Process for packaging a polyurethane foam filled article of furniture

Abstract

A process for packaging a polyurethane foam filled article of furniture, comprising the steps of: (a) providing a polyurethane foam filled article of furniture having an initial volume; (b) reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume, comprising at least one of the steps of: (1) decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and (2) compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and (c) associating the polyurethane foam filled article of furniture with a package.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates in general to a process for packaging furniture, and more particularly, to a process for packaging a polyurethane foam filled article of furniture.

[0003] 2. Background Art

[0004] Processes for packaging furniture have been known in the art for several years. Furthermore, processes for packaging polyurethane foam filled articles of furniture have likewise been known in the art. Such polyurethane foam filled articles of furniture may comprise structures which, among others, are analogous to the chairs disclosed in: U.S. Pat. No. 6,279,184 B1; U.S. patent application Ser. No. 09/941,064, Entitled “Frameless Chair;” U.S. patent application Ser. No. ______, Entitled “Frameless Chair;” and U.S. Provisional Patent Application Serial No. 60/276,593, all of which are hereby incorporated herein by reference in their entirety. Alternatively, articles of furniture may comprise structures which include a component or components which are polyurethane foam filled, as well as a component or components which are not polyurethane foam filled, such as, for example, a futon comprising a polyurethane foam filled article and a frame. While such conventional packaging processes for polyurethane foam filled articles of furniture or components of furniture have become popular, the size of the packaged articles of furniture, among other things, remains largely problematic. In particular, using boxes, bags, or conventional packages to retain polyurethane foam filled articles of furniture requires that the box, bag, or conventional package be of substantial size. Consequently, conventional means of shipping, such as, for example, the United Parcel Service (UPS), Federal Express, or the United States Postal Service, may be expensive and/or unfeasible inasmuch as restrictions on the size of packages may drastically increase the price or even prohibit such large items from being shipped.

[0005] It is therefore an object of the present invention to provide a process for packaging a polyurethane foam filled article of furniture which, among other things, remedies the aforementioned detriments and/or complications associated with packaging polyurethane foam filled articles of furniture.

SUMMARY OF THE INVENTION

[0006] The present invention is directed to a process for packaging a polyurethane foam filled article of furniture comprising the steps of: (a) providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume; (b) associating the polyurethane foam filled article of furniture with a bag, wherein the bag has an aperture; (c) reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and (d) associating the polyurethane foam filled article of furniture with a package.

[0007] In a preferred embodiment of the present invention, the step of providing a polyurethane foam filled article of furniture includes the step of providing a polyurethane foam filled article of furniture having a density of polyurethane foam ranging from between approximately 1.0 and approximately 4.0 pounds per cubic foot.

[0008] In another preferred embodiment of the present invention, the step of providing a polyurethane foam filled article of furniture includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner, wherein the outer liner is flexible and at least partially gas permeable. In this embodiment, the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner preferably includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner which is substantially spherical.

[0009] In yet another preferred embodiment of the present invention, the step of associating the polyurethane foam filled article of furniture with a bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, through the aperture. In this embodiment, the step of placing the polyurethane foam filled article of furniture inside of the bag may include the step of placing the polyurethane foam filled article of furniture inside of the bag, wherein the bag is fabricated from a substantially airtight material.

[0010] In accordance with the present invention, the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume comprises the steps of: (a) providing a vacuum source, wherein the vacuum source is capable of decreasing air pressure within a confined area; (b) associating the vacuum source with the aperture of the bag, wherein a substantially airtight seal is formed between the vacuum source and the aperture of the bag; (c) decreasing air pressure within the confined area of the bag via the vacuum source and, in turn, the polyurethane foam filled article of furniture; and (d) reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

[0011] In a preferred embodiment of the present invention, the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately two-thirds of the initial volume. Preferably, the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-half of the initial volume, and most preferably, the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-third of the initial volume.

[0012] In another preferred embodiment, the present invention may comprise the step of sealing the bag to substantially preserve the reduced volume of the polyurethane foam filled article of furniture after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

[0013] In yet another preferred embodiment of the present invention, the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume less than the initial volume of the polyurethane foam filled article of furniture and which has a volume greater than the reduced volume of the polyurethane foam filled article of furniture.

[0014] The present invention is also directed to a process for packaging a polyurethane foam filled article of furniture comprising the steps of: (a) providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume; (b) compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and (c) associating the polyurethane foam filled article of furniture with a package.

[0015] In a preferred embodiment, the invention further comprises the step of associating the polyurethane foam filled article of furniture with a mold before the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume. In this embodiment, preferably the step of associating the polyurethane foam filled article of furniture with a mold includes the step of providing a mold having at least one binding agent therein.

[0016] In another preferred embodiment, the invention further comprises the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent after the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

[0017] In yet another preferred embodiment, the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least two binding agents, wherein two of the at least two binding agents are perpendicular to each other. Alternatively, the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least two binding agents, wherein two of the at least two binding agents are parallel to each other.

[0018] In yet another preferred embodiment, the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least three binding agents, wherein two of the at least three binding agents are parallel to each other, and wherein one of the at least three binding agents is perpendicular to two of the at least three binding agents.

[0019] In another preferred embodiment, the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least four binding agents, wherein at least two of the at least four binding agents are parallel to each other, and wherein at least two of the at least four binding agents are perpendicular to each other.

[0020] Preferably, the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume is repeated at least once.

[0021] Furthermore, the present invention is directed to a process for packaging a polyurethane foam filled article of furniture comprising the steps of: (a) providing a polyurethane foam filled article of furniture having a first initial length and a second initial length; (b) associating the polyurethane foam filled article of furniture with a mold and at least two binding agents; (c) compressing the first initial length of the polyurethane foam filled article of furniture to a first reduced length; (d) binding at least one of the at least two binding agents parallel to the first reduced length of the polyurethane foam filled article of furniture; (e) compressing the second initial length of the polyurethane foam filled article of furniture to a second reduced length; (f) binding at least one of the at least two binding agents parallel to the second reduced length of the polyurethane foam filled article of furniture; and (g) associating the polyurethane foam filled article of furniture with a package.

[0022] In accordance with the present invention, a process for packaging a polyurethane foam filled article of furniture is disclosed as comprising the steps of: (a) providing a polyurethane foam filled article of furniture having an initial volume; (b) reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume, comprising at least one of the steps of: (1) decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and (2) compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and (c) associating the polyurethane foam filled article of furniture with a package.

[0023] In a preferred embodiment, the invention further comprises the step of associating the polyurethane foam filled article of furniture with at least one binding agent after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

[0024] In yet another preferred embodiment, the invention further comprises the steps of: (a) associating the polyurethane foam filled article of furniture with a bag having an aperture before the step of decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and (b) sealing the bag to substantially preserve the reduced volume of the polyurethane foam filled article of furniture after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

[0025] In another preferred embodiment of the present invention, a process for packaging a polyurethane foam filled article of furniture comprises the steps of: (a) providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume; (b) associating the polyurethane foam filled article of furniture with a bag, wherein the bag has an aperture; (c) associating the polyurethane foam filled article of furniture and the bag with an unassembled package having at least one binding agent therein; (d) reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume, comprising at least one of the steps of: (1) decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and (2) compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; (e) binding the reduced volume of the polyurethane foam filled article of furniture with the at least one binding agent; and (f) assembling the unassembled package around the reduced volume of the polyurethane foam filled article of furniture.

[0026] Furthermore, the present invention is directed to a polyurethane foam filled article of furniture packaged according to at least one of the above-identified methods.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The invention will now be described with reference to the drawings wherein:

[0028] FIG. 1 of the drawings is a schematic representation of a process for packaging a polyurethane foam filled article of furniture showing, among other things, the step of reducing an initial volume of a polyurethane foam filled article of furniture to a reduced volume;

[0029] FIG. 2 of the drawings is a schematic representation of a process for packaging a polyurethane foam filled article of furniture showing, among other things, the step of compressing an initial volume of a polyurethane foam filled article of furniture to a reduced volume;

[0030] FIG. 3 of the drawings is a schematic representation of a process for packaging a polyurethane foam filled article of furniture showing, among other things, the step of compressing an initial volume of a polyurethane foam filled article of furniture to a reduced volume in association within a mold;

[0031] FIG. 4 of the drawings is a schematic representation of a process for packaging a polyurethane foam filled article of furniture showing, among other things, the step of compressing an initial volume of a polyurethane foam filled article of furniture to a reduced volume a plurality times while in association within a mold; and

[0032] FIG. 5 of the drawings is a fragmentary, schematic representation of a process for packaging a polyurethane foam filled article of furniture showing, among other things, an unassembled package having four binding agents therein, the step of associating the unassembled package with a polyurethane foam filled article of furniture, and the step of assembling the package.

DETAILED DESCRIPTION OF THE DRAWINGS

[0033] While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.

[0034] It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings with like reference characters. It will further be understood that FIGS. 1-4 are merely schematic representations. As such, some of the components may be distorted from their actual scale for pictorial clarity.

[0035] Referring now to the drawings, and to FIG. 1 in particular, a schematic representation of a first embodiment of process 10 for packaging polyurethane foam filled article of furniture 12 is shown, which generally comprises providing step 30, bag associating step 40, reducing step 50, and package associating step 60.

[0036] For purposes of the present disclosure, providing step 30 generally comprises the step of providing a polyurethane foam filled article of furniture 12 which has an initial volume 14A. Polyurethane foam filled article of furniture 12 may be frameless and may comprise an outer liner which is flexible, at least partially gas permeable, and, upon filling with polyurethane foam, substantially spherical. While polyurethane foam filled article of furniture 12 is shown in FIG. 1 as comprising a square cross-section, it will be understood that polyurethane foam filled article of furniture 12 may comprise any one of a number of other cross-sections, such as, but not limited to, substantially circular, substantially polygonal, and/or substantially arbitrary, including those disclosed in all references previously identified and incorporated herein. It will be further understood that, in order to be functional in accordance with the present invention, the polyurethane foam within the outer liner comprises a density which ranges between approximately 1.0 and approximately 4.0 cubic foot. Moreover, it will be understood that polyurethane foam filled article of furniture 12 may be one component of an article of furniture which may comprise frameless and non-frameless components.

[0037] Bag associating step 40 generally comprises the step of associating polyurethane foam filled article of furniture 12 with a bag 16 having an aperture 18. More particularly, bag associating step 40 includes the step of placing polyurethane foam filled article of furniture 12 inside bag 16, through aperture 18. Bag 16 may comprise any one of a number of sizes, shapes, and/or materials—with the only limitation being that it must be capable of retaining polyurethane foam filled article of furniture 12. Examples of suitable materials for fabricating bag 16 include conventional substantially airtight, flexible materials such as, for example, a bag fabricated from plastic, natural and/or synthetic materials, etcetera. Aperture 18 may comprise any one of a number of sizes and shapes—its only limitation being that it must be capable of allowing polyurethane foam filled article of furniture 12 to pass therethrough.

[0038] Reducing step 50 generally comprises the step of reducing initial volume 14A of polyurethane foam filled article of furniture 12 to a reduced volume 14B. As is shown in FIG. 1, initial volume 14A of polyurethane foam filled article of furniture 12 is shown in step 50A, prior to reducing step 50, and reduced volume 14B of polyurethane foam filled article of furniture 12 is shown in step 50B, subsequent to reducing step 50.

[0039] Reducing step 50 may include providing a vacuum source 52 which is capable of decreasing air pressure within a confined area, such as, for example, bag 16. Vacuum source 52 may then be associated with aperture 18 of bag 16 such that a substantially airtight seal is formed between vacuum source 52 and bag 16 via a sealing member 19. For purposes of the present disclosure, vacuum source 52 may comprise a centrifugal blower manufactured by Paxton Products of Camarello, California. Sealing member 19 may comprise any one of a number of sealers including, but not limited to, a drawsting, clamp, ring, elastic band, tie, clip, or any other sealing structure known to those having ordinary skill in the art with the present disclosure before them. Next, vacuum source 52 may decrease air pressure within bag 16 and, in turn, within polyurethane foam filled article of furniture 12 to the extent that the air pressure within bag 16 and polyurethane foam filled article of furniture 12 is less than atmospheric pressure. As such, bag 16 and polyurethane foam filled article of furniture 12 are reduced from initial volume 14A to reduced volume 14B.

[0040] Reduced volume 14B of polyurethane foam filled article of furniture 12 may be approximately two-thirds of initial volume 14A or less. Preferably, reduced volume 14B of polyurethane foam filled article of furniture 12 is approximately one-half of initial volume 14A or less, and more preferably, reduced volume 14B of polyurethane foam filled article of furniture 12 is approximately one-third of initial volume 14A or less.

[0041] Reducing step 50 may also comprise the step of sealing bag 16 to substantially preserve reduced volume 14B of polyurethane foam filled article of furniture 12 via sealing member 19 or any other means for preserving reduced volume 14B known to those having ordinary skill in the art with the present disclosure before them. It will be understood that “substantially preserving reduced volume 14B” will generally mean that reduced volume 14B may not increase to equal initial volume 14A until such preserving means which are employed are deployed from bag 16 and polyurethane foam filled article of furniture 12.

[0042] Package associating step 60 generally comprises associating polyurethane foam filled article of furniture 12 with a package 20. Package 20 may comprise a size which is substantially smaller than conventional packages for polyurethane foam filled articles of furniture inasmuch as process 10 for packaging polyurethane foam filled article of furniture 12 results in a substantial reduction in size of polyurethane foam filled article of furniture 12. As such, package 20 may comprise a volume less than initial volume 14A of polyurethane foam filled article of furniture 12, yet must comprise a volume at least slightly greater than reduced volume 14B of polyurethane foam filled article of furniture 12. Preferably, package 20 may comprise a volume only slightly greater than two-thirds of initial volume 14A of polyurethane foam filled article of furniture 12, and more preferably, package 20 may comprise a volume only slightly greater than one-third of initial volume 14A of polyurethane foam filled article of furniture 12. Package 20 may be fabricated from a number of different materials known to those with ordinary skill in the art having the present disclosure before them, such as, for example, papers, woods, plastics, metals, alloys, composites, and/or combinations thereof.

[0043] Referring now to FIG. 2, a schematic representation of a second embodiment of process 10 for packaging polyurethane foam filled article of furniture is shown, which generally comprises providing step 30, compressing step 70, and package associating step 60.

[0044] For purposes of the present disclosure, it will be understood that providing step 30, package associating step 60, and all associated steps and/or elements as are shown in FIG. 2 are analogous to providing step 30, package associating step 60, and all associated steps and/or elements as are shown in FIG. 1 and described above.

[0045] Compressing step 70 generally comprises the step of compressing initial volume 14A of polyurethane foam filled article of furniture 12 to a reduced volume 14B via 5 compressor 72. As is shown in FIG. 2, initial volume 14A of polyurethane foam filled article of furniture 12 is shown in step 70A, prior to compressing step 70, and reduced volume 14B of polyurethane foam filled article of furniture 12 is shown in step 70B, subsequent to compressing step 70. It will be understood that compressor 72 may comprise any one of a number of structures, including compression rams and/or pistons which are actuated, for example, pneumatically, electrically, hydraulically, etcetera. It will be understood that compressing step 70 may be repeated at least once until initial volume 14A is reduced to a satisfactory reduced volume.

[0046] Reduced volume 14B of polyurethane foam filled article of furniture 12 may be approximately two-thirds of initial volume 14A or less. Preferably, reduced volume 14B of polyurethane foam filled article of furniture 12 is approximately one-half of initial volume 14A or less, and more preferably, reduced volume 14B of polyurethane foam filled article of furniture 12 is approximately one-third of initial volume 14A or less.

[0047] Referring now to FIG. 3, a schematic representation of a third embodiment of process 10 for packaging polyurethane foam filled article of furniture is shown, which generally comprises providing step 30, mold associating step 90, compressing step 70, binding step 100, and package associating step 60.

[0048] For purposes of the present disclosure, it will be understood that providing step 30, compressing step 70, package associating step 60, and all associated steps and/or elements as are shown in FIG. 3 are analogous to providing step 30, compressing step 70, package associating step 60, and all associated steps and/or elements as are shown in FIGS. 1 and 2 and described above.

[0049] Mold associating step 90 generally comprises the step of associating a mold 74 with polyurethane foam filled article of furniture 12 such that at least a portion of polyurethane foam filled article of furniture 12 is placed inside mold 74.

[0050] Mold 74 may retain at least a portion of polyurethane foam filled article of furniture 12 before, during, and after compressing step 70. Moreover, mold 74 may provide a boundary for polyurethane foam filled article of furniture 12 such that during compressing step 70, at least a portion of compressor 72 lowers inside of mold 74 to compress polyurethane foam filled article of furniture 12 to a geometry and/or volume substantially analogous to or lesser than the geometry and/or volume of mold 74. Mold 74 may be fabricated from any one of a number of materials suitable for molds which are known to those having ordinary skill in the art with the present disclosure before them—its only limitations being that it must be capable of retaining at least a portion of polyurethane foam filled article of furniture 12 before, during, and after compressing step 70 and that the geometry and/or volume of mold 74 be conducive to compressor 72 fitting inside of mold 74 during compressing step 70.

[0051] Binding step 100 generally comprises the step of binding reduced volume 14B of polyurethane foam filled article of furniture 12 with at least one binding agent 76 to substantially preserve reduced volume 14B. It is contemplated that at least one binding agent 76 be provided within mold 74 prior to mold associating step 90. Alternatively, at least one binding agent 76 may be loosely fitted around polyurethane foam filled article of furniture 12 before mold associating step 90. Although not shown, it is contemplated that two binding agents 76 can be associated with polyurethane foam filled article of furniture 12 to preserve reduced volume 14B. In this embodiment, two binding agents 76 may be substantially parallel and/or substantially perpendicular to each other while in association with polyurethane foam filled article of furniture 12. Furthermore, although not shown, it is contemplated that three binding agents 76 be associated with polyurethane foam filled article of furniture 12 to preserve reduced volume 14B. In this embodiment, two binding agents 76 may be substantially parallel to each other and one binding agent 76 may be substantially perpendicular to the other two binding agents 76 while in association with polyurethane foam filled article of furniture 12. In yet another embodiment incorporating binding agents 76, it is contemplated that four binding agents 76 be associated with polyurethane foam filled article of furniture 12 to preserve reduced volume 14B. In this embodiment, two binding agents 76 may be substantially parallel to each other, and two binding agents 76 may be substantially perpendicular to the other two binding agents 76 while in association with polyurethane foam filled article of furniture 12. In general, it is contemplated that any number of binding agents 76 may be associated with polyurethane foam filled article of furniture 12 such that reduced volume 14B is substantially preserved. Binding agents 76 may be fabricated from any one of a number of binding agents known to those having ordinary skill in the art, such as, for example, rope, twine, string, bands, clamps, strips, bungee cords or agents made from plastics, fabrics, elastics, woods, metals, alloys, composites, natural resins, synthetic resins and/or any combinations thereof.

[0052] In this embodiment, it is further contemplated that preserving reduced volume 14B of polyurethane foam filled article of furniture 12 may also be accomplished through the following steps in place of or in addition to binding step 100. First, once polyurethane foam filled article of furniture 12 is provided, as in providing step 30, it is associated with bag 16 having aperture 18, as in bag associating step 40 (FIG. 1). Next, initial volume 14A of polyurethane foam filled article of furniture 12 is compressed via compressor 72 to reduced volume 14B, as in compressing step 70 (FIG. 2). Reduced volume 14B may be preserved by sealing bag 16 via sealing member 19. Polyurethane foam filled article of furniture 12 may then be associated with package 20 for shipping, as in package associating step 60. However, it is also contemplated that preserving reduced volume 14B of polyurethane foam filled article of furniture 12 may be accomplished after compressing step 70 by placing polyurethane foam filled article of furniture 12 directly into package 20 to substantially preserve reduced volume 14B of polyurethane foam filled article of furniture 12, as is shown in FIG. 2, thereby excluding binding step 100.

[0053] Referring now to FIG. 4, a schematic representation of a fourth embodiment of process 10 for packaging polyurethane foam filled article of furniture 12 is shown, which generally comprises providing step 100, mold associating step 110, first compressing step 120, first binding step 130, second compressing step 140, second binding step 150, and package associating step 160.

[0054] Providing step 100 comprises the step of providing polyurethane foam filled article of furniture 12 which has a first initial length 114A and a second initial length 114B.

[0055] Mold associating step 110 generally comprises associating polyurethane foam filled article of furniture 12 with mold 74 and at least two binding agents 76. At least one binding agent 76 may be associated with polyurethane foam filled article of furniture 12 parallel to first initial length 114A, and at least one binding agent 76 may be associated with polyurethane foam filled article of furniture 12 parallel to second initial length 114B. As such, at least two binding agents 76 may be perpendicular to each other. As shown in FIG. 4, preferably, mold 74 has at least four binding agents 76 therein such that at least two binding agents 76 are associated with polyurethane foam filled article of furniture 12 parallel to first initial length 114A, and at least two binding agents 76 may be associated with polyurethane foam filled article of furniture 12 parallel to second initial length 114B. As such, two binding agents 76 will preferably be perpendicular to two other binding agents 76.

[0056] First compressing step 120 generally comprises compressing first initial length 114A of polyurethane foam filled article of furniture 12 to a first reduced length 114C via compressor 72. As is shown in FIG. 4, first initial length 114A of polyurethane foam filled article of furniture 12 is shown in step 120A, prior to first compressing step 120, and first reduced length 114C of polyurethane foam filled article of furniture 12 is shown in step 120B, subsequent to first compressing step 120. Subsequent to first compressing step 120, first reduced length 114C of polyurethane foam filled article of furniture 12 may be approximately two-thirds of first initial length 114A or less. Preferably, first reduced length 114C of polyurethane foam filled article of furniture 12 is approximately one-half of first initial length 114A or less, and more preferably, first reduced length 114C of polyurethane foam filled article of furniture 12 is approximately one-third of first initial length 114A or less.

[0057] First binding step 130 generally comprises binding first reduced length 114C of polyurethane foam filled article of furniture 12 with at least one binding agent 76 which may be parallel to first reduced length 114C. For purposes of the present disclosure, first binding step 130 is analogous to binding step 100. Preferably, first binding step 130 generally comprises binding first reduced length 114C of polyurethane foam filled article of furniture 12 with at least two binding agents 76 which may be parallel to first reduced length 114C.

[0058] Second compressing step 140 generally comprises compressing second initial length 114B of polyurethane foam filled article of furniture 12 to a second reduced length 114D via compressor 72. As is shown in FIG. 4, second initial length 114B of polyurethane foam filled article of furniture 12 is shown in step 140A, prior to second compressing step 140, and second reduced length 114D of polyurethane foam filled article of furniture 12 is shown in step 140B, subsequent to second compressing step 140. Subsequent to second compressing step 140, second reduced length 114D of polyurethane foam filled article of furniture 12 may be approximately two-thirds of second initial length 114B or less. Preferably, second reduced length 114D of polyurethane foam filled article of furniture 12 is approximately one-half of second initial length 114B or less, and more preferably, second reduced length 114D of polyurethane foam filled article of furniture 12 is approximately one-third of second initial length 114B or less.

[0059] Second binding step 150 generally comprises binding second reduced length 114D of polyurethane foam filled article of furniture 12 with at least one binding agent 76 which may be parallel to second reduced length 114D. For purposes of the present disclosure, second binding step 150 is analogous to binding step 100. Preferably, second binding step 150 generally comprises binding second reduced length 114D of polyurethane foam filled article of furniture 12 with at least two binding agents 76 which may be parallel to second reduced length 114D.

[0060] Package associating step 160 generally comprises associating polyurethane foam filled article of furniture 12 with package 20. For purposes of the present disclosure, package associating step 160 is analogous to package associating step 60.

[0061] Although not shown, it is contemplated that a fifth embodiment of process 10 for packaging polyurethane foam filled article of furniture 12 generally comprise providing step 30, bag associating step 40, a reducing step, and/or package associating step 60. It is further contemplated that binding step 100 be included in this embodiment.

[0062] For purposes of the present disclosure, it will be understood that providing step 30, bag associating step 40, package associating step 60, and all associated steps and/or elements are analogous to providing step 30, bag associating step 40, package associating step 60, binding step 100, and all associated steps and/or elements as are shown in FIGS. 1-4 and described above. The reducing step may comprise decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source as in reducing step 50 (FIG. 1) or, alternatively, the reducing step may comprise compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume as in compressing step 70 (FIG. 2 or 3).

[0063] Referring now to FIG. 5, a schematic representation of a sixth embodiment of process 10 for packaging polyurethane foam filled article of furniture 12 is contemplated, which generally comprises providing step 30, bag associating step 40, package associating step 170, at least one of reducing step 50 and compressing step 70, binding step 100, and package assembling step 180. FIG. 5 is a fragmentary representation of a sixth embodiment showing a bird's-eye-view of package 20, package associating step 170, and package assembling step 180.

[0064] For purposes of the present disclosure, it will be understood that providing step 30, bag associating step 40, reducing step 50, compressing step 70, binding step 100, and all associated steps and/or elements are analogous to those shown in FIGS. 1-4 and described above.

[0065] Package associating step 170 generally comprises associating initial volume 14A of polyurethane foam filled article of furniture 12 with package 20 which may be at least partially unassembled and having at least one binding agent 76 therein. As shown in FIG. 5, preferably, package 20 has at least four binding agents 76 therein. Furthermore, it is contemplated that at least one of reducing step 50 and compressing step 70 occur while polyurethane foam filled article of furniture 12 is associated with package 20. As such, subsequent to reducing step 50 or compressing step 70, reduced volume 14B of polyurethane foam filled article of furniture 12 may be associated with package 20.

[0066] Package assembling step 180 generally comprises assembling package 20 substantially around reduced volume 14B of polyurethane foam filled article of furniture 12 after binding the at least one binding agents 76 around reduced volume 14B of polyurethane foam filled article of furniture 12.

[0067] It will be understood that after polyurethane foam filled article of furniture 12 has been associated with package 20 in accordance with the processes disclosed herein, package 20 may be shipped using a substantially reduced sized package which can materially reduce shipping costs. It will be further understood that such a reduced sized package additionally avails the manufacturer with a plurality of shipping options not hereto available inasmuch as larger packages can eliminate a plurality of cost effective shipping options.

[0068] The foregoing description and drawings merely explain and illustrate the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.

Claims

1. A process for packaging a polyurethane foam filled article of furniture, comprising the steps of:

providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume;

associating the polyurethane foam filled article of furniture with a bag, wherein the bag has an aperture;

reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and

associating the polyurethane foam filled article of furniture with a package.

2. The process according to claim 1, wherein the step of providing a polyurethane foam filled article of furniture includes the step of providing a polyurethane foam filled article of furniture having a density of polyurethane foam ranging from between approximately 1.0 and approximately 4.0 pounds per cubic foot.

3. The process according to claim 1, wherein the step of providing a polyurethane foam filled article of furniture includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner, wherein the outer liner is flexible and at least partially gas permeable.

4. The process according to claim 3, wherein the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner which is substantially spherical.

5. The process according to claim 1, wherein the step of associating the polyurethane foam filled article of furniture with a bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, through the aperture.

6. The process according to claim 5, wherein the step of placing the polyurethane foam filled article of furniture inside of the bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, wherein the bag is fabricated from a substantially airtight material.

7. The process according to claim 1, wherein the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume comprises the steps of:

providing a vacuum source, wherein the vacuum source is capable of decreasing air pressure within a confined area;

associating the vacuum source with the aperture of the bag, wherein a substantially airtight seal is formed between the vacuum source and the aperture of the bag;

decreasing air pressure within the confined area of the bag via the vacuum source and, in turn, the polyurethane foam filled article of furniture; and

reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

8. The process according to claim 1, wherein the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately two-thirds of the initial volume.

9. The process according to claim 1, wherein the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-half of the initial volume.

10. The process according to claim 1, wherein the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-third of the initial volume.

11. The process according to claim 1, further comprising the step of sealing the bag to substantially preserve the reduced volume of the polyurethane foam filled article of furniture after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

12. The process according to claim 1, wherein the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume less than the initial volume of the polyurethane foam filled article of furniture.

13. The process according to claim 1, wherein the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume greater than the reduced volume of the polyurethane foam filled article of furniture.

14. A process for packaging a polyurethane foam filled article of furniture, comprising the steps of:

providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume;

compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and

associating the polyurethane foam filled article of furniture with a package.

15. The process according to claim 14, wherein the step of providing a polyurethane foam filled article of furniture includes the step of providing a polyurethane foam filled article of furniture wherein the polyurethane foam has a density of polyurethane foam ranging from between approximately 1.0 and approximately 4.0 pounds per cubic foot.

16. The process according to claim 14, wherein the step of providing a polyurethane foam filled article of furniture includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner, wherein the outer liner is flexible and at least partially gas permeable.

17. The process according to claim 16, wherein the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner which is substantially spherical.

18. The process according to claim 14, further comprising the step of associating the polyurethane foam filled article of furniture with a mold before the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

19. The process according to claim 18, wherein the step of associating the polyurethane foam filled article of furniture with a mold includes the step of providing a mold having at least one binding agent therein.

20. The process according to claim 18, further comprising the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent after the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

21. The process according to claim 14, further comprising the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent after the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

22. The process according to claim 21, wherein the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least two binding agents, wherein two of the at least two binding agents are perpendicular to each other.

23. The process according to claim 21, wherein the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least two binding agents, wherein two of the at least two binding agents are parallel to each other.

24. The process according to claim 21, wherein the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least three binding agents, wherein two of the at least three binding agents are parallel to each other, and wherein one of the at least three binding agents is perpendicular to two of the at least three binding agents.

25. The process according to claim 21, wherein the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least four binding agents, wherein at least two of the at least four binding agents are parallel to each other, and wherein at least two of the at least four binding agents are perpendicular to each other.

26. The process according to claim 14, further comprising the step of associating the polyurethane foam filled article of furniture with a bag, wherein the bag has an aperture, before the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

27. The process according to claim 26, wherein the step of associating the polyurethane foam filled article of furniture with a bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, through the aperture.

28. The process according to claim 27, wherein the step of placing the polyurethane foam filled article of furniture inside of the bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, wherein the bag is fabricated from a substantially airtight material.

29. The process according to claim 26, further comprising the step of sealing the bag to substantially preserve the reduced volume of the polyurethane foam filled article of furniture after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

30. The process according to claim 14, wherein the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately two-thirds of the initial volume.

31. The process according to claim 14, wherein the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-half of the initial volume.

32. The process according to claim 14, wherein the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-third of the initial volume.

33. The process according to claim 14, wherein the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume is repeated at least once.

34. The process according to claim 14, wherein the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume less than the initial volume of the polyurethane foam filled article of furniture.

35. The process according to claim 14, wherein the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume greater than the reduced volume of the polyurethane foam filled article of furniture.

36. A process for packaging a polyurethane foam filled article of furniture, comprising the steps of:

providing a polyurethane foam filled article of furniture having a first initial length and a second initial length;

associating the polyurethane foam filled article of furniture with a mold and at least two binding agents;

compressing the first initial length of the polyurethane foam filled article of furniture to a first reduced length;

binding at least one of the at least two binding agents parallel to the first reduced length of the polyurethane foam filled article of furniture;

compressing the second initial length of the polyurethane foam filled article of furniture to a second reduced length;

binding at least one of the at least two binding agents parallel to the second reduced length of the polyurethane foam filled article of furniture; and

associating the polyurethane foam filled article of furniture with a package.

37. The process according to claim 36, wherein the step of associating the polyurethane foam filled article of furniture with a mold and at least two binding agents includes the step of associating the polyurethane foam filled article of furniture with a mold having at least four binding agents therein.

38. The process according to claim 37, wherein the step of binding at least one of the at least two binding agents parallel to the first reduced length of the polyurethane foam filled article of furniture includes the step of binding at least two of the at least four binding agents parallel to the first reduced length of the polyurethane foam filled article of furniture.

39. The process according to claim 38, wherein the step of binding at least one of the at least two binding agents parallel to the second reduced length of the polyurethane foam filled article of furniture includes the step of binding at least two of the at least four binding agents parallel to the second reduced length of the polyurethane foam filled article of furniture.

40. A process for packaging a polyurethane foam filled article of furniture, comprising the steps of:

providing a polyurethane foam filled article of furniture having an initial volume;

reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume, comprising at least one of the steps of:

decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and

compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and

associating the polyurethane foam filled article of furniture with a package.

41. The process according to claim 40, further comprising the step of associating the polyurethane foam filled article of furniture with at least one binding agent after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

42. The process according to claim 40, further comprising the steps of:

associating the polyurethane foam filled article of furniture with a bag having an aperture before the step of decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and

sealing the bag to substantially preserve the reduced volume of the polyurethane foam filled article of furniture after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.

43. A process for packaging a polyurethane foam filled article of furniture, comprising the steps of:

providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume;

associating the polyurethane foam filled article of furniture with a bag, wherein the bag has an aperture;

associating the polyurethane foam filled article of furniture and the bag with an at least partially unassembled package having at least one binding agent therein;

reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume, comprising at least one of the steps of:

decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and

compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume;

binding the reduced volume of the polyurethane foam filled article of furniture with the at least one binding agent; and

assembling the unassembled package around the reduced volume of the polyurethane foam filled article of furniture.

44. A polyurethane foam filled article of furniture packaged according to at least one of claims 1-43.