Device and procedure for packing a mattress filling

Abstract

 A device (11) for packing a mattress filling (12) comprising a box-type L-shaped body (52) with prismatic section featuring successive interconnected compression chamber (54) and expulsion chamber (56) inside which two pistons (64, 66) slide in succession. The body (52) is provided with a first aperture (58) via which a first piston (64) can be inserted inside to press a filling (12) in the final part of the first chamber (54) until it is aligned with the second chamber (56), in the middle of the body (52). A second aperture (60) is provided for the insertion of a second piston (66) to expel the compressed filling towards an outlet (62) where a rigid container (70) is positioned.

Description

[0001] The present invention concerns a device for packing a mattress filling and a procedure for packing a mattress filling. The invention also refers to mattress fillings that are compressed in order to be compacted and inserted into a packing container.

[0002] The above types of mattress fillings are currently made of latex or polyurethane and, at times, features through holes to make them lighter.

[0003] These through holes are currently made by compressing the mattress filling by means of rollers and then punching its surface. However, since the rollers make the outer surfaces of the mattress filling to slide one on the other, the through holes are oblique with respect to these surfaces.

[0004] Said mattress fillings are often packed in vacuum-packaging for successive sale.

[0005] For this purpose, they are firstly placed in a wrapping usually made of flexible plastic material. The wrapping is then connected to a vacuum pump which extracts the air from the inside of the wrapping and produces a package with compact height or thickness, maintaining the filling length of approximately 2 metres, even if rolled or similar.

[0006] However, this packing procedure not only requires the use of complex and expensive machinery but the packaging obtained is not always reliable.

[0007] Additionally, when the wrapping is damaged or torn, air enters which increases the volume of the product inside, making it bulky and creating problems with transport, storage and handling.

[0008] Furthermore, when the mattress increases in volume it tends to tear the wrapping further, beginning a process that can lead to complete rupture of the wrapping.

[0009] Another important factor to be noted in this respect is that customers are reluctant to buy a mattress with packing damaged to the extent that air has penetrated inside.

[0010] Conventional packings may also be unsafe because if a person accidentally pierces the wrapping, he/she could be injured. Evidently, the problem is further aggravated if there are children in the vicinity of the vacuum-packed mattresses.

[0011] The aim of this invention is therefore to eliminate the above technical problems, producing a simple and inexpensive device and procedure for packing mattress fillings.

[0012] Another aim of the invention is to produce a packing device and procedure that permit the production of reliable safe packaging, although arranged in limited spaces.

[0013] These and other aims, according to the present invention, are achieved by producing a device for packing mattress fillings according to claim 1.

[0014] The present invention also refers to a procedure for packing mattress fillings according to claim 8.

[0015] The advantage of the device according to the present invention is that it permits the production of packages with limited bulk which are easy to transport and store. On the whole, therefore, these packages are easy to handle.

[0016] Furthermore, even when the outer packaging is damaged or torn, it is able to contain the mattress filling without complete destruction of the packaging.

[0017] Another advantage of the invention becomes clear in the light of the fact that at present there are no standard dimensions for mattresses.

[0018] At least nine different sizes of single mattress are commonly found, varying from 80x190 cm (0.8 x 1.9 m) to 90x200 cm (0.9 x 2.0 m). It should also be noted that double mattresses or mattresses with other specific dimensions are produced according to special requirements.

[0019] Both manufacturers and sellers are therefore required to produce and sell mattresses in all possible different sizes.

[0020] Advantageously, instead by using the packing device and procedure according to the present invention, it is possible to produce one single mattress filling, the dimensions of which correspond roughly to the maximum dimensions of the single mattresses currently on the market (at present 90x200 cm, i.e. 0.9 x 2.0 m) and to use this filling together with a cover having the required mattress dimensions to be sold.

[0021] The same considerations apply to double mattresses in the various dimensions possible and to mattresses of other standard dimensions.

[0022] Further characteristics and advantages of a device and a procedure for packing mattress fillings according to the present invention will become clearer from the following illustrative description intended as a non-restrictive example, referring to the attached schematic drawings, in which:

• Figure 1 shows a schematic plan view of a device for packing mattress fillings according to the invention, containing a filling to be packed;
• Figure 2 shows a schematic plan view of the device of figure 1, in a step of compressing the mattress filling;
• Figure 3 shows a schematic plan view of the device of figure 1, in a step of expelling the mattress filling into a rigid container;
• Figure 4 shows a cross section of the device for packing mattress fillings according to the invention, taken along the line IV-IV of figure 1;
• Figure 5 shows a schematic plan view of a mattress filling punching machine;
• Figure 6 shows a schematic view, enlarged and with front elevation, of the punching machine of figure 5; and
• Figure 7 shows an enlarged detail of figure 5.

[0023] With reference to figures 1-4, a packing device 11 is shown for packing or wrapping a mattress filling 12.

[0024] The filling 12 can be made of polyurethane foam or latex of any density, moulded or cut in the required dimensions.

[0025] In addition, in the preferred embodiments as will be seen below, the filling 12 features through holes 14 which, in addition to making it lighter, increase its compressibility.

[0026] The holes 14 are perpendicular with respect to the two largest walls of the filling 12 and can also have different dimensions.

[0027] In particular the holes 14 can have different dimensions in specific areas of the filling 12, according to requirements. For example they can be larger at the two ends of the filling 12 designed to support the head and feet of a user and smaller in the central area of the filling 12, as compared with the above mentioned end holes.

[0028] In this way the filling flexes to adapt to the user, with different load-bearing capacity.

[0029] The holes 14 are made using a punching machine 16.

[0030] The machine 16 comprises a rectangular fixed plate 18 provided with a lead screw 20 on each of its corners.

[0031] The lead screw 20 is coupled with a threaded pin 22 from which a cylindrical tang 24 protrudes; a thrust bearing 26 which supports a moving plate 28 locates on the tang 24.

[0032] The moving plate 28 is also rectangular and features four through holes 13 on its corners, in which the threaded tangs 24 fit without engaging.

[0033] A sprocket 30 is fitted on each tang 24, on the opposite side with respect to the bearings 26.

[0034] The four sprockets 30 engage with a chain 32 which can be driven by means of an actuator not shown.

[0035] The moving plate 28 also features four additional through holes 15 again to be found on its corners.

[0036] At each of said through holes 15, the plate 28 carries integrally an enlarged element 36 which acts as a guide for a column 34.

[0037] Actually, a sliding guide column 34, shaped and fastened to the fixed plate 18, is inserted in each of the through holes 15 and tubular elements 36.

[0038] The punching machine 16 is also provided with a mobile unit 38 with a number of punches 40. In different embodiments, the punches 40 can be all the same size or sized differently. In this case, the punches 40 positioned at the longitudinal ends of the machine 16 can have larger dimensions (i.e. diameter) while those corresponding to the central part will have smaller dimensions (i.e. diameter).

[0039] The mobile unit 38 can be driven by means of an actuator, not shown for the sake of simplicity.

[0040] The ends of the punches 40 are inserted in guide through holes 17 made on the plate 28. Aligned with the holes 17, the fixed plate 18 is provided with profiled through seats 19 in each of which a bush 42 is inserted and locked. For example, the bushes 42 feature a protruding edge which abuts against a shoulder 21 of the same seat 19.

[0041] The punching machine 16 makes the through holes 14 in the mattress filling 12 as described below.

[0042] Firstly the filling 12 is inserted between the fixed plate 18 and the moving plate 28.

[0043] Then, by rotating the chain 32, and therefore the threaded pins 22 inside the lead screw 20, the moving plate 28 is positioned against the filling 12. The moving plate 28 moves down, compressing the filling as required.

[0044] At this point the mobile unit 38 is activated as indicated by the arrow F in figure 6, so that the punches 40 pierce the filling 12 and locate in the bushes 42 of the fixed plate 18.

[0045] Then, the filling 12 in which the through holes 14 have been made can then be taken out by resetting first the mobile unit 38 and then the moving plate 28 to their initial position.

[0046] The waste material, removed from the filling 12, passes through the bushes 42 and is collected in a container, not shown for the sake of simplicity. It is important to note that this material can be very conveniently re-used, for example as padding for cushions.

[0047] Finally, it should be noted that the fixed plate 18, together with the moving plate 28, the mobile unit 38 and related punches 40, are interchangeable with similar components of different sizes. The filling 12 is packed very simply and quickly, using the device 11.

[0048] The device 11 consists of a box-type L-shaped body (52) with prismatic section comprising successive compression chamber 54 and expulsion chamber 56 positioned at right angles to each other.

[0049] The body 52 features three apertures 58, 60 and 62.

[0050] Via the aperture 58, positioned at one fist end, a sliding piston 64 can be inserted inside the body 52. In addition, via the aperture 60, positioned at the end of the sliding path of the first piston 64, an extraction piston 66 can be inserted inside body 52; said aperture 60 faces an outlet 62 positioned at the other end of the body 52. The compression chamber 54 is defined by a side portion of the body 52, by the piston 58 and the piston 66 which closes the aperture 60. Moreover, the chamber 54 is also defined and separated from the chamber 56 by a removable guillotine-type intermediate partition 68.

[0051] The expulsion chamber 56 is located in a part of the body 52 successive and opposite to the one provided with aperture 58. The chamber 56 is defined not only by a different lateral part of the body 52 (from the part that defines the chamber 54), but also by the guillotine partition 68.

[0052] At one end of the chamber 56 is the outlet 62 from which the filling 12 is expelled after being compacted.

[0053] Both the piston 64 and piston 66 are moved by means of drive systems not shown; these are positioned in line with the pistons or at the side of the body 52.

[0054] A container 70 which is to contain the filling 12 can be fitted on the part of the body 52 forming the expulsion chamber 56.

[0055] The container 70 is rigid and is usually parallelepipedal with rounded corners. The container 70 is made to measure in cardboard or rigid plastic.

[0056] The present invention also concerns a procedure for packing a mattress filling.

[0057] The filling 12 to be packed is placed inside the compression chamber 54 of the L-shaped body 52, with the aperture 60 closed by the piston 66 and the guillotine partition 68 lowered to form the side of the chamber 54.

[0058] The procedure of the invention provides for an initial compression phase performed by the piston 64 which compresses the filling 12 inside the chamber 54. The piston 64 moves until the compression chamber 54 size is similar to the transverse size of chamber 56.

[0059] At this point the guillotine partition 68 is raised so that chambers 54 and 56 communicate and the container 70 can be fitted on the part of the body 52 that forms the chamber 56.

[0060] In the second phase of the procedure, the piston 66 is translated and pushes the already compressed filling 12 towards the chamber 56.

[0061] The piston 66 pushes the filling 12 so that it passes firstly into chamber 56, then comes out of chamber 56 via the outlet 62 and is inserted in the container.

[0062] When the filling begins to come out via the outlet 62 it abuts against the bottom of the container 70. The piston 66 continues to translate, pushing the filling 12 which, in its turn, pushes the container 70 which slides off the body 52.

[0063] In practice when the piston 66 arrives at the end of its stroke near the outlet 62, the filling 12 will have been fully inserted in the container 70. In its turn, the container 70 will have come right off the body 52.

[0064] The machine in question can implement the procedure described using many different types of mattress filling. The fillings can be provided with holes 14 or be without holes, without this affecting correct operation of the device and the procedure.

[0065] The filling 12, for single mattresses for example, with one standard size, and packed as described, can be inserted in covers of different sizes according to requirements to obtain ready-to-use mattresses of different sizes.

[0066] In practice, since at least nine different main sizes of single mattress are commonly found, one single standard size mattress, corresponding to the maximum size required, compacted as described, can be inserted very easily into a cover with the desired and required dimensions.

[0067] The same consideration and simplification applies to fillings for double mattresses or with other specific requirements. Here again, one single standard size can be used, packed as described and inserted in different-sized covers to obtain ready-to-use mattresses in the various sizes required.

[0068] This reduces the need to produce different mattresses of different sizes and permits considerable financial savings. Only the covers are required in different sizes.

[0069] The versatility of the present invention is therefore obvious.

[0070] In practice, it has been observed that the device and procedure for packing a mattress filling, according to the invention, are particularly advantageous as they are simple and permit compact packing which is easy to transport, to store and, above all, to handle.

[0071] Furthermore, as already mentioned, the fillings, packed as described, can also be used inserted in covers of different sizes. This makes them very flexible and a very attractive proposition from the commercial point of view.

[0072] The device and the procedure for packing mattress fillings as conceived above can be modified and varied in a number of ways, all falling within the scope of the invention; furthermore, all the details can be replaced by technically equivalent elements. In practice any materials can be used and the dimensions can be of any size according to technical requirements.

Claims

1. A device (11) for packing a mattress filling (12) characterized in that it comprises a box-type L-shaped body (52) with prismatic section featuring a successive and interconnected compression chamber (54) and expulsion chamber (56) inside which two pistons (64, 66) slide in succession. Said body (52) is provided with a first aperture (58) via which a first piston (64) can be inserted inside to press a filling (12) in the final part of said first chamber (54) until it is aligned with said second chamber (56), in the middle portion of the body (52), a second aperture being provided (60) for the insertion of a second piston (66) to expel the compressed filling towards an outlet (62) where a rigid container (70) is positioned.

2. Device (11) according to claim (1) characterised in that said compression chamber (54) is separated from the expulsion chamber (56) by a partition (68) opposite to said second piston (66).

3. Procedure for packing a mattress filling (12) characterised in that said filling (12) is previously inserted into a compression chamber (54), a compression piston (64) then compacts the filling (12), reducing its dimensions, after which said filling (12) compacted as above is expelled from said body (52) into a container (70).

4. Procedure according to claim 3, characterised in that the filling (12) is compressed and punched before being inserted into the compression chamber to be compacted.

5. Procedure according to claim 4, characterised in that said filling (12) is punched by means of holes with different diameters in different parts of the filling.

6. Procedure according to claim 3, characterised in that said filling (12) is obtained initially by moulding or cutting from a suitable material.

7. Procedure according to any one of the claims from 2 to 6, characterised in that polyurethane foam or latex of any density is used for the filling (12).

8. Punching machine (16) for mattress fillings (12), characterised in that it comprises a fixed plate (18) coupled with a moving plate (28), said filling (12) being positioned between the fixed plate (18) and the moving plate (28). Said punching machine (16) also comprises at least one mobile unit (38) fitted with a number of punches (40) for punching said filling once said two plates (18, 28) have compressed said filling.

9. Punching machine (16) according to claim 8, characterised in that said punches (40) cross first through holes (17) of the moving plate (28) and second the through holes (42) of said fixed plate (18).

10. Punching machine (16) according to claim 8, characterised in that said fixed plate (18) is fitted with a number of lead screws (20) coupled with threaded pins (22), from which a tang (24) protrudes; said tang is rotably connected to said moving plate (28), an actuator of at least one threaded pin (22) being envisaged and said threaded pins (22) being connected by means of a drive element (32).

11. Punching machine (16) according to claim 10, characterised in that the threaded tang (24) is fitted with a sprocket (30) which can be rotated by means of a chain (32).

12. Punching machine (16) according to claim 8, characterised in that the fixed plate (18) is fitted with a number of guides (34) which slide in the through holes (15) of said moving plate (28).

13. Mattress filling (12) made of polyurethane foam or latex with a number of through holes (14), characterised in that said through holes (14) are perpendicular to the two largest walls of said filling (12) and are made after said filling has been compressed to a pre-set thickness.

14. Mattress filling (12) according to claim 13, characterised in that said through holes (14) are of different dimensions in pre-set areas of said filling (12).

Drawing