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  Method of packaging an innerspring mattressThe Patent Description & Claims data below is from USPTO Patent Application 20070204566. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001]1. Field of the Invention [0002]The present invention relates to a method of packaging a innerspring mattress. [0003]2. Reference to Related Art [0004]Mattresses, including innerspring mattresses, are known in the industry. For instance in Wells (U.S. Pat. No. 5,509,642) describes an innerspring structure for a mattress comprising a plurality of outer coils extending generally parallel with each other to collectively form top and bottom face surfaces of the innerspring structure. One or more of the outer coils has an inner coil of preferably similar shape wound within and generally coaxially with the respective outer coil. Helical lacing wire wraps adjacent end turns of the inner and outer coaxially aligned coils together to form reinforced coil units in an area of the innerspring structure to increase the firmness of an area of the mattress utilizing the invention. [0005]Richmond (U.S. Pat. No. 6,149,143) describes an innerspring structure for a mattress comprising a row of outer coils formed from a continuous piece of wire with the coils interconnected with interconnection segments and a row of inner coils similarly formed. The interconnection segments of the coils form coil heads for pairs of adjacent coils and each head includes a first linear portion disposed generally parallel to the row. The row of inner coils is positioned together and generally coaxially with the row of outer coils for forming reinforced coil units. A helical lacing structure winds around portions of the inner and outer coils to couple the coils together into reinforced coil units and the first linear portions of the coils are configured for being captured with at least approximately three loops of the helical lacing structure for forming a row of reinforced coil units. [0006]However, problems with these, and the other existing innerspring mattresses known in the art, include high transportation and storage costs, given their bulky and awkward shape. As such, retail mattress stores are often limited in the number of mattresses they store on site. This, in turn, often lead to delays and inefficiencies in delivering the mattresses to customers. [0007]It is therefore an object of the present invention to remedy these problems by reducing the costs associated with transporting and storing innerspring mattresses. SUMMARY OF THE INVENTION [0008]The present invention relates to a method of packaging an innerspring mattress. The packaging method described herein includes placing an uncompressed innerspring mattress into a first enclosure means, such as a plastic or cloth bag. The bag is preferably open on one or more sides to allow the mattress to be easily placed into it. The mattress is then compressed, preferably by a mechanical press machine. The compression could also be accomplished by creating a vacuum within the first enclosure means, or by through other means. The bag is then closed and sealed, thereby maintaining the mattress in its state of reduced thickness. The mattress and bag are then rolled into a cylinder shape and preferably taped so as to keep the mattress from unrolling. Alternatively, the mattress and first enclosure means can be folded before rolling. In an embodiment, the rolled mattress can placed into a second enclosure means, such as a second bag. This second bag could be made from a variety of materials, including, but not limited to, polyurethane (PE), plastic, or cloth or other fabric. [0009]This method allows the rolling of the mattress to be carried out by hand. In its thin, compressed state, the mattress and first bag can be folded and rolled without the use of mechanical assistance. As such, costly equipment investments can be reduced. Alternatively, the folding and/or rolling could be accomplished with mechanical assistance. [0010]Generally, mattresses can be constructed using a variety of support systems, such as air, water, foam, or springs. The term "innerspring mattress" is used herein to describe any bedding apparatus that generally encloses springs in a compartment. The compartment that encloses the springs can be made from a variety of materials, including but not limited to foam, fabric, fiber, felt, or plastic. However, the material that encloses the springs can be made from any suitable material. The term "mattress" includes not only the typical finished consumer bedding product that typically contains fabric padding surrounding the apparatus. As used herein, a "mattress" may also include an apparatus that does not include any cover around the enclosed springs. Such a mattress is often referred to as a mattress "core". A mattress "core" could be packaged and/or sold separately from a mattress cover, wherein the cover can be placed on or around the core. Mattress covers could vary in attributes such as firmness, height, etc. In any event, the term "mattress" as used herein may include a mattress "core", as well as a mattress that includes a covering. [0011]The term "foam" can include materials such as latex foam, viscoelastic foam and other polyurethane-type foams. The springs contained in mattresses are typically made from steel and usually provides at least a portion of the structure of the mattress. The term "spring" as used herein can include a variety of structures that provide or allow movement by elastic force. This includes the typical spiral shaped springs, but can also include other shapes or mechanisms, including but not limited to Z shaped springs, and/or spacers or other devices that provide structure and/or elastic force to the mattress. [0012]The method described herein is ideally suited to foam encased innerspring mattresses using pocket springs, due to the increased flexibility of pocket springs. However, foam encasement and/or pocket springs are not requirements or limitations of the invention. Typically, wire support that encircles the perimeter of the mattress is used to provide stability to the mattress. However in this invention, it is not recommended that such a configuration be used, since such an embodiment would create a greater likelihood of damaging the mattress during the packaging process. Preferably, pocket springs will be used that are individually wrapped with adhesive-bonded fabric. The adhesive-bonded fabric pockets are not only used for wrapping the spring, but also for isolating the springs from the foam material that encases them. [0013]However, this method may also be utilized on other types of spring mattresses, including, but not limited to, Bonnel type springs that have knotted end turns on the springs. BRIEF DESCRIPTION OF THE DRAWINGS [0014]FIG. 1 is a perspective view of a partially sectionalized group of three attached pocket coils. [0015]FIG. 2 is a perspective view of attached pocket coils. [0016]FIG. 3 is a perspective view of a mattress according to the invention. [0017]FIG. 4 is a perspective view of a mattress inside of a packaging bag. [0018]FIG. 5 is a perspective view of a mattress inside of a packaging bag shown in its compressed state. [0019]FIG. 6 is a perspective view of a folded mattress and packaging bag. [0020]FIG. 7 is a perspective view of a folded mattress and packaging bag after it has been compressed and rolled into a cylinder shaped roll and taped. [0021]FIG. 8 is a perspective view of the rolled mattress and packaging bag, placed in a second bag. Continue reading... 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