Modular mattress system

Abstract

A modular mattress system having at least one mattress block which includes an array of resilient coil springs, along with a foam pad, and a washable/dryable fabric mattress cover. The components of the modular mattress system are compressible into an air evacuable bag for purposes of storing, shipping, and disposal. The size, firmness, type of foam pad, pattern and color of the fabric mattress cover, and type of securable seam available for the fabric mattress cover used in the modular mattress system may be specified by the consumer. Mattress size ranges from Crib size through King size, with custom sizes available as well. Various methods of specifying, ordering, and distributing the modular mattress system are detailed. The care, maintenance, assembly and usage of the modular mattress system are discussed.

1 . A mattress comprising:
 a plurality of mattress blocks, each of said mattress blocks including an array of resilient coils, the array of coils being enclosed in a mattress block covering material.   
   
   
       2 . The mattress of  claim 1 , wherein the mattress blocks are arranged in a fabric mattress cover having a top layer, a bottom layer, and at least one sidewall. 
   
   
       3 . The mattress of  claim 2 , wherein the fabric mattress cover includes a selectively sealable seam, the selectively sealable seam providing access to an interior of the fabric mattress cover for inserting or removing the mattress blocks. 
   
   
       4 . The mattress of  claim 3 , wherein the selectively securable seam is disposed along an intersection of the bottom layer of the fabric mattress cover and at least one of the at least one sidewalls of the fabric mattress cover. 
   
   
       5 . The mattress of  claim 2 , further comprising a layer of foam disposed between the mattress blocks and a surface of the fabric mattress cover. 
   
   
       6 . The mattress of  claim 1 , wherein each of the mattress blocks is adapted to be compressed to a compact condition upon sealing the mattress block in a compressible, air evacuable container and evacuating air from the air evacuable container. 
   
   
       7 . The mattress of  claim 1 , wherein each of the resilient coils of each of the mattress blocks is individually wrapped in a compressible material. 
   
   
       8 . The mattress of  claim 1 , wherein the fabric mattress cover is machine washable. 
   
   
       9 . A method of packaging a mattress, comprising:
 selecting a fabric mattress cover having a top layer, a bottom layer, and at least one sidewall separating the top and bottom layers, the fabric mattress cover including a selectively securable seam;   selecting a plurality of mattress blocks, each of the mattress blocks including an array of resilient coils, the array of coils being enclosed in a mattress block covering material, and the plurality of mattress blocks configurable to occupy an interior of the fabric mattress cover;   securing at least the plurality of mattress blocks in a compressible, air evacuable container; and   evacuating air from the air evacuable container, thereby compressing the mattress blocks.   
   
   
       10 . The method of  claim 9 , further comprising securing the fabric mattress cover in the air evacuable container with the plurality of mattress blocks prior to evacuating air from the air evacuable container. 
   
   
       11 . The method of  claim 9 , further comprising selecting a foam pad to be disposed in the interior of the fabric mattress cover between the plurality of mattress blocks and one of the top and bottom layers of the fabric mattress cover. 
   
   
       12 . The method of  claim 11 , further comprising securing the foam pad in the air evacuable container with the plurality of mattress blocks prior to evacuating air from the air evacuable container. 
   
   
       13 . The method of  claim 9 , further comprising identifying a mattress size, and wherein, in selecting the fabric mattress cover, selecting the fabric mattress cover to have dimensions corresponding to the identified mattress size. 
   
   
       14 . The method of  claim 9 , further comprising identifying at least one characteristic of a portion of the mattress and wherein, in selecting the mattress blocks, at least one of the selected mattress blocks provides the identified characteristic. 
   
   
       15 . The method of  claim 14 , wherein the identified characteristic is stiffness. 
   
   
       16 . The method of  claim 14 , wherein in selecting the mattress blocks, the at least one mattress block providing the selected characteristic includes distinguishing indicia on an exterior of the mattress block covering material, the indicia indicating that mattress block provides the selected characteristic. 
   
   
       17 . The method of  claim 9 , further comprising identifying a desired stiffness of at least a portion of the mattress, and in selecting at least one of the fabric mattress cover, the mattress blocks, and the foam pad, the combined stiffness of the selected fabric mattress cover, the mattress blocks, and the foam pad provides the desired stiffness. 
   
   
       18 . A method of assembling a mattress, comprising:
 opening a fabric mattress cover having a bottom layer, a top layer, at least one side wall separating the bottom and top layers, and a selectively securable seam;   arranging a plurality of mattress blocks in the fabric mattress cover, each of the mattress blocks including an array of resilient coils, the array of coils being enclosed in a mattress block covering material; and   securing the selectively securable seam.   
   
   
       19 . The method of  claim 18 , further comprising, prior to securing the selectively sealable seam, inserting a foam pad between the plurality of mattress blocks and one of the layers of the fabric mattress cover. 
   
   
       20 . A method of ordering, packaging, and distributing mattresses, comprising:
 providing an interface between a customer and a mattress distributor;   identifying a mattress size;   selecting a fabric mattress cover having a top layer, a bottom layer, and at least one sidewall separating the top and bottom layers, the fabric mattress cover including a selectively securable seam, and having dimensions corresponding to the identified mattress size;   selecting a plurality of mattress blocks from a mattress block supply, each of the selected mattress blocks including an array of resilient coils, the array of coils being enclosed in a mattress block covering material, and the plurality of selected mattress blocks configurable to occupy an interior of the selected fabric mattress cover;   enclosing at least the plurality of selected mattress blocks in a compressible, air evacuable container;   evacuating the air from the air evacuable container, thereby compressing the selected mattress blocks; and   inserting the fabric mattress cover and the compressed air evacuable container having the compressed mattress blocks therein into a shipping container.   
   
   
       21 . The method of  claim 20 , further comprising identifying a plurality of additional mattress characteristics selected from the group of firmness of at least a portion of a mattress, fabric mattress cover exterior color, fabric mattress cover exterior pattern, and foam pad type, and wherein in selecting the fabric mattress cover and plurality of mattress blocks, the selected fabric mattress cover and selected mattress blocks correspond to the identified characteristic. 
   
   
       22 . A modular mattress system, comprising:
 a fabric mattress cover having a top layer, a bottom layer, and at least one sidewall separating the top and bottom layers, the fabric mattress cover including a selectively securable seam;   a plurality of mattress blocks arranged in the fabric mattress cover, each of said mattress blocks including an array of resilient coils, the array of coils being enclosed in a mattress block covering material; and   a foam pad disposed between the plurality of mattress blocks and one of the top and bottom layers of the fabric mattress cover.   
   
   
       23 . The modular mattress system of  claim 22 , wherein the stiffness of the fabric mattress cover, the stiffness of at least one of the plurality of mattress blocks, and the stiffness of the foam pad are selectable, whereby the modular mattress system has a selectable resulting stiffness.