Aircraft Headrest Assembly with Flexible Wire Frame and Tensioned Fabric Cover
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Solution Overview
Problem
Conventional headrests for aircraft seats are heavy, inflexible, and fail to accommodate various head sizes and shapes, with adjustable features being underutilized and complex, and are not easily customizable or serviceable, posing challenges for comfort and safety.
Innovation Solution
A headrest assembly featuring a flexible wire frame with a concave curve supported by a fabric cover, eliminating solid cushioning and incorporating an adjustment mechanism with guide rails and friction members for vertical adjustment, allowing the headrest to be lightweight, customizable, and serviceable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid cushioning is applied over a rigid support, then structural strength is improved, but weight increases and flexibility decreases
Solution Approach 1:
The patent replaces solid cushioning with a stretched fabric cover that acts as a flexible shell. The fabric is tensioned over a flexible support structure (wire frame), creating a hollow pocket that provides both structural integrity and flexibility. This eliminates heavy solid cushions while maintaining strength through the tensioned membrane structure.
Solution Approach 2:
The headrest combines a flexible wire frame support structure with a fabric cover to create a composite construction. The wire frame provides the rigid support framework while the fabric cover provides the cushioning surface, achieving both strength and weight reduction through material composition.
2Strength
If solid cushioning is applied over a rigid support, then structural strength is improved, but flexibility and adaptability to different head sizes decrease
Solution Approach 1:
The stretched fabric cover creates a flexible surface that can conform to various head shapes and sizes. The hollow pocket behind the fabric allows the material to deform and adapt to different anatomical features while the wire frame maintains overall structural support.
Solution Approach 2:
The headrest construction allows dynamic adaptation through the flexible fabric surface that can change shape in response to different head positions and sizes. The wire frame provides stable support while the fabric cover dynamically adjusts to accommodate various passengers.
3Adaptability or versatility
If adjustable mechanisms are incorporated, then adaptability to different positions is improved, but device complexity and weight increase
Solution Approach 1:
The flexible fabric cover and wire frame construction inherently provides adaptability without requiring complex mechanical adjustment mechanisms. The flexible structure can passively adapt to different head positions and angles through its material properties rather than active mechanical adjustment.
4Area of stationary object
If knitted fabrics are applied tightly over solid cushions, then coverage is improved, but weight increases and ease of maintenance decreases
Solution Approach 1:
The stretched fabric cover is mounted in a loose manner over the wire frame, creating a hollow pocket that allows the fabric to be easily removed and replaced. This loose mounting approach contrasts with tight application over solid cushions, significantly improving maintenance ease while maintaining full coverage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The flexible wire frame and tensioned fabric cover provide a comfortable, universal fit for different head sizes, reducing weight and complexity while enabling easy adjustment and maintenance, enhancing passenger comfort and safety.
Implementation Method 1
friction members engaging the spaced guide rails
Data Source
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AI summary
A headrest assembly including a plate (34) attachable to a front side of a seat back (22), a flexible support structure (36) attached to the plate, and a continuous fabric cover (50) stretched over the flexible support structure and tensioned to create a hollow pocket behind the fabric cover and forward of the plate to allow the fabric cover to depress inward toward the plate in response to loading on a center portion of the fabric cover. The flexible support may be a flexible wire frame having symmetrical side portions angled away from the plate to induce a concave curve in the fabric cover to cradle the head of a seat occupant. The assembly may further include an adjustment mechanism (54) for adjusting the position of the headrest relative to the seat back.