METHOD AND SYSTEM FOR SHIPPING MATTRESSES
A method and system for packaging and shipping multiple bedding products. The method includes compressing a stack of compressed and sealed mattresses between an upper shipping support and a lower shipping support and restraining subsequent expansion of the compressed and sealed mattresses with bands enclosing the upper and lower shipping supports and the stack of compressed and sealed mattresses.
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This application is a continuation-in-part of and claims the priority date of Utility application Ser. No. 12/266,137, entitled METHOD AND SYSTEM FOR PREPARING MATTRESSES FOR SHIPMENT, filed on Nov. 06, 2008, which is a continuation of Utility application Ser. No. 11/581,200, entitled METHOD AND SYSTEM FOR PREPARING MATTRESSES FOR SHIPMENT, filed on Oct. 13, 2006, now U.S. Pat. No. 7,458,193, both of which this application incorporates by reference in their entirety.
FIELD OF THE INVENTIONA method for packaging and shipping multiple bedding products, more particularly a method for packaging and shipping multiple compressed mattresses or futons together for sea and land transportation.
BACKGROUND OF THE INVENTIONPresent 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 INVENTIONThe 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 shipping mattresses includes: inserting a plurality of mattresses into separate protective bags, with at least one of the plurality of mattresses in each protective bag; compressing individually at least one of the protective bags; retaining the compression of the at least one of the compressed protective bags; placing all of the protective bags on a first support; placing a second support on top of all of the protective bags; compressing all of the protective bags between the first support and the second support; and coupling the first support and the second support together, said coupling restraining expansion of all of the protective bags. The method may also include the steps of uncoupling the first support and the second support and restoring at least one mattress to its precompression thickness.
In some embodiments according to the present invention, at least one protective bag may contain more than one mattress. Compressing the plurality of mattresses may include compressing each mattresses to a predetermined-set height. In other embodiments according to the present invention, the method may also include placing the plurality of mattresses within air-impervious bags prior to compressing. The air-impervious bag may be sealed after compressing. 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 shipping mattresses may include means for: inserting a plurality of mattresses into separate protective bags, with at least one of the plurality of mattresses in each protective bag; compressing individually at least one of the protective bags; retaining the compression of the at least one of the compressed protective bags; placing all of the protective bags on a first support; placing a second support on top of all of the protective bags; compressing all of the protective bags between the first support and the second support; and coupling the first support and the second support together, said coupling restraining expansion of all of the protective bags. The system may also include means for uncoupling the first support and the second support and restoring at least one mattress to its precompression thickness.
In some embodiments according to the present invention, at least one protective bag may contain more than one mattress. Compressing the plurality of mattresses may include compressing each mattresses to a predetermined-set height. In other embodiments according to the present invention, the system may include means for placing the plurality of mattresses within air-impervious bags prior to compressing. The air-impervious bag may be sealed after compressing. 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.
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.
For a better understanding of the present invention, reference is made to the figures, in which:
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 ft3 in space, with a recommended 2350 ft3 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.
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.
In Step 56, the compressed and sealed mattress 605 is placed on a support together with other compressed and sealed mattresses 605.
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
In Step 58, a second support is placed on top of the plurality of individual compressed and sealed mattresses 605.
In Step 60, the plurality or stack of individual compressed and sealed mattresses 605 is further compressed.
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
Weights and dimensions, for example, as presented above, are given as examples and may be varied within the scope of the invention.
In Step 62, the upper support 815 and the lower support 700 are coupled together.
Referring now to
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Multiple mattresses may be compressed in each air-impervious bag, so the protective bag 2000 may be manufactured in any number of shapes and sizes to accommodate any number of mattresses. Compressing multiple mattresses in each air-impervious bag 105 may permit faster preparation for shipment. However, doing so may result in uneven compression and damage to the mattresses. For example, although not limited thereto, if two mattresses are inserted into an air-impervious bag 105 for compression, with or without a protective bag 2000, the compression to a pre-determined height may be accomplished by over-compressing one of the mattresses and under-compressing the other. Individual mattresses may be vacuum-sealed in air-impervious bags and one or more inserted into each protective bag, although not limited thereto.
The protective bag 2000 may be manufactured so that it retains the compression of a compressed mattress or mattresses, obviating the need for an air-impervious bag 105 to retain the compression. In such a way, an individual mattress (or multiple mattresses) may be compressed and inserted (while compressed) into the protective bag 2000. The size and shape of the protective bag 2000 then restrains decompression of the compressed mattress or mattresses. In the alternative, the protective bag 2000 could be used in conjunction with an air-impervious bag 105 to retain compression, enclosed within the air-impervious bad 105 as shown in
During shipment, the compressed mattresses may be exposed to a variety of harsh surroundings. Shipping palettes, for example, may be used as supports and may have sharp edges or contain inadvertent nails or other irregularities which may puncture the air-impervious bags. In this case, the protective bag 2000 may help to protect the mattresses from damage. In an alternative, cross-member bars may be used as one or both supports to limit contact with the compressed mattresses and retain compression.
Coupling means such as metal bands, although not limited thereto, may be used to compress and/or retain compression of the stack of compressed mattresses. Coupling means may be used to compress further the plurality of mattresses between the first and second supports with a tensioner, although not limited thereto. This method of compressing further the plurality of mattresses may cause damage to the mattresses if the bands come in contact with the mattresses. A protective bag 2000 may protect the mattresses from such contact. In an alternative, a protective side panel may be used. A protective side panel may secure the top and bottom supports to each other and retain compression of the stack without the need for a securing strap, although not limited thereto.
Shipping a plurality of compressed mattresses in accordance with the present teachings is more efficient and yields better quality control since the mattresses are safely protected in the compressed assembly. Once the shipment arrives at the destination, the compressed mattresses can be removed from the supports and decompressed. If a coupling restraint is used, it may be decoupled in order to free the compressed mattresses (either individually or in subsets of more than one mattress) from each other. The mattresses may then be removed from the supports and decompressed further, although not limited thereto.
Referring now to
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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.
Claims
1. A method for preparing mattresses for shipment, the method comprising the steps of:
- inserting a plurality of mattresses into separate protective bags, with at least one of the plurality of mattresses in each protective bag;
- compressing individually at least one of the protective bags holding at least one of the plurality of mattresses;
- retaining the compression of the at least one of the compressed protective bags holding at least one of the plurality of mattresses;
- placing all of the protective bags each holding at least one of the plurality of mattresses on a first support;
- placing a second support on top of all of the protective bags each holding at least one of the plurality of mattresses;
- compressing all of the protective bags each holding at least one of the plurality of mattresses between the first support and the second support; and
- coupling the first support and the second support together, the coupling restraining expansion of all of the protective bags each holding at least one of the plurality of mattresses.
2. The method of claim 1 further comprising the step of:
- uncoupling the first support and the second support.
3. The method of claim 1 further comprising the step of:
- restoring at least one mattress to its precompression thickness.
4. The method of claim 1, wherein compressing individually the at least one of the protective bags comprises:
- compressing at least one of the protective bags holding at least one of the plurality of mattresses to a predetermined height.
5. The method of claim 1 further comprising the step of:
- placing at least one of the protective bags holding at least one of the plurality of mattresses within a bag made from substantially air-impervious material prior to the compressing individually at least one of the protective bags.
6. The method of claim 5 wherein the retaining the compression is accomplished by:
- sealing the substantially air-impervious bag.
7. The method of claim 6, wherein sealing the substantially air-impervious bag comprises:
- sealing an open end of the substantially air-impervious bag with a heated element.
8. The method of claim 1, wherein the plurality of mattresses comprises:
- at least ten mattresses.
9. The method of claim 8, wherein the plurality of mattresses comprises:
- twenty-two or fewer mattresses.
10. The method of claim 1, wherein the compressing all of the protective bags comprises:
- compressing all of the protective bags each holding at least one of the plurality of mattresses to a predetermined height.
11. The method of claim 1, wherein the compressing all of the protective bags comprises:
- compressing with a press.
12. The method of claim 1, wherein the first support is a shipping pallet.
13. The method of claim 1, wherein the second support is a shipping pallet.
14. The method of claim 1, wherein the coupling comprises:
- placing at least one band around the first support, the second support, and all of the protective bags each holding at least one of the plurality of mattresses; and
- tightening the at least one band.
15. The method of claim 1, wherein at least one protective bag has means to aid in carrying the at least one protective bag.
16. A plurality of compressed mattresses prepared by a process comprising the steps of:
- inserting a plurality of mattresses into separate protective bags, with at least one of the plurality of mattresses in each protective bag;
- compressing individually at least one of the protective bags holding at least one of the plurality of mattresses;
- retaining the compression of the at least one of the compressed protective bags holding at least one of the plurality of mattresses;
- placing all of the protective bags each holding at least one of the plurality of mattresses on a first support;
- placing a second support on top of all of the protective bags each holding at least one of the plurality of mattresses;
- compressing all of the protective bags each holding at least one of the plurality of mattresses between the first support and the second support; and
- coupling the first support and the second support together, the coupling restraining expansion of all of the protective bags each holding at least one of the plurality of mattresses.
17. A method for preparing mattresses for shipment, the method comprising the steps of:
- compressing a plurality of mattresses;
- inserting at least one of the plurality of compressed mattresses in a protective bag;
- retaining the compression of the plurality of compressed mattresses;
- placing the plurality of compressed mattresses on a first support;
- placing a second support on top of the plurality of compressed mattresses;
- compressing the plurality of compressed mattresses between the first support and the second support; and
- coupling the first support and the second support together, the coupling restraining expansion of the plurality of further compressed mattresses.
18. A method for shipping mattresses, the method comprising the steps of:
- compressing a plurality of mattresses;
- retaining the compression of the plurality of compressed 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;
- coupling the first support and the second support together, the coupling restraining expansion of the plurality of further compressed mattresses to form a stack assembly; and
- shipping the stack assembly from a first location to a second location.
19. The method of claim 18 further comprising the step of:
- uncoupling the first support and the second support.
20. The method of claim 18 further comprising the step of:
- restoring at least one mattress to its precompression thickness.
21. The method of claim 18 further comprising the step of:
- placing at least one of the plurality of mattresses within an air-impervious bag prior to the compressing a plurality of mattresses.
22. The method of claim 21 wherein at least one air-impervious bag contains more than one of the plurality of mattresses.
23. A plurality of compressed mattresses prepared by a process comprising the steps of:
- compressing a plurality of mattresses;
- retaining the compression of the plurality of compressed 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;
- coupling the first support and the second support together, the coupling restraining expansion of the plurality of further compressed mattresses to form a stack assembly; and
- shipping the stack assembly from a first location to a second location.
Type: Application
Filed: Jul 13, 2009
Publication Date: Dec 3, 2009
Applicant: Primo International (Montreal)
Inventors: Niaina Andria (Sainte-Catherine), George Itzkovitz (Hampstead)
Application Number: 12/501,776
International Classification: B65B 63/02 (20060101);