Foam Mattress Packaging Folding and Rolling Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for packaging rectangular foam mattresses result in large packaging sizes during transport and storage, as the compressed mattresses still require significant space, even when rolled up.
Innovation Solution
The method involves folding the foam mattress over its shorter sides and rolling it up along its longer sides to form a mattress roll, which is then secured to prevent re-rolling, allowing for a significant reduction in pack size by making the height of the roll correspond to half of the shorter sides, enabling smaller outer packaging or accommodating two mattresses in a single box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the foam mattress is compressed and rolled up along its longer sides, then the packaging size is reduced, but the height of the roll remains large (equal to the length of the long side)
Solution Approach 1:
The patent changes the dimension along which the mattress is rolled. Instead of rolling along the long side (producing a roll with height equal to the long side), the mattress is folded along the long side and then rolled along the short side. This dimensional change results in a roll height equal to half the short side length, significantly reducing the packaging height and enabling better space utilization in transport and storage.
2Reliability
If the foam mattress is compressed and placed in outer packaging, then the mattress is protected, but the packaging requires relatively large space
Solution Approach 1:
The patent applies preliminary actions by first compressing the mattress and then folding it along the long side before rolling and packaging. This preliminary folding action reduces the effective dimensions of the mattress, allowing it to be rolled into a compact cylinder with reduced height, which subsequently fits into smaller outer packaging while maintaining protection.
3Productivity
If the foam mattress is compressed by a stamp or roller, then the air escapes and the mattress is compacted, but the compressed mattress still requires significant space
Solution Approach 1:
The patent segments the packaging process into distinct stages: compression, folding, and rolling. By separating the folding action from the rolling action and performing the fold along the long side before rolling along the short side, the method achieves more efficient volume reduction. This segmentation allows each action to optimize the shape and dimensions for the next step, resulting in a more compact final package.
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 approach reduces the packaging height by half, allowing for either smaller packaging or the ability to fit two mattresses in a standard-sized box, thereby simplifying transport and storage by minimizing space requirements.
Implementation Method 1
the entire foam mattress is compressed by a stamp or roller, causing the air contained within the foam to escape
Implementation Method 2
secure the mattress roll with a fixing agent to prevent it from unrolling
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a method for packaging a rectangular foam mattress. The method comprises the following steps: - compressing the foam mattress, - folding the foam mattress along its shorter sides, - rolling the foam mattress along its longer sides to form a mattress roll, - fixing the mattress roll with a fixing agent to prevent it from unrolling. The invention further comprises a rectangular foam mattress packaged in an outer packaging.