The present disclosure relates to mattresses, and in particular crib mattresses.
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.
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.
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.
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.
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.
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.
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.
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.
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In the embodiment illustrated in
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.
Referring to
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.
In the embodiment of
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).
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As illustrated in the implementation of
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.
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.
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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.
Number | Date | Country | |
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62011570 | Jun 2014 | US |