AU729002B2 - Connector bracket suitable for beds - Google Patents

Description

P/00/01 1 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Connector bracket suitable for beds KC.: The following statement is a full description of this invention, including the best method of performing it known to me/us: R-flMFI MO~RVA01fl7 n FHPMELCD\97063016.4 CONNECTOR BRACKET SUITABLE FOR BEDS This invention relates generally to a connector bracket. The bracket has particular utility in the assembly of beds and it is this application which will be primarily described in this specification. It is emphasised, however, that the bracket has a wide utility, particularly for the assembly of timber rails and uprights.

A variety of arrangements have been proposed over time for securely mounting the main side rails of bed bases to respective uprights or legs. Where both rails and uprights are timber, a mounting system in common use entails a two-part bracket in which three aligned tongues at a vertical edge of one component wedge into matching slots in the other component. The tongued component is fastened to the end of the rail with the tongues projecting. This arrangement facilitates assembly of the bed, but has the disadvantage that subsequent movement of the bed tends to cause deformity of the slotted component. This degrades the wedging fit and loosens the assembly a loose and squeaky bed is the result, because the end faces of the rails are no longer firmly in contact with the respective side faces of the uprights.

~This last mentioned requirement is satisfied by arrangements which utilise angular brackets bolted both to rails and uprights but this simple arrangement has other disadvantages, i.e. protruding bolts, the need for separate fasteners, and significantly *:**igreater time and effort in assembly. Connection arrangements which utilise crossed bores in the ends of the rails respectively retaining fasteners and rotatable head locking inserts, address these disadvantages but are a complication at the manufacturing stage and involve multiple components for both the manufacturer and the assembler.

It is an object of the invention to provide a novel bracket which, at least in one or more particular embodiments, may be utilised as a connector bracket in bed assembly that

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FHPMELCD00371006.9 -2at least in part alleviates one or more of the aforementioned disadvantages of known arrangements.

The invention accordingly provides, in a first aspect, a connector bracket including: an integral body having first and second generally planar portions mutually inclined at a substantial angle at a bend in the bracket, the first portion being relatively wider from the bend than the second portion; an array of apertures in said first portion for receiving fasteners to secure the first portion to a first surface; and at least two undercut blind slots in an edge of said second portion that is remote from the first portion and is generally parallel to said bend, said slots having respective mouths opening at said edge for receiving the shanks of respective headed stud means carried by a second surface and locating the shanks in respective undercut portions of the slots, whereby 15 to connect said first and second surfaces together.

An especially useful form of the bracket has the two planar portions arranged substantially at 900 to each other.

S. The first portion is advantageously of generally rectangular configuration, .extending further parallel to the bend than transverse to it.

The blind slots are preferably double undercut so that the bracket can be suspended on the stud means in either of two opposite orientations.

In a second aspect, the invention extends to a bed including four corner uprights and two side rails joining the uprights in pairs, wherein the rails are mounted to the uprights by respective right angle brackets according to the first aspect of the invention, coupled to a pair of headed stud means carried by the uprights. The headed stud means preferably have threaded shanks. These shanks may be directly screwed into the uprights, or may be engaged in matching threaded inserts provided in the uprights. The heads are advantageously hexagonal heads, but may also be any other suitable form, for example FHPMELCD97063016.4 3 domed heads with hexagonal sockets to receive allen keys. One preferred form of the stud means is a hexagonal head screw, e.g. a coach screw, engaged directly into the upright.

The invention will be further described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a connecting bracket according to an embodiment of the invention; Figure 2 shows the bracket mounted to a bed side rail being presented for engagement with an upright; Figure 3 illustrates a subsequent assembly of the rail and upright utilising the bracket of Figure 1; Figure 4 is a plan view of the assembly; Figure 5 is a plan view of a flat blank for a modified form of bracket prior to bending; Figure 6 is a plan view of a flat blank of a further embodiment of bracket prior to bending; and S "Figure 7 is a fragmentary enlargement of part of Figure 6, better depicting the detail of the blind undercut slots.

The illustrated bracket 10 is formed from a flat generally rectangular blank cut or ."stamped from mild steel plate or sheet for example of 2.0mm gauge. The blank has been bent at a fold line 12 parallel to its longer dimension to define respective generally planar portions hereinafter referred to as mounting plate 14 and flange 16. Mounting plate 14 is substantially wider from fold line 12 than flange 16, indeed about twice the width of the flange in the particular illustrated example.

555o55 S"Mounting plate 14 is provided with an array of apertures 15 for receiving fasteners such as wood screws 20 by which the bracket may be secured onto a surface 6 of a component such as a timber bed side rail 5. One configuration of apertures 15 is illustrated but a variety of others are possible according to the application.

FHPMELCD\97063016.4 4 Flange 16 extends to a longitudinal edge 25 of the bracket remote from mounting plate 14 and bend line 12, to which edge 25 is parallel. Pressed from the flange 16 and open at edge 25 are a pair of double undercut blind slots 30,31. Slots 30,31 are spaced well apart and indeed are disposed much nearer to either end of the flange than to each other.

Each slot 30,31 essentially comprises a straight back edge 32 parallel to fold line 12 and nearer to this fold line than to edge 25, and, linking each end of back edge 32 smoothly into edge 25, a pair of S or backward-S shaped edges 34. Edges 34 thereby define both the mouth 36 of the slot and the respective undercut portions 38,39.

Figure 5 is a precision drawing of an exemplary flat blank 111 for a modified form of bracket, prior to bending at fold line 112. Measurements are in millimetres and like parts are indicated by like reference numerals preceded by a The bracket to be formed from this blank is not identical to that illustrated in Figures 1 to 3 in that the mouths 136 of double undercut slots 130, 131 are essentially straight sided with radiused corners.

Figures 2 to 3 illustrate how a bracket 10 may be employed to mount bed rail 5 to a timber upright or leg 7. A front or rear face 8 of upright 7 is prefitted with a pair of *threaded inserts 40,41 whose centre to centre spacing is equal to the centre to centre spacing of slot mouths 36. When it is desired to assemble the bed, respective hexagonalheaded studs 50,51 are engaged with inserts 40,41, but not rotated wholly home. The flange 16 of a bracket 10 mounted at the end of rail 5 is brought up to the studs 50,51 so as to receive the shanks of the studs through slot mouths 36. The bracket is then lowered to bring the studs into the upper undercut portion (39 in the figures). The heads 52 of the *a studs 50,51 are now engaged and rotated securely home to lock the flanges between the heads 52 and upright face 8.

*a The optimum arrangement is to position inserts 40,41 in upright 7 and to mount bracket 10 to rail 5 in such a fashion that the end face 6a of the rail 5 squarely abuts the opposing face 8 of upright 7, and that the inside main face 6b of rail 5 is flush with the inside face 8a of upright 7. This condition is best seen in Figure 4.

FHPMELCD\97063016.4 Figures 6 and 7 illustrate a blank 211 for a further embodiment of bracket. Like parts are indicated by like reference numerals preceded by a Apart from including an alternative arrangement of screw apertures 215, this blank has two additional features.

Each end or undercut portion 238, 239 of slots 230, 231 includes opposed straight but mutually tapered side edge portions 60, 61 for accommodating stud shanks of variable diameter.

The second additional feature is a manufacturing facility. By setting the blankcutting die to form a blank having, set back from each end, aligned pairs of notches 62 with rounded edges 63, minimal adjustment of the tool will allow a shorter blank (with rounded corners) to be stamped out at these notches.

It will be appreciated that the arrangements of the illustrated embodiments are advantageous for both the bed manufacturer and the assembler. The mounting utilises preformed brackets 10 and threaded inserts 40,41 which can readily be fitted to the rails and uprights. There are no protruding parts during delivery and transport since the studs S"50,51 can be kept separate and easily engaged for assembly. The assembly process is especially simple and positive. The resultant assembly is susceptible to easy -disengagement in the event that it is desired to dismantle the bed, and is a very positive mounting to maintain firm face-to-face contact of rail and upright when the bed is moved around the room or otherwise subjected to stresses during use.

Where it is desired to further reduce manufacturing costs, the inserts 40,41 may be dispensed with, and the studs instead provided as screws, e.g. hexagonal head coach screws, directly screwed into drilled blind bores in the uprights. Another possibility is dome head screws, having hexagonal sockets to receive allen keys.

The double undercutting of slots 30,31 allows the bracket to be attached with either of opposite orientations, whereby a single configuration of bracket can be used at either end of either rail. More than two undercut slots may of course be provided.

FHPMELCD\97063016.4 6 It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

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Claims (14)

1. A connector bracket including: an integral body having first and second generally planar portions mutually inclined at a substantial angle at a bend in the bracket, the first portion being relatively wider from the bend than the second portion; an array of apertures in said first portion for receiving fasteners to secure the first portion to a first surface; and at least two undercut blind slots in an edge of said second portion 10 that is remote from the first portion and is generally parallel to said bend, said slots having respective mouths opening at said edge for receiving the shanks of respective headed stud means carried by a second surface and locating the shanks in respective undercut portions of the slots, whereby to connect said first and second surfaces together.

S2. A connector bracket according to claim 1 wherein said angle is substantially 900

3. A connector bracket according to claim 1 or 2 wherein said first planar portion is of generally rectangular configuration, extending further parallel to 20 said bend than transverse to it.

4. A connector bracket according to any preceding claim wherein said blind slots are double undercut so that the bracket can be suspended on the stud means in either of two opposite orientations. A connector bracket according to any preceding claim wherein said blind slots include opposed mutually tapered side edge portions for accommodating shanks of variable diameter.

FHPMELCD00371006.9 -8-

6. A connector bracket according to claim 1 and substantially as hereinbefore described with reference to Figures 1 to 4 or 5, or 6 and 7 of the accompanying drawings.

7. A connector bracket according to any preceding claim, formed in steel plate or sheet.

8. A blank for a connector bracket according to any preceding claim, cut or stamped from steel plate or sheet.

9. A bed including four corner uprights and two side rails joining the uprights in pairs, wherein the rails are mounted to the uprights by respective angled brackets according to any one of claims 1 to 7 coupled to a pair of headed stud means carried by the uprights.

10. A bed according to claim 9 wherein said headed stud means have threaded shanks.

11. A bed according to claim 10 wherein said shanks are directly screwed into 15 said uprights of the bed. ee

12. A bed according to claim 10 wherein said shanks are engaged in matching threaded inserts provided in said uprights.

13. A bed according to any one of claims 9 to 12 wherein each of said headed stud means is a hexagonal head screw engaged directly into the respective said upright. David Ronald Durance by Freehills Carter Smith Beadle Patent Attorneys for the Applicant

14 November 2000