Sleeper Bunk Lattice Support and Pivoting Rails
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Solution Overview
Problem
Existing sleeper bunks in vehicles lack flexibility and efficiency in design, requiring multiple molds for various vehicle sizes and complicating manufacturing, while also not providing adequate support and safety features.
Innovation Solution
A sleeper system with upper and lower bunks featuring a lattice support structure and extruded metal rails that pivot between stored and operable positions, incorporating a latch system and safety restraints, allowing for customizable design and assembly for different vehicle sizes with improved manufacturability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional sleeper bunk designs are used for different vehicle sizes, then multiple molds are required, but manufacturing complexity and cost increase
Solution Approach 1:
The sleeper bunk system is designed with universal components that can be adapted to different vehicle sizes. The frame structure uses standardized rails and support members that can be configured for various bunk positions and dimensions, allowing a single mold design to serve multiple vehicle applications rather than requiring size-specific molds for each vehicle type.
Solution Approach 2:
The sleeper bunk is divided into modular components including the frame, lattice support, mattress base, and positioning mechanisms. This segmentation allows individual components to be manufactured using standard molds and then assembled in different configurations to suit various vehicle sizes, reducing the need for multiple specialized molds.
2Area of stationary object
If sleeper bunks are designed to move between stored and operable positions, then space efficiency improves, but structural support and safety may be compromised
Solution Approach 1:
The sleeper bunk incorporates movable components including the frame that can pivot between stored and operable positions, and the mattress base that can be raised or lowered. These dynamic elements are designed with reinforced joints and support structures that maintain structural integrity during movement and when supporting user weight in the operable position.
Solution Approach 2:
The lattice support structure is pre-assembled and rigidly attached to the frame before the bunk is installed in the vehicle. This preliminary structural preparation ensures that the support framework is already strengthened and positioned correctly to handle the stresses of movement and weight-bearing operations.
3Reliability
If sleeper bunks include safety restraints and latch systems, then user safety improves, but device complexity increases
Solution Approach 1:
The safety restraint system is integrated with the bunk frame structure rather than being a separate additive component. The latch mechanisms are incorporated into the frame's moving parts, combining the structural elements with safety functions to minimize overall system complexity while maintaining comprehensive safety features.
Data Source
AI summary
In one aspect, a sleeper bunk is provided that includes a support for a mattress. The support includes an assembly of support portions each having at least one surface arranged to support an underside of the mattress. The sleeper bunk includes at least one mount connected to the support and configured to facilitate movement of the support and the mattress thereon between a raised orientation and a lowered orientation. The support portions have overlapping portions configured to distribute a load from the mattress between the support portions.