Patent Description:
Most of the existing mattresses, especially the spring mattresses, are one-piece monolithic components. Their overall volume is large, which therefore requires a large space for handling or storage, and high cost for storage and transportation. The construction of the existing spring mattresses has heretofore presented a barrier to packaging in a form convenient for delivery. In addition, after the user receives the mattresses, it is difficult to carry them, due to their large volumes, and especially when carrying them in a limited space, for example, in a room, they may easily rub and touch the walls of the room, causing damage and scratch. In addition to large volume, the existing mattress is also too heavy to be carried by the user himself. Users can only carry it or make bed with the help of others, causing great inconveniences in daily use.

Although currently there are some mattresses assembled from multiple mattress core blocks, it is still difficult to save the space occupied and the transportation costs for the packaging and handling of the various parts of one mattress before assembling. In addition, packaging costs are high, and packaging integrity is difficult to guarantee.

Such mattresses and their packaging systems are known from <CIT>, <CIT>, <CIT>, <CIT>.

Therefore, the present invention aims to overcome one or more of the above-mentioned problems in the prior art.

In order to solve the above-mentioned problems in the prior art, the present invention proposes a mattress package, which can greatly improve packaging efficiency, reduce packaging costs and transportation costs, and allows users to handle, assemble and use flexibly, with improved convenience and comfort in use.

According to one aspect of the present invention, a mattress package is provided, comprising:.

Preferably, the plurality of core rolls and the covering roll are placed, or at least being arrangeable, in parallel in the box, and the core rolls are substantially the same in length and optionally substantially the same in width measured at an unrolled state. In this configuration, the mattress core can be packed in a box as small as possible and the cost for delivery can be reduced to the minimum. Also, the box can be avoided from creating any large empty space therein which is prone to collapse when receiving heavy collision during transportation. Furthermore, the consumers can easily assemble unrolled core segments by themselves without the need of distinguishing them from each other.

In an embodiment, the sum of the lengths of the core rolls is equal to a length or width of the mattress core.

In an embodiment, the length of the covering roll is substantially the same as the length of each core roll. In this way, the space in the box can be used efficiently, reducing the risk of collapse caused by large empty space in the box.

In an embodiment, the mattress package comprises two to six core rolls, preferably, three core rolls.

In an embodiment, the box is a cardboard box, for example, a corrugated fiberboard box.

In an embodiment, the core segments each comprise one or more core subsegments arranged in a row along its unrolling direction.

In an embodiment, the core subsegments are pieces in the form of spring cores, such as pocket spring cores, or latex cores, or sponge cores.

In an embodiment, each core subsegment is selected from a first base module and a second base module, the first and second base modules being the same in length but different in width ranging from <NUM>~<NUM>, preferably <NUM> or <NUM>. By doing so, the production efficiency can be greatly improved because mattress core of many sizes can be obtained with these base modules which requires no redesign or modification of the equipment for these base modules.

Preferably, the core segments each comprise at most three base modules.

Preferably, the core segments each comprise one first base module and one second base module. Preferably, the base modules are arranged in a same or different sequence among core rolls; and preferably the base modules in the core segment(s) to be assembled as a middle section of the mattress core are arranged in a sequence different from those in the core segments to be assembled as end sections of the mattress core.

In an embodiment, the cover material comprises a mattress cover for wrapping around the mattress core and a functional pad for covering the mattress core.

Preferably, the mattress cover is provided with elastic strips for holding the mattress core at its corners.

According to another aspect of the present invention, a method for packaging a mattress is provided, wherein the mattress comprises: a plurality of core segments arranged side-by-side in one direction of the lengthwise and widthwise directions of the mattress and preferably being substantially the same in length and optionally substantially the same in width, wherein a mattress core is formed by assembling the core segments; and a cover material provided for covering the mattress core,
wherein the method comprises following steps:.

Preferably, the method comprises a step of compressing each core segment in its thickness direction before rolling up.

In an embodiment, the core segments each comprise one or more core subsegments. Preferably, each core subsegment is selected from a first base module and a second base module, the first and second base modules being the same in length but different in width ranging from <NUM>~<NUM>, preferably <NUM> or <NUM>. And the method comprises, before the step of compressing, a step of packing the one or more core subsegments in each core segment into a bag, with the core subsegments being arranged in a row along the rolling direction of the core segments.

According to the mattress package of the present invention, the mattress, especially the spring mattress, can be transported at greatly reduced cost in transportation, and is no longer subject to the limitations of expensive and inconvenient packaging and transportation and a lack of diversity in use, and the popularity of the modular mattress can be improved. In addition, the mattress thus obtained, i.e. of a 'mattress in a box' product type, is convenient for consumers to purchase, transport or assemble by themselves, and consumers can splice the mattress segments or change or adjust the assembling pattern according to their own needs.

Further disclosure, objects, advantages and aspects of the present invention may be better understood by those skilled in the relevant art by reference to the following description of preferred embodiments taken in conjunction with the accompanying drawings, which are given by way of illustration only and thus not limitative of the present invention, and in which:.

Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. Moreover, references to various elements described herein are made collectively or individually when there may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular may also be construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims∘.

In the following description, where directionally related terms are used such as 'top', 'upper', 'bottom', 'lower', 'above', 'below', 'sides' and the like, these are understood to be with reference to a mattress that is configured and positioned for use, such as lying flat on a bed base, unless the context requires otherwise. Terms referring to the 'length/lengthwise' and 'width/widthwise' of a mattress or its components should be understood to be with reference to two main dimensions for defining an outline of a mattress whereby the lengthwise dimension is equal to or bigger than the widthwise dimension for a mattress.

Hereinbelow, the terms 'first', 'second', etc. are only used to distinguish each other, rather than to indicate the degree of importance and order, and the premise of mutual existence, etc..

Referring to <FIG>, the mattress M to be packaged according to the packaging method of the present invention mainly includes a mattress core <NUM> and a cover material <NUM> covering/wrapped on the mattress core. Herein "cover material" means all the woven or nonwoven materials covering from above or below or surrounding the mattress core. The mattress core is assembled by multiple core blocks. The cover material <NUM> comprises a mattress cover <NUM> and a functional pad <NUM> to be laid on the mattress core, such as a comfort pad. As shown in <FIG>, the mattress cover <NUM> may comprise an upper covering part <NUM> and a lower covering part <NUM>. The core blocks are placed in a box-shaped cavity defined by the lower covering part. The size of the well-assembled mattress is basically the same as the size of the mattress cover. The four corners of the mattress cover are also provided with elastic bands or strips <NUM> for restraining the movement of the core blocks in the box-shaped cavity. In order to provide better comfort, a comfort pad is placed on an upper side of the mattress core. The comfort pad can be placed directly on the mattress core and then covered by the upper covering part of the mattress cover. Preferably, four corners of the comfort pad are all fixed by means of elastic strips.

For all types of mattresses on the market, mattress cores of corresponding sizes and appropriate assembling patterns can be designed according to the present invention. For the convenience of explanation and understanding, a concept of core segment is introduced to explain the rolling-up scheme.

<FIG> shows a side-by-side arrangement of three core segments <NUM>', <NUM>', <NUM>' (as shown by the dotted bordered rectangles in <FIG>) intended for forming a single bed mattress core <NUM> having a dimension for example of approximately <NUM>~<NUM> length and <NUM>~<NUM> width.

In each core segment, there is only one core subsegment <NUM>. Among the core segments, core subsegments are in the same shape and size, i.e. having same length and width. Each core segment can be rolled along a rolling direction R into a core roll <NUM>, <NUM>, <NUM>, as shown in <FIG>. And each core roll has a same length measured along its lengthwise direction (i.e. in the axial direction of the roll) and a same width measured at an unrolled state (i.e. unrolled width).

Once unrolled and laid flat, each core segment returns to its original size with a same length and a same width (i.e. unrolled width). These unrolled core segments can be assembled on site directly by the users themselves. All the assembling work can be completed, for example, under brief instructions or directions on a commodity brochure, to get a mattress core of a custom-made size, without the need of asking help from workers.

Although it is shown in <FIG> that the rolling direction R is coincident with the widthwise direction of the intended mattress, each core segment can be rolled along the lengthwise direction of the intended mattress. Similarly, three core rolls having a same length and a same diameter (or unrolled width) can also be obtained. Therefore, the rolling direction R can be determined according to the length and width of the specific mattress core segment, and the main consideration is whether the length of the roll formed meets the requirements of transportation or delivery.

Although in the embodiment shown there are three core segments aligned (or arranged in a row) in the lengthwise direction of the intended mattress core, it will be appreciated that two or more than three core segments can be aligned in the lengthwise direction of the intended mattress core, with each core segment sharing the same length and the same width.

<FIG> shows a side-by-side arrangement of three core segments <NUM>', <NUM>', <NUM>' intended for forming a double-bed mattress core having a dimension for example of approximately <NUM>~<NUM> length and <NUM>~<NUM> width. The mattress core <NUM> can be designed to have a dimension of, for example, <NUM> length and <NUM> width.

In each core segment, there are two core subsegments <NUM> in the same shape and size, i.e. having a same length and a same width of, for example <NUM>~<NUM>, preferably <NUM> or <NUM>. The two core subsegments are aligned in the widthwise direction of the intended mattress core. Each core segment can be rolled along a rolling direction R into a core roll <NUM>, <NUM>, <NUM>, as shown in <FIG>. And each core roll thus obtained has a substantially same length measured along its lengthwise direction and a substantially same diameter measured in its cross section. Once unrolled and laid flat, each core segment returns to its original size with a substantially same length and a substantially same width (i.e. unrolled width).

<FIG> shows a side-by-side arrangement of three core segments <NUM>', <NUM>', <NUM>' intended for forming a double-bed mattress core having a dimension for example of approximately <NUM>~<NUM> length and <NUM>~<NUM> width. The mattress core <NUM> can be designed as having a dimension of, for example, <NUM> length and <NUM> width.

Different from the second embodiment, the core subsegments in each core segment of this third embodiment are the same in length, but are different in width. The length and width of the mattress core subsegment are measured according to the lengthwise direction and widthwise direction of the mattress core respectively, regardless of whether it meets the condition that the length is greater than or equal to the width. For example, the first core subsegment 100a has a width of <NUM> and a length of <NUM>, and the second core subsegment 100b has a width of <NUM> and a length of <NUM>. Hence, the sum of the widths of the first core subsegment and the second core subsegment is substantially equal to <NUM> which is a typical width of a mattress for a double bed.

Each core segment comprising the first and second core subsegments aligned in the widthwise direction of the intended mattress core can then be rolled along a rolling direction R into a core roll <NUM>, <NUM>, <NUM>, as shown in <FIG>. And each core roll thus obtained has a same length measured along its lengthwise direction and a same diameter measured in its cross section. Once unrolled and laid flat, each core segment returns to its original size with a substantially same length and a substantially same width (i.e. unrolled width).

<FIG> shows an arrangement of three core segments <NUM>', <NUM>', <NUM>' (as shown by the dotted bordered rectangles in <FIG>) intended for forming a double-bed mattress core <NUM> having a dimension for example of approximately <NUM>~<NUM> length and <NUM>~<NUM> width.

Different from the third embodiment, among core segments, the first and second core subsegments are arranged in different sequences (along the widthwise direction, as shown in <FIG>). As shown in <FIG>, the core subsegments in the core segment corresponding to a middle section of the intended mattress core are arranged in a sequence different from those in the core segments corresponding to end sections of the intended mattress core.

Accordingly, each core segment is rolled up into a core roll <NUM>, <NUM>, <NUM> along the rolling direction R, as shown in <FIG>. From especially <FIG>, it can be seen that, among core rolls, the core subsegments 100a, 100b are arranged in different sequences also. In the embodiment shown, in the core roll corresponding to the middle section of the intended mattress core, the second core subsegment 100b is located in the innermost area of the core roll and the first core subsegment 100a is in the outermost area of the core roll. While core rolls corresponding to the end sections of the intended mattress core have the first core subsegments 100a in the innermost area and the second core subsegments 100b in the outermost area.

However, when viewed from the outside, these core rolls are substantial the same, sharing a same length and a same diameter measured in its cross section. Once unrolled and laid flat, each core segment returns to its original size with a same length and a same width (i.e. unrolled width).

<FIG> is a diagrammatic illustration of a mattress core <NUM> to be assembled by three identical core segments <NUM>', <NUM>', <NUM>' each of which has three core subsegments <NUM> aligned in the widthwise direction of the intended mattress core. Thus, different from the second embodiment, each core segment has more than two core subsegments. In the embodiment shown, core subsegments in each core segment are identical to each other in shape and size, for example, having a dimension of <NUM>~<NUM> length and <NUM>~<NUM>, preferably, <NUM> width. It will be appreciated that core subsegments in each core segment can be different in size.

As shown in <FIG>, each core segment can be rolled along the rolling direction R into a core roll <NUM>, <NUM>, <NUM>. And the core rolls obtained each have a substantially same length measured along its lengthwise direction and a substantially same diameter measured in its cross section.

<FIG> shows a mattress core of the same size as that of <FIG>, comprising a <NUM>×<NUM> array of the core subsegments in the same size, for example, with <NUM>~<NUM> length and <NUM>~<NUM>, preferably, <NUM> width. The difference between the mattress cores of <FIG> and <FIG> lies in that their core segments <NUM>', <NUM>', <NUM>' extend in different directions, and also their rolling directions are different from each other. As shown in <FIG>, the length of each core roll is about one third of the width of the intended mattress core and the unrolled width of each core roll is substantially the same as the length of the intended mattress core.

From the description of all the above embodiments, it can be seen that, the sum of the length of multiple core rolls <NUM>, <NUM> and <NUM> corresponds to the length or width of the mattress core <NUM>. Therefore, the modularization of the mattress core and the rolling of the core segments allow the packaging size of the core roll to be reduced in such a flexible way that almost mattress core of any size can be easily packaged for transportation.

Although it is shown in the above embodiments that three core rolls are formed for each mattress core. However, for those skilled in the art, the specific number of core rolls can be different according to the specific size of the mattress core. The size of the core subsegments <NUM> in each core segment can be same or different to each other.

Herein, "basically the same" and "the same" both mean the two under comparison are basically the same or identical with or without differences falling within a permissible error range, and without taking into account shape and/or size differences caused by the connection structures between the core subsegments or the connection structures between the core segments.

The core subsegments intended for a mattress core of any conventional size can be selected from the base module(s) with a predefined length and a predefined width. The predefined width of the base module can be selected from <NUM>-<NUM>, preferably <NUM> or <NUM>. The predefined length of the base module can be selected from <NUM>-<NUM>, preferably <NUM>.

Taking the second embodiment for an example (as shown in <FIG>), six base modules having a dimension of <NUM> length and <NUM> width are selected as core subsegments to make up a <NUM>×<NUM> mattress core. While, once base modules, each of which has <NUM> (length) ×<NUM> (width), are selected, a mattress core of <NUM>×<NUM> can be made up.

Similarly, the mattress core of the third embodiment can be made up by choosing three pieces of a first base module in <NUM> × <NUM> size as the first core segments 100a and three pieces of a second base module in <NUM> ×<NUM> size as the second core segments 100b and putting them together in the pattern according to the third embodiment as shown in <FIG>.

For reducing the movement between the core subsegments (base modules), as shown in the fourth embodiment (<FIG>), the core subsegments are arranged in a same or different sequence among core segments. Also, this staggered arrangement of the core subsegments makes it possible to provide diversities in for example, softness, so as to meet different needs of the customers. This is widely applied for a couple bed. Of course, since now the mattress core is made up based on modules, users can easily change or move the modules to adapt to their specific needs, without involving much effort in the reorganization of the entire mattress core.

The number of specific base modules in each core segment can be designed according to the size of selected base module and the size of the intended mattress core. Preferably, a core segment comprises at most three base modules, thereby avoiding dividing a mattress core into too many modules in an inefficient manner.

For a special mattress core whose size is different from that for a conventional single bed or double bed, some of the core subsegments can be selected from the base modules, and the rest of the core subsegments with special size can be customized on demand.

As mentioned above, a mattress core is basically composed of multiple core subsegments. The material of the core subsegments can be the same or different. For example, the core subsegments or the core segment composed of core subsegments can be pieces in the form of a spring core, such as a pocket-spring core, or a latex core or a sponge core (such as a foam mattress core), etc..

The existing spring mattress core is mainly composed of one-piece monolithic mattress core block, which is not only big but also bulky. But the spring mattress, especially the pocket-spring mattress which has a plurality of interconnected encased helical springs coupled together usually in regular array to form specific geometric dimensions (each helical spring being arranged in a closed pocket made of fabric, nonwoven or the like), is welcomed by the majority of users, because it can provide lasting elasticity.

The packaging method based on modularization according to the present invention has obvious advantages in terms of convince in packaging and cost in transportation, especially for the spring mattress core (or rather, the pocket-spring mattress core).

Hereinbelow, a packaging method for a mattress according to the present invention will be described with reference to <FIG>.

In order to facilitate packaging and reduce the package size, it is preferable that the mattress core segments are compressed prior to rolling.

Before compressing, each core segment is put within a plastic bag or envelope with one open end through which air can be removed from within the bag before the open end is sealed.

Each core segment is compressed into a flattened form with reduced thickness in the plastic bag or envelope. During compression, air is removed from within the bag, and then the bag is sealed by hot sealing. In the flattened condition of the core segment, the springs therein are compressed to at least near their minimum height. Compression of the core segment to the flattened form may involve reduction of height by an order of magnitude or more, for example from more than ten centimeters (for example, <NUM> centimeters) down to one or two centimeters or so.

The method of packing the mattress according to the present invention comprises the step of rolling the flattened core segment into a rolled, generally cylindrical form. At the end of rolling, an additional external wrapping of the plastic film around the coiled core segment can be provided by several more turns. The coiled core segment and the covering plastic film can then be secured using adhesive tape, string, strapping or the like.

In addition to the step of rolling the core segments, the method of packaging a mattress according to the present invention further comprises a step of rolling up the cover material.

As shown in <FIG>, the mattress core is covered with a cover material <NUM>. These cover materials are wrapped on the outside of the mattress core <NUM>, which can protect the mattress core on the one hand and provide room for improvement in comfort of the mattress on the other hand.

As shown in <FIG>, the cover material <NUM> comprises a mattress cover <NUM> which is substantially in the form of a bag and a functional mattress <NUM> whose size matches the mattress cover and/or the mattress core. For simplifying the packaging process, the function pad can be laid flat in the mattress cover.

After the mattress cover is closed, the general shape and size are consistent with the matching mattress core. Referring to the embodiment shown in <FIG>, the mattress core is assembled by three core segments along the lengthwise direction. The corresponding upper covering part <NUM> of the mattress cover is facing upward, and two imaginary folding lines extending in the widthwise direction are selected at one third and two thirds of the length of the mattress cover. Along the first folding line, one-third portion on a first end of the mattress cover is folded onto the rest part of the mattress cover, and then another one-third portion on a second end of the mattress cover is folded onto the top along the second folding line. The shape and size of the folded mattress cover are basically consistent with the shape and size of the core segment of the matched mattress core, as shown in <FIG>. Next, the folded mattress cover is rolled in the same direction as the rolling direction of the core segment, as shown in <FIG>. At the end of rolling, it is fixed by wrapping a plastic film. Therefore, a covering roll <NUM> as shown in <FIG> is obtained.

The core rolls and covering rolls obtained are then placed in a box <NUM>, for example, cardboard box (preferably a corrugated fiberboard box) in a suitable size. A corrugated fiberboard box is a commonly used packing that is of low economic cost and strong enough to withstand the collision and extrusion in the whole process of transportation, and can therefore be used to protect the core rolls in the box from any damage.

Referring to mattress package <NUM> shown in <FIG>, three core rolls <NUM>, <NUM> and <NUM> for forming an entire mattress core and a covering roll <NUM> for covering the mattress core are placed in the packaging box <NUM>. The axes of the core rolls and the covering roll are basically parallel to each other.

Because the cover material is folded into the same shape and size as the core segment before rolling, and the rolling direction is the same as that of the core segment, the covering roll thus obtained and core rolls have basically the same length. In this way, when the core rolls and the covering roll are placed in the packaging box in parallel, the upper ends of these rolls are basically flush and roughly consistent with the height of the packaging box. Therefore, a higher packing rate can be obtained. In addition, in the embodiment shown, since there are four rolls each of which occupies about one quarter of the cross-sectional area of the packaging box, the packaging box can get into a balanced/stable state where local weak parts of the packaging box caused due to uneven force can be avoided from occurring.

In the process of transportation, the mattress packages need to be stacked and transported to a designated location in the warehouse by an automated guided vehicle. In the process of stacking, according to the maximum allowable height of stacking, the packages can be placed either in a horizontal position or in a vertical position. No matter in what position they are placed, the core rolls and covering roll therein can be well protected without collapse or deformation.

Using the packaging method according to the present invention, a pocket-spring mattress of a typical thickness, for example <NUM>, may be packed into a packaging box having approximate dimensions <NUM>×<NUM>×<NUM>.

It will of course be appreciated that mattresses of different dimensions may result in different package sizes and therefore packages or parcels that can be transported with lower cost, as will be apparent from the foregoing description.

Following transport of the mattress package to its location for intended use, the covering roll <NUM> is taken out from the box, unfolded and laid on the predetermined position. The mattress cover <NUM> is opened and then the functional pad <NUM> inside is taken out.

The core segments can be deployed by taking out the core rolls <NUM>, <NUM>, <NUM> from the box, cutting off the tape and/or plastic film, unfolding the core rolls and piercing the bag to allow air to enter and depressurize the core segments. The natural resilience of the springs will then cause the core segments to return to its original form by unrolling with little or no assistance from the user.

The core segments are assembled according to the installation method described in the product manual. For example, a mark of installation orientation is printed on each core segment. According to the mark, users can determine which side of the related core segment corresponds to the length or width direction of the intended mattress. The assembling operation of the core segments can be directly carried out in the cavity defined by the lower covering part <NUM> of the mattress cover <NUM>. The elastic strips <NUM> at the four corners of the mattress cover can help to restrain the core segments <NUM> and prevent them from moving.

Next, as shown in <FIG>, the functional pad <NUM> is laid on the well-assembled mattress core <NUM>. The four corners of the functional pad are secured under the elastic strips <NUM>, thereby fixing the functional pad on the mattress core with the help of the elastic strips.

The upper covering part <NUM> of the mattress cover is laid flat on the mattress core, and the mattress cover is closed by a zipper <NUM> or other means. Thus, a finished mattress is formed and ready for use.

The method according to the present invention allows to pack a mattress in a box of a size that is manageable for transportation. The packaged configuration enables a purchaser to transport the mattress home from the retail establishment themselves, and permits convenient delivery by commercial transportation agencies. This in turn increases opportunities for users to purchase the mattress product online and have it delivered.

Claim 1:
A mattress package (<NUM>), comprising:
a plurality of core rolls (<NUM>, <NUM>, <NUM>) formed by rolling up core segments (<NUM>', <NUM>', <NUM>'), wherein a mattress core (<NUM>) is formed by assembling the core segments;
a covering roll (<NUM>) formed by rolling up a cover material (<NUM>) configured for covering the mattress core; and
a box (<NUM>) containing the plurality of core rolls (<NUM>, <NUM>, <NUM>) and the covering roll (<NUM>).