Modular Adjustable Bed Frame Assembly With Tool-Free Telescoping Joints
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Solution Overview
Problem
Conventional adjustable beds are cumbersome and costly to ship and assemble, often requiring heavy machinery for delivery and assembly, which increases freight and assembly costs, and may not be suitable for larger individuals due to flimsy construction.
Innovation Solution
A modular adjustable bed design that splits into two or more sections, allowing for assembly by a single adult without tools, using a semi-permanent engagement mechanism with sliding tubes and a locking mechanism, and optional additional motors for adjustable positions, enabling efficient shipping and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional adjustable beds are shipped and assembled as complete units, then structural strength and rigidity are maintained, but shipping costs increase and assembly becomes difficult without heavy machinery
Solution Approach 1:
The bed frame is divided into multiple modular sections that can be shipped separately and assembled by the end user. Each section contains standardized connection points with locking mechanisms that maintain structural integrity when assembled, resolving the contradiction between ease of assembly and structural strength.
2Ease of operation
If modular sections are connected with simple assembly mechanisms, then assembly becomes easy without tools, but connection strength and rigidity may be compromised
Solution Approach 1:
The connection mechanism is designed to be self-locking through a cam-action system where the connecting arm automatically locks into place when inserted into the receiving structure. This eliminates the need for tools or heavy machinery while maintaining strong, rigid connections between modular sections.
3Reliability
If heavy machinery is used for delivery and assembly, then structural integrity is preserved, but freight costs and assembly complexity increase
Solution Approach 1:
Dividing the bed into modular sections that can be easily transported and assembled reduces the need for heavy machinery, thereby lowering freight costs and simplifying assembly while maintaining structural integrity through standardized connection mechanisms.
Solution Approach 2:
The self-locking connection mechanism allows end users to assemble the bed themselves without requiring professional assembly services or heavy equipment, reducing both assembly complexity and associated costs while ensuring reliable structural integrity.
4Adaptability or versatility
If the bed is designed as a complete unit, then structural rigidity is maintained, but adaptability for different user needs and configurations is reduced
Solution Approach 1:
The modular design allows different sections to be configured in various arrangements to meet different user needs while standardized connection mechanisms ensure structural rigidity is maintained across all configurations.
Solution Approach 2:
The standardized connection system and modular sections can be adapted for different bed types and configurations (e.g., hospital beds, home beds, different sizes) while maintaining structural integrity, providing universal applicability across multiple use cases.
Data Source
AI summary
In an adjustable bed having juxtaposed between a mattress and a floor an articulated frame, and one or more wired motors operating on the articulated frame so that the mattress resting atop the frame is adjusted in contour, the articulated frame is modular, and ships in two or more modular frame sections each of which is sufficiently small so as to fit upon a standard shipping pallet of 48″ by 48″. Moreover, and further, the two or more modular frame sections semi-permanently engage by sliding protrusions—preferably steel tubes—extending from spaced-parallel frame rails of a one section into a complimentary cavities of the frame rails—preferably steel tubes of square cross section—of a next frame section. This sliding assembly may be done by one adult man, without use of tools. The extensive contact between the telescoping members makes that the connection, and the modular adjustable bed itself, is suitably strong.