THIS INVENTION relates generally to beds and, more specifically, to a bed base construction method and a bed base constructed in using said method.

BACKGROUND TO THE INVENTION A bed base usually consists of a rectangular base defined by a pair of elongate opposed sides, a foot side, and a head side.

The sides are connected at four corners of the rectangular base. A plurality of transversely extending slats are commonly disposed between, and supported by, the opposed sides. The four sides and the slats present a surface upon which a mattress may be placed. In some instances, the slats are replaced with a planar wooden board functioning as an alternative mattress supporting surface. After assembly of the components of the bed base, a plastics material is passed over the connected components thereby to provide the bed base with a more aesthetically pleasing finish.

It is commonly known that wood has become the norm in construction of bed bases as it is readily available and relatively affordable. For instance, chipboard is quite often used as it comprises compressed waste wood bound together with synthetic resin. However, bed bases manufactured from wood are known to be fragile. As a result, it is not uncommon to find a bed owner replace a bed base before replacing the associated mattress.

Furthermore, bed bases are usually transported together with associated mattresses to retailers, customers and the like. In so doing, a substantial percentage of loading space is occupied by the bed bases alone. Volume wise, air comprises more than 50% of the space taken up by the bed base and, as such, a lot of loading space is wasted when mattresses and bed bases are transported.

The invention, summarized and described below, is however believed to address the abovementioned drawbacks associated with existing bed bases. In fact, the applicant believes that a substantial saving, not only in fuel but also in transport cost per bed unit, can be realized if a larger number of mattresses and bed bases can be transported on the load beds of ubiquitous transport vehicles.

SUMMARY OF THE INVENTION

In broad terms, this invention provides a bed base comprising a plurality of nestable sides from which the bed base is assembled.

The invention also provides for the bed base to comprise two elongate sides, a head side and a foot side; the two elongate sides being releasably engageable with the head side and the foot side respectively thereby to, in use, define a generally rectangular perimeter for the bed base; the head side and foot side forming a first nested combination with the two elongate sides forming a second nested combination, which nested combinations are abuttingly positionable in a space saving relationship relative to each other when the bed base is stowed away or transported. The invention provides for each of the two elongate sides, head side and foot side to comprise an elongate limb connected via a bend to a shorter limb.

Preferably, each limb is generally planar and formed from sheet metal. There is also provided for elongate edges of the limbs to terminate in flanges. The limbs may include engagement means operable to permit the engagement of limbs of the respective sides with each other and their manual disengagement from each other. The engagement means may comprise a first engaging formation provided on the elongate limb of each side and a second, complementary engaging formation provided on the short limb of each side.

Elongate limbs of the elongate sides may be provided with apertures suitably shaped to allow fitment of ends of transversely extending slats therein.

There is also provided for the apertures and/or engagement means to be integrally formed with the limbs. Preferably, the apertures are equidistantly spaced apart and defined in an upper flange portion of each elongate limb.

Each flange portion may be L-shaped when viewed in outline to define first and second projections extending at right angles relative to each other. Typically, the upper flange portion is formed at an upper elongate edge of each elongate limb or side.

Each aperture may be formed to extend partially across the first projection and partially across the second projection.

In an embodiment of the invention, the ends of the slats are notched thereby to permit a friction fit between each slat end and borders of an aperture to which the slat is fitted. Each lower L-shaped flange further comprises a plurality of openings for securing a leg for the bed base to the respective sides. Alternatively, limbs of the planar elongate sides may be in the form of a thin walled mild steel on which suitable indicia and/or representations are provided. Further alternatively, limbs of the elongate sides may be in the form of a thin walled grid, which is lightweight and generally planar.

In addition, the respective sides may comprise reinforcing plates that extend across their side walls. Preferably, the plates are substantially boomerang- shaped. The invention also extends to a bed base construction method, comprising: forming, from a planar material, a set of bed base sides, each side defining an elongate limb connected via a bend to a shorter limb; providing the respective limbs of the bed base sides with engagement means operable to permit the engagement of limbs of the respective sides with each other and their manual disengagement from each other; and forming a plurality of slats, of equal length, from tubular material for use as mattress support.

The method may include forming legs from a planar material for supporting the respective sides from below, the legs comprising securement means for securing the legs to the respective sides.

The method may include forming notches near ends of the slats thereby to permit a friction fit between each slat end and borders of an aperture to which the slat is fitted

The method may include forming, from a generally planar material, reinforcing plates for securement to each corner of the bed base. BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the invention is now described, by way of example, with reference to the accompanying non-limiting diagrammatic drawings. In the drawings:

Figure 1 shows a perspective exploded view of a bed base and its components in accordance with an embodiment of the invention; Figure 2 shows a slat inserted into the bed base of Figure 1 ;

Figure 3 shows a perspective view of a corner of the bed base of Figure

1 ; Figure 4 shows a side view of engagement means securing limbs of the sides of the bed base of Figure 1 ;

Figure 5 shows a perspective view of the bed base of Figure 1 , with sides thereof being shown in nested configuration; and

Figure 6 shows a perspective view of the bed base in assembled configuration.

DETAILED DESCRIPTION OF THE DRAWINGS

This description is presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how at least one of the several forms of the invention may be embodied in practice.

In the Figures, reference numeral 10 generally refers to a bed base in accordance with the invention.

As shown in Figure 1 , the bed base consists of several components which can be assembled to form a bed base as and when required. As a result, the bed base 10 greatly facilitates transport as components thereof can be neatly packed in an abutting relationship relative to each other. In fact, several components thereof are nestable within one another.

The bed base 10, as shown in Figure 1 , mainly consists of two elongate sides 12, a head side 14 and a foot side 16. The two elongate sides 12 are releasably engageable with the head side 14 and the foot side 16 respectively thereby to, in use, i.e. after assembly, define a generally rectangular perimeter for the bed base 10.

The head side 14 and foot side 16 form a first nested combination as they are shaped and configured to be mirror images of each other. The two elongate sides 12 also form a second nested combination as they are shaped and configured to be mirror images of each other, as shown in Figures 1 and 5. The nested combinations are abuttingly positionable in a space saving relationship relative to each other when the bed base is stowed away or during transport. As shown in Figure 5, the bed base components in nested configuration are easily locatable within cuboid shaped packaging such as an elongate cardboard box.

Each of the two elongate sides 12, head side 14 and foot side 16 defines an elongate limb connected via a bend 18 to a shorter limb, as best shown in Figure 3. Each limb is generally planar and bent from sheet metal, preferably, but not necessarily, mild steel. It is however envisaged that material other than a metal alloy may be employed in forming the sides 12, 14 and 16 as long as each of such sides are provided with a planar side wall. For instance, a plastics moulding process is not excluded from the scope of the invention and it will be appreciated that plastic moulded sides 12, 14 and 16 may be formed in other embodiments of this invention.

As can be seen from Figure 1 and 2 specifically, a flange is formed along each of two opposing elongate edges of each limb of the respective sides 12, 14, and 16. As such, an upper flange portion 28 and a lower flange portion is defined. These flange portions 28 and 30 are generally L-shaped, when viewed in section, and extend along the length of each limb of the respective sides 12, 14, and 1 6.

The limbs also include engagement means 20 operable to permit the engagement of limbs of the respective sides 12, 14, and 16 with each other and their manual disengagement from each other. The engagement means 20 may comprise a first engaging formation, such as a hole for receiving a bolt and nut, provided on the elongate limb of each side and a second, complementary engaging formation or hole provided on the short limb of each side. As shown in Figures 3 and 4, these holes are typically formed in a depressed, or dimple, section of the sides 12, 14, and 16. This ensures a more secure and stronger engagement between respective sides because shear forces against the bolt, which would naturally apply when the bolt is under load, is reduced.

Although engagement means 20 in the form of nuts, bolts and holes are shown and described, it will be appreciated that in other non-shown embodiments of the invention, other engagement means such as, for example, clip-in or screw-fit mechanisms may be employed to bring about engagement of the limbs of the respective sides 12, 14, and 16 with each other; and their manual disengagement from each other.

Furthermore, as shown in Figure 2, each of the two elongate limbs of the elongate sides 12 is provided with apertures 22 suitably shaped to permit friction fitment of ends 26 therein. These ends 26 are defined longitudinally opposite each other on each slat 24, that extends transversely between the sides 12 to, in use or operatively, provide the bed base 10 with rigidity. As can be seen in Figure 2, these apertures 22 are equidistantly spaced apart and defined in an upper flange portion 28 of each elongate limb of each elongate side 12. As best shown in Figure 2, each upper flange portion 28 is L-shaped, when viewed in section. Each aperture 22 is furthermore formed in the generally planar sheet metal of the upper flange portion 28 so as to extend partially across a first sideways extending projection 36 of the L-shaped flange portion 28 and partially across a second downwardly extending projection 38 of the L-shaped flange portion 28. The above- described configuration of the upper flange portion 28 with unique apertures therein ensures a firm seating arrangement is established between transversely extending slats and the respective sides 12.

Evident from Figure 2 is that notches (not shown) are provided near ends 26 of the slats 24. These notches allow each slat 24 to operatively slide into position over a remaining sheet metal part of respective second downwardly extending projections 38. This is believed to further enhance the friction fit between each slat 24 and borders of the respective upper flange portions 28, defining the aperture 22, to which the slat 24 is fitted.

As best show in Figure 1 , each lower L-shaped flange 30 includes a plurality of openings through which suitable securing means such as bolts can extend, for securing a leg 32 for the bed base 10 to corners of the respective sides 12, 14, and 16. The legs 32, as shown in Figure 1 are also preferably formed from thin walled mild steel, but other leg formations and materials are also believed to fall within the ambit of the invention claimed herein.

The fact that the limbs of the planar elongate sides 12 is typically in the form of a thin walled mild steel also provides the opportunity to secure or apply suitable indicia 40 and/or representations, as shown in Figure 6, onto a flat surface provided by the thin walled mild steel.

In other embodiments of the invention, a hinge mechanism may even be incorporated between the head side 16 and the remainder of the bed base 10, thereby to allow a person to hingedly access a void defined below the mattress supporting surface. It is also envisaged in further alternative embodiments of the current invention that limbs of the elongate sides 12 may be in the form of a thin walled see-through grid, which is lightweight and generally planar thereby further facilitating portability and ease of transportation.

Referring to Figure 1 and 6, engagement between respective sides 12, 14, and 16 are effected by suitable positioning of reinforcing plates 34 that extend across corner portions of the connected side walls. Preferably, the plates are substantially boomerang-shaped thereby to mirror the outline of the curved corners of the bed base 10, as shown in Figure 3.

It will be appreciated that the invention also extends to a construction method for a bed base 10, which method includes the following steps.

Firstly, from a material having the capability to form a planar article, a set of bed base sides 12, 14, and 16 is formed, each side 12, 14, 16 defines an elongate limb connected via a bend to a shorter limb. Typically, the material is a sheet metal alloy such as mild steel. Thereafter, the respective limbs of the bed base sides 1 2, 14, 1 6 are provided with engagement means operable to permit the engagement of limbs of the respective sides 1 2, 14, 1 6 with each other and their manual disengagement from each other.

Finally, a plurality of slats of equal length and from a tubular material, for use as mattress support, are cut before the sides 12, 14, and 16 are nested and packed together with the slats 24 and optionally legs 32 into suitable packaging. It is envisaged that either a plastics material or cardboard material can be utilized as packaging material for the bed base components.

The applicant believes that the bed base 10 of the invention addresses shortcomings associated with ubiquitous bed bases in that a neat, sturdy, easy to assemble and aesthetically pleasing bed base is provided to the furniture industry.

The invention for which patent protection is sought is now defined by way of the appended set of claims.