Process for packaging a mattress

Abstract

The present invention relates, in general, to a process for packaging a mattress. More particularly, it relates to a process for packaging a mattress so as to minimize bulk, while keeping the structural characteristics of the mattress unchanged and preserving its integrity.

Description

[0001] PROCESS FOR PACKAGING A MATTRESS

[0002] Specification

[0003] The present invention relates, in general, to a process for packaging a mattress.

[0004] More particularly, it relates to a process for packaging a mattress so as to minimize bulk, while keeping the structural characteristics of the mattress unchanged and preserving its integrity.

[0005] As is known, the problem of bulk in the marketing of mattresses has represented a significant challenge in the sector.

[0006] To solve this problem, various solutions have been developed, including simple packaging, compression packaging, vacuum rolling, and vacuum rolling with folding.

[0007] The latter technology represents the most recent evolution in the sector, making it possible to further reduce the space occupied by mattresses before shipment.

[0008] In the vacuum rolling with folding procedure, the mattress is initially bagged and subjected to pressing. In this step, the product is wrapped in an antistatic polyethylene film, while closure of the edges is performed by a transverse sealing bar.

[0009] Subsequently, a hydraulic press uniformly compresses the mattress, limiting distortion of the product.

[0010] After th is first step, if the required packaging provides for folding, the mattress is transferred onto a folding machine, where it is folded in half or into three parts along the long side. If, on the other hand, folding is not necessary, the product is sent directly to the rolling machine.At this point, the mattress is brought into the rolling machine, where it is progressively compressed and rolled until the final format is reached. During this step, the product can be sealed with a tail closure, wrapped in a polyethylene film or in stretch film for greater protection.

[0011] The final result is a cylinder of variable dimensions, ready to be shipped with or without further outer packaging.

[0012] Vacuum rolling, even when with folding, has some critical issues.

[0013] One of the main problems is the ratio between the height of the mattress and the diameter of the rolled cylinder: the greater the height of the mattress, the greater the diameter obtained after rolling, limiting the possibility of further reducing bulk.

[0014] Moreover, the rolling process applies non-uniform mechanical pressure on the surface of the mattress, causing deformations and potential structural damage.

[0015] This irregular stress can compromise the quality of the product, making further integrity checks necessary after packaging.

[0016] The purpose of the present invention is to provide a process for packaging a mattress that overcomes the problems of the known art.

[0017] A further purpose is to provide a process for packaging a mattress that makes it possible to obtain a final package that is compact and easy to handle.

[0018] A still further purpose is to provide a process for packaging a mattress that makes it possible to have a mattress which, once unpacked, is quickly usable and does not show non-conformities due to the packaging itself.

[0019] These and other purposes are achieved, according to the invention, by a process for packaging a mattress according to the appended claims.

[0020] The process is based on a process comprising bagging and compression of the mattress, followed by at least one folding, longitudinal or transverse, so as toobtain a compact parallelepiped final format.

[0021] Once folded, the mattress can be sealed and subjected to further pressing, ensuring an optimal reduction in volume and better protection against external agents.

[0022] The invention makes it possible to obtain a more effective reduction in bulk compared to the rolling technique, without compromising the quality of the mattress.

[0023] Moreover, the uniform compression applied during the process ensures better preservation of the internal structure of the product, avoiding the irregular deformations that occur in traditional processes.

[0024] Further features and details may be better understood from the following description, given by way of non-limiting example, as well as from the attached drawing table, in which:

[0025] figure 1 is a schematic view of the packaging process according to the invention, identifying six successive packaging steps.

[0026] With reference to the attached figures, 10 identifies a mattress that must be packaged so as to reduce its dimensions as much as possible for transport, while at the same time keeping its characteristics intact once unpacking has been carried out.

[0027] In the first step (step 1), bagging and compression of the mattress 10 take place.

[0028] In this step, the product is wrapped with a high-strength polyethylene protective film, while the press exerts uniform compression to reduce its thickness.

[0029] A mattress 10' is thus obtained, which is moved in step 2 from the press to a folding machine.

[0030] In the subsequent step 3, the first folding step takes place, namelylongitudinal folding, in which the mattress 10' is folded along the longer side into three parts along two first folding lines 12, 14. This operation makes it possible to significantly reduce its length, optimizing the occupied space.

[0031] Subsequently, in step 4, the second folding step takes place, namely transverse folding, in which the mattress 10" is folded along the shorter side into three parts along two second folding lines 16, 18.

[0032] This operation makes it possible to further reduce its dimensions.

[0033] Subsequently, in step 5, the mattress 10"' is sealed and pressed, obtaining the mattress 10iv in the final configuration.

[0034] In fact, once the foldings have been completed, the mattress is again subjected to compression and sealed in order to ensure its stability and prevent the passage of air into the package.

[0035] Finally, in the last step, step 6, the mattress 10iv is brought to the shipping area.

[0036] The mattress, now completely packaged, has assumed a rectangular parallelepiped shape, thus proving easier to handle and more suited to the logistical requirements of the sector.

[0037] The foldings may vary in number, for example two or four folds instead of three, depending on packaging requirements.

[0038] Moreover, it is possible to first carry out one or more foldings transversely, that is, on the shorter side, and then carry out one or more foldings of the longer side.

[0039] Variants and embodiments different from those previously illustrated are possible, and are to be considered as comprised within the scope of protection defined by the appended claims.For example, it is possible to modify the type of material used for bagging in order to obtain greater strength and better vacuum tightness.

[0040] Moreover, according to a variant of the invention, the process forming the subject matter of the invention provides for bagging and compression of the mattress. The package comprising the mattress thus bagged is vacuum -packed so as to further reduce its dimensions and keep the mattress itself intact during the storage steps.

[0041] Subsequently, folding of the bagged and compressed mattress takes place, with the related package being vacuum-packed.

[0042] In particular, the folding may be longitudinal or transverse, or one or more longitudinal folds and / or one or more transverse folds may be carried out.

Claims

CLAIMS1)A process for packaging a mattress (10), characterized in that it comprises at least one of the following steps:- at least one longitudinal folding of a mattress (10') into at least two parts;- at least one transverse folding of the mattress (10") into at least two parts.2)A process for packaging a mattress (10) according to the preceding claim, wherein both of the following steps take place:- at least one longitudinal folding of a mattress (10') into at least two parts;- at least one transverse folding of the mattress (10") into at least two parts.3)A process for packaging a mattress (10) according to the preceding claim, wherein the longitudinal folding takes place before the transverse folding.4)A process for packaging a mattress (10) according to claim 2, wherein the transverse folding takes place before the longitudinal folding.5)A process for packaging a mattress (10) according to any one of the preceding claims, wherein, before the folding steps, the following step takes place:- bagging of the mattress (10).6)A process for packaging a mattress (10) according to the preceding claim, wherein, before the folding steps, and after bagging of the mattress, the bagged mattress is vacuum-packed and / or compressed.7)A process for packaging a mattress (10) according to the preceding claim, wherein in the bagging and compression of the mattress (10) the product is wrapped with a high-strength polyethylene protective film, while the press exerts uniform compression to reduce its thickness.8)A process for packaging a mattress (10) according to any one of the preceding claims, wherein, after the folding steps, the following operations take place:sealing and final pressing of the mattress (10"').9)A process for packaging a mattress (10) according to any one of the preceding claims, wherein in the longitudinal folding the mattress is folded along the longer side into at least two parts along at least one first folding line (12, 14).10) A process for packaging a mattress (10) according to any one of the preceding claims, wherein in the transverse folding the mattress is folded along the shorter side into at least two parts along at least one second folding line (16, 18).11) A process for packaging a mattress (10) according to any one of the preceding claims, wherein, following the folding steps, the mattress assumes a compact final configuration that is substantially parallelepipedal.12) A process for packaging a mattress (10) according to claim 11, wherein said final configuration is a rectangular parallelepiped.13) A process for packaging a mattress (10) according to any one of claims 2 to 12, wherein the longitudinal folding takes place by folding the mattress along the longer side into three parts along two first folding lines (12, 14).14) A process for packaging a mattress (10) according to any one of claims 2 to 13, wherein the transverse folding takes place by folding the mattress along the shorter side into three parts along two second folding lines (16, 18).15) A process for packaging a mattress (10) according to any one of claims 6 to 14, wherein, after bagging and compression of the mattress, the package comprising the mattress is vacuum -packed, so as to further reduce its dimensions and keep the mattress itself intact during the storage steps.16) A process for packaging a mattress (10) according to claim 15, wherein the folding is carried out on the bagged and compressed mattress, with the related package being vacuum-packed.17) A process for packaging a mattress (10) according to any one of claims 8 to 16, wherein, once the foldings have been completed, the mattress is again subjected to compression and sealed in order to ensure its stability and prevent the passage of air inside the package.18) A process for packaging a mattress (10) according to any one of claims 9 to 17, wherein the longitudinal folding and / or the transverse folding are carried out with a number of folds equal to two or four.19) A process for packaging a mattress (10) according to any one of claims 2 to 18, wherein the process comprises a plurality of longitudinal foldings and / or a plurality of transverse foldings.20) A process for packaging a mattress (10) according to any one of the preceding claims, wherein, after a first bagging and compression step, the mattress is transferred from a press to a folding machine.21) A process for packaging a mattress (10) according to any one of the preceding claims, wherein, before the folding steps, the mattress is bagged and is vacuum-packed and / or compressed, wherein the process comprises at least one longitudinal folding of the mattress and at least one transverse folding of the mattress, and wherein, after the folding steps, the mattress is sealed and subjected to final pressing, so as to obtain a compact final configuration that is substantially parallelepipedal.22) A process for packaging a mattress (10) according to any one of the preceding claims, wherein, before the folding steps, the mattress is bagged and compressed, wherein the process comprises a longitudinal folding of the mattress and subsequently a transverse folding of the mattress, and wherein, after the folding steps, the mattress is sealed and pressed again, so as to obtain a compact finalconfiguration that is substantially parallelepipedal.

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