Pultruded Adjustable Bed Frame for Lightweight Modular Assembly
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Solution Overview
Problem
Current adjustable bed frames are constructed from numerous discrete steel or aluminum components, making assembly time-consuming and costly, with heavy materials increasing shipping expenses and inefficiencies.
Innovation Solution
The use of pultruded components for an adjustable bed frame, which are integrally manufactured to reduce the number of components needed, offering high strength, reduced weight, and modular design for simplified assembly and packaging, along with electrical non-conductivity to prevent electrostatic discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional discrete steel or aluminum components are used to construct adjustable bed frames, then structural strength is achieved, but assembly complexity and time increase significantly
Solution Approach 1:
Multiple discrete steel or aluminum components are merged into a single integrally formed pultruded component. The pultruded frame member incorporates features that would traditionally require separate parts and assembly operations, thereby reducing assembly complexity while maintaining structural strength through the continuous fiber-reinforced composite structure.
Solution Approach 2:
The patent employs pultruded fiber-reinforced composite materials to replace traditional discrete metal components. This composite material approach provides equivalent or superior structural strength to steel and aluminum while enabling integral formation of complex geometries that would otherwise require multiple assembled parts.
2Strength
If traditional steel or aluminum components are used, then structural integrity is maintained, but weight increases leading to higher shipping costs
Solution Approach 1:
The patent uses pultruded fiber-reinforced composite materials to replace traditional metal components. These composites provide equivalent structural integrity to steel and aluminum while significantly reducing weight, thereby lowering shipping costs and improving handling efficiency without compromising the frame's load-bearing capacity.
3Adaptability or versatility
If multiple discrete components are assembled together, then structural flexibility is achieved, but manufacturing time and labor costs increase
Solution Approach 1:
The patent integrates multiple functional features and structural elements into a single pultruded frame member. This merging reduces the number of discrete components that need to be manufactured and assembled, thereby improving manufacturing efficiency while the integral design maintains the necessary structural flexibility for adjustable bed configurations.
Solution Approach 2:
The pultrusion process preliminarily forms the complete frame member with all necessary structural features, connection points, and geometries during a single manufacturing operation. This preliminary formation eliminates the need for subsequent assembly operations, significantly improving manufacturing efficiency while preserving structural flexibility.
Data Source
AI summary
Pultruded frames for an adjustable bed are described herein. The pultruded frames may include various components such as connection/joining and reinforcing structures. The various components and frame parts may be combined in multiple configurations to form light weight and strong adjustable bed frames.