Foldable and shippable adjustable bed assembly
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Solution Overview
Problem
Conventional bedding products, especially adjustable ones, face challenges in transportation and assembly due to their size and weight, which restricts shipping options and increases costs, making it difficult for consumers to receive them directly through common carriers.
Innovation Solution
The development of collapsible and foldable bed bases and frames that can be configured into a clamshell shape, allowing for easy assembly without tools, and using lightweight materials to meet shipping standards, enabling them to be shipped via common carriers like UPS and FedEx.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional bedding products are made with standard sizes and weights, then they provide adequate support and comfort, but they exceed shipping carrier restrictions and increase transportation costs
Solution Approach 1:
The bed assembly is divided into multiple sections (head section, foot section, and intermediate section) that can be folded relative to each other. This segmentation allows the bed to be collapsed into a compact configuration for shipping while maintaining full size and functionality when assembled, resolving the contradiction between weight reduction and assembly complexity.
2Volume of moving object
If bed assemblies are designed to be foldable for shipping, then they meet carrier restrictions, but they require complex hinge mechanisms and assembly procedures
Solution Approach 1:
The head and foot sections are folded inward toward the intermediate section in a nested configuration, with the decking surfaces of the head and foot sections positioned within or adjacent to the intermediate section. This nesting approach maximizes compactness while minimizing the complexity of hinge mechanisms required, as sections fold toward a central point rather than requiring multiple independent folding points.
3Productivity
If conventional bedding products are shipped through standard carriers, then delivery is convenient, but size and weight restrictions limit shipping options and increase costs
Solution Approach 1:
The bed assembly transitions between two states: a compact folded state for shipping that meets carrier restrictions, and a fully assembled state that provides adequate structural support and comfort. The hinge connections enable this dynamic transformation, allowing the structure to be lightweight and compact during transport while maintaining strength and stability during use.
4Strength
If bed assemblies use thicker frame members for structural support, then they maintain strength and durability, but they increase weight and dimensional weight beyond shipping limits
Solution Approach 1:
The frame members are designed with varying thicknesses and configurations in different locations. Critical load-bearing areas have sufficient thickness for strength, while non-critical areas use thinner members to reduce overall weight. The hinge connections and folding mechanisms are strategically positioned to maximize structural efficiency with minimal material, allowing the bed to meet both strength requirements and shipping weight limits.
Data Source
AI summary
A bed assembly includes a foldable multi-section bed base and a compressible mattress. The decking of the bed base defines a cavity in a folded position, and the compressible mattress is contained within the cavity. The decking also including folded portions to further decrease the dimensions of the bed assembly in the folded position.