WO2017127381A1

WO2017127381A1 - Platform hotel bed frame

Info

Publication number: WO2017127381A1
Application number: PCT/US2017/013851
Authority: WO
Inventors: Richard S. Polevoy; Paul E. Carlson; Robert L. Naas; Michael W. KONIECZNY; Kurt R. WERNER; Howard Scott Ryan
Original assignee: Finger Lakes Intellectual Property, Llc
Priority date: 2016-01-19
Filing date: 2017-01-18
Publication date: 2017-07-27
Also published as: US20170202365A1; CA3011806A1

Abstract

A platform bed frame particularly adapted for hotel use is provided including a pair of slat supporting rails that have a plurality of cavities along the length of the slat supporting rails. A plurality of slats form a mattress supporting surface and span between the slat supporting rails and have end lower conforming surfaces that fit into the cavities to secure the slats to the slat supporting rails. There are side rails and end rails that snap onto the slat supporting rails so that the assembly of the platform bed frame can be accomplished without the use of tools. There are two component legs that also allow an adjustment of the height of the platform supporting platform between a high and a low position. In the low position a foundation may be included underlying the mattress and a lesser number of slats can be used.

Description

PLATFORM HOTEL BED FRAME

FIELD OF THE INVENTION

[0001] The present invention relates to a bed frame for supporting a mattress and, more particularly, to a platform bed frame specially designed for commercial sleeping facilities, such as hotels.

BACKGROUND OF THE INVENTION

[0002] A traditional sleep surface consists of a mattress and box spring or foundation supported on a bed frame. Bed frames are usually constructed of wood or metal. Of the metal type of bed frame there are decorative and functional types. The highly ornamented types would include brass beds with head boards and foot boards. The functional types include the instamatic type, the Hollywood type and the metal bed bases.

[0003] As box springs and foundations have become increasingly unnecessary and unpopular with the insurgence of no-flip one sided mattresses, the popularity of platform beds has arisen. Platform beds or beds for mattresses alone are typically taller than other bed frames in order to bring the sleep surface up to a standard height without a foundation. Also they would typically have a platform or deck that acts as the mattress support surface replacing the foundation.

Platform beds can be either wood or metal and either decorative or purely functional.

[0004] The hotel industry uses primarily bed bases because they are inexpensive. They are considered durable and they block the space under the bed. Because they block the space under the bed, that space doesn't need to be cleaned and guests do not have the opportunity to leave items in this location. The typical bed base consists of four rolled steel panels that are linked together at the corners and form the structure of the base. These are bisected on top by tubular steel cross rails. The ends are upturned and capped to form retaining clips that hold the bedding. It is recognized that these clips can be a hazard to people walking around the bed as they often protrude beyond the mattress and are often concealed by bedding fabrics. [0005] The current hotel bed bases are held together with bolts and nuts, thus requiring tools for the assembly. It is also recognized that the metal panels have sharp edges and can injure the assembler. In addition, the fasteners are difficult to handle and often loosen over time making the frame noisy and unstable.

[0006] Accordingly, it would be advantageous to have a platform bed frame usable for commercial installation, such as hotels, that overcomes the disadvantages and drawbacks heretofore outlined.

SUMMARY OF THE INVENTION

[0007] The invention described herein is a platform type bed that uses new technology to combine the structural elements of a functional platform bed and the visual appeal of the decorative platform bed. Accordingly, the present invention overcomes the deficiencies of the prior art with respect to platform bed frames intended for hotel use and where the bed frame assembly is adapted to support a mattress and, in turn, is supported on a floor.

[0008] Additionally, the present platform bed frame has further advantageous features, such as a tool free, drop-together assembly and two height options, that is, a regular bed height and platform bed height. As such, with the present platform bed configured in its platform height, only a mattress is needed, however, if the bed is in its regular, or lower height, a foundation as well as a mattress can be used.

[0009] The product of the present invention is superior to both regular bed frames and platform type bed frames and incorporates a unique structure and use of materials. Basically, the present inventive platform bed frame has several features that make it superior to current hotel bed bases

[00010] The present platform bed frame invention includes panels to block access under the bed and it can be configured to a height in which a box spring is not required.

[00011] It has a supporting deck surface that supports a mattress without the need for a box spring. This deck surface is re-enforced to allow the use of support foam mattresses, no-flip mattresses, pocketed coil mattresses and hybrid mattresses. [00012] The supporting deck surface has a consistent lip all the way around the edge to retain the mattress in a stable location. The constant lip assures that there are no sharp protruding clips to injure users. The legs are composite resin and the steel structure is entirely encased, thereby eliminating any sharp edges and makes handling for assembly safe.

[00013] The frame is dropped together and the sides and ends snap in place making the assembly simple and tool free. The wedge type of construction will not loosen over time and remain free from movement that can cause noise such as squeaking.

[00014] If constructed in the platform version, without privacy panels, the platform version allows for storage of household items under the bed in the area that is normally occupied by the foundation.

[00015] Because the side rails are not the primary load bearing elements, the support rails support the deck in a unique way that allows the legs to be recessed under the bed. This creates the visual illusion that the bed is floating and also reduces the chances of kicking the bed and incurring potential injury.

[00016] These and other features and advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[00017] Fig. 1 is a perspective view of the platform bed frame of the present invention at the tall height with privacy panels installed thereon/

[00018] Fig. 2 is a side view of the platform bed frame of Fig 1 showing the privacy panels.

[00019] Fig. 3 is an end view of the platform bed frame of Fig 1.

[00020] Fig. 4 is a top view of the platform bed frame showing the surface and the slats that support the mattress. [00021] Fig. 5 is an exploded view illustrating the main components of the platform bed frame of Fig 1.

[00022] Fig. 6 is a cross sectional side view of a leg located at the foot end of the platform bed frame.

[00023] Fig 7 is a perspective view, partly in cross section, showing a leg at the foot end of the platform bed frame with a slat in position to be installed.

[00024] Fig. 8 is a side cross sectional view showing the foot support end of the platform bed frame with a slat in position to be installed.

[00025] Fig. 9 is a cross section view of the leg at the foot end of the platform bed frame showing the separate components making up a leg.

[00026] Fig. 10 is a side view of the leg at the foot end of the platform bed frame showing the separate components making up a leg.

[00027] Fig. 11 is an exploded view of the leg at the foot end of the platform bed frame and shows the joining of a leg to a slat rail.

[00028] Fig. 12 is a cross section of the side rail showing the engagement thereof with the foot support end of the platform bed frame.

[00029] Fig. 13(A,B) is a perspective view of the head support end with the side panels removed.

[00030] Fig. 14 is an exploded view of the slat support rail 76 and illustrating the nesting of the support rail blocks in the construction of the assembled slat rail with the side panels removed.

[00031] Fig. 15 is a top view of a slat.

[00032] Fig. 16 is an exploded view of the entire platform bed frame illustrating the assembly thereof. DETAILED DESCRIPTION OF THE INVENTION

[00033] Turning first to Fig. 1 there is shown, a perspective view of the platform bed frame 20 constructed in accordance with the present invention. As can be seen, the platform bed frame 20 is assembled and ready for a mattress and is comprised of end rails 22 and side rails 26. The platform bed frame 20 will be referred to as having a head end 24 and a foot end 28 simply for reference in describing the various components.

[00034] The end rails 22 and side rails 26 are constructed of steel and will be explained later. As also can be seen, the end rails 22 and side rails 26 are supported by legs 30 and, in the exemplary embodiment, the legs 30 are constructed in two sections, that is, there is an upper leg 32 and a lower leg 34 and, as will be seen, the upper and lower legs 32, 34 are removably affixed to each other such that the lower leg 34 can be separated from the upper leg 32 by the user if desired. The platform bed frame 20 employs six legs 30, with three legs 30 provided along each lateral side of the platform bed frame 20, however, only 4 are shown in Fig 1.

[00035] As also can be seen in Fig 1, there are end panels 36, preferably comprised of extruded plastic, located at both the head end 24 and foot end 28 the platform bed frame 20 and plastic side panels 38, it being seen that similar panels are positioned as a mirror image of the end and side panels 36, 38 illustrated in Fig 1. As will become clear, the end and side panels 36, 38 are optional and can be removed by the user if desired, however, when present, the panels prevent objects from going underneath the platform bed frame 20 and avoid the need for personnel to remove those objects.

[00036] The end and side panels 36, 38 can readily be installed and removed by fastening or attaching means provided on the legs 30. In the exemplary embodiment, the end and side panels 36, 38 may be provided as single panels, however, it can be seen that each of the end and side panels 36, 38 may be comprised of two panels or three panels or more, i.e. an upper and lower panel, or two or more side by side panels making up each of the end and side panels 36, 38. he side panels 36, 38 may be flush with the legs 30 to prevent dust from accumulating underneath the platform bed frame 20 and prevent patrons from leaving articles such as shoes behind. Further, in Fig 1, there are a plurality of slats 42 that form the supporting surface for the mattress. In the exemplary embodiment, there are eight slats 42, however, there can be a greater or lesser number of slats 42 used in constructing the platform bed frame 20 of the present invention. To complete the supporting surface for the mattress, the slats 42 include caps that are located at the upper surface of each slat 42 and, as shown, there are two end caps 44 and one middle cap 46 on each slat 42. The end caps 44 and middle cap 46 can preferably be injection molded plastic resin and the intermediate caps 48 also plastic resin but created in the extrusion manufacturing process.

[00037] Accordingly, the upper supporting surface of the platform bed frame 20 supports a mattress and each of the end rails 22 and side rails 26 have an upper edge 50, 52, respectively, that is elevated above that supporting surface so as to retain the mattress properly positioned on the supporting surface so that it cannot slide from the proper position on the platform bed frame 20. The upper edges 50, 52 combine to form a continuous edge that stabilizes a mattress sitting atop of the platform bed frame 20.

[00038] Turning then to Fig 2, there is a side view of the platform bed frame 20 of the present invention. As can be seen in Fig 2, the side rail 26 is supported by the legs 30 and the underside area of the platform bed frame 20 is contained by the side panels 38 intermediate those legs 30. As also shown, there is a corner member 54 that provides a smooth transition between the end rails 22 and the side rails 26 that will be later explained. There is a corner member 54 located at each of the four corners of the platform bed frame 20. The legs 30 may not be centered with respect to the platform bed frame 20. Rather the front legs 30 may be provided near to the front end so that the platform bed frame rests when positioned near to a wall to minimize or prevent vacant space. The legs 30 may be positioned so as to be inset at the foot of the bed frame 20 to provide more vacant space. In Fig 3, there is an end view of the platform bed frame 20 of the present invention. Again, there can be seen in Fig 3, the end rail 26 is support by the legs 30 and the underside area of the platform bed frame 20 is closed in by the end panel 38 intermediate those legs 30. As also shown, the corner member 54 is located between the end rail 22 and the side rail 26. The side panels 36 attach underneath the leg 30 with a fastening means 33.

[00039] Turning to Fig 4, there is a top view of the present platform bed frame 20 and showing the individual slats 42 extending or spanning between the side rails 26. A corner member 54 is provided in each of the four corners. The slats 42 may be positioned

approximately one inch apart from each other. [00040] Turning next to Fig 5, there is an exploded view of the platform bed frame 20 of the present invention. There can also be seen a head support end 56 and a foot support end 58 that are affixed at the opposed ends of a slat supporting rail 59. There is also shown a plurality of support rail blocks 60 that are included in the slat supporting rail 59, each forming a cavity 62 therein for receipt of the slats 42 in a manner to be described. The side panels 36, 38 may be provided in three pieces, and the side panels 36, 38 attach to the legs with a fastening means 33.

The side panels 36, 38 may be provided in a three piece construction. The fastening means 33 may be a hook that attaches to the leg 30. Fastening means may be provided on each piece of the side panels 36, 38 for engaging the multiple pieces of the side panels 36, 38. Each slat has 42 has downward attachment or piece 43 that fits into the cavity 62 of the supporting rail 59 to form a connection with the slat 42 and supporting rail 59. A corner member 54 connects each end rail

22 and side rail 26 to surround the assembly.

[00041] Also, there may be a down wedge present to interfit into a third support rail in the case of a king sized bed frame where additional support is needed.

[00042] Taking next, Fig 6, there is a cross sectional side view of a leg 30 located at the foot end 28 of the platform bed frame 20. In this Fig, it can be seen that the foot 30 supports the slat supporting rail 59 as well as the slats 42 seated into the cavities 62 of the support rail blocks 60 of the slot supporting rail 59.

[00043] As can be seen, and will be later detailed, the slats 42 have a lower surface 64 that is shaped to seat in the complementary shaped block cavities 62 to secure the slats 42 in a stable position on the slot supporting rail 59 of the platform bed frame 10. In addition, the foot support end 58 is affixed to the slot supporting rail 59 and supports the end rail 22. The leg 30 is a two piece construction with an upper leg 32 and a lower leg 32 that may snap together or fasten together via a fastening means to engage and form the leg 30. It is thereby possible to remove one piece, i.e. either the upper leg 32 or the lower leg 34 so that the leg 30 may be adjusted to different heights, for instance, about 10" or about 16" in total height. Thereby, space may be provided under the bed frame 20 for storage.

[00044] Fig 7 is a perspective view, partly in cross section, showing a leg 30 at the foot end 28 of the platform bed frame 20 with a slat 42 in position to be assembled thereto. As noted, the slat 42 is in position to be lowered onto the cavity 62 of the foot support end 58. A slat end base 66 is affixed to the slat 42 such that the end of the slat 42 is comprised of the end cap 44 and the end base 66 and the end base 66 includes a wedge 68 depending downwardly that interfits into the cavity 62 formed in the foot support end 58 to install the slat 42 into the platform bed frame 20. The leg 30 is a two piece construction with an upper leg 32 and a lower leg 34 that may snap together or fasten together via a fastening means to engage and form the leg 30. It is thereby possible to remove one piece, i.e. either the upper leg 32 or the lower leg 34 so that the leg 30 may be adjusted to different heights, for instance, about 10" or about 16" in total height. Thereby, space may be provided under the bed frame 20 for storage.

[00045] A pair of angle irons 70 are used to strengthen the slats 42 and the slat end bases 66 are clam shelled to the angle irons 70 and are affixed to the angle irons 70 by means of rivets passing through slotted holes in the angle irons 70. The affixation is carried out by the manufacturer. The middle cap 46 is snapped into place and oriented by means of molded in pins (not shown) that correspond with stamped holes in the angle iron 70.

[00046] Fig 8 is a side cross sectional view showing the foot support end 58 of the platform bed frame 20 with a slat 42 in position to be installed therein. In Fig 8, there can be seen the foot support end 58 having a cavity 62 formed therein with the end rail 22 affixed to the distal end of the foot support end 58. The end of the slat 42 can also be seen and wherein the end cap 44 and the end base 66 of the slat 42 are extrusions that surround the pair of steel angle irons 70 to provide strength to the slats 42. As such, the wedge 68 extends downwardly from the end base 66 and the lower surface 64 of the end base 66 of the slat 42 is shaped to conform to internal shape of the cavity 62. The leg 30 is a two piece construction with an upper leg 32 and a lower leg 34 that may snap together or fasten together via a fastening means to engage and form the leg 30. It is thereby possible to remove one piece, i.e. either the upper leg 32 or the lower leg 34 so that the leg 30 may be adjusted to different heights, for instance, about 10" or about 16" in total height. Thereby, space may be provided under the bed frame 20 for storage.

[00047] Turning then to Fig 9, there is a cross sectional view of the leg 30 at the foot end

28 of the platform bed frame 20 showing the separate components making up a leg 30.

Accordingly, as can be seen, the leg 30 is comprised of the upper leg 32 and lower leg 34 that is removable affixed to the upper leg 32. Thus, the lower leg 34 has a projection 72 extending upwardly therefrom and which interfits into a recess 74 formed in the upper leg 32. The upper and lower legs 32, 34 may be thereby affixed together by a force fit and yet separated by the user as desired in case the user wants to lower the platform bed frame 20 by removing the lower legs 34 and letting the platform bed frame 20 be supported on the floor solely by the upper legs 32. In this way, the bed height is at the standard sleep surface with only a mattress. If the lower legs 34 are removed, the sleep surface is lower. In such case, smaller side and end panels can be installed between the legs 30. The side and end panels may be fastened to the leg 30 by a fastening means 33 such as a hook or clamp.

[00048] Accordingly, the platform bed can be oriented in a high or platform elevation or a low, regular elevation depending on whether both an upper and lower leg are used or just an upper leg is used and which then sits on the floor to put the platform bed frame 20 into its regular or lower elevation. In such case, the number of slats 42 can be reduced, that is, as an example, if the lower bed elevation is chosen, the number of slats 42 may be reduced from 9 to 3 slats.

[00049] In Fig 10, is a side view of the leg 30 at the foot end of the platform bed frame 20 showing the separate components making up a leg 30. Again, there can be seen the joining of an upper leg 32 and a lower leg 34 featuring a projection 72 extending upwardly and which interfits into a recess 74 formed in the upper leg 32. The side and end panels may be fastened to the leg 30 by a fastening means 33 such as a hook or clamp.

[00050] Turning to Fig. 11, there is an exploded view of the leg 30 at the foot end 28 of the platform bed frame 20 and showing the joining of a leg 30 to the slat supporting rail 59. As such, the upper leg 32 has a recess 78 forming opposed upper flanges 80 and the slat supporting rail 59 interfits into that recess 78. As shown, the slat supporting rail 59 includes a pair of angle irons 82 and the upper leg 32 can be firmly affixed to the slat supporting rail 59 by means such as providing holes 84 in the angle irons 82 through which fasteners (not shown) can pass and secured in the holes 86 in the upper surface of the upper flanges 80 of the upper leg 32. That securement can be carried out by the manufacturer. There may be provided an outcropping or protrusion 35 on the leg 30, either the upper leg 32 or lower leg 34, as a receiver for receiving a tab on the side panels so that the side panels may snap into place and engage the leg 30.

[00051] Turning then to Fig 12, there a is a cross sectional view of a foot support end 58 and showing the engagement thereof with an end rail 22 of the platform bed frame 20. The end rail 22 is comprised of an angle iron 88 that is encased within a extruded plastic housing 90 and both end rails 22 and side rails 26 are similarly constructed. Thus, the plastic housing 90 may be extruded to the desired length and the angle iron 88 slipped into that housing 90 in assembling an end rail 22. [00052] In attaching the end rail 22 to the foot support end 58, a lower tab 92 formed in the extruded plastic housing 90 can be affixed behind a notch 94 in the foot support end 58 to secure the lower portion of the end rail 22 to the foot support end 58 and then the upper portion of the end rail 22 can be pivoted upwardly so that a small tooth 96 engages the horizontal upper surface 98 of the foot support end 58 such that the end rail 22 can be simply manually snapped onto the foot support end 58 to affix the end rail 22 to the slat supporting rail 59 without the need for tools. Turning then to Fig 13 A, there is a cross sectional view of a head support end 56 of the platform bed frame 20. As can be seen, the head support end 56 is affixed to the slat support rail 59 with the legs 30 supporting that slat support rail 59 so that the head support end 56 is ready to have an end rail snapped onto or attached to the head support end 56. Fig 13 A also shows the cavities 62 that are formed in the support rail blocks 60 to receive the ends of slats 42 (Fig 1) The side panels 36 are attached to the legs 30 using a fastening means 33 such as a hook or fastener.

[00053] Turning now to Fig 13B, there is a cross sectional view of a head support end 56 of the platform bed frame 20. As can be seen, the head support end 56 is affixed to the slat support rail 59 with the legs 30 supporting that slat support rail 59 so that the head support end 56 is ready to have an end rail 22 snapped onto the head support end 56. Fig 13B also shows the cavities 62 that are formed in the support rail blocks 60 to receive the ends of slats 42 (Fig 1) The side panels 36are attached to the legs 30 using a fastening means 33 such as a hook or fastener.

[00054] Turning now to Fig 14, there is an exploded view of the slat support rail 59 and illustrating the nesting of the support rail blocks 60 in the construction of the assembled slat supporting rail 59 with the side panels removed. As can be seen, the support rail blocks 60 all interfit with each other by means of having an open end 102 and a closed end 104 so that the closed end 104 of one support rail block 60 interfits into the open end 102 of an adjacent support rail block 60. The foot support end 58 interfits into the open end 102 of the last support rail block 60. The support rail blocks 60 are also all secured together further by means of the angle irons 82 that sandwich the support blocks 60 therebetween. There may be provided an outcropping or portrusion 35 on the leg 30, either the upper leg 32 or lower leg 34, as a receiver for receiving a tab on the side panels so that the side panels may snap into place and engage the leg 30. The side and end panels may also be fastened to the leg 30 by a fastening means 33 such as a hook or clamp. The leg 30 is a two piece construction with an upper leg 32 and a lower leg 34 that may snap together or fasten together via a fastening means to engage and form the leg 30. It is thereby possible to remove one piece, i.e. either the upper leg 32 or the lower leg 34 so that the leg 30 may be adjusted to different heights, for instance, about 10" or about 16" in total height. Thereby, space may be provided under the bed frame 20 for storage.

[00055] In Fig 15, there is a top view of a slat 42 of the platform bed frame 20 of the present invention. In this instance, the slat 42 is divided into 3 parts. Two pieces of angle iron 70 run along length of slat 42 and may be encased in a molding.

[00056] Finally, in Fig 16, there is an exploded view of the entire platform bed frame illustrating the assembly thereof.

[00057] While the present invention has been set forth in terms of a specific embodiment or embodiments, it will be understood that the present platform bed frame herein disclosed may be modified or altered by those skilled in the art to other configurations. Accordingly, the invention is to be broadly construed and limited only by the scope and spirit of the claims appended hereto.

Claims

What is claimed is:

1. A platform bed frame assembly for supporting a mattress, the bed frame assembly adapted to be positioned on a floor, the bed frame assembly comprising at least two legs, at least two slat supporting rails having a plurality of cavities along the length of the slat supporting rails, a plurality of slats that span between the slat supporting rails, the slats having end lower surfaces adapted to conform to the plurality of cavities.

2. A platform bed frame for supporting a mattress according to claim 1 further comprising side rails and end rails adapted to be affixed to the slat supporting rails wherein the legs support the slat supporting rails.

3. The platform bed frame of claim 1 wherein the legs are adaptable to differing heights.

4. The platform bed frame of claim 3 wherein the legs are adaptable to two different heights.

5. The platform bed frame of claim 1 wherein the legs comprise at least upper and lower legs that are removably affixed together.

6. The platform bed frame of claim 1 wherein the assembly further comprises panels extending between the legs.

7. The platform bed frame of claim 2 wherein the side rails and end rails combine to form a continuous upper edge that retains a mattress in a fixed position atop the platform bed frame.

8. The platform bed frame of claim 1 wherein each slat supporting rail is comprised of a pair of angle irons with a plurality of support rail blocks sandwiched therebetween.

9. The platform bed frame of claim 1 wherein a -plurality of cavities are formed in or by the support rail blocks in the slat supporting rails.

10. The platform bed frame of claim 2 wherein the side rails and end rails are each comprised of an angle iron surrounded by an extruded plastic housing.

11. The platform bed frame of claim 10 wherein the side rails and end rails are affixed to the slat supporting rails.

12. The platform bed frame of claim 11 wherein the side rails and end rails are either snapped or screwed to the slat supporting rails.

13. The platform bed frame of claim 11 wherein the corners between the side rails and end rails are fitted so that the side rails form an unbroken perimeter.

14. The platform bed frame of claim 1 wherein a perimeter forms an upstanding lip to contain the mattress.

15. The platform bed frame of claim 1 wherein the slats form a deck for supporting the mattress.

16. The platform bed frame of claim 6 wherein the panels are connected to the legs via a fastening means.

17. The platform bed frame of claim 6 wherein the panels contain a tab adapted to engage a receiver on the legs.

18. The platform bed frame of claim 6 wherein the panels are removable.

19. The platform bed frame of claim 6 wherein end panels provide lateral stability.

20. A method for assembling a platform bed frame comprising the steps of:

a) providing a pair of slat supporting rails having a plurality of cavities along the length of the slat supporting rails, a plurality of legs supporting the slat supporting rails above a floor and side rails and end rails, and

b) inserting a plurality of slats having formations at opposite ends thereof into the slat supporting rails by inserting the formations into the cavities of the leg supporting slats.

21. The method for assembling a platform bed frame according to claim 20 further comprising c) attaching the side rails and end rails onto the slat supporting rails.

22. The method of claim 21 wherein the step of attaching the side rails onto the slat supporting rail comprises affixing the side rail and end rails onto the slat supporting rails.

23. The method of claim 22 wherein the affixing is performed by either snapping or screwing.

24. The method of claim 20 wherein the step of providing a pair of slat supporting rails having a plurality of cavities along the length of the slat supporting rails comprises providing a pair of slat supporting rails having a plurality of support rail blocks, each support rail block having a cavity formed therein.