Foldable Adjustable Bed Base with Pre-Attached Pivoting Leg Assemblies
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Solution Overview
Problem
Conventional adjustable bed bases require assembly of leg assemblies post-shipping, necessitating tools and skilled assembly, leading to increased costs and customer frustration due to potential improper assembly.
Innovation Solution
A foldable adjustable bed base design with pre-attached leg assemblies that pivot between a raised position for storage and a lowered position for use, utilizing push pin assemblies and U-shaped mounting brackets for tool-less assembly and compact shipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If leg assemblies are shipped separately in an unassembled state, then shipping efficiency and cost are improved, but assembly time and complexity increase
Solution Approach 1:
The patent combines the leg assemblies with the bed base frame by pre-attaching them during manufacturing. The leg assemblies are integrated into the frame structure and can be folded against the frame, merging what were previously separate components into a unified assembly that ships together as one unit.
Solution Approach 2:
The leg assemblies are designed to fold against and nest within the frame structure during shipping. The legs can be positioned in a compact configuration that fits within the overall footprint of the bed base, allowing efficient space utilization in the shipping container.
2Strength
If conventional assembly with hardware and tools is used, then structural strength is improved, but ease of assembly deteriorates
Solution Approach 1:
The leg assemblies are pre-attached to the frame during manufacturing, performing the assembly service beforehand. This eliminates the need for the consumer to perform assembly operations, tools, or hardware installation, while still achieving the required structural strength through factory-controlled attachment processes.
Solution Approach 2:
The attachment of leg assemblies to the frame is performed in advance during manufacturing rather than at the consumer location. This preliminary action ensures proper assembly with appropriate strength while removing the assembly burden from the end user.
3Ease of operation
If leg assemblies are pre-attached to the frame, then ease of assembly is improved, but shipping volume increases
Solution Approach 1:
The leg assemblies are designed with dynamic folding capability, allowing them to transition between an extended position for use and a folded position for shipping. This dynamic configuration enables the same structure to occupy different volumes depending on whether it is in service or transport mode.
Solution Approach 2:
The leg assemblies utilize three-dimensional folding motion to reduce their effective shipping volume. By folding the legs against the frame in multiple dimensions rather than extending them linearly, the overall package volume is minimized while maintaining the same functional structure.
4Productivity
If components are shipped separately for assembly, then manufacturing efficiency is improved, but customer satisfaction deteriorates
Solution Approach 1:
The leg assemblies are attached to the frame during the manufacturing process rather than being shipped separately for final assembly. This preliminary attachment action simplifies the customer experience while the manufacturing process itself is designed to efficiently handle the integrated assembly as a single unit.
Data Source
AI summary
An adjustable bed base may be folded in half for shipping without removing the leg assemblies. The leg assemblies are adjustable in length and may be secured in a raised position to facilitate folding the adjustable bed base. To change the length of the leg assembly, a hollow leg is moved inside a hollow receiver and fixed in place by a first push pin assembly. A second push pin assembly inside the hollow receiver fixes the leg assembly in a lowered position and a raised position for storage or shipment. Each hollow receiver is pivotally secured to a mounting bracket welded to a foldable frame of the adjustable bed base.