Compact Foundation Unit Kit for Flat-Pack Shipping and Assembly

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Solution Overview

Problem

Existing foundation units occupy significant space and are costly to ship due to their large size, making it impractical to transport them efficiently in a disassembled form for cost-effective assembly.

Innovation Solution

A compact foundation unit kit comprising elongated truss rails, end caps, and cross slats oriented in a parallel fashion with binding straps for easy disassembly and reassembly, allowing for partial disassembly for shipping, with optional triangular reinforcements and side filler strips for enhanced stability and completion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If foundation units are shipped in assembled form, then assembly quality is ensured, but shipping costs increase significantly

Engineering Contradiction:

Improveassembly qualityVSAvoidshipping costs

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The foundation unit is divided into modular components (truss rails, end caps, cross slats, binding straps) that can be shipped in a compact disassembled state and assembled at the destination. This segmentation reduces shipping volume and costs while maintaining assembly quality through standardized connection interfaces and included hardware.

Inventive Principle:

Principle #1Segmentation

2Loss of energy

If foundation units are disassembled for shipping, then shipping costs are reduced, but assembly complexity increases

Engineering Contradiction:

Improveshipping costsVSAvoidassembly process

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

Components are pre-cut to precise dimensions and pre-drilled with connection holes during manufacturing. The binding straps are pre-formed with attachment points, and all necessary hardware is pre-packaged with the kit. This preliminary preparation simplifies the on-site assembly process despite the disassembled shipping state.

Inventive Principle:

Principle #10Preliminary action

3Volume of moving object

If foundation units are made compact for shipping, then space occupancy is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improveshipping spaceVSAvoidmanufacturing process

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The foundation unit is segmented into flat-packable components (truss rails, end caps, cross slats) that can be efficiently stacked and shipped in compact configurations. This segmentation enables reduced volume occupancy while the standardized manufacturing processes for each component type maintain ease of production.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS8176581B2Compact foundation unit kit and method of making same

Publication Date: 2012.05.15 ROCK ISLAND INDS

AI summary

A compact foundation unit kit and a method of making a foundation unit from the kit. The kit comprises at least three elongated, generally flat truss rails, four generally flat end caps and a plurality of generally flat cross slats, with the truss rails, end caps and cross slats oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with their flat sides in contact. A binding maintains the truss rails, end caps and cross slats in that orientation. The method includes providing the kit, opening the kit and orienting the truss rails in a parallel, spaced position, then affixing one of the end caps to each end of the truss rails, inverting the partially formed foundation, and affixing the last two end caps to opposite ends of the truss rails, then finally affixing the cross slats to the truss rails in a spaced, parallel orientation. The foundation can then be finished in a conventional fashion.