Packaging arrangement and method for packaging

Abstract

The disclosure relates to a packaging arrangement for storage and transport of electrically adjustable beds of a modular bed system which can be dismantled into individual components, the bed system being configured to form one or more different bed types which are different in terms of width and/or length. The beds are beds of a family of beds, comprise at least an upper leg sector, a lower leg sector, a seat sector and a torso sector, and have a plurality of bed plates for carrying a mattress. The packaging arrangement is suitable for accommodating a quantity of components of a single bed of each bed type of the bed system and the quantity of the components comprises at least the plurality of bed plates, at least one cross member and at least two longitudinal members. A width B of the packaging arrangement corresponds substantially to the width of a bed plate of a bed type, a length L of the packaging arrangement corresponds substantially to the length of one or the sum of the lengths of two bed plates of a bed type, and a base area of the packaging arrangement is substantially identical for all bed types of the bed system. A height H of the packaging arrangement is given by: H≤/2, where G is a limit for length plus girth of the packaging arrangement.

Claims

1. A single bed of a family of beds and a packaging arrangement for storage and transport of the single bed, the family of beds comprising one or more different bed types that are different in width, in length, or in width and length, wherein the single bed is electrically adjustable, wherein the single bed: comprises at least an upper leg sector, a lower leg sector, a seat sector and a torso sector; and is adapted to be dismantled into individual components, the packaging arrangement containing the individual components, wherein: the individual components comprise at least one cross member, at least two longitudinal members, and a plurality of bed plates that are adapted for carrying a mattress; the torso sector of the single bed comprises at least two of the plurality of bed plates that are either rigid or movable relative to each other; and the longitudinal members and the cross member of the single bed in the packaging arrangement are not firmly connected to one another, wherein: a width B of the packaging arrangement substantially corresponds to a width of a bed plate of a bed type of the single bed; a length L of the packaging arrangement substantially corresponds to a length of one bed plate or to a sum of lengths of two bed plates of the bed type of the single bed; a base area of the packaging arrangement is substantially identical for all bed types of the family of beds; and a height H of the packaging arrangement is given by: H≤(G−L−2B)/2, where G is a limit for length plus girth of the packaging arrangement, and wherein for the single bed, a direction of a length of each of the plurality of bed plates of the single bed is arranged along a direction of a width of the single bed, and the length of a bed plate of the plurality of bed plates of the single bed determines the width of the single bed.

2. The single bed and the packaging arrangement according to claim 1, wherein G is 130 inches.

3. The single bed and the packaging arrangement according to claim 1, wherein the width B of the packaging arrangement substantially corresponds to the width of the widest of the bed plates.

4. The single bed and the packaging arrangement according to claim 3, wherein the length of each of the at least two longitudinal members in a packaged state corresponds at most to the greater value of two lengths L1 and L2, where L1 is the length of the bed plate of the widest of the bed types and L2 is twice the length of the bed plate of the narrowest of the bed types.

5. The single bed and the packaging arrangement according to claim 1, wherein, for all bed types, each of the plurality of bed plates has a width selected from two different widths.

6. The single bed and the packaging arrangement according to claim 1, wherein, for all bed types, the plurality of bed plates includes exactly five bed plates.

7. The single bed and the packaging arrangement according to claim 1, wherein a width of the widest of the bed plates substantially corresponds to a width of two adjacent longitudinal members lying on a side.

8. The single bed and the packaging arrangement according to claim 1, wherein the bed plates have a thickness between 15 mm and 22 mm.

9. The single bed and the packaging arrangement according to claim 1, wherein each of the at least two longitudinal members are symmetrical with respect to a plane of symmetry perpendicular to a main axis of extension of the respective longitudinal member.

10. The single bed and the packaging arrangement according to claim 1, wherein the at least two longitudinal members are arranged symmetrically with respect to one another.

11. The single bed and the packaging arrangement according to claim 1, wherein each of said at least two longitudinal members have a maximum height between 180 mm and 200 mm.

12. The single bed and the packaging arrangement according to claim 1, wherein at least one longitudinal member comprises drives and mechanics for adjusting at least one of the upper leg sector, the lower leg sector, the seat sector and the torso sector.

13. The single bed and the packaging arrangement according to claim 1, wherein voids between a quantity of components are filled with filling elements.

14. The single bed and the packaging arrangement according to claim 13, wherein the filling elements comprise a storage for further accessories, and wherein the filling elements comprise symmetrical identical parts.

15. The single bed and the packaging arrangement according to claim 1, wherein the bed plates are arranged in a stacked manner, in a side-by-side manner, or in the stacked manner and the side-by-side manner with respect to the base area.

16. The single bed and the packaging arrangement according to claim 1, wherein the packaging arrangement comprises two packaging units arranged in a stacked manner with respect to the base area.

17. The single bed and the packaging arrangement according to claim 16, wherein the base areas of the packaging units are the same.

18. The single bed and the packaging arrangement according to claim 16, further comprising an outer packaging containing the two packaging units.

19. The single bed and the packaging arrangement according to claim 16, further comprising a strap adapted to hold the packaging arrangement together.

20. The single bed and the packaging arrangement according to claim 16, wherein the two packaging units have the same or different heights; and a sum of the heights is at most (G−L−2B)/2.

21. The single bed and the packaging arrangement according to claim 1, wherein for the single bed, the plurality of bed plates of the single bed are arranged in a single plane, and a length of the single bed is not less than the width of the single bed.

22. A method for forming a single bed of a family of beds and forming a packaging arrangement for storage and transport of the single bed, the family of beds comprising one or more different bed types that are different in width, in length, or in width and length, wherein the method comprises forming the single bed, wherein: the single bed is electrically adjustable; the single bed comprises at least an upper leg sector, a lower leg sector, a seat sector and a torso sector; the torso sector of the single bed comprises at least two of a plurality of bed plates that are either rigid or movable relative to each other; the plurality of bed plates are adapted for carrying a mattress; and the single bed is adapted to be dismantled into individual components, wherein the method comprises forming the packaging arrangement containing the individual components, wherein: the individual components comprise at least one cross member, at least two longitudinal members, and the plurality of bed plates; the longitudinal members and the cross member in the packaging arrangement are not firmly connected to one another; a width B of the packaging arrangement substantially corresponds to a width of a bed plate of a bed type of the single bed; a length L of the packaging arrangement substantially corresponds to a length of one bed plate or to a sum of lengths of two bed plates of the bed type of the single bed; a base area of the packaging arrangement is substantially identical for all bed types of the family of beds; and a height H of the packaging arrangement is given by: H≤(G−L−2B)/2, where G is a limit for length plus girth of the packaging arrangement, and wherein forming the single bed comprises: arranging a direction of a length of each of the plurality of bed plates of the single bed, along a direction of a width of the single bed, wherein the length of a bed plate of the plurality of bed plates of the single bed determines the width of the single bed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantageous embodiments of the disclosure are explained in more detail in the following by means of figures. In the figures, identical or equivalent components are provided with identical reference signs (with or without suffixes). Characteristics already described with the help of reference signs are not necessarily provided with reference signs in all figures.

(2) In the figures:

(3) FIGS. 1 and 2 show different views of an exemplary dismantable bed of a modular bed system suitable for packaging according to the improved concept;

(4) FIGS. 3 and 4 show different views of a first packaging unit according to the improved concept;

(5) FIG. 5 shows an exemplary second packaging unit;

(6) FIGS. 6 to 8 show second exemplary packaging units for different bed types of the bed system; and

(7) FIG. 9 shows an exemplary packaging arrangement comprising a first and a second packaging unit.

DETAILED DESCRIPTION

(8) FIG. 1 shows a side view of a bed 1 of a modular bed system that can be dismantled into individual components. FIG. 2 shows an isometric view of the same bed 1.

(9) The side view of FIG. 1 shows one of at least two longitudinal members 2 of bed 1, which comprises arms 5 of an adjustment mechanism 6 and the adjustment mechanism 6. Bed plates 4 are attached to the arms 5 of the longitudinal member 2. In addition, foot elements 7 are attached to the longitudinal member 2. The adjustment mechanism 6 of the longitudinal members 2 consists of a series of joints and arms 5 to which the bed plates 4 are attached. Both longitudinal members 2 have mounting possibilities for connection to at least one cross member 3, typically at one or both ends of the longitudinal members 2, and for connection to the bed plates 4. In some configurations only one of the longitudinal members 2 comprises an adjustment mechanism 6, which also controls the arms 5 of the second longitudinal member.

(10) The isometric view in FIG. 2 shows the connection of the longitudinal members 2 by at least one cross member 3 and the subdivision of the supporting surface for the mattress by the bed plates 4 into different sectors 8-11. The lying surface is divided into a torso sector 8, a seating sector 9, an upper leg sector 10 and a lower leg sector 11. The torso sector 8 is divided into a head sector 8a and a neck sector 8b. Consequently, the exemplary bed 1 comprises five sectors that can be adjusted relative to each other by means of the adjustment mechanism 6, which can include a drive, in order, for example, to enable different lying or sitting positions for a user.

(11) For reasons of stability, each of the bed plates 4 is one-piece, i.e. made of one piece. The width of a bed plate 4 is always smaller than the length of the bed plate 4. Since the bed plates 4 are arranged so that the shorter side of the bed plate 4 is parallel to the main axis of extension of the longitudinal member 2, the length of a bed plate 4 determines the width of the bed 1. Consequently, the length of the bed plates 4, and thus also the length of at least one cross member 3, can be adapted to standardized mattress sizes. The example in FIGS. 1 and 2 shows a bed 1 for a TwinXL mattress measuring 79.7 inches*37.2 inches. Other common mattress sizes include Queen Size (79.7 inches*58.3 inches), King Size (79.7 inches*74.4 inches) as well as the comparatively slightly longer California King size (82.5 inches*70.5 inches). As shown, the bed plates 4 are not flush with the bed frame or with longitudinal and cross members 2, 3. The resulting overhangs are typically in the range of 30-40 cm and are limited by the stiffness and strength of the bed plates 4.

(12) The length of the longitudinal members 2 can be identical for all bed types. For long bed types, such as California King, the bed plates 4 are mounted with a larger overhang. In other words, the distances between the bed plates 4 are larger for long bed types than for shorter bed types. Wide bed types, such as the King Size bed type, in some designs include a third longitudinal member 2, e.g. arranged between the other two longitudinal members 2 for better support of the centre of the lying surface.

(13) FIG. 3 shows a top view of a first packaging unit 12a of a packaging arrangement 12. FIG. 4 shows a corresponding isometric view. The first packaging unit 12a, for example, comprises all components of a bed 1 of a bed system that are independent of the bed type. Such components include, for example, the at least two longitudinal members 2, the adjusting mechanism 6 with drives and motors, as well as connecting elements. For example, the motors are integrated coaxially within the longitudinal members 2. As a result, the shape of the longitudinal member 2 on two of the six side faces is flat over the entire length and without protruding parts, allowing the longitudinal member 2 to be inserted flat in a package 13.

(14) For the embodiment with one-piece longitudinal members 2, which cannot be further dismantled, the result is a long, narrow packaging 13 which has a negative effect on the surface. However, this long, narrow packaging has the advantage that it can be held more easily under the arm, for example, and can therefore be transported more easily by a single person than if it were square packaging that fits more easily on a pallet.

(15) When designing the longitudinal member 2, it should be noted that the longitudinal member 2 has only a small dimension in the plane which includes the protruding arms 5 for the adjustment. In the side view of FIG. 1, the longitudinal member 2 has a low overall height, advantageously in the range of 150-200 mm. Thus two longitudinal members can be arranged next to each other on a surface that is not wider than the widest of the bed plates 4, which specifies the minimum width B of the packaging arrangement 12.

(16) FIGS. 3 and 4 show a first packaging unit 12a of packaging arrangement 12. The essentially symmetrical arrangement of the longitudinal members 2 to each other in one plane can be seen. The longitudinal members are prevented from slipping by filling elements 14 in the voids of packaging 13 and by securing them with straps 16. In addition, some of the voids are filled with boxes 15, which may contain small components such as cabling, power supply units and fasteners. A length L of packaging unit 12a, except for the packaging thickness, is defined by the length of a bed plate of the widest bed type, e.g. King Size, or of two bed plates 4 of the narrowest bed type, e.g. TwinXL. As the first and second packaging units 12a, 12b preferably have an identical base area, the length of the first packaging unit is therefore longer than necessary, so that additional filling elements 14 may be necessary at the respective ends of the packaging 13, which may also be boxes 15.

(17) FIG. 5 shows an exploded view of an exemplary second packaging unit 12b. The second packaging unit 12b, for example, comprises all components of a bed 1 of a bed system that are dependent on the bed type. Such components include, for example, at least one cross member 3 and bed plates 4.

(18) FIG. 5 shows how the packaging 13 of the second packaging unit 12b first contains two bed plates 4 with the larger width. The bed plates 4 with the smaller width are arranged above them, so that a narrow cavity is created in the packaging 13, which is filled with filling elements 14 and other components, such as the cross members 3, a remote control 18 and a battery 19. The third bed plate 4 with the larger width in packaging 13 serves as the top layer, which ensures additional protection of the components in the intermediate layer. This also results in a package that is more stable to external forces. Other flat components, such as a side pocket 20 and operating or assembly instructions 21 can be arranged on the surface course. Kraft paper 17 can be placed between the bed plates 4 to protect against damage.

(19) The second packaging unit 12b with the bed plates 4 can be used as a support for the first packaging unit 12a or gives the latter additional stability and protection. The packaging 13 of the first packaging unit 12a and the second packaging unit 12b can each be closed with straps 16. Alternatively or additionally, an outer packaging or straps can fix the entire packaging arrangement 12 consisting of the first and second packaging units 12a, 12b together. The packaging arrangement is formed, for example, by stacking the first and second packaging units 12a, 12b and aligning them flush with each other. In other words, a base area of the first packaging unit 12a and a base area of the second packaging unit 12b are aligned congruently with each other. The total height H of the packing arrangement 12, i.e. the sum of the heights of the first and second packing units 12a, 12b, are always given by: H≤(G−L−2B)/2 where G is the dimension limit for standard shipping, i.e. length plus girth.

(20) FIGS. 6 to 8 show different embodiments of the second packaging unit 12b for different bed types of the bed system. In detail, FIG. 6 shows an arrangement of the bed type dependent components of the TwinXL bed type, FIG. 7 of the Queen Size bed type and FIG. 8 of the King Size bed type. The figures show that the footprint of the second packaging unit 12b, which, moreover, essentially corresponds to the footprint of the first packaging unit 12a, is essentially identical for all bed types.

(21) The optimum packaging size shows that in the cases of the TwinXL bed type and the King Size bed type, which is essentially twice as wide, no filling elements 14 are required on the end faces of the packaging, as the bed plates 4 make optimum use of the length L of the packaging 13.

(22) FIG. 9 shows an exemplary packaging arrangement 12 in which the packaging 13 of the first and second packaging units 12a, 12b are stacked and aligned flush with one another. The essentially same base area of the first and second packaging units 12a, 12b can be seen. An outer packaging and/or belts can be used to fix the packaging units 12a, 12b together for storage and transport in a material-saving way.

(23) The figures show examples of packaging arrangement embodiments. Further embodiments deviating from the examples are possible according to the improved concept and result from the described embodiments. Various embodiments differ, for example, in the exact arrangement of the components in the packaging arrangement, in the number of packaging units and/or in the components of the bed system. For example, beds can have different numbers of sectors, bed plates, longitudinal members and/or cross members.