Patent Publication Number: US-7895813-B2

Title: Method for preparing mattresses for shipment

Description:
This application is a continuation of and claims the priority date of Utility Application Ser. No. 11/581,200, entitled METHOD AND SYSTEM FOR PREPARING MATTRESSES FOR SHIPMENT, filed on Oct. 13, 2006, now issued U.S. Pat. No. 7,458,193, which this application incorporates by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     A method for packaging multiple bedding products, more particularly a method for packaging multiple compressed mattresses or futons together for sea and land transportation. 
     BACKGROUND OF THE INVENTION 
     Present methods for packaging an individual mattress or another compressible bedding product employ compression and/or application of a vacuum to ensure ease of transport of the individual mattress. Other bedding components, such as one or more pillows, a topper, a duvet or bed covering, etc, may be vacuum packed and compressed along with the mattress for shipment. 
     Present methods address neither mass merchant size shipments where dozens of mattresses form a shipment nor reliability issues encountered by the compressed individual mattresses during shipment. An air leak at a sealed end of the mattress packaging results in decompression of the previously compressed mattress during transport or storage. Usually, no facility is available to recompress the mattress and to permit transportation of the mattress in a compressed state for the remainder of the trip. 
     It would be advantageous for mattresses to be bulk packaged for shipment in such a way as to preserve their compression in spite of failures of sealing systems. 
     BRIEF SUMMARY OF THE INVENTION 
     The needs of the invention set forth above as well as further and other needs and advantages of the present invention are achieved by the embodiments of the invention described herein below. 
     According to one aspect of the present invention, a method for preparing mattresses for shipment includes compressing individually a plurality of mattresses, placing the plurality of compressed mattresses on a first support, placing a second support on top of the plurality of compressed mattresses, compressing further the plurality of compressed mattresses between the first support and the second support, and coupling the first support and the second support together where coupling restrains expansion of the plurality of further compressed mattresses. 
     In some embodiments according to the present invention, compressing individually the plurality of mattresses may include compressing individually the plurality of mattresses to a predetermined-set height. In other embodiments according to the present invention, the method may also include placing each of the plurality of mattresses within an air-impervious bag prior to compressing each of the plurality of mattresses. The air-impervious bag may be sealed after compressing each of the plurality of mattresses. An open end of the air-impervious bag may be sealed with a heated element. Prior to sealing the air-impervious bag, the air-impervious bag may be substantially evacuated. 
     In further embodiments according to the present invention, placing the plurality of compressed mattresses on a first support may include, but is not limited to, placing at least ten compressed mattresses on the support. Placing the plurality of compressed mattresses on a first support may also include, but is not limited to, placing twenty-two or fewer compressed mattresses on the support. 
     In additional embodiments according to the present invention, compressing further the plurality of compressed mattresses between the first support and the second support may include compressing the plurality of compressed mattresses to another predetermined-set height. In some embodiments according to the present invention, compressing further the plurality of compressed mattresses between the first support and the second support may include compressing with a press. In certain embodiments according to the present invention, the first support may be a shipping palette. In still other embodiments according to the present invention, the second support may be a shipping palette. In still further embodiments according to the present invention, at least one band may be placed around the first support, the second support, and the plurality of further compressed mattresses and may be tightened. The at least one band may include a steel band. Tightening the at least one band may include tightening with a steel strapping tensioner. A first and a second end of the at least one band may be coupled with a double notched steel strapping sealer. In still additional embodiments according to the present invention, exposed surfaces of the further compressed plurality of mattresses, coupled to the first support and to the second support, may covered with a wear-resistant material. 
     According to another aspect of the invention, a system for preparing mattresses for shipment includes means for compressing individually a plurality of mattresses, means for placing the plurality of compressed mattresses on a first support, means for placing a second support on top of the plurality of compressed mattresses, means for compressing further the plurality of compressed mattresses between the first support and the second support, and means for coupling the first support and the second support together, where the means for coupling restrains expansion of the plurality of further compressed mattresses. 
     In certain embodiments according to the invention, the system may include means for sealing an open end of an air-impervious bag enclosing the individual compressed mattress. The system may include means for evacuating substantially the air-impervious bag. In other embodiments according to the present invention, the system may include means for detecting compression of the individual mattress to a predetermined-set height. 
     For a better understanding of the present invention, together with other and further objects thereof, reference is made to the accompanying drawings and detailed description and its scope will be pointed out in the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a better understanding of the present invention, reference is made to the figures, in which: 
         FIG. 1  is a flowchart of a method according to an embodiment of the present invention for packaging a plurality of mattresses for shipment; 
         FIG. 2  is a pictorial illustration of a prior art mattress enclosed within an air-impervious plastic bag; 
         FIG. 3A  is a pictorial illustration of an embodiment according to the present invention of insertion of a mattress enclosed within an air-impervious bag into a press; 
         FIG. 3B  is a pictorial illustration of an embodiment according to the present invention of placement of a mattress enclosed within an air-impervious bag in a press; 
         FIG. 4A  is a pictorial illustration of an embodiment according to the present invention of placement of a mattress, enclosed within an air-impervious bag, in a press; 
         FIG. 4B  is a pictorial illustration of an embodiment according to the present invention of compression of a mattress, enclosed within an air-impervious bag, in a press and evacuation of the air-impervious bag; 
         FIG. 4C  is a pictorial illustration of an embodiment according to the present invention of lowering of a heated bar and partial sealing of an air-impervious bag enclosing a compressed mattress; 
         FIG. 4D  is a pictorial illustration of an embodiment according to the present invention of lifting of a heated bar and withdrawal of a vacuum hose from a partially sealed air-impervious bag containing a compressed mattress; 
         FIG. 4E  is a pictorial illustration of an embodiment according to the present invention of lowering of a heated bar and completion of sealing of an air-impervious bag enclosing a compressed mattress; 
         FIG. 5  is a pictorial illustration of an embodiment according to the present invention of raising of a heated bar and removal of a compressed and sealed mattress enclosed within an air-impervious bag from a press; 
         FIG. 6  is a pictorial illustration of an embodiment according to the present invention of stacking of compressed and sealed mattresses upon a lower shipping palette; 
         FIG. 7  is a pictorial illustration of an embodiment according to the present invention of placing of an upper shipping palette on top of a stack of compressed and sealed mattresses; 
         FIG. 8A  is a pictorial illustration of an embodiment according to the present invention of insertion within a press of an assembly of a stack of compressed and sealed mattresses, a lower shipping palette, and an upper shipping palette; 
         FIG. 8B  is a pictorial illustration of an embodiment according to the present invention of placement within a press of an assembly of a stack of compressed and sealed mattresses positioned, a lower shipping palette, and an upper shipping palette; 
         FIG. 8C  is a pictorial illustration of an embodiment according to the present invention of lowering a press plate, compressing a stack of compressed and sealed mattresses to a stack predetermined-set height, and attaching of protective strips; 
         FIG. 8D  is a pictorial illustration of an embodiment according to the present invention of securing bands to an assembly of a stack of compressed and sealed mattresses, a lower shipping palette, and an upper shipping palette; 
         FIG. 8E  is a pictorial illustration of an embodiment according to the present invention of removing a secured and compressed assembly from a press; 
         FIG. 9  is a pictorial illustration of an embodiment according to the present invention of an upper shipping palette having rounded edges and coupled to a band with a retaining clip; and 
         FIG. 10  is a pictorial illustration of an embodiment according to the present invention of installation of a protective layer around a compressed and secured assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention relates to a method of packaging multiple bedding products using a containment container such as a crate or several shipping supports, such as, but not limited to, palettes, to further compress a stack of already individually compressed bedding products, such as, but not limited to, mattresses. Upon application of further compression, the already compressed bedding products fit within an even smaller space, allowing for cost effective transport and storage. Compression enhances transportation cost efficiency, since it is possible to use less space within a cargo container than would be required to ship conventionally vacuumed and compressed individual mattresses. A standard cargo container employed in ship, rail, highway, and air transportation contains approximately 2690 ft 3  in space, with a recommended 2350 ft 3  load volume, and is approximately 39 feet and 6 inches in length, approximately 7 feet and 9 inches in width, and approximately 8 feet and 10 inches in height. Of course, it should be realized that the present invention may be used with non-standard cargo containers as well. 
     In addition, restraints, such as, but not limited to, bands, associated with further compression, minimize reexpansion of the bedding products due to failure of seals associated with the packaging of individual compressed mattresses. Sealing failures may occur within a packaged individual compressed mattress or futon and result in a decompressed state, that is, expanded. 
       FIG. 1  contains a flowchart  50  of a method according to an embodiment of the present invention for preparing a plurality of mattresses for transport. In Step  54 , individual mattresses  110  are compressed and sealed. In  FIG. 2 , the individual mattress  110 , is inserted into a bag  105  made of an air-impervious material and open at one end or side  115  in accordance with the prior art. The air-impervious bag  105  may be made of, but is not limited to, plastic, for example, polyethylene, polypropylene, or polymethyl methacrylate. Walls of the air-impervious bag  105  are sufficient to withstand subsequent pressures generated by evacuation of the air from the air-impervious bag  105  and from compression of the mattress  110 , for example, approximately in the range of 0.004 to 0.006 inches thick. 
       FIG. 3A  and  FIG. 3B  show placement of the individual mattress  110  enclosed in the air-impervious bag  105  within a press  205  in accordance with an embodiment of the present invention. The press  205  may be, but is not limited to, an hydraulic press employing a vertical hydraulic press plate  207 , as made by Jinbaoma Furniture Manufacture Co., Ltd. The press  205  comprises a position sensor  215  that is coupled to a controller  220  and that detects a position  315  of the press plate  207  at which the mattress  110  has been squeezed to a predetermined height  305 . The controller  220  is coupled to at least one valve  225  controlling the flow of hydraulic fluid from a pressure source  226  to an at least one hydraulic actuator  227  coupled to the press plate  207  and capable of raising and lowering the press plate  207 . 
     As the press plate  207  is lowered, an opening  210  between the press plate  207  and a lower press support  208  of the press  205  is reduced, thereby squeezing or compressing the individual mattress  110  resting upon the lower press support  208  and enclosed by the air-impervious bag  105  to the predetermined-set height  305 . When the press plate  207  reaches the position  315  such that the opening  210  substantially corresponds to the predetermined-set height  305  of the mattress  110 , a signal from the position sensor  215  to the controller  220  results in a halt to vertical movement of the press plate  207 . 
     Compression of the individual mattress  110  is kept within the limits of the elastic structure of the individual mattress  110  and is halted before damage is done to the individual mattress  110  which may adversely affect the resilience of the individual mattress  110  and the ability of the individual mattress  110  to have its thickness restored to the precompression thickness. Typically, the thickness of an individual mattress is reduced to approximately 35% of the original uncompressed thickness. For example, although not limited thereto, an individual mattress  110  originally approximately 12 inches thick may be reduced to approximately 4 inches thick. 
       FIG. 3B  and  FIG. 4A  show, in accordance with an embodiment of the present invention, at least one vacuum hose  410  inserted in the open side  115  of the air-impervious bag  105 . The at least one vacuum hose  410  is attached to a vacuum source  420 , for example, but not limited to, a transfer pump or a trapping pump, coupled to the controller  220 . Air is withdrawn or evacuated from the individual mattress  110  and from the interior  118  of the air-impervious bag  105  as the mattress  110  is squeezed or compressed by the press plate  207  between the press plate  207  and the lower press support  208 . 
       FIG. 4B  illustrates completion of the squeezing and the evacuation of the air-impervious bag  105  to the predetermined set height  305  of the mattress  110 , in accordance with an embodiment of the present invention.  FIG. 4C  illustrates the first stage of sealing the open end  115  of the air-impervious bag  105  to substantially preserve the evacuated interior  118  of the air-impervious bag  105 , in accordance with an embodiment of the present invention. Sealing may be heat sealing and may be carried out by, but is not limited to, a press  205  including an electrically heated element or bar  510  attached to a vertical hydraulic actuator  515 . 
       FIG. 4C  illustrates the electrically heated bar  510  initially sealing the middle  330  (see  FIG. 3B ) of the open side  115  of the air-impervious bag  105  and squeezing closed the at least one vacuum hose  410 , in accordance with an embodiment of the present invention.  FIG. 4D  illustrates the heated bar  510  being briefly lifted and the at least one vacuum hose  410  withdrawn from the interior  118  of the air-impervious bag  105 , in accordance with an embodiment of the present invention.  FIG. 4E  illustrates, in accordance with an embodiment of the present invention, the electrically heated bar  510  being lowered again to complete the sealing of the open side  115  of the air-impervious bag  105 .  FIG. 5  illustrates, in accordance with an embodiment of the present invention, raising the heated bar  510  and the press plate  207  and removing the compressed or squeezed and sealed individual mattress  605  from the press  205 . 
     In Step  56 , the compressed and sealed mattress  605  is placed on a support together with other compressed and sealed mattresses  605 .  FIG. 6  illustrates, in accordance with an embodiment of the present invention, placing the compressed and sealed individual mattress  605  upon a lower shipping palette or support  700  on top of and aligned with other previously compressed and sealed individual mattresses  605  in a stack  610 . The top  820  of the lower shipping palette  700  may be covered with protective material  825 , possibly, but not limited to corrugated cardboard. The lower shipping palette  700  may be made of an array of parallel wooden pieces  705  held in position by an orthogonal array of wooden crosspieces or crossbars  710  (see  FIG. 5 ). 
     Depending upon the initial size and resilience of the individual mattresses  110 , a maximum, of approximately 12 compressed and sealed individual mattresses  605 , corresponding to an initially approximately 16 inch thick mattress  110 , to approximately 22 compressed and sealed individual mattresses  605 , corresponding to an initially approximately 8 inch thick mattress  110 , may be stacked upon the lower shipping palette  700 . 
     Although the individual compressed and sealed mattresses  605  are compressed and aligned horizontally, adjacent individual compressed and sealed mattresses  605  do not lie flat upon one another. As a consequence of their compression, individual compressed and sealed mattresses  605  have waves and bumps that create spaces between the individual compressed and sealed mattresses  605 . (See  FIG. 6 ). 
     In Step  58 , a second support is placed on top of the plurality of individual compressed and sealed mattresses  605 .  FIG. 7  illustrates, in accordance with an embodiment of the present invention, following stacking of the desired number of individual compressed and sealed mattresses  605  upon the lower shipping palette or lower shipping support  700 , covering the top  805  of the uppermost individual compressed and sealed mattress  802  by a protective material  810 , possibly, but not limited to, corrugated cardboard and positioning the upper shipping palette or upper shipping support  815 , possibly made of wood and possibly similar in construction to the lower shipping palette  700 , on top of the upper protective layer  810 . Combination of the compressed and sealed individual mattresses  605 , the lower shipping palette  700 , and the upper shipping palette  815  forms an assembly  800 . 
     In Step  60 , the plurality or stack of individual compressed and sealed mattresses  605  is further compressed.  FIG. 8A  and  FIG. 8B  illustrate, in accordance with an embodiment of the present invention, placing the assembly  800  within a press  905 , possibly, but not limited to, an hydraulic press, employing a vertical hydraulic press plate  907 , as made by Phoenix. The press  905  comprises a sensor  915  that is coupled to a controller  920  and that detects the position of the press plate  907  when the mattress stack  610  has been squeezed to a predetermined set height  1010 . The controller  920  is coupled to at least one hydraulic actuator  927 , coupled to the press plate  907  and capable of raising and lowering the press plate  907 . 
       FIG. 8C  illustrates, in accordance with an embodiment of the present invention, lowering the press plate  907  and compressing the stack  610  of individual compressed and sealed individual mattresses  605  to the stack predetermined-set height  1010 . As the press plate  907  is lowered, an opening  910  between the press plate  907  and a floor  950  is reduced, thereby compressing the stack  610  resting upon the lower shipping palette  700 , which, in turn, rests upon the floor  950 , to the stack predetermined-set height  1010 . When the press plate  907  reaches a position  1115  corresponding to the height of the stack  610  reaching the stack predetermined- set height  1010  and resulting in a compressed assembly  1000 , a signal from the position sensor  915  to the controller  920  results in a halt to vertical movement of the press plate  907 . 
     The weight of the compressed assembly  1000  is kept between substantially 1500 pounds and substantially 2000 pounds for ease of handling. The height of the compressed assembly  1000  is kept between substantially 47 inches and substantially 49 inches for ease of handling, loading, and unloading and for safety considerations, including avoidance of a propensity for tipping off when handled with a forklift during storage on a higher section of a warehouse racking system. 
     The compressed assembly  1000 , as illustrated in  FIG. 8C , should not exceed approximately 8 feet in height if to be shipped in a 40 foot Hi Cube container having an internal height of substantially 8 feet and 10 inches. For regular 40 foot containers and 20 foot containers having an internal height of substantially 7 feet and 10 inches, the compressed assembly  1000  should not exceed approximately 7 feet in height. The space left between the height of the compressed assembly  1000  and the internal height of the container may allow for ease of loading and unloading. In addition, one or more compressed assemblies  1000  may be stacked upon one another in a shipping container, provided that the total height of the stacked compressed assemblies  1000  does not exceed approximately 8 feet in the case of a Hi Cube container. 
     Weights and dimensions, for example, as presented above, are given as examples and may be varied within the scope of the invention. 
       FIG. 8C  also illustrates, in accordance with an embodiment of the present invention, locking the press plate  907  in position and attaching protective strips  1005  of material, possibly, but not limited to, polyurethane foam or felt padding, to the upper shipping palette  815  and to the lower shipping palette  700 . The protective strips  1005  run along the sides  615  (see  FIG. 6 ) of the stack  610  of compressed and sealed individual mattresses  605  between the upper shipping palette  815  and the lower shipping palette  700 . 
       FIG. 8D  illustrates, in accordance with an embodiment of the present invention, preserving the height of the mattress stack  610  at the stack predetermined set height  1010 , by, but not limited to, securing the upper shipping palette  815  and the lower shipping palettes  700  together. Securing may be by tightening, possibly, but not limited to, bands  1105 , possibly, but not limited to steel, encompassing the lower supporting pallet  700 , the mattress stack  610  of compressed and sealed individual mattresses  605 , and the upper shipping palette  815 . 
       FIG. 9  illustrates, in accordance with an embodiment of the present invention, rounding of an edge  1205  of the upper shipping palette  815  in contact with the band  1105  to prevent abrasion and eventual breakage of the bands  1105 . Edges  1205  of the lower palette  700  may be similarly rounded. The tightened bands  1105  may be secured to the upper shipping palette  815  and to the lower shipping palette  700  by retaining clips  1305  secured to the upper shipping palette  815  and/or to the lower shipping palette  700  to prevent movement. 
     In Step  62 , the upper support  815  and the lower support  700  are coupled together.  FIG. 8D  also illustrates, in accordance with an embodiment of the present invention, tightening the bands  1105  with, for example, a steel strapping tensioner  1120 , and securing a first end  1130  and a second end  1135  of the band  1105 , for example, with a double notched steel strapping sealer  1125 . The protective strips  1005  separate the bands  1105  from contact with the individual compressed and sealed mattresses  605 . 
       FIG. 8E  illustrates, in accordance with an embodiment of the present invention, after the compressed assembly  1000  containing the individual compressed and sealed mattresses  605  has been secured with the bands  1105  to form the secured and compressed stack assembly  1100 , raising the press plate  907  and removing the secured and compressed assembly  1110  comprised of individual compressed and sealed mattresses  605 . 
       FIG. 10  illustrates, in accordance with an embodiment of the present invention, covering the sides  1115  of the secured and compressed assembly  1110 , with at least one protective layer  1405  of wear-resistant material and securing the protective layer  1405  with a holder  1150 . The protective layer  1405  may be, but is not limited to, cardboard, fabric, or a combination of cardboard and fabric. 
     Although the invention has been described with respect to various embodiments, it should be realized that this invention is also capable of a wide variety of further and other embodiments within the spirit and the scope of the appended claims.