U.S. patent application number 14/143003 was filed with the patent office on 2015-07-02 for mattress package.
The applicant listed for this patent is Todd M. Morgan, Eric Marshall TeVault, Steven W. Tyree. Invention is credited to Todd M. Morgan, Eric Marshall TeVault, Steven W. Tyree.
Application Number | 20150183567 14/143003 |
Document ID | / |
Family ID | 53480927 |
Filed Date | 2015-07-02 |
United States Patent
Application |
20150183567 |
Kind Code |
A1 |
TeVault; Eric Marshall ; et
al. |
July 2, 2015 |
MATTRESS PACKAGE
Abstract
A mattress package having a barrier layer which encapsulates the
entire mattress, two skid pads which cover and protect the top and
bottom portion of the mattress, and two side trays which cover and
protect the left and right sides of the mattress. The side trays
cover a portion of the skid pads and the entire assembly is banded
by two or more securing bands. Two or more handles are positioned
on the front and back surfaces of the side trays on both the left
and right sides. The handles provide grips for the mattress package
to facilitate handling. The mattress package provides sufficient
strength and protection to the mattress while utilizing a minimal
amount of packaging materials.
Inventors: |
TeVault; Eric Marshall;
(Winston Salem, NC) ; Morgan; Todd M.;
(Kernersville, NC) ; Tyree; Steven W.; (High
Point, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TeVault; Eric Marshall
Morgan; Todd M.
Tyree; Steven W. |
Winston Salem
Kernersville
High Point |
NC
NC
NC |
US
US
US |
|
|
Family ID: |
53480927 |
Appl. No.: |
14/143003 |
Filed: |
December 30, 2013 |
Current U.S.
Class: |
206/326 |
Current CPC
Class: |
B65D 85/07 20180101;
B65D 81/055 20130101; B65D 81/058 20130101 |
International
Class: |
B65D 81/05 20060101
B65D081/05 |
Claims
1. A mattress package comprising: a barrier layer which
substantially encloses a mattress; two skid pads which are
positioned over a top side and a bottom side of the mattress and
over the barrier layer; two side trays having a floor and four side
walls, the four side walls having a plurality of apertures thereon
which serve as gripping points; wherein a first side tray is
positioned over the right side of the mattress and a second side
tray is positioned over the left side of the mattress, and wherein
the two side trays are secured to the mattress using two or more
removable straps which wrap around the mattress package, and
wherein the plurality of apertures for each side tray is formed
entirely on a single planar surface of the side tray.
2. The mattress package of claim 1, wherein the two skid pads and
two side trays are made of double walled corrugated cardboard.
3. The mattress package of claim 1, wherein the barrier layer is a
polyethylene bag.
4. The mattress package of claim 1, wherein the two side trays
extend over a top surface and a bottom surface of the mattress for
approximately 9 inches.
5. The mattress package of claim 1, wherein the two side trays each
contain eight apertures which serve as gripping points.
6. The mattress package of claim 1, wherein the length of each of
the two side trays is approximately equal to the length of the
mattress.
7. The mattress package of claim 1, wherein the width of each of
the two skid pads is less than or equal to the width of the
mattress.
8. The mattress package of claim 1, wherein each of the two side
trays extend over a portion of the two skid pads.
9. The mattress package of claim 1, wherein the two side trays are
secured to the mattress using four removable straps.
10. The mattress package of claim 1, wherein there are six gripping
points on a top surface of the mattress, six gripping points on a
bottom surface of the mattress, two gripping points on a top side
surface of the mattress and two gripping points on a bottom side
surface of the mattress.
Description
RELATED APPLICATIONS
[0001] This patent application is a continuation of U.S. patent
application Ser. No. 13/357,865, filed Jan. 25, 2012 which claims
priority to U.S. Patent Application No 61/435,967, filed on Jan.
25, 2011. The aforementioned United States patent applications are
incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention pertains generally to packaging and
protective covering, and more particularly to packaging for
mattresses or other products of similar characteristics, shapes or
dimensions.
BACKGROUND OF THE INVENTION
[0003] The packaging of mattresses for shipping, distribution,
handling and eventual sale presents a formidable challenge given
the size and nature of the product. Mattresses are too large for
practical packaging in a separate container such as a box, yet must
have substantial protection from damage and soiling to maintain the
"as new" condition required for retail marketing and sale. This has
led to the widespread use of heavier gauge plastic film as a
wrapping material which encapsulates the mattress. The formation of
a plastic film package about a mattress has been automated, as
descried for example, in U.S. Pat. Nos. 5,934,041, 6,178,723 and
6,273,257. These packages typically produce a fused seam of the
plastic sheet material about the perimeter of the mattress which,
although strong enough to keep the sealed plastic package intact,
does not provide any greater barrier than the inherent strength of
the plastic sheet material. The strength of this type of packaging
is in many instances inadequate to protect the product completely
from the factory to final installation in a purchaser's bedroom.
This is largely due to the substantial size and weight of modern
day mattresses, and the handling tendency to stock and mown the
so-packaged mattress along the peripheral border, Because such
package has no built-in gripping points, the plastic material is
further stressed by gripping of a section of material by the
handlers. Once the plastic is torn, either as a result of such
handling or from abrasion, the mattress upholstery is readily
exposed to soiling and damage, which significantly reduces the
retail value or even prevents retail sale of the product. Given the
substantially cost and handling requirements of these types of
products, returns and recalls due to failure of the packaging are
extremely costly to the manufacturer.
[0004] Thus there is a need for a mattress package which provides
adequate protection while providing convenient gripping points and
which utilizes a minimal amount of material.
SUMMARY OF THE INVENTION
[0005] The mattress packaging of the present disclosure and related
inventions is described herein as having a barrier layer which
substantially encloses a mattress, two skid pads which are
positioned over a top side and a bottom side of the mattress and
over the barrier layer, and two side trays having a floor and four
side walls, the four side walls having a plurality of apertures
thereon which serve as gripping points. A first side tray is
positioned over the right side of the mattress and a second side
tray is positioned over the left side of the mattress and the two
side trays are secured to the mattress using two or more removable
straps which wrap around the mattress package.
[0006] In another aspect of the invention, a mattress package is
described as having a substantially rectangular mattress having a
top surface, a bottom surface opposite and parallel to the top
surface and four side walls perpendicular to and extending between
the top and bottom surface, a barrier layer comprising two sheets
of material which are closed around a mattress on four sides, a
first skid pad which comprises a u-shaped channel having a floor
and two side walls wherein a first side wall of the mattress is
inserted into the u-shaped channel, a second skid pad which
comprises a u-shaped channel having a floor and two side walls
wherein a second side wall of the mattress, located opposite the
first side, is inserted into the u-shaped channel, a first side
tray which comprises a floor, two side walls and two end walls,
wherein a third side of the mattress is inserted into the first
side tray, and a second side tray which comprises a floor, two side
walls and two end walls, wherein a fourth side wall of the mattress
is inserted into the second side tray and at least two removable
straps attached horizontally around the mattress over the first and
second side trays.
DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a side tray of the Mattress
Package of the present invention.
[0008] FIG. 2 is a top view of a representative die cut of a side
tray used in the Mattress Package of the present invention.
[0009] FIG. 3 is an exploded view of a mattress and components of
the Mattress Package of the present invention,
[0010] FIG. 4 is a perspective view of a fully assembled Mattress
Package of the present invention.
[0011] FIG. 5 is a top view of a representative die cut of an
alternate embodiment of the side tray used in the Mattress Package
of the present invention.
DETAILED DESCRIPTION OF PREFERRED AND ALTERNATE EMBODIMENTS
[0012] The mattress packaging of the present disclosure and related
inventions provides sufficient protection to the mattress while
minimizing the amount of materials used. The packaging material
includes a plastic wrapping or bag, two cardboard skid pads, and
two cardboard side trays,
[0013] A barrier layer 42 (shown in FIG. 4) is first positioned
around the mattress 50 to protect the mattress 50 from dirt,
debris, rain, snow or any other substance coming in contact with
the mattress 50. In a preferred embodiment, the barrier layer 42 is
a 4-mil polyethylene bag-like structure, although any suitable
material producible in sheet or bag form and which can be sealed by
thermal or mechanical means can be used. The barrier layer 42
envelopes the entire mattress 50 and includes one open end through
which the mattress is inserted. Once the mattress 50 is completely
covered by the barrier layer 42, the open end is closed using an
adhesive or other thermal or mechanical closing mechanism.
[0014] Two skid pads 40 are used to protect the top and bottom
sides of the mattress perimeter 52. Each skid pad 40 consists of a
single piece of cardboard having two fold lines along which each
skid pad 40 is folded to form a U-shaped channel having a floor and
two side walls into which each end of the mattress is inserted. The
skid pads 40 protect the top and bottom sides and border of the
mattress 50.
[0015] A fully assembled side tray 10, shown in FIG. 1 includes a
floor A or bottom and four side walls B, C, D, E with an open top
through which a long side of a mattress 50 is inserted. A die cut
of a side tray 10 is shown in FIG. 2. The side tray 10 contains
three elongate panels. A main panel A is connected to a first side
panel B along a first fold line 12 and a second side panel C along
a second fold line 14. In a preferred embodiment, the main panel A,
first B and second C side panels are each approximately 811/4''
long, with the main panel A being approximately 12 13/16'' wide and
each of the first B and second side panels being approximately
87/8'' wide. Side tab F is connected to one distal end of side
panel B along fold line 16 and side tab C is connected to the
opposite distal end of side panel B along fold line 18. Side tab H
is connected to one distal end of side panel C along fold line 20
and side tab I is connected to the opposite distal end of side
panel C along fold line 22. End tab D is connected to one distal
end of main panel A along fold line 24 and end tab E is connected
to the opposite distal end of main panel A along fold line 26. End
tab D is further connected to intermediate tab J along fold line 28
and intermediate tab J is connected to locking tab K along fold
line 30. End tab E is further connected to intermediate tab L along
fold line 32 and intermediate tab L is connected to locking tab M
along fold line 34.
[0016] As further shown in FIG. 2, side panels B and C each contain
three apertures 36 which are evenly spaced apart from the
horizontal center of the panel. Each aperture 36 is approximately
five inches wide having a substantially oval shape to accommodate
the hand of a user. Two outer apertures 36a, 36c are strategically
positioned approximately 20 inches from each end of each side panel
with approximately 12 13/16 inches between a center aperture 36b
and the two outer apertures 36a, 36c. Each aperture is used as a
gripping point or handle for ease of lifting and transporting a
mattress 50 contained therein. Each of the side tabs F, G, H, I,
end tabs D, E and locking tabs K, M also contain an aperture 38
thereon which correspond to handles or gripping points located at
the distal ends of each side tray 10. The handles or apertures 38
located at each short end of each side tray 10 are substantially
rectangular being approximately 3.5 inches wide and 2.5 inches
tall. The three handles 36a-36c run along each of the side panels
B, C so that when the side trays 10 are inserted over the side
perimeter of a mattress 52, handles or gripping points are
available on both the front and back side of the mattress 50 and
also on both the left and right sides of the mattress 50 to
facilitate lifting, pushing, pulling or otherwise moving the
enclosed mattress 50.
[0017] An alternate embodiment of side panels B and C is shown in
FIGS. 5-7. The outer apertures 36a, 36c, are positioned at a
45-degree angle with respect to the horizontal top edge of the
panel. Both apertures are angled outward so they are each slanting
in a different direction, as shown in the figures. The center
aperture 36b has an inverted heard shape and is located at the
horizontal center of each panel. Each side of the inverted-heart
shape is positioned approximately 45-degrees from the horizontal
bottom edge of each panel. Each of the outer apertures 36a, 36c is
approximately 5-inches long and approximately 2-inches wide, with
the center aperture 36b being approximately 4-inches wide.
[0018] To construct the side trays 10 from the die cut, side panels
B and C are folded upward along fold lines 12 and 14 so that they
are perpendicular to main panel A. Next, side tab pairs F and H and
G and I are folded inward along fold lines 16 and 20 and 18 and 22
respectively. Then, end tabs D and E are folded upward so that each
end tab is parallel with folded side tabs F and H and G and I. The
end tab is folded along lines 28 and 30 and 32 and 34 so that
locking tabs K and M are folded downward over the inside surface of
end tabs D and E respectively so that the apertures located on each
of the panels K and D and M and E are in alignment Locking
mechanisms N and O are then folded through the upper edge of the
aligned apertures located in tabs K and D and M and E to secure the
panels together in their upright position, forming two end walls
with openings 38 which serve as handles or gripping points at each
end of the side tray.
[0019] An exploded view of a mattress with packaging components is
shown in FIG. 3. Once top and bottom mattress 50 ends are inserted
into each of the skid pad channels 40, the side trays 10 are
inserted over the right and left sides of the mattress perimeter
52. The side trays 10 partially extend over each skid pad 40, as
shown in FIG. 4, to secure each skid pad 40 to the top or bottom
mattress ends. Once the skid pads 40 and side trays 10 are in
place, the entire mattress 50 with packaging is banded by two or
more, preferably four, plastic straps or bands 44 to secure the
side trays 10 to the mattress 50. The straps or bands 44 should
bind the packaging to the mattress 50 without obstructing use of
the handles 36a-36e, 38. The vertical sides of the mattress and a
portion of the horizontal surfaces of the mattress proximate to the
border are protected by the frame-like structure created by the two
skid pads 40 in combination with the two side trays 10. The sides
and border 52 of the mattress are particularly vulnerable or
susceptible to damage because, due to the large size and weight of
mattresses, they are often moved by pushing, pulling or sliding the
mattress along while it is in a vertical position, resting on
either the left or right side of the mattress or on the top or
bottom side of the mattress. The frame-like structure also makes it
conducive to stack the mattresses horizontally during loading,
unloading, shipping or storage thereof. The skid pads 40 and side
trays 10 may have increased strength and durability by using double
walled corrugated cardboard.
[0020] FIG. 5 illustrates an alternate embodiment of a side tray 10
with openings 36a, 36b and 36c which are configured and oriented
for ergonomic gripping and handling of the package.
[0021] Compared to traditional mattress packaging, which may
consist in one form of several layers of heavy gauge plastic which
is wrapped several times around a mattress, the mattress package of
the present invention provides a less costly solution by using
inexpensive material, namely, cardboard and polyethylene. The
packaging of the present invention also provides increased
visibility of the mattress at arrival, including the mattress tag
or label. This provides the opportunity to inspect the mattress
without having to open the packaging. The frame-like packaging in
combination with the barrier layer minimizes the amount of material
that is used which in turn generates less waste.
* * * * *