Mattress Packaging Machine with Adjustable Conveyor Compression

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Solution Overview

Problem

Existing packaging machines for mattresses cause severe warping and creasing due to insufficient compression, necessitating the use of plastic film for protection, which results in waste and inefficiency.

Innovation Solution

A packaging machine with adjustable conveyor belts and synchronized roller rotation minimizes mattress warping by applying controlled compression, using paper-based packaging and eliminating the need for plastic film.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If film packaging is used for mattresses, then protection against soiling and damage is achieved, but plastic waste is generated and disposal effort increases

Engineering Contradiction:

Improveprotection against soiling and damageVSAvoidplastic waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent replaces single-use plastic film with reusable fabric covers that can be removed, cleaned, and reused multiple times. The fabric cover serves the protective function while being sustainable and reusable, directly addressing the waste problem.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The patent changes the material parameter from plastic film to fabric, fundamentally altering the properties of the packaging material to be reusable and environmentally friendly while maintaining protective capabilities.

Inventive Principle:

Principle #35Parameter changes

2Volume of moving object

If low compression is applied during rolling, then mattress structure is preserved, but volume reduction is insufficient

Engineering Contradiction:

Improvetransport volumeVSAvoidmattress structure

Core Design Contradiction:

Volume of moving objectVSShape

Solution Approach 1:

The patent applies preliminary compression during the rolling process itself, integrating the compression function into the rolling mechanism. This allows the mattress to be compressed to a compact form during packaging while the fabric cover protects it, achieving both volume reduction and structure preservation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses a flexible fabric cover that can conform to the compressed mattress shape, providing protection while allowing the necessary compression for volume reduction. The flexible nature of the fabric enables it to adapt to the compressed form without causing damage.

Inventive Principle:

Principle #30Flexible shells and thin films

3Volume of moving object

If high compression is applied during rolling, then volume is reduced, but severe warping and creases occur in the ticking

Engineering Contradiction:

Improvetransport volumeVSAvoidticking integrity

Core Design Contradiction:

Volume of moving objectVSShape

Solution Approach 1:

The flexible fabric cover acts as a protective shell during compression, distributing the compressive forces evenly and preventing direct contact between compression elements and the mattress ticking. This eliminates warping and creases while enabling effective volume reduction.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent provides beforehand protection by enclosing the mattress in a fabric cover before compression occurs. This cushioning layer prevents the compression forces from directly damaging the ticking, avoiding warping and creases.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Speed

If frictional engagement is used to drive mattresses through rollers, then rolling is achieved, but axial ejection is hindered

Engineering Contradiction:

Improverolling speedVSAvoidaxial ejection

Core Design Contradiction:

SpeedVSEase of operation

Solution Approach 1:

The fabric cover creates a smooth surface that reduces friction between the mattress and the rollers during ejection. This flexible shell allows the mattress to be easily pushed axially through the winding drum without the frictional engagement that would otherwise hinder ejection.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The machine achieves tighter mattress rolling with reduced warping, minimizing volume and eliminating plastic waste while ensuring gentle handling and visually appealing rolls.

Implementation Method 1

inserted into a diffusion-permeable packaging, e.g., made of polyethylene

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

The mattress to be conveyed rests on at least one of these conveyor belts, and at least one further one of these conveyor belts rests on the mattress to be conveyed for pre-compression

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP4603401A1Packaging machine

Publication Date: 2025.08.20 FILLMATIC POLSTERIND MASCHEN

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AI summary

The invention relates to a packaging machine 1 for mattresses with a winding drum 3, rollers 10 for rolling mattresses conveyed into the winding drum 9, a drive 11 for rotating the rollers 10, an access 12 for the mattresses to the winding drum 9, which is essentially parallel to the longitudinal axis of the winding drum 9, and a feed area 2 for the mattresses in front of the access 12 for the mattresses to the winding drum 9. The feed area 9 has conveyor belts 3, 4 located at a distance from one another, each of which is separately connected to a motor 7 for conveying mattresses via the conveyor belts 3, 4 to the access 12 of the winding drum 9.