METHODS OF MANUFACTURING, COMPRESSING, ROLLING, FOLDING AND PACKAGING MATTRESSES

Abstract

A method of manufacturing and packaging a mattress includes compressing a finished mattress to flatten the finished matter and rolling said finished mattress into a cylinder. The method includes placing the compressed and rolled mattress into a bag, and sealing the bag to form a sealed bag containing the compressed and rolled finished mattress. The method includes providing an elongated container having a closed bottom end and an open upper end, and passing the sealed bag containing the compressed and rolled finished mattress through the open upper end and into the elongated container. A cap is placed over the open upper end of the elongated container.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present patent application claims benefit of U.S. Provisional Application No. 62/144,786, filed Apr. 8, 2015, and is related to U.S. patent application Ser. No. 14/627,762, filed Feb. 20, 2015, now U.S. 2015/0251843, the disclosures of which are hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present application is generally directed to mattresses and mattress toppers, and is more particularly related to methods of making and packaging mattresses and mattress toppers.

2. Description of the Related Art

Mattresses are bulky items that are difficult to transport and move from a retail store to a home. Traditionally, mattresses have been packaged and sold in a flat configuration, whereby the mattresses have the same size and dimension in a store as they do when placed atop a box spring or mattress support to make a bed. Recently, there have been efforts directed to compressing mattresses before placing the mattresses in a box, and there is now an entire industry dedicated to compressing foam and coil mattresses for retail packaging.

Commonly assigned U.S. Pat. No. 8,905,412 to Michael Fux, the disclosure of which is hereby incorporated by reference herein, discloses a wheeled container for bedding products, such as mattresses, including a container having an upper end and a lower end with a bottom surface that extends to a lower edge of the container, a pair of wheels rotatably mounted to the lower edge of the container, and a handle mounted to the container, on the same side of the container as the pair of wheels. A bedding product, such as a mattress or a mattress topper, is disposed inside the container. The mattress may be a memory foam mattress that is compressed and placed in a sealed bag. The container has a storage configuration in which a bottom face of the container is parallel to the ground, and a moving configuration in which the container is tilted onto the pair of wheels for rolling the container over the ground. When the container has been rolled to a desired location, it may be returned to the upright, storage configuration.

In spite of these advances there remains a need for improved packages for bedding products such as mattresses and mattress toppers that make it easier for consumers to transport mattresses and mattress toppers from retail stores to the home. There also remains a need for packages for mattresses and mattress toppers that are easy to ship from a manufacturing location to a retail location, that are stackable, and that are re-useable after the bedding product has been removed from the package.

SUMMARY OF THE INVENTION

In one embodiment, a package for bedding products preferably includes an elongated container having a closed bottom end and an open upper end, a removeable cap covering the open upper end of the container, and a flexible bag containing a compressed bedding product, whereby the flexible bag containing the compressed bedding product is disposed inside the elongated container. In one embodiment, the flexible bag containing the bedding product is sealed to form an air-tight parcel disposed within the elongated container.

The bedding product may be a coil mattress, a memory foam mattress, or a mattress topper. In one embodiment, the bedding product contained within the flexible bag is folded in half so that a head of the bedding product is aligned with a foot of the bedding product, and rolled from one lateral edge of the bedding product to an opposite lateral edge of the bedding product.

In one embodiment, the elongated container is an elongated tube made of paper, cardboard or cellulose, and the removeable cap is made of plastic, cellulose or metal. The elongated tube when observed from a top plan view may have various cross-sectional shapes including circles, squares, rectangles, triangles, polygons, hexagons, and/or octagons. In one embodiment, the elongated tube has a cylindrical shape and a circular cross-section.

In one embodiment, the elongated container has one or more recesses formed therein for enabling an individual to secure, hold and/or transport the package. An outer label or sheet may be placed over an outer surface of the elongated container. The label may have printed foil graphics, and the label may be fastened to the outer surface of the elongated container. In one embodiment, the elongated container may be embossed with a label or a design.

In one embodiment, a package preferably includes at least one wheel coupled with the closed bottom end of the elongated container for enabling the package to be rolled over a surface.

In one embodiment, a plurality of elongated containers may be stacked side-by-side atop a moveable structure, such as a pallet.

In one embodiment, a package for a mattress preferably includes an elongated tube having a closed bottom end and an open upper end, a removeable cap covering the open upper end of the elongated tube, and a flexible bag containing a compressed mattress, whereby the flexible bag containing the compressed mattress has an air-tight seal and is disposed inside the elongated tube.

The compressed mattress contained within the flexible bag may be folded so that a head of the compressed mattress is aligned with a foot of the compressed mattress, and rolled from one lateral edge of the compressed mattress to an opposite lateral edge of the compressed mattress.

In one embodiment, a plurality of stacked packages containing bedding products preferably includes a pallet having a top surface, a plurality of elongated containers positioned side-by-side over the top surface of the pallet, each elongated container including a closed bottom end and an open upper end, a removeable cap covering the open upper end of the elongated container, and a flexible bag containing a compressed bedding product, whereby the flexible bag containing the compressed bedding product is disposed inside the elongated container.

In one embodiment, a mattress is compressed and packed into a tube shaped container. The tube shaped container has a closed bottom end and an open top end that is covered by a cap.

In one embodiment, a memory foam mattress is folded in half so that the head of the mattress is folded to meet the foot of the mattress. The memory foam mattress is compressed. The mattress is then rolled from one lateral edge to the opposite lateral edge while being further compressed. The folded, rolled and compressed memory foam mattress is then placed in a flexible bag, such as a plastic bag, and the bag is seal to form an air-tight package. The sealed air-tight package that contains a compressed memory foam mattress is then inserted into an open end of a tub and slid into the tube until the mattress abuts against the closed bottom end of the tube. The cap is then positioned atop the open end of the tube to close the mattress tube container.

The mattress tube containers have a smaller footprint than the size of a normal mattress which minimizes the amount of space needed for shipping and display at stores. The mattress tube containers are preferably stored in an upright vertical orientation which maximizes the number of containers that may be placed onto a pallet.

In one embodiment, the tube portion of the container is made of paper, cardboard or cellulose material and the cap is made of plastic, cellulose or metal.

In one embodiment, the outer surface of the container may have one or more recesses formed therein to enable individuals to secure, hold, and transport the mattress tube container.

In one embodiment, an outer label or sheet is placed over the outer surface of the container. The label may have printed foil graphics. The outer label or sheet may be glued or applied to the outer surface using well known fastening methodologies.

In one embodiment, the mattress tube container may be embossed with a label and/or design.

In one embodiment, one or more mattress toppers may be placed inside a container.

In one embodiment, a container has a cylindrical shape with a round cross section when observed from a top plan view. In other embodiments, the containers may have different shapes when observed from top plan views including rectangular, triangular, polygon, hexagon, octagon, or any shape that is useful for enhancing container strength or facilitating nesting of the containers adjacent one another (e.g., when stacked atop a pallet).

In one embodiment, the containers may include wheels that are mounted to lower ends of the containers for enabling the containers to be rolled over a surface for transporting from a first location to a second location. The containers may have wheels and function as described in commonly assigned U.S. Pat. No. 8,905,412 to Michael Fux, the disclosure of which is hereby incorporated by reference herein.

In one embodiment, a method of manufacturing and packaging a mattress includes providing a finished mattress, compressing the finished mattress, and after compressing the mattress, rolling the mattress into a cylinder. In one embodiment, the compressed and rolled mattress is placed into a bag, and the bag is sealed.

In one embodiment, the finished mattress is a coil mattress, a memory foam mattress, or a mattress topper.

In one embodiment, the method includes providing an elongated container, and after sealing the bag with the compressed and rolled mattress inside the sealed bag, inserting the sealed bag with the compressed and rolled mattress into the elongated container. In one embodiment, the elongated container has a closed bottom end and an open upper end. In one embodiment, the inserting step includes passing the sealed bag containing the compressed and rolled mattress through the open upper end and into the elongated container. In one embodiment, a removable cap may be placed over the open upper end of the elongated container.

In one embodiment, the method includes folding the mattress in half so that a head of the mattress is aligned with a foot of the mattress. In one embodiment, the folding step occurs prior to the rolling step. In one embodiment, the rolling step includes rolling the mattress from one lateral edge of the mattress to an opposite lateral edge of the mattress. The mattress may be compressed a first time to flatten the mattress and a second time when rolling the mattress.

In one embodiment, tape may be applied to the rolled mattress to maintain the rolled mattress in the cylinder shape or the rolled configuration.

In one embodiment, the sealed bag has an air-tight seal, a vacuum seal, or a hermetic seal.

In one embodiment, the finished mattress is assembled by disposing a coil layer between a first foam substrate and a second foam substrate, and joining a first major surface of the coil layer to a major surface of the first foam layer and a second major surface of the coil layer to a major surface of the second foam layer to form a first mattress subassembly. In one embodiment, the first mattress subassembly is inserted into a fire resistant cover to form a second mattress subassembly. The second mattress subassembly is preferably disposed inside a mattress cover to form a finished mattress that is subject to the compressing and rolling steps disclosed herein.

In one embodiment, adhesive or glue may be applied to the first and second major surfaces of the coil layer during the joining step.

In one embodiment, the compressing step includes flattening the finished mattress. In one embodiment, the rolling step may include further compressing the finished mattress as the finished mattress is rolled into the cylinder.

In one embodiment, a method of manufacturing and packaging a mattress includes compressing a finished mattress to flatten the finished matter, and after the compressing step, rolling the finished mattress into a cylinder. In one embodiment, the compressed and rolled finished mattress is placed into a bag, and the bag is sealed to form a sealed bag containing the compressed and rolled finished mattress.

In one embodiment, a method includes providing an elongated container having a closed bottom end and an open upper end, and the sealed bag containing the compressed and rolled finished mattress is passed through the open upper end of the elongated container and disposed inside the elongated container. In one embodiment, a cap is place over the open upper end of the elongated container to cover the open end.

In one embodiment, prior to the rolling step, the finished mattress may be folded so that a head of the finished mattress is aligned with a foot of the finished mattress. In one embodiment, after the folding step, the finished mattress is rolled from one lateral edge to an opposite lateral edge of the finished mattress. The finished mattress may be compressed during the rolling step.

These and other preferred embodiments of the present invention will be described in more detail below.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a front elevation view of a package for a bedding product including an elongated container and a cap covering an upper end of the elongated container, in accordance with one embodiment of the present invention.

FIG. 2 shows a rear elevation view of the package of FIG. 1.

FIG. 3 shows a top plan view of the package shown in FIGS. 1 and 2.

FIG. 4 shows a top plan view of the package of FIG. 1 including a flexible bag containing a folded, rolled and compressed bedding product, in accordance with on embodiment of the present invention.

FIG. 5 shows a perspective view of packages for bedding products, in accordance with one embodiment of the present invention.

FIG. 6 shows a perspective view of a shipping and storage pallet and a plurality of the packages shown in FIG. 1 stacked side-by-side atop the pallet, in accordance with one embodiment of the present invention.

FIG. 7 shows a schematic top plan view of the packages and the pallet shown in FIG. 6.

FIG. 8 shows another schematic top plan view of the packages and the pallet shown in FIG. 6.

FIGS. 9A and 9B show a package for a bedding product, in accordance with one embodiment of the present invention.

FIGS. 10A and 10B show a package for a bedding product, in accordance with one embodiment of the present invention.

FIG. 11 shows a package for a bedding product, in accordance with one embodiment of the present invention.

FIG. 12 shows a package for a bedding product, in accordance with another embodiment of the present invention.

FIG. 13 shows a package for a bedding product, in accordance with yet another embodiment of the present invention.

FIG. 14 shows a package for bedding products, whereby the elongated container has recesses for gripping and transporting the package, in accordance with one embodiment of the present invention.

FIG. 15 shows a plurality of packages having elongated containers with a square cross-sectional shape, in accordance with one embodiment of the present invention.

FIG. 16 shows a plurality of packages having elongated containers with a triangular cross-sectional shape, in accordance with one embodiment of the present invention.

FIG. 17 shows a plurality of packages having elongated containers with a hexagonal cross-sectional shape, in accordance with one embodiment of the present invention.

FIG. 18 shows a package for bedding products including an elongated container having at least one wheel coupled with a lower end of the elongated container, in accordance with one embodiment of the present invention.

FIG. 19 shows a package for bedding products including an elongated container having wheels coupled with a lower end of the elongated container, in accordance with one embodiment of the present invention.

FIGS. 20A-20D show a method of making a foam substrate for a mattress, in accordance with one embodiment of the present invention.

FIGS. 21A-21D show a method of making a mattress using the foam substrate of FIGS. 20A-20D and a coil layer, in accordance with one embodiment of the present invention.

FIGS. 22A-22E show a method of placing the mattress subassembly of FIG. 21 D into a fire resistant cover, in accordance with one embodiment of the present invention.

FIGS. 23A-23D show a method of placing the subassembly of FIG. 22E inside a mattress cover, in accordance with one embodiment of the present invention.

FIGS. 24A-24E show a method of compressing and rolling a mattress, in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION

Referring to FIGS. 1-3, in one embodiment, a package 20 for storing bedding products, such as a compressed memory foam mattress, preferably includes an elongated container 22 having a closed bottom end 24, an open top end 26, and a lid 28 or cap that covers the opening at the top end 26 of the elongated container 22. In one embodiment, the lid 28 may be opened and removed for providing access to the container opening so that one or more bedding products may be placed into and/or removed from the elongated container 22. In one embodiment, the elongated container is an elongated tube having a cylindrical shape and a circular cross-section when observed from a top plan view. In one embodiment, the elongated tube may have other cross-sectional shapes including but not limited to square, rectangle, triangle, polygon, hexagon and octagon.

In one embodiment, the lid 28 preferably has a recess formed therein that serves as a grip for the container 20.

In one embodiment, the elongated container 22 has side walls. The outer surfaces of the side walls may be embossed with a label or a design. In one embodiment, the lid may be embossed with a label or a design.

The package 20 is preferably designed for being stacked next to and/or atop other similarly configured packages. In one embodiment, the package 20 has a flat top, a cylindrical shaped side wall and a flat bottom. The flat top and bottom surfaces of the package enable the package 22 to be stacked atop other similarly configured and dimensioned packages.

The package 20 may be provided in different sizes (e.g., different diameters) for accommodating bedding products different sizes, e.g., King size mattresses, Queen size mattresses, twin mattresses, etc.

In one embodiment, the package 20 desirably includes a label that is a laminate including a subsurface layer having an ink label printed thereon and a transparent outer layer that covers the ink printed label. The label may include one or more of the features disclosed in U.S. Pat. No. 8,875,875 to Michael Fux, the disclosure of which is hereby incorporated by reference herein. The transparent outer layer preferably provides a glossy appearance for the package 20. In one embodiment, the label may be a printed foil label. In one embodiment, the label may be secured to the outer surface of the elongated container 22 using glue or other well known attachment components.

Referring to FIGS. 4 and 5, in one embodiment, a bedding product such as a compressed mattress 30 is configured for insertion into the opening 32 at the top end 26 of the elongated container 22 of the package 20 (FIGS. 1-2). In one embodiment, a mattress is prepared for storage in the package 20 by first folding a memory foam mattress in half so that the head of the mattress overlies the foot of the mattress. The mattress is compressed as it is folded in half. The mattress is then rolled into a cylinder from one lateral side to an opposite lateral side, as the mattress is being further compressed. The folded, rolled and compressed mattress 30 is then placed inside a flexible bag 34 and the flexible bag is sealed to form an air-tight seal. In one embodiment, the compressed mattress 30 may be rolled around a core and held in a rolled configuration using tape.

In one embodiment, when closed, the flexible storage bag may be vacuum sealed and/or hermetically sealed. In one embodiment, the flexible storage bag 34 may have vent openings formed therein.

In one embodiment, after the bedding product has been removed from the elongated container 22, the elongated container may be re-used as a storage receptacle. Thus, in one embodiment, the present application discloses a package that minimizes waste.

Referring to FIGS. 6 and 7, in one embodiment, a plurality of packages 20A-20F containing bedding products are placed atop a shipping and storage pallet 50. Referring to FIGS. 6-8, in one embodiment, at least six packages 20A-20F may be placed atop a pallet 50 having a 40″×48″ outer dimension.

FIGS. 9A-9B and 10A-10B show different designs for mattress tube containers, in accordance with various embodiments of the present invention.

Referring to FIGS. 9A-9B, in one embodiment, a package 120 for bedding products preferably includes an elongated tube 122 having a closed bottom end 124, an open upper end 126, and a cap 128 that covers the open upper end 126. The lower end of the package 120 may include a bottom piece 160 made of plastic, metal or cellulose material that closes the lower end of the elongated tube. The cap 128 preferably includes tabs 162 that may be cut away or peeled away to release the cap from the open upper end 126 of the elongated tube 122.

Referring to FIGS. 10A-10B, in one embodiment, a package 220 for bedding products preferably includes an elongated tube 222 having a closed bottom end 224, an open upper end 226, and a cap 228 that covers the open upper end 226. The lower end of the package 220 may include a bottom piece 260 made of plastic, metal or cellulose material that closes the lower end of the elongated tube. The cap 228 is preferably taped to the upper end of the tube. When opening the package 220, the tape may be cut or peeled away to release the cap 228 from the open upper end 226 of the elongated tube 222.

Referring to FIG. 11, in one embodiment, a package 320 includes an elongated tube 322 having a cap 328 that is snap-fit to the open upper end 326 of the elongated tube 322.

Referring to FIG. 12, in one embodiment, a package 420 includes an elongated tube 422 having a cap 428 that is telescopically received over the open upper end 426 of the elongated tube. The package may include a tear-away or cut-away section for releasing the cap 428 from the elongated tube 422. The cap 428 may then be lifted away from the open upper end 426 of the elongated tube 422 for accessing the bedding products disposed within the elongated tube.

Referring to FIG. 13, in one embodiment, a package 520 includes an elongated tube 522 having a cap 528 that is taped or stapled to the open upper end 526 of the elongated tube 522.

Referring to FIG. 14, in one embodiment, a package 620 for bedding products has one or more recesses 670 that enable individuals to grip and transport the package. In one embodiment, a recess 670′ is formed in the lid 628 that covers the open end of the container.

Referring to FIG. 15, in one embodiment, packages 720 for bedding products have elongated tubes 722 having square cross-sectional shapes when observed from a top plan view. The square elongated tubes 722 may be stacked side-by-side atop a surface, such as the top surface of a shipping pallet. The square cross-sectional shape of the elongated tubes and the side-by-side stacking maximizes space atop a surface, such as the top surface of a pallet.

Referring to FIG. 16, in one embodiment, packages 820 for bedding products have elongated tubes 822 having triangular cross-sectional shapes when observed from a top plan view. The triangular shaped elongated tubes 822 may be stacked side-by-side atop a surface, such as the top surface of a shipping pallet. The triangular shape of the elongated tubes and the side-by-side stacking maximizes space atop a surface, such as the top surface of a pallet.

Referring to FIG. 17, in one embodiment, packages 920 for bedding products have elongated tubes 922 having hexagonal cross-sectional shapes when observed from a top plan view. The hexagonal shaped elongated tubes 922 may be stacked side-by-side atop a surface, such as the top surface of a shipping pallet. The hexagonal shape of the elongated tubes and the side-by-side stacking maximizes space atop a surface, such as the top surface of a pallet.

Referring to FIG. 18, in one embodiment, a package 1020 for bedding products preferably has at least one wheel 1080 coupled with a closed bottom end 1024 of an elongated container 1022. In one embodiment, the elongated container may be in a vertical orientation for storage and tilted onto the at least one wheel 1080 for rolling the package over a surface. In one embodiment, the at least one wheel enables a customer to roll the package out of a retail establishment and to a vehicle, or from the vehicle to a home or apartment.

Referring to FIG. 19, in one embodiment, a package 1120 for bedding products preferably has a plurality of wheel 1180A, 1180B coupled with a closed bottom end 1124 of an elongated container 1122. In one embodiment, the wheels 1180A, 1180B enable the package 1120 to be rolled over a surface. In one embodiment, the wheels enables a customer to roll the package 1120 out of a retail establishment and to a vehicle, or from the vehicle to a home or apartment.

Referring to FIGS. 20A-20D, in one embodiment, foam substrates are assembled. In one embodiment, the foam substrate comprises a single layer of foam having a length and a width that is suitable for use in manufacturing a mattress, such as a memory foam mattress. In one embodiment, two or more foam layers having a similar length and width are joined together such as by using an adhesive or glue. In one embodiment, a water base glue is dispensed evenly across a major surface of a first foam layer for joining a second foam layer to the first foam layer. In one embodiment, the water base glue is applied at a rate of about three to five grams per square foot. Using too much glue or adhesive (e.g., a rate greater than 3-5 grams per square foot) may result in decompression issues for an assembled foam layers or assembled mattresses.

Referring to FIG. 20A, in one embodiment, a stack 1200 of foam layers 1202 are provided. In one embodiment, the foam layers are separate elements that are not joined together.

Referring to FIG. 20B, in one embodiment, the foam layers 1202 are measured to confirm the lengths, widths, and thicknesses of the respective foam layers. Measuring the foam layers 1202 ensures that the foam layers match the size of a coil substrate that will be joined to the foam layers. The foam layers 1202 may conform to various mattress sizes including but not limited to single, twin, queen, king, California king, etc.

Referring to FIG. 20C, in one embodiment, a foam substrate 1204 includes separate foam layers 1202 (FIG. 20B) that are positioned atop a mattress forming support surface 1206.

Referring to FIG. 20D, in one embodiment, the foam substrate 1204 includes a first foam layer 1202A and a second foam layer 1202B that have approximately the same length, width and thickness. The foam layers 1202A, 1202B are joined together, such as by applying a glue or adhesive to the opposing major faces of the foam layers. In one embodiment, three or more foam layers may be joined together in a similar manner to provide a foam substrate.

Referring to FIG. 21A, in one embodiment, a coil layer 1208, such as a pocket coil layer, having a length, a width, and a thickness, is positioned atop the foam substrate 1204 (FIG. 20C).

Referring to FIG. 21B, in one embodiment, the coil layer 1208 is joined to the foam substrate 1204 using an adhesive or glue. In one embodiment, a glue 1210 is applied over a major surface of the coil layer 1208. In one embodiment, the glue is applied in a pattern of a picture frame border around the perimeter of the coil layer 1208. In one embodiment, the glue is a hot melt glue. In one embodiment, the glue is only applied to the top and bottom major faces of the coil layer 1208 and is not applied to the sides of the coil layer.

Referring to FIG. 21C, in one embodiment, a bottom major surface of the coil layer 1208 is aligned with and joined with a top major surface of a first foam substrate 1204A. The coil layer 1008 and the first foam substrate 1204A may be joined using an adhesive or glue.

Referring to FIGS. 21C and 21D, in one embodiment, a top major surface of the coil layer 1208 is aligned with and joined with a bottom major surface of a second foam substrate 1204B. The coil layer 1008 and the second foam substrate 1204B may be joined using an adhesive or glue.

Referring to FIG. 22A, in one embodiment, a mattress subassembly that is assembled together as shown in FIGS. 20A-20D and 21A-21D is placed inside a fire resistant cover 1210. In one embodiment, the fire resistant cover 1210 is made of a textile component that complies with federal laws and regulations regarding using flame retardant materials for mattresses. In one embodiment, the fire resistant cover 1210 is removed from a storage container and positioned on a stuffer machine 1212. In one embodiment, the seam of the fire resistant cover 1210 is placed at a center point of a bracket structure 1214 of the stuffer machine 1212.

Referring to FIGS. 22B-22E, the mattress subassembly is inserted into the fire resistant cover 1210 by activating the stuffer machine. In one embodiment, the stuffer machine is activated by pushing a button or stepping on a foot pedal.

In one embodiment, once the mattress subassembly is inserted into and/or stuffed into the fire resistant cover 1210, the second subassembly is removed from the stuffer machine and advanced to a sewing stage.

Referring to FIG. 22C, in one embodiment, excess material 1216 on the fire resistant cover 1210 is lightly pulled to remove slack. In one embodiment, the fire resistant cover should not be stretched during the steps shown in FIGS. 22A-22E as this may cause the first resistant cover to not function properly.

Referring to FIG. 22D, in one embodiment, the excess material 1216 is cut away from the second subassembly using a cutting machine 1218. Referring to FIG. 22E, in one embodiment, the cut end of the fire resistant cover 1210 is sewn together along a sewn seam 1220. In one embodiment, after the first resistant cover 1210 is sewn, the fire resistant cover is inspected to insure that no gaps exist. In one embodiment, an excess threads around the fire resistant cover 1210 are removed and/or trimmed.

Referring to FIG. 23A, in one embodiment, the second subassembly is inserted into a mattress cover 1222. In one embodiment, the mattress cover is positioned atop the mattress forming support surface 1206. In one embodiment, the mattress cover 1222 is removed from a storage container or bin and unfurled or spread out over the mattress forming support surface 1206.

Referring to FIG. 23B, the second subassembly is placed into the mattress cover 1222 and the mattress cover is closed, such as by sewing the mattress cover shut. A finished mattress 1224 has been assembled.

Referring to FIG. 23C, in one embodiment, the finished mattress 1224 is inspected for any stains and imperfections. In one embodiment, the mattress cover 1222 is checked to ensure that all or the seams and borders match evenly.

Referring to FIG. 23D, in one embodiment, the finished mattress 1224 is placed into a flexible bag 1226 such as a plastic or polymer bag that is capable of being sealed to form an air-tight or hermetic seal.

Referring to FIG. 24A, in one embodiment, the finished mattress 1224 that is disposed inside the sealable bag 1226 is advanced to a compression machine 1228 that is adapted to compress the finished mattress 1224. FIG. 24A shows the compression machine 1228. FIG. 24B shows the compressed finished mattress 1224 inside the sealable bag 1226.

Referring to FIGS. 24C-24E, in one embodiment, after the finished mattress 1224 is compressed, the bag 1226 is sealed shut. Referring to FIG. 24D, in one embodiment, after the bag 1226 is sealed, the finished mattress is folded in half from the head to the toe. Referring to FIG. 24E, in one embodiment, the folded mattress is inserted into a roll unit 1230. In one embodiment, after the mattress is rolled, tape is applied to the bag 1226 to maintain the air-tight or hermetic seal. The compressed and rolled mattress is now ready for insertion into the packaging shown and described herein (e.g., the tube shown in FIG. 4). In one embodiment, if the sealable bag is punctured or torn at any time during the packaging process, the finished mattress and bag should be removed from the machine and another bag should be used to cover the finished mattress.

Referring to FIGS. 4, 5, and 24E, in one embodiment, the compressed, rolled and sealed mattress is configured for insertion into the opening 32 at the top end 26 of the elongated container 22 of the package 20 (FIGS. 1-2). In one embodiment, the mattress is prepared for storage in the package 20 by first folding the mattress in half so that the head of the mattress overlies the foot of the mattress. The mattress may be compressed as it is folded in half. The mattress is then rolled into a cylinder 1232 from one lateral side to an opposite lateral side, as the mattress is being further compressed. The folded, rolled and compressed mattress 1232 is then placed inside a flexible bag and the flexible bag is sealed to form an air-tight seal. In one embodiment, the compressed mattress may be rolled around a core and held in a rolled configuration using tape.

In one embodiment, when closed, the flexible storage bag may be vacuum sealed and/or hermetically sealed. In one embodiment, the flexible storage bag may have vent openings formed therein.

In one embodiment, the mattress may be compressed and rolled without folding the mattress. In one embodiment, the compressed and rolled mattress may be placed inside the sealable bag before, during, or after it is being compressed and rolled. In embodiments where the mattress is folded, the compressed, folded and rolled mattress may be placed inside the sealable bag before, during, or after it is compressed, folded and rolled.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, which is only limited by the scope of the claims that follow. For example, the present invention contemplates that any of the features shown in any of the embodiments described herein, or incorporated by reference herein, may be incorporated with any of the features shown in any of the other embodiments described herein, or incorporated by reference herein, and still fall within the scope of the present invention.

Claims

1. A method of manufacturing and packaging a mattress comprising:

providing a finished mattress;

compressing said finished mattress;

after compressing said mattress, rolling said mattress into a cylinder;

placing said compressed and rolled mattress into a bag;

sealing said bag.

2. The method as claimed in claim 1, further comprising:

providing an elongated container;

after sealing said bag with said compressed and rolled mattress inside said sealed bag, inserting said sealed bag with said compressed and rolled mattress into said elongated container.

3. The method as claimed in claim 2, wherein said elongated container has a closed bottom end and an open upper end, and wherein the inserting step comprises passing said sealed bag with said compressed and rolled mattress through said open upper end and into said elongated container.

4. The method as claimed in claim 3, further comprising placing a removable cap over said open upper end of said elongated container.

5. The method as claimed in claim 1, wherein said finished mattress is selected from the group consisting of coil mattresses, memory foam mattresses, and mattress toppers.

6. The method as claimed in claim 1, further comprising folding said mattress in half so that a head of said mattress is aligned with a foot of said mattress.

7. The method as claimed in claim 6, wherein the folding step occurs prior to the rolling step.

8. The method as claimed in claim 7, wherein the rolling step comprises rolling said mattress from one lateral edge of said mattress to an opposite lateral edge of said mattress.

9. The method as claimed in claim 1, wherein the rolling step comprises rolling said mattress from one lateral edge of said mattress to an opposite lateral edge of said mattress.

10. The method as claimed in claim 1, wherein the rolling step comprises rolling said mattress around a core.

11. The method as claimed in claim 10, further comprising applying tape to said rolled mattress to maintain said rolled mattress in the cylinder.

12. The method as claimed in claim 1, wherein the sealing said bag step comprises forming an air-tight seal, a vacuum seal, or a hermetic seal.

13. The method as claimed in claim 2, wherein said elongated container comprises an elongated tube made of paper, cardboard or cellulose, and said cap is made of plastic, cellulose or metal.

14. The method as claimed in claim 13, wherein said elongated tube has a cylindrical shape and a circular cross-section.

15. The method as claimed in claim 1, wherein the providing a finished mattress step comprises:

disposing a coil layer between a first foam substrate and a second foam substrate;

joining a first major surface of said coil layer to a major surface of said first foam layer and a second major surface of said coil layer to a major surface of said second foam layer to form a first mattress subassembly;

inserting said first mattress subassembly into a fire resistant cover to form a second mattress subassembly;

inserting said second mattress subassembly into a mattress cover to form said finished mattress.

16. The method as claimed in claim 15, further comprising applying adhesive or glue to said first and second major surfaces of said coil layer during the joining step.

17. The method as claimed in claim 1, wherein the compressing step comprises flattening said finished mattress.

18. The method as claimed in claim 1, wherein the rolling step comprises further compressing said finished mattress as said finished mattress is rolled into the cylinder.

19. A method of manufacturing and packaging a mattress comprising:

compressing a finished mattress to flatten said finished matter;

after the compressing step, rolling said finished mattress into a cylinder;

placing said compressed and rolled finished mattress into a bag;

sealing said bag to form a sealed bag containing said compressed and rolled finished mattress;

providing an elongated container having a closed bottom end and an open upper end;

passing said sealed bag containing said compressed and rolled finished mattress through said open upper end and into said elongated container;

covering said open upper end of said elongated container with a cap.

20. The method as claimed in claim 19, further comprising:

prior to the rolling step, folding said finished mattress so that a head of said finished mattress is aligned with a foot of said finished mattress; and

after the folding step, rolling said finished mattress from one lateral edge to an opposite lateral edge of said finished mattress.