Compressible mattress

Abstract

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

1 . A compressible mattress comprising:
 a foam core in a shape of mattress, said foam core perforated by at least one hole through a face of the core.   
     
     
         2 . The compressible mattress of  claim 1  wherein the at least one hole comprises a plurality of holes through the face of the mattress. 
     
     
         3 . The compressible mattress of  claim 2  wherein the plurality of holes are axially aligned with one another. 
     
     
         4 . The compressible mattress of  claim 2  wherein the plurality of holes are even distributed across the face of the mattress. 
     
     
         5 . The compressible mattress of  claim 2  wherein the plurality of holes are each perforated clear through opposed faces of the mattress. 
     
     
         6 . The compressible mattress of  claim 2  wherein a diameter of each of the plurality of holes is within a diameter range of 8 mm-20 mm. 
     
     
         7 . The compressible mattress of  claim 6  wherein the diameter range is between 10 mm-15 mm. 
     
     
         8 . The compressible mattress of  claim 7  wherein the diameter range is between 12-13 mm. 
     
     
         9 . The compressible mattress of  claim 7 , wherein the mattress comprises a crib mattress having face dimensions of about 27 ⅝″-28 ⅝″ wide and 51 ¾″-53″ long, and wherein the mattress has a thickness between a range of 4″-6″ thick, and wherein the plurality of holes are bored through the thickness with openings on both opposed faces. 
     
     
         10 . The compressible crib mattress of  claim 9  wherein the plurality of holes comprises between 80 to 160 holes evenly spaced across the faces of the mattress. 
     
     
         11 . The compressible mattress of  claim 1 , further comprising a protective layer surrounding the foam core, the protective layer comprising a waterproof, air permeable membrane. 
     
     
         12 . The compressible mattress of  claim 11 , wherein the protective layer is sealed around the foam core. 
     
     
         13 . The compressible mattress of  claim 11 , further comprising an air permeable outer protective layer over the protective layer. 
     
     
         14 . The compressible mattress of  claim 13 , wherein the outer protective layer comprises a decorative layer. 
     
     
         15 . The compressible mattress of  claim 14 , wherein the outer protective layer is removably secured over the protective layer. 
     
     
         16 . A compressed mattress comprising the mattress of  claim 1 , after compression into a compressed state and secured within a sealed, airtight packaging. 
     
     
         17 . A compacted mattress comprising the compressed mattress of  claim 16 , compacted and secured in the compact state by a container. 
     
     
         18 . The compacted mattress of  claim 17  wherein the container comprises one of a plastic bag, a cardboard box, and a fastener. 
     
     
         19 . A method of manufacturing a compressed mattress, comprising:
 boring a plurality of holes through a thickness of a foam core to produce a mattress;   inserting the mattress into a flexible, air tight packaging;   compressing the packaging and the mattress; and, sealing an open end of the flexible, air tight packaging to produce a compressed mattress sealed within the flexible, air tight packaging in a compressed form.   
     
     
         20 . The method of  claim 19 , wherein the method further comprises: after boring the plurality of holes, wrapping the bored foam core with a waterproof air permeable protective layer, and sealing the waterproof air permeable protective layer around the bored foam core to produce the mattress. 
     
     
         21 . The method of  claim 20 , wherein the method further comprises: after sealing the waterproof air permeable protective layer around the bored foam core, wrapping and securing an outer protective layer over the protective layer to produce the mattress. 
     
     
         22 . The method of  claim 19 , further comprising:
 compacting the compressed mattress, and securing the compacted compressed mattress within a second packaging.   
     
     
         23 . The method of  claim 19 , wherein the compressing comprises:
 inserting the flexible, air tight packaging containing the mattress between platens of a press;   pressing the platens together to compress the packaging and the mattress; and,   wherein the sealing comprises:   sealing the open end before releasing the platens and withdrawing the sealed packaging containing the compressed mattress from the press.