This invention relates to bunk beds and particularly folding bunk beds that pivot between a horizontal sleep position and a vertical storage position.
Bunk beds are commonly used in applications where living space is limited, such as in small apartments and recreational vehicles. To further utilize living space in such applications, bunk beds often have sleeping decks that are hinged to the wall so that they can be pivoted into a storage position when not used. Folding bunk beds have been developed that are both manually and automatically operated. While popular for utilizing available living space, conventional manual and automatic folding bunk beds have several practical shortcomings.
Heretofore, the bed decks are hinged to the wall or a wall mounted frame at a fixed point, which limits the size of the bed decks to the height of the space above the decks. In a recreational vehicle application, where ceiling heights are relatively low, bed decks typically are limited to twin bed sizes. Consequently, a folding bunk bed that can accommodate larger bed decks is still desirable.
Furthermore, cables are used to support the bed decks in both manual and automatic folding bed decks. In automatic folding bunk beds, the cables are wound to winches that actuate the bed deck between their sleep and storage positions. Cable lengths and tensions must be matched precisely to ensure that the bed decks are level. Cable slack, binding and unspooling are frequent problems that seriously detract from the operation of cable actuated folding bunk beds. A more compact, safe and reliable automatic folding bunk bed is still desirable, particularly for applications where space and height is limited.
The various embodiments, both manually operated and power operated, of the folding bunk beds of this invention use a vertically shifting pivot point to accommodate larger bed decks. The bed decks are hinged to carriages that slide on vertically mounted shaft (a smooth rod for manually operated embodiments and a threaded screw shaft for power operated embodiments) within a wall frame. Bed decks are mounted to support arms that are pivotally connected to the carriages. A linkage mechanism or guide track allows the bed decks to pivot simultaneously between a horizontal sleep position and a vertical storage position as the carriages shift along the shafts. The vertically shifting pivot point allows the bed decks to kneel down, that is to fold up at a pivot point lower on the wall. The shifting pivot point not only accommodates larger bed decks and eliminates the problems associated with cable supports, but allows bed decks to overlap in the storage position.
Accordingly, the bunk beds of this invention have several advantages over conventional folding bunk beds. In particular, the bunk beds of this invention accommodate larger bed decks.
Another advantage is that the bed decks can be overlapped in the storage position, which allows a lower bed deck limited only by ceiling height.
Another advantage is that the screw shaft actuation mechanism is more reliable than cable actuated mechanisms and does not require complex mechanical adjustments.
Another advantage is that the actuation mechanism is enclosed entirely within the wall frame, which reduces unsightly cable and reduces possible safety hazards.
Another advantage is that the mattress and bedding can be stored on the bed decks when the bunk beds are in the vertical storage positions.
Other advantages will become apparent upon a reading of the following description.
A preferred embodiment of the invention has been depicted for illustrative purposes only wherein:
The preferred embodiments herein described are not intended to be exhaustive or to limit the invention to the precise form disclosed. They are chosen and described to best explain the invention so that others skilled in the art might utilize its teachings. The figures illustrate two different embodiments of the bunk bed of this invention. Both embodiments of this invention are intended for use in applications where living space is limited or confined, such as in recreational vehicles.
Wall frame 20 secures bunk bed 10 to the interior walls of a structure or vehicle and provide the structural supports for the bunk bed. Wall frame 20 is mountable to an interior wall of a house or recreational vehicle (not shown) using screws, bolts, adhesive or other suitable methods well known in the arts. Wall frame 20 includes a pair of uprights 22, which are constructed of a section of metal U-channel. As shown, each upright 22 has two elongated longitudinal slots (upper 23 and lower 25). A long shaft 36 is vertically disposed within each upright 22. Shaft 36 is a steel rod that is secured within the upright by brackets 38.
Carriage 30 is a section of metal channel having a cross section generally configured to shiftably conform to the interior of uprights 22. Carriage 30 has an L-shaped tab 32 that is bent or formed to protrude from opposite ends of the carriages. Two bearing blocks 34 are seated at opposite ends of the carriages. Bearing blocks 34 are constructed of a plastic, nylon, teflon or similar low friction material. Bearing blocks 34 have central bores 35 through which shaft 36 extends. As shown, carriages 30 are shiftably disposed within upright 22, so that L-tab 32 extends through upright slots 23 and 25. The low friction properties of bearing blocks 34 allow them to slide freely along rod 36 so that L-tabs 32 move between the ends of upright slots 23 and 25.
Bed decks 50 and 52 are flat sheets of laminated wood, fiberboard or other suitable material, which support the mattress and bedding. Bed decks 50 and 52 are pivotally connected to carriages 30 by support arms 40. Deck support arms 40 are long metal brackets that have a horizontal flange 42 extending along theirs bottom edge upon which bed decks 40 and 42 are secured. Each support arm 40 also has a joggle 44 along their upper edge such that the proximal end of the arm is wider than the distal end. Deck support arms 40 have a lateral through bore 55 in the upper corner of their proximal end. Deck support arms 40 are pivotally connected to carriages 30 by fasteners (a bolt and nut), which extend through bores 45 and through bores 33 in L-tabs 32. A linkage 46, which is a long metal strap, is pivotally connected to uprights 22 and deck support arms 40 of lower deck 52. Linkage 46 is pivotally connected at one end to a central point of deck support arm 40 and at the other end to the side of uprights 22. Upper and lower bed decks 40 and 42 are pivotally connected by a pair of long bed posts 62, which support the outer edge of the bed decks when in the horizontal sleep position. Bed posts 48 are hinged to brackets mounted to bed decks 50 and 52 so that the post supports the bed decks in the sleep position and folds with the bed decks in the storage position. Bed decks 50 and 52 also include a bottom support plate 56, which helps support the decks in the sleep position. Support plates 56 have a spring loaded lock bar 58, which is used with a wall mounted lock bracket 54 to secure the bed decks in the horizontal sleep position.
As shown in
The actuation mechanism includes an electric motor 72, a coupler 73, two gear boxes 74, a drive axle 75, a pair of screw shafts 76 and two pairs of bearing blocks 78. Ideally, motor 72 is a conventional reversible AC electric motor, although any suitable reversible motor can be employed. Typically, an electrical switch or electronic control (not shown) is connected to motor 72, which controls and selectively reverses the motor to operate bunk bed 10. The switch or control can be mounted to the wall frame, mounted to an interior wall or used as part of a wireless remote control system as desired. Such electric switches and electronic controls are well known in the arts.
As shown, motor 72 is secured to the outside of the wall frame at the upper end of one of the uprights. Exteriorly mounting motor 72 to the wall frame allows for greater installation flexibility. Motor 72 is operably connected to gear boxes 74 by a coupler 73. Screw shafts 76 are disposed longitudinally within the uprights and are operably connected to gear boxes 74. Each screw shaft 36 carries a pair of spaced (upper and lower) bearing blocks 78, which traverse up and down the screw shafts when the shaft is turned. Each bearing block 78 has a threaded through bore through which screw shaft 76 is turned and a tab 79, which protrudes slightly from one of the two slots in the uprights. Because both bearing blocks are carried onto the same threaded screw shafts, the bearing blocks move in unison with the rotation of the screw shaft, which eliminates the need for the carriage structure of bunk beds 10 and 60. The rotation of screw shafts 76 reciprocates bearing blocks 78 up and down the screw shaft, which pivots the bed decks between the sleep position (
One skilled in the art will note several advantages of the bunk beds of this invention over the prior art. The vertically shifting pivot point allows the bed decks to kneel down, that is to fold up at a pivot point lower on the wall. The shifting pivot point not only accommodates larger bed decks and eliminates the problems associated with cable supports, but allows bed decks to overlap in the storage position. Bunk beds of this invention are designed so that the depth of the support arms allows the mattress and bedding of each bunk to be folded with the bed deck for convenient storage. The depth of the support arm can also be increased so that the lower bed decks will overlap the upper deck in the storage position. With the lower deck overlapping and covering the upper deck in the storage position, the size of the lower bed deck is limited only by ceiling height.
The pivot point of the support arms, that is the location where the support arm is pivotally connected to the bearing blocks (the axis of bore), allows the bottom edge of the deck support arms to kick out as the carriage or bearing blocks begin to move down the shafts from the top of the upright slots, which is important to account for the mattress and bedding supported on bed decks and to prevent the bed decks from binding when folded into the storage position. Without the joggle in the support arms and locating the pivot point sufficiently above the bottom flange of the support arm, the bed decks would bind and not fold flat vertically between the wall frame.
Another advantage is that the screw shaft actuation mechanism is more reliable than the cable actuated mechanisms and does not require complex mechanical adjustments. Cable adjustment, tension and winding problems are eliminated by the use of screw shafts. In addition, the screw actuation mechanism can reliably produce more lifting power so that larger bed decks, mattresses and bedding can be employed. The actuation mechanism is enclosed entirely within the wall frame, which reduces unsightly cable and reduces possible safety hazards. The screw shafts, axles and gear boxes are enclosed within the wall frame, and the motor is mounted to the exterior of the wall frame for convenient service and replacement.
While directed at folding bunk bed applications, the teaching of this invention can be expanded to folding counter top applications, as well. The bed decks can be fashioned to double as a counter top or table, as required. The bunk beds of this invention have a simple design and fold flat against the interior wall to maximize living space. In addition, the automated actuation mechanism of this invention can be applied to folding counter tops, as well as bed decks.
It is understood that the above description does not limit the invention to the details given, but may be modified within the scope of the following claims.
Number | Date | Country | |
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60554946 | Mar 2004 | US |