Folding unit for use in a mattress packaging line

Abstract

A folding unit is provided, which allows the mattress to be folded on the first axis upstream of at least one roll unit positioned in the extending direction of a first axis in a mattress packaging line. The folding unit includes at least one table on which the mattress is positioned, and at least one pressure element for at least partial compression of the mattress in a vertical axis, at least one first carrier and at least one second carrier, and at least one movement mechanism to which at least one of said first carrier and second carrier are connected in a way that allows them to be moved on a second axis and a vertical axis to be folded over each other, wherein at least one of the first carrier and the second carrier is in the form of a conveyor to advance the mattress on the first axis.

Description

CROSS REFERENCE TO THE RELATED APPLICATIONS

[0001] This application is the national phase entry of International Application No. PCT / TR2024 / 050593, filed on Jun. 4, 2024, which is based upon and claims priority to Turkish Patent Application No. 2023 / 011319, filed on Sep. 12, 2023, the entire contents of which are incorporated herein by reference.TECHNICAL FIELD

[0002] The invention relates to a folding unit to allow the mattress to be folded on the first axis in a mattress packaging line that allows the mattress to be packaged.BACKGROUND

[0003] The mattress packaging line refers to a production process designed to produce mattresses serially and efficiently. The purpose of this line is to produce and package the finished mattress products by combining different parts and components of the mattresses. The packaging line usually includes these steps: First, the materials and components required for mattress packaging are prepared. Then, the framework, which is the cornerstone of the mattress, is created. The spring system is integrated into the framework and then the upholstery material that will cover the mattress, usually foam and upholstery fabric, is placed.

[0004] Mattress sewing and assembly is carried out by combining the framework and upholstery material. The mattresses produced go through testing and quality control processes to ensure quality and comfort. Finally, the completed mattresses are properly packaged for shipping and storage. Thanks to the use of automation and mass production systems, the mattress packaging line optimizes the production process and ensures the post-production packaging of the high-quality and consistent products in the mattress industry. Some problems may arise in the mattress packaging lines due to the complexity of the process. In the mattress packaging, various problems may be encountered during the folding process of the mattresses before rolling. These can be listed as follows:

[0005] Material and Sewing Problems: If the seams, edges or coating of the mattresses are not made of high quality, tearing, seam opening or coating damage may occur during the folding process. Fold Evenness: The mattress folding process requires the mattress to be folded evenly and neatly. If the folding process is not done properly, the wrinkles and unevenness may occur on the mattress.

[0006] Mattress Height Problems: The thickness of some mattresses or the density of the materials inside can make folding difficult. High-profile mattresses in particular can be more difficult to fold, which can affect the packaging process.

[0007] Mattress Reforming Problems: During the folding process, the mattress materials can temporarily deform, especially materials such as memory foam. This can make it difficult to re-open the mattress properly and affect the quality of the product.

[0008] Mattress Smoothness: The mattress folding process requires the mattress to be folded completely flat and preserving its original form. If the mattress folds unevenly or crookedly, the problems may arise during packaging and lead to the customer dissatisfaction.

[0009] Packaging Problems: Folding should be performed to the appropriate size and shape for the final packaging and transportation of the mattress. If the mattress is jammed or damaged during the packaging process, or if the packaging materials do not provide adequate protection, this may increase the risk of damage to the mattress during transportation.

[0010] As a result, all the above-mentioned problems have made it necessary to realize a novelty in the relevant technical field.SUMMARY

[0011] The present invention relates to a folding unit to eliminate the above-mentioned disadvantages and bring the new advantages to the relevant technical field.

[0012] An object of the invention is to provide a folding unit with improved folding function in mattress packaging lines.

[0013] In order to accomplish all the objects mentioned above and to be revealed from the detailed description below, the present invention is a folding unit to allow the mattress to be folded on the first axis upstream of at least one packaging unit positioned in the extending direction of a first axis in a mattress packaging line. Accordingly, the novelty is that it includes at least one table on which the mattress is positioned, and at least one pressure element for at least partial compression of the mattress positioned on said table in a vertical axis, at least one first carrier and at least one second carrier for folding the mattress on the table, and at least one movement mechanism to which at least one of said first carrier and second carrier are connected in a way that allows them to be moved on a second axis and a vertical axis to be folded over each other, wherein at least one of the first carrier and the second carrier is in the form of a conveyor to advance the mattress on the first axis. Thus, the mattress can be folded practically and quickly and moved along the first axis.

[0014] A possible embodiment of the invention is characterized in that the table includes at least one third carrier for folding the mattress twice. Thus, the mattress can be packed and transported in a smaller and more compact size.

[0015] Another possible embodiment of the invention is characterized in that said movement mechanism is located on both the second carrier and the third carrier. Thus, the mattress can be folded with the vertical and horizontal movements in both directions and transferred to the packaging stage.

[0016] Another possible embodiment of the invention is characterized in that the movement mechanism includes at least one first part positioned on the chassis and at least one second part positioned on the table, and said first part is configured to be moved in the direction of the second axis, and the second part is configured to be moved in the vertical axis. Thus, the mattress can be folded in a precise and controllable manner and ready for packing.

[0017] Another possible embodiment of the invention is characterized in that it includes at least one first drive element to move the first carrier in the vertical axis. Thus, the mattress can be compressed vertically and reached the desired firmness when folded.

[0018] Another possible embodiment of the invention is characterized in that it includes at least one bridge for positioning the pressure element on the table. Thus, the pressure element ensures even and uniform compression of the mattress.

[0019] Another possible embodiment of the invention is characterized in that it includes at least one pressure drive element to which the pressure element is connected to move it on the vertical axis. Thus, the precise control can be achieved during the vertical compression of the mattress.

[0020] Another possible embodiment of the invention is characterized in that it includes at least one pushing handle in addition to the conveyor-shaped carrier for advancing the folded mattress on the first axis. Thus, the desired speed and balance can be achieved while the mattress is advanced on the first axis.

[0021] Another possible embodiment of the invention is characterized in that it includes at least one roll to protect the mattress while folding on the table. This can prevent the mattress from being damaged during the folding process.

[0022] Another possible embodiment of the invention is characterized in that it includes at least one intermediate space on the table to allow the pressure element to be at least partially embedded therein. Thus, the mattress can be compressed more smoothly and regularly during the folding process.

[0023] Another possible embodiment of the invention is characterized in that it includes at least one pressing unit upstream of the first axis direction and alt least one packaging unit downstream thereof to advance the mattress in the first axis. Thus, after the pressing process, the mattress is folded and transferred to the packaging stage and is prepared to take up less space.

[0024] Another possible embodiment of the invention is characterized in that it includes the steps of positioning the mattress on the table, compressing the mattress by moving the pressure element on the vertical axis, folding at least one of the first carrier and the second carrier over the other, and providing the first carrier and the second carrier to advance the mattress on the first axis with the conveyor structure. Thus, the mattress can be folded practically and quickly and moved along the first axis.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 shows a representative perspective view of the mattress packaging line on which the folding unit of the invention is located.

[0026] FIG. 2 shows a representative perspective view of the folding unit of the invention.

[0027] FIG. 3 shows a representative perspective view of the folding unit of the invention in the pressure position.

[0028] FIG. 4 shows a representative perspective view of the folding unit of the invention in its first folding position.

[0029] FIG. 5 shows a representative perspective view of the folding unit of the invention in its second folding position.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0030] In this detailed description, the subject of the invention is only described with the examples without any limiting effect for a better understanding of the subject.

[0031] FIG. 1 shows a representative perspective view of the mattress packaging line (10) on which the folding unit (13) of the invention is located. Accordingly, the mattress packaging line (10) of the invention is configured to allow the manufactured mattress (Y) to be packaged. For this purpose, the mattress packaging line (10) includes at least one packaging unit (11), at least one pressing unit (12), at least one folding unit (13) and at least one roll unit (14). With these units working synchronously with each other, the mattress (Y) can be packaged in a predetermined manner.

[0032] The packaging unit (11) located in the mattress packaging line (10) includes the basic stage in which the packaging begins after the mattress (Y) is manufactured. At this stage, the mattress (Y) is positioned in a packaging material from opposite sides. After this positioning, the mattress (Y) is driven towards the pressing unit (12).

[0033] The pressing unit (12) located in the mattress packaging line (10) allows the mattress (Y) to be compressed and shaped. The pressing unit (12) allows the mattress (Y) to be compressed and its volume to be reduced. For this purpose, the mattress (Y) is compressed from opposite sides in the pressing unit (12) and the air in the packaging material is removed by the pressing method. Thus, a mattress (Y) with reduced volume is obtained.

[0034] FIG. 2 shows a representative perspective view of the folding unit (13) of the invention. Accordingly, the folding unit (13) in the mattress packaging line (10) ensures that the mattresses are folded into appropriate sizes and shapes before packaging. Folding is performed to facilitate storage and transportation of the mattress (Y). By means of the folding unit (13), the mattress (Y) is folded onto itself in at least one layer, thus narrowing the package area. The edges and corners of the folded mattress (Y) in the folding unit (13) are expected to be aligned on top of each other.

[0035] The roll unit (14) located in the mattress packaging line (10) ensures that the mattresses (Y) are sized appropriately for storage and transportation. At this stage, the aim is to transport the mattresses (Y) safely and deliver them to the customer without any problems. The roll unit (14) aims to round the folded mattress (Y) and wrap it with the packaging so that the mattress (Y) has a smaller area. In addition, the additional operations such as labeling can be performed in the roll unit (14) to assist transportation.

[0036] In the mattress packaging line (10), the packaging unit (11), pressing unit (12), folding unit (13) and roll unit (14) are positioned in the direction of at least one first axis (I), allowing the mattress (Y) to be produced by continuously advancing it in the direction of the first axis (I). Thus, instead of taking up a large area in the area in which the mattress packaging line (10) is positioned, it is positioned in a narrower and longer way (1343) that is easier to control.

[0037] FIG. 3 shows a representative perspective view of the folding unit (13) of the invention in the pressure position (P0). Accordingly, the folding unit (13) is positioned between the pressing unit (12) and the roll unit (14) and allows the mattress (Y) to be folded a predetermined number of times. In a possible embodiment of the invention, the folding unit (13) folds the mattress (Y) once, and in the preferred embodiment, it folds twice.

[0038] The folding unit (13) includes at least one table (132) on at least one chassis (131), at least one bridge (133) and at least one pressure element (134). The mattress (Y) is positioned on the said table (132) and the folding operation is performed thereon. The bridge (133) is positioned on the table (132) with the struts (1331) extending on opposite sides of the table (132) and the extension (1332) therebetween. The bridge (133) substantially allows the pressure element (134) to be positioned on the table (132). When the mattress (Y) is positioned on the table (132), the pressure element (134) is moved in the vertical axis (III) and allows the mattress (Y) to be pressed from the center. To allow this, the pressure element (134) includes at least one pressure component (1341) part and at least one support (1342) part. Said pressure component (1341) part is the part of the pressure element (134) that puts pressure on the mattress (Y). In a possible embodiment of the invention, the pressure component (1341) may be cylindrical, or it may be in the form of a plate in the alternative embodiments. Said support (1342) part allows the connection of the pressure component (1341) onto the bridge (133). The pressure element (134) is also connected to at least one pressure drive element (1343). Said pressure drive element (1343) allows the pressure element (134) to be moved vertically. There are preferably two pressure elements (134) in the folding unit (13), and the mattress (Y) can be held at a predetermined tightness. Additionally, there is at least one intermediate space (1326) between the carriers for the pressure element (134) to be placed on the table (132). Said intermediate space (1326) improves the folding accuracy of the mattress (Y).

[0039] The table (132) consists of at least two, preferably three parts. There is at least one first carrier (1321) and at least one second carrier (1322) on the table (132). In the preferred embodiment of the invention, in addition to the first carrier (1321) and the second carrier (1322), there is at least one third carrier (1323) positioned next to them. The first carrier (1321), the second carrier (1322) and the third carrier (1323) are substantially conveyors. The first carrier (1321), the second carrier (1322) and the third carrier (1323) each include at least one band (1324) and at least one carrier drive element (1325) to rotate said band around itself. On the table (132), the first carrier (1321) is in the center, the second carrier (1322) and the third carrier (1323) are positioned on either side of the first axis (I). The first carrier (1321), the second carrier (1322) and the third carrier (1323) are positioned in the direction of the first axis (I) and advance the mattress (Y) by folding it in the direction of the first axis (I). At least one of the first carrier (1321), second carrier (1322) and third carrier (1323) is in a vacuum structure. In the preferred embodiment of the invention, only the first carrier (1321) is in a vacuum structure. In this way, it is provided that the mattress (Y) is advanced with the desired precision.

[0040] The first carrier (1321) is connected to a first drive element (13211) for at least partial movement on the table (132) in the vertical axis (III) (assumed to be perpendicular to the ground). By means of the first drive element (13211), the first carrier (1321) can be approached or moved away from the pressure element (134). The second carrier (1322) and the third carrier (1323) are configured to be at least partially displaced on the vertical axis (III) and at the same time to approach and move away from the first carrier (1321). The fact that the second carrier (1322) and the third carrier (1323) are moved relative to the first carrier (1321) also means that they are moved on the second axis (II). The second axis (II) is essentially the axis perpendicular to the first axis (I) and parallel to the ground. Therefore, the second carrier (1322) and the third carrier (1323) each include at least one movement mechanism (135). At least one of the first carrier (1321), second carrier (1322) and third carrier (1323), preferably each of them, includes at least one roll (1327). Said roll (1327) is configured to rotate freely around itself to prevent damage to the mattress (Y) during folding.

[0041] The movement mechanism (135) is located between the chassis (131) and the table (132), especially between the second carrier (1322) and the third carrier (1323). The movement mechanism (135) includes at least one first part (1351) and at least one second part (1352). Said first part (1351) is located on the chassis (131). Said second part (1352) is positioned on the table (132). The first part (1351) is configured to be at least partially displaced on the chassis (131) in the direction of the second axis (II). Therefore, the movement mechanism (135) includes at least one first part drive element (13511). The first part (1351) drive element moves the first part (1351) on the second axis (II) by means of at least one belt (13512). The second part (1352) is connected to the first part (1351) in such a way that it is at least partially displaced on the vertical axis (III). Therefore, the movement mechanism (135) includes at least one second part drive element (13521). By means of the movement mechanism (135), the second carrier (1322) and the third carrier (1323) are displaced both in the vertical axis (III) and in the second axis (II), allowing the mattress (Y) to be folded over each other.

[0042] FIG. 4 shows a representative perspective view of the folding unit (13) of the invention in its first folding position (P1). Accordingly, when the mattress (Y) is desired to be folded in single layer, the mattress (Y) is placed on the table (132) and the pressure element (134) is moved in the vertical axis (III) and the mattress (Y) is compressed from two opposite sides. Subsequently, one of the second carrier (1322) and the third carrier (1323) (preferably the second carrier (1322)) are moved in the vertical axis (III) and the second axis and positioned on the first carrier (1321). Finally, the conveyor-shaped carriers move the mattress (Y) from both sides on the first axis (I) and advance it to the roll unit (14). Thus, the mattress (Y) is folded in single layer and transferred to the roll unit (14).

[0043] FIG. 5 shows a representative perspective view of the folding unit (13) of the invention in its second folding position (P2). Accordingly, when the mattress (Y) is desired to be folded in two layers, the mattress (Y) is placed on the table (132) and the pressure element (134) is moved in the vertical axis (III) and the mattress (Y) is compressed from two opposite sides. Subsequently, the second carrier (1322) and the third carrier (1323) are moved successively on the vertical axis (III) and the second axis (II) and positioned on the first carrier (1321). Finally, the conveyor-shaped carriers move the mattress (Y) from both sides on the first axis (I) and advance it to the roll unit (14). Thus, the mattress (Y) is folded in two layers and transferred to the roll unit (14).

[0044] In the preferred embodiment of the invention, there is at least one pushing arm (1328) in the folding unit (13). Said pushing arm (1328) is configured to be moved in the direction of the first axis (I) in the folding unit (13). In this way, the backflow between the carriers is prevented when the mattress (Y) is moved on the first axis (I).

[0045] Some of the benefits provided by this structure of the mattress packaging line (10) are as follows:

[0046] Efficiency and High Production Capacity: The modular and synchronized design of this structure optimizes the packaging process of mattress (Y) and enables high production capacity. Each unit works in harmony, creating an efficient production flow.

[0047] Fast Production and Response Time: Thanks to this structure, the mattresses (Y) can be produced serially, thus responding quickly to increases in demand. Synchronization of the production processes supports fast and on-time production.

[0048] Space Saving: Positioning the mattress packaging line (10) in a narrow and long structure saves production space and enables more effective use.

[0049] Ease of Use and Control: Each unit is designed to be easily accessible and controllable for operators carrying out different production stages of the mattress (Y).

[0050] Ease of Packaging and Transportation: The folding unit (13) and the roll unit (14) ensure that the mattresses (Y) take up less space during transportation and storage, reducing logistics costs.

[0051] The scope of protection of the invention is described in the attached claims and cannot be limited to what is explained in this detailed description for the exemplary purposes. It is clear that a person skilled in the art can produce similar embodiments in the light of what is explained above, without deviating from the main theme of the invention.REFERENCE NUMBERS IN THE DRAWINGS10 Mattress Packaging Line

[0053] 11 Package Unit

[0054] 12 Pressing Unit

[0055] 13 Folding Unit

[0056] 131 Chassis

[0057] 132 Table

[0058] 1321 First Carrier

[0059] 13211 First Drive Element

[0060] 1322 Second Carrier

[0061] 1323 Third Carrier

[0062] 1324 Band

[0063] 1325 Carrier Drive Element

[0064] 1326 Intermediate Space

[0065] 1327 Roll

[0066] 1328 Pushing Handle

[0067] 133 Bridge

[0068] 1331 Strut

[0069] 1332 Extension

[0070] 134 Pressure Element

[0071] 1341 Pressure Component

[0072] 1342 Support

[0073] 1343 Pressure Drive Element

[0074] 135 Movement Mechanism

[0075] 1351 First Part

[0076] 13511 First Part Drive Element

[0077] 13512 Belt

[0078] 1352 Second Part

[0079] 13521 Second Part Drive Element

[0080] 14 Roll Unit

[0081] P0 Pressure Position

[0082] P1 First Folding Position

[0083] P2 Second Folding Position

[0084] I First Axis

[0085] II Second Axis

[0086] III Vertical Axis

[0087] Y Mattress

Examples

Embodiment Construction

[0030]In this detailed description, the subject of the invention is only described with the examples without any limiting effect for a better understanding of the subject.

[0031]FIG. 1 shows a representative perspective view of the mattress packaging line (10) on which the folding unit (13) of the invention is located. Accordingly, the mattress packaging line (10) of the invention is configured to allow the manufactured mattress (Y) to be packaged. For this purpose, the mattress packaging line (10) includes at least one packaging unit (11), at least one pressing unit (12), at least one folding unit (13) and at least one roll unit (14). With these units working synchronously with each other, the mattress (Y) can be packaged in a predetermined manner.

[0032]The packaging unit (11) located in the mattress packaging line (10) includes the basic stage in which the packaging begins after the mattress (Y) is manufactured. At this stage, the mattress (Y) is positioned in a packaging material ...

CROSS REFERENCE TO THE RELATED APPLICATIONS

[0001] This application is the national phase entry of International Application No. PCT / TR2024 / 050593, filed on Jun. 4, 2024, which is based upon and claims priority to Turkish Patent Application No. 2023 / 011319, filed on Sep. 12, 2023, the entire contents of which are incorporated herein by reference.TECHNICAL FIELD

[0002] The invention relates to a folding unit to allow the mattress to be folded on the first axis in a mattress packaging line that allows the mattress to be packaged.BACKGROUND

[0003] The mattress packaging line refers to a production process designed to produce mattresses serially and efficiently. The purpose of this line is to produce and package the finished mattress products by combining different parts and components of the mattresses. The packaging line usually includes these steps: First, the materials and components required for mattress packaging are prepared. Then, the framework, which is the cornerstone of the mattress, is created. The spring system is integrated into the framework and then the upholstery material that will cover the mattress, usually foam and upholstery fabric, is placed.

[0004] Mattress sewing and assembly is carried out by combining the framework and upholstery material. The mattresses produced go through testing and quality control processes to ensure quality and comfort. Finally, the completed mattresses are properly packaged for shipping and storage. Thanks to the use of automation and mass production systems, the mattress packaging line optimizes the production process and ensures the post-production packaging of the high-quality and consistent products in the mattress industry. Some problems may arise in the mattress packaging lines due to the complexity of the process. In the mattress packaging, various problems may be encountered during the folding process of the mattresses before rolling. These can be listed as follows:

[0005] Material and Sewing Problems: If the seams, edges or coating of the mattresses are not made of high quality, tearing, seam opening or coating damage may occur during the folding process. Fold Evenness: The mattress folding process requires the mattress to be folded evenly and neatly. If the folding process is not done properly, the wrinkles and unevenness may occur on the mattress.

[0006] Mattress Height Problems: The thickness of some mattresses or the density of the materials inside can make folding difficult. High-profile mattresses in particular can be more difficult to fold, which can affect the packaging process.

[0007] Mattress Reforming Problems: During the folding process, the mattress materials can temporarily deform, especially materials such as memory foam. This can make it difficult to re-open the mattress properly and affect the quality of the product.

[0008] Mattress Smoothness: The mattress folding process requires the mattress to be folded completely flat and preserving its original form. If the mattress folds unevenly or crookedly, the problems may arise during packaging and lead to the customer dissatisfaction.

[0009] Packaging Problems: Folding should be performed to the appropriate size and shape for the final packaging and transportation of the mattress. If the mattress is jammed or damaged during the packaging process, or if the packaging materials do not provide adequate protection, this may increase the risk of damage to the mattress during transportation.

[0010] As a result, all the above-mentioned problems have made it necessary to realize a novelty in the relevant technical field.SUMMARY

[0011] The present invention relates to a folding unit to eliminate the above-mentioned disadvantages and bring the new advantages to the relevant technical field.

[0012] An object of the invention is to provide a folding unit with improved folding function in mattress packaging lines.

[0013] In order to accomplish all the objects mentioned above and to be revealed from the detailed description below, the present invention is a folding unit to allow the mattress to be folded on the first axis upstream of at least one packaging unit positioned in the extending direction of a first axis in a mattress packaging line. Accordingly, the novelty is that it includes at least one table on which the mattress is positioned, and at least one pressure element for at least partial compression of the mattress positioned on said table in a vertical axis, at least one first carrier and at least one second carrier for folding the mattress on the table, and at least one movement mechanism to which at least one of said first carrier and second carrier are connected in a way that allows them to be moved on a second axis and a vertical axis to be folded over each other, wherein at least one of the first carrier and the second carrier is in the form of a conveyor to advance the mattress on the first axis. Thus, the mattress can be folded practically and quickly and moved along the first axis.

[0014] A possible embodiment of the invention is characterized in that the table includes at least one third carrier for folding the mattress twice. Thus, the mattress can be packed and transported in a smaller and more compact size.

[0015] Another possible embodiment of the invention is characterized in that said movement mechanism is located on both the second carrier and the third carrier. Thus, the mattress can be folded with the vertical and horizontal movements in both directions and transferred to the packaging stage.

[0016] Another possible embodiment of the invention is characterized in that the movement mechanism includes at least one first part positioned on the chassis and at least one second part positioned on the table, and said first part is configured to be moved in the direction of the second axis, and the second part is configured to be moved in the vertical axis. Thus, the mattress can be folded in a precise and controllable manner and ready for packing.

[0017] Another possible embodiment of the invention is characterized in that it includes at least one first drive element to move the first carrier in the vertical axis. Thus, the mattress can be compressed vertically and reached the desired firmness when folded.

[0018] Another possible embodiment of the invention is characterized in that it includes at least one bridge for positioning the pressure element on the table. Thus, the pressure element ensures even and uniform compression of the mattress.

[0019] Another possible embodiment of the invention is characterized in that it includes at least one pressure drive element to which the pressure element is connected to move it on the vertical axis. Thus, the precise control can be achieved during the vertical compression of the mattress.

[0020] Another possible embodiment of the invention is characterized in that it includes at least one pushing handle in addition to the conveyor-shaped carrier for advancing the folded mattress on the first axis. Thus, the desired speed and balance can be achieved while the mattress is advanced on the first axis.

[0021] Another possible embodiment of the invention is characterized in that it includes at least one roll to protect the mattress while folding on the table. This can prevent the mattress from being damaged during the folding process.

[0022] Another possible embodiment of the invention is characterized in that it includes at least one intermediate space on the table to allow the pressure element to be at least partially embedded therein. Thus, the mattress can be compressed more smoothly and regularly during the folding process.

[0023] Another possible embodiment of the invention is characterized in that it includes at least one pressing unit upstream of the first axis direction and alt least one packaging unit downstream thereof to advance the mattress in the first axis. Thus, after the pressing process, the mattress is folded and transferred to the packaging stage and is prepared to take up less space.

[0024] Another possible embodiment of the invention is characterized in that it includes the steps of positioning the mattress on the table, compressing the mattress by moving the pressure element on the vertical axis, folding at least one of the first carrier and the second carrier over the other, and providing the first carrier and the second carrier to advance the mattress on the first axis with the conveyor structure. Thus, the mattress can be folded practically and quickly and moved along the first axis.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 shows a representative perspective view of the mattress packaging line on which the folding unit of the invention is located.

[0026] FIG. 2 shows a representative perspective view of the folding unit of the invention.

[0027] FIG. 3 shows a representative perspective view of the folding unit of the invention in the pressure position.

[0028] FIG. 4 shows a representative perspective view of the folding unit of the invention in its first folding position.

[0029] FIG. 5 shows a representative perspective view of the folding unit of the invention in its second folding position.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0030] In this detailed description, the subject of the invention is only described with the examples without any limiting effect for a better understanding of the subject.

[0031] FIG. 1 shows a representative perspective view of the mattress packaging line (10) on which the folding unit (13) of the invention is located. Accordingly, the mattress packaging line (10) of the invention is configured to allow the manufactured mattress (Y) to be packaged. For this purpose, the mattress packaging line (10) includes at least one packaging unit (11), at least one pressing unit (12), at least one folding unit (13) and at least one roll unit (14). With these units working synchronously with each other, the mattress (Y) can be packaged in a predetermined manner.

[0032] The packaging unit (11) located in the mattress packaging line (10) includes the basic stage in which the packaging begins after the mattress (Y) is manufactured. At this stage, the mattress (Y) is positioned in a packaging material from opposite sides. After this positioning, the mattress (Y) is driven towards the pressing unit (12).

[0033] The pressing unit (12) located in the mattress packaging line (10) allows the mattress (Y) to be compressed and shaped. The pressing unit (12) allows the mattress (Y) to be compressed and its volume to be reduced. For this purpose, the mattress (Y) is compressed from opposite sides in the pressing unit (12) and the air in the packaging material is removed by the pressing method. Thus, a mattress (Y) with reduced volume is obtained.

[0034] FIG. 2 shows a representative perspective view of the folding unit (13) of the invention. Accordingly, the folding unit (13) in the mattress packaging line (10) ensures that the mattresses are folded into appropriate sizes and shapes before packaging. Folding is performed to facilitate storage and transportation of the mattress (Y). By means of the folding unit (13), the mattress (Y) is folded onto itself in at least one layer, thus narrowing the package area. The edges and corners of the folded mattress (Y) in the folding unit (13) are expected to be aligned on top of each other.

[0035] The roll unit (14) located in the mattress packaging line (10) ensures that the mattresses (Y) are sized appropriately for storage and transportation. At this stage, the aim is to transport the mattresses (Y) safely and deliver them to the customer without any problems. The roll unit (14) aims to round the folded mattress (Y) and wrap it with the packaging so that the mattress (Y) has a smaller area. In addition, the additional operations such as labeling can be performed in the roll unit (14) to assist transportation.

[0036] In the mattress packaging line (10), the packaging unit (11), pressing unit (12), folding unit (13) and roll unit (14) are positioned in the direction of at least one first axis (I), allowing the mattress (Y) to be produced by continuously advancing it in the direction of the first axis (I). Thus, instead of taking up a large area in the area in which the mattress packaging line (10) is positioned, it is positioned in a narrower and longer way (1343) that is easier to control.

[0037] FIG. 3 shows a representative perspective view of the folding unit (13) of the invention in the pressure position (P0). Accordingly, the folding unit (13) is positioned between the pressing unit (12) and the roll unit (14) and allows the mattress (Y) to be folded a predetermined number of times. In a possible embodiment of the invention, the folding unit (13) folds the mattress (Y) once, and in the preferred embodiment, it folds twice.

[0038] The folding unit (13) includes at least one table (132) on at least one chassis (131), at least one bridge (133) and at least one pressure element (134). The mattress (Y) is positioned on the said table (132) and the folding operation is performed thereon. The bridge (133) is positioned on the table (132) with the struts (1331) extending on opposite sides of the table (132) and the extension (1332) therebetween. The bridge (133) substantially allows the pressure element (134) to be positioned on the table (132). When the mattress (Y) is positioned on the table (132), the pressure element (134) is moved in the vertical axis (III) and allows the mattress (Y) to be pressed from the center. To allow this, the pressure element (134) includes at least one pressure component (1341) part and at least one support (1342) part. Said pressure component (1341) part is the part of the pressure element (134) that puts pressure on the mattress (Y). In a possible embodiment of the invention, the pressure component (1341) may be cylindrical, or it may be in the form of a plate in the alternative embodiments. Said support (1342) part allows the connection of the pressure component (1341) onto the bridge (133). The pressure element (134) is also connected to at least one pressure drive element (1343). Said pressure drive element (1343) allows the pressure element (134) to be moved vertically. There are preferably two pressure elements (134) in the folding unit (13), and the mattress (Y) can be held at a predetermined tightness. Additionally, there is at least one intermediate space (1326) between the carriers for the pressure element (134) to be placed on the table (132). Said intermediate space (1326) improves the folding accuracy of the mattress (Y).

[0039] The table (132) consists of at least two, preferably three parts. There is at least one first carrier (1321) and at least one second carrier (1322) on the table (132). In the preferred embodiment of the invention, in addition to the first carrier (1321) and the second carrier (1322), there is at least one third carrier (1323) positioned next to them. The first carrier (1321), the second carrier (1322) and the third carrier (1323) are substantially conveyors. The first carrier (1321), the second carrier (1322) and the third carrier (1323) each include at least one band (1324) and at least one carrier drive element (1325) to rotate said band around itself. On the table (132), the first carrier (1321) is in the center, the second carrier (1322) and the third carrier (1323) are positioned on either side of the first axis (I). The first carrier (1321), the second carrier (1322) and the third carrier (1323) are positioned in the direction of the first axis (I) and advance the mattress (Y) by folding it in the direction of the first axis (I). At least one of the first carrier (1321), second carrier (1322) and third carrier (1323) is in a vacuum structure. In the preferred embodiment of the invention, only the first carrier (1321) is in a vacuum structure. In this way, it is provided that the mattress (Y) is advanced with the desired precision.

[0040] The first carrier (1321) is connected to a first drive element (13211) for at least partial movement on the table (132) in the vertical axis (III) (assumed to be perpendicular to the ground). By means of the first drive element (13211), the first carrier (1321) can be approached or moved away from the pressure element (134). The second carrier (1322) and the third carrier (1323) are configured to be at least partially displaced on the vertical axis (III) and at the same time to approach and move away from the first carrier (1321). The fact that the second carrier (1322) and the third carrier (1323) are moved relative to the first carrier (1321) also means that they are moved on the second axis (II). The second axis (II) is essentially the axis perpendicular to the first axis (I) and parallel to the ground. Therefore, the second carrier (1322) and the third carrier (1323) each include at least one movement mechanism (135). At least one of the first carrier (1321), second carrier (1322) and third carrier (1323), preferably each of them, includes at least one roll (1327). Said roll (1327) is configured to rotate freely around itself to prevent damage to the mattress (Y) during folding.

[0041] The movement mechanism (135) is located between the chassis (131) and the table (132), especially between the second carrier (1322) and the third carrier (1323). The movement mechanism (135) includes at least one first part (1351) and at least one second part (1352). Said first part (1351) is located on the chassis (131). Said second part (1352) is positioned on the table (132). The first part (1351) is configured to be at least partially displaced on the chassis (131) in the direction of the second axis (II). Therefore, the movement mechanism (135) includes at least one first part drive element (13511). The first part (1351) drive element moves the first part (1351) on the second axis (II) by means of at least one belt (13512). The second part (1352) is connected to the first part (1351) in such a way that it is at least partially displaced on the vertical axis (III). Therefore, the movement mechanism (135) includes at least one second part drive element (13521). By means of the movement mechanism (135), the second carrier (1322) and the third carrier (1323) are displaced both in the vertical axis (III) and in the second axis (II), allowing the mattress (Y) to be folded over each other.

[0042] FIG. 4 shows a representative perspective view of the folding unit (13) of the invention in its first folding position (P1). Accordingly, when the mattress (Y) is desired to be folded in single layer, the mattress (Y) is placed on the table (132) and the pressure element (134) is moved in the vertical axis (III) and the mattress (Y) is compressed from two opposite sides. Subsequently, one of the second carrier (1322) and the third carrier (1323) (preferably the second carrier (1322)) are moved in the vertical axis (III) and the second axis and positioned on the first carrier (1321). Finally, the conveyor-shaped carriers move the mattress (Y) from both sides on the first axis (I) and advance it to the roll unit (14). Thus, the mattress (Y) is folded in single layer and transferred to the roll unit (14).

[0043] FIG. 5 shows a representative perspective view of the folding unit (13) of the invention in its second folding position (P2). Accordingly, when the mattress (Y) is desired to be folded in two layers, the mattress (Y) is placed on the table (132) and the pressure element (134) is moved in the vertical axis (III) and the mattress (Y) is compressed from two opposite sides. Subsequently, the second carrier (1322) and the third carrier (1323) are moved successively on the vertical axis (III) and the second axis (II) and positioned on the first carrier (1321). Finally, the conveyor-shaped carriers move the mattress (Y) from both sides on the first axis (I) and advance it to the roll unit (14). Thus, the mattress (Y) is folded in two layers and transferred to the roll unit (14).

[0044] In the preferred embodiment of the invention, there is at least one pushing arm (1328) in the folding unit (13). Said pushing arm (1328) is configured to be moved in the direction of the first axis (I) in the folding unit (13). In this way, the backflow between the carriers is prevented when the mattress (Y) is moved on the first axis (I).

[0045] Some of the benefits provided by this structure of the mattress packaging line (10) are as follows:

[0046] Efficiency and High Production Capacity: The modular and synchronized design of this structure optimizes the packaging process of mattress (Y) and enables high production capacity. Each unit works in harmony, creating an efficient production flow.

[0047] Fast Production and Response Time: Thanks to this structure, the mattresses (Y) can be produced serially, thus responding quickly to increases in demand. Synchronization of the production processes supports fast and on-time production.

[0048] Space Saving: Positioning the mattress packaging line (10) in a narrow and long structure saves production space and enables more effective use.

[0049] Ease of Use and Control: Each unit is designed to be easily accessible and controllable for operators carrying out different production stages of the mattress (Y).

[0050] Ease of Packaging and Transportation: The folding unit (13) and the roll unit (14) ensure that the mattresses (Y) take up less space during transportation and storage, reducing logistics costs.

[0051] The scope of protection of the invention is described in the attached claims and cannot be limited to what is explained in this detailed description for the exemplary purposes. It is clear that a person skilled in the art can produce similar embodiments in the light of what is explained above, without deviating from the main theme of the invention.REFERENCE NUMBERS IN THE DRAWINGS10 Mattress Packaging Line

[0053] 11 Package Unit

[0054] 12 Pressing Unit

[0055] 13 Folding Unit

[0056] 131 Chassis

[0057] 132 Table

[0058] 1321 First Carrier

[0059] 13211 First Drive Element

[0060] 1322 Second Carrier

[0061] 1323 Third Carrier

[0062] 1324 Band

[0063] 1325 Carrier Drive Element

[0064] 1326 Intermediate Space

[0065] 1327 Roll

[0066] 1328 Pushing Handle

[0067] 133 Bridge

[0068] 1331 Strut

[0069] 1332 Extension

[0070] 134 Pressure Element

[0071] 1341 Pressure Component

[0072] 1342 Support

[0073] 1343 Pressure Drive Element

[0074] 135 Movement Mechanism

[0075] 1351 First Part

[0076] 13511 First Part Drive Element

[0077] 13512 Belt

[0078] 1352 Second Part

[0079] 13521 Second Part Drive Element

[0080] 14 Roll Unit

[0081] P0 Pressure Position

[0082] P1 First Folding Position

[0083] P2 Second Folding Position

[0084] I First Axis

[0085] II Second Axis

[0086] III Vertical Axis

[0087] Y Mattress

Examples

Embodiment Construction

[0030]In this detailed description, the subject of the invention is only described with the examples without any limiting effect for a better understanding of the subject.

[0031]FIG. 1 shows a representative perspective view of the mattress packaging line (10) on which the folding unit (13) of the invention is located. Accordingly, the mattress packaging line (10) of the invention is configured to allow the manufactured mattress (Y) to be packaged. For this purpose, the mattress packaging line (10) includes at least one packaging unit (11), at least one pressing unit (12), at least one folding unit (13) and at least one roll unit (14). With these units working synchronously with each other, the mattress (Y) can be packaged in a predetermined manner.

[0032]The packaging unit (11) located in the mattress packaging line (10) includes the basic stage in which the packaging begins after the mattress (Y) is manufactured. At this stage, the mattress (Y) is positioned in a packaging material ...

Claims

1. A folding unit to allow a mattress to be folded on a first axis in a mattress packaging line, wherein the folding unit comprises at least one table and at least one pressure element for at least partial compression of the mattress positioned on the table in a vertical axis,at least one first carrier and at least one second carrier for folding the mattress on the table, andat least one movement mechanism, wherein at least one of the first carrier and the second carrier are connected to the movement mechanism in a way, and the way allows the first carrier and the second carrier to be moved on a second axis and the vertical axis to be folded over each other,wherein at least one of the first carrier and the second carrier is in a form of a conveyor to advance the mattress on the first axis.

2. The folding unit according to claim 1, wherein the folding unit is positioned upstream of at least one roll unit positioned in an extending direction of the first axis.

3. The folding unit according to claim 1, wherein the table comprises at least one third carrier for folding the mattress twice.

4. The folding unit according to claim 1, wherein the movement mechanism is located on both the second carrier and a third carrier.

5. The folding unit according to claim 1, wherein at least one of the first carrier, the second carrier, and a third carrier is in a vacuum structure.

6. The folding unit according to claim 5, wherein the first carrier is in the vacuum structure.

7. The folding unit according to claim 1, wherein the movement mechanism comprises at least one first part positioned on a chassis and at least one second part positioned on the table, the first part is configured to be moved in a direction of the second axis, and the second part is configured to be moved in the vertical axis.

8. The folding unit according to claim 1, wherein the folding unit comprises at least one first drive element to move the first carrier in the vertical axis.

9. The folding unit according to claim 1, wherein the folding unit comprises at least one bridge for positioning the pressure element on the table.

10. The folding unit according to claim 1, wherein the folding unit comprises at least one pressure drive element, wherein the pressure element is connected to the pressure drive element to move the pressure element on the vertical axis.

11. The folding unit according to claim 1, wherein the folding unit comprises at least one pushing handle in addition to conveyor-shaped carriers for advancing a folded mattress on the first axis.

12. The folding unit according to claim 1, wherein the folding unit comprises at least one roll to protect the mattress while folding on the table.

13. The folding unit according to claim 1, wherein the folding unit comprises at least one intermediate space on the table to allow the pressure element to be at least partially embedded therein.

14. The folding unit according to claim 1, wherein the folding unit comprises at least one pressing unit upstream of a first axis direction and at least one roll unit downstream thereof to advance the mattress in the first axis.

15. A method for operating a folding unit to allow a mattress to be folded while being advanced on a first axis in a mattress packaging line wherein the method comprises steps ofpositioning the mattress on a table,compressing the mattress by moving at least one pressure element on a vertical axis,folding at least one of a first carrier and a second carrier over the other, andproviding the first carrier and the second carrier to advance the mattress on the first axis with a conveyor structure.

16. The folding unit according to claim 3, wherein the movement mechanism is located on both the second carrier and the third carrier.

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