Mattress Folding Device for Low-Plastic Compression Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mattress packaging methods result in significant plastic waste and increased shipping costs due to the use of vacuum-sealed film webs and securing agents, which are necessary for maintaining the compressed state of rolled mattresses.
Innovation Solution
A folding device comprising two rectangular belts with a movable lifting bar and a hold-down device that compresses and folds mattresses without vacuum packaging, utilizing an electronic control system to manage the folding process, allowing for automated 'nano-packaging' and reducing the need for plastic film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum-sealed film webs and securing agents are used to package rolled mattresses, then the mattresses can be maintained in a compressed state for transport, but plastic waste increases and shipping costs rise
Solution Approach 1:
The invention extracts and eliminates the film web and securing agent from the packaging system. Instead of using external plastic materials to maintain compression, the mattress is folded and rolled using only its own structural properties, removing the source of plastic waste while maintaining the compressed state through mechanical folding geometry
Solution Approach 2:
The mattress serves its own packaging function through its inherent material properties. The folding mechanism uses the mattress's own elasticity and structural characteristics to maintain compression without external securing agents, allowing the product to package itself without additional plastic materials
2Volume of moving object
If vacuum-sealed film webs are used to package mattresses, then the mattresses can be compressed and maintained in a reduced volume, but the complexity of the packaging process increases
Solution Approach 1:
The invention removes the vacuum sealing equipment and film web supply system from the packaging process. The folding device uses simple mechanical belts and folding bars to achieve compression, eliminating complex vacuum technology while maintaining reduced packaging volume through pure mechanical folding actions
Solution Approach 2:
The invention changes the packaging approach from vacuum-based compression to folding-based compression. By altering the fundamental mechanism from removing air to creating folded geometric structures, the system achieves volume reduction through simpler mechanical means that don't require complex vacuum equipment
3Stability of the object's composition
If securing agents are applied to prevent mattress rolls from re-rolling, then the mattresses remain stable during transport, but additional materials and costs are incurred
Solution Approach 1:
The invention extracts the securing agent from the system entirely. The folded mattress structure maintains its stability through its geometric configuration and the mechanical constraints of the folding device, eliminating the need for additional securing materials while preventing re-rolling during transport
Solution Approach 2:
The folded mattress structure is self-stabilizing through its geometric design. The multiple folds and compression create internal structural integrity that prevents spontaneous re-rolling, allowing the mattress to maintain stability without external securing agents
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
Significantly reduces packaging size and plastic consumption, enabling the use of smaller boxes for shipping, while eliminating the need for vacuum film and securing agents, thus lowering costs and waste.
Implementation Method 1
The second of the substantially rectangular belts is pivotally mounted on the lifting bar for folding and compressing a mattress positioned by the positioning bar over the two belts and the lifting bar
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a folding device (1) for mattresses, comprising first and second essentially rectangular belts (2, 3) which are separate and adjacent to one another to form a common plane as a support for mattresses, a lifting bar (6) which is movable essentially perpendicular to the plane between the first and second rectangular belts (2, 3), a mobile hold-down device (9) which is movable over the first belt (2) and a mattress lying thereon, and a positioning bar (11) which is movable over this first belt (2) for positioning a mattress lying thereon over the first and second belts (2, 3) and the lifting bar (6). The second belt (3) is pivotally mounted on the lifting bar (6) for folding and compressing a mattress positioned by the positioning bar (11) and fixed by the hold-down device (9) on the first belt (2).