Modular Lightweight Bed Assembly for Rapid Temporary Deployment
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Solution Overview
Problem
Conventional beds are expensive, difficult to transport, and require significant space and time to set up, making them impractical for temporary and large-scale sleeping solutions, especially in emergency situations.
Innovation Solution
A lightweight bed assembly kit comprising interconnected slats and runners forming a grid with a U-shaped channel support frame and a corrugated covering for a smooth sleeping surface, allowing for easy assembly, disassembly, and transportation, with components made from plastic corrugated board for improved comfort and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional beds are used, then sleeping comfort is provided, but cost and transportation difficulty increase significantly
Solution Approach 1:
The bed is divided into modular components including a frame made from extruded aluminum profiles, a separate mattress unit, and interchangeable slat sets. This segmentation allows each component to be manufactured independently using standardized processes, reducing overall assembly complexity while maintaining structural integrity.
Solution Approach 2:
The aluminum extrusion profiles serve multiple functions: they form the bed frame structure, provide mounting points for various slat configurations, and enable adjustable bed heights. This multi-functionality reduces the number of different component types needed, simplifying manufacturing while providing versatile bed configurations.
2Productivity
If conventional mattresses and frames are transported, then sleeping quarters are provided, but transportation cost and time increase
Solution Approach 1:
The bed components are pre-assembled into compact modules during manufacturing, with the frame, mattress, and slats configured in a space-efficient arrangement. This preliminary preparation eliminates time-consuming on-site assembly operations, allowing rapid deployment while minimizing transportation volume and time.
3Adaptability or versatility
If conventional beds are stored, then sleeping quarters are available, but storage space requirements increase
Solution Approach 1:
The bed components are designed to nest within each other when disassembled for storage. The slats insert into the frame profiles, the mattress folds or compresses to fit within the frame structure, and all components can be stored in a compact configuration that minimizes warehouse or storage facility space requirements.
4Ease of operation
If conventional beds are used, then sleeping comfort is provided, but weight and portability decrease
Solution Approach 1:
The bed structure uses lightweight aluminum extrusions with optimized wall thicknesses and cross-sectional geometries that maintain structural strength while minimizing weight. The mattress utilizes high-density foam materials that provide comfort support at reduced weight compared to traditional spring mattresses, achieving portability without sacrificing sleeping comfort.
Data Source
AI summary
A lightweight bed assembly kit includes slats and runners adapted for connection to each other at spaced apart locations to form a grid. A U-shaped channel member is adapted for connection to the grid to form a support frame. A covering constructed to form a substantially smooth sleeping surface for an adult human is sized and shaped to be disposed on a top surface of the support frame. A method of assembling a lightweight bed includes arranging runners and slats transversely to each other and connecting the runners and slats together to form a grid. A U-shaped channel member is connected to the grid to form a support frame. A covering constructed to form a substantially smooth sleeping surface is mounted on a top surface of the support frame. A second support frame can be connected to the first support frame by another U-shaped channel member.