Foam Mattress Packaging With Heat-Sealed Recyclable Paper
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Solution Overview
Problem
Existing methods for packaging foam mattresses are complex, require manual labor, and use environmentally unfriendly, non-recyclable plastic films, necessitating a more efficient and eco-friendly alternative.
Innovation Solution
Utilizing a paper web coated with a thin layer of weldable material, such as thermoplastic polyurethane, to create a recyclable packaging that securely holds the compressed foam mattress, achieved through welding and cutting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic film is used to secure the compressed foam mattress, then the packaging is secure and protective, but the packaging becomes environmentally unfriendly and non-recyclable
Solution Approach 1:
The patent changes the material parameter from plastic to paper, specifically using a paper web with a melting point between 150-200°C. This parameter change enables the material to be recyclable and environmentally friendly while still providing secure packaging through controlled melting and welding processes that create strong seals.
Solution Approach 2:
The patent creates a composite material by combining paper with a heat-sealable coating layer. This composite structure leverages the recyclability and eco-friendliness of paper while adding the heat-sealing properties needed for secure packaging, resolving the contradiction between environmental friendliness and packaging security.
2Object-affected harmful factors
If paper web is used without weldable coating, then the packaging is environmentally friendly, but the paper tears or fails to seal with sufficient strength
Solution Approach 1:
The patent changes the physical-chemical parameters of the paper web by introducing a heat-sealable coating with specific melting properties (150-200°C). This enables the paper to be welded together through controlled heating, achieving strong seals while maintaining the environmental benefits of paper packaging.
3Strength
If sufficient time is allowed for adhesive bond to cure, then the bonding strength is sufficient, but the production process becomes uneconomical due to time required
Solution Approach 1:
The patent replaces the chemical adhesive bonding process with a thermal welding process. Instead of using adhesives that require time to cure, the heat-sealable coating is melted and welded together through applied heat and pressure, creating strong bonds immediately without waiting for chemical curing, thus significantly improving production speed.
Solution Approach 2:
The patent utilizes the phase transition of the heat-sealable coating from solid to liquid (melting) and back to solid (cooling). This phase transition enables rapid welding of the paper web without requiring time-consuming adhesive curing, as the material can be melted and sealed instantly through controlled heating and cooling cycles.
4Ease of manufacture
If existing packaging methods are used, then the packaging process is established, but the process is complex and requires manual work
Solution Approach 1:
The patent merges multiple packaging operations into a single integrated process. The paper web is applied, welded, and sealed in one continuous operation through a unified packaging system, eliminating the need for separate manual steps and reducing overall system complexity while simplifying manufacturing.
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
Enables compact, easy-to-implement, and environmentally friendly packaging of foam mattresses, reducing packaging size and eliminating the need for plastic, while maintaining structural integrity.
Implementation Method 1
welding the paper web on the rear side in the direction of travel by creating at least one weld seam to connect the laterally projecting edge areas of the paper web
Implementation Method 2
the weldable material arranged inside is heated and welded under pressure
Implementation Method 3
the entire foam mattress is compressed using a stamp or roller, allowing the air contained in the foam to escape
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: - guiding the foam mattress (20) through a paper web curtain (25) of a paper web (26) which is essentially made of paper (41) and coated on one side with a weldable material (43), - welding the paper web (26) in the area of the side located at the rear in the direction of movement of the foam mattress (20) by creating at least one weld seam (45) to join the laterally projecting edge areas, so that the top (28) and the bottom (30) are joined to form a paper package (32) and two lateral openings (34) remain, - separating the paper package (32) from the remaining paper web (26) connected to the paper package (32), wherein a separation line (47) created by the separation runs along the weld seam (45),that both the paper packaging (32) and the remaining detached paper web (26) are welded, - Compressing the foam mattress (20), - Closing the side openings (34) by welding. - Folding or rolling up the packaged foam mattress (20), - Fixing the mattress roll (38) with a fixing agent (40) to prevent it from returning to its original shape.