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Title:
MODULAR SUPPORT FRAME
Document Type and Number:
WIPO Patent Application WO/2024/086865
Kind Code:
A1
Abstract:
A modular support frame is formed by assembling at least two flat panel sections, each panel section comprising: opposite parallel long sides defining the panel section's length and opposite short sides defining the panel section's height; pairs of first slots provided along a first long side of the panel section; and pairs of second slots alternately provided along the first long side and the opposite second long side of the panel section; wherein the two panel sections are interleaved at their respective pairs of first slots to form an upstanding support segment comprising a series of polygonal structures along the segment's length; and wherein the segment is adapted to interlock along its length with an adjacent similar segment by way of the pairs of second slots.

Inventors:
SWERSKY BENJAMIN BRETT (AU)
Application Number:
PCT/AU2022/051291
Publication Date:
May 02, 2024
Filing Date:
October 27, 2022
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
YONA PTY LTD (AU)
International Classes:
A47C19/00
Attorney, Agent or Firm:
BOSH IP PTY LTD (AU)
Download PDF:
Claims:
CLAIMS:

1. A modular support frame formed by assembling at least two flat panel sections, each panel section comprising: opposite parallel long sides defining the panel section’s length and opposite short sides defining the panel section’s height, pairs of first slots provided along a first long side of the panel section, and pairs of second slots alternately provided along the first long side and the opposite second long side of the panel section; wherein the two panel sections are interleaved at their respective pairs of first slots to form an upstanding support segment comprising a series of polygonal structures along the segment’s length; and wherein the segment is adapted to interlock along its length with an adjacent similar segment by way of the pairs of second slots.

2. The modular support frame claimed in claim 1 , wherein the segments are interlocked at overlapping panel faces.

3. The modular support frame claimed in claim 2, wherein the overlapping panel faces are connected between two cross-over points of the interlocked segments.

4. The modular support frame claimed in claim 2 or 3, wherein the overlapping panel faces are defined between a pair of second slots.

5. The modular support frame claimed in any one of the preceding claims, wherein creases are provided to continue from the second slots along the height of the panel section to define fold lines at the second slots and creases.

6. The modular support frame claims in any one of the preceding claims, wherein the panel sections in a segment are connected at their respective ends by way of a catching hook.

7. The modular support frame claimed in claim 6, wherein each catching hook on a panel section comprises a notch that engages with an oppositely directed corresponding notch on the other panel section. The modular support frame claimed in claim 6 or 7, wherein the catching hooks at the ends of a panel section face an opposite direction relative to the first long side, such that the first slots on the first side of one panel section engage the other panel section in one engaging direction, and the catching hooks on the one panel section engage the other panel section in an opposite engaging direction. The modular support frame claimed in any one of the preceding claims, wherein more than two segments are adjacently interlocked along their length to form larger support frames. The modular support frame claimed in any one of the preceding claims, wherein the panel sections are formed from a fibrous board material. A modular support frame kit comprising two or more identical flat panels, each panel comprising: opposite parallel long sides defining the panel’s length and opposite parallel short sides defining the support frame’s height, pairs of first slots provided along a first long side of the panel, and pairs of second slots alternately provided along the first long side and the opposite second long side of the panel; wherein the panels are adapted to interleave at their respective pairs of first slots to form an upstanding support segment comprising a series of polygonal structures along the segment’s length; and wherein the segment is adapted to interlock along its length with an adjacent similar segment by way of the pairs of second slots. A panel adapted to create a modular support frame when assembled with another like panel, the panel comprising: opposite parallel long sides defining the panel’s length and opposite parallel short sides defining the support frame’s height, pairs of first slots provided along a first long side of the panel, and pairs of second slots alternately provided along the first long side and the opposite second long side of the panel section; wherein the panel is adapted to interleave with similar pairs of first slots of a like panel to form an upstanding support segment comprising a series of polygonal structures along the segment’s length.

13. The panel claimed in claim 12, wherein groups of first and second slots are equidistantly positioned along the first long side in a series of four slots.

14. The panel claimed in claim 12 or 13, wherein the pairs of second slots are spaced at equal intervals along the second long side.

15. The panel claimed in any one of claims 12 to 14, wherein each pair of second slots on the first side is positioned between a pair of first slots.

16. The panel claimed in any one of claims 12 to 15, wherein slots on both long sides of the panel sections form a repeating equidistant pattern of slots in the order of:

Description:
MODULAR SUPPORT FRAME

Field of Invention

[0001] The present invention relates to a modular support frame that can be assembled and collapsed from a flat pack kit to a support structure when assembled. By way of example, the support frame could be used as furniture, including load- bearing furniture such as bed bases.

Background of the Invention

[0002] Structures formed from lightweight foldable planar materials have the benefit of being easily transportable and can also exhibit high strength when compressive forces are applied in the planar direction. This can make such structures suitable for use as temporary elevated platforms or furniture, such as shelving, seating and even bed bases. Such materials include lightweight timber sheets and corrugated cardboard that may not be particularly strong when forces are applied perpendicularly of the sheet’s plane but can sustain substantial loads applied into the planar direction of the sheet, namely parallel with the sheet’s plane.

[0003] Collapsible frames formed from an interconnected web of upstanding cardboard sections have been used to make bed frames. US 10,480,557 discloses an example of a construction kit for the assembly and installation of a collapsible frame structure in the form of a bed base, platform, or the like. That patent discloses using at least two, if not three, different types of flat components in the assembly of a bed frame. The different component types have different sizes, shapes and corresponding configurations of slots to enable assembly of the flat components into a bed frame. Careful attention is required in assembling the different component types to ensure their correct orientation, assembly order and positioning to produce a frame assembly of rhomboid cell structures when viewed from above.

[0004] Such kits are marketed to the average, unskilled person who wishes to assemble the frame themselves at home, but the disclosure of US 10,480,557 can be confusing and confronting to assemble. Furthermore, before adding further flat components to increase the size of the collapsible frame, corner sections need to be first removed and then reinserted after the additional flat components are assembled. The corner components provide extra strength at the corners of the structure but add a level of complexity in assembly and modification of the frame. [0005] Building on the drawbacks associated with lightweight collapsible frames, the present invention seeks to provide a modular support frame that is able to be assembled relatively easily and quickly yet exhibits strength and flexibility to function as a load-bearing structure.

Summary of the Invention

[0006] According to the invention there is provided a modular support frame formed by assembling at least two flat panel sections, each panel section comprising: opposite parallel long sides defining the panel section’s length and opposite short sides defining the panel section’s height, pairs of first slots provided along a first long side of the panel section, and pairs of second slots alternately provided along the first long side and the opposite second long side of the panel section; wherein the two panel sections are interleaved at their respective pairs of first slots to form an upstanding support segment comprising a series of polygonal structures along the segment’s length; and wherein the segment is adapted to interlock along its length with an adjacent similar segment by way of the pairs of second slots.

[0007] In accordance with another aspect the invention also provides a modular support frame kit comprising two or more identical flat panels, each panel comprising: opposite parallel long sides defining the panel’s length and opposite parallel short sides defining the support frame’s height, pairs of first slots provided along a first long side of the panel, and pairs of second slots alternately provided along the first long side and the opposite second long side of the panel; wherein the panels are adapted to interleave at their respective pairs of first slots to form an upstanding support segment comprising a series of polygonal structures along the segment’s length; and wherein the segment is adapted to interlock along its length with an adjacent similar segment by way of the pairs of second slots.

[0008] In another aspect there is still further provided a panel adapted to create a modular support frame when assembled with another like panel, the panel comprising: opposite parallel long sides defining the panel’s length and opposite parallel short sides defining the support frame’s height, pairs of first slots provided along a first long side of the panel, and pairs of second slots alternately provided along the first long side and the opposite second long side of the panel section; wherein the panel is adapted to interleave with similar pairs of first slots of a like panel to form an upstanding support segment comprising a series of polygonal structures along the segment’s length.

[0009] The term ‘modular support frame’ as used herein refers to a support structure formed from as few as two panels (also referred herein as panel sections), where the two panels are interwoven to form a support segment. The support segment is a long upstanding structure that can form a support frame to support a load on top of the frame. A modular support frame may also be formed from more than two panels to create a larger support structure by joining together adjacent segments at their respective pairs of second slots. Accordingly, in a preferred embodiment a pair of second slots on a first segment interlocks with a pair of second slots in a second segment to form a larger support frame.

[0010] An advantage of the modular support frame is that it is relatively easy to assemble because the flat panel sections have similar interconnecting slot configurations and can be of similar shapes and sizes meaning fewer different types of components are required. In fact, in a preferred embodiment of the invention the two flat panel sections are identical and are assembled by inverse positioning, namely by positioning one panel section upside-down relative to the other whereby the panel sections can be interleaved to form segments. In forming a segment, the panels are inversely oriented so that the long sides provided with the pairs of first slots face together and interweave. In so doing, the segments will be formed with pairs of second slots opening upwardly along one side of the segment’s length and pairs of second slots opening downwardly along an opposite side of the segment’s length, such that adjacent segments can be interlocked along adjoining lengths by inter-engaging downwardly opening second slots of one segment with upwardly opening second slots of the adjacent segment.

[0011] A width of the support frame can be increased by interlocking further segments together repeatedly in series. The more segments that are added in parallel onto a free side of a segment the wider the frame will become.

[0012] It is foreseeable in a particular embodiment to also provide for extension in a lengthwise direction and namely in a direction perpendicular to the extension direction described in the previous paragraph. An adaptor piece could be provided to allow length-wise, or series, connection of two segments or even two support frames by engaging adjacent ends. [0013] The location of the slots preferably define creases or fold lines at which the panel sections can be bent. In an embodiment, the second slots define fold lines. The material of the panel sections can be a foldable material that is flexible and will bend along a plane of the panel section, or can be more rigid but will bend or fold at crease lines. A material that exhibits good compressive strength along its width in the direction of the height of the frame is advantageous. Examples of such materials include cardboard - plain, corrugated, laminated or the like; lightweight timber such as balsa wood, plasterboard, plastics such as corrugated plastic board, composites, compressed biomass, etc.

[0014] The series of polygonal structures along the segment’s length are defined in plan view and provide strength to the frame in a vertical orientation analogous to a honeycomb structure whereby a load applied across an upper surface of the frame, and across the polygonal structures, is well supported by the top to bottom compressive strength of the panel section. The nature of the polygonal structure coupled with the interleaved panel sections provide a high load bearing surface suitable for supporting the weight of humans, and other heavy objects, without buckling.

[0015] The polygonal structures are formed with upstanding panel faces of the panel segments in between cross-over points. In one embodiment, the polygonal structure is a hexagon, but could be an octagon, decagon, dodecagon. In a preferred embodiment, the polygonal structure has six or more sides. An advantage of a hexagonal structure or a polygon structure with a greater number of sides is that the panels do not need to undergo extreme folding, which can weaken the panels especially if they material used is cardboard. A polygonal structure of a hexagon or greater provides a gentle panel fold and greater preservation of strength.

[0016] The term ‘panel sections’ and ‘panels’ are both used herein to generally refer to long flat and generally rectangular substrates that are used as the building elements for constructing the polygonal structures and for constructing the segments that in turn create the modular support frame. However, while reference to panels in the plural is commonly used herein, the term ‘panel sections’ is used to convey an understanding that each segment could instead be formed by folding a single panel onto itself and interleaving correspondingly positioned slots. In this example, rather than using two similar but separate panels where one panel is turned inversely to the other, the panel sections could be formed end to end to as part of a longer panel that is folded over onto itself about a centreline where the slots are reflected inversely. [0017] In an embodiment of the invention, the adjacent segments are interlocked at overlapping panel faces being defined by the area of panel in between two slots on each panel. Specifically, the overlapping panel face is defined by the area between a pair of second slots. In other words, the separate segments are not interlocked at a single slot cross-over point on each panel but at two cross-over points between which an overlapping panel face connection is defined. Engaging segments at two slots at each connection on a panel section means the panel faces in between the two slots of each panel will lie against each other effectively creating an upstanding double wall between each segment. This increases the effective strength of the frame assembly to bear a higher maximum load than an assembly where components interlock simply by crossing over at a single point.

[0018] In the above-described embodiment where adjacent segments interlock at overlapping panel faces, the two cross-over points at which the interleaved panel sections engage are defined by the pairs of second slots, also referred to as segment interlocking slots. Accordingly, it follows that the pairs of first slots are panel section interleaving slots.

[0019] In one aspect described herein, groups of first and second slots are equidistantly positioned along the first long side in a series of groups of four slots. The four slots comprise one pair of each first and second slots. Each pair of second slots on the first side is positioned in between a pair of first slots, where the second slots in a pair are positioned closer to one another than the first slot in a pair. On the second long side, pairs of second slots form groups of two slots where the groups are spaced at equal intervals along the second long side.

[0020] The slots on both long sides of the panel sections will therefore form a repeating equidistant pattern of slots in the order of:

Where A = a first slot in a pair (panel section interleaving slot), and B = a second slot in a pair (segment interlocking slot).

Brief Description of the Figures

[0021] In order that the invention be more clearly understood and put into practical effect, reference will now be made to preferred embodiments of an assembly in accordance with the present invention. The ensuing description is given by way of non- limitative example only and is with reference to the accompanying drawings, wherein: [0022] Figure 1 illustrates a first panel in accordance with a first embodiment of the invention;

[0023] Figure 2 illustrates a second panel in accordance with a first embodiment of the invention;

[0024] Figure 3 illustrates the first and second panels of the first embodiment interleaved together to form a first segment;

[0025] Figure 4 illustrates a second segment created using the first and second panels of the first embodiment;

[0026] Figure 5 illustrates the first and second segments interlocked to form a support frame in accordance with an embodiment of the invention;

[0027] Figure 6 illustrates a series of interlocked segments forming a larger support frame;

[0028] Figure 7 illustrates a panel in accordance with a second embodiment of the invention;

[0029] Figure 8 illustrates a segment formed from interleaving together two panels illustrated in Figure 7; and

[0030] Figure 9 illustrates two segments illustrated in Figure 8 interlocked together to form a support frame of the second embodiment.

Detailed Description:

[0031] In the description that follows a modular support frame 10 is described with reference to the drawings and by specific application to a bed base frame. However, it is to be understood that the support frame 10 may be formed in a variety of shapes and sizes depending on application. In its simplest form the support frame 10 will be a segment formed from two panels (discussed further below) having an indefinite length. As a larger structure the support frame 10 will be a multi-segment structure having an indefinite width. Other applications of the modular support frame to a bed base are possible and may apply to other structures such as furniture (seating, tables), or structures capable of supporting a load and/or providing a raised platform, such as a raised stage or fashion runway.

[0032] The support frame 10 uses building base components from which a larger structure can be created by assembling multiple units of the same base components in an uncomplicated manner. More base components can be added to the structure to increase its size, or removed to reduce its size.

[0033] Figures 1 to 6 illustrate panels, segments and a support structure relating to a first embodiment of the invention. Figures 7 to 9 illustrate panels, segments and a support structure relating to a second embodiment of the invention. The first and second embodiments are similar in features and like features are assigned the same reference numbers in both embodiments. The main difference between the embodiments lies in the notches or hooks at the ends of the panels, which will be described in further detail below.

[0034] Figures 1 and 2 illustrate a first panel 12 and a second panel 14 (also referred to as a panel section) that form the single component used to construct the support frame 10. An example of the final constructed support frame 10 is illustrated in Figure 6 and is shown in the shape of a square or rectangle which size is dictated by the number of panels used. The size and shape of the support frame of that shown in Figure 6 is suitable for use as a bed base.

[0035] In the embodiment described herein, the first and second panels 12, 14 are identical in shape, size and slot configuration. The panels are designed to be identical, for ease of manufacture and simplicity of use, yet to also interact with each other to build a larger structure. The only difference with respect to the panel 12 and panel 14 is that they are oriented inversely of each other. In other words, second panel 14 is oriented upside-down with respect to panel 12. It is oriented so in order to engage with the first panel.

[0036] Both first and second panels 12, 14 are long rectangular planar sheets formed from a bendable material, or at least a material that if rigid can bend at fold lines provided transversely of the panel. The rectangular panels have first and second opposite long parallel sides 16, 17 and short sides 18, which are opposite parallel short sides of the rectangle but need not be parallel. The long sides 16, 17 define the length, L, of the panel, while the short sides 18 define the height, H, of the panel which will typically define the height of the support frame 10.

[0037] Slots are provided along the first long side 16 and the second long side 17. The slots are open at the long sides and continue transversely of the panel to terminate approximately midway of the panel’s height, h. With the slots extending to at least midway of the panel height, once interleaved the panels form a segment 20 and will sit flush on a surface along the panel’s long side 16 or 17. The location of the slots can also serve as the location of fold lines 25 assisted by creases 27 continuing on from some of the slots to extend to the opposite side thereby creating a fold line 25 across the height of the panel. The fold lines 25 are lines of weakness occurring at the slots and include creases 27, scores, skip cuts or some other line of weakness continuing from the slot termination point transversely along the panel to the opposite long side. The slots are configured to enable first and second panels 12, 14 to interleave with each other but also allow an interleaved panel assembly, namely a segment 20, to interlock with other segments. Accordingly, there are two types of slots.

[0038] The first type of slot is the panel section interleaving slot 22, also referred to herein as slot A. The second type of slot is the segment interlocking slot 24, referred to as slot B. The slots are generally provided in pairs. Pairs of slot A are formed along the first long side 16 of the panels 12, 14, and will only be formed on one of the two opposite long sides because these first slots will inter-engage with corresponding pairs of slots of an inversely positioned panel to allow the panels to be interleaved. On the other hand, pairs of slot B are provided alternately on the first long side 16 and on the second long side 17 along the length of the panel. Alternating placement of B-type slots on both long sides facilitates inter-engagement of two adjacent segments 20, as will be described further below. Alternating the location of slot pairs B on one long side and then the other coordinates interlocking slots on one segment to align with interlocking slots on an adjacent segment.

[0039] Figure 1 illustrates panel 12 in a flat pack arrangement before assembly while Figure 2 illustrates panel 14 in a curved wave-like position ready to be assembled with a corresponding panel. In Figure 1 it is noted that the pair of slots A on first panel 12 are facing upwardly whereas in Figure 2 the pair of slots A on the second panel 14 are facing downwardly. The upward-facing A slots of panel 12 are brought to meet and engage with the downward-facing A slots of panel 14 to form the interleaved two-panel configuration shown in Figure 3: a segment 20.

[0040] Segment 20 is intended to stand upright and provide strong structural support to a load on top of the segment. When seen in plan view, a series of polygonal structures, or polygonal cells, are formed as part of the segment by virtue of the interleaving panels 12, 14. Similar to a honeycomb pattern, the polygonal cells provide a strength to the segment, and to the overall support frame 10. The sides of the polygon cells are defined by panel faces 26, which are defined as the panel area between any two slots A and/or B. A panel face 26 forms between two slots regardless of whether the slot is also associated with a fold line. For example, with reference to Figure 3, a panel face 26 exists between two B-type slots, where both B-type slots also occur at fold lines. However, a panel face 26 also exists between an A-type slot and a B- type slot where a fold line occurs at the B-type slot but not at the A-type slot. [0041] Polygonal cells in the form of hexagon cells 28 are illustrated in the drawings. A hexagon cell pattern is formed because there are three panel faces between each pair of A slots where panels 12 and 14 will intersect. Three panel faces 26 on each panel 12, 14 will create a sixsided cell structure 28. Dependent on the number of panel faces between each pair of panel intersecting slots, a greater number of polygonal sided structures can be formed. For example, the polygonal cell structures could instead be an octagon, a decagon, a dodecagon, or higher. However, given the symmetrical nature of the intersecting panels it is foreseeable the polygonal structures will always have an even number of sides. The more sides present in the polygon structure, the less extreme folding of the panels is required as a gentler curve will be created instead. A hexagonal structure 28 is already less vulnerable to tearing and is stronger than a four-sided rhomboid structure.

[0042] All slots of both types A and B are evenly distributed, equidistantly, along the panel length on either the first long side 16 or the second long side 17. As shown in Figure 1 , the slots follow a repeating pattern of four equidistant slots on the first long side 16 followed by two equidistant slots on the second long side 17 and then returning to the start of the pattern of four slots on the first long side 16. The four slots on the first long side 16 comprise one pair of slots A and one pair of slot B, where the pair of slots B are located in between the pair of slot A. Put another way, the spacing between slots B on the first side 16 is equal to one panel face, whereas the spacing between slots A on the first side 16 is three panel faces because two B slots are located therebetween.

[0043] The pattern order of the slots can be represented schematically as follows for each panel:

[0044] The order of the slots determines the structure to be created. Each A type slot is constantly spaced three panel faces from the next A type slot on the same long edge of the panel. Each B type slot is spaced only one panel face from its pair but spaced two panel faces from the next pair. Put another way, each pair of B type slots is spaced two panel faces from the next pair but on alternating long edges. The distance between any two slots can be termed a minimum base slot length 30. [0045] With the A slots spaced 3 base slot lengths from each other, two inter-engaging panels 12, 14 can intercept at respective A slots progressively along their length I to form a segment 20 of hexagonal cells 28.

[0046] With the B slots spaced in pairs by 2 base slot lengths from each other, adjacent segments can be interlocked along their lengths L to increase a width W of the support frame structure. Interlocked segments 20 are illustrated in Figures 5 and 6. The pairs of B slots will form on opposite outside panel faces 32 of each hexagonal cell, namely on panel faces that are free from any cross-over intersection between panels. The entire panel face 32 between the B slots in each pair will overlap and interlock with an adjacent panel face 32 in the next segment. Accordingly, two segments can be interlocked along their lengths by sliding the outside panel face 32 of one segment over the outside panel face 32 of another segment. Figure 5 illustrates two segments interlocked at their outside panel faces 32.

[0047] This means that panel segments 20 can be adjoined side by side not by being interlocked at a single slot cross-over point on each segment, but by engaging across two slots on each segment so that the outside panel faces lie flat against each other creating a double wall engagement and effectively doubling the frame’s strength at the segment joins. Furthermore, fixing the segment double wall join at two slots will create a more stable connection between two segments that is less likely to twist and buckle than a cross-over join at a single slot. Certainly, the modular support frame formed in this way will be able to support the weight of a mattress above and occupant(s) of the bed.

[0048] Further panel segments can be joined to the structure in parallel to increase the width W of the support frame as shown in Figure 6 where five segments are illustrated interlocked to form a support frame 10 of width W and length L. Any number of segments can be added to the frame as desired simply by slotting segment 20 next to segment 20.

[0049] It is also foreseeable that the segments 20 or support frame 10 could be increased in length L. An adaptor piece (not shown) could be provided to allow length-wise, or series, connection of two segments 20 by engaging adjacent end hexagonal cells 28. Taking this concept further, a different adaptor piece (also not shown) could be used to lengthen a support frame 10, as shown in Figure 6. For example, two such support frames 10 could be engaged end-to-end via an adaptor piece bridging over the end hexagonal cells 28 of one support frame 10 and the end cells of an adjacent support frame. [0050] Each cell 28 is connected to an adjacent cell 28 in a manner that adds strength to the support frame. Put another way, if the length of a multi-segment support frame (longitudinal of a segment) is attributed an x-direction and the width is attributed a y-direction, then neighbouring cells are connected in the y-direction by their adjacent faces while in the x-direction they connect by their corners, or vertices. Connecting cells by their panel faces, in particular, makes for a strong and stable connection.

[0051] The short sides 18 of each panel 12, 14 are provided with connecting hooks 33 with notches 34 that will close off the end of a segment into a hexagonal cell by catching the hook 33 and notch 34 of the first panel 12 with an inversely oriented hook 33 and notch 34 of the second panel 14. As shown in Figure 1 , hooks 33 are provided at both ends 18 of panel 12 and both hooks are ‘notched’ in, or face, the same direction. In Figure 1 the notches 34 open upwardly so that the hooks also face upwardly and in the direction of the first long side 16. Accordingly, when identical panel 14 is oriented inversely with end hooks and notches facing downwardly, corresponding hooks on panels 12, 14 can catch and connect the ends of the segment 20.

[0052] In the second embodiment of a panel 40 illustrated in Figures 7 to 9 the hooks 33 and notches 34 face the opposite direction relative to the first side 16. In this embodiment the hooks 33, and opening of the notches, face away from and in the opposite direction to first side 16, instead facing in the direction of second side 17. Both hooks 33 at the end of each panel 40 face the same direction, namely toward second side 17.

[0053] Interleaving panels to form a segment occurs by interleaving together the first sides 16 of inversely facing panels. This is true of both the first and second embodiments. Providing catching hooks facing away from the first side 16 can create a more secure connection of the panels. In other words, where the A-type slots 22 of a panel hook over the interleaved panel, the catching hooks will hook under the interleaved panel. This alternating over and under engagement for each panel will reduce the likelihood of the interleaved panels inadvertently separating. Each panel 40 is therefore secured in opposite directions, namely the direction in which the panel is inserted for assembly to form a segment 42 and the opposite direction for removal. To disassemble segment 42 the interleaved panels 40 panels are first disengaged at their hook ends and then pulled apart in opposite directions.

[0054] Figure 9 illustrates the end faces 44 of a support frame 45 folded inwardly to provide a neat finish at the end of the structure. While the folded end panels 44 are illustrated in relation to the second embodiment, the feature of folding end panels is equally applicable to the first embodiment. [0055] The fold lines 25 of the panels can be created to have more or less intense creasing, which will affect the pliability of a fold. A more intense or heavier crease will allow a panel to fold more easily and to hold its fold. This may, for example, be appropriate when folding in end faces 44 to neatly finish off the structure. A fold that holds well is also useful when expanding the structure to its full length or pack down flat, which configuration it is more likely to keep with an intense crease.

[0056] A less intense fold will provide more elasticity which can improve the connection between interleaved panels. A more elastic crease could also assist in filling spaces such as packing boxes, which can be useful when using one size box to package different-sized frame supports. Of course, the intensity of a fold would not only depend on the type of crease formed but also the weight and nature of the material in which it is formed, e.g. the weight of cardboard.

[0057] In the application where the support frame 10, 45 forms a bed base, the panels 12, 40 are dimensioned to form segments 20, 42 that will roughly span the width of a single bed. Adding segments together side-by-side to increase the frame 10, 45 in the W direction as illustrated in Figure 6, will define the length of the bed. Placing two support frames 10, 45 side- by-side will increase the width of the bed from a single bed width to a queen or king size bed width. Using multiples of segments 20, 42 and support frames 10, 45 allows users to assemble a variety of bed sizes. Additionally, the nature of the cross-over engagement between the panels 12, 40 forming segments 20, 42, and the overlapping engagement of the segments 20, 42 forming the support frame 10, 45 provides the support frame with inherent flexibility in expansion and contraction in length L and width W directions. Accordingly, a user may make finer adjustments to the size of their bed base to suit a specific mattress simply by expanding or contracting the assembled frame to desired rectangular dimensions.

[0058] In one embodiment described herein specifically in relation to forming bed bases, the panels are dimensioned to an optimum geometry such that when assembled the frame can be expanded or contracted, or used modularly, to form most standard bed base sizes. For example, a panel size having a length of 1570mm - 1580mm and a height of 250mm - 300mm will suit assembly of most standard bed base sizes.

[0059] To assist an end user in assembling the support frame 10, 45 the panels 10, 40 can be pre-assembled into a support frame 10, 45 and packed flat. When a user opens the packed frame there is no need for them to assemble the panels into segments or adjoin the segments together. They simply pull the assembly open to expand to a desired configuration. If the support frame is no longer required, a user can compress the assembly into a flat configuration for storage.

[0060] In a variation to the embodiment illustrated in the drawings each segment may in fact be formed from one blank that is folded or doubled up on itself to form two panels connected end to end, rather than being formed from two separate panels. In this instance the slot configuration would need to shift to the opposite edges after a centre fold line in order that the two ends of the single panel blank can still interleave with each other. Accordingly, the term “panels’ as used in the description and claims encompasses one panel blank folded over to form two pre-connected panels, as well as two separate panels.

[0061] Additional parts are envisaged as extra modular components that could be added. For example, under bed storage could be accommodated by removing a segment in a larger frame structure and replacing it with a bridging component having a cavity for storage. Alternatively, a segment could simply be removed and in its space a drawer could be inserted for storage. The bridging component and/or drawer would be dimensioned similar to a segment to neatly replace the segment.

[0062] In yet another variation the height of the modular support frame 10 may be increased by stacking support segments formed by panels one on top of the other. Accordingly, not only can the support frame increase in size to become wider by interconnecting segment alongside segment, but it can also increase in height by interconnecting segment on top of segment. Such an embodiment is not illustrated in the drawings but may involve introducing a third type of slot that would allow vertical interconnection from a panel above with a panel below. Alternatively, vertical interconnection may be achieved simply by placing one modular support frame 10 on top of the other, and using retainers to secure the vertically stacked frames against relative sliding movement.

[0063] The presently described modular support frame is easy to assemble in that the level of assembly complexity is low due to there only being one basic unit having only one shape and size - panel 12,14 - from which an entire structure can be built. Also, the size of the structure is easily adjustable simply by adding or removing units without compromising the integrity and strength of the overall structure. The double wall flat face connection between segments 20 provides reinforced strength at regular points throughout the structure.

[0064] The modular support frame would find utility in an endless range of applications where raised surfaces may be desired. Some non-limiting examples include, stage platforms, fashion runways, raised walkways, bed bases, seating, tables and benches, furniture in general. [0065] It is envisaged that the panels can be decorated or surface finished as desired depending on the application. For example, the panels may be covered in a decorative fabric without compromising the bendability/foldability of the panel or access to the slots. Such a decorative panel may be suitable as a seating surface or a bed base. Alternatively, the panels could be laminated in a plastics to create a smooth or waterproof surface for outdoor use. The options on adjusting the appearance of the panels to suit different applications are endless.

[0066] It is a requirement that the panels be made from a foldable or bendable material that is flexible and will bend along a plane of the panel. Or the material can be more rigid but will be able to bend or fold at crease lines or hinges. It is also preferable that the material shows good compressive strength along its width in the direction of the height of the frame. The material used to form the panels may well vary in strength from corrugated cardboard to hinged metal plates. It is however envisaged that using a cardboard-based material will provide consumers with an affordable alternative as well as appeal to consumer’s environmental ethics of using recycled or recyclable material.

[0067] It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

[0068] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, namely, to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[0069] It is to be understood that the aforegoing description refers merely to preferred embodiments of invention, and that variations and modifications will be possible thereto without departing from the spirit and scope of the invention, the ambit of which is to be determined from the following claims.