Machine for packaging mattresses

The machine (100) comprises a supply station (S1) destined to receive a mattress (M) to be conveyed to a rolling station (S2) comprising a plurality of rolling rollers (1), partly arranged in a fixed section (21) of the station (S2) and partly arranged in an openable section (22), arranged in respective curved lines to define internally thereof a practically-cylindrical rolling chamber (10) with horizontal axes. Sliding organs (3) are interposed between the fixed section (21) and the openable section (22), for regulating a mutual distance between the fixed section (21) and the openable section (22) in order to vary, within a predetermined range, a base area of the rolling chamber (10) and in order to determine corresponding rolling diameters of the mattress (M) comprised between a minimum value (D1) and a maximum value (D2).

TECHNICAL FIELD

The invention relates to the technical sector of mattress packaging.

For mattresses made of a spongy material, for example latex, and not provided with springs, the prior art comprises a packaging process which includes spiral-rolling of the mattress and the stabilizing of the resulting configuration, for example by insertion thereof in a bag.

The rolling operation can be preceded by a stage of compressing the mattress in order to reduce the thickness thereof and therefore to reduce to the maximum diameter of the spiral-rolled mattress.

BACKGROUND ART

On Aug. 9, 2005, the present applicant obtained an Italian patent for industrial invention, no. 1,329,172, relating to a “Method and Apparatus for Packaging Mattresses”.

The above-mentioned patent concerns mattresses already inserted in corresponding enveloping bags, which are supplied to a press with the open side of the bag facing upstream, and are there subjected to a compressing action which reduces the thickness thereof.

At the end of the compressing action, a welding bar is activated to stably join the flaps of the bag about the mattress, thus preventing the mattress from newly expanding after the press is re-opened.

The bag is advantageously of a size such that posteriorly of the welding there remains a length, or “tail” which is destined to receive, at the transversal end edge, a strip of adhesive tape, which at the end of the rolling process will stabilize the spiral configuration of the mattress.

The apparatus of the above-cited patent advantageously exhibits a spiral-rolling station which comprises two half-shells, of which one is fixed and the other is hinged thereto, such as to be able to open inferiorly in order to enable the completed package to be unloaded.

A first operating limit of the above technical solution relates to the fact that the apparatus can only roll mattresses inserted in bags, and the bags must be of a suitable length to enable stabilization, using adhesive tape, of the above-mentioned spiral-rolled configurations.

Further, the above-described apparatus is conformed such that the external diameter of the roll obtained is fixed, independently of the thickness of the mattress.

In other words, a smaller spiral cannot be obtained to reduce overall packaged size, when the thickness of the mattress would permit such a reduction, and vice versa.

SUMMARY OF THE INVENTION

The aim of the present invention is thus to provide a machine for packaging mattresses which is conformed such as to enable a variation in rolled-up diameter from a minimum to a maximum, to be defined according to the thickness thereof.

A further aim of the invention consists in providing a machine which can package mattresses independently of the fact that they are already packaged, or not, in a relative bag.

The above mention aims are obtained, in accordance with the contents of the claims, by a machine for packaging mattresses, of a type comprising a supply station destined to receive a horizontally-arranged mattress to be conveyed to a rolling station comprising a plurality of rolling rollers, partly arranged in a fixed section of the station and partly arranged in an openable section, arranged in respective curved lines to define internally thereof a practically-cylindrical rolling chamber, the machine being characterized in that it further comprises sliding organs, interposed between the fixed section and the openable section, for regulating a mutual distance between the fixed section and the openable section in order to vary, within a predetermined range, a base area of the rolling chamber and in order to determine corresponding rolling diameters of the mattress comprised between a minimum value and a maximum value.

BEST MODE FOR CARRYING OUT THE INVENTION

With reference to the above-mentioned figures of the drawings,100denotes in its entirety the packaging machine of the invention, comprising, in a known way, a supply station S1destined to receive a horizontally-lying mattress M, to be conveyed to a rolling station S2, arranged downstream of the supply station S1, in which rolling station S2the mattress M will be spiral-rolled in order to facilitate transport and stocking thereof.

In the illustrated machine100, the supply station S1is provided with known pressors P and welding means (the latter not illustrated) which are made operative only with already-bagged mattresses M (bag B), while for non-bagged mattresses M they are deactivated, as will be more fully explained herein below.

Alternatively, machines can be provided without the pressor organs and the welding means, if the machines are destined only to roll non-bagged mattresses M.

The rolling station S2comprises a plurality of rolling rollers1, arranged partly in a fixed section21of the station S2and partially in an openable section22, in respective curved lines, defining, internally thereof, a rolling chamber10having a practically cylindrical shape and a horizontal axis.

In the fixed section21, means25are located upstream of the rolling chamber10, for supporting the mattress when the mattress arrives in an extended configuration from the supply station S1, and for guiding the mattress towards the upper inlet10A of the rolling chamber10.

The means for supporting and guiding25, in the embodiment of figures from1to6, are constituted by a lower horizontal roller plane26and a deviator roller27, located above the lower horizontal roller plane26, close to the inlet10A.

The deviator roller27intercepts the front end of the mattress M and directs it towards the inlet10A.

In the invention, the machine100comprises sliding organs3, interposed between the fixed and openable sections21and22, which regulate the mutual distance between the fixed and openable sections21and22within a predetermined range, in order to change the base area of the rolling chamber10.

The displacement between the fixed section21and the openable section22gives rise to slight variations in the profile of the base area of the rolling chamber10, due to the fact that the radii of curvature, on which the fixed and openable sections21,22are arranged, are obviously unchanged and the respective centres thereof can coincide only at a predetermined point of the permitted opening between the sections21,22.

In the enclosed figures of the drawings, as a non-limiting embodiment, the profile is seen to be close to a circumference in proximity of the maximum distance position between the fixed section21and the openable section22(FIGS. 6,13), while it is more oval in the minimum distance position (FIGS. 5,12).

However, it is stressed that the above-described variations do not minimally influence the operability of the machine, as it is entirely obvious that the rolled mattress, once it has exited the rolling chamber10, spontaneously finds the regular form to be assumed by elastic reaction.

The sliding organs3are constituted, for example, by horizontal stems30(of which only one is visible inFIGS. 5 and 6) symmetrically arranged and made integral to the sides of the fixed section21, respective sleeves31being slidably coupled to the stems30, the sleeves31being made integral to the bearing structure220of the openable section22.

A horizontal rack32is fixed to at least one of the sleeves31, which rack32is destined to enmesh with a pinion33associated to a motor34, preferably electronically-controlled, for example of the brushless or step type.

The motor34is managed by a control unit, not illustrated; by means of a control panel (also not illustrated) connected to the control unit the operator can set the required measurement for the rolling diameter for the mattress M; there follows activation of the motor34in one direction or another to determine the translation of the openable section22with respect to the fixed section21between the positions corresponding to the minimum base area (FIGS. 1 and 5) and the maximum base area (FIGS. 2 and 6) of the rolling chamber10.

A jack221is associated, in a known way, to the bearing structure220of the openable section22, which jack221commands the rotation of the openable part22according to an axis X that coincides with the axis of a roller IA, for inferiorly opening the rolling chamber10at end of operations.

The machine100further comprises dispensing organs4, associated to the rolling station S2, for supplying the rolling station S2, in phase relation with the rolling of the mattress M, with a film40of waterproof material unwinding from a reel41which will be wound about the mattress M in strict adherence thereto.

The reel41is supported in the upper part of the machine100and the film40, which exhibits a greater width than the width of the mattress M, is unwound in a downwards direction and transits between the dispensing organs4constituted, for example, by transversal pliers42, openable and closable by first jacks43, respectively for allowing transit and holding the film40, with the pliers42activated in a perpendicular direction to the opening and closing direction by second jacks44supported by the bearing structure220of the openable section22(FIGS. 3,4A,4B).

A welding bar5is provided internally of the rolling chamber10, which welding bar5is mobile in a more-or-less vertical direction by action of relative actuators50, also supported on the structure220(FIGS. 5 and 6).

The welding bar5acts transversally on the film40at the end of the winding operation, as will be more fully described herein below.

Finally, the machine100comprises welding means6located downstream of the rolling station S2, which act on the heads of the tubular package which has exited the rolling station S2in order to close and seal the heads (FIGS. 1 and 2).

The functioning of the machine100will now be described; the machine100according to the present invention exhibits various similarities with the apparatus described in the patent belonging to the same applicant and mentioned in the premises to the present document.

Differently to the above-mentioned apparatus, the machine100can package, as already mentioned, mattresses M provided with a bag B or without the bag.

In a case where the mattress M is non-bagged, the pressor organs and the welding means in the supplying station S1are deactivated; the rolling diameter to be obtained is regulated by setting the control panel which commands the motor34of the sliding organs3.

The salient stages of the functioning cycle are schematically illustrated in figures from7to8C, considering, purely by way of example, that as in this case the mattress cannot be pre-compressed, a large-size rolling chamber10is required for a maximum rolling diameter D2.

InFIG. 7, the mattress M, in a stretched configuration, is about to be introduced into the rolling chamber10, in which it is to be spiral-wound, as illustrated inFIG. 8A.

The dispensing organs4are activated in phase-relation with the entrance of the terminal part of the mattress M into the chamber10, with the closing of the transversal pliers42and the descent thereof (see alsoFIG. 4B) in order to introduce the film40into the rolling chamber10, and to enable the film40to be inserted between the mattress M and the rollers1.

The pliers42are then opened and made to rise into the initial position (see alsoFIG. 4A), while the film40is unwound from the reel41and wound, for a predetermined number of revolutions of the reel41, in strict adherence on the mattress M; at this point the welding bar5is activated to descend until it intercepts the tubular package thus realized, in order to cut the now-wound length of film40from the reel41, and to join the posterior end of the cut length of film40to the underlying spires of the same film40(FIG. 8B).

Then the jack221is activated to open the openable section22, enabling the unloading of the tubular package, which package is then conveyed by force of gravity to the welding means6which act on the heads of the package to close and seal them (FIG. 8C).

For mattresses M with envelope-type covers B, the pressors organs P and the connected welding means are activated, then the rolling diameter is regulated which in this case, and purely by way of example, and with the mattress M precompressed, is considered to be the minimum rolling diameter D1.

The mattresses M are introduced into the supply station S1with the open side of the envelope B facing backwards (FIG. 9), and are vertically compressed by the pressor organs P in order to reduce the thickness thereof; the welding means6are activated in phase relation to stabilize the configuration with the closing of the open side (FIG. 10).

The successive stages, illustrated inFIGS. 11A,11B,11C, are the same as those previously described for the unpacked mattress, with reference toFIGS. 8A,8B,8C.

With an already-bagged mattress M, a package is obtained which offers a double protection and enables the final retailer to remove the film40, so that the mattress can be extended, while leaving the mattress itself protected by the bag B.

InFIGS. 12,13two construction variants of the rolling station S2are illustrated, which two variants are preferably used in combination, even though, from a functional point of view, they are independent of one another.

The first of the variants relates to the means25for supporting and guiding the mattress M towards the inlet10A of the rolling chamber10.

Apart from the lower horizontal roller, the means25, in the variant, comprise a second upper horizontal roller28, opposite the first, which is destined to contact the mattress M superiorly.

The horizontal upper roller28is included in place of the deviator roller27and optimizes the same functions as performed by the deviator roller27.

To this end, the upper horizontal roller28is advantageously associated to the bearing structure220of the openable section22, conformed for the purpose.

Consequently, the upper roller28follows the movements of the openable section22in the adjustments of the dimensions of the rolling chamber10, maintaining the same position with respect to the pivot roller1A of the rolling chamber10; thus the roller28is always located ideally for directing the end of the mattress M towards the inlet10A, whatever the size preset for the rolling chamber10, and therefore independently of the variations in the dimensions of the inlet10A which derive therefrom (seeFIGS. 12 and 13).

The second of the variants relates to the low part of the rolling chamber10, in the zone where the two adjacent rollers1B, IC are neared to one another, respectively belonging one to the fixed section21and the other to the openable section22.

Oscillating arms29(of which only one is visible) are hinged to the ends of one of the two rollers, for example the roller1B of the fixed section21; the oscillating arms29rotatably support a supplementary roller1S.

The arms29are activated by an actuator, not illustrated, which determines for them and for the associated supplementary roller15two extreme positions Z1, Z2, one of which positions is a rest position, in which the supplementary roller15is external of the rollers1B,1C and another of which positions is a work position, in which the supplementary roller15is interposed between the rollers1B,1C.

The rest position Z1is set in phase relation with the minimum dimensions of the rolling chamber10, when the fixed section21and the openable section22are close or side-by-side (FIG. 12) and, consequently, the rollers1B,1C are sufficiently close to one another in order to guarantee continuity of the relative rolling diameter.

By increasing the dimensions of the rolling chamber10, with a progressive distancing of the openable section22with respect to the fixed section21, the two rollers1B,1C are distanced and a space is created between them, which interrupts the continuity of the rolling diameter and can cause catching and jagging of the front end of the mattress M in the initial stage of rolling.

When the space between the rollers1B,1C is sufficient, the supplementary roller1S is arranged in the relative work position Z2, interposing between the two, such as to re-establish the continuity (FIG. 13) and ensure a regular rolling operation.

A further construction variant, not illustrated, relates to the location of the welding means6, which instead of being downstream of the rolling station S2, as illustrated, can be placed at the same position thereas.

In this case, the means6comprise, at the sides of the rolling chamber10, pressor organs which act in cooperation with nozzles for blowing hot air, for crushing and welding the film40to the heads of the tubular package obtained after the rolling stage.

With the above-described variant, a finished package is advantageously obtained internally of the rolling chamber10, with obvious savings in terms of times and space occupied.

From the above the advantageous characteristics of the machine of the invention are evident. The invention enables adjustment of the rolling diameter of the mattress from a minimum to a maximum, to be defined according to the thickness of the mattress.

The versatility of the machine is further increased by the fact that mattresses can be packaged independently of whether they have been inserted or not in a bag.

The described machine, in the version comprising all of the variants, exhibits an optimal functioning in any operating condition, guaranteeing a high degree of reliability.

The technical solutions adopted to obtain the peculiarities described above are simple, reliable and with modest costs, such as not to significantly impact on the total costs for realizing the machine.

The above description is, however, intended as a non-limiting example, so any modifications to details, introduced for technical, functional or productive reasons, are considered to enter within the ambit of protection as defined by the following claims.