Extruded Beam Frame with Kerf Bending for Articulating Bed Assembly
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Solution Overview
Problem
The existing manufacturing processes for articulating bed frames require significant tooling, labor, and multiple part numbers due to varying sizes, and often involve heavy mechanical fasteners and welding, making them cumbersome and costly to produce.
Innovation Solution
An extruded metal frame with an inner flange and support channel is cut to form side and end elements, using saw kerfs for bending to create the frame, which allows for easy assembly with minimal tooling and simple fasteners, enabling the production of frames in various sizes with reduced part numbers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If assembled wood and/or metal frames are employed to support articulating elements, then the frame can provide structural support, but the manufacturing requires significant tooling, labor, and multiple part numbers for varying sizes
Solution Approach 1:
The patent applies universality by designing a single extruded beam profile that serves multiple functions: it provides structural support, incorporates integrated bolster attachment features through the upper inner flange, and includes support channels for articulating elements. This universal beam design can be adapted to various bed sizes (twin, queen, king, super king) by simply varying the cut lengths and kerf positions, eliminating the need for multiple specialized part numbers for each size configuration.
Solution Approach 2:
The patent merges multiple previously separate components into a single integrated extruded beam structure. The beam combines the functions of side rails, end rails, bolster supports, and articulating element supports into one continuous extrusion. This merging reduces assembly complexity and eliminates the need for separate attachment brackets and fasteners that would otherwise be required to connect multiple frame parts.
2Strength
If welding or heavy mechanical fasteners are required for assembly, then the frame achieves structural integrity, but the assembly becomes cumbersome and costly
Solution Approach 1:
The patent merges the functions of separate attachment components into the extruded beam itself. The upper inner flange integrates bolster attachment features directly into the beam structure, eliminating the need for separate brackets. The support channel is formed as an integral part of the extrusion, providing built-in support for articulating elements without requiring additional fasteners or connectors.
Solution Approach 2:
The extruded beam design provides self-service by incorporating all necessary attachment features directly into the beam structure. The upper inner flange and support channel are formed as integral parts of the extrusion process, meaning the beam serves its own attachment needs without requiring external brackets, fasteners, or complex assembly operations. This self-contained design simplifies assembly while maintaining structural integrity.
Data Source
AI summary
An articulating bed frame incorporates an extruded metal frame shape which is formed into any desired bed size by slicing of kerfs in the extrusion for side lengths with bending at the kerfs around sized base plate elements to create the completed frame. The frame employs an extruded beam having an inner flange and a support channel formed therein. The extruded beam is cut to form frame side elements and end elements and a plurality of support blocks are received in and support by the support channel. The support blocks engage a cradle supporting a seat section of an articulating structure.