CA3064368A1

CA3064368A1 - Methods, apparatus, and systems for multi-mattress compression packing

Info

Publication number: CA3064368A1
Application number: CA3064368A
Authority: CA
Inventors: Josh Micklos; Jeff Quinn; Bruce Miller
Original assignee: Sinomax USA Inc
Current assignee: Sinomax USA Inc
Priority date: 2018-12-10
Filing date: 2019-12-09
Publication date: 2020-06-10
Also published as: US20200223576A1

Abstract

Methods of compressing and sealing a plurality of mattresses in an air-impermeable, pliable outer container; and assemblies comprising such a plurality of mattresses. The plurality of mattresses may be rolled into a cylindrical shape for transport from a manufacturer to a distribution center or a retail location. Each mattress may be enclosed in an air-permeable, pliable decorative container that may be suitable for display or transfer to customers. The methods and the assemblies may allow greater efficiency in shipping mattresses to a distribution center or a retail location, and/or greater efficiency in preparing mattresses for display or transfer to customers of the retail location.

Description

. .
. .
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.

. .
' 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.

[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;

[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;

[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 . , 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.

[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 . .
. .
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 . , ' 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 . .
. .
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 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 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 . .
' 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 =
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.

. =
'

[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 =
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.

=

[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.

[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:

=

[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

[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.

Claims

What is claimed is:

1. 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.

2. The method of claim 1, further comprising:
rolling 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.

3. The method of claim 1, further comprising:
transporting the rolled sealed second container to a retail location.

4. The method of claim 3, wherein transporting comprises at least one of ground transportation, sea transportation, or air transportation.

5. The method of claim 3, further comprising:
unsealing the rolled sealed second container at the retail location.

6. The method of claim 5, further comprising:
removing one of the first containers containing one of the foam mattresses from the second container after unsealing; and displaying the first container containing the foam mattress to customers of the retail location, transferring the first container containing the foam mattress to a customer's possession, or both.

7. The method of claim 1, wherein four foam mattresses and four first containers are compressed.

8. The method of claim 1, wherein six foam mattresses and six first containers are compressed.

9. The method of claim 1, wherein eight foam mattresses and eight first containers are compressed.

10. The method of claim 1, wherein each first container comprises a cloth.

11. The method of claim 1, wherein the second container comprises a plastic.

12. 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.

13. The assembly of claim 12, wherein each first container comprises a cloth

14. The assembly of claim 12, wherein the second container comprises a plastic.

15. The assembly of claim 12, wherein each foam mattress is in a state of at least partial compression.

16. The assembly of claim 12, wherein the second container is sealed.

17. The assembly of claim 12, wherein the assembly has a cylindrical shape.

18. The assembly of claim 12, wherein the second container contains four foam mattresses and four first containers; six foam mattresses and six first containers; or eight foam mattresses and eight first containers.

19. 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.

20. The method of claim 19, further comprising:
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.

21. The method of claim 20, further comprising:
transporting the rolled sealed first container to a retail location.

22. The method of claim 21, further comprising:
unsealing the rolled sealed first container at the retail location.

23. The method of claim 22, further comprising:
removing one of the foam mattresses from the first container after unsealing;
and displaying the foam mattress to customers of the retail location, transferring the foam mattress to a customer's possession, or both.