AU2020202926A1 - System of folding flat bunk bed and folding method - Google Patents

Abstract

A fold flat bunk bed system comprising two bedding frames pivotably connected utilising at least four hinges fastened to each frame. When in a lowered position, the lower hinges on the lower bed frame and on the upper bed frame are located on the bottom forward corner. The upper hinges on the lower bed frame and on the upper bed frame are located on the upper rear corner enabling the upper bed frame to pivot in an arc from parallel horizontally to parallel vertically and ultimately placing the upper bed frame above the lower bed frame. 13/13 100 HI o 300 -- 300 1000 ------ 300 ----- I II----------- I MtL FIG. 13

Description

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SYSTEM OF FOLDING FLAT BUNK BED AND FOLDING METHOD FIELD OF THE INVENTION

[0001] The present invention relates to a system of fold flat bunk bed and the folding

method thereof.

BACKGROUND TO THE INVENTION

[0002] There is a need to have an applicable bedding arrangement in a forward fold camper trailer setup. As with most forward fold campers, the full tent and all beds are to

fold down into the rear storage cell which has limited space. Most of these styles of trailers offer a full-size queen bed which is typically attached to the underside of the closed lid

which when unfolded sits over the front of the trailer creating the main bed. The remaining

section of the storage cell would then typically have a series of cushions which are arranged for a small sized double bed which is marketed as the kids sleeping area. Alternately the

area can be set-up as a seating area with a small folding table which is factory pre-installed. When the second bed area is set-up, it significantly reduces the available living space left

within the camper.

[0003] There have been attempts to solve this issue, however the attempts made

would typically utilise a tube style modular bunk placed into the available space within the storage cell. This method is time consuming to assemble and once in place may become

unstable due to not being attached to the body of the camper and only having four points of

contact which are legs on top of sheet metal or timber lids which are placed over storage bins.

[0004] A known folding bunk bed is provided by US Patent No. 7,207,076. The folding bunk beds of the patent fold between a horizontal sleeping position and a vertical storage

position. The folding bunk beds use vertically shifting pivot points to accommodate larger bed decks. The bed decks are hinged to carriages that slide on vertical shafts mounted

within a wall frame. Thus the wall on which the folding bunk bed is mounted needs to be a loading bearing wall. In a camper trailer setting, there are not any bearing walls at all and

thus this invention does not work for a fold camper.

[0005] The object of this invention is to provide a system of a fold flat bunk bed and the folding method thereof to address the above shortcomings.

[0006] Another object of this invention is to provide a system of a fold flat bunk bed and the folding method thereof that suits a forward fold camper trailer setup which can be

easy and quick to fold or unfold, and it is stable for anybody to sleep on.

SUMMARY OF THE INVENTION

[0007] In a first aspect the invention comprises a fold flat bunk bed system comprising

two bedding frames pivotably connected utilising at least four hinges fastened to each frame;

wherein in a lower position, the lower hinges on the lower bed frame and on the upper bed frame are located on the bottom forward corner;

wherein the upper hinges on the lower bed frame and on the upper bed frame are located on the upper rear corner enabling the upper bed frame to pivot in an arc from parallel

horizontally to parallel vertically and ultimately placing the upper bed frame above the lower bed frame.

[0008] In preference the hinges are fastened to each frame utilising bolts, washers and

nuts.

[0009] In preference the fold flat bunk bed system includes a rear wall, a left wall and a

right wall which are raised into positions to support weight and remove side to side movement of the upper bed frame.

[0010] In preference the fold flat bunk bed system includes a gap between the two bed frames when they are in the lowered position to allow for movement whilst erecting.

[0011] In preference the fold flat bunk bed system includes a stopper attached to the upper bed frame between the two bed frames which is to stop rear wall during raising.

[0012] In preference the fold flat bunk bed system includes a recess cut along front

edges of the bed frames.

[0013] In preference the fold flat bunk bed system includes safety locks engaged to hold the walls into place.

[0014] In preference the lower bed frame comprises an extended rear wall, its top edge

slightly higher than other side plates of the lower bed frame to allow the side walls and rear wall to stack in the folded away position.

[0015] In preference the fold flat bunk bed system includes a slight rebate to back bed fixed wall to allow the hinges from the fixing wall to be fitted but allowing the rear wall to

raise up and sit flush.

[0016] In preference the fold flat bunk bed system includes a rebate around the safety locks to allow more efficient stacking.

[0017] In preference the fold flat bunk bed system includes gas struts with one side fixed on the upper hinges in the lower position and the other side fixed on the lower bed

frame.

[0018] In preference the fold flat bunk bed system includes safety rails which are fitted

to the bed frames.

[0019] In preference the fold flat bunk bed system includes at least one ladder fitted to

the bed frames.

[0020] In preference the fold flat bunk bed system includes dowels and security latches which make the ladder fully engaged with the lower bed frame.

[0021] In preference the lower bed unit is permanently attached to a camper wall via a hinge setup to allow tilting of the lower bed unit for access to storage.

[0022] In a further aspect of the invention there is propose a folding method for the fold flat bunk bed system as described above including moving the upper bed frame to

travel in an arc from parallel horizontally to parallel vertically and ultimately placing the upper bed frame above the lower bed frame and moving the upper bed frame to travel in

an arc from parallel vertically to parallel horizontally and ultimately placing the upper bed

frame beside the lower bed frame.

[0023] The installation of the fold flat bunk bed enables the beds to be folded down into the storage cell for transport. It also allows for fast set-up into the designed bed arrangement which then frees up additional living space while maintaining an area for seating even with a folding table.

[0024] Furthermore, the fold flat bunk bed system provided by the present invention

makes the beds semi-permanently attached to the storage cell which provides stability. The system can be quick to set-up in minutes. Once it is set-up, the bed frames are rigid and

provide a safe sleeping area. Once implemented for use the system allows quick pack down,

fast set-up and once set-up frees up valuable space within the living quarters. When folded away the unit fits well within the space available in the storage cell.

[0025] It should be noted that any one of the aspects mentioned above may include any of the features of any of the other aspects mentioned above and may include any of the

features of any of the embodiments described below as appropriate.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for

those skilled in the art to perform the invention. The Detailed Description is not to be

regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows.

[0027] Figure 1 is a three-dimensional front view of the fold flat bunk bed system in the lowered position embodying the invention;

[0028] Figure 2 is a schematic right view of the fold flat bunk bed system in the lowered position embodying the invention;

[0029] Figure 3A is a schematic right view of the fold flat bunk bed system in an erecting position embodying the invention;

[0030] Figure 3B is a three-dimensional right view of the fold flat bunk bed system in an

erecting position embodying the invention

[0031] Figure 4 is a right side view of the fold flat bunk bed system in the erected position embodying the invention;

[0032] Figure 5A is a three-dimensional side view of the rear wall of the fold flat bunk

bed system according to a preferred embodiment of the invention;

[0033] Figure 5B is a close-up view of the safety lock according to a preferred

embodiment of the invention;

[0034] Figure 6A is a schematic left view of the fold flat bunk bed system in the erected

position according to a preferred embodiment of the invention;

[0035] Figure 6B is a schematic right view of the fold flat bunk bed system in the erected position according to the preferred embodiment of the invention;

[0036] Figure 7A is a three-dimensional view of a removable safety rail of the fold flat bunk bed system according to a preferred embodiment of the invention;

[0037] Figure 7B is a three-dimensional view of the safety rail hooked over the side of the bed frame according to a preferred embodiment of the invention;

[0038] Figure 8A is a three-dimensional view of a removable ladder of the fold flat bunk bed system according to a preferred embodiment of the invention;

[0039] Figure 8B is a three-dimensional view of the ladder upper hook fitting to the

upper bed frame according to a preferred embodiment of the invention

[0040] Figure 8C is a three-dimensional close-up view of the ladder lower dowels fully

engaged with the lower bed frame and a security latch engaged according to a preferred embodiment of the invention;

[0041] Figure 8D is a three-dimensional view of the ladder fully installed to the upper bed frame and the lower bed frame according to a preferred embodiment of the invention;

[0042] Figure 9 is a schematic view of an addition of a gas strut to the rear hinge according to a preferred embodiment of the invention;

[0043] Figure 10 is a cross-section view of a typical hinge to bed connection according

to a preferred embodiment of the invention;

[0044] Figure 11 is a three-dimensional back side view of the fold flat bunk bed system

in the lowered position according to a preferred embodiment of the invention;

[0045] Figure 12 is a close-up view of the stopper added on the upper bed frame of the

fold flat bunk bed system in the lowered position according to a preferred embodiment of the invention; and

[0046] Figure 13 is a sectional view of the fold flat bunk bed system placed in a forward

fold camper trailer setup according to a preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0047] The following detailed description of the invention refers to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the

drawings and the following description to refer to the same and like parts. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the

purposes of clarity or illustration.

[0048] The fold flat bunk bed system 10 of the present invention is preferably placed in

a forward fold camper trailer setup. In some embodiments, as shown in Figure 13, the fold

flat bunk bed system 10 of the present invention is placed in the rear storage cell which can be easy and quick to fold or unfold in the directions of dotted arrows along the dotted line.

As the illustration in Figure 13 shows, it consists of at least two bed frames, an upper bed frame 100 and a lower bed frame 200. In some embodiments of the present invention, each

of the bed frames is made with identical or similar shape, structure and size. The two bedding frames are connected by hinges 300.

[0049] The above-mentioned bed frames are frames to hold and support bedding mattresses. Each frame will require the front of the frame to have a recess cut to allow the

mattress side edge to be exposed and minimise the risk of injury from the exposed frame

edge during entry and exit. The bed frames can be made of wood or other light weight and solid material as well, for instance plastic or bamboo. The two bedding frames are then

joined together utilising four equal length "legs" which refer to the hinges 300.

[0050] Depending on how the design is implemented, the lower frame 200 can be retained in place by screwing, gluing or etc. to allow the fold flat bunk bed system 10 provided by the present invention to be retained in place for stability and safety purposes.

[0051] The components of the fold flat bunk bed system 10 of the present invention

and the way in which the components are connected are described in detail with reference to the drawings.

[0052] Figure 1 illustrates a three-dimensional front view of the fold flat bunk bed

system 10 in the lowered position embodying the invention. As shown in Figure 1, the upper bed frame 100 with a lowered position is in the foreground, while the lower bed frame 200

is in the rear with a rear wall 201laying down in it.

[0053] Figure 2 is a schematic right view of the fold flat bunk bed system 10 in the

lowered position embodying the invention. The two bedding frames are connected utilising at least four hinges 300 fastened to each frame utilising bolts 400, washers 500 and T-nuts

or nuts 600. It shows the two right hinges 300 with bolts 400 and washers 500 of the fold flat bunk bed system 10, but not the two left hinges which are mirrored on the other side of

the fold flat bunk bed system 10. The type of nuts (not shown here) used depends on the

material of hinges 300 and the bed frames.

[0054] As the illustration of the Figure 2 shows, the placement of the hinges 300 will

need to be as follows. In the lowered position, one end of the lower hinge 320 on the lower bed frame 200 will need to be placed on the bottom forward corner 211of the lower bed

frame 200 and the other end of the lower hinge 321 on the upper bed frame 100 will also

need to be placed on the bottom forward corner 111of the upper bed frame 100. Then the

upper hinge 300 will need to be placed as follows. In the lowered position, one end of the upper hinge 310 on the lower bed frame 200 will need to be placed on the upper rear

corner 212 of the lower bed frame 200 and the other end of the upper hinge 311 on the upper bed frame 100 will need to be placed on the upper rear corner 112 of the upper bed

frame 100. This process will need to be mirrored on both ends of the bed frames. These enable the upper bed frame 100 to travel in an arc from parallel horizontally to parallel

vertically, ultimately placing the upper bed frame 100 above the lower bed frame 200. It

should be noted that there is a necessary gap between the two bed frames when they are in the lowered position to allow for movement whilst erecting as shown in Figure 2.

[0055] Figure 3A is a schematic right view of the fold flat bunk bed system 10 in an erecting position embodying the invention. As shown in Fig 3A, during the erection, the

upper bed frame 100 is raised by a pull force. The upper bed frame 100 and the lower bed frames 200 keep parallel during the whole course of erection. Moreover, the upper hinges

300 remain parallel with the lower hinges 300 with the movement of the upper bed frame

100 from the lowered position to the upper position which means an erected position. Furthermore, the upper hinges 300 in the lowered position become the right hinges 300 in

the erected position and the lower hinges 300 in the lowered position become the left hinges 300 in the erected position. Figure 3B shows a three-dimensional right view of the

fold flat bunk bed system 10 in an erecting position embodying the invention with stacked side walls and the rear wall 201. Accordingly, the cross section of right or left view of the

fold flat bunk bed system 10 in an erecting position is an active parallelogram.

[0056] When the upper bed frame 100 moves to the erected position right above the

lower bed frame 200, it will stop and retain in the erected position as shown in Figure 4. It

also means that when the bed frames in the erected position, not only the upper bed frames 100 and the lower bed frames 200 keep parallel, but the right hinges 300 also

remain parallel with the left hinges 300 on the both side of the fold flat bunk bed system 10. All the hinges 300 are vertical with both the upper bed frames 100 and the lower bed

frames 200. It indicates that the hinges rotate against the hinge joints from the horizontal position as shown in Figure 2 to the parallel position as shown in Figure 4.

[0057] In some embodiments of the present invention, as illustrated in Figure 4 there are three folding walls, a rear wall 201, two side walls which are a left wall 202 and a right

wall 203. In a preferred embodiment, they are permanently attached to the lower bed

frame 200. When the upper bed frame 100 is in the erected position, the folding walls utilise hinges to allow 90-degree movement from the laying down position to the standing

upright position which will be described below.

[0058] In some embodiments of the present invention, these bed frames are installed

allowing the rear wall 201 to fold down onto the lower bed frame 200 or mattress and the two side walls folding down under the rear wall 201. Figure 11 is a three-dimensional back side view of the fold flat bunk bed system in the lowered position according to a preferred embodiment of the invention. As illustrated in Figure 11, the walls can be stacked inside the lower bed frame 200. They will then be raised individually into their upright position starting with the side walls to fill the space between the outside edges of each bed frame creating walls which offer support for the upper bed frame 100 and removing the ability for the upper bed frame 100 to travel through its arc into its lowered position.

[0059] Further, for easy storage, the lower bed frame 200 is designed to contain the

walls in it. In some embodiments of the present invention, the lower bed frame 200 has an extended rear wall 220 whose top edge is little bit higher than other side plates of the lower

bed frame 200 as illustrated in Figure 11. The extended rear wall 220 will need to be 1 x times the thickness of the material higher to allow the side walls and rear wall 201 to stack

in the folded away position.

[0060] Further, there is a slight rebate in the back and side fixed bed walls which allows

the hinges from the fixing walls to be fitted but allows the rear wall 201and side walls 202

and 203 of the lower bed frame 200 to rise up and sit flush. In addition, a rebate around the safety lock will be possibly provided to allow more efficient stacking.

[0061] Further, an additional small stopper 101 is added on the upper bed frame 100 to stop the rear wall 201 during raising. As illustrated in Figure 12, it shows a close-up view of

the stopper 101in the gap between the two bed frames of the fold flat bunk bed system 10 in the lowered position according to a preferred embodiment of the invention.

[0062] In some embodiments of the present invention, once the walls have been raised into position, they will be retained into position utilising small pad bolt style locks removing

the chances of the walls from falling away and the upper bed frame 100 dropping to its

lowered position. For added additional security or safety to the system, the pad bolt locks could be upgraded to lockable pad bolts locks.

[0063] Figure 5A is a three-dimensional view of the rear wall 201 of the fold flat bunk

bed according to a preferred embodiment of the invention. As shown in Figure 5A, on the bottom edge of the rear wall 201, there are three hinges 800 connecting the rear wall 201 with the lower bed frame 200. On the top edge of the rear wall, there are three safety locks

900 to hold the rear wall 201 into place after the rear wall 201 is raised into the standing upright position. A close-up view of the safety locks 900 is shown in Figure 5B. In another

preferred embodiment of the invention, the rear wall 201is carved out for two or more windows on it for the purpose of ventilating.

[0064] Figure 6A is a schematic left view of the fold flat bunk bed system 10 in the

erected position according to a preferred embodiment of the invention. Figure 6B is a schematic right view of the fold flat bunk bed system 10 in the erected position according to

the preferred embodiment of the invention. The left wall 202 and the right wall 203 can be erected separately on the both ends of the bed frames to fill the space between the outside

edges of each bed frame creating walls which offer support for the upper bed frame 100 and removing the ability for the upper bed frame 100 to travel through its arc into its

lowered position. In another preferred embodiment of the invention, the left and right wall are separately carved out for at least one window on them for the purpose of ventilating.

[0065] To add additional safety, each of the bed frames has been fitted with a

removable safety rail 204 which is hooked over the side of each bed frame extending upwards as illustrated in Figure 7A and 7B. Once removed, the safety rail 204 can be stored

on the top of the upper bed frame 100 for storage and transport.

[0066] Further, in a preferred embodiment of the present invention, to access the

upper bed, a removable ladder 205 will be fitted to the front of the beds and attached to prevent it from falling away as shown in Figure 8A. The ladder 205 is designed so that the

upper end of the ladder 205 is fitted with a full width hook which will hook over the frame of the upper bed frame 100 as shown in Figure 8B. Once in this position, the lower section

of the ladder 205 can rest against the lower bed frame 200. To retain the ladder 205 in

place, it is fitted with three dowels which fit into three corresponding recesses within the lower bed frame 200, then retained in place with another of the small pad bolts locks as

shown in Figure 8C. The ladder 205 and its retaining method provide additional support and rigidity to the set-up bunk beds. Figure 8D shows the ladder 205 fully installed to the upper

bed frame 100 and the lower bed frame 200.

[0067] Further, in a preferred embodiment of the present invention, additional gas

struts 330 are provided by the fold flat bunk bed system 10 with one side fixed on the rear hinges which are the upper hinges 320 in the lower position and the other side fixed on the

lower bed frame 200. It will assist with the erection of the upper bed frame 100 as shown in Figure 9.

[0068] Referring to the connection of a hinge 300 and the bed frames, a cross-section

view of a typical hinge 300 to bed connection is shown in Figure 10. As the illustration of Figure 10, the hinges 300 are fastened to the bed frame end walls through the combination

of bolts 400 and nuts 600. From the right to the left, there are a bolt 400, a washer 500, the hinge 300 on one side of the bed frame end wall and a T-nut on the other side of the bed

frame end wall. In order to add strength, an anti-crush spacer 700 is added in the assembled node.

[0069] The fold flat bunk bed system 10 provided by the present invention is designed to fold and unfold easily and quickly. Meanwhile, given that the fold flat bunk bed system 10

is arranged in a camper trailer for users to sleep or hold items with a certain weight, it is

practical and convenient to use. Moreover, it makes the beds semi-permanently attached to the storage cell which provides stability. The system can be quick to set-up in minutes. Once

it is set-up, the bed frames are rigid and provide a safe sleeping area. Once implemented for intended use the system allows quick pack down, fast set-up and once set-up frees up

valuable space within the living quarters. When folded away the unit fits well within the space available in the storage cell.

[0070] The present invention also provides a folding method for the fold flat bunk bed system 10. The method comprises steps of pulling or pushing the upper bed frame 100 to

travel in an arc from parallel horizontally to parallel vertically and ultimately placing the

upper bed frame 100 above the lower bed frame 200 or in the adverse way, which is pulling or pushing the upper bed frame 100 to travel in an arc from parallel vertically to parallel

horizontally and ultimately placing the upper bed frame 100 beside the lower bed frame 200.

[0071] The reader will now appreciate the present invention which provides a system of a fold flat bunk bed and the folding method thereof.

LIST OF COMPONENTS

[0072] The drawings include the following integers.

upper bed frame 100 stopper 101

bottom forward corner 111

upper rear corner112 lower bed frame 200

rear wall 201 left wall 202

right wall 203 safety rail 204

ladder205 bottom forward corner 211

upper rear corner 212

extended rear wall 220 hinge 300

end of the upper hinge 310 other end of the upper hinge 311

end of the lower hinge 320

other end of the lower hinge 321

gas strut 330 bolt 400

washer 500 nut600

spacer 700 hinge 800

safety lock 900

[0073] Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus. Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in this field.

[0074] In the present specification and claims (if any), the word "comprising" and its

derivatives including "comprises" and "comprise" include each of the stated integers but does not exclude the inclusion of one or more further integers.

Claims (16)

1. A fold flat bunk bed system comprising two bedding frames pivotably connected

utilising at least four hinges fastened to each frame; wherein in a lower position, the lower hinges on the lower bed frame and on the

upper bed frame are located on the bottom forward corner;

wherein the upper hinges on the lower bed frame and on the upper bed frame are located on the upper rear corner enabling the upper bed frame to pivot in an arc

from parallel horizontally to parallel vertically and ultimately placing the upper bed frame above the lower bed frame.

2. The fold flat bunk bed system of claim 1, wherein the hinges are fastened to each

frame utilising bolts, washers and nuts.

3. The fold flat bunk bed system of claim 1 comprising a rear wall, a left wall and a right

wall which are raised into positions to support weight and remove side to side

movement of the upper bed frame.

4. The fold flat bunk bed system of claim 1 comprising a gap between the two bed

frames when they are in the lowered position to allow for movement whilst erecting.

5. The fold flat bunk bed system of claim 1 comprising a stopper attached to the upper

bed frame between the two bed frames which is to stop rear wall during raising.

6. The fold flat bunk bed system of claim 1 including a recess cut along front edges of

the bed frames.

7. The fold flat bunk bed system of claim 3 including safety locks engaged to hold the walls into place.

8. The fold flat bunk bed system of claim 3, wherein the lower bed frame comprises an extended rear wall, its top edge slightly higher than other side plates of the lower

bed frame to allow the side walls and rear wall to stack in the folded away position.

9. The fold flat bunk bed system of claim 8 including slight rebate to back bed fixed wall

to allow the hinges from the fixing wall to be fitted but allowing the rear wall to raise up and sit flush.

10. The fold flat bunk bed system of claim 7 including a rebate around the safety locks to allow more efficient stacking.

11. The fold flat bunk bed system of any one of claim 1 to 10 including gas struts with

one side fixed on the upper hinges in the lower position and the other side fixed on the lower bed frame.

12. The fold flat bunk bed system of any one of claim 1 to 10 including safety rails which are fitted to the bed frames.

13. The fold flat bunk bed system of any one of claim 1 to 10 including at least one ladder fitted to the bed frames.

14. The fold flat bunk bed system of claim 13 including dowels and security latches

which make the ladder fully engaged with the lower bed frame.

15. The fold flat bunk bed system of any one of claim 1 to 10 wherein the lower bed unit

is permanently attached to a camper wall via a hinge setup to allow tilting of the lower bed unit for access to storage.

16. A folding method for the fold flat bunk bed system of claim 1 including moving the upper bed frame to travel in an arc from parallel horizontally to parallel vertically

and ultimately placing the upper bed frame above the lower bed frame and moving

the upper bed frame to travel in an arc from parallel vertically to parallel horizontally and ultimately placing the upper bed frame beside the lower bed frame.