Folding apparatus

Abstract

The invention relates to a folding device (1) for mattresses, comprising first and second essentially rectangular belts (2, 3) which are separate and adjacent to one another to form a common plane as a support for mattresses, a lifting bar (6) which is movable essentially perpendicular to the plane between the first and second rectangular belts (2, 3), a mobile hold-down device (9) which is movable over the first belt (2) and a mattress lying thereon, and a positioning bar (11) which is movable over this first belt (2) for positioning a mattress lying thereon over the first and second belts (2, 3) and the lifting bar (6). The second belt (3) is pivotally mounted on the lifting bar (6) for folding and compressing a mattress positioned by the positioning bar (11) and fixed by the hold-down device (9) on the first belt (2).

Description

[0001] The invention relates to a folding device for mattresses having the features of claim 1.

[0002] In the following, the term 'mattresses' includes cushions and mattress toppers. Mattresses are commercially available in various sizes, for example, 90 cm x 100 cm or 70 cm x 200 cm. Mattresses are generally rectangular in shape, with their length exceeding their width.

[0003] For transport and storage of mattresses from the manufacturer to the retailer or from the retailer to the end customer, mattresses are preferably packaged in a space-saving manner. For this purpose, mattresses are compressed so that any air contained within the mattress escapes, resulting in a reduced mattress height. Before this vacuum-packing process, the mattress is wrapped in a film strip, which is then sealed after vacuum-packing.

[0004] DE 10 2019 116 645 A1 discloses a method for packaging a rectangular foam mattress, comprising the following method steps: - compressing the foam mattress, - folding the foam mattress along its shorter sides, - rolling the foam mattress along its longer sides into a mattress roll, and securing the mattress roll with a securing agent to prevent it from re-rolling. A disadvantage of this prior art is that mattresses are packaged in film webs, vacuum-sealed, and sealed, and after rolling up, the mattress rolls are secured with a securing agent, resulting in the corresponding effort and plastic waste when the mattresses are used.

[0005] The object of the invention is to create a folding device for mattresses that overcomes the disadvantages of the prior art and further reduces the packaging size of folded and rolled mattresses and thus shipping costs.

[0006] The solution is achieved with a folding device for mattresses having the features of claim 1. Advantageous embodiments of the invention are disclosed in the subclaims and in a combination of the folding device for mattresses with a packaging machine for rolling mattresses for packaging.

[0007] According to the invention, a mattress folding device comprises first and second substantially rectangular belts which are separate and adjacent to one another to form a plane as a common support for a mattress. A lifting bar is arranged between the substantially rectangular belts and is movable substantially perpendicular to the plane. A mobile hold-down device of the folding device according to the invention is movable, in operation, over the first of the substantially rectangular belts and a mattress lying thereon, and a positioning bar is provided over this substantially rectangular belt for positioning a mattress lying thereon over both belts and the lifting bar. The second of the substantially rectangular belts is pivotally mounted on the lifting bar for folding and compressing a mattress positioned by the positioning bar over the two belts and the lifting bar and fixed to the first belt by the hold-down device.After folding in the folding device according to the invention, the mattress's extension in one direction is reduced by folding, and its volume is reduced by compression on the first belt. Advantageously, the folding device according to the invention folds and compresses non-compressed and non-vacuum-packaged mattresses between two belts. A folded mattress cannot unfold again between the belts, resulting in significantly reduced packaging sizes and lower plastic consumption by eliminating the film web that is required when vacuum-packaging a mattress according to the prior art. Furthermore, the folding device according to the invention advantageously saves shipping costs, as significantly smaller boxes can be used for mattresses folded and compressed according to the invention. Automated "nano-packaging" is possible with the folding device according to the invention without prior pressing.

[0008] According to an advantageous embodiment of the invention, the hold-down device is height-adjustable for mattresses of different heights.

[0009] According to a further advantageous embodiment of the invention, the folding device for mattresses is provided with an electronic control device by means of which the lifting bar, the hold-down device and the positioning bar can each be controlled separately.

[0010] According to a further advantageous embodiment of the invention, light barriers are provided for the electronic control device, with which the positions of the lifting bar, hold-down device and / or positioning bar can be monitored.

[0011] According to a further advantageous embodiment of the invention, mattresses having at least one symmetry property are positioned with one of their symmetry axes above the lifting bar for the smallest possible edge length of the mattress after folding.

[0012] According to a further advantageous embodiment of the invention, rectangular mattresses are positioned with their shorter axis of symmetry above the lifting bar for the smallest possible edge length of the mattress after folding.

[0013] According to a further advantageous embodiment of the invention, pivoting from the second belt to the first belt takes place before lifting the lifting bar.

[0014] According to a further advantageous embodiment of the invention, the belts of the folding device according to the invention are designed as circulating conveyor belts for transporting folded mattresses from the folding device according to the invention and a packaging machine as disclosed in DE 196296606 is provided with a nozzle-shaped feed area, a winding drum and a forming tube substantially coaxial with the winding drum.The belts of the folding device according to the invention are connected to the nozzle-shaped feed area for transferring folded mattresses into this nozzle-shaped feed area, in which folded mattresses are conveyed under compression into the winding drum of the packaging machine, rolled in the winding drum, and, once the rolled format is completed, folded mattresses are pushed along the winding drum into a forming tube that is essentially coaxial with the winding drum, and at the end of this tube a rolled and folded mattress is inserted into a paper sack, bag, or sleeve. According to the invention, non-pressed and non-vacuum-packed mattresses can be folded, compressed, and fed into a roll-packing machine using two belts in the folding device according to the invention. By feeding them directly to the feed area of the packaging machine using the two belts, folded mattresses cannot unfold or shift on the way into the winding drum.With the inventive combination of the folding device and packaging machine, it is advantageously possible to significantly reduce the packaging size for rolled and folded mattresses while reducing plastic consumption by eliminating the need for vacuum film. With the inventive combination of the folding device and packaging machine, shipping costs can be saved, as significantly smaller boxes can be used for storing and transporting rolled and folded mattresses for automated "nano-packaging" of previously unpressed mattresses. The disclosure of DE 196296606 is incorporated into the application.

[0015] The invention is illustrated below using a preferred embodiment. Shown are: Fig. 1 a perspective view of a folding device according to the invention, Fig. 2 a cross-sectional view of the folding device according to the invention, Fig. 3 a cross-sectional view of the folding device in an operating position according to the invention, Fig. 4 a perspective view of the folding device in this operating position according to the invention, Fig. 5 a cross-sectional view of the folding device in a further operating position according to the invention, Fig. 6 a perspective view of the folding device in this further operating position according to the invention, Fig. 7 a cross-sectional view of the folding device in a final position according to the invention, and Fig. 8 a perspective view of the folding device in this final position according to the invention.

[0016] Fig. 1, 2 : A folding device 1 for mattresses (not shown) has a first substantially rectangular belt 2 and a second substantially rectangular belt 3, which form a common plane, wherein longer sides 4, 5 of the first substantially rectangular belt 2 and of the second substantially rectangular belt 3 are aligned parallel to each other. The common plane forms a support for rectangular mattresses up to 2.5 m long, up to 2 m wide, and 50 to 200 mm high.

[0017] Between the first belt 2 and the second belt 3, a lifting bar 6 is provided, movable perpendicular to the plane, along the longer sides 4, 5 of the first and second belts 3. In its initial position, the lifting bar 6 does not extend into the plane spanned by the first and second belts 2, 3.

[0018] The first belt 2 is mounted on a frame 7 and the second belt 3 on a lifting frame 8 which is movable perpendicular to the plane and on whose longer side 5 the lifting bar 6 is mounted.

[0019] A mobile hold-down device 9 is movable from a starting position on the longer side 4 along guide rails 10 parallel to the plane and to the longer sides 4, 5 over the first belt 2 and any mattress lying thereon, depending on the length or width of the mattress. For mattresses of different heights, the mobile hold-down device 9 is movable perpendicular to the plane, in particular to be able to fix any mattress lying thereon to the first belt 2 by pressure.

[0020] A positioning bar 11 is movable along second guide rails 12 parallel to the plane and to the longer sides 4, 5 over the first belt 2 for positioning a mattress lying thereon centrally over both belts 2, 3 and the lifting bar 6.

[0021] The mobile hold-down device 9 and the positioning bar 11 are each driven separately by electrical / pneumatic means. Light barriers and electronic control devices (not shown) are provided to control the mobile hold-down device 9 and the positioning bar 11 depending on the dimensions of the mattresses to be folded.

[0022] The belts 2, 3 are each designed as conveyor belts circulating around drive shafts 13, 14. The drive shafts 13, 14 tension the belts 2, 3 at their shorter sides 15, 16. Each of the belts 2, 3 is electrically driven in the same direction by motors 17, 18.

[0023] If a rectangular mattress is placed on the two belts 2, 3 with the shorter side approximately parallel to the longer sides 4, 5 of the belts 2, 3, the mattress is positioned by the positioning bar 11 over both belts 2, 3 and the lifting bar 6 parallel to the longer sides 4, 5 of the belts 2, 3, by the positioning bar 11, which is parked in a starting position on the longer side 4, controlled by the electronic control devices, parallel to the longer sides 4, 5 and the plane over the first belt 2 until it reaches the lifting bar 6, until the mattress is in a predeterminable middle position monitored by light barriers.The mobile hold-down device 9, parked in its starting position on the longer side 4, is moved, under the control of the electronic control devices, parallel to the longer sides 4, 5 and the plane over the first belt 2 and the mattress until just before the middle of the longer side of the mattress and in any case before reaching the lifting bar 6. There, the mobile hold-down device 9 is lowered and fixes the mattress on the first belt 2.

[0024] Fig. 3, 4 : Identical features are identified by the reference numerals from Fig. 1, 2 The lifting bar 6 is lifted by the lifting frame 8, which is movable perpendicular to the plane, against the mattress fixed on the first belt 2. The mattress bends around the mobile hold-down device 9 with its section resting on the second belt 3, thus further stabilizing the mattress in its position fixed on the first belt 2. The second belt 3, which is pivotally mounted on the lifting bar 6, pivots 90° relative to the first belt 2 and folds the mattress accordingly in the direction of the first belt 2. The second belt 3 can also be pivoted before the lifting bar 6 is raised.

[0025] Fig. 5, 6 : Identical features are identified by the reference numerals from Fig. 1-4 The mattress remains held in position above the first belt 2. The second belt 3, pivotally mounted on the lifting bar 6, pivots further toward the first belt 2 and folds the portion of the mattress resting on the second belt 3 further toward the first belt 2.

[0026] Fig. 7, 8 : Identical features are identified by the reference numerals from Fig. 1-6 The mobile hold-down device 9 is moved back to its starting position on the longer side 4 of the first belt 2. The second belt 3, pivotally mounted on the lifting bar 6, pivots into a final position over and parallel to the first belt 2, further folding the mattress and compressing it accordingly between the first and second belts 2, 3.

[0027] The first and second belts 2, 3 of the folding device 1, designed as circulating conveyor belts for mattresses, are placed with their shorter sides 15, 16 against an infeed area of a packaging machine (not shown). The belts 2, 3, which are electrically driven in the same direction by motors 17, 18, convey the mattresses folded by the folding device 1 into the infeed area of the packaging machine, which has a winding drum and a forming tube that is essentially coaxial with the winding drum. Folded mattresses are conveyed further into the winding drum of the packaging machine under pre-compression in the infeed area, rolled and compressed in the winding drum, and after the rolled format is completed, the folded mattresses are pushed out along the winding drum into a forming tube that is essentially coaxial with the winding drum, and at the end of this tube, the rolled and folded mattresses are inserted into a paper sack, bag, or sleeve.

[0028] After a folded mattress has been delivered, the second belt 3 swings back over the lifting frame 8 and is lowered with the lifting bar 6 to a level with the first belt 2. Positioning bar 11 is back in its starting position on the longer side 4 of the first belt 2 and the folding device 1 is ready to receive another mattress.

Claims

1. A folding device (1) for mattresses, comprising: - first and second essentially rectangular bands (2, 3) which are separate and adjacent to one another to form a common plane for supporting mattresses, - a lifting bar (6) which is movable essentially perpendicular to the plane between the first and second rectangular bands (2, 3), - a mobile hold-down device (9) which is movable over the first band (2) and a mattress lying thereon, and - a positioning bar (11) which is movable over this first band (2) for positioning a mattress lying thereon over the first and second bands (2, 3) and the lifting bar (6), the second band (3) being pivotally mounted on the lifting bar (6) for folding and compressing a mattress positioned by the positioning bar (11) and fixed by the hold-down device (9) on the first band (2).

2. Folding device (1) for mattresses according to claim 1, characterized in that the hold-down device (9) is height adjustable.

3. Folding device (1) for mattresses according to one of the preceding claims, characterized in that an electronic control device is provided by means of which the lifting bar (6), the hold-down device (9) and the positioning bar (11) can each be controlled separately.

4. Folding device (1) for mattresses according to the preceding claim, characterized in that Light barriers are provided for the electronic control device.

5. Folding device (1) for mattresses according to one of the preceding claims, characterized in that Mattresses with at least one symmetry property are positioned with one of their symmetry axes above the lifting bar (6) for the smallest possible edge length of the mattress after folding.

6. Folding device (1) for mattresses according to the preceding claim, characterized in that Rectangular mattresses are positioned with their shorter axis of symmetry above the lifting bar (6) to ensure the smallest possible edge length of the mattress after folding.

7. Folding device (1) for mattresses according to one of the preceding claims, characterized in that Swiveling from the second belt (3) to the first belt (2) takes place before lifting the lifting bar (6).

8. Folding device (1) for mattresses according to one of the preceding claims, characterized in thatthe first and second belts (2, 3) are designed as circulating conveyor belts for transporting folded mattresses and a packaging machine is provided with a nozzle-shaped feed area, a winding drum and a forming tube substantially coaxial with the winding drum, wherein the belts of the folding device (1) are connected to the nozzle-shaped feed area and folded mattresses are transferred into this nozzle-shaped feed area, in which folded mattresses are conveyed under compression into the winding drum of the packaging machine, rolled in the winding drum and, after completion of the rolled format, folded mattresses are pushed out along the winding drum into a forming tube substantially coaxial with the winding drum and, at the end of which tube, rolled and folded mattresses are introduced into a sack, bag or sleeve.

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