EVACUATED BAG WITH MATTRESS AND REUSE OF RESEALED BAG AFTER RELEASE OF VACUUM
In embodiments, a mattress is bagged, compressed, and sealed at a first geographic location. A bag utilized for the bagging has an openable and closeable vent. The bagged, compressed, and sealed mattress is shipped to a destination, second geographic location. It may be warehoused in the bagged, compressed, and sealed state, and may also be further transported to distributors or retailers. At a desired point, the bagged, compressed, and sealed mattress is vented before the final end use. Such may occur before delivery to the retailer or retail customer. The vent is reclosed and the bagged uncompressed and sealed mattress is then delivered to the retailer or end user. A bagged, compressed, sealed mattress has an openable and closeable vent.
This application claims priority to U.S. Provisional Application No. 62/273,143 filed Dec. 30, 2015. Said application is incorporated by reference herein.
FIELD OF THE DISCLOSUREThe present invention relates to innerspring mattresses and more particularly to a packaged mattress assembly including an innerspring mattress.
BACKGROUND OF THE INVENTIONMattresses are bulky items that are expensive to ship. Upon sale and delivery to retail customers, the mattresses must be aesthetically perfect, undamaged and clean. Mattresses typically have a fabric covering that can retain dirt, dust and debris. Such soiling is unacceptable prior to delivery to the end consumer and thus mattresses need to be protected during shipment. Mattresses may be manufactured at remote locations, for example overseas, and shipped by cargo container in ships or by truck to a destination country. At such destination country, the mattresses are shipped, typically by truck, to distributors, warehouses, retailers, and ultimately end users. It is advantageous to bag, compress, and seal mattresses at their site of manufacture prior to overseas or other distant shipment due to the reduced volume and corresponding savings in the shipment. For commodity items such as mattresses, margins can be low and any savings, in shipping, packaging, handling can be significant.
SUMMARY OF THE INVENTIONIn embodiments, a mattress is bagged, compressed, and sealed at a first geographic location. A bag utilized for the bagging has an openable and closeable vent. The bagged, compressed, and sealed mattress is shipped to a destination, second geographic location. It may be warehoused in the bagged, compressed, and sealed state, and may also be further transported to distributors or retailers. At a desired point, the bagged, compressed, and sealed mattress is vented before the final end use. Such may occur before delivery to the retailer or retail customer. The vent is reclosed and the bagged uncompressed and sealed mattress is then delivered to the retailer or end user.
In embodiments, the bag is a rectilinear prism shaped form fitting bag sized to standard sized mattresses and has a closed, openable, and recloseable vent thereon before the bagging. In other embodiments, a recloseable vent is added during the process of compressing, bagging, and sealing the bagged mattress.
A feature and advantage of embodiments of the invention is that the bag in which the mattress is bagged, compressed, sealed, and shipped, from a first location to a second location is maintained on the mattress after the mattress is vented and allowed to expand to its normal size. Said bag may be resealed to keep dirt, debris, out of the packaged mattress.
A feature and advantage of embodiments is that the mattress can be vented, allowing the bagged compressed mattress to return to it original size manually without any hand tools. In embodiments the vent can be reclosed after venting without any hand tools and without adding any further materials or things.
The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE DRAWINGSWhile this invention may be embodied in many different forms, there are described in detail herein specific embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.
In the embodiment of
Referring to
The form fitting bags may be about the size of standard size mattresses with extra material on one end. Examples of mattress sizes include king, queen, full, twin and crib. A king size mattress may have a width of about 76 inches and a length of about 80 inches. A queen size mattress may have a width of about 60 inches and a length of about 80 inches. A full size mattress may have a width of about 53 inches and a length of about 75 inches. A twin size mattress may have a width of about 38 inches and a length of about 75 inches. A crib size mattress may have a width of about 28 inches and a length of about 52 inches. So the mattresses are corresponding sized with some extra room for easy insertion and with extra material on an open end of the bag for sealing, see
The bag wall (such as, for example, bag wall 122) may comprise various materials without deviating from the spirit and scope of this detailed description. In some useful embodiments, the bag wall comprises polymeric film. Polymeric film materials that may be suitable in some applications include: polyethylene terephthalate (PET), polypropylene (PP), polyvinyl chloride (PVC), polyethylene (PE), high density polyethylene (HDPE), low density polyethylene (LDPE) and biaxially oriented polypropylene (BOPP). The bag wall (such as, for example, bag wall 122) may have various thickness values without deviating from the spirit and scope of this detailed description. In an embodiment, the bag wall of a bag of a packaged mattress assembly has a thickness between about 10 mil and about 0.5 mil. In an embodiment, the bag wall of a bag of a packaged mattress assembly has a thickness between about 6 mil and about 1.0 mil. In an embodiment, the bag wall of a bag of a packaged mattress assembly has a thickness between about 4 mil and about 1.5 mil. In an embodiment, the bag wall of a bag of a packaged mattress assembly has a thickness of about 3 mil. In all cases, the thickness is sufficient to not allow the compressed sealed mattress bag to deform or rip to allow unintended venting of the bag.
With reference to
The packaged mattress assembly 100 of
The adhesive strip 132 may be partially or completely removed from the bag wall 122 to release the packaged mattress assembly 100 from the compressed evacuated state. The packaged mattress assembly 100 may transition to the uncompressed non evacuated state when the adhesive strip is partially or completely removed to open the vent 130. Once the packaged mattress assembly 100 is in the uncompressed non evacuated state, the adhesive strip 132 may be replaced on the slit 134 to reseal the bag 102.
With reference to
With continuing reference to
Various methods may be used to assemble the packaged mattress assembly 100 and to place the packaged mattress assembly in the compressed evacuated state without deviating from the present detailed description. Examples of such methods are disclosed in the following United States Patents, which patents are hereby incorporated by reference in their entirety: U.S. Pat. No. 3,611,524, U.S. Pat. No. 5,622,030, U.S. Pat. No. 6,098,378, U.S. Pat. No. 7,458,193, and U.S. Pat. No. 7,895,813. Examples of additional methods are disclosed in the following published United States patent applications, which patent applications are hereby incorporated by reference in their entirety: US2007/0204566, US2014/0157518, and US2015/0274356.
A packaged mattress assembly may include various valve structures without deviating from the spirit and scope of this detailed description. Examples of such valve structures are disclosed in the following United States Patents, which patents are hereby incorporated by reference in their entirety: U.S. Pat. No. 1,555,373, U.S. Pat. No. 1,917,535, U.S. Pat. No. 2,859,932, U.S. Pat. No. 3,600,727, U.S. Pat. No. 5,632,291, U.S. Pat. No. 8,579,870, U.S. Pat. No. 4,924,899, U.S. Pat. No. 6,960,113, U.S. Pat. No. 3,141,261, and U.S. Pat. No. 4,758,198.
In the embodiment of
In
In some cases, the internal pressure PI present inside cavity 128 may be less than the external pressure PE while a mattress located inside the cavity 128 is in a compressed evacuated state. When this is the case, the adhesive strip 132 may prevent de-evacuation of the mattress 104 and the bag 102 may maintain the mattress 104 in the compressed evacuated state. In the embodiment of
In
With continuing reference to
If desired, the adhesive strip 132 may be replaced over the slit 134 after the pressure has equalized thereby closing the vent 130. In some useful methods in accordance with this detailed description, the bag may remain in position surrounding the mattress while the mattress is handled, stored and transported. When this is the case, the bag may serve to protect the mattress from soiling, staining and abrasion while the mattress is handled, stored and transported.
In an embodiment, a packaged mattress comprises a mattress and a bag having a bag wall. The bag wall may carry an openable and closeable valve in fluid communication with a cavity defined by the bag wall for providing the necessary venting when the bagged, compressed, and sealed mattress is converted to the bagged uncompressed mattress. A packaged mattress assembly may include various valves without deviating from the spirit and scope of this detailed description. Examples of such valves are disclosed in the following United States Patents, which patents are hereby incorporated by reference in their entirety: U.S. Pat. No. 1,555,373, U.S. Pat. No. 1,917,535, U.S. Pat. No. 2,859,932, U.S. Pat. No. 3,600,727, U.S. Pat. No. 5,632,291, and U.S. Pat. No. 8,579,870. Generally these valves will be attached to the bags before the bags are provided for the bagging, compressing, and sealing the mattresses.
In some useful embodiments, the packaged mattress may be disposed inside an intermodal shipping container while the packaged mattress is transported from the first geographic region to the second geographic location. The intermodal shipping container may be transported using ocean going vessels, railroads, airplanes, and/or over-the-road vehicles. Intermodal shipping containers that may be suitable in some applications are disclosed in the following United States Patents, which patents are hereby incorporated by reference in their entirety: U.S. Pat. No. 2,853,968, U.S. Pat. No. 4,082,051, U.S. Pat. No. 7,827,738, and U.S. Pat. No. 9,004,832.
At block 150B, an openable and closeable vent on the bag is opened at the second geographic region to release the packaged mattress from the compressed evacuated state to an uncompressed non evacuated state. In some useful embodiments, the step of opening an openable and closeable vent on the bag at the second geographic region occurs at a warehouse of a retail distributor or a wholesale distributor. In other useful embodiments, the step of opening an openable and closeable vent on the bag at the second geographic region occurs in or proximate to a delivery vehicle that delivers the packaged mattress to an end user who has purchased the mattress.
At block 150C, the openable and closeable vent is closed at the second geographic region. In some useful methods in accordance with this detailed description, the vent may be resealed and the bag may remain in position surrounding the mattress while the mattress is handled, stored and transported. When this is the case, the bag may serve to protect the mattress from soiling, staining and abrasion while the mattress is handled, stored and transported.
At block 150D, the uncompressed non evacuated packaged mattress is delivered with the closed vent to an end user who has purchased the mattress.
Various methods may be used to assemble a packaged mattress assembly and to place the packaged mattress assembly in a compressed evacuated state without deviating from the present detailed description. Such methods may include the step of providing a plurality of suitably sized bags. Each bag may comprise a bag wall having an interior surface defining a cavity. Each bag may also include a vent configured to be selectively opened and closed. For example, the vent may comprises an adhesive strip overlaying a slit in the bag wall.
A mattress may be inserted into the cavity of each bag. The bag and the mattress may then be placed in a hydraulic press capable of compressing the mattress. The mattress may then be compressed using the hydraulic press. As the mattress is compressed, air will be expelled from the cavity of the bag. If desired, additional air may be removed from the cavity of the bag using one or more vacuum pumps. An opening of the bag may be sealed. In some cases, a heat sealing process may be used to seal the opening of the bag. For example, the bag wall me be squeezed between two heated bars covered with Teflon coated fiberglass causing the inner surface of the bag wall to be welded to itself along a heat seal line.
Methods which may be suitable in some applications are disclosed in the following United States Patents, which patents are hereby incorporated by reference in their entirety: U.S. Pat. No. 3,611,524, U.S. Pat. No. 5,622,030, U.S. Pat. No. 6,098,378, U.S. Pat. No. 7,458,193, and U.S. Pat. No. 7,895,813. Examples of additional methods are disclosed in the following published United States patent applications, which patent applications are hereby incorporated by reference in their entirety: US2007/0204566, US2014/0157518, and US2015/0274356.
Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.
Claims
1. A packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising:
- a bag having a bag wall, the bag wall having an interior surface and exterior surface, the interior surface defining a cavity, the mattress disposed inside the cavity;
- the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state;
- whereby when the packaged mattress is in the compressed evacuated state, the bag wall having an openable and closeable vent in fluid communication with the cavity, the openable and closeable vent comprising an adhesive strip overlaying a slit in an exterior surface of the bag wall, the adhesive strip being positioned to cover and close the slit in the bag wall, whereby when the packaged mattress is in the compressed evacuated state, the adhesive strip prevents de-evacuation of the packaged mattress and maintains the packaged mattress in the compressed evacuated state, and whereby the adhesive strip may be at least partially removed for releasing the packaged mattress from the compressed evacuated state, whereby the packaged mattress goes to the uncompressed non evacuated state, the adhesive strip replaceable on the slit when the mattress is in the uncompressed non evacuated state.
2. The packaged mattress of claim 1, wherein the bag is form fit to the packaged mattress when the packaged mattress is in the uncompressed non evacuated state.
3. The packaged mattress of claim 1, wherein the adhesive strip comprises a tab adapted and dimensioned to be grasped between a thumb and a finger of a hand when the mattress is in the compressed evacuated state.
4. The packaged mattress of claim 3, wherein the tab comprises a part of the adhesive strip that is folded so that a first portion of the substrate overlaps a second portion of the substrate with the adhesive covering the first portion is adhered to the adhesive covering the second portion.
5. The packaged mattress of claim 4, wherein the seal is broken when the adhesive strip is peeled away from the exterior surface of the bag wall.
6. The packaged mattress of claim 1, wherein an interior pressure inside the cavity is less than an atmospheric pressure outside of the cavity so that the atmospheric pressure on the exterior surface of the bag wall applies compressive forces to the mattress.
7. The packaged mattress of claim 6, wherein:
- the mattress is biased to assume a relaxed shape in which the mattress has a first thickness; and
- the compressive forces applied to the mattress urge the mattress to assume a compressed shape in which the mattress has a second thickness that is smaller than the first thickness.
8. The packaged mattress of claim 1 wherein the closed vent is defined by a slit in the mattress wall, the slit openable and closeable.
9. The packaged mattress of claim 8 wherein the slit is openable and closeable by a strip of adhered material covering the slit.
10. A packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising:
- a bag having a bag wall, the bag wall having an interior surface and exterior surface, the interior surface defining a cavity, the mattress disposed inside the cavity, the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state, the mattress having a length and a width defined by a top side surface and a bottom side surface of the mattress, the length and width substantially the same when the packaged mattress is in the compressed evacuated state and when the packaged mattress is in the uncompressed non evacuated state;
- the bag configured such that when the packaged mattress is in the uncompressed non evacuated state, the bag is form fit to the mattress;
- whereby when the packaged mattress is in the compressed evacuated state, the bag wall having a defined venting region visually identifiable and differentiated on the bag wall, the defined venting region in fluid communication with the cavity, the wall having a closed vent manually openable without separate tools at the venting region for releasing evacuation in the packaged mattress whereby the packaged mattress goes to the uncompressed non evacuated state;
- the vent closeable after the packaged mattress is in it uncompressed non evacuated state without using separate tools or components.
11. The packaged mattress of claim 10 wherein the closed vent is defined by a slit in the mattress wall, the slit openable and closeable.
12. The packaged mattress of claim 11 wherein the slit is openable and closeable by a strip of adhered material covering the slit.
13. The packaged mattress of claim 10 wherein the closed vent has an openable and closeable valve in a circular air passageway.
14. The packaged mattress of claim 10 wherein the vent comprises a pair of sealable edge surfaces.
15. The packaged mattress of claim 10 where in the closed vent is utilizable for evacuating the packaged mattress to the compressed evacuated state.
16. The packaged mattress of claim 10, wherein the bag is form fit to the packaged mattress when the packaged mattress is in the uncompressed non evacuated state.
17. The packaged mattress of claim 10, wherein the adhesive strip comprises a tab configured to be grasped between a thumb and a finger of a hand when the mattress is in the compressed evacuated state.
18. The packaged mattress of claim 17, wherein the tab comprises a part of the adhesive strip that is folded so that a first portion of the substrate overlaps a second portion of the substrate with the adhesive covering the first portion is adhered to the adhesive covering the second portion.
19. The packaged mattress of claim 18, wherein the seal is broken when the adhesive strip is peeled away from the exterior surface of the bag wall.
20. A packaged mattress, the packaged mattress having a compressed evacuated state and being releasable to an uncompressed non evacuated state, the packaged mattress comprising:
- a bag having a bag wall, the bag wall having an interior surface and exterior surface, the interior surface defining a cavity, the mattress disposed inside the cavity;
- the mattress having a thickness direction and having a reduced thickness measured in the thickness direction when packaged mattress is in the compressed evacuated state and having an expanded normal thickness when in the uncompressed non evacuated state;
- whereby when the packaged mattress is in the compressed evacuated state, the bag wall having an openable and closeable vent in fluid communication with the cavity, the openable and closeable vent comprising an adhered strip overlaying an exterior surface of the bag wall, the adhered strip being positioned to cover and close a slit in the bag wall, whereby when the packaged mattress is in the compressed evacuated state, the adhered strip prevents de-evacuation of the packaged mattress and maintains the packaged mattress in the compressed evacuated state, and whereby the adhered strip may be at least partially removed to de-evacuate the packaged mattress releasing the packaged mattress to the uncompressed non evacuated state, the adhered strip replaceable on the exterior surface of the bag wall; and
- a seal formed at the vent and the exterior surface of the bag wall so that the adhesive strip prevents fluid communication between the passageway and an outside atmosphere.
Type: Application
Filed: Dec 30, 2016
Publication Date: Jul 6, 2017
Inventor: Stephen R. STICKLER (Oak Ridge, NC)
Application Number: 15/395,628