx.x series cast aluminum alloys, 5xx.x series cast aluminum alloys, 6xx.x series cast aluminum alloys, 8xx.x series cast aluminum alloys, and / or 9xx.x series cast aluminum alloys). In another non-limiting example, the structural shield 230 is made of magnesium or a magnesium alloy. In one non-limiting example, the structural shield 230 is made of magnesium alloy WE43-T5, although in other embodiments, other magnesium alloys may be used as needed.

[0047] The structural cover 230 can be constructed using various forming techniques as needed. In some embodiments, the structural cover 230 is constructed using techniques including, but not limited to, injection molding, vacuum forming, forging, casting, additive manufacturing, machining, combinations thereof, or other desired techniques. In a non-limiting embodiment, the structural cover 230 can be formed by a combination of casting or forging and additive manufacturing. In various aspects, the structural cover 230 is integrally or uniformly formed as a single component. In other aspects, the first cover 242 and the second cover 244 can each be integrally formed as a single component, which are connected together as needed by various suitable mechanisms, devices, or techniques. In some embodiments, integrally forming the structural cover 230 (or the first cover 242 and the second cover 244) allows various components that are typically separate components to be integrally formed with the cover itself, thereby providing component reduction and / or weight reduction for the passenger seat assembly. As some non-limiting examples, the table pivot 250 and / or table stop 252 can be integrally formed with the structural cover 230. Various other components of the passenger seat can be integrally formed with the structural cover 230 as needed.

[0048] In some embodiments, the structural cover 230 disclosed herein may optionally have a reduced wall thickness compared to existing structures, thereby reducing the weight of the entire passenger seat assembly. As some non-limiting examples, the wall thickness of the structural cover 230 may be less than or equal to about 0.080 inches, for example less than or equal to about 0.060 inches, for example about 0.040 inches. In other embodiments, the structural cover 230 may have various other wall thicknesses as needed.

[0049] like Figure 2 and 3 As shown, the lower support 228 includes a front end 254 and a rear end 256 opposite to the front end 254. The specific shape of the lower support 228 should not be considered a limitation of the invention. Compared to the upper support 226, the lower support 228 does not include an inner surface and / or a central cavity extending along the length of the lower support. In other words, the cross-sectional shape of the lower support 228 may differ from the cross-sectional shape of the upper support 226. In some non-limiting embodiments, the center of the cross-sectional shape of the lower support 228 may be solid, rather than a positioning element with a hole for the base tube (discussed below). In some aspects, the front end 254 may be the foremost portion of the support assembly 214. In various aspects, the rear end 256 may be the rearmost and / or bottommost portion of the support assembly 214, although it does not need to be the rearmost and / or bottommost portion. Figure 2 and Figure 3In one example, a portion of the upper support 226 extends rearward from the rear end 256. In other embodiments, the lower support 228 may be a structural cover similar to the structural cover 230 and may define a central cavity such that the lower support 228 is hollow. In such embodiments, the lower support 228 may be a separate component connected to the upper support 226 as needed via various suitable connectors or connection mechanisms, or the lower support 228 and the upper support 226 may be formed as an integral or monolithic component.

[0050] In various embodiments, the lower support 228 includes one or more holes 258 extending through the thickness of the lower support 228 and defined between a front end 254 and a rear end 256, the one or more holes 258 receiving and engaging one or more base tubes of the passenger seat assembly. Figure 2 and Figure 3 In one embodiment, the lower support 228 includes two holes 258. In other embodiments, other suitable interfaces for the base frame tubes may be provided. The lower support 228 may also include interfaces for other components of the seat base of the passenger seat assembly, as needed. The lower support 228 may be constructed from various materials suitable for engaging one or more base frame tubes and the upper support 226, as needed.

[0051] The upper support 226 can be connected to the lower support 228 near the second end 234. In various examples, the lower support 228 may include an interface 266 for connecting the upper support 226 to the lower support 228. Figure 2 As best shown, in Figure 2 and 3 In one embodiment, interface 266 includes a ridge 268 having a mounting hole 270. Various other types of interface 266 may be used as needed, and it may not be necessary to include a ridge 268 and / or a mounting hole 270. In some cases, the lower support 228 may be partially received within the central cavity 236, although this is not necessary in other examples (see, for example...). Figure 4 The upper support 226 can be connected to the support 228 by various suitable devices or mechanisms as needed, including but not limited to mechanical fasteners.

[0052] In some cases, connectors and / or other components that engage with features of the seat back may optionally be provided on the structural cover 230 and extend outward from the outer surface 248. Such connectors and / or other components may be connected to the structural cover 230 via various suitable mechanisms or devices as needed, or they may be integrally or integrally formed with the structural cover 230. Figure 2 and 3 In one embodiment, the structural cover 230 includes a table pivot 250 and a table stop 252 integrally formed with the structural cover 230.

[0053] Optionally, such as Figure 2 and 3 As shown, the support assembly 214 includes a handrail pivot 260 supported near a first end 232 of the upper support 226. The handrail pivot 260 can be connected to the upper support 226 via various suitable means or mechanisms as needed. In some aspects, the handrail pivot 260 includes one or more pivot slots 262 that engage with a handrail, allowing the handrail to pivot relative to the support assembly 214.

[0054] The support assembly 214 can be referred to as a "split" support assembly, which can be superior to conventional supports. In one aspect, the split support assembly 214 can maximize the inertia of the upper support 226 and reduce the required mass to achieve the necessary stiffness to withstand forces from armrests, seat backs, etc. The split support assembly 214 can also optionally reduce the number of components required for the support by embedding one or more components (e.g., reinforcements, table stops, pivots, etc.) into the structural housing. In some cases, the split support assembly 214 can reduce the amount of material waste caused by the typical crescent shape of conventional supports. The split support assembly 214 can also optimize the stiffness and strength requirements of the sections connecting armrests, seat backs, etc., independently of the stiffness and strength requirements of the sections connecting one or more base frame tubes that need to withstand a 16G load.

[0055] Figure 4 and Figure 5 Another embodiment of the support assembly 414 is shown, which is substantially similar to support assembly 214 and includes an upper support 426 and a lower support 428. The upper support 426 is similar to upper support 226 and includes a structural shield 430. Compared to upper support 226, the structural shield 430 of the upper support 426 has a different shape than structural shield 230, and the structural shield 430 is integral and does not include the first shield 242 and the second shield 244. Figure 4 As shown, interface component 464 can connect armrest pivot 260 to upper support 426. The lower support 428 is substantially similar to the upper support 426, except that interface 266 includes a ridge 468 with two fixing holes 270.

[0056] Figure 6 and 7Another embodiment of the support assembly 614 is shown, which is substantially similar to support assembly 214 and includes an upper support 626 and a lower support 628. The upper support 626 is similar to upper support 226 and includes a structural cover 630. Compared to upper support 226, the structural cover 630 of the upper support 626 has a different shape than structural cover 230, and the structural cover 630 is integral and does not include a first cover 242 and a second cover 244. The lower support 628 is substantially similar to lower support 628, except that the interface 266 includes a flange 672 that engages the upper support 626 and secures the lower support 628 to the upper support 626, without requiring separate fasteners or other connecting devices. Compared to support assembly 214, the table pivot 650 and table stop 652 are separate components supported on the structural cover 630.

[0057] Figure 8 Examples of handrails 812 with structural shields 830 according to various embodiments are shown. Similar to structural shield 230, structural shield 830 includes a first shield 842 and a second shield 844. Compared to structural shield 230, the second end 234 of structural shield 830 does not include a second opening 240. Figure 8 In one embodiment, the central opening 278 is configured to receive the actuator 874 of the handrail 812, and the cable 876 for the actuator 874 can be accommodated within the central cavity 236.

[0058] Figure 9 and 10 An integral or monolithic support 901 according to various embodiments is shown. In some embodiments, the support 901 may be a passageway support configured to engage with one end of one or more base frame (or structural) tubes. In some embodiments, the support 901 is integrally formed by casting or forging a metallic material including, but not limited to, aluminum, aluminum alloys, magnesium, or magnesium alloys. Figure 9 and 10 As shown, the support 901 includes a first end 903, a second end 905, a first surface 907, and a second surface 909. In some embodiments, the second end 905 may include a mounting feature 911 integrally formed with the support 901. When the passenger seat is assembled with the support 901, various features (including but not limited to armrests) may be connected to the support 901 via the mounting feature 911.

[0059] As in Figure 9As best illustrated, in some embodiments, the first surface 907 includes one or more positioning recesses and / or anchor points 913A-C that can engage with other components of the passenger seat assembly. The number, shape, size, and location of the positioning recesses 913A-D should not be considered as a limitation of the invention. In some embodiments, the positioning recesses 913A-B are configured to engage with the base tube of the passenger seat assembly, and the positioning recesses and / or anchor points 913C-D are configured to engage with additional structures of the passenger seat. As a non-limiting example, the anchor point 913C may be an attachment point for a seatbelt for the passenger seat. Figure 10 Ideally, the positioning recesses 913A-D may be omitted from the second surface 909 compared to the first surface 907. In some embodiments, the second surface 909 may be the outermost part of the passenger seat assembly when the passenger seat is assembled with the support 901.

[0060] Figure 11 and 12 Another embodiment of the support assembly 1114 according to various embodiments is shown. The support assembly 1114 is similar to the support assembly 214 and includes an upper support 1126 and a lower support 1128. The lower support 1128 is substantially similar to the lower support 228, except that the lower support 1128 has a different shape or profile, and the ridge 968 of the user interface 266 has a different profile or shape than the ridge 268.

[0061] The upper support 1126 is similar to the upper support 226 and includes a structural cover 1130 having a first cover 1140 and a second cover 1142. Compared to the upper support 226, where the first cover 242 and the second cover 240 are joined in the front-rear direction, the first cover 1140 and the second cover 1142 are joined in the left-right direction. Compared to the upper support 226, the upper support 1126 also omits the opening 238 (i.e., the upper support 1126 only includes the second opening 240). Furthermore, compared to the upper support 226, the armrest pivot 1162 is integrally formed with the structural cover 1126. Figure 11 and 12In one embodiment, the table pivot 250 and / or table stop 252 are integrally or integrally formed with each of the first cover 1140 and the second cover 1142. In different embodiments, the first cover 1140 and / or the second cover 1142 are integrally or integrally formed by casting or molding and may comprise aluminum, aluminum alloy, magnesium, or magnesium alloy, and the first cover 1140 and the second cover 1142 are connected by fastening mechanisms (e.g., screws, adhesives, bolts, pins, hooks, and other suitable mechanisms as desired). In other embodiments, the first cover 1140 and / or the second cover 1142 may be formed by other techniques as needed, may be constructed from various other materials as needed, and may be connected by other techniques as needed. In other embodiments, the structural cover 1130 may be formed as a single integral or integral component.

[0062] Figure 13 An embodiment of a base frame assembly 1302 according to certain embodiments of the present invention is shown. Compared with base frame assembly 102, base frame assembly 1302 includes a first integral base frame 1315A and a second integral base frame 1315B, the first integral base frame 1315A and the second integral base frame 1315B being connected together to form base frame assembly 1302.

[0063] The following description refers to a first integral base frame 1315A, but the description also applies to a second integral base frame 1315B unless otherwise stated. Optionally, the second integral base frame 1315B may be mirror-image of the first integral base frame 1315A, although this is not required in other embodiments. The first integral base frame 1315A is integrally or monolithically formed by various techniques, including but not limited to casting, forging, and / or additive manufacturing. In some embodiments, the first integral base frame 1315A is made of a metallic material, including but not limited to aluminum, aluminum alloys, magnesium, or magnesium alloys. In a non-limiting embodiment, the first integral base frame 1315A is formed by casting or forging magnesium or magnesium alloys.

[0064] like Figure 13 As shown, the first integral base frame 1315A includes a leg portion 1317 integrally or integrally formed with at least one tube portion 1310. Figure 13 In some embodiments, the leg portion 1317 is integrally or integrally formed with two tube portions 1310. In embodiments having more than one tube portion 1310, the leg portion 1317 extends from both tube portions 1310, and one tube portion 1310 is forward (or backward) relative to the other tube portion 1310. The leg portion 1317 extends in a vertical direction, while the tube portions 1310 extend in a horizontal direction.

[0065] In addition to the leg portion 1317 and at least one tube portion 1310, the first integral base frame 1315A may optionally include one or more additional features integrally formed with the leg portion 1317 and at least one tube portion 1310. In some embodiments, the first integral base frame 1315A includes at least one support portion 1314 integrally formed with one or more tube portions 1310. The seat back may optionally be attached to the at least one support portion 1314. Figure 13 In one embodiment, the first integral base frame 1315A includes two support portions 1314. In an embodiment where the first integral base frame 1315A includes more than one tube portion 1310, the at least one support portion 1314 may extend from these tube portions 1310 at a location offset from the support leg portion 1317. In an embodiment where the first integral base frame 1315A includes more than one support portion 1314, the support leg portion 1317 may optionally be located between adjacent support portions 1314.

[0066] In some embodiments, the outrigger 1317 may optionally include a first outrigger 1319, a second outrigger 1321, and a base outrigger 1323 extending between the first outrigger 1319 and the second outrigger 1321. Optionally, the first integral base frame 1315A may, as needed, add and / or remove portions integrally formed with the outrigger 1317, one or more tube portions 1310, and / or other portions. Other integrally formed features may include, but are not limited to, a support inflator portion 1325, a support partition portion 1327, and / or a support roller portion 1329 integrally formed with one or more tube portions 1310.

[0067] In some embodiments, forming the base frame assembly 1302 may include connecting a tube portion 1310 of a first integral base frame 1315A to a corresponding tube portion 1310 of a second integral base frame 1315B. The connecting tube portions 1310 may be joined using various suitable techniques or mechanisms, including but not limited to welding, mechanical fasteners, adhesives, combinations thereof, or other desired mechanisms. In other embodiments, the base frame assembly 1302 may be formed by joining and / or otherwise connecting other portions of the integral base frames 1315A-B.

[0068] Figure 14 A base frame assembly 1402 according to various embodiments is shown. Base frame assembly 1402 is substantially similar to base frame assembly 1302 because it is integrally or monolithically formed. Compared to base frame assembly 1302, base frame assembly 1402 includes legs 1417, supports 1414 formed by additive manufacturing, and tubular portions 1310 formed by casting or forging. Figure 14As shown, the legs 1417 and the brace 1414 include a mesh network 1431. While shown as a uniform mesh network 1431 (e.g., the shape and size of the supports 1433 and openings 1435 of the mesh network 1431 are uniform), in other embodiments, the mesh network 1431 need not be uniform, and the mesh network 1431 may have areas with enlarged supports 1433 / reduced openings 1435 (e.g., to increase the structural performance of that area) and / or areas with enlarged openings 1435 / reduced supports 1433 (e.g., to provide weight savings and / or if a portion does not require specific structural performance). The frame assembly 1402 may include other features or components similar to those discussed for the frame assembly 1302.

[0069] The following provides a collection of exemplary embodiments, including at least some explicitly listed as “examples,” which provide additional descriptions of various exemplary embodiments based on the concepts described herein. These descriptions are not intended to be mutually exclusive, exhaustive, or limiting; and this disclosure is not limited to these illustrative examples, but includes all possible modifications and variations within the scope of the published claims and their equivalents.

[0070] Example 1. A method of producing a support assembly for a passenger seat assembly, the method comprising: forming an upper support by forging or casting at least one of an aluminum alloy or a magnesium alloy, the upper support including a central cavity extending through the upper support; and connecting the upper support to a lower support, wherein the lower support is configured to receive at least one seat crossbeam tube, and wherein the upper support extends away from the lower support such that one end of the upper support is spaced apart from the lower support.

[0071] Example 2. Any method of the foregoing or subsequent examples or combinations thereof, wherein forming includes forging or casting the aluminum alloy.

[0072] Example 3. A method of any of the foregoing or subsequent examples or combinations thereof, wherein forming includes forging or casting the magnesium alloy.

[0073] Example 4. A method of any of the foregoing or subsequent examples or combinations thereof, wherein the forming upper support includes forming at least one of a table stop or a table pivot together with the upper support.

[0074] Example 5. A method of any of the foregoing or subsequent examples or combinations thereof, wherein connecting the upper support to the lower support includes an interface for attaching the upper support to the lower support.

[0075] Example 6. A method for any of the foregoing or subsequent examples or combinations thereof, wherein forming the upper support includes forging or casting a first shield, forging or casting a second shield separate from the first shield, and joining the first shield to the second shield.

[0076] Example 7. A method of any of the foregoing or subsequent examples or combinations thereof, wherein forming the upper support includes forming an upper support with a wall thickness of 0.40 inches.

[0077] Example 8. A method of any of the foregoing or subsequent examples or combinations thereof, wherein forming the upper support further includes forming an auxiliary component using the upper support by additive manufacturing.

[0078] Example 9. A method of any of the foregoing or subsequent examples or combinations thereof, wherein the auxiliary component includes at least one of a table stop or a table pivot.

[0079] Example 10. A method of any of the foregoing or subsequent examples or combinations thereof, wherein the lower support comprises an aluminum alloy.

[0080] Example 11. A method of producing a passenger seat assembly, the method comprising: forming a structural cover by casting or forging an aluminum or magnesium alloy into a first portion of the structural cover, and forming a second portion of the structural cover via additive manufacturing, wherein the second portion includes a mesh structure; and connecting the structural cover to an auxiliary component of the passenger seat assembly.

[0081] Example 12. A method of any of the foregoing or subsequent examples or combinations thereof, wherein the structural cover is an upper support, wherein the auxiliary member is a lower support configured to receive at least one seat crossbeam tube, and wherein engaging the structural cover with the auxiliary member includes attaching the structural cover to the lower support such that the structural cover extends away from the lower support such that the end of the upper support is spaced apart from the lower support.

[0082] Example 13. A method of any of the foregoing or subsequent examples or combinations thereof, wherein forming the structural shield includes forming the structural shield having a central cavity extending through the structural shield.

[0083] Example 14. A method of any of the foregoing or subsequent examples or combinations thereof, wherein the structural guard is a handrail and wherein the auxiliary component is a support.

[0084] Example 15. A structural cover for a passenger seat assembly, the structural cover including a hollow body including a first end, a second end opposite to the first end, and a central cavity between the first end and the second end, wherein the wall thickness of the structural cover is less than 0.08 inches, and wherein the structural cover comprises a magnesium alloy.

[0085] Example 16. A structural shield of any of the foregoing or subsequent examples or combinations thereof, wherein at least a portion of the structural shield comprises a mesh structure.

[0086] Example 17. A structural cover for any of the foregoing or subsequent examples or combinations thereof, wherein the structural cover is an upper support that can be connected to a lower support configured to receive at least one seat crossbeam tube.

[0087] Example 18. A structural shield for any of the foregoing or subsequent examples or combinations thereof, wherein the wall thickness is 0.04 inches.

[0088] Example 19. A structural cover for any of the foregoing or subsequent examples or combinations thereof, wherein the structural cover is a handrail.

[0089] Example 20. A structural cover for any of the foregoing or subsequent examples or combinations thereof, wherein an auxiliary component is integral with the structural cover, and wherein the auxiliary component includes at least one of a table pivot or a table stop.

[0090] Example 21. A method of forming a passenger seat, the method comprising: integrally forming a first base frame, wherein the first integral base frame includes a first leg and a first tube; integrally forming a second base frame, wherein the integral second base frame includes a second leg and a second tube; and connecting the first base frame to the second base frame, wherein connecting the first base frame to the second base frame forms a base frame assembly of the passenger seat.

[0091] Example 22. A method of any of the foregoing or subsequent examples or combinations thereof, wherein integrally forming the first base frame includes casting a magnesium alloy into the first base frame, and wherein integrally forming the second base frame includes casting a magnesium alloy into the second base frame.

[0092] Example 23. A method of any of the foregoing or subsequent examples or combinations thereof, wherein the first leg extends vertically from the first tube, wherein the first tube is elongated horizontally, wherein the second leg extends vertically from the second tube, and wherein the second tube is elongated horizontally.

[0093] Example 24. A method of any of the foregoing or subsequent examples or combinations thereof, wherein engaging the first tube portion of the first base frame with the second tube portion of the second base frame comprises engaging the first tube portion with the second tube portion.

[0094] Example 25. A method of any of the foregoing or subsequent examples or combinations thereof, wherein integrally forming the first base frame includes integrally forming the first integral base frame having a third tube portion, wherein the leg portion extends vertically from both the first tube portion and the third tube portion, wherein the third tube portion is offset from the first tube portion in a rearward direction.

[0095] Example 26. A method of any of the foregoing or subsequent examples or combinations thereof, wherein integrally forming the first base frame includes integrally forming a support portion with the first tube portion and the third tube portion, wherein the support portion extends from the first tube portion and the third tube portion at a location offset from the first leg portion.

[0096] Example 27. A method of any of the foregoing or subsequent examples or combinations thereof, wherein integrally forming the first base frame includes integrally forming at least one of a base leg, a support leg, a support roller, a support partition, or a support inflator with the first tube and the first leg.

[0097] Example 28. An integral base frame for a passenger seat, the integral base frame including legs and a tube integrally formed with the legs, wherein the legs extend from the tube in a vertical direction and wherein the tube extends in a horizontal direction.

[0098] Example 29. An integral base frame of any of the foregoing or subsequent examples or combinations thereof, wherein the tube is a first tube, and wherein the base frame further includes a second tube integrally formed with the leg, wherein the second tube is offset in a rearward direction from the first tube.

[0099] Example 30. An integral base frame of any of the foregoing or subsequent examples or combinations thereof, further comprising at least one support portion integrally formed with the first tube portion and the second tube portion, wherein the at least one support portion is offset from the support leg portion.

[0100] Example 31. An integral base frame of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one support portion includes a first support portion and a second support portion integrally formed with the first tube portion and the second tube portion, wherein the support leg portion is located between the first support portion and the second support portion.

[0101] Example 32. Any monolithic base frame of the foregoing or subsequent examples or combinations thereof, further comprising at least one of a support inflator, a support partition or a support roller integrally formed with the tube portion.

[0102] Example 33. An integral base frame of any of the foregoing or subsequent examples or combinations thereof, wherein the leg portion includes a first leg, a second leg and a base leg extending between the first leg and the second leg, wherein the base leg is integrally formed with the first leg and the second leg.

[0103] Example 34. A passenger seat including a frame assembly, the frame assembly comprising: a first integral frame including a first leg and a first tube integrally formed therewith, wherein the first leg extends vertically from the first tube and wherein the first tube extends horizontally; and an integral second frame including a second leg and a second tube integrally formed therewith, wherein the second leg extends vertically from the second tube and wherein the second tube extends horizontally, wherein the first integral frame is attached to the second integral frame to form the frame assembly, and wherein the frame assembly is configured to support a seat back of the passenger seat.

[0104] Example 35. A passenger seat of any of the foregoing or subsequent examples or combinations thereof, further comprising the seat back, wherein the seat back is pivotally connected to the base frame assembly such that the seat back is pivotable relative to the base frame assembly.

[0105] Example 36. A passenger seat of any of the foregoing or subsequent examples or combinations thereof, wherein the first integral base frame is attached to the second integral base frame such that the first tube is connected to the second tube.

[0106] Example 37. A passenger seat of any combination of the foregoing or subsequent examples, wherein the first integral base frame is connected to the integral second base frame such that the second tube is offset from the first tube in a rearward direction.

[0107] Example 38. A passenger seat of any of the foregoing or subsequent examples or combinations thereof, wherein the first integral base frame further comprises: a third tube integrally formed with the first outrigger portion, wherein the third tube portion is offset in a rearward direction from the first tube portion; and at least one support portion integrally formed with the first tube portion and the third tube portion, wherein the at least one support portion is offset from the outrigger portion.

[0108] Example 39. A passenger seat of any of the foregoing or subsequent examples or combinations thereof, wherein the first integral base frame further includes at least one of a bracket inflator, a bracket partition or a bracket roller integrally formed with the tube portion.

[0109] Example 40. A passenger seat of any combination of the foregoing or subsequent examples, wherein the first leg portion includes a first leg, a second leg, and a base leg extending between the first leg and the second leg, wherein the base leg is integrally formed with the first leg and the second leg.

[0110] Different arrangements of the components depicted in the accompanying drawings or described above, as well as components and steps not shown or described, are possible. Similarly, some features and sub-combinations are useful and can be used without reference to other features and sub-combinations. The description of embodiments of the invention is for illustrative purposes and not for limiting purposes, and alternative embodiments will become apparent to the reader of this patent. Therefore, the invention is not limited to the embodiments described above or shown in the drawings, and various embodiments and modifications can be made without departing from the scope of the claims.

Claims

1. A method for producing a support assembly (214) for a passenger seat assembly, the method comprising: An upper support (226) is formed, the upper support (226) including a central cavity (236) extending through the upper support (226), wherein the upper support (226) is a structural shield (230) having a first end (232) and a second end (234) opposite to the first end (232), wherein the upper support (226) is hollow along the length of the structural shield (230) and includes at least one opening providing an entrance to the central cavity (236), wherein forming the upper support (226) includes forging or casting an aluminum or magnesium alloy into a first portion of the upper support (226), and forming a second portion of the upper support (226) by additive manufacturing, wherein the second portion includes a mesh structure; and The upper support (226) is connected to the lower support (228), wherein the lower support (228) is configured to receive at least one base tube (110), and wherein the upper support (226) extends away from the lower support (228) such that one end of the upper support (226) is spaced apart from the lower support.

2. The method of claim 1, wherein, The upper support (226) is formed together with the upper support (226) to form at least one of a table stop (252) or a table pivot (250).

3. The method of claim 1, wherein, Connecting the upper support (226) and the lower support (228) includes attaching the upper support (226) to the interface of the lower support (228).

4. The method of claim 1, wherein, Forming the upper support (226) includes forging or casting a first shield (242), forging or casting a second shield (244) separate from the first shield (242), and connecting the first shield (242) and the second shield (244).

5. The method of claim 1, wherein, Forming the upper support (226) includes forming an upper support (226) with a wall thickness of 0.40 inches.

6. The method of claim 1, wherein, Forming the upper support (226) also includes forming auxiliary components on the upper support (226) by additive manufacturing.

7. The method of claim 6, wherein, The auxiliary component includes at least one of a table stop or a table pivot.

8. The method according to claim 1, wherein, The lower support (228) is made of aluminum alloy.

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