Note: Descriptions are shown in the official language in which they were submitted.
CA 02858899 2014-08-06
COMPRESSIBLE MATTRESS
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
[00041 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
CA 02858899 2014-08-06
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.
2
CA 02858899 2014-08-06
[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
Figure 1 illustrates a foam core.
Figure 2 illustrates a perforation operation on the foam core.
Figure 3 illustrates a perforated foam core after the operation of Figure 2.
Figure 4 illustrates a cut away view of an embodiment of the compressible
mattress.
Figure 5 illustrates the compressible mattress after insertion in a packaging.
Figure 6 illustrates a compressing operation on the mattress and packaging.
Figure 7 illustrates the compressed mattress and packaging in a compressed
state.
Figure 8 illustrates a rolling operation being performed on the compressed
mattress and
packaging of Figure 7.
Figure 9 illustrates a rolled compressed mattress within a container after the
operation of
Figure 8.
Detailed Description
100101 Referring to Figure I, 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
CA 02858899 2014-08-06
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.
[0011] In the embodiment illustrated in Figure 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.
100121 In the case of a standard crib mattress, the size of the foam core 10
would be
about 27 5/8" - 28 5/8" wide, and 51 3/4" - 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.
[0013] Referring to Figure 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.
[0014] In an implementation, a diameter of the holes may be within a diameter
range of
8mm - 20 mm. In an aspect, the diameter may be within a diameter range of lOmm
- 15
mm. In an aspect, the diameter may be within a diameter range of 12 - 13 mm.
4
CA 02858899 2014-08-06
[0015] In the embodiment of Figure 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.
[0016] 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).
[0017] Referring to Figure 3, the foam core 10 is illustrated after the
perforation
operation of Figure 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.
[0018] Referring to the embodiment of Figure 4, an embodiment of a
compressible
mattress 30 is illustrated. In the embodiment of the mattress 30, the
perforated foam core
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
Figure 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.
[0019] As illustrated in the implementation of Figure 4, the mattress 30 may
further
comprise an air permeable outer protective layer 25 wrapped over the
protection layer 20.
5
CA 02858899 2014-08-06
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.
[00201 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 FM, 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.
100211 Figure 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.
100221 Referring to Figure 5, the compressible mattress 30 of Figure 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 Figure 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
Figure 5 indicate a direction of compression to be applied to compress the
mattress 30.
100231 Referring to Figure 6, the mattress 30 within packaging 35 of Figure 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
6
CA 02858899 2014-08-06
sealing, laser, adhesive, or other known means, to prevent the ingress of air
through
opening 40 back into the packaging 35.
[0024] While the embodiment of Figure 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.
[0025] Referring to Figure 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
Figure 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).
[0026] In the embodiment of Figure 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
[0027] 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.
7
=
