Double Spiral Roll Packaging for Compressed Mattress Transportation
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Solution Overview
Problem
The high bulkiness of mattresses results in significant transportation and storage costs, necessitating compression and rolling, but further space-saving methods are needed to lower delivery costs to consumers.
Innovation Solution
Packaging two compressed mattresses as a double spiral roll within a cylindrical shape using a rolling wrapper and mechanical roller, with the mattresses sealed in an airtight sheath to prevent expansion, and securing the wrapper with tape after rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If mattresses are rolled and compressed into cylindrical rolls, then transportation and storage space is reduced, but the cost of additional packaging materials and processing increases
Solution Approach 1:
The patent combines two separate mattress packaging operations into a single integrated process. Two mattresses are rolled simultaneously using one roller mechanism and packaged together in a single box, merging what would traditionally be two separate packaging operations into one unified process, thereby reducing overall complexity while maintaining space efficiency
Solution Approach 2:
The mattress rolling process is segmented into distinct phases: the first mattress is rolled completely, then the second mattress is rolled in the same apparatus. This segmentation allows the use of a single complex device for multiple tasks, reducing the need for duplicate equipment while maintaining the space-saving benefits of individual mattress rolling
2Reliability
If two mattresses are packaged separately, then each mattress can be individually protected, but transportation and storage efficiency is reduced
Solution Approach 1:
Two mattresses are merged into a single packaging unit by rolling them together in one box. The mattresses are positioned and rolled in the same apparatus, then secured together with a single packaging system, achieving both individual protection and transportation efficiency through combined packaging
Solution Approach 2:
The second mattress is effectively nested within the same packaging space as the first mattress by rolling both in the same box. The mattresses are arranged and secured in a way that maximizes space utilization while maintaining individual mattress integrity and protection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for more efficient use of space during transportation and storage, reducing costs and enabling mattresses to be sold at a lower price by packaging two mattresses in a single compact unit.
Implementation Method 1
The sheath is sealed such that air is prevented from re-entering the sheath, which would allow the compressed mattress to expand
Data Source
AI summary
Mattresses are packaged by successively rolling two compressed mattresses into a roll in which a rolling wrapper forms a spiral when viewed from an end of the roll. The bottom surface of a first mattress is placed on the wrapper such that the wrapper wraps around a first end of the mattress. The first end is then inserted between the bars of a mechanical roller. The first end is bent over onto the top surface of the mattress, and the mattress is rolled. The bottom surface of a second mattress is placed on the wrapper, and the first mattress is further rolled until successive portions of the bottom surface of the first mattress become adjacent to successive portions of the top surface of the second mattress. The wrapper is cut, and a first location near the cut edge is taped to a second location one revolution earlier on the wrapper.