Method for packaging a foam mattress

Abstract

The invention relates to a method for packaging a rectangular foam mattress. The method comprises the following steps: - guiding the foam mattress (20) through a paper web curtain (25) of a paper web (26) which is essentially made of paper (41) and coated on one side with a weldable material (43), - welding the paper web (26) in the area of ​​the side located at the rear in the direction of movement of the foam mattress (20) by creating at least one weld seam (45) to join the laterally projecting edge areas, so that the top (28) and the bottom (30) are joined to form a paper package (32) and two lateral openings (34) remain, - separating the paper package (32) from the remaining paper web (26) connected to the paper package (32), wherein a separation line (47) created by the separation runs along the weld seam (45),that both the paper packaging (32) and the remaining detached paper web (26) are welded, - Compressing the foam mattress (20), - Closing the side openings (34) by welding. - Folding or rolling up the packaged foam mattress (20), - Fixing the mattress roll (38) with a fixing agent (40) to prevent it from returning to its original shape.

Description

[0001] The present invention relates to a method for packaging a foam mattress.

[0002] There are a variety of different foam mattresses available. These are made of PUR foam, for example, and are sold under names such as cold foam, gel foam, comfort foam, memory foam, or even latex.

[0003] Such foam mattresses are available in different dimensions, for example 90 cm x 100 cm, 70 cm x 200 cm, etc. They are essentially rectangular in shape, with the length usually exceeding the width.

[0004] The transport and storage of such foam mattresses from the manufacturer to the retailer, or from the retailer to the end customer, is problematic. Space-saving packaging for such a foam mattress can be achieved, for example, by compressing it for transport and storage purposes. Using a suitable production machine, the entire foam mattress is compressed using a stamp or roller, allowing the air contained in the foam to escape. Typically, the foam mattress is placed in plastic packaging, such as shrink-wrapped film, before compression. The significantly reduced foam mattress is then rolled up and usually shipped in suitable outer packaging, such as a cardboard box.

[0005] Such a method is described in EP 195 755 A1. Similar methods are disclosed in JP 3 206 408 U and WO 2019 / 046892 A1. The described methods for packaging mattresses are complex and require manual work. US 2015 / 203221 A1 and EP 2 379 412 B1 also disclose a method for packaging a foam mattress using a sheet of heat-sealable plastic.

[0006] Another disadvantage of these processes is that the plastic film is usually environmentally unfriendly and non-recyclable. However, this is necessary to secure the compressed and folded or rolled foam mattress in its transport or storage form.

[0007] The object of the invention is to propose an alternative method for packaging a foam mattress that enables the most environmentally friendly packaging possible. It is essential that the packaging size is still as small as possible. The method should be quick and easy to implement and change existing processes for packaging foam mattresses as little as possible.

[0008] According to the invention, the object is achieved by a method having the method steps of claim 1.

[0009] The core idea of the present invention is therefore to use paper instead of plastic for packaging the foam mattress. This seemed impossible due to the forces that would occur as the foam mattress returned to its original shape. There was either a risk that the paper itself would tear or that the paper packaging would not be able to be sealed with sufficient strength. Sufficiently secure bonding of a paper web is not possible, or, if possible at all, only possible if sufficient time is allowed for the bond to cure. However, this makes the production process uneconomical due to the time required.

[0010] However, contrary to expectations, by coating the paper web with the thinnest possible layer of weldable material according to the invention, it is possible to weld sections of the paper web together to form a package.

[0011] The paper or paper web should have sufficient strength and / or strength to keep the folded or rolled foam mattress in its shape. Paper with a mass of approximately 90 to 130 g / m², preferably 110 g / m², has been shown to be suitable for this purpose. The layer thickness of the weldable material should be as thin as possible, particularly to provide a recyclable, environmentally friendly packaging material. A layer thickness of 15 µm to 30 µm, particularly 20 µm, has proven to be sufficiently weldable and resistant. A suitable weldable material, for example, is thermoplastic polyurethane (TPU).

[0012] According to the invention, the foam mattress is first guided through a paper web curtain, so that a section of the paper web is then applied to the underside and top of the foam mattress. The width of the paper web exceeds the width of the foam mattress and therefore extends beyond the sides of the foam mattress. The paper web also extends sufficiently beyond the sides on the rear side of the foam mattress in the direction of travel to allow for subsequent welding.

[0013] This is followed by welding the paper web on the rear side in the direction of travel by creating at least one weld seam to connect the laterally projecting edge areas of the paper web, so that the top and bottom of the paper web are joined to form a paper package. For this purpose, preferably two movable elements of a welding device can be moved toward each other in the direction of the paper web and pressed together, so that the weldable material arranged inside is heated and welded under pressure. Two lateral openings remain.

[0014] The paper packaging is then separated from the remaining, still connected, paper web. A separation line is created along the weld seam, resulting in a separation line that is welded together, so that both the paper packaging and the remaining separated paper web are welded together. This is important because, after the new paper packaging has been separated, a continuous paper web is required for the packaging of the next foam mattress. For this purpose, the weld seam can be made wide enough so that the separation line runs within the weld seam. Alternatively, two parallel weld seams can be created, with the resulting separation line then running between the two weld seams.

[0015] Preferably, the device is provided with two paper reels, each feeding a paper web from above and below. A device with only a single paper reel is also conceivable, with the paper web then being redirected accordingly.

[0016] The resulting paper packaging is preferably separated from the remaining paper web by a cutting process. For this purpose, a knife blade can be guided from one side along the weld seam. It has proven advantageous if the knife blade is aligned at an angle to the paper web. Alternatively, a cutting roller can be used, which is guided along the weld path and unrolls while cutting.

[0017] In a particularly preferred embodiment, the cut is produced by a knife which is moved essentially perpendicularly through the paper web. The knife blade of the knife is aligned towards the top or bottom of the paper web and moved in this direction during the cutting process, wherein the knife blade has a length which corresponds at least to the width of the paper web. In order to carry out the cutting process faster and more reliably, it is advantageous if the knife blade is not straight, but is, for example, serrated or wavy, preferably resembling shark teeth. As a result, it does not come into contact with the paper web over its entire length at the same time, but rather the knife blade sections closest to the paper web hit the paper web first and cut into it. This effectively prevents the paper web from tearing during the cutting process.

[0018] If two parallel welded webs are created, the cutting process preferably takes place while the welding device is still closed. The knife blade is guided between the two parallel elements of the welding device and cuts the paper web. The welding device thus also advantageously serves to keep the paper web in position under tension.

[0019] The welding process and the cutting of the paper web using one or more knife blades can also be performed simultaneously, which accelerates the production process. For example, two welding bars can be provided per weld seam, which move toward each other and are pressed together for the welding process. Coupled to these bars is a knife blade that cuts the paper web simultaneously or with a slight delay.

[0020] In this state, the foam mattress is compressed and reduced in height within the paper packaging, which is still open on both sides. This is achieved, for example, by compression using at least one roller or a stamp. This allows air to escape from the foam mattress and the still-open sides of the paper packaging, so that after the paper packaging is subsequently closed, a compressed foam mattress remains with a significantly reduced height.

[0021] After compression is complete, the side openings are also sealed by welding the overlapping protruding paper web sections. For this process, the already partially welded foam mattress can be rotated 90° each time, but additional welding devices can also be provided on the sides of the foam mattress to prevent rotation.

[0022] The packaged foam mattress is then folded or rolled up and secured with a fixing agent to prevent it from returning to its original shape.

[0023] The securing means can be formed, for example, by a simple adhesive strip. Advantageously, the securing means can also be designed as a kind of bag into which the mattress roll is inserted and which encloses it. The bag can also be used directly as outer packaging, eliminating the need for additional outer packaging.

[0024] Overall, environmentally friendly, recyclable paper packaging can be produced.

[0025] An advantageous packaging machine suitable for carrying out the method according to the invention has a transport table on which the foam mattress to be packaged can be placed. The foam mattress is first fed via the transport table to a packaging unit, which places the foam mattress in a paper package.

[0026] The compressed and packed foam mattress can be folded first, preferably along its shorter sides, and then rolled up into a mattress roll along its longer sides (the long sides). This makes it possible to significantly reduce the packing dimensions of the foam mattresses to be transported. A mattress roll of a foam mattress with, for example, a width of 1 m and a length of 2 m is thus only 0.5 m high.

[0027] The invention is explained in more detail with reference to the following figures. The figures are merely schematic representations and, in particular, are not to scale. They are not intended to limit the scope of the invention; they serve merely to illustrate the invention. They show: Figure 1: a schematic diagram of a foam mattress in front of a paper web curtain, Figure 2: a foam mattress in a partially sealed paper packaging from above, Figure 3: a compressed foam mattress in a sealed paper packaging from above, Figure 4: a compressed foam mattress being folded over its shorter sides, Figure 5: a compressed and folded foam mattress being rolled up along its longer sides, Figure 6: a mattress roll being placed into an outer packaging.

[0028] The Figures 1 to 6show a foam mattress 20 and illustrate the inventive and optional process steps that lead to packaging.

[0029] The rectangular foam mattress 20, for example, has two shorter sides 22 (transverse sides) and two longer sides 24 (longitudinal sides) (see also Fig. 2 ).

[0030] In a first process step, the foam mattress 20 is inserted into a paper web curtain 25 of a paper web 26 (cf. Fig. 1 ), so that the paper web 26 covers an upper side 28 and a lower side 30 of the foam mattress 20 after passing through (cf. Fig. 2 ).

[0031] The Figures 1-3 illustrate that the paper web 26 is formed from paper 41 which is coated with a weldable material 43. In particular Figure 1 shows that the two facing sides of a paper web 26 can be welded together via the weldable material 43. In Fig. 1 a weld seam 45 is visible, which was created during packaging of the previous foam mattress 20.

[0032] Fig. 2 shows that first the rear opening in the direction of movement of the foam mattress 20 is welded. The direction of movement of the foam mattress 20 is shown by the arrow. Fig. 2 Two parallel weld seams 45 can be seen, which were created by corresponding welding devices not shown.

[0033] By means of a cutting device (not shown), a produced paper packaging 32, which is still open on both its long sides 24, is separated from the remaining paper web 26. A separating line 47 is in Fig. 2 visible between the two weld seams 45. Fig. 2also illustrates that one of the two weld seams 45 closes the rear opening of the paper packaging 32, while the other weld seam 45 rejoins the paper web 26 separated by the cutting device so that the next foam mattress 20 can be packaged accordingly.

[0034] The paper packaging 32, which is sealed on its front and rear sides, is subjected to a compression process in which the foam mattress 20 contained therein is compressed. This is followed by the welding of the side openings, so that a circumferentially welded paper packaging 32 is created (see Fig. 3 ).

[0035] Fig. 4 illustrates that the compressed and packaged foam mattress 20 can be folded over its shorter sides 22 in a next process step.

[0036] In the process example shown, the compressed and folded foam mattress is then rolled up along its longer sides 24 into a mattress roll 38. Due to the previous folding over its shorter sides 22, a relatively small mattress roll 38 is thus created.

[0037] The mattress roll 38 is fixed in its rolled-up position by means of a fixing means 40, in the embodiment shown an adhesive strip, in order to prevent it from rolling up again.

[0038] Figure 6 shows an outer packaging 42 formed by a carton, preferably made of cardboard. The outer packaging 42 has dimensions that barely exceed the dimensions of the mattress roll 38, particularly in terms of height. Alternatively, the mattress roll 38 can also be placed in a sturdy paper bag.

[0039] The invention is not limited to the illustrated embodiment, but also encompasses further embodiments that utilize the invention. In particular, the paper packaging 32 can also be formed by a prefabricated bag that is sealed on one side after compression. Reference symbol

[0040] 20Foam mattress 22Cross sides 24Long sides 25Paper curtain 26Paper web 28Top 30Bottom 32Paper packaging 38Mattress roll 40Fixing agent 41Paper 42Outer packaging 43Weldable material 45Weld seam 47Parting line

Claims

1. A method for packing a foam mattress (20) with an upper side (28), with the following procedural steps: - guiding the foam mattress (20) through a paper sheet curtain (25) of a paper sheet (26), which essentially consists of paper (41) and is coated on one side with a weldable material (43), such that the continuous side wall (39) of the foam mattress (20) initially comes into contact with the weldable material (43), after which an upper side (28) and a lower side (30) of the foam mattress (20) are covered with the paper sheet (26), wherein the share of the paper sheet (26) arranged on the upper side (28) and the lower side (30) of the foam mattress (20) respectively protrudes laterally over the foam mattress (20), and the weldable material (43) of the paper sheet (26) are arranged facing and opposite, - welding the paper sheet (26) in the area of the rear side as viewed in the direction of movement of the foam mattress (20) by generating at least one welded seam (45) for connecting the laterally protruding edge areas, so that the upper side (28) and the lower side (30) are connected to yield a paper packaging (32), and two lateral openings (34) remain, - separating the paper packaging (32) from the remaining paper sheet (26) connected with the paper packaging (32), wherein a dividing line (47) generated by the separation runs along the welded seam (45) in such a way that both the paper packaging (32) as well as the remaining separated paper sheet (26) are welded, - compressing the foam mattress (20) by pressing it together, - sealing the lateral openings (34) and welding together the respectively protruding paper sheet sections lying one above the other, - folding or rolling up the packaged foam mattress (20), - fixing the mattress roll (38) with a fixing agent (40), so as to prevent movement back into the original shape.

2. The method according to claim 1, characterized in that the dividing line (47) is generated by a knife, the knife blade of which is initially aligned in the direction of one of the sides of the paper sheet (26) at the beginning of the cutting process, and is moved along the welded seam (45) and parallel to the latter coming from one side.

3. The method according to claim 1, characterized in that the dividing line (47) is generated by a knife, the knife blade of which is aligned diagonally in the direction of the upper side (28) or the lower side (30) of the paper sheet (26) at the beginning of the cutting process, and is moved in the direction of the upper side (28) or lower side (30) during the cutting process, so that the knife blade cuts from one side of the paper sheet (26) to the other side of the paper sheet (26).

4. The method according to claim 1, characterized in that the dividing line (47) is generated by a knife, the knife blade of which is initially aligned in the direction of the upper side (28) or the lower side (30), and is moved in this direction during the cutting process, wherein the knife blade has a length corresponding to at least a width of the paper sheet (26).

5. The method according to claim 4, characterized in that the knife blade is designed in such a way that sections of the knife blade are arranged at varying distances toward the front in the cutting direction.

6. The method according to claim 5, characterized in that the knife blade is corrugated or zigzagged in design.

7. The method according to one of claims 1 to 6, characterized in that the welded seam (45) is wide enough in design that the dividing line (47) is arranged inside of the welded seam (45).

8. The method according to one of claims 1 to 6, characterized in that two parallel running welded seams (45) are generated, and the dividing line (47) generated while separating the paper packaging (32) runs between the two welded seams (45).

9. The method according to one of claims 1 to 8, characterized in that the packaged foam mattress (20) is folded over its short sides and rolled up along its longer sides (24) into a mattress roll (38).

10. The method according to one of claims 1 to 9, characterized in that a paper bag serves as the fixing agent (40), into which the packaged, folded or rolled foam mattress (20) is introduced.

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