AU2016277727A1

AU2016277727A1 - Evacuated bag with mattress and reuse of resealed bag after release of vacuum

Info

Publication number: AU2016277727A1
Application number: AU2016277727A
Authority: AU
Inventors: Stephen R. Stickler
Original assignee: Ashley Furniture Industries LLC
Current assignee: Ashley Furniture Industries LLC
Priority date: 2015-12-30
Filing date: 2016-12-23
Publication date: 2017-07-20
Also published as: US20170190494A1; CN106927146A; WO2017117549A1

Abstract

In embodiments, a mattress is bagged, compressed, and sealed at a first geographic location. A bag utilized for the bagging has an openable and closeable vent. The bagged, compressed, and sealed mattress is shipped to a destination, second geographic location. It may be warehoused in the bagged, compressed, and sealed state, and may also be further transported to distributors or retailers. At a desired point, the bagged, compressed, and sealed mattress is vented before the final end use. Such may occur before delivery to the retailer or retail customer. The vent is reclosed and the bagged uncompressed and sealed mattress is then delivered to the retailer or end user. A bagged, compressed, sealed mattress has an openable and closeable vent. I'(') , yt

Description

2016277727 23 Dec 2016

EVACUATED BAG WITH MATTRESS AND REUSE OF RESEALED BAG AFTER RELEASE OF VACUUM

FIELD OF THE DISCLOSURE 5 The present invention generally relates to innerspring mattresses and more particularly, but not exclusively, to a packaged mattress assembly including an innerspring mattress.

BACKGROUND OF THE INVENTION

Mattresses are bulking items that are expensive to ship. Upon sale and delivery to retail customers, the mattresses must be aesthetically perfect, undamaged and clean. Mattresses 0 typically have a fabric covering that can retain dirt, dust and debris. Such soiling is unacceptable prior to delivery to the end consumer and thus mattresses need to be protected during shipment. Mattresses may be manufactured at remote locations, for example overseas, and shipped by cargo container in ships or by truck to a destination country. At such destination country, the mattresses are shipped, typically by truck, to distributors, warehouses, retailers, and ultimately 5 end users. It is advantageous to bag, compress, and seal mattresses at their site of manufacture prior to overseas or other distant shipment due to the reduced volume and corresponding savings in the shipment. For commodity items such as mattresses, margins can be low and any savings, in shipping, packaging, handling can be significant.

SUMMARY OF THE INVENTION 20 A first aspect of the present invention provides a packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising: 1 2016277727 23 Dec 2016 a bag having a bag wall, the bag wall having an interior surface and exterior surface, the interior surface defining a cavity, the mattress disposed inside the cavity; the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an 5 expanded normal thickness when in the uncompressed non evacuated state; whereby when the packaged mattress is in the compressed evacuated state, the bag wall having an openable and closeable vent in fluid communication with the cavity, the openable and closeable vent comprising an adhesive strip overlaying a slit in an exterior surface of the bag wall, the adhesive strip being positioned to cover and close the slit in the bag wall, whereby 0 when the packaged mattress is in the compressed evacuated state, the adhesive strip prevents deevacuation of the packaged mattress and maintains the packaged mattress in the compressed evacuated state, and whereby the adhesive strip may be at least partially removed for releasing the packaged mattress from the compressed evacuated state, whereby the packaged mattress goes to the uncompressed non evacuated state, the adhesive strip replaceable on the slit when the 5 mattress is in the uncompressed non evacuated state. A second aspect of the invention provides a packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising: a bag having a bag wall, the bag wall having an interior surface and exterior surface, the 20 interior surface defining a cavity, the mattress disposed inside the cavity, the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal 2 2016277727 23 Dec 2016 thickness when in the uncompressed non evacuated state, the mattress having a length and a width defined by a top side surface and a bottom side surface of the mattress, the length and width substantially the same when the packaged mattress is in the compressed evacuated state and when the packaged mattress is in the uncompressed non evacuated state; 5 the bag configured such that when the packaged mattress is in the uncompressed non evacuated state, the bag is form fit to the mattress; whereby when the packaged mattress is in the compressed evacuated state, the bag wall having a defined venting region visually identifiable and differentiated on the bag wall, the defined venting region in fluid communication with the cavity, the wall having a closed vent 0 manually openable without separate tools at the venting region for releasing evacuation in the packaged mattress whereby the packaged mattress goes to the uncompressed non evacuated state; the vent closeable after the packaged mattress is in it uncompressed non evacuated state without using separate tools or components. 5 A third aspect of the invention provides a packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising: a bag having a bag wall, the bag wall having an interior surface and exterior surface, the 20 interior surface defining a cavity, the mattress disposed inside the cavity; 3 2016277727 23 Dec 2016 the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state; whereby when the packaged mattress is in the compressed evacuated state, the bag wall 5 having an openable and closeable vent in fluid communication with the cavity, the openable and closeable vent comprising an adhered strip overlaying an exterior surface of the bag wall, the adhered strip being positioned to cover and close a slit in the bag wall, whereby when the packaged mattress is in the compressed evacuated state, the adhered strip prevents de-evacuation of the packaged mattress and maintains the packaged mattress in the compressed evacuated state, 0 and whereby the adhesive strip may be at least partially removed to de-evacuate the packaged mattress releasing the packaged mattress to the uncompressed non evacuated state, the adhesive strip replaceable on the ; and a seal formed at the vent and the exterior surface of the bag wall so that the adhesive strip prevents fluid communication between the passageway and an outside atmosphere. 5 A fourth aspect of the present invention provides a bagged, compressed, and sealed mattress, the bagged, compressed, and sealed mattress in an evacuated state, the bag sized and shaped to the size of the mattress in an uncompressed state, the bag sealed to be air tight, the bag comprising an openable and closeable vent wherein the bagged, compressed, and sealed mattress can be vented allowing the mattress to expand to the uncompressed state, and wherein the vent 20 can be closed such that the bag is sealed. 4 2016277727 23 Dec 2016 A fifth aspect of the invention provides a packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising: a bag having a bag wall, the bag wall having an interior surface and exterior surface, the 5 interior surface defining a cavity, the mattress disposed inside the cavity; the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state; whereby when the packaged mattress is in the compressed evacuated state, the bag wall 0 having an openable and closeable vent in fluid communication with the cavity, the openable and closeable vent comprising an adhered strip overlaying an exterior surface of the bag wall, the adhered strip being positioned to cover and close a slit in the bag wall, whereby when the packaged mattress is in the compressed evacuated state, the adhered strip prevents de-evacuation of the packaged mattress and maintains the packaged mattress in the compressed evacuated state, 5 and whereby the adhesive strip may be at least partially removed to de-evacuate the packaged mattress releasing the packaged mattress to the uncompressed non evacuated state, the adhesive strip replaceable on the exterior surface of the bag wall; and a seal formed at the vent and the exterior surface of the bag wall so that the adhesive strip prevents fluid communication between the passageway and an outside atmosphere. 20

In a six aspect of the invention, a mattress is bagged, compressed, and sealed at a first geographic location. A bag utilized for the bagging has an openable and closeable vent. The bagged, 5 2016277727 23 Dec 2016 compressed, and sealed mattress is shipped to a destination, second geographic location. It may be warehoused in the bagged, compressed, and sealed state, and may also be further transported to distributors or retailers. At a desired point, the bagged, compressed, and sealed mattress is vented before the final end use. Such may occur before delivery to the retailer or retail customer. 5 The vent is reclosed and the bagged uncompressed and sealed mattress is then delivered to the retailer or end user.

In embodiments, the bag is a rectilinear prism shaped form fitting bag sized to standard sized mattresses and has a closed, openable, and recloseable vent thereon before the bagging. In other embodiments, a recloseable vent is added during the process of compressing, bagging, and 0 sealing the bagged mattress. A feature and advantage of embodiments of the invention is that the bag in which the mattress is bagged, compressed, sealed, and shipped, from a first location to a second location is maintained on the mattress after the mattress is vented and allowed to expand to its normal size. Said bag may be resealed to keep dirt, debris, out of the packaged mattress. 5 A feature and advantage of embodiments is that the mattress can be vented, allowing the bagged compressed mattress to return to it original size manually without any hand tools. In embodiments the vent can be reclosed after venting without any hand tools and without adding any further materials or things.

20 BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: Figure 1 is an isometric view showing a mattress. 6 2016277727 23 Dec 2016

Figure 2 is an exploded isometric view showing a packaged mattress assembly.

Figure 2A is a perspective view of a conforming form fit bag of a rectilinear prism shape with a vent means thereon.

Figure 2B is a perspective view of a bagged mattress using the bag of Figure 2A. 5 Figure 2Cis a perspective view of a bagged, compressed, and sealed mattress in the form fitting bag of Figure 2A.

Figure 3 is an isometric view showing a packaged mattress assembly including a vent.

Figure 4A through figure 4D are a series of stylized isometric views illustrating the operation of a vent shown in figure 3. 0 Figure 5 is a flowchart illustrating an exemplary method in accordance with this detailed description.

Figures 6-10 are discrete steps that may be substituted for or added to Figure 5. Additionally these steps may be utilized in any combination and/or order to define embodiments of the invention. 5 While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended 20 claims. 7 2016277727 23 Dec 2016 DETAILED DESCRIPTION OF THE DRAWINGS While this invention may be embodied in many different forms, there are described in detail herein specific embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular 5 embodiments illustrated.

Figure 1 is an isometric view showing a mattress 104 in accordance with the present detailed description. In the exemplary embodiment of figure 1, the mattress 104 comprises an innerspring assembly including a plurality of springs. A quilted cover of the mattress 104 can be seen covering the innerspring assembly in figure 1. In the embodiment of figure 1, no external 0 forces are acting on the mattress 104 and the mattress is free to assume a uncompressed state. With reference to figure 1, it will be appreciated that the mattress 104 has a thickness T1 when the mattress 104 is in the uncompressed state. With continuing reference to figure 1, it will be appreciated that the mattress 104 has a length L and a width W defined by a top side surface 136 and a bottom side surface 138 of the mattress 104 in the embodiment of figure 1. 5 Figure 2 is an exploded isometric view showing a packaged mattress assembly 100 in accordance with the present detailed description. The packaged mattress assembly 100 of figure 2 includes a bag 102 having a bag wall 122. The bag wall 122 has an interior surface 124 and an exterior surface 126. The interior surface 124 of the bag wall 122 defines a cavity 128 that is dimensioned to receive a mattress 104. The packaged mattress assembly 100 of figure 2 includes 20 a vent 130 that may be selectively opened and closed. The vent 130 comprises an adhesive strip 132 overlaying a slit 134 in the bag wall 122 in the embodiment of figure 2. In the embodiment of figure 2, the vent 130 is in a closed state with the adhesive strip 132 positioned to cover and close the slit 134 in the bag wall 122. 8 2016277727 23 Dec 2016

In the embodiment of figure 2, no external forces are acting on the mattress 104 and the mattress 104 is free to assume an uncompressed state. With reference to figure 2, it will be appreciated that the mattress 104 has a thickness T1 when the mattress 104 is in the uncompressed state. In the embodiment of figure 2, the cavity 128 defined by the interior 5 surface 124 of the bag wall 122 is dimensioned to receive the mattress while the mattress is in the uncompressed state shown in figure 2.

Referring to Figure 2A, in some useful embodiments, the bag 102’ is configured such that when the packaged mattress assembly 100 is in the uncompressed non evacuated state, the bag 102’ is form fit to the mattress 104. The term “form fit” may be taken to mean that the bag wall 0 122 of the bag 102’ generally conforms to the shape of the mattress 104 in the noncompressed state. Figure 2B illustrates a mattress in the form fitting bag and Figure 2C illustrates the bagged, compressed, and sealed mattress in the form fitting bag.

The form fitting bags may be about the size of standard size mattresses with extra material on one end. Examples of mattress sizes include king, queen, full, twin and crib. A king 5 size mattress may have a width of about 76 inches and a length of about 80 inches. A queen size mattress may have a width of about 60 inches and a length of about 80 inches. A full size mattress may have a width of about 53 inches and a length of about 75 inches. A twin size mattress may have a width of about 38 inches and a length of about 75 inches. A crib size mattress may have a width of about 28 inches and a length of about 52 inches. So the mattresses 20 are corresponding sized with some extra room for easy insertion and with extra material on an open end of the bag for sealing, see Figure 2B. Thus the bag sizes may be, for example, as follows: 9 2016277727 23 Dec 2016

King (inches) Queen(inches) Full(inches) Twin(inches) Crib(inches) 76 to 79 width 60 to 63 width 53 to 55 width 38 to 40 width 28 to 30 width 80 to 84 length 80 to 84 length 75 to 78 length 75 to 78 length 52 to 54 length 7 to 9 depth 7 to 9 depth 7 to 9 depth 7 to 9 depth 3 to 5 depth 76 to 79 width 60 to 63 width 53 to 55 width 38 to 40 width 28 to 30 width 80 to 84 length 80 to 84 length 75 to 78 length 75 to 78 length 52 to 54 length 10 to 12 depth 10 to 12 depth 10 to 12 depth 10 to 12 depth 5 to 7 depth 76 to 79 width 60 to 63 width 53 to 55 width 38 to 40 width 80 to 84 length 80 to 84 length 75 to 78 length 75 to 78 length 14 to 16 depth 14 to 16 depth 14 to 16 depth 14 to 16

The bag wall (such as, for example, bag wall 122) may comprise various materials without deviating from the spirit and scope of this detailed description. In some useful embodiments, the bag wall comprises polymeric film. Polymeric film materials that may be 5 suitable in some applications include: polyethylene terephthalate (PET), polypropylene (PP), polyvinyl chloride (PVC), polyethylene (PE), high density polyethylene (HDPE), low density polyethylene (LDPE) and biaxially oriented polypropylene (BOPP). The bag wall (such as, for example, bag wall 122) may have various thickness values without deviating from the spirit and scope of this detailed description. In an embodiment, the bag wall of a bag of a packaged 10 mattress assembly has a thickness between about 10 mil and about 0.5 mil. In an embodiment, the bag wall of a bag of a packaged mattress assembly has a thickness between about 6 mil and about 1.0 mil. In an embodiment, the bag wall of a bag of a packaged mattress assembly has a 10 2016277727 23 Dec 2016 thickness between about 4 mil and about 1.5 mil. In an embodiment, the bag wall of a bag of a packaged mattress assembly has a thickness of about 3 mil. In all cases, the thickness is sufficient to not allow the compressed sealed mattress bag to deform or rip to allow unintended venting of the bag. 5 Figure 3 is an isometric view showing a packaged mattress assembly 100 in accordance with the present detailed description. The packaged mattress assembly 100 of figure 3 comprises a mattress 104 and a bag 102 having a bag wall 122. In the embodiment of figure 3, the mattress 104 is located inside a cavity 128 defined by an interior surface of the bag wall 122. In the embodiment of figure 3, the packaged mattress assembly 100 is in a compressed evacuated state. 0 With reference to figure 3, it will be appreciated that an internal pressure PI is present inside cavity 128. An external pressure PE is applied to the exterior surface 126 of the bag wall 122 by the surrounding atmosphere ATM. The internal pressure PI present inside the cavity 128 is less than the external pressure PE while the packaged mattress assembly 100 is in the compressed evacuated state shown in figure 3. The external pressure PE of the surrounding 5 atmosphere is applying compressive forces on the mattress 104 due to the pressure differential between the internal pressure PI and the external pressure PE.

The packaged mattress assembly 100 of figure 3 includes a vent 130 that may be selectively opened and closed. The vent 130 comprises an adhesive strip 132 overlaying a slit 134 in the bag wall 122 in the embodiment of figure 3. In the embodiment of figure 3, the vent 20 130 is in a closed state with the adhesive strip 132 positioned to cover and close the slit 134 in the bag wall 122. When this is the case, the adhesive strip 132 may prevent de-evacuation of the packaged mattress assembly 100 so that the packaged mattress assembly 100 remains in the compressed evacuated state. 11 2016277727 23 Dec 2016

The adhesive strip 132 may be partially or completely removed from the bag wall 122 to release the packaged mattress assembly 100 from the compressed evacuated state. The packaged mattress assembly 100 may transition to the uncompressed non evacuated state when the adhesive strip is partially or completely removed to open the vent 130. Once the packaged 5 mattress assembly 100 is in the uncompressed non evacuated state, the adhesive strip 132 may be replaced on the slit 134 to reseal the bag 102.

With reference to figure 3, it will be appreciated that the mattress 104 has a thickness T2 when the mattress 104 is in the compressed evacuated state. Thickness T2 is smaller than thickness T1 shown in figure 2. In some useful embodiments, the mattress has a reduced 0 thickness when the packaged mattress assembly is in the compressed evacuated state and has an expanded normal thickness when the packaged mattress assembly is in the uncompressed non evacuated state.

With continuing reference to figure 3, it will be appreciated that the mattress 104 has a length L and a width W. In some useful embodiments, the mattress has a length and a width 5 defined by a top side surface and a bottom side surface of the mattress and the length and width are substantially the same when the packaged mattress assembly is in the compressed evacuated state and when the packaged mattress assembly is in the uncompressed non evacuated state. The phrase “substantially the same” may be defined as within 15%, or where the mattress and structure therein is within the same footprint, but the side wall material/fabric of the mattress 20 may upon compression may extend outwardly no more than one half the thickness of the mattress.

Various methods may be used to assemble the packaged mattress assembly 100 and to place the packaged mattress assembly in the compressed evacuated state without deviating from 12 2016277727 23 Dec 2016 the present detailed description. Examples of such methods are disclosed in the following United States Patents, which patents are hereby incorporated by reference in their entirety: US3611524, US5622030, US6098378, US7458193, and US7895813. Examples of additional methods are disclosed in the following published United States patent applications, which patent 5 applications are hereby incorporated by reference in their entirety: US2007/0204566, US2014/0157518, and US2015/0274356. A packaged mattress assembly may include various valve structures without deviating from the spirit and scope of this detailed description. Examples of such valve structures are disclosed in the following United States Patents, which patents are hereby incorporated by 0 reference in their entirety: US1555373, US1917535, US2859932, US3600727, US5632291, US8579870, US4924899, US6960113, US3141261, and US4758198.

In the embodiment of figure 3, the adhesive strip 132 comprises a tab 140 configured to be grasped between a thumb and a finger of a hand. In some useful methods in accordance with this detailed description, the bag 102 may remain in position surrounding the mattress 104 while 5 the mattress 104 is handled, stored and transported. When this is the case, the bag will serve to protect the mattress 104 from soiling, staining and abrasion while the mattress 104 is handled, stored and transported.

Figure 4A through figure 4D are a series of stylized isometric views illustrating the operation of vent 130 shown in the previous figure. Figure 4A through figure 4D may be 20 collectively referred to as figure 4. Two portions of a bag 102 are shown in figure 4. Bag 102 of figure 4 comprises a bag wall 122 having an interior surface 124 defining a cavity 128. A vent 130 is also visible in figure 4. The vent 130 comprises an adhesive strip 132 and a slit 134 defined by the bag wall 122 in the embodiment of figure 4. 13 2016277727 23 Dec 2016

In figure 4A, the adhesive strip 132 of vent 130 can be seen overlaying the slit 134 in the bag wall 122. The adhesive strip 132 is positioned to cover and close the slit 134 in the bag wall 122 in the embodiment of figure 4A. With reference to figure 4A, it will be appreciated that an internal pressure PI is present inside cavity 128. An external pressure PE is applied to the 5 exterior surface 126 of the bag wall 122 by the surrounding atmosphere ATM. In the embodiment of figure 4A, the internal pressure PI is less than the external pressure PE.

In some cases, the internal pressure PI present inside cavity 128 may be less than the external pressure PE while a mattress located inside the cavity 128 is in a compressed evacuated state. When this is the case, the adhesive strip 132 may prevent de-evacuation of the mattress 0 104 and the bag 102 may maintain the mattress 104 in the compressed evacuated state. In the embodiment of figure 4, the vent 130 may be selectively opened and closed. The vent 130 may be opened, as desired, for transitioning the packaged mattress assembly 100 from a compressed evacuated state to an uncompressed non evacuated state. Opening the vent 130 may allow the internal pressure PI to equalize with an external pressure PE of the surrounding atmosphere 5 ATM.

In figure 4B, a tab 140 of the adhesive strip 132 can be seen being grasped between a thumb and a finger of a hand. In the embodiment of figure 4, the tab 140 is formed by folding a substrate 142 of the adhesive strip 132 so that a first portion 146 of the substrate 142 overlaps a second portion 148 of the substrate 142. An adhesive covering of the adhesive strip 132 may 20 adhere the first portion 146 to the second portion 148. In figure 4B, a portion of the adhesive strip 132 has been peeled away from the bag wall 122 so that a small portion of the slit 134 is uncovered. However, most of the slit 134 remains covered by the adhesive strip 132 in the embodiment of figure 4B. 14 2016277727 23 Dec 2016

Figure 4C is an additional isometric view showing adhesive strip 132 and slit 134 of vent 130. With reference to figure 4C, it will be appreciated that the adhesive strip 132 comprises an adhesive layer 144 overlaying a substrate 142. By comparing figure 4C with figure 4B, it will be appreciated that the tab 140 of adhesive strip 132 has been pulled further in a direction D in the 5 embodiment of figure 4C relative to the embodiment of figure 4B. Pulling tab 140 in direction D has caused more of the slit 134 to be uncovered in the embodiment of figure 4C.

With continuing reference to figure 4C, it will be appreciated that the vent 130 has been opened by peeling the adhesive strip 132 away from a portion of the slit 134. In the embodiment of figure 4A, an internal pressure PI is present inside cavity 128 defined by an inner surface xx 0 124 the bag wall 122. An external pressure PE is applied to the exterior surface 126 of the bag wall 122 by the surrounding atmosphere ATM. Opening the vent 130 has allowed the internal pressure PI to equalize with the external pressure PE in the exemplary embodiment of Figure 4C.

If desired, the adhesive strip 132 may be replaced over the slit 134 after the pressure has equalized thereby closing the vent 130. In some useful methods in accordance with this detailed 5 description, the bag may remain in position surrounding the mattress while the mattress is handled, stored and transported. When this is the case, the bag may serve to protect the mattress from soiling, staining and abrasion while the mattress is handled, stored and transported.

Figure 4D is an additional isometric view showing the slit 134 in the bag wall 122. In the embodiment of figure 4D, the adhesive strip has been completely separated from the exterior 20 surface 126 of the bag wall 122. Accordingly, the slit 134 is completely unobstructed in the embodiment of figure 4D.

In an embodiment, a packaged mattress comprises a mattress and a bag having a bag wall. The bag wall may carry an openable and closeable valve in fluid communication with a 15 2016277727 23 Dec 2016 cavity defined by the bag wall for providing the necessary venting when the bagged, compressed, and sealed mattress is converted to the bagged uncompressed mattress. A packaged mattress assembly may include various valves without deviating from the spirit and scope of this detailed description. Examples of such valves are disclosed in the following United States Patents, which 5 patents are hereby incorporated by reference in their entirety: US1555373, US1917535, US2859932, US3600727, US5632291, and US8579870. Generally these valves will be attached to the bags before the bags are provided for the bagging, compressing, and sealing the mattresses.

Figure 5 is a flowchart illustrating an exemplary method in accordance with this detailed 0 description. At block 150A of the flowchart, a packaged mattress is transported in a bag in a compressed evacuated state from a first geographic region to a second geographic region. In some useful embodiments, the first geographic region is proximate to a mattress manufacture location and the second geographic region includes locations in which the retail sale of mattresses is conducted. In some embodiments, the first geographic region and the second 5 geographic region are more than 1,000 miles away from one another.

Figures 6-10 illustrate steps that may provide variations of the method illustrated in Figure 5. Any or all of the steps of Figure 5 may be replaced with any combination of the steps of Figures 6-10 in embodiments.

In some useful embodiments, the packaged mattress may be disposed inside an 20 intermodal shipping container while the packaged mattress is transported from the first geographic region to the second geographic location. The intermodal shipping container may be transported using ocean going vessels, railroads, airplanes, and/or over-the-road vehicles. Intermodal shipping containers that may be suitable in some applications are disclosed in the 16 2016277727 23 Dec 2016 following United States Patents, which patents are hereby incorporated by reference in their entirety: US2853968, US4082051, US7827738, and US9004832.

At block 150B, an openable and closeable vent on the bag is opened at the second geographic region to release the packaged mattress from the compressed evacuated state to an 5 uncompressed non evacuated state. In some useful embodiments, the step of opening an openable and closeable vent on the bag at the second geographic region occurs at a warehouse of a retail distributor or a wholesale distributor. In other useful embodiments, the step of opening an openable and closeable vent on the bag at the second geographic region occurs in or proximate to a delivery vehicle that delivers the packaged mattress to an end user who has 0 purchased the mattress.

At block 150C, the openable and closeable vent is closed at the second geographic region. In some useful methods in accordance with this detailed description, the vent may be resealed and the bag may remain in position surrounding the mattress while the mattress is handled, stored and transported. When this is the case, the bag may serve to protect the mattress 5 from soiling, staining and abrasion while the mattress is handled, stored and transported.

At block 150D, the uncompressed non evacuated packaged mattress is delivered with the closed vent to an end user who has purchased the mattress.

Various methods may be used to assemble a packaged mattress assembly and to place the packaged mattress assembly in a compressed evacuated state without deviating from the present 20 detailed description. Such methods may include the step of providing a plurality of suitably sized bags. Each bag may comprise a bag wall having an interior surface defining a cavity. Each bag may also include a vent configured to be selectively opened and closed. For example, the vent may comprises an adhesive strip overlaying a slit in the bag wall. 17 2016277727 23 Dec 2016 A mattress may be inserted into the cavity of each bag. The bag and the mattress may then be placed in a hydraulic press capable of compressing the mattress. The mattress may then be compressed using the hydraulic press. As the mattress is compressed, air will be expelled from the cavity of the bag. If desired, additional air may be removed from the cavity of the bag 5 using one or more vacuum pumps. An opening of the bag may be sealed. In some cases, a heat sealing process may be used to seal the opening of the bag. For example, the bag wall me be squeezed between two heated bars covered with Teflon coated fiberglass causing the inner surface of the bag wall to be welded to itself along a heat seal line.

Methods which may be suitable in some applications are disclosed in the following 0 United States Patents, which patents are hereby incorporated by reference in their entirety: US3611524, US5622030, US6098378, US7458193, and US7895813. Examples of additional methods are disclosed in the following published United States patent applications, which patent applications are hereby incorporated by reference in their entirety: US2007/0204566, US2014/0157518, and US2015/0274356. 5 Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following 20 illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention. 18 2016277727 23 Dec 2016

Prior art, if any, described herein is not to be taken as an admission that the prior art forms part of the common general knowledge in any jurisdiction.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations 5 such as “comprises" or “comprising" is used in an inclusive sense, that is to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. 19

Claims

CLAIMS What is claimed is:

1. A packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising: a bag having a bag wall, the bag wall having an interior surface and exterior surface, the interior surface defining a cavity, the mattress disposed inside the cavity; the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state; whereby when the packaged mattress is in the compressed evacuated state, the bag wall having an openable and closeable vent in fluid communication with the cavity, the openable and closeable vent comprising an adhesive strip overlaying a slit in an exterior surface of the bag wall, the adhesive strip being positioned to cover and close the slit in the bag wall, whereby when the packaged mattress is in the compressed evacuated state, the adhesive strip prevents deevacuation of the packaged mattress and maintains the packaged mattress in the compressed evacuated state, and whereby the adhesive strip may be at least partially removed for releasing the packaged mattress from the compressed evacuated state, whereby the packaged mattress goes to the uncompressed non evacuated state, the adhesive strip replaceable on the slit when the mattress is in the uncompressed non evacuated state.
2. The packaged mattress of Claim 1, wherein the bag is form fit to the packaged mattress when the packaged mattress is in the uncompressed non evacuated state.
3. The packaged mattress of Claim 1, wherein the adhesive strip comprises a tab configured to be grasped between a thumb and a finger of a hand when the mattress is in the compressed evacuated state.
4. The packaged mattress of Claim 3, wherein the tab comprises a part of the adhesive strip that is folded so that a first portion of the substrate overlaps a second portion of the substrate with the adhesive covering the first portion is adhered to the adhesive covering the second portion.
5. The packaged mattress of Claim 4, wherein the seal is broken when the adhesive strip is peeled away from the exterior surface of the bag wall.
6. The packaged mattress of Claim 1, wherein an interior pressure inside the cavity is less than an atmospheric pressure outside of the cavity so that the atmospheric pressure on the exterior surface of the bag wall applies compressive forces to the mattress.
7. The packaged mattress of Claim 6, wherein: the mattress is biased to assume a relaxed shape in which the mattress has a first thickness; and the compressive forces applied to the mattress urge the mattress to assume a compressed shape in which the mattress has a second thickness that is smaller than the first thickness.
8. The packaged mattress of claim 1 wherein the closed vent is defined by a slit in the mattress wall, the slit openable and closeable.
9. The packaged mattress of claim 8 wherein the slit is openable and closeable by a strip of adhered material covering the slit.
10. A packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising: a bag having a bag wall, the bag wall having an interior surface and exterior surface, the interior surface defining a cavity, the mattress disposed inside the cavity, the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state, the mattress having a length and a width defined by a top side surface and a bottom side surface of the mattress, the length and width substantially the same when the packaged mattress is in the compressed evacuated state and when the packaged mattress is in the uncompressed non evacuated state; the bag configured such that when the packaged mattress is in the uncompressed non evacuated state, the bag is form fit to the mattress; whereby when the packaged mattress is in the compressed evacuated state, the bag wall having a defined venting region visually identifiable and differentiated on the bag wall, the defined venting region in fluid communication with the cavity, the wall having a closed vent manually openable without separate tools at the venting region for releasing evacuation in the packaged mattress whereby the packaged mattress goes to the uncompressed non evacuated state; the vent closeable after the packaged mattress is in it uncompressed non evacuated state without using separate tools or components.
11. The packaged mattress of claim 10 wherein the closed vent is defined by a slit in the mattress wall, the slit openable and closeable.
12. The packaged mattress of claim 11 wherein the slit is openable and closeable by a strip of adhered material covering the slit.
13. The packaged mattress of claim 10 wherein the closed vent has an openable and closeable valve in a circular air passageway.
14. The packaged mattress of claim 10 wherein vent comprises a pair of sealable edge surfaces.
15. The packaged mattress of claim 10 where in the closed vent is utilizable for evacuating the packaged mattress to the compressed evacuated state.
16. The packaged mattress of Claim 10, wherein the bag is form fit to the packaged mattress when the packaged mattress is in the uncompressed non evacuated state.
17. The packaged mattress of Claim 10, wherein the adhesive strip comprises a tab configured to be grasped between a thumb and a finger of a hand when the mattress is in the compressed evacuated state.
18. The packaged mattress of Claim 17, wherein the tab comprises a part of the adhesive strip that is folded so that a first portion of the substrate overlaps a second portion of the substrate with the adhesive covering the first portion is adhered to the adhesive covering the second portion.
19. The packaged mattress of Claim 18, wherein the seal is broken when the adhesive strip is peeled away from the exterior surface of the bag wall.
20. A method, comprising: transporting a packaged mattress in a bag in a compressed evacuated state from a first geographic region proximate to a mattress manufacture location, to a second geographic retail sales region at least 1,000 miles away; opening an openable and closeable vent on the bag at the second geographic region to release the packaged mattress from the compressed evacuated state to an uncompressed non evacuated state; closing the openable and closeable vent at the second geographic region; delivering the uncompressed non evacuated packaged mattress with the closed vent to an end user that has purchased the mattress.
21. The method of claim 20 wherein the step of opening an openable and closeable vent on the bag at the second geographic region occurs at a warehouse of one of a retail distributor and a wholesale distributor.
22. The method of claim 20 wherein the step of opening an openable and closeable vent on the bag at the second geographic region occurs in or proximate to a delivery vehicle that delivers the packaged mattress to the end user. 23. the method of claim 20, wherein the step of opening an openable and closeable vent on the bag comprises pulling a tab at the vent to effectuate the opening.
24. The method of claim 23 wherein the step of pulling the tab includes the step of at least partially removing an adhesive strip from the vent.
25. The method of claim 23 further comprising replacing the adhesive strip thereby closing the vent.
26. A packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising: a bag having a bag wall, the bag wall having an interior surface and exterior surface, the interior surface defining a cavity, the mattress disposed inside the cavity; the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state; whereby when the packaged mattress is in the compressed evacuated state, the bag wall having an openable and closeable vent in fluid communication with the cavity, the openable and closeable vent comprising an adhered strip overlaying an exterior surface of the bag wall, the adhered strip being positioned to cover and close a slit in the bag wall, whereby when the packaged mattress is in the compressed evacuated state, the adhered strip prevents de-evacuation of the packaged mattress and maintains the packaged mattress in the compressed evacuated state, and whereby the adhesive strip may be at least partially removed to de-evacuate the packaged mattress releasing the packaged mattress to the uncompressed non evacuated state, the adhesive strip replaceable on the ; and a seal formed at the vent and the exterior surface of the bag wall so that the adhesive strip prevents fluid communication between the passageway and an outside atmosphere.
27. A bagged, compressed, and sealed mattress, the bagged, compressed, and sealed mattress in an evacuated state, the bag sized and shaped to the size of the mattress in an uncompressed state, the bag sealed to be air tight, the bag comprising an openable and closeable vent wherein the bagged, compressed, and sealed mattress can be vented allowing the mattress to expand to the uncompressed state, and wherein the vent can be closed such that the bag is sealed.
28. A packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising: a bag having a bag wall, the bag wall having an interior surface and exterior surface, the interior surface defining a cavity, the mattress disposed inside the cavity; the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state; whereby when the packaged mattress is in the compressed evacuated state, the bag wall having an openable and closeable vent in fluid communication with the cavity, the openable and closeable vent comprising an adhered strip overlaying an exterior surface of the bag wall, the adhered strip being positioned to cover and close a slit in the bag wall, whereby when the packaged mattress is in the compressed evacuated state, the adhered strip prevents de-evacuation of the packaged mattress and maintains the packaged mattress in the compressed evacuated state, and whereby the adhesive strip may be at least partially removed to de-evacuate the packaged mattress releasing the packaged mattress to the uncompressed non evacuated state, the adhesive strip replaceable on the exterior surface of the bag wall; and a seal formed at the vent and the exterior surface of the bag wall so that the adhesive strip prevents fluid communication between the passageway and an outside atmosphere.