AU2008201223B2

AU2008201223B2 - Slat Support

Info

Publication number: AU2008201223B2
Application number: AU2008201223A
Authority: AU
Inventors: David Fealy
Original assignee: COAST RV Pty Ltd
Current assignee: COAST RV Pty Ltd
Priority date: 2007-01-08
Filing date: 2008-03-14
Publication date: 2014-06-05
Anticipated expiration: 2028-01-08
Also published as: AU2008201223A1

Abstract

Abstract A slat support structure including a limiter 51 preferably of metal and thereby having a linear rigid body of torsional strength greater than the wooden slats. The limiter is able to be received by the spine 31 between and parallel to two adjacent slats 25 but 5 could be positioned under the slats. The limiter 51 further includes limiter placement means 52 such as cross members near respective ends of the linear rigid body and able to engage the upper sides of adjacent slats greater than half way to the side rails. The structure and system allows deformation of the slats but limits the torsional deformation. CmJ e~N Lo~

Description

SLAT SUPPORT This invention relates to a slat bed system comprising a bed base formed by a plurality of Slats sup-Ported in a planar manner between side rails t .o support, a inatess. it is particularly 5 great uto provi ding a limitg support to slats to avoid breakages duo to xessive binding of slats, low quality slats, and variable torsional support of slats due to their natural wooden nature. Generally in the field -f bedding, sIat beds are formed by two elongated bears forming side 10 rails with each with their own special formations on opposing internal surfaces to hold respective ends of the bed sl.ats. Usually this is achieved1 by the formations cormprisinlg ledges being specially moulded into the beam. This can rnean that the beams are specially forrned ahd directly correspond with the opposing sp ciallv formed beam. If any damage occurs to one of the special beams it could result in the need to replace the entire beddirg 15 structure, The use of a continuous ledge or a groove formed along the length of the supporting beams allows the bed slats to move. It is necessary for the user of the bed to reposition the bed slats at regular intervals. Although this may be an inc nVeNiece it can also jeopardize the 2D construction of the bed Another difficulty with self-assembled beds is that it is important for the slats of the bed to be spaced evenly and for the spacirig to comply with the spacing that is required by mattress manufacturers to avoid the mattress guarantee being void. Thisnspacing is typically seventy 25 milliiitrs. By incorrect spacing of bed slatS undue weight can be- placed on a slat resulting in breakage or weakening of the slat, In order to avo id such. problems the usual approach has been to supply more substantIally sized s!ats. This lessens the flexibility arid resulting comfort of slat beds. 30 However the problem of slat beds that the present invention is directed is the multiple differences of slats.in creating a variety of slat bed systems, Different manufacturers can use slightly different lengths or different thicknesses of slats or different quality wood. Therefore a retailer of beds must have a niultitude of different (lats to be able to supply the range of slat bed systems. Another problem is that if anyone Or morer slats are damaged, mislaid or 35 not delivered it is not piossible to use other slats to create the bed slat system. Instead the retailer must order and wait for delivery of the new specific slats. Further the retailer cannot be certain that each bed frorn the s3me supplier will uniforrmily meet the quality criteria of the It is therefore an aim of the invention to provide a slat support, which overcomes this problem and allows construction of slat beds to contra variations of slats: 5 It is A further object of the invention to provide an improved slat support structure which overcomes or at least ameliorates the problems of the prior art. According to the invention there is provided a slat deformation limiter for limiting deformation of elongate wooden slatsof a slat bed in which a plurality of slats. are laid adjacent one 10 another in a spaced apart parallel configuration to support a mattress, the slat deformation imiter corprising; a. a central elongate support for supporting and maintaining the slats spaced apart; the dehtral support including a pair of spaced apart bottom linear rails for extending substantially perpendicular to the 16ngth of the. slats between opposite 15 erids of the slat bed arid beneath the slats for supporting the stats during flexing of the slats, a pair of spaced apart top linear rails extending substantially parallel to the bottom rails, and a plurality of connectors extending between thetop and bottom raiis to-connect them together, adjacent conneators defining a space to receive a slat, the central support being configured to engage the slats substantially, centrally between 2.0 opposite ends of the slsts and b. a linear rigid body of torsional strength greater than that of the slats, the 1near body being positioned perpendicular to the central support substantially centrally of the elongate length of the central support- and between the top :and bottom rails, the linear body being arranged for positioning between a pair of 25 adjacer.it slats ahd extending diose to-the opposite ends of the slats, the linear body including laterally extending members at each Opposite end for bearing against upper surfaces of the pair ot adjacent sits; c: whereby in use, when a, downward load is- applied to the slats, the central support and the slats tend to flex downwardly and the linear body supports the slats 30 and the central support against downward flexing by the laterally extending members bearing at each opposite end against the upper surfaces of the pair of adjacent slats between which the linear body is positioned and by the linear body bearing upwardly against the top rails of the central support. 35 The central support can be integral with the linear rigid body but at least partially offset to the engagement means- to allow limited torsional deformation of the slats. However more preferably the central support is separate from the linear rigid body and engages a plurality of slats and loosely engages a central portion of the linear rigid body of two adjacent slatsr In one form the central support is a spine that can extend Qentrally across a plurality of slats. The spine can include a box like framework allowing loose fOting of individual slats within spaced side openings and the linear rigid body able to tit between adjacent sists through the side openings of the spine, 5 The laterally extending members are able to engage the one or more adjacent slats at a positierr greater than half way to the distal ends of the s al forn the central portion. It can be seen that the direct or indirect engagement of the linear rigid body at the central 10 portion of the slats is providing opposing force to the direct or indirect engagerment of-the linear rigid body on the opposite side. In accordance with the lnvention there is also provided a slat deformation limiter for limiting deformation of elongate wooden slats of a slat bed in which a plurality of rlaits are laid 15 adjacent one another- in a spaced apart parallel configuration to support a mnatttess, the :slat deformation limiter comprising, a. a central elpngate support for supporting and riaintaining the slats spaced apart, the central support including a pair of spaced apart bottom linear rails for extending substantially perpendicular to the length of the slats between opposite 20 ends of the slat bed and beneath the slats for supporting the slats during flexing of the slats, a pair of spaced apart top linear rails extending substantially parallel to th~e bottom. raIls, and a plurality of connectors extending between the top and bottom rails to c6nnect them together, adjacent connectors defining a space between the top and bottom rails to receive a slat, the central support being configured to engage the slats 25 sub !ahtiallV ceritrelly bWtween opposite ends ofthe slats, and b, a linear rigid body of torsional strength greater than that .of the slats, the line~a body being positioned perpendicular to the central support substantially centrally of the elongate length of the certral support and between the top and bottom rails, the near body being arranged for positioning between a pair of 30 adjacent slats and extending close to the opposite ends of the slats, the linear body including laterally extending members. at each Opposite end for bearing against upper surfaces of the pair of adjacent slats; c. whereby when a doWnward load is applied to the slats, the central support and the slats tend to flex downwardly and the linear body supports the slats and the 35 central support against doWnWard flexing by bearing at cach opposite end against the upper surfaces of the pair of adjacent slats between which the linear body is positioned And by bearing upwardly against the top rails of the central support. 3 The invention also provides a method of supporting a mattressusing slats including a) providing two side rails held in spaced parallel configuration for supporting ends of slats e-xtending therebetween' b) providing a plurality of slats held in linear array for extending. between the 5 side rails and being supported thereon; c) providing a limiter having a linear rigid body of torional strength greater than that the Slats and able to be positioned betwen and para!Ilel to two adjacent slats, the limiter further including limiter placement means- near respective ends of the linear rigid body and able to engage the adjacent slats greater than half way to 10 the side rails wherein the flex of the planar array of -slats and spine is limited by the limiter. The methrid of the invention car also include: d).providing a.spine for spacing and unifying the plurality of slats into an array 15 while furthe for positioriin and uhifyirig the limiter into the array. It can be seer that the limiter allows the array of wooden slats to. flex thereby provide a comfortable support of the rattress-while limiting the extent of thatflex of slats so the imit of the torsional strength of individual slats is not met which would result in breakage of. slats. 20 Genersly the .limiter would be a metal rod or tube, However only one or possibly two limiters are required for 6n entire bed structure so it has significant advantages and it is not necessary to replace slats with metal slats or the like. It is further seen that this spine and limiter are combining to form a support structure in .two 5 directions so that the array of slats is further strengthe ed along the length of the bed as well as across the width of the bed. In order that thf invention is more readily understood an embodiment will be described by way of-illustration only with reference to the drawings wherein: 30 Figure 1 is a diagrammatic exploded view of a !lat support in accordance with an embodiment of the invention; Figure 2 is a vertical cross section of a slat support without limiter showing flex of slat array 3o5 Figure 3 is a vertical cross section of a slat -support With limiter showing. limiting flex.;of slat array. 4 Referring to. the drawings there is shown a slat support structure having two spaced side rails 21 having supporting formations 23 on opposing inner sides. There is a plurality 6f linear slats 25 arranged in parallel formation and supported at opposing ends on the opposing inner sides of the rwo spaced side rails 21. 5 Dhe structure further includes a spine 31 having receiving means for receiving a middle portion of each slat'and haviriy a spacing means for s ac;ng adjacent slats o that the slats and spine form a planar array for supporting a mattress 10 The spine 31 is comprised of two bottom linear support rails 32 extending in a plene and forming a support under the slats 25, The spine 31 further includes two parallel top linear strengthening rails 34 extending in a plane above the slats 25 and extending parallel but within the two bottOim linear support rails 32. A plurality of C shaped connectors 33 connect all four rails together and are spaced along the length of the four rails to form receiving 15 cavitiesalowing slats'to slide through and be suoorted on the bottom linear support radil 32 and caged within the top linear strengthening rails 34 a rd adjacent C shaped connectors 33. The -slat support structUre includes a limiter 51 prefer rably of rmietal and thereby having a linear rigid body of torsional strength greater than the wooden slats. The limiter is able to be 2.0 received by the spine 31 between and parallel to two adjacent slats 25 but coUld be positioned under the slats. The limiter 5.1 further includes limiter placement means 52 such as cross members near respective ends of the linear rigid body and able to engage the upper sides of adjacent slats greeter than half way to the side rails. 25 In this way -the fle: 6f the planar erray of slats and opine is limited by the limiter and the central weight to the array of siats is transferred by the! torsional strength of the limiter to the ends of the slats which are adjacent the solid supporting formations of the side rails. The limiter could be retrofitted to known slat arrays by providing a iiricar rigid body of 3. torsional strer:Igth greater than that the wooden slats and able to be received by a spine between and parallel to two adjacer slats, the limiter further. including -limiter placement means near respective, ends of the linear rigid body and able to engage the adjacent slats greater than halfway to the side rails wherein the fek of the planar array of slats and spine is lirnited by the limiter, If required the system can be retrofitted by inclusion of a matching 35 limiter and sprite wherein the spihe predeterrmihes the spacing end the sizing of the limiter is determined to fit.the spacing in the spine to allow rnuvment but to provide a holding position of the limiter.

In use the method of supporting a rnattress using slats including a) providing two side rails held in spared parallel configuration for supporting ends of slats extendng therebetween. b) providing a plurality of slats held in linear array for extending between the 5 side rails and being supported thereon, c) providing a limiter having a linear rigid body of torsional strength greater than that the slats and able to be positioned between and paraloll to two adjacent slats, the- limiter further including limiter placement means near respective ends of the linear rigid body and able to engage the. adjaceit.lats greater than half way to 10 the side rails wherein the flex of the planar array of slats and spine is limited by the limiter; and d) providing a spine for spacing and unifying the plurality of slats irito an array while further for positioning and, unifying the limter into the array. 15 It can be seen that the limiter allows the array of wooden slats to flex thereby provide comfortable support of the mattress while limiting the extent of that flex of slats so the limit of the torsional strength of individual slats is not met wh ich would result in breakage of slats. Generally the limiter would be a metal rod or tube, However only one or possibly two limiters are required for an entire bed structure so it has significant advantages and it is not 20 necessary to replace slats wlth metal slats or the Irke. It is further seen that this spine and limiter are combining to form a support structure in two directions so that the array of slats is further strngtheod. along the length of the bed as well as across the width of the bed. 25 It should be understood that the above is of a preferred embodiment, Clearly a.person skilled in the art will understand the invention and see other alternatives without any inventive element and such are included within the scope of thi invention as defined in. the following claims.. 30 6

Claims

1. A slat deformation limiter for lmiting deformation of elongate wooden slats of a slat bed in which a plurality of slats are laid adjacent one another in a spaced apart parallel 5 configuration to support a mattress, the slat deformatioh limiter compnsing; a, a central elongate support for supporting and maintaining the slats spared apart, the central support 'including a pair of spaced apart bottOm linPar rails for extending substantially perpendicular to the length of the slats between opposite ends of the slat bed and beneath the slats for supporting the slats during flexing of IQ the slats, a pair of spaced apart top linear rails extending substantially parallel to the bottom rails, and a plurality of connectors extending between the top and bottom rails to connect them together, adjacent connectors defining a space to receive a slat, the contlral support being configured to engage the slats, substantially centrally between oppositerends of the slats, and; 15 b. a linear rigid body of torsional strength greater than that of the slats, the linear body being positioned perpendicular to the central support substantially centrally of the elongate length of the ceitrei support and between the ip arid bottom rails, the linear body being arranged for positioning between a pair of adjacent alats and extending close to the opposite ends of the slats, the linear body 20 including laterally extending members at each opposite- end for bearing against upper surfaces of the pair of adjacent slats; c. whereby in use, when a downward load is applied to the slats, the central support and the slats tend to flex downWardly rid the linear body supports the slats and the central support against downward flexing by the laterally extending 25 hiembers bearing at bach opposite end against the, upper surfaces of the pair of adjacent slats between which the linear body is positioned and by the linear body bearing upwardly against the top rails of the central support.

2. A slat deformation limiter system according to claim 1 wherein the central support 30 is integral with the linear body but is spaced from the laterally extending members to allow limited torsional deformation of the slats.

3. A slat support structure having a, two spaced side rails having supporting formations on opposing inner 35 sides b: a plurality of a linear slats arranged adjacent one another in a spaced apart parallel configuration and supported at oppsite ends on the. opposing inner sides of the two spaced side rails; c. a central elongate support having openings. for receiving a central portion of each slat arid being operable to space adjacent sas apart, -the operiings being defined by a pair of spaced apart bottorn linear rails for extending substantially perpendicular to the length of the slats between opposite ends of the slat bed and 5 beneath the slats for supporting tho -slats during flexing of the slats, a pair of spaced apart top linear rails extending substantially parallel. to the bottom rails, and a. plurality of connectors extending between the top arid bfttem rails to connect them together, adjacent -connectors defining a separate opening between the top and. bottom rails to receive a slat; 10 whereih the slats end central support form a planar array for supporting a mattress; and wherein the siat support structure includes a linear rigid body of torsional strength greater than that of the slats, the linear body being positioned perpendicular to the central support substantially centrally of the elongate length of the central support and 15 through an opening fornied betweh the top and bottom rails, the linea- body being positioned between a pair of adjacent. slats and extending close to the opposite ends of the slats, the lineal- body including laterally extending ern bers at each opposite endfor bearing against upper surfaces of the pair of adjacent -slats wherein when a downward load is applied to the slats, the. central support and the slats tend to flex downwardly And the linear 20 body supports. the ad the central support against downward flexing by the laterally eteiding rhermbor bearing at each opposite end ag jnst the upper surfaces of the pair of adjacerit slats between which te linear body is posit oned and by the linear body bearing upwardly against the top rails of the central support. 25

4. A slat deforrna.tion limiter for'limitin deferrIiafioh of elongate wooden slats of a slat bed in \Nhich a plurality of -slats are laid adjacent one another in a spaced apart parallel configuration to support a mattress, the slat deformation imiter corn prising, a a central elongate support for supporting and maintaining the slats spaced apart, the. central support including a pair of spaced apart bottom linear rails for 30 extending substantially perp.rnidicular to the length of the slats between opposite ends of the slat bed and beneath the slats for supporting the slats during flexing of the slats, a pair of spaced apart top linear rails extending substantially parallel to the bottom rails, and a plurality of connectors extending betWeer the top and bottom rafls to connect them together, adjacent -connectors defining a space to 35 receive a slat, the central support .being configured tO engage the 3lats substantially centrally between opposite ends of the slats Andt b. a linear rigid body of torsinal strength greater thn that of the slats, the linear bo.dy being positioned perpendicular to the central support subs ftia I ly centrally of the elongate length of the central support and between the top and bottom rails, the linear body being arranged for positioning between a pair of adjacent slats and extending close to the opposite ends of the slais, the linear body including laterally extending members at each opposite end for benrihg against upper surfaces of the pair of adjacent slats; c. whereby when a downward load is applied to the sats, the central support andi the slats tend to flex downwardly and the Inear body supports the slats and the central support against downward flexing by bearing at each opposite end against the upper surfaces of the Pair of adjacent siats between which the linear body is 0 positioned and by bearing upwardly against The top ra1 of-the central support. A slat deformation limiter system substanti Ily as hereinbefore described with referende-to the drawings.

5 S. A slat suppo-rt structure substantially as hereirtefore described with reference to the drawings.