Abstract:
In an implementation a compressible mattress is provided that may be compressed at a manufacturing location and inserted into packaging; the packaging, maintaining the compressed state of the compressed mattress. The compressed mattress may be shipped in the compressed state within the packaging to a distributor or retail store for display and sale. After sale and transport to a customer location in the compressed state, the packaging may be removed and the mattress decompresses and expands until it reaches an expanded form.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to mattresses, and in particular crib mattresses. 
       BACKGROUND 
       [0002]    Mattresses are bulky objects, which are costly to ship, store, or display for sale. Their size typically makes it uneconomical to manufacture mattresses far from the customer location, as shipping costs can make the sale cost prohibitive. Similarly, the cost to store and display mattresses at the retail location typically restricts their distribution to specialised retailers. Crib mattresses in particular are smaller value items, but have similarly large built-in costs for shipping, storing or displaying the mattresses for sale, that may be disproportionate to the value of the actual item. 
         [0003]    There is a need for a mattress and a method of making a mattress that is less costly to ship, store and display. In particular, there is a need for a mattress that may be manufactured in a compressed, highly compact form, transported in the compact form, displayed and retailed in the compact form, and then expandable at the customer location into an expanded form that has standard mattress dimensions and performance. In an aspect, there is a need for a crib mattress that may be transported and displayed in a smaller, compact form factor to reduce the costs of shipment and retail, and ease the purchase and conveyance of the crib mattress. 
       SUMMARY 
       [0004]    In an implementation a compressible mattress is provided that may be compressed at a manufacturing location and inserted into packaging. The packaging maintaining the compressed state of the compressed mattress. In some aspects, the compressed mattress may be further compacted and stored within a container that secures the mattress in its compacted state. The compressed mattress may be shipped in the compressed state within the packaging to a distributor or retail store for display and sale. After sale and transport to a customer location in the compressed state, the packaging may be removed and the mattress decompresses and expands until it reaches an expanded form. 
         [0005]    A variety of mattress shapes and form factors may be provided. The mattress may include a waterproof protective layer to protect the mattress from liquids. The mattress may include a second outer protective layer over the waterproof protective layer. The mattress may include a coloured protective covering. Where the second outer protective layer is provided, it may comprise the coloured protective covering layer. 
         [0006]    In an implementation, a method is provided for manufacturing a compressible mattress. The method may comprise: boring a plurality of holes through a thickness of a foam core (in an aspect, the holes being axially aligned with a compressing direction of the foam core) to produce a compressible mattress; inserting the mattress into an open end of a flexible-walled air tight packaging; compressing the mattress and packaging in the compressing direction; and, sealing the open end of the flexible air tight packaging to produce a compressed mattress. In an aspect, the mattress further comprises a protection layer over the bored foam core, wherein the method further comprises, before the foam mattress is inserted into the open end of the packaging, wrapping the bored foam core with a protection layer (the protection layer may comprise a waterproof breathable fabric) to produce the compressible mattress. 
         [0007]    In an aspect, the implementation may further comprise compacting the compressed mattress by rolling or folding the compressed mattress to fit within a container, such as a box or plastic wrap, which secures the compacted mattress in its compact form. In an aspect, the container may comprise a decorative layer for presentation, for instance on a retail shelf In an aspect the packaging may comprise the decorative layer for presentation, and the container securing the compacted mattress may comprise a clear-walled container, ribbon, adhesive, string, or similar means that may secure the compacted mattress in its compact form and still display the decorative packaging. 
         [0008]    In an aspect, the compressing may comprise placing the flexible air tight packaging containing the mattress between platens of a press, and pressing the platens of the press towards one another to compress the flexible air tight packaging and the mattress. In the aspect, the action of the platens compresses and evacuates the flexible air tight packaging. 
         [0009]    In an aspect, after wrapping the bored foam core with the protective layer, the method further comprises wrapping an outer protective layer over the protective layer, before inserting the mattress into the open end of the flexible air tight packaging. 
     
    
     
       FIGURES 
         [0010]      FIG. 1  illustrates a foam core. 
           [0011]      FIG. 2  illustrates a perforation operation on the foam core. 
           [0012]      FIG. 3  illustrates a perforated foam core after the operation of  FIG. 2 . 
           [0013]      FIG. 4  illustrates a cut away view of an embodiment of the compressible mattress. 
           [0014]      FIG. 5  illustrates the compressible mattress after insertion in a packaging. 
           [0015]      FIG. 6  illustrates a compressing operation on the mattress and packaging. 
           [0016]      FIG. 7  illustrates the compressed mattress and packaging in a compressed state. 
           [0017]      FIG. 8  illustrates a rolling operation being performed on the compressed mattress and packaging of  FIG. 7 . 
           [0018]      FIG. 9  illustrates a rolled compressed mattress within a container after the operation of  FIG. 8 . 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    Referring to  FIG. 1 , a foam core  10  for a compressible mattress is illustrated. The foam core  10  may be cut from larger bulk foam stock into the final form factor of the mattress. The foam is a standard foam used for foam mattresses in the industry. A density of the foam may be selected to provide for selected mattress firmness, as is known. Due to the operations below, however, the density selected for the compressible mattress may provide for a slightly different firmness from a regular foam mattress. Accordingly, the density may be selected to provide for a desired firmness after the holing operation described below. For instance, the density of the foam core  10  may be slightly higher than that required for a standard foam mattress, to achieve a desired mattress firmness after the holing operation. 
         [0020]    In the embodiment illustrated in  FIG. 1 , the foam core  10  has been cut into a standard mattress shape. The size and dimensions of the foam core  10  is selected based upon the intended end use, and typically conforms to several standard form factors used throughout the industry. The foam core  10  may be cut into non-standard shapes and sizes, including cylinders, wedges, and other shapes, depending upon the intended end use. 
         [0021]    In the case of a standard crib mattress, the size of the foam core  10  would be about 27 ⅝″-28 ⅝″ wide, and 51 ¾″-53″ long, as is currently the standard in the industry. The thickness of foam core  10  may vary, but will typically be provided within a range of 4″-6″ for a crib mattress. 
         [0022]    Referring to  FIG. 2 , a perforating or holing machine  100  is illustrated with the foam core  10 . The perforating machine  100  includes a number of pins or spikes  105  that may be lowered and pressed through the body of the foam core  10  to bore a plurality of holes through the foam core  10 . The hole pattern created by the pins  105  may be regularly spaced to produce an even distribution of holes across the face of the foam core  10 . In an aspect, for a standard-sized crib mattress, approximately 80-160 holes may be bored through the face of the foam core  10 . In an aspect, the holes are bored clear through the mattress thickness. 
         [0023]    In an implementation, a diameter of the holes may be within a diameter range of 8 mm-20 mm. In an aspect, the diameter may be within a diameter range of 10 mm-15 mm. In an aspect, the diameter may be within a diameter range of 12-13 mm. 
         [0024]    In the embodiment of  FIG. 2 , the plurality of holes are bored through a face of the foam core  10 . The axis of the each of the plurality of holes aligned with an intended compressing direction of a compressive force to be applied to the compressible mattress. 
         [0025]    In an embodiment, the plurality of holes may be aligned at right angles to an intended compressing direction of the compressive force. For instance, in an aspect the form factor may comprise a cylindrical foam core, not shown in the Figures, with one or more holes bored through the cylindrical foam core approximately parallel to a central axis of the cylinder. In an aspect, the bored cylindrical foam core may be compressed in a compressing direction roughly perpendicular to the axis of the cylinder and the bored hole(s). 
         [0026]    Referring to  FIG. 3 , the foam core  10  is illustrated after the perforation operation of  FIG. 2 . In the embodiment, a plurality of holes  15  evenly spaced across a face of the foam core  10  are illustrated. In an aspect, the perforated foam core  10  comprises a compressible mattress. 
         [0027]    Referring to the embodiment of  FIG. 4 , an embodiment of a compressible mattress  30  is illustrated. In the embodiment of the mattress  30 , the perforated foam core  10  is illustrated assembled with a protection layer  20  (“inner layer”) that is resistant to penetration by water or other liquids, but is air permeable. In an aspect, the protection layer  20  may comprise a waterproof breathable fabric. While the compressible mattress may comprise only the foam core  10  with the plurality of holes  15 , the embodiment of  FIG. 4  provides a layer of protection to protect the foam core  10  from liquids or moisture. Implementations that may comprise a crib mattress, for instance, protection layer  20  provides a barrier that prevents the foam core  10  from absorbing fluids, including bodily fluids. In an aspect, the protection layer  20  may be permanently secured over the foam core  10 , for instance by stitching, heat sealing, adhesive, zipper, or other known means for affixing and sealing a waterproof breathable fabric. 
         [0028]    As illustrated in the implementation of  FIG. 4 , the mattress  30  may further comprise an air permeable outer protective layer  25  wrapped over the protection layer  20 . 
         [0029]    The outer protective layer  25  may comprise, for instance, a coloured or patterned fabric layer. In some embodiments, the outer protective layer  25  may comprise a water resistant fabric to facilitate cleaning. 
         [0030]    In an aspect, the outer protective layer  25  may be removably secured over the foam core  10  and protective layer  20  to facilitate removal for cleaning, for instance using a zipper, Velcro™, buttons, or other known means. In an aspect the outer protective layer  25  may be permanently secured over the foam core  10  and protective layer, for instance by stitching. In the aspect, the outer protective layer  25  may preferably be provided with a stain resistant washable fabric, such as a water resistant fabric. In an aspect, the outer protective layer  25  may further comprise a decorative layer, such as a coloured or patterned fabric. 
         [0031]      FIG. 4  thus illustrates a cut-away view of a compressible mattress  30 . In this embodiment, outer protective layer  25  would be the exterior surface of the mattress  30 . Inclusion of the outer protective layer  25  is an optional feature of the mattress  30 . In an alternate embodiment, the mattress  30  may comprise the perforated foam core  10  and the protective layer  20 , in which case the protective layer  20  would be the exterior surface of the mattress  30 . In a further embodiment, the mattress  30  may comprise only the perforated foam core  10 . 
         [0032]    Referring to  FIG. 5 , the compressible mattress  30  of  FIG. 4  is illustrated after insertion within a packaging  35  in the form of a flexible air tight vessel such as a plastic bag. In the embodiment of  FIG. 5 , the packaging  35  comprises a clear-walled plastic bag with an opening  40  at an opening end  45  of the packaging  35 . The arrows depicted in  FIG. 5  indicate a direction of compression to be applied to compress the mattress  30 . 
         [0033]    Referring to  FIG. 6 , the mattress  30  within packaging  35  of  FIG. 5  is illustrated in place between the platens  115 ,  120  of a press  110 . In the embodiment, when the action of the press presses the platens  115 ,  120  together, the mattress  30  is compressed and the packaging  35  is evacuated through the opening  40 . After the press  110  has been compressed, the opening end  45  may be sealed, for instance with heat sealing, laser, adhesive, or other known means, to prevent the ingress of air through opening  40  back into the packaging  35 . 
         [0034]    While the embodiment of  FIG. 5  illustrates a single opening  40 , the packaging  35  may have a plurality of openings  40 . For instance, the packaging  35  may comprise a tube with openings  40  at opposed ends. Alternatively, the packaging may comprise a pair of sheets to be placed around the mattress  30  with openings  40  defined by the mating edges of the sheets. It has been found, however, convenient to select a packaging  35  that comprises a bag with a single opening  40  for ease of assembly and sealing. 
         [0035]    Referring to  FIG. 7 , after sealing the opening end  45 , the press may be released and the compressed packaged mattress  32  extracted. The compressed packaged mattress  32  comprising the mattress  30  after compression, and sealed within the sealed air tight packaging  35  which maintains the mattress  30  in its compressed form. Referring to  FIG. 8 , the compressed packaged mattress  32  may be further compacted, for instance by rolling as shown or folding, and placed within a container  50 . The container  50  maintaining the compressed packaged mattress  32  in its compacted form (i.e. rolled form or folded form). 
         [0036]    In the embodiment of  FIG. 9 , the container  50  comprises a bag or sleeve into which the rolled compressed packaged mattress  32  may be inserted to produce a packaged, rolled, compressed, and packaged mattress  32 . The container  50  maintaining the compressed packaged mattress  32  in its rolled form for transport, display and retail. In some embodiments the container  50  may comprise a decorative layer 
         [0037]    A portion of the disclosure of this patent document contains material which is or may be subject to one or more of copyright, design patent, industrial design, or unregistered design protection. The rights holder has no objection to the reproduction of any such material as portrayed herein through facsimile reproduction of the patent document or patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all rights whatsoever.