Note: Descriptions are shown in the official language in which they were submitted.
. .
. .
METHODS, APPARATUS, AND SYSTEMS FOR MULTI-MATTRESS
COMPRESSION PACKING
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[001] Generally, the present disclosure relates to packing and shipping
compressible articles of
commerce, and, more specifically, to packing and shipping mattresses.
DESCRIPTION OF THE RELATED ART
[002] Foam mattresses, such as viscoelastic or "memory foam" mattresses,
provide desirably
high levels of firmness and support for many users. They do so in part by
being porous, thereby
retaining ambient air. However, the volume and mass of air in a foam mattress
is undesirable
when packing a foam mattress by the manufacturer and shipping the foam
mattress to a
distribution center, a retailer, or a consumer.
[003] Foam mattress manufacturers have attempted to reduce the volume and mass
of foam
mattresses for shipment by compressing an individual mattress and rolling the
mattress into
cylindrical shape for transport in a non-pliable box, such as a cardboard box
having a rectangular
prism shape. However, inefficiencies remain. For example, a large amount of
processing time
and effort is required to compress these individual mattresses and roll them
in the manner
performed in the state of the art. Further, for example, a cylindrical rolled
mattress cannot fully
occupy a rectangular prism box, and individual boxes require handling to
palletize at a
manufacturer and depalletize at a distribution center, a retailer, or a
consumer.
[004] The present disclosure may address and/or at least reduce one or more of
the problems
identified above.
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SUMMARY OF THE INVENTION
[005] The following presents a simplified summary of the disclosure in order
to provide a basic
understanding of some aspects of the disclosure. This summary is not an
exhaustive overview of
the disclosure. It is not intended to identify key or critical elements of the
disclosure or to
delineate the scope of the disclosure. Its sole purpose is to present some
concepts in a simplified
form as a prelude to the more detailed description that is discussed later.
[006] In one embodiment, the present disclosure relates to a method,
comprising placing each
of a plurality of foam mattresses into each of a plurality of air-permeable,
pliable first containers,
such that each first container contains one of the foam mattresses;
compressing the plurality of
first containers each containing one of the foam mattresses, to yield a
plurality of compressed
first containers each containing one of the foam mattresses in a compressed
state; sealing the
plurality of compressed first containers into an air-impermeable, pliable
second container, to
yield a sealed second container containing a plurality of compressed first
containers each
containing one of the foam mattresses in a compressed state.
[007] In one embodiment, the present disclosure relates to an assembly,
comprising a plurality
of foam mattresses; a plurality of air-permeable, pliable first containers,
wherein each first
container contains one of the foam mattresses; and an air-impermeable, pliable
second container
enclosing the plurality of first containers each containing one of the foam
mattresses.
[008] In one embodiment, the present disclosure relates to a method,
comprising compressing a
plurality of foam mattresses, to yield a plurality of compressed foam
mattresses; and sealing the
plurality of foam mattresses into an air-impermeable, pliable first container,
to yield a sealed first
container containing the plurality of compressed foam mattresses.
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[009] In one embodiment, the present disclosure relates to an assembly,
comprising a plurality
of foam mattresses; and an air-impermeable, pliable first container enclosing
the foam
mattresses.
[0010] In one embodiment, the present disclosure relates to a method,
comprising compressing a
plurality of foam mattresses, to yield a plurality of compressed foam
mattresses; sealing the
plurality of foam mattresses into an air-impermeable, pliable first container,
to yield a sealed first
container containing the plurality of compressed foam mattresses; and rolling
the sealed first
container into a cylindrical shape, to yield a rolled sealed first container
containing the plurality
of foam mattresses in a compressed state.
[0011] In one embodiment, the present disclosure relates to an assembly,
comprising a plurality
of foam mattresses, wherein each of the foam mattresses is at least partially
compressed and the
plurality of foam mattresses are rolled together into a cylindrical shape; and
an air-impermeable,
pliable first container enclosing the foam mattresses.
[0012] The present disclosure may provide for transportation of mattresses
with a greater
reduction in volume and/or with a reduced need for handling at the
manufacturer, a distribution
center, a retailer, or a consumer, compared to previously techniques of
mattress transportation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The disclosure may be understood by reference to the following
description taken in
conjunction with the accompanying drawings, in which like reference numerals
identify like
elements, and in which:
[0014] Fig. 1 illustrates a stylized top view of a mattress and a decorative
container, in
accordance with embodiments herein;
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[0015] Fig. 2 illustrates a stylized side view of the mattress and the
decorative container, in
accordance with embodiments herein;
[0016] Fig. 3 illustrates a stylized sectional view along the line B-B' of the
mattress after
placement into the decorative container shown in Fig. 2, in accordance with
embodiments herein;
[0017] Fig. 4 illustrates a stylized sectional view along the line A-A' of the
mattress after
placement into the decorative container shown in Fig. 1, in accordance with
embodiments herein;
[0018] Fig. 5 illustrates a stylized sectional view along the line A-A' of the
mattress after closure
of the decorative container shown in Fig. 4, in accordance with embodiments
herein;
[0019] Fig. 6 illustrates a stylized side view of a plurality of mattresses
each in a decorative
container prior to compression, in accordance with embodiments herein;
[0020] Fig. 7 illustrates a stylized side view of the plurality of mattresses
each in a decorative
container shown in Fig. 6 after compression, in accordance with embodiments
herein;
[0021] Fig. 8 illustrates a stylized side view of the plurality of mattresses
each in a decorative
container shown in Figs. 6 and 7 after sealing of an airtight container around
the plurality of
mattresses, in accordance with embodiments herein;
[0022] Fig. 9 illustrates a stylized end view of the plurality of mattresses
each in a decorative
container of Figs. 6-8 after rolling of the plurality of mattresses into a
cylindrical assembly, in
accordance with embodiments herein;
[0023] Fig. 10 illustrates a stylized side view of a plurality of mattresses
prior to compression, in
accordance with embodiments herein;
[0024] Fig. 11 illustrates a stylized side view of the plurality of mattresses
shown in Fig. 10 after
compression, in accordance with embodiments herein;
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[0025] Fig. 12 illustrates a stylized side view of the plurality of mattresses
shown in Figs. 10-11
after sealing of an airtight container around the plurality of mattresses, in
accordance with
embodiments herein;
[0026] Fig. 13 illustrates a stylized end view of the plurality of mattresses
of Figs. 10-12 after
rolling of the plurality of mattresses into a cylindrical assembly, in
accordance with
embodiments herein;
[0027] Fig. 14 illustrates a flow chart of a method, in accordance with
embodiments herein;
[0028] Fig. 15 illustrates a flow chart of a method, in accordance with
embodiments herein; and
[0029] Fig. 16 illustrates a flow chart of a method, in accordance with
embodiments herein.
[0030] While the subject matter disclosed herein is susceptible to various
modifications and
alternative forms, specific embodiments thereof have been shown by way of
example in the
drawings and are herein described in detail. It should be understood, however,
that the
description herein of specific embodiments is not intended to limit the
disclosure to the particular
forms disclosed, but on the contrary, the intention is to cover all
modifications, equivalents, and
alternatives falling within the spirit and scope of the disclosure as defined
by the appended
claims.
DETAILED DESCRIPTION
[0031] Various illustrative embodiments of the disclosure are described below.
In the interest of
clarity, not all features of an actual implementation are described in this
specification. Of course,
it will be appreciated that, in the development of any such actual embodiment,
numerous
implementation-specific decisions must be made to achieve the developers'
specific goals, such
as compliance with system-related and business-related constraints, which will
vary from one
implementation to another. Moreover, it will be appreciated that such a
development effort
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might be complex and time-consuming, but would be a routine undertaking for
those of ordinary
skill in the art having the benefit of this disclosure.
[0032] The present subject matter will now be described with reference to the
attached figures.
Various structures, systems and devices are schematically depicted in the
drawings for purposes
of explanation only and to not obscure the present disclosure with details
that are well known to
those skilled in the art. Nevertheless, the attached drawings are included to
describe and explain
illustrative examples of the present disclosure. The words and phrases used
herein should be
understood and interpreted to have a meaning consistent with the understanding
of those words
and phrases by those skilled in the relevant art. No special definition of a
term or phrase, i.e., a
definition that is different from the ordinary and customary meaning as
understood by those
skilled in the art, is intended to be implied by consistent usage of the term
or phrase herein. To
the extent that a term or phrase is intended to have a special meaning, i.e.,
a meaning other than
that understood by skilled artisans, such a special definition will be
expressly set forth in the
specification in a definitional manner that directly and unequivocally
provides the special
definition for the term or phrase.
[0033] Embodiments herein are directed to sealed assemblies of compressed
mattresses that are
more conveniently and relatively inexpensively transportable from a
manufacturer to a retail
location and to a retail customer. The compressed mattresses may each be
placed in a decorative
container or alternatively, a non-decorative container prior to compressing
and sealing. The
decorative container may be suitable for display to a customer at the retail
location. The sealed
assemblies may be readily opened and the contents readily displayed to
customers at the retail
location or transferred to a customer's possession. As such, embodiments
herein provide an
increased efficiency in packaging, transporting, receiving, and processing
mattresses for display.
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[0034] Turning to Fig. 1 and a Fig. 2, a stylized top view and a stylized side
view of a mattress
110 and a decorative container 120, in accordance with embodiments herein, are
illustrated. The
mattress 100 has a generally rectangular profile in top view. In many
embodiments, the
rectangular profile may comprise curved edges. In one embodiment, the mattress
110 may be a
foam mattress, i.e., may comprise one or more layers of foam. The layer(s) of
foam may
comprise polyurethane, viscoelastic polymers, and non-viscoelastic polymers,
among other
materials known to the person of ordinary skill in the art. In a further
embodiment, the mattress
110 may consist of one or more layers of foam.
[0035] The decorative container 120 comprises an air-permeable, pliable
material. In one
embodiment, the decorative container 120 may comprise a cloth, such as wool,
cotton, linen,
velour, velvet, or silk, among others. In some embodiments, the decorative
container 120 may be
may be formed of other pliable materials, such as a flexible polyurethane
material. The
decorative container 120 comprises a main pocket 121 (from the vertical dashed
line to the right
end of decorative container 120 in Fig. 1) and a flap 122 (from the vertical
dashed line to the left
end of decorative container 120 in Fig. 1). The main pocket 121 is sized
slightly larger than the
mattress 110, as exemplified by the dotted lines in Fig. 1. Accordingly, if
the mattress 110 is
placed inside the main pocket 121 of the decorative container 120, the flap
122 may be closed.
The flap 122 may be retained in a closed position by mating of a first flap
closure element 124
with a second flap closure element 126 disposed at a corresponding location on
an outer surface
of the main pocket 121.
[0036] The first flap closure element 124 and the second flap closure element
126 may be
selected from hook and loop fabric (such as is known under the tradename
VELCRO ), snap
closures, buttons and buttonholes, or zippers, among others known to the
person of ordinary skill
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in the art. Hook and loop fabric may be desirable, in that it is likely to
permit greater
compressibility of a mattress 110 contained in the decorative container 120,
as will be discussed
in more detail below. In the depicted embodiment, the first flap closure
element 124 comprises a
hook fabric or a loop fabric, and the second flap closure element 126
comprises the other of the
hook fabric or the loop fabric. The extent and exact location of the first
flap closure element 124
and the second flap closure element 126 are not critical, and may be varied.
[0037] In embodiments, the first flap closure element 124 and the second flap
closure element
126 may be omitted, and the flap 122 may be not especially retained in a
closed position.
[0038] In another embodiment, the flap 122, the first flap closure element
124, and the second
flap closure element 126 may all be omitted, and be replaced with a neck and
accompanying
drawstring (not shown), thereby rendering the decorative container 120 similar
to smaller
decorative containers known for liquor bottles, perfume bottles, and other
items. Drawing closed
the neck of a decorative container 120 may be considered equivalent to the
closing of the flap
122 by mating of the first flap closure element 124 and the second flap
closure element 126.
[0039] In the depicted embodiment, the decorative container 120 comprises
handles 128,
specifically, four handles 128a, 128b, 128c, and 128d, disposed with two on
each side of the
main pocket 121. In other embodiments, the decorative container 120 may
comprise more or
fewer than four handles 128, and/or comprise handles 128 in other locations on
the decorative
container 120 or with different dimensions or orientations than those shown.
In still other
embodiments, the decorative container 120 may lack handles 128. The handles
128, if included,
may facilitate handling of the decorative container 120, especially after
placement of a mattress
110 in the main pocket 121. In some embodiments, in addition to serving the
function of
facilitating handling of the decorative container 120, the handles 128 may
also serve as an
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optional decorative function, contributing to the distinct look and feel of
the decorative container
120.
[0040] Figs. 3-4 each show a cross-sectional view of the mattress 110 and the
decorative
container 120 after placing the mattress 110 in the decorative container 120.
The section shown
in Fig. 3 is taken along line B-B' in Fig. 2 and the section shown in Fig. 4
is taken along line A-
A' in Fig. 1. In Figs. 3-4, the flap 122 of the decorative container 120 is
open.
[0041] Fig. 5 shows a cross-sectional view of the mattress 110 and the
decorative container 120,
taken along line A-A', after the flap 122 of the decorative container 120 has
been closed, thereby
yielding a mattress assembly 500. In the depicted embodiment, the hook or loop
first flap closure
element 124 and the loop or hook second flap closure element 126 provide a
closed closure
structure 127.
[0042] Turning to Fig. 6, a stylized side view of a plurality 510 of mattress
assemblies 500, e.g.,
as depicted, four mattress assemblies 500a, 500b, 500c, and 500d, prior to
compression, is
depicted. The mattress assemblies 500 are stacked and collated to provide the
plurality 510. The
plurality 510 has the shape of a rectangular prism, with a height
substantially equal to the height
of each mattress assembly 500 times the number of mattress assemblies 500.
Although four
mattress assemblies 500a-500d are shown in Figs. 6-9, in other embodiments,
any plural number
of mattress assemblies 500, such as two, three, five, six, seven, or eight,
among other plural
numbers, may be acted upon in the compression, sealing, and rolling processes
depicted and
described below.
[0043] Surrounding the plurality 510 is an air-impermeable, pliable outer
container 550. The
outer container 550 may comprise a plastic or another material that is capable
of providing an
air-impermeable function. The outer container 550 comprises at least one
opening 555, through
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which air may be expelled in compression and which may be sealed. Such air-
impermeable
containers are generally known in the art and need not be described in detail.
.
[0044] Fig. 6 shows that the plurality 510 surrounded by the outer container
550 is placed in a
compression apparatus 600, specifically, wherein the compression apparatus 600
is in an
uncompressed state 600a. The compression apparatus 600 is capable of providing
a
predetermined level of controllable compression that is capable of compressing
one or more
mattresses to a predetermined compression level. The compression apparatus 600
comprises a
lower rigid body 612 and an upper rigid body 614. At least one of the lower
rigid body 612 and
the upper rigid body 614 is configured to be controllably movable relative to
the other rigid body
612 or 614.
[0045] Fig. 7 shows a stylized side view of the plurality 510 after
compression, at which time the
compression apparatus 600 is in a compressed state 600b. "After compression"
refers to partial
or complete compression of the mattresses 110 contained within the plurality
510. Desirably, the
mattresses 110 are essentially maximally compressed, but the disclosure is not
so limited.
Generally, compression may be effected by moving at least one of the lower
rigid body 612 and
the upper rigid body 614 relative to the other rigid body 612 or 614. During
compression, some
or essentially all air contained within pores of the mattresses 110 is forced
out of each mattress
110, through the air-permeable decorative container 120, and out the opening
555 of the outer
container 550. Because the decorative container 120 and the outer container
550 are pliable, the
expulsion of air during compression tends to conform the outer container 550
to the plurality
510.
[0046] Although Figs. 6-7 depict compression performed by mechanical action of
rigid bodies
612 and 614, in other embodiments, not shown, compression may be achieved by
the application
CA 3064368 2019-12-09
of vacuum to the opening 555 of the outer container 550. For example, in some
embodiments,
an air removal mechanism may be comprised in the air compression apparatus
600, wherein the
air removal mechanism may prompt or assist the compression of the mattresses
510 by removing
air (e.g., using a vacuum process) from the mattresses.
[0047] Because of compression, the volume of the plurality 510 may be reduced,
which may
reduce costs associated with shipping the mattresses 110 of the plurality 510.
For example, a
reduced volume may allow more mattresses 110 to be transported in a shipping
container,
tractor-trailer trailer, train car, etc. of a given volume than would be
possible without
compression. Further, because each mattress 110 of the plurality 510 is
compressed within a
decorative container 120, and the decorative container 120 may be suitable for
display to
customers at a retail location and/or transfer of the mattress 110 contained
therein to a customer,
handling by the retailer's staff between an unloading dock, a stockroom, and a
showroom may be
reduced, thereby reducing the retailer's labor costs.
[0048] Fig. 8 shows a stylized side view of the plurality 510 after the
opening 555 of the outer
container 550 has been sealed, thereby yielding a sealed assembly 800
comprising a plurality 510
of mattress assemblies 500a-d. Sealing the opening 555 of the outer container
550 can be
performed using any known technique for which the outer container 550 and the
opening 555
have been configured, such as by heat sealing, application of adhesive, or the
like. Sealing the
opening 555 of the outer container 550 prevents the ingress of air into the
outer container 550
and accordingly maintains in a compressed state the mattresses 110 within the
mattress
assemblies 500 in the plurality 510.
[0049] In one embodiment, the outer container 550 may completely surround the
plurality 510,
e.g., may cover the entirety of each of the six faces of the rectangular prism
shape of the plurality
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510. In other embodiments, the outer container 550 may cover only some of the
faces of the
rectangular prism shape of the plurality 510. For example, the outer container
550 may cover
four faces of the plurality 510, leaving two opposed faces of the plurality
510 uncovered. In a
particular example, the uncovered faces may be those opposed faces contacted
by the rigid
bodies 612 and 614. In such an example, the outer container 550 is considered
sealed when the
outer container 550 is conformed to the plurality 510 such that expansion of
the mattresses 510
in the plurality 510 is inhibited by the outer container 550.
[0050] The sealed assembly 800 may be shipped as-is, with a significant
reduction in shipping
costs for reasons described above. Alternatively, even greater volume
efficiency, and even
greater reduction in shipping costs, may be achieved by rolling the plurality
510 of mattress
assemblies 500, to yield a rolled sealed assembly 900, seen in end view in
Fig. 9. In Fig. 9, the
rolled sealed assembly 900 comprises a plurality 510 of four mattress
assemblies which have
been rolled and sealed inside outer container 550.
[0051] Figs. 6-9 depict an order of compressing, sealing, and rolling that may
be varied as a
routine matter by the person of ordinary skill in the art. Different
compression apparatus
600.may allow one or more of compressing, sealing, and/or rolling to be
performed at
substantially the same time or in a different order.
[0052] Regardless of how a sealed assembly 800 or a rolled sealed assembly 900
is formed, the
sealed assembly 800 or the rolled sealed assembly 900 may be transported, such
as by ground
transportation (e.g., truck or rail), sea transportation (e.g., cargo ship),
or air transportation (e.g.,
airplane) to a retailer. Thereafter, the sealed assembly 800 or the rolled
sealed assembly 900 may
be unsealed at the retail location. In one embodiment, the sealed assembly 800
or the rolled
sealed assembly 900 may be unsealed by the simple expedient of an employee of
the transport
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company or of the retail location cutting the outer container 550 with a
utility knife, shears, or
other handheld cutting tool. During or after unsealing, the sealed assembly
800 or the rolled
sealed assembly 900 may be readily broken down into a compact volume for
recycling or other
disposal.
[0053] Upon unsealing the sealed assembly 800 or the rolled sealed assembly
900, the mattresses
110 contained therein will be in fluid communication with the atmosphere of
the retail location,
and accordingly will expand/decompress by the ingress of air through an
opening which was
formed in the outer container 550 by the unsealing event. During or after
unsealing, the sealed
assembly 800 or the rolled sealed assembly 900 may be readily broken down
Subsequently, each
of the mattress assemblies 500a-500d within the now-unsealed sealed assembly
800 or rolled
sealed assembly 900 may be removed. Because each mattress assembly 500
contains a mattress
110 within a decorative container 120, and the decorative container 120 is
suitable for visual
presentation to customers, at least one of displaying the decorative container
120 containing the
mattress 110 to customers of the retail location, transferring the decorative
container 120
containing the mattress 110 to a customer's possession (e.g., by delivering
the decorative
container 120 containing the mattress 110 to the customer's home or by
providing the decorative
container 120 containing the mattress 110 to the customer for the customer to
take home), or
both may be performed.
[0054] The embodiments described with reference to Figs 1-9 include the
placement of a
mattress 110 into a decorative container 120. Turning now to Figs. 10-13, a
second set of
embodiments is described, which differ from the embodiments of Figs. 1-9 by
omitting the
decorative container 120. In these embodiments, a plurality 1010 of mattresses
110 (e.g., four
mattresses 110a, 110b, 110c, and 110d) are compressed and sealed in outer
container 550, to
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yield a sealed assembly 1200 or a rolled sealed assembly 1300. The sealed
assembly 1200 or the
rolled sealed assembly 1300 may then be transported to a retail location,
unsealed, and each
mattress 110 may be displayed to customers or transferred to a customer's
possession.
[0055] Turning now to Fig. 14, a flow chart depiction of a method 1400
according to
embodiments of the present disclosure is shown. The method 1400 comprises
placing (at 1410)
each of a plurality of foam mattresses into each of a plurality of air-
permeable, pliable first
containers, such that each first container contains one of the foam
mattresses. In one
embodiment, the number of foam mattress may be four, six, or eight.
Alternatively or in addition,
the first containers may each comprise a cloth.
[0056] The method 1400 also comprises compressing (at 1420) the plurality of
first containers
each containing one of the foam mattresses, to yield a plurality of compressed
first containers
each containing one of the foam mattresses in a compressed state. Further, the
method 1400
comprises sealing (at 1430) the plurality of compressed first containers into
an air-impermeable,
pliable second container, to yield a sealed second container containing a
plurality of compressed
first containers each containing one of the foam mattresses in a compressed
state. In one
embodiment, the second container may comprise a plastic.
[0057] In embodiments, the method 1400 may further comprise rolling (at 1440)
the sealed
second container into a cylindrical shape, to yield a rolled sealed second
container containing a
plurality of compressed first containers each containing one of the foam
mattresses in a
compressed state. Alternatively or in addition, the method 1400 may comprise
transporting (at
1450) the sealed second container (whether rolled or not rolled) to a retail
location. In
embodiments, transporting (at 1450) may comprise at least one of ground
transportation, sea
transportation, or air transportation.
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[0058] The method 1400 may additionally further comprise unsealing (at 1460)
the sealed
second container at the retail location. The method 1400 may yet further
comprise removing (at
1470) one of the first containers containing one of the foam mattresses from
the second container
after unsealing (at 1460).
[0059] Subsequently, the method 1400 may still additionally comprise
displaying (at 1480) the
first container containing the foam mattress to customers of the retail
location, transferring (at
1490) the first container containing the foam mattress to a customer's
possession, or both.
[0060] Turning now to Fig. 15, a flow chart depiction of a method 1500
according to
embodiments of the present disclosure is shown. The method 1500 has some
similar features to
the method 1400 shown in Fig. 14 and described above. The method 1500 differs
from the
method 1400 at least by omitting the air-permeable, pliable container of each
foam mattress.
[0061] The method 1500 comprises compressing (at 1520) a plurality of foam
mattresses, to
yield a plurality of compressed foam mattresses; and sealing (at 1530) the
plurality of foam
mattresses into an air-impermeable, pliable first container, to yield a sealed
first container
containing the plurality of compressed foam mattresses.
[0062] In embodiments, the method 1500 may comprise rolling (at 1540) the
sealed first
container into a cylindrical shape, to yield a rolled sealed first container
containing the plurality
of foam mattresses in a compressed state. Alternatively or in addition, the
method 1500 may
comprise transporting (at 1550) the sealed first container (which may or may
not be rolled) to a
retail location. In embodiments, transporting (at 1550) may comprise at least
one of ground
transportation, sea transportation, or air transportation.
[0063] The method 1500 may yet further comprise unsealing (at 1560) the sealed
first container
at the retail location. The method 1500 may still additionally comprise
removing (at 1570) one of
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the foam mattresses from the first container after unsealing. Subsequently,
the method 1500 may
comprise displaying (at 1560) the foam mattress to customers of the retail
location, transferring
(at 1570) the foam mattress to a customer's possession, or both.
[0064] Turning now to Fig. 16, a flow chart depiction of a method 1600
according to
embodiments of the present disclosure is shown. The method 1600 has some
similar features to
the method 1400 shown in Fig. 14 and described above. The method 1600 differs
from the
method 1400 at least by making optional the air-permeable, pliable container
of each foam
mattress and requiring that the sealed first container be rolled into a
cylindrical shape.
[0065] In embodiments, the method 1600 may comprise placing (at 1610) each of
a plurality of
foam mattresses into each of a plurality of air-permeable, pliable containers,
such that each first
container contains one of the foam mattresses.
[0066] The method 1600 comprises compressing (at 1620) the plurality of foam
mattresses
(which may but need not be disposed each in an air-permeable, pliable
container), to yield a
plurality of foam mattresses each in a compressed state. Further, the method
1600 comprises
sealing (at 1630) the plurality of compressed foam mattresses into an air-
impermeable, pliable
first container, to yield a sealed first container containing a plurality of
compressed foam
mattresses. Subsequently, the method 1600 comprises rolling (at 1640) the
sealed first container
into a cylindrical shape, to yield a rolled sealed first container containing
a plurality of
compressed foam mattresses.
[0067] In embodiments, the method 1600 may further comprise transporting (at
1650) the rolled
sealed first container to a retail location. In embodiments, transporting (at
1650) may comprise at
least one of ground transportation, sea transportation, or air transportation.
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[0068] The method 1600 may additionally further comprise unsealing (at 1660)
the rolled sealed
first container at the retail location. The method 1600 may yet further
comprise removing (at
1670) one of the foam mattresses (which may, but need not, be contained in an
air-permeable,
pliable container) from the first container after unsealing (at 1660).
[0069] Subsequently, the method 1600 may still additionally comprise
displaying (at 1680) the
foam mattress to customers of the retail location, transferring (at 1690) the
foam mattress to a
customer's possession, or both.
[0070] Though each method 1400, 1500, or 1600 refers to either all foam
mattresses being
placed each alone in an air-permeable, pliable container or none being so
placed, a mixture
within a single air-impermeable, pliable container (such as the outer
container 550 shown in
Figs. 6-13) of bare mattresses and mattresses placed each alone in an air-
permeable, pliable
container may be implemented by the person of ordinary skill in the art as a
routine matter.
[0071] In embodiments, the present disclosure may relate to one or more of the
following
numbered paragraphs:
[0072] 301. An assembly, comprising:
[0073] a plurality of foam mattresses; and
[0074] an air-impermeable, pliable first container enclosing the foam
mattresses.
[0075] 302. The assembly of claim 301, wherein the first container comprises a
plastic.
[0076] 303. The assembly of claim 301, wherein each foam mattress is in a
state of at least
partial compression.
[0077] 304. The assembly of claim 303, wherein each foam mattress is in a
state of essentially
maximal compression.
[0078] 305. The assembly of claim 304, wherein the first container is sealed.
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[0079] 306. The assembly of claim 304, wherein the assembly has a cylindrical
shape.
[0080] 307. The assembly of claim 301, wherein the first container contains
four foam
mattresses.
[0081] 308. The assembly of claim 301, wherein the first container contains
six foam
mattresses.
[0082] 309. The assembly of claim 301, wherein the first container contains
eight foam
mattresses.
[0083] 401. A method, comprising:
[0084] compressing a plurality of foam mattresses, to yield a plurality of
compressed foam
mattresses;
[0085] sealing the plurality of foam mattresses into an air-impermeable,
pliable first container, to
yield a sealed first container containing the plurality of compressed foam
mattresses; and
[0086] rolling the sealed first container into a cylindrical shape, to yield a
rolled sealed first
container containing the plurality of foam mattresses in a compressed state.
[0087] 402. The method of claim 401, further comprising:
[0088] placing each of a plurality of foam mattresses into each of a plurality
of air-permeable,
pliable second containers, such that each second container contains one of the
foam mattresses;
prior to compressing the plurality of foam mattresses.
[0089] 403. The method of claim 401, further comprising:
[0090] transporting the rolled sealed first container to a retail location.
[0091] 404. The method of claim 403, wherein transporting comprises at least
one of ground
transportation, sea transportation, or air transportation.
[0092] 405. The method of claim 403, further comprising:
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=
[0093] unsealing the rolled sealed first container at the retail location.
[0094] 406. The method of claim 405, further comprising:
[0095] removing one of the foam mattresses from the first container after
unsealing; and
[0096] displaying the foam mattress to customers of the retail location,
transferring the foam
mattress to a customer's possession, or both.
[0097] 407. The method of claim 406, further comprising:
[0098] placing each of a plurality of foam mattresses into each of a plurality
of air-permeable,
pliable second containers, such that each second container contains one of the
foam mattresses;
prior to compressing the plurality of foam mattresses; and
[0099] retaining the foam mattress in the second container containing the foam
mattress when
removing and displaying, transferring, or both the foam mattress.
[00100] 408. The method of claim 401, wherein four foam mattresses are
sealed in the
first container.
[00101] 409. The method of claim 401, wherein six foam mattresses are
sealed in the
first container.
[00102] 410. The method of claim 401, wherein eight foam mattresses are
sealed in the
first container.
[00103] 411. The method of claim 401, wherein each first container
comprises a plastic.
[00104] 412. The method of claim 401, wherein the second container
comprises a cloth.
[00105] 501. An assembly, comprising:
[00106] a plurality of foam mattresses, wherein each of the foam mattresses
is at least
partially compressed and the plurality of foam mattresses are rolled together
into a cylindrical
shape; and
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[00107] an air-impermeable, pliable first container enclosing the foam
mattresses.
[00108] 502. The assembly of claim 501, wherein the first container
comprises a plastic.
[00109] 503. The assembly of claim 501, wherein each foam mattress is in a
state of
essentially maximal compression.
[00110] 504. The assembly of claim 501, further comprising a plurality of
air-
permeable, pliable second containers, wherein each of the second containers
contains one of the
foam mattresses.
[00111] 505. The assembly of claim 504, wherein each second container
comprises a
cloth.
[00112] 506. The assembly of claim 501, wherein the first container
contains four foam
mattresses.
[00113] 507. The assembly of claim 501, wherein the first container
contains six foam
mattresses.
[00114] 508. The assembly of claim 501, wherein the first container
contains eight foam
mattresses.
[00115] The particular embodiments disclosed above are illustrative only,
as the
disclosure may be modified and practiced in different but equivalent manners
apparent to those
skilled in the art having the benefit of the teachings herein. For example,
the process steps set
forth above may be performed in a different order. Furthermore, no limitations
are intended to
the details of construction or design herein shown, other than as described in
the claims below.
It is, therefore, evident that the particular embodiments disclosed above may
be altered or
modified and all such variations are considered within the scope and spirit of
the disclosure.
Accordingly, the protection sought herein is as set forth in the claims below.
CA 3064368 2019-12-09
