WO2002065874A1

WO2002065874A1 - Mattress packaging

Info

Publication number: WO2002065874A1
Application number: PCT/US2002/005418
Authority: WO
Inventors: Michael Stephen Defranks; Michael Scott Notheis
Original assignee: Dreamwell Ltd
Priority date: 2001-02-20
Filing date: 2002-02-20
Publication date: 2002-08-29

Abstract

A package for a mattress assembly (10) which comprises a wrapper (20) enclosing the mattress (10) and attachable handles (30) which when attached to the wrapper (20) are used to carry the mattress (10). The wrapper (20) and handles (30) have sufficient properties such that neither fail when the handles (30) are used to carry the mattress assembly (10). The handels (30) ahve a bonding adhesive on a bottom surface (46) for adhering to theouter surface (249 of the wrapper (20). the handles (20) are adjustable in that they are placed on the wrapper (20) at a position convenient for the specific person carrying the mattress (10). The handle (30) has a center support poriton (52) which forms a grip (50) for teh carrier's hand. The invention also relates to a method of carrying a mattress (10) by inserting a mattress (10) into a wrapper (20), sealing the mattress (10) within the wrapper (20) and attaching the adjustable landles (30) across opposite sides of the mattres (10) and carrying the mattress assembly (10) by the attached handles (30).

Description

MATTRESS PACKAGING

Background Of The Invention

The present invention relates to mattress packaging. More specifically, the present invention relates to mattress packaging which includes an improved protective wrapper and an attachable handle thereby providing a protecting covering for the mattress during shipping and storage as well as a way of carrying a packaged mattress. By their nature, mattresses are cumbersome and difficult for persons to carry due to their size, weight, and flexibility. In addition, mattresses do not have convenient gripping means and thus, it is difficult to obtain a good grip on a mattress.

Recently, mattresses have become even more difficult to carry due to the increased weight of mattress assemblies. Due to this increased weight, (a modem assembly may weigh close to two hundred pounds) two persons are required to carry a mattress. However, it is often difficult for each person to grasp a mattress at a convenient and comfortable location when the persons carrying the mattress are of different heights due to a lack of gripping means. Carrying a mattress is made even more difficult due to the fact that mattresses are susceptible to damage if carried improperly. For instance, if a mattress is carried "flat", i.e., in a position in which the sleeping surfaces are parallel to the ground, it may bend, thereby damaging the interior components of the mattress. Thus, a mattress is preferably carried on its side so as to prevent internal damage to the mattress. However, it is difficult to carry a mattress on its side without a gripping means.

After manufacture, a mattress assembly is typically moved from a manufacturing facility to a storage facility, from the storage facility to a transport vehicle, from the transport vehicle to a retail outlet, and from the retail outlet to the customer. As part of such transport, mattresses are often manually carried. Thus, carrying a mattress involves large amounts of labor which is increased due to a lack of convenient carrying means. Thus, there is a need for a means of manually carrying a packaged mattress which does not damage the mattress and which is convenient for the user.

During the handling and transport discussed above, mattresses may be subjected to a myriad of potentially damaging activities and environments. For instance, mattresses may be dragged on the ground, gripped in various manners, put in contact with other objects, exposed to rain or moisture, etc. Therefore, mattresses are typically wrapped in a protective wrapper, such as plastic or shrink-wrap, to protect the mattress from damage. The wrappers are typically installed by the mattress manufacturer and remain on the mattress until delivery to the customer so the appearance of the packaging its self is important in the sale of the product. The wrapper encloses the mattress and may be sealed by various means such as by thermo or high frequency welding. These mattress wrappers are typically made of inexpensive plastic materials which when subjected to the rigors of handling, transport, and storage discussed above, often fail or tear, thus leading to damage to the mattress as well as a poor appearance of the packaging. In recent years, the increasing weight of mattress assemblies has led to increased failure of such wrappers which often split at the welded seam or tear during handling. Thus, there is a need for a protective wrapper with sufficient tensile strength, impact strength, tear resistance, and sealability, to withstand the increased requirements associated with new heavier mattress assemblies.

A user may attempt to carry a mattress by its wrapper. However, this is difficult because the wrapper is difficult to grasp because it slides across the surface of the mattress. In addition, grasping the wrapper itself to lift the mattress often tears the wrapper or splits the wrapper at its seam, especially when used with the heavy mattress assemblies discussed above. Grasping the wrapper and sliding the mattress along the floor also tends to tear the wrapper and damage the mattress.

A person may attempt to carry a mattress wrapped in a protective wrapper by squeezing the wrapper and mattress, i.e., applying compressive force to each side of the mattress in an effort to obtain a sufficient grip to pick up the mattress, such as by pressing opposite sides of the mattress between his or her arms. However, as described above, the inner surface of the wrapper tends to slide against the outer surface of the mattress. In addition, it is difficult for a person to supply such force for long periods of time. Furthermore, the mattress springs may be damaged due to the prolonged isolated compression of a small area of the mattress springs. Manufactures have recognized the difficulty of handling mattresses, and as a result, often include built-in turning handles attached to the sides of a mattress to provide a grip by which to control amattress, as shown in U.S. PatentNo. 5,214,8 10 and 5,632,054. However, these handles are meant to be used for the rotation of a mattress on a bed and are typically insufficient for carrying a mattress. Thus, attempting to carry a mattress by its turning handles often leads to tlie handles pulling off of the mattress. In addition, such handles are covered by the protective wrapper discussed above and therefore are very difficult to grasp when wrapped. Furthermore, such handles are typically placed on the "long" side of the mattress, making it difficult to use them to raise the mattress sufficiently off tlie floor for convenient movement. In addition, such handles are typically only available on mattresses, which are periodically rotated and are not available on non-rotated bedding assemblies such as box springs and non-flip mattresses. Furthermore, such handles are permanently attached to the mattress and are not adjustable.

To assist in the transport of mattresses, several methods and packages have been developed which compress, wrap, then enclose a mattress into a separate container having a handle, as described in U.S. PatentNo. 4,711,067 and 6,098,378. However, such methods are not helpful if the mattress is at full size, i.e. not compressed. In addition, such methods cannot be used on non-compressing articles such as box springs. Furthermore, such methods require an additional container in addition to the wrapper for holding the mattress.

Some moving companies have developed mattress covers with handles for use when carrying a mattress. However, these covers are in addition to tlie wrapper installed by a manufacturer prior to shipment from the factory and are thus an additional packaging or container applied post delivery. In addition, these covers are expensive and are thus removed from the mattress after transport, by the movers and are not used to protect the mattress in storage. Furthermore, these covers are too costly to be used by a manufacturer on each mattress produced. Furtliermore, the handles on such covers are not adjustable and are generally bulky such that they would take up too much room for cost effective storage.

Thus, there is a need for an inexpensive packaging which may be applied by a manufacturer, protects the mattress during shipment and storage and allows for convenient carrying without damaging the mattress. Objects Of The Current Invention

It is an object of the invention to provide a package for a mattress which protects Hie mattress during handling and facilitates carrying H e mattress.

It is another object of Hie current invention to provide a package which allows a mattress to be conveniently carried on its side.

It is a further object of the invention to provide a package for a mattress, which facilitates carrying mattresses of varying sizes.

It is a further object of the invention to provide a mattress package which allows persons of differing heights to cany a mattress easily and conveniently. It is a further object of the current invention to provide a mattress package which is easily adjusted to the heights of tlie users.

It is a further object to provide a package which protects the mattress from the environment but is also easily carried.

It is a further object to provide a protective package for a mattress which can support the mattresses weight.

It is a further object to provide a protective package which allows for the convenient carrying of a protectively wrapped mattress.

It is a further object to provide a protective package which allows a protective wrapper to be used as a carrying means. It is a further object to provide a protective package for a mattress with a convenient handle.

Summary Of The Invention

As discussed above, mattresses are wrapped in protective wrappers after manufacture. These prior art wrappers tend to fail when used with new, heavier mattress assemblies, and such mattresses are difficult to manually carry and transport.

The present invention improves over the prior art by providing a mattress package comprising an improved wrapper and an attachable handle, which together provide a protective package that facilitates carrying the mattress. The first aspect of the package of the present invention is an improved wrapper with characteristics that allow use with heavy mattress assemblies without failure. After a thorough evaluation of available raw materials, a high-grade plastic film is used for the wrapper. The physical characteristics which are most important relative to tlie wrapper's success are tensile strength, elongation, impact strength, tear resistance and sealability. Tlie improved wrapper allows for the use of the wrapper with heavier mattress assemblies so that tl e wrapper can be used to carry tl e mattress. Particularly, the improved wrapper provides for seals that do not fail when used in connection with heavy mattress assemblies. However, in addition to the protective wrapper, a means to carry the heavy, cumbersome new mattress assemblies is also needed. Thus, the incorporation of a handle onto the package to assist in managing the heavy mattress assemblies is desirable. However, widespread use of a handle is dependent upon proper placement of the handle, which in turn is dependent upon an individual's size and strength as well as tl e specific application. Therefore, the handles of the present invention may be applied to the package when and where needed. Thus, the package of the present invention comprises a readily attachable handle applied to the mattress wrapper by the persons who will carry the mattress. The improved characteristics of the wrapper allow the wrapper itself to be a carrying "container" to which a handle can be applied for carrying conform the package of the present invention.

Given that the weight of mattresses is often nearly two hundred pounds, a very strong handle substrate with a quick acting adhesive is used. The mattress assembly's weight is such that two people are required for its safe transportation. Therefore, in a preferred embodiment, two handles are applied to the wrapper and are used, one for each person, at each end of the mattress. Because tl e handles are applied by the individuals who will do the lifting, the placement of the handles on the mattress is selected in accordance with each person's individual characteristics. Once applied, the handles have quick and sufficient adhesive strength to carry the product without detaching. Of course, the wrapper of tlie invention also has sufficient characteristics to allow for the lifting of the mattress by the handles attached to Hie wrapper without tearing.

The handle is made of an adhesive strip having exposed adhesive sections on tlie underside at each end and a non-adhesive section in the middle to create a comfortable grip. The handle is applied across the thickness of an already wrapped mattress with both adhesive sections attached to the portion of the wrapper covering the sleeping surfaces of the bed such that the non-adhesive section fonns a loop which can be grasped for lifting the mattress.

Thus, tlie combination of the improved wrapper and the self-adhesive handles attached thereto has solved tlie above-mentioned problems by providing a protective package which allows easy carrying of the mattress.

Brief Description Of Drawings:

The foregoing and other novel features and advantages of the invention will be better understood upon a reading of the following detailed description taken in conjunction with the accompanying drawings herein.

Fig. 1 is a perspective view of a mattress package with a wrapper and attached handles in accordance with present invention.

Fig.2 is a side view of a handle for use with the package of the current invention.

Fig.3 is a top view of a handle for use with the package of the invention. Fig. 4 is a top view of a mattress enclosed in a mattress package comprising a wrapper having handles attached.

Fig. 5 is a perspective view showing a handle attached to the wrapper of a mattress package.

Fig. 6 shows tl e lifting of the mattress by the mattress handles attached to the wrapper of the mattress package.

Fig. 7 shows a mattress lifted by two persons using the handle and wrapper of the mattress package of the present invention.

Best Mode for Carrying Out the Invention Although the description below refers to the packaging of a "mattress," it will be understood that the package of the present invention is not limited to use with a mattress and may apply to other bed assemblies such as box springs and the like, as well as other similar bulky items.

Referring to Hie drawings, and initially to FIG. 1, the mattress package of the current invention is illustrated showing wrapper 20 with attached handles 30 enclosing a mattress assembly 10. Wrapper 20 is flexible and fully encloses mattress 10 within itself. Wrapper 20 is generally rectangular in shape and of a size such that mattress 10 can conveniently be housed inside it with a space between tlie mattress 10 and tlie wrapper 20 such that the mattress can slide within tl e wrapper. Seam 60 is located around tlie perimeter of wrapper 20. The mattress 10 may be inserted into and enclosed by wrapper 20 by a variety of methods such as an automatic mattress wrapper machine or by manual means. Wrapper 20 may be sealed by various means such as by thermo or high frequency welding. Due to the improved properties of the wrapper 20, seam 60 remains intact even when the wrapper 20 is used to carry heavy mattress assemblies, such as mattress 10.

The wrapper 20 is made of synthetic weldable material capable of withstanding the stresses associated with tlie transport of heavy mattress assemblies and the use of handles 30 attached to the outer surface of the wrapper 20. The properties of tl e wrapper 20 that are most important are tensile strength, elongation, impact strength, tear resistance, and sealability. In a preferred embodiment, the wrapper 20 has a tensile strength between 10,000 and 5,500 psi minimum MD, and between 10,000 and 5,700 psi minimum TD, elongation between 1500 and 1000 % MD, and between 1500 and 1100 % TD; Drop Dart Impact Strength between 2000 and 900 grams minimum; Elmendorf Tear Strength between 3200 and 1500 grams miniinum MD, and between 3200 and 1600 grams minimum. TD. The wrapper 20 may be made of a film that is a metallocene catalyzed hexene linear low-density polyethelene blend product manufactured by Essex Plastics with the following specifications: 5500 psi minimum MD and 5700 psi minimum TD; elongation of 1000%- MD and 1100%TD; Drop Dart Impact strength of 900 grams minimum; and Elmendorf Tear strength of 1500 grams minimum MD and 1600 grams minimum TD.

As discussed above, a convenient means for carrying modern heavy mattress assemblies, such as mattress 10, is provided through the use of tl e handles 30 attached to wrapper 20. Due to the weight of the mattress 10, a very strong handle substrate with quick acting adhesive is required. Handle 30 comprises a generally rectangular substrate backing strip 32 having a non-adhesive top surface 42 and an adhesive bottom surface 46 (FIG. 3). Support 52 is located at the longitudinal center of the strip 32 and attached to adhesive surface 46. Together, support 52 and strip 32 form grip 50 to allow a hand to grasp handle 30. Thus, as shown in FIG.2, handle 30 has adhesive sections 44 with bottom adhesive surfaces 46 separated by support 52. Support 52 may be made of paper or other material so as to provide a convenient gripping surface. Support 52 helps prevent strip from wrinkling and provides a non-stick surface for gripping so that the user's hand does not stick to the handle, h addition, tl e support may contain writing or designs, such as a company name or logo, which may be seen through tlie transparent ship. The handle 30 is attached to wrapper 20 at position p by adhesive sections 44 such that bottom adhesive surfaces 46 adhere to the outer surface 24 of H e wrapper 20. Because the handle 30 is readily attachable and may be attached by a user who will be carrying the mattress 10, the position p of attachment of the handle 30 to the mattress 10 varies with the desires of the user. For instance, a shorter person may want to attach a handle 30 at a point lower than that of a taller person. In addition, other handles 30 may be attached, thus allowing for different users to adjust the position of the handles.

In one embodiment, handles 30 are attached opposite from each other on each side of the mattress 10 so that each handle 30 extends across thickness t of the mattress 10 so that the adhesive surfaces 46 of adhesive portions 44 are attached to Hie exterior surface of wrapper 20 which covers tlie sleeping surfaces 16 of mattress 10 (as shown in FIG. 1).

When attached to the wrapper 20, grip 50 forms a loop 70 (FIG. 4) for convenient grasping. Because the handle 30 is attached to both sides of tlie wrapper 20, this decreases the potential wobbling of the mattress when being carried. Although tlie drawings show the handle grip 50 extending from the short side 12 of the mattress, one skilled in the art would apply the handles 30 any number of different arrangements.

The handle 30 must have strength to support the weight of the mattress 10 without failing and sufficient adhesive strength not to pull loose from the wrapper 20. In one embodiment the handle is made of polyester fiber, having dimensions of 1-3/8" wide x 32" long with 18" non-adhesive backing section, and a load carry of 250 lbs. A handle meeting these specifications is manufactured by 3M under the name ScotchPad™ Carry Handle.

Thus, used in conjunction with each other, wrapper 20 and handle 30 provide a mattress package which protects a mattress and provides a convenient carry means. The attachment of the handle 30 directly onto the wrapper 20 eliminates the need of an additional container for carrying the mattress 10 and allows for adjustment of the placement of the handles 30 due to the requirements of the particular individual doing the carrying. In testing by the inventor, the wrapper has withstood the transportation and handling requirements of bedding products up to 2001bs. In addition, the handles have been used to carry mattresses weighing up to 200 lbs. Thus, the package of the present invention could allow for the shipment of a mattress wrapped by the manufacturer in the wrapper 20, such that different users could attach handles 30 for easy moving of the mattress 10.

Given that the weight of mattresses is often nearly two hundred pounds, a very strong handle substrate and quick acting adhesive is required. Handle 30 is applied by the individuals, who are doing the lifting, such that the height of the handle is appropriate for each person 80 (Fig. 7). Once applied, the handle 30 adheres to the outer surface 24 of the wrapper 20. Handle 30 has adhesive sections on each end and a non-adhesive section in the middle to facilitate a comfortable grip. The handle 30 is applied across the thickness of an already wrapped mattress 10 with both adhesive sections attached to the wrapper 20 creating a loop with the non adhesive section from which to grab and 'ease its transportation. One such handle is manufactured by 3M under the name ScotchPad™ Carry Handle having a load carry of 250 pounds and dimensions of 1-318" wide x 32" long with 18" non- adhesive section centered along the length. The combination of improved quality plastic wrapper for proper product protection and the use of self-adhesive handles to facilitate handling have solved the abovementioned problems.

Claims

Claims:

1) A package for a mattress comprising: a wrapper for enclosing tlie mattress; and at least one attachable handle attached to the wrapper such that tlie mattress package may be carried by the handle.

2) The package of claim 1 wherein the wrapper has psi, minimum MD of about 5500 and psi minimum TD of about 5700.

3) The package of claim 1 wherein the wrapper has elongation of about 1000%

MD and elongation of about 1100 % TD.

4) The package of claim 1 wherem the wrapper has drop dart impact strength of about 900 grams minimum.

5) The package of claim 1 wherem the wrapper has Elmendorf Tear strength of about 1500 grams minimum MD and about 1600 grams minimum TD.

6) The package of claim 1 wherein the wrapper has psi minimum MD of about 5500, psi minimum TD of about 5700, elongation of about 1000% MD, elongation of about 1100 % TD, drop dart impact strength of about 900 grams minimum, and Elmdorf Tear strength of about 1500 grams minimum MD and about 1600 grams minimum TD.

7) The package of claim 1 wherein the at least one attachable handle has a load carry of about 2501bs.

8) The package of claim 1 wherein the at least,one attachable handle is made of biaxially oriented polyester film with polyester yam filament reinforcement.. 9) The package of claim 1 wherein tl e at least one attachable handle is attached to tl e wrapper across a thickness of the mattress package.

10) The package of claim 1 wherein the wrapper is sealable.

11) The package of claim 1 wherein the handle is adhesively bonded to the wrapper.

12) Tlie package of claim 1 wherein the handle comprises: a backing strip having a top and bottom surface; and an adhesive disposed upon a portion of tlie bottom surface of the backing strip, the adhesive for attaching the at least one attachable handle to a surface of an object to be carried, wherein the adhesive is bonded to an exterior surface of the wrapper.

13) The package of claim 12 wherein the handle fiirther comprises a non-adhesive support located on the bottom suiface of the strip, the support defining a grip for a human hand.

14) The package of claim 13 wherein the support is made of paper.

15) The package of claim 1 wherein the wrapper is constructed from a material selected from the group of materials consisting of low-density polyethylene, linear low- density polyethylene, metallocene catalyzed linear low-density polyethylene, multilayer linear low-density polyethylene, cross-laminated isotropically-oriented polyethylene, high-density polyethylene, nylon, nylon-core co-extruded polyethylene, split nylon-core co-extruded polyethylene, split nuylon-core co-extruded polyethylene, woven polypropylene scrim, plpolypropylene, polyester or combinations thereof.

16) A mattress package comprising: a mattress; a wrapper for enclosing the mattress; and at least one attachable handle attached to the wrapper such that the wrapper and the mattress are lifted by the lifting of tl e handle.

17) The mattress package of claim 16 wherein Hie wrapper has psi minimum MD of about 5500, psi minimum TD of about 5700, elongation of 1000% MD, elongation of 1100 % TD, drop dart impact strength of 900 grams minimum, and Elmdorf Tear strength of about 1500 grams minimum MD and 1600 grams minimum TD.

18) A wrapper for a mattress, wherein the wrapper has psi minimum MD of about 5500; psi minimum TD of about 5700; elongation of 1000% MD; elongation of 1100 % TD; drop dart impact strength of 900 grams minimum; and

Elmdorf Tear strength of about 1500 grams minimum MD and 1600 grams minimum TD.

19) A method of carrying a mattress comprising tlie steps of a) enclosing a mat ress assembly in a wrapper sufficient to support Hie weight of the mattress; b) attaching at least one attachable handle to the wrapper; and c) lifting tlie handle such that tl e wrapper lifts the mattress assembly.

20) The method of claim 19 further comprising the step of sealing the wrapper.

21) The method of claim 20 wherein Hie at least one handle is attached across the thickness of the mattress. 22) The method of claim 21 wherein the at least one handle is attached to tlie wrapper at a position adjusted for a person to carry tlie mattress.