Systems and methods relating to a corner block for a mattress

1 . A corner block for squaring a corner of a mattress comprising,

first and second legs each having inner and outer terminal ends, the first leg extending from an inner end of the second leg at an angle to the second leg, both legs including inner and outer surfaces, the inner surfaces of the first and second legs intersecting at a transition section, the transition section being sized and shaped for interfitting around a corner of a mattress frame, the outer surfaces of the first and second legs intersecting at a vertex of an angle, the first and second legs each having a height of between about 4 inches and about 10 inches, and a length of between about 4 inches and 10 inches measured from the vertex to the terminal end of a respective leg along the outer surface of the respective leg.

2 . The corner block of claim 1 , wherein the corner block is formed from a shape resilient polymer material.

3 . The corner block of claim 1 , wherein the transition section is curved to interfit around a corner of a mattress frame.

4 . The corner block of claim 1 , wherein the angle is about 90 degrees.

5 . The corner block of claim 1 , wherein the length is between about 4 inches and about 6 inches.

6 . The corner block of claim 1 , wherein the height is between about 4 inches and about 6 inches.

7 . The corner block of claim 2 , wherein the polymer material has a density of between about 18 kilograms/meter 3 and about 28 kilograms/meter 3 .

8 . The corner block of claim 1 , wherein the first and second legs are formed integrally with each other.

9 . The corner block of claim 1 having a distance from a vertex of the angle where the outer surfaces of the first and second legs intersect and an apex of the curved transition section being between about ½ inch and about 2 inches.

10 . The corner block of claim 1 having a distance from the vertex of the angle where the outer surfaces of the first and second legs intersect and an apex of the curved transition section being between about 1 inch and about 2 inches.

11 . The corner block of claim 1 , wherein the first and second legs have a thickness of between about ¼ inch and about 2 inches.

12 . The corner block of claim 1 , wherein the first and second legs have a thickness of between about ½ inch and about 1 inch.

13 . The corner block of claim 1 , wherein the first and second legs have a thickness that decreases from the inner end of each of the legs to the terminal end of each of the legs.

14 . The corner block of claim 1 , wherein the outer surfaces of the first and second legs each include first and second sections, the first section of each leg extends from the vertex at approximately a right angle to each other, and the second section of each leg extends from a terminal end of a respective first section of each leg along an axis angled inward relative to a respective axis of the respective first section.

15 . The corner block of claim 1 , wherein the inner surfaces of the first and second legs includes a carved out portion sized and shaped to interfit over a corner of a mattress frame.

16 . The corner block of claim 1 , wherein the block comprises a material selected from the group consisting of polyurethane, polystyrene, polymer, wood, metal, polyurethane foam, visco-elastic foam, latex, polyethylene foam, polystyrene, cardboard, cellulose, wood, wire, plastic molded part, polypropylene, and acrylonitrile butadiene styrene (ABS).

17 . A mattress comprising:

a mattress frame; and

at least one corner block having first and second legs each having inner and terminal ends, the first leg extending from an inner end of the second leg at an angle to the second leg, both legs including inner and outer surfaces, the inner surfaces of the first and second legs intersecting at a transition section, the transition section being sized and shaped for interfitting around a corner of the mattress frame, the outer surfaces of the first and second legs intersecting at a vertex of an angle, the first and second legs each having a height of between about 4 inches and about 10 inches, and a length of between about 4 inches and 10 inches measured from the vertex to the terminal end of a respective leg along the outer surface of the respective leg.

18 . The mattress of claim 17 , wherein the corner block is formed from a shape resilient polymer material.

19 . The mattress of claim 17 , wherein the transition section is curved to interfit around a corner of a mattress frame.

20 . The mattress of claim 17 , wherein the corner block includes a corner block assembly having at least two corner blocks connected by a sidewall.

21 . The mattress of claim 17 , wherein the mattress is a crib mattress.

22 . A method of manufacturing a mattress comprising,

attaching a corner block to a curved corner of a mattress frame, the corner block being sized and shaped for interfitting around the curved corner and for transforming the curved corner into a substantially square corner, and

covering the mattress including the corner block with a mattress upholstery.

23 . The method of claim 22 comprising,

inserting the mattress into a polymer bag,

reducing pressure in the bag sufficiently to compress the mattress,

sliding a mattress cover over the mattress while the mattress is in a compressed state, and

permanently closing the mattress cover.

24 . The method of claim 23 comprising, removing the polymer bag prior to permanently closing the mattress cover.

25 . The method of claim 23 comprising, leaving the polymer bag within the mattress cover.

26 . The method of claim 22 , wherein attaching a corner block includes attaching a corner block assembly having a plurality of corner blocks connected by a sidewall.