Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: METHOD FOR PREPARING MATTRESSES FOR SHIPMENT AND STACK
OF MATTRESSES PREPARED USING SUCH METHOD
FIELD OF THE INVENTION
The invention generally relates to the packaging of mattresses for shipment,
and more
particularly, to the packaging of mattresses for shipment in containers using
air, sea or
ground transportation.
BACKGROUND
Large quantities of mattresses are imported from overseas into Canada and the
United
States, in particular from China and other Asian countries. The importation of
large
quantities of mattresses is driven by the reality that manufacturers in China
and other
Asian countries are able to produce mattresses at a lower cost than
manufacturers in
North America. When these mattresses are being transported, they are typically
packaged
and carried via ship in containers. There is a cost associated with the
shipping, which is in
part a function of the volume occupied by the mattresses.
In view of reducing shipping costs, various methods have been used for
packaging
mattresses for shipment to allow placing more mattresses in a given container.
As will be
appreciated, if a larger number of mattresses can be packaged within a given
space, the
shipping costs associated with any individual mattress will be lower. One
example of a
method of preparing mattresses for shipment is suggested in U.S. Patent No.
7,458,093
and U.S. Patent No. 7,895,813. Generally speaking, the suggested approach
includes first
individually compressing and wrapping mattresses, for example, by vacuum
sealing each
individual mattress. Following this, a set of individually compressed
mattresses is stacked
between upper and lower shipping supports. The stack of mattresses is then
further
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compressed between the supports, which are then fastened to one another using
coupling
restraints in the form of straps. Following this, the stacked mattresses with
the upper and
lower shipping supports can be placed within a container for shipping.
Approaches of the type described above advantageously may allow a larger
number of
mattresses to fit within a given container and thus may enhance transportation
cost
efficiency.
A deficiency associated with assemblies of stacked mattresses prepared using
methods of
the type described above is that, on occasion the straps and/or the shipping
supports get
damaged during transport or handling due in part to the pressure exerted on
these
components by the compressed stack of mattresses. When damage occurs, the
result in
some cases is that the compressed mattresses expand within the containers used
for the
shipment. This expansion within the containers often makes removing the
mattresses
from such containers without damaging the mattresses difficult. As a result,
the cost
savings achieved by packing a larger number of mattresses per container is
reduced by
the cost of the damaged mattresses, which often can no longer be sold to
customers.
In light of the above, there is a need in the industry for providing an
improved assembly
of stacked mattresses and an improved method for preparing such an assembly
that
alleviates, at least in part, the deficiencies with existing assemblies and
methods.
SUMMARY
In accordance with a first aspect, the invention relates to an assembly of
stacked
mattresses comprising a first pallet, a second pallet, a plurality of
mattresses positioned
between the first pallet and the second pallet and straps coupling the first
pallet to the
second pallet. The plurality of mattresses is in a compressed state between
the first pallet
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and the second pallet and the straps restrain expansion of the plurality of
mattresses. The
second pallet is comprised of a supporting member and a plurality of elongated
reinforcing members extending across the supporting member, at least some of
the
reinforcing members including respective strap guiding members extending
longitudinally along the elongated reinforcing member. At least some of the
straps
engage respective ones of the strap guiding members of the plurality of
elongated
reinforcing member of the second pallet.
In accordance with a first specific example of implementation, at least some
of the strap
guiding members are comprised of hollow tubular portions extending
longitudinally
along the elongated reinforcing members of the second pallet and at least some
of the
straps pass through at least some of the hollow tubular portions.
In accordance with a second specific example of implementation, at least some
of the
strap guiding members are comprised of U-shaped portions extending
longitudinally
along the elongated reinforcing members of the second pallet and wherein the
at least
some of the straps are positioned within at least some of the U-shaped
portions, the U-
shaped portions restraining movement of the at least some straps relative to
the
supporting member of the second pallet.
In accordance with another alternative specific example of implementation, at
least some
of the strap guiding members extend longitudinally along the elongated
reinforcing
members of the second pallet and are comprised of a combination of hollow
tubular
portions and U-shaped portions positioned end-to-end.
In specific practical implementations, the strap guiding members may be made,
for
example, of a metallic material and/or a plastic material. The supporting
member of the
second pallet may be made at least in part of a wood-based material, such as
for example
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a medium-density fiberboard (MDF) or a plywood material. The straps used to
couple
the first pallet to the second pallet may be made of any suitable material
such as for
example nylon, polypropylene and synthetic steel composite. Advantageously, it
has
been found that, in some cases, straps made of synthetic steel composite tend
to be less
affected by temperature variations, and in particular tend to be less affect
by cold
temperatures, than similarly sized nylon straps which may render such straps
more
durable and less likely to break that nylon straps.
In specific practical implementations, the supporting member of the second
pallet has a
surface area substantially similar to a surface area of an individual mattress
in the
plurality of mattresses. In non-limiting implementations, the supporting
member of the
second pallet may have a substantially rectangular shape.
In specific implementations, the plurality of mattresses may include any
suitable number
of mattresses. The number of mattresses in practical implementations may
generally be
selected based upon the number of mattresses that, when compressed between the
two
pallets, can reasonably fit within the specific container that is to be used
for the shipment.
In a specific implementation, the first pallet has a configuration similar to
that of the
second pallet and is comprised of:
i) a supporting member; and
ii) a plurality of elongated reinforcing members extending across the
supporting member, at least some of the elongated reinforcing
members including respective strap guiding members extending
longitudinally along the elongated reinforcing members.
In the assembly, at least some straps engage respective ones of the strap
guiding members
of the plurality of elongated reinforcing members of the first pallet.
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In accordance with another aspect, the invention relates to a pallet for use
in shipping
bedding products. The pallet comprises a supporting member and a plurality of
elongated
reinforcing members extending across the supporting member. At least some of
the
elongated reinforcing members include respective strap guiding members
extending
longitudinally along the elongated reinforcing members.
In accordance with a first specific implementation, at least some of the strap
guiding
members are comprised of hollow tubular portions extending longitudinally
along the
elongated reinforcing members, the hollow tubular portions being adapted for
receiving
there through straps.
In accordance with a second specific implementation, at least some of the
strap guiding
members are comprised of U-shaped portions extending longitudinally along the
elongated reinforcing members. The U-shaped portions are configured to receive
therein
straps and for restraining movement of straps positioned therein.
In specific practical implementations, the strap guiding members may be made,
for
example, of a metallic material or a plastic material. The supporting member
of the
second pallet may be made at least in part of a wood-based material, such as
for example
a medium-density fiberboard (MDF) or a plywood material. The straps used to
couple
the first pallet to the second pallet may be made of any suitable material
such as for
example nylon, polypropylene and synthetic steel composite.
In accordance with another aspect, the invention relates to the use of a
pallet of the type
described above for shipping bedding products, such as for example mattresses,
pillows
and the like.
In accordance with another aspect, the invention relates to a method for
preparing
mattresses for shipment. The method comprises providing a first pallet and a
second
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pallet. The second pallet is comprised of a supporting member and of a
plurality of
elongated reinforcing members extending across the supporting member, at least
some of
the elongated reinforcing members including respective strap guiding members
extending
longitudinally along the elongated reinforcing members. The method further
comprises
placing a plurality of mattresses on a surface of one of the first pallet and
the second
pallet and placing the other one of the first pallet and the second pallet on
top of the
plurality of mattresses. The method also comprises compressing the plurality
of
mattresses between the first pallet and the second pallet and coupling the
first pallet to the
second pallet using straps, the straps restraining expansion of the compressed
plurality of
mattresses. At least some of the straps engage respective ones of the strap
guiding
members of the plurality of elongated reinforcing members of the second
pallet.
In accordance with a first specific example of implementation, at least some
of the strap
guiding members are comprised of hollow tubular portions extending
longitudinally
along the elongated reinforcing members. In the method, the step of coupling
the first
pallet to the second pallet includes passing at least some of the straps
through at least
some of the hollow tubular portions.
In accordance with a second specific example of implementation, at least some
of the
strap guiding members are comprised of U-shaped portions extending
longitudinally
along the elongated reinforcing members. In the method, the step of coupling
the first
pallet to the second pallet includes positioning at least some of the straps
within at least
some of the U-shaped portions. In some implementations, the U-shaped portions
may
restrain movement of the at least some straps relative to the supporting
member of the
second pallet.
In a specific practical implementation, the supporting member of the second
pallet has a
surface area substantially similar to a surface area of an individual mattress
in the
plurality of mattresses.
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In specific implementations, the plurality of mattresses may include any
suitable number
of mattresses. The number of mattresses in practical implementations may
generally be
selected based upon the number of mattresses that, when compressed between the
two
pallets, can reasonably fit within the specific container that is to be used
for the shipment.
Practical implementations may include placing two or more mattresses upon the
first
pallet.
In a specific implementation, the method further comprising compressing
individually the
mattresses in the plurality of mattresses prior to placing the plurality of
mattresses on the
first pallet.
In a specific implementation, the first pallet has a configuration similar to
that of the
second pallet and is comprised of:
i) a supporting member; and
ii) a plurality of elongated reinforcing members extending across the
supporting member, at least some of the elongated reinforcing
members including respective strap guiding members extending
longitudinally along the elongated reinforcing members.
In this specific implementation, coupling the first pallet to the second
pallet may further
include engaging at least some of the straps with respective ones of the strap
guiding
members of the plurality of elongated reinforcing members of the first pallet.
In accordance with another aspect, the invention relates to an assembly of
stacked
mattresses prepared for shipment in accordance with a method of the type
defined above.
In accordance with another aspect, the inventions relates to an assembly of
stacked
mattresses. The assembly comprises a first pallet, a second pallet, a
plurality of
mattresses positioned between the first pallet and the second pallet and
straps coupling
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the first pallet to the second pallet. The plurality of mattresses is in a
compressed state
between the first pallet and the second pallet and the straps restrain
expansion of the
plurality of mattresses. The second pallet is comprised of a supporting member
and of a
plurality of elongated grove members extending across the supporting member.
At least
some of the straps engage respective ones of the elongated grove members of
the second
pallet.
These and other aspects of the invention will now become apparent to those of
ordinary
skill in the art upon review of the following description of embodiments of
the invention
in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of embodiments of the invention is provided below, by
way of
example only, with reference to the accompanying drawings, in which:
Figure 1 shows an assembly of stacked mattresses in accordance with a specific
example
of implementation of the invention.
Figures 2A and 2B are perspective views of a pallet suitable for use in an
assembly of the
type shown in Figure 1 in accordance with a first embodiment of the invention.
Figures 2C and 2D are perspective views of a pallet suitable for use in an
assembly of the
type shown in Figure 1 in accordance with a second embodiment of the
invention.
Figures 2E and 2F are perspective views of a pallet suitable for use in an
assembly of the
type shown in Figure 1 in accordance with a third embodiment of the invention.
Figure 3 is perspective views of a variant of the pallet depicted in Figures
2A and 2B.
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Figure 4 is a flowchart of a method for preparing an assembly of mattresses of
the type
depicted in Figure 1 in accordance with a specific example of implementation
of the
invention;
Figure 5 is a perspective view of a first pallet on which a plurality of
mattresses has been
stacked in accordance with a specific example of implementation of the
invention.
Figure 6 is a perspective view of the first pallet of Figure 5, on which a
plurality of
mattresses has been stacked, where a second pallet is being placed on top of
the plurality
of mattresses in accordance with a specific example of implementation of the
invention.
Figure 7 is a variant of Figure 6 in which protective material has been used
to protect the
mattresses.
Figures 8A shows a plurality of mattresses positioned between a first pallet
and a second
pallet prior to being placed within a press for compressing the plurality of
mattresses in
accordance with an embodiment of the present invention.
Figures 8B shows the plurality of mattresses of Figure 8A positioned within
the press.
Figure 8C shows the plurality of mattresses of Figure 8A being compressed by
the press.
Figure 8D shows the plurality of mattresses of Figure 8A wherein the first and
second
pallets are being coupled to one another using straps.
Figure 8E shows the plurality of mattresses of Figures 8A-8D being removed
from the
press after the step depicted in Figure 8D.
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Figure 9 shows a coupling device fastening a strap used for coupling the
pallets of an
assembly of mattresses of the type depicted in Figure 1 in accordance with a
specific
embodiment of the present invention.
Figure 10 shows an assembly of stacked mattresses in accordance with a variant
of the
invention.
In the drawings, embodiments of the invention are illustrated by way of
example. It is to
be expressly understood that the description and drawings are only for the
purpose of
illustrating certain embodiments of the invention and are an aid for
understanding. They
are not intended to be a definition of the limits of the invention.
DETAILED DESCRIPTION
Figure 1 shows a specific non-limiting example of an assembly of stacked
mattresses. As
shown, the assembly 790 includes a first pallet 401, a second pallet 501 and a
plurality of
mattresses 302 positioned between the first pallet 401 and the second pallet
501. In this
example, the first pallet 401 is a lower pallet and the second pallet 501 is
an upper pallet.
The plurality of mattresses 302 is arranged in a stack atop the first pallet
401 and the
second pallet 501 is positioned on top of the plurality of mattresses 302. The
assembly
790 also includes straps 510 coupling the first pallet 401 to the second
pallet 501. In a
specific implementation, the plurality of mattresses 302 is in a compressed
state between
the first pallet 401 and the second pallet 501 and the straps 510 restrain the
expansion of
the plurality of mattresses 302. In the example depicted, an optional
protective cover 908
shields the plurality of stacked mattresses from outside elements. The
optional protective
cover 908 may be made of any suitable material which may include, without
being
limited to corrugated cardboard, packaging paper, plastic wrapping and/or a
woven nylon
protective material.
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In the example depicted, the upper (or second) pallet 501 includes a
supporting member
502 and a plurality of elongated reinforcing members 503 extending across the
supporting member 502. The reinforcing members 503 include respective strap
guiding
members 504 extending longitudinally along the elongated reinforcing member
503. The
straps 510 engage respective ones of the strap guiding members 504 as they
couple
together the first and second pallets 401 501. Advantageously, the elongated
strap
guiding members 504 may restrain movement of the straps 510 relative to the
supporting
member 502 and in that manner may reduce the amount of wear endured by the
straps,
which in turn may reduce the likelihood the straps will break. In this
specific example,
the elongated strap guiding members 504 include hollow tubular portions
extending
longitudinally along the elongated reinforcing members 503. The hollow tubular
portions
accommodate the straps 510, which pass through the hollow tubular portions.
In another example, not show in Figure 1, the elongated strap guiding members
may
include U-shaped portions extending longitudinally along the elongated
reinforcing
members. The U-shaped portions are configured to accommodate the straps 510,
which
would be positioned within the U-shaped portions, the U-shaped portions
restraining the
lateral movement of at least some straps relative to the supporting member. It
is to be
appreciated that the elongated strap guiding members 504 may be otherwise
configured
to restrain movement of the straps 510 relative to the supporting member 502
and such
alternatives will become apparent to the person skilled in the art in light of
the present
document.
In yet another example of implementation, not show in Figure 1, instead of
reinforcing
members 503, the pallet may include a supporting member and a plurality of
elongated
grove members formed on a surface of the supporting member and extending
across it.
The grove members are shaped to accommodate the straps, which would be
positioned
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within the grove members, and restrain the lateral movement of at least some
straps
relative to the supporting member.
In the specific example depicted, the lower (or first) pallet 401, is
configured in a manner
similar to the upper (or second) pallet 501 and includes a supporting member
402 and a
plurality of elongated reinforcing members 403 extending across the supporting
member
402. The reinforcing members 403 include respective strap guiding members 404
extending longitudinally along the elongated reinforcing member 403.
The straps 510 engage respective ones of the strap guiding members 404 and
strap
guiding members 504 as they couple the first and second pallets 401 501 with
one
another. The straps 510 may be made of any suitable material such as nylon,
polypropylene, synthetic steel composite or any other suitable material. In
some
embodiments, the straps 510 may be steel bands. In the example depicted, the
ends of the
strap 510 are coupled together with respective coupling devices 810.
In the example depicted, optional protective strips 910 positioned on the
sides of the
stack of compressed mattresses 302 may be provided. These protective strips
910 are
generally aligned with the straps 510 extending between the first and second
pallets 501
401. More specifically, in some embodiments, the protective strips may be
positioned to
be generally aligned with the strap guiding members 404 and strap guiding
members 504.
Moreover, in some embodiments, the protective strips 910 may be placed on top
of the
protective cover 908, while in other embodiments the protective cover 908 may
overlay
the protective strips 910. The optional protective strips 910 may be made of
any suitable
material which may include, without being limited to polyurethane foam or felt
padding.
The use of protective strips 910 may advantageously reduce friction between
the straps
510 and the stacked mattresses 302 and hence reduce the likelihood the straps
will
damage the mattresses during transport.
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Figures 2A and 2B are perspective views showing a configuration of a pallet
201 that
may be used for the first pallet 401, the second pallet 501 or both the first
and second
pallets 401 501 of an assembly of stacked mattresses of the type shown in
Figure 1 in
accordance with a first embodiment of the invention.
Figure 2A shows a perspective view of a first surface 207 of the pallet 201
and Figure 2B
shows a perspective view of a second surface 206 of the pallet 201.
As depicted, the pallet 201 includes a supporting member 202 and a plurality
of
elongated reinforcing members 203 (where 203x, denote a specific elongated
reinforcing
member from the plurality of elongated reinforcing members 203) extending
across the
supporting member 202. In this example, the supporting member 202 has a first
surface
207 and a second surface 206 and the plurality of elongated reinforcing
members 203 are
attached to the first surface 207 of the supporting member 202. In Figures 2A
and 2B five
elongated reinforcing members 203a, 203b, 203c, 203d, and 203e are shown;
however, it is
to be appreciated that the number of reinforcing members on a pallet may be
more or less
than five in alternative implementations of the invention. In practical
implementations, a
pallet having two or more elongated reinforcing members will be preferred.
The supporting member 202 may be made, for example, at least in part of wood,
plastic,
metal, and/or any other suitable material. More specifically, in some
embodiments, the
supporting member 202 may be made at least in part of wood-based materials
which may
include one or more wooden planks, plywood planks, boards and the like. The
supporting
member 202 may have a surface area that is substantially similar to a surface
area of an
individual mattress 301 in the stack of mattresses 302 in order to distribute
the pressure
exerted by the compressed mattresses over the surface of the supporting member
202. In
specific practical implementations, the supporting member 202 may have a
substantially
rectangular shape generally corresponding to the shaped the mattresses being
shipped. In
specific practical implementations, the supporting member 202 may be a single
sheet of
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plywood or a single sheet of medium-density fiberboard (MDF) that has
dimensions
(length and width) substantially similar to the dimensions of the mattress
301. In
implementations in which the supporting member 202 is a single sheet of
plywood or
medium density fiberboard, the single sheet of plywood or medium density
fiberboard
may have any suitable thickness. In non-limiting implementations, a sheet of
plywood
having a thickness in the range of 'A inch to 2 inches may be used. It is
noted that the
reinforcing members 204 increase the tensile strength of such a sheet of
plywood and
therefore permit a sheet of plywood of a lesser thickness to be used without
compromising the solidity of the pallet 201.
As shown in Figure 2A, the pallet 201 includes a plurality of elongated
reinforcing
members 203 extending across the supporting member 202. The elongated
reinforcing
members 203 may be made of wood, plastic, metal, and/or any other suitable
material.
The elongated reinforcing members 203 may be positioned alongside one another
in a
spaced-apart relationship over the surface 207 of the supporting member 202 in
the
manner depicted in Figure 2A for example.
At least some of the elongated reinforcing members 203 include respective
strap guiding
members 204 extending longitudinally along the elongated reinforcing member
203.
While all the reinforcement members shown in Figure 2A include strap guiding
members
204, it is to be appreciated that in alternative embodiment only some
reinforcing member
203 may include strap guiding members 204. As such, the number of strap
guiding
members 204 need not be the same as the number of reinforcing members 203. In
the
embodiment illustrated in Figures 2A and 2B, five strap guiding members 204a,
204b,
204e, 204d, and 204e are shown; however, it is to be appreciated that the
number of strap
guiding members may be more or less than five in alternative implementations
of the
invention. In practical implementations, a pallet having two or more strap
guiding
members will be preferred.
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The strap guiding members 204 may be configured to receive and guide one or
more
straps 510 (not shown in Figures 2A and 2B ¨ shown in Figure 1) over the
surface 207 of
the supporting member. At least some of the straps 510 engage respective ones
of the
strap guiding members 204 of the plurality of elongated reinforcing member 203
of the
pallet 201. In other words, the strap guiding members 204 may be configured to
receive
and guide one or more straps 510 longitudinally along the reinforcing members
203. In
the embodiment depicted in Figures 2A and 2B, the strap guiding members 204
are
comprised of hollow tubular portions extending longitudinally along the
reinforcing
members 203. In the cases where the strap guiding members 204 comprises hollow
tubular portions, at least some of the straps 510 pass through at least some
of the hollow
tubular portions.
The hollow tubular portions may be of a generally square, rectangular, semi-
circular
cross-sectional shape or of any other suitable shape. For example, the strap
guiding
members 204 may be A500 grade steel structural square tubes having a height of
2
inches, width of 2 inches and a wall thickness of 1/8 of an inch. However, the
dimensions
of the strap guiding members 204 are not limited to the example given above
and any
suitable dimension and cross-section may be used. By way of an example, the
strap
guiding members 204 may be made at least in part of metal, plastic or wood
square or
rectangular tubes having a height in the range of 1/2 an inch to 4 inches, a
width in the
range of in the range of 1/2 an inch to 4 inches and a wall thickness in the
range of 0.065
of an inch to % an inch.
The elongated reinforcing members 203 may be fastened to the surface 207 of
supporting
member 202 using any suitable fastener or any suitable binding material. For
example,
the plurality of elongated reinforcing members 203 may be fastened to the
supporting
member 202 by one or more screws, nails, tacks, brackets or any other suitable
mechanical fastener. In alternative embodiments, the reinforcing members 203
may be
bound to the supporting member 202 using a glue, an adhesive or any suitable
chemical
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binder. In the non-limiting embodiment depicted in Figures 2A and 2B, the
reinforcing
members 203 includes interface members 205 for fastening to the supporting
member
202. The interface members 205 may be positioned between the strap guiding
members
204 and the supporting member 202 and may facilitate the fastening or binding
of the
reinforcing members 203 to the supporting member 202 during assembly of the
pallet
201. The one or more interface members 205 may be comprised of elongated
strips of
plastic, wood, metal, and/or any other suitable material.
Figure 3 shows a pallet 201", which is a variant of pallet 201 shown in
Figures 2A and
2B, in which the elongated reinforcing members 203" are fastened to the
surface 207 of
supporting member 202 using a set of brackets or braces 222 positioned at
different
locations along the length of the respective elongated reinforcing members
203". The
brackets or braces 222 may be made of any suitable material, such as metal,
steel or
nylon strapping.
Figures 2C and 2D are perspective views of another configuration of a pallet
201' that
may be used for the first pallet 401, the second pallet 501 or both the first
and second
pallets 401 and of an assembly of the type shown in Figure 1 in accordance
with a second
embodiment of the invention. In this alternative configuration, the pallet
201' has some
components similar to the components of pallet 201 shows in Figures 2A and 2B.
For
ease of understanding, the components that are common to the two
configurations have
been given the same reference numerals.
As depicted, the pallet 201' includes a supporting member 202 and a plurality
of
elongated reinforcing members 203' extending across the supporting member 202.
In this
example, the supporting member 202 has a first surface 207 and a second
surface 206 and
the plurality of elongated reinforcing members 203' are attached to the first
surface 207
of the supporting member 202. As shown in Figure 2C, the pallet 201' includes
a
plurality of elongated reinforcing members 203' extending across the
supporting member
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202. The elongated reinforcing members 203' may be made of wood, plastic,
metal,
and/or any other suitable material and may be fastened to the supporting
member 202 in a
manner similar to the fastening of elongated reinforcing members 203 described
with
reference to the embodiment of Figures 2A and 2B. The elongated reinforcing
members
203' may be positioned alongside one another in a spaced-apart relationship
over the
surface 207 of the supporting member 202. In Figures 2C and 2D five elongated
reinforcing members 203a, 203b, 203'c, 203d, and 203'e are shown; however, it
is to be
appreciated that the number of reinforcing members on a pallet may be more or
less than
five in alternative implementations of the invention. In practical
implementations, a pallet
having two or more elongated reinforcing members will be preferred.
At least some of the elongated reinforcing members 203' include respective
strap guiding
members 204' extending longitudinally along the elongated reinforcing member
203'.
While all the reinforcement members shown in the figure including strap
guiding
members 204', it is to be appreciated that in alternative embodiment only some
reinforcing member 203' may include strap guiding members 204'. As such, the
number
of strap guiding members 204' need not be the same as the number of
reinforcing
members 203'.
The strap guiding members 204' may be configured to receive and guide one or
more
straps 510 (not shown in Figures 2C and 2D ¨ shown in Figure 1) over the
surface 207 of
the supporting member 202. At least some of the straps 510 engage respective
ones of
the strap guiding members 204' of the plurality of elongated reinforcing
member 203' of
the pallet 201. In other words, the strap guiding members 204' may be
configured to
receive and guide one or more straps 510 longitudinally along the reinforcing
members
203'.
In this embodiment, at least some of the strap guiding members 204' are
comprised of U-
shaped portions extending longitudinally along the reinforcing members 203'.
The U-
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shaped portions are configured for receiving therein one or more straps 510
(not shown in
Figures 2C and 2D). The U-shaped portions may be of a generally triangular,
square,
rectangular or semi-circular cross-sectional shape having an opening forming a
channel
for receiving therein one or more straps. The strap guiding members 204' may
be made
-- of any suitable material including metal, plastic or wood and may be of any
suitable
dimension for receiving therein one or more straps. In a specific
implementation, the U-
shaped channels may have a width in the range of 1/2 an inch to 4 inches, a
leg or flange
height in the range of in the range of 1/2 an inch to 4 inches and a wall or
web thickness
in the range of an 1/8 of an inch to 1/2 an inch.
Although in Figures 2A to 2D the elongated reinforcing members 203 203' have
been
illustrated as unitary components that traverse the supporting member 202, it
will be
appreciated that this need not be the case in all embodiments. For example,
each
reinforcing members 203 203' may be formed by multiple (2 or more) elongated
reinforcing member segments arranged substantially end to end to traverse the
surface of
supporting member 202.
In addition, while the embodiments depicted in Figures 2A, 2B, 2C and 2D show
the
-- strap guiding members 204 204' as being either hollow tubular portions or U-
shaped
portions, it is to be appreciated that, in other alternative implementations
(not shown in
the Figures), at least some of the strap guiding members may be comprised of a
combination of hollow tubular portions and U-shaped portions positioned end-to-
end
across the surface of the supporting member. In such an alternative
configurations, the
-- hollow tubular portions of the strap guiding members may prevent straps
engaged in the
strap guiding members from being displaced.
Figures 2E and 2F are perspective views of a variant of the pallets shown in
Figures 2A,
2B, 2C and 2D and which may be used for the first pallet 401, the second
pallet 501 or
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both the first and second pallets 401 and of an assembly of the type shown in
Figure 1 in
accordance with a third embodiment of the invention. In this alternative
configuration,
the plurality of reinforcing members 203 203' including strap guiding members
204
204' are replaced by a plurality of elongated grove members 2003. More
specifically, as
depicted, the pallet 2001 includes a supporting member 2002 in which a
plurality of
elongated grove members 2003 extending across the supporting member 2002 have
be
defined. In this example, the supporting member 2002 has a first surface 2007
and a
second surface 2006 and the plurality of elongated grove members 2003 are
formed on
the first surface 2007 of the supporting member 2002. As shown in Figure 2E,
the pallet
2001 includes a plurality of elongated grove members 2003 extending across the
supporting member 2002. The elongated grove members 2003 may be positioned
alongside one another in a spaced-apart relationship over the surface 2007 of
the
supporting member 2002. In Figures 2E and 2D five elongated grove members
2003a,
2003b, 2003,e 2003d, and 2003e are shown; however, it is to be appreciated
that the
number of grove members on a pallet may be more or less than five in
alternative
implementations of the invention. In practical implementations, a pallet
having two or
more elongated grove members will be preferred.
The elongated grove members 2003 are configured for receiving and guiding one
or more
straps 510 (not shown in Figures 2D and 2E) over the surface 2007 of the
supporting
member 2002. At least some of the straps engage respective ones of the
elongated grove
members 2003 of the pallet 2001. In other words, the elongated grove members
2003
may be configured to receive and guide one or more straps 510 longitudinally
along the
reinforcing members 2003.
In this embodiment, at least some of the elongated grove members 2003 are
formed as U-
shaped portions extending longitudinally along the reinforcing members 2003.
The U-
shaped portions are configured for receiving therein one or more straps (not
shown in
Figures 2C and 2D). The U-shaped portions may be of a generally triangular,
square,
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rectangular or semi-circular cross-sectional shape having an opening forming a
channel
for receiving therein one or more straps. The elongated grove members 2003 may
be
formed directly on the surface of the supporting member 2002 by using any
suitable
machining technique and may be of any suitable dimension for receiving therein
one or
more straps.
In a specific implementation, the supporting member 2002 may be made of may be
made,
for example, at least in part of wood, plastic, metal, and/or any other
suitable material and
the elongated grove members 2003 are formed within the surface of the
supporting
member 2002. In a specific implementation, the U-shaped channels may have a
width in
the range of 1/2 an inch to 6 inches and a leg or flange height in the range
of in the range
of 1/2 an inch to 2 inches. It is noted that the leg or flange height will
depending on the
thickness of the supporting member 2002. Optionally, portions of the elongated
grove
members 2003 may be covered (not shown in the figures) to prevent straps
engaged in
the grove members 2003 from being displaced once the assembly of mattresses is
formed.
Returning now to the embodiment depicted in Figure 1, the first pallet 401
and/or the
second pallet 501 may be constructed or may comprise any of the embodiments
discussed
above regarding the pallet 201, 201', 2001 and/or 201" described with
reference to
Figures 2A, 2B, 2C, 2D, 2E and 2F and 3. It is to be appreciated that, in
practical
implementations, the first pallet 401 and the second pallet 501 need not be
identical to
each other. For instance, the first pallet 401 may be made according to the
embodiment
depicted in Figures 2A and 2B and the second pallet 501 may be made according
to the
embodiment depicted in Figures 2C and 2D. Furthermore, as can be seen from the
discussion above, the first pallet 401 and the second pallet 501 may be made
of wood,
plastic, metal, other suitable materials and/or any combination of these
aforementioned
materials. Alternatively still, the first pallet 401 or the second pallet 501
may be a
standard shipping pallet or skid of the type known in the art, for example of
the type
described ISO Standard 6780: "Flat pallets for intercontinental materials
handling ¨
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Principal dimensions and tolerances", while the other pallet may be made
according to
one the embodiments described previously with reference to Figures 2A, 2B, 2C,
2D, 2E,
2F and 3.
Figure 4 is a flowchart showing a method 100 that may be used for preparing an
assembly of stacked mattresses of the type depicted in Figure 1.
As shown, at step 101, a first pallet 401 and a second pallet 501 are
provided. Next at
step 102, mattresses are stacked upon the first pallet 401. Then, at step 103
the second
pallet 501 is placed on top of the plurality of stacked the mattresses. At
step 104 the
mattresses between the first pallet 401 and the second pallet 501 are
compresses to reduce
the height of the stack of mattresses. Then, at step 105, the first pallet 401
and the second
pallet 501 are coupled together to restrain expansion of the compressed
mattresses 302.
The coupling of the first pallet 401 to the second pallet 501 may be done
using any
suitable mechanism such as for example by using straps 510. Once the first
pallet 401 and
the second pallet 501 are coupled together, the assembly of mattresses 790 may
be placed
within a container (not shown) and may be transported to a desired
destination, via rail,
ship or truck for example. Each of the steps of the method 100 will now be
discussed in
more detail with reference to Figures 5, 6, 7 and 8A to 8E.
At step 101, a first pallet 401 and a second pallet 501 are provided. The
first pallet 401
and/or the second pallet 501 may be constructed according to any of the
embodiments
discussed above regarding the pallet 201, 201', and/or 201". For the purpose
of the
present example, the process described will consider that both the first
pallet 401 and the
second pallet 501 are constructed in the manner described with reference to
pallet 201
described with reference to Figures 2A and 2B.
At step 102 of the method 100, mattresses are stacked on the first pallet 401,
which is
illustrated in the perspective view shown in Figure 5. In this specific
embodiment, the
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first pallet 401 is a lower pallet and several individual mattresses 301 are
placed on the
first pallet 401 to form a stack of mattresses 302. Optionally, each of the
individual
mattresses 301 may have been previously compressed prior to being placed upon
the first
pallet 401. For example, the compression of the individual mattress 301 prior
to stacking
on the first pallet 401 may follow the suggested approach described in U.S.
Patent No.
7,458,093 and U.S. Patent No. 7,895,813.
Following this, at step 103 of the method 100, a second pallet 501 is placed
upon the
stack of mattresses 302, which is illustrated in the perspective view shown in
Figure 6. In
this example, the second pallet 501 is shown with straps 510 having been
passed through
the respective strap guiding members 504.
Optionally, protective materials may be used to protect the mattresses from
the first pallet
401 and/or the second pallet 501. This variant is illustrated in the
perspective view
shown in Figure 7. As shown, protective materials 604 and/or 608 are placed on
top of
and below the stack of mattresses 302 to protect the mattresses from the first
and second
pallets 401 501. In this example, the upward facing surface of the first
pallet 401 is
covered with a protective material 604, such as, but not limited to corrugated
cardboard,
packaging paper, plastic wrapping and/or any other suitable material.
Similarly, the top of
the plurality of mattresses 302 is also covered with a protective material
608, such as, but
not limited to corrugated cardboard, packaging paper, plastic wrapping and/or
any other
suitable material.
Optionally still, not shown in Figure 6 and 7, protective strips 910 (shown in
Figure 1)
and/or a protective cover 908 (also shown in Figure 1) may also be added to
protect the
stack of mattresses 302.
For example, a protective cover 908, such as a protective sheath, may be used
to cover
the periphery of the stack of mattresses 302. The protective cover 908 may be
wrapped
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around the sides of the stack of mattresses 302 and between the upper or
second pallet
501 and the lower or first pallet 401. Such protective sheath may be made of
any suitable
material such as corrugated cardboard, packaging paper, plastic wrapping
and/or any
other suitable material, to further protect the mattresses. The protective
cover 908 may be
made of the same material as the protective material 604 and 608 used to
protect the top
and bottom of the stack of mattresses 302 from the respective second pallet
501 and first
pallet 401 or may be a different material.
Optional protective strips 910 may be positioned on the sides of the stack of
compressed
mattresses 302. The optional protective strips 910 may be made of any suitable
material
which may include, without being limited to, polyurethane foam or felt
padding. The
protective strips 910 may be positioned generally along the sides of the stack
of
mattresses 302 between the upper or second pallet 501 and the lower or first
pallet 401.
More specifically, in some embodiments, the protective strips may be
positioned to be
generally aligned with the strap guiding members 404 and strap guiding members
504.
Moreover, in some embodiments, the protective strips 910 may be paced on top
of the
protective cover 908, while in other embodiments the protective cover 908 may
overlay
the protective strips 910. (For examples of embodiments illustrating the
protective strips
910 and protective cover 908 see Figures 1 and 10).
After the second pallet 501 has been placed upon the stack of mattresses 302,
the process
proceeds to step 104.
At step 104 of the method 100, the stack of mattresses 302 between the first
pallet 401
and the second pallet 501 is compresses in order to reduce the height of the
stack of
mattresses. Figures 8A to 8E illustrate an example, in accordance with a non-
limiting
embodiment of the present invention, of a process for compressing the stack of
mattresses
302 and a device for effecting such compressing. For the purpose of
simplifying the
description, in Figures 8A to 8E the combination including the stack of
mattresses 302,
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the first pallet 401 and the second pallet 501 will be designated as a group
as assembly
700.
Figures 8A and 8B illustrate, in accordance with an embodiment of the present
invention,
placing the assembly 700 within a press 705, possibly, but not limited to, a
hydraulic
press employing a vertical hydraulic press plate 707. The press 705 comprises
a sensor
715 that is coupled to a controller 720 and that detects the position of the
press plate 707
when the mattress stack 302 has been squeezed to a predetermined set height
770. The
controller 720 is coupled to at least one hydraulic actuator 727, coupled to
the press plate
707 and capable of raising and lowering the press play 707.
Figure 8C illustrates, in accordance with an embodiment of the present
invention,
lowering the press plate 707 and compressing the stack of mattresses 302 to
the stack
predetermined-set height 770. As the press plate 707 is lowered, an opening
710 between
the press plate 707 and a floor 750 is reduced, thereby compressing the stack
of
mattresses 302 resting upon the lower of first pallet 401, which, in turn,
rests upon the
floor 750, to the stack predetermined-set height 770. When the press plate 707
reaches a
position 770 corresponding to the height of the stack of mattresses 302
reaching the stack
predetermined-set height 780 and resulting in a compressed assembly of
mattresses 790,
a signal from the position sensor 715 to the controller 720 results in a halt
to vertical
movement of the press plate 707. Figure 8C also illustrates, in accordance
with an
embodiment of the present invention, locking the press plate 707 in position
and passing
one or more straps 510 through each of the strap guiding members 404 of the
first pallet
401 and through each of the strap guiding members 504 of the second pallet
501. Figure
8C also shows at least some of the straps 510 engaging respective ones of the
strap
guiding members 504 of the plurality of elongated reinforcing member 503 of
the second
pallet 501. Figure 8C also shows at least some of the straps 510 engaging
respective ones
of the strap guiding members 404 of the plurality of elongated reinforcing
member 403 of
the first pallet 401.
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After the assembly 700 has been compressed, the process proceeds to step 105.
At step 105 of the method 100, the first pallet 401 and the second pallet 501
are coupled
together to restrain expansion of the plurality of mattresses and to maintain
the stack of
mattresses 302 in a compressed state and at substantially the stack
predetermined set
height 770. Figure 8D illustrates, in accordance with an embodiment of the
present
invention, the first and second pallets 401 501 being coupled together using a
plurality of
straps 510.
In the specific example shown in the Figures, for each of the strap guiding
members 503
on the second pallet 501 there is a corresponding strap guiding members 403 on
the first
pallet 401 in which at least one of the straps 510 passes through. In
accordance with a
specific and non-limiting example, in the case where the first pallet member
401 has strap
guiding members 404a, 404b, ... and 404, and the second pallet member 501 has
strap
guiding members 504a, 504b, ... and 504,, then straps 510a, 510b, ... and 510,
may
engage respective strap guiding members. For example, strap 510a may engage
strap
guiding members 404a and 504a, strap 510b may engage strap guiding members
404b and
504b, and so forth.
Depending on the type of straps used, ends of the straps may be coupled
together with a
connector or coupling device. Figure 9 illustrates, in accordance with an
embodiment of
the present invention, a coupling device 810 that may be used to connecting
the two ends
of a strap 510 together. The coupling device 810 may be embodied in any
suitable device
including for example a metal strapping joint, a buckle or any other
mechanism. In the
specific example shown in Figure 9, in this embodiment, the coupling device
810 is a
metal strapping joint with a set of notches 820 in order to securely fasten
both ends of the
strap together. For example, to couple the ends of the strap 510 together,
this may be
done with a strapping sealer, such as a double notched strapping sealer, or
any other
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suitable mechanical device. Furthermore, a band 850 may also be coupled around
the
coupling device 810 and the strap 810 to assist in securing the coupling
device in place.
Figure 8E illustrates, in accordance with an embodiment of the present
invention, after
the compressed assembly of mattresses 790 containing the stack of mattresses
302 has
been secured or coupled with the straps 510, raising the press plate 707 and
removing the
secured and compressed assembly of stacked mattresses 790 from the press 705.
In non-
limiting implementations, the weight of the compressed assembly of mattresses
790 may
be kept between substantially 1500 pounds and substantially 2000 pounds for
ease of
handling. The height of the compressed assembly of mattresses 790 may be kept
between
substantially 47 inches and substantially 49 inches for ease of handling,
loading, and
unloading and for safety considerations, including avoidance of a propensity
for tipping
off when handled with a forklift during storage on a higher section of a
warehouse
racking system.
The compressed assembly of stacked mattresses 790, as illustrated in Figure
8E, should
preferably not exceed approximately 8 feet in height if to be shipped in a 40
foot Hi Cube
container having an internal height of about 8 feet and 10 inches. For
conventional 40
foot containers and 20 foot containers having an internal height of
substantially 7 feet and
10 inches, the compressed assembly of stacked mattresses 790 should preferably
not
exceed approximately 7 feet in height. The space left between the height of
the
compressed assembly of stacked mattresses 790 and the internal height of the
container
may allow for ease of loading and unloading. In addition, one or more
compressed
assemblies of stacked mattresses 790 may be stacked upon one another in a
shipping
container, provided preferably that the total height of the stacked compressed
assemblies
790 does not exceed approximately 8 feet in the case of a Hi Cube container.
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Weights and dimensions, presented above, have been given for the purpose of
example
only and practical implementations of the components presented in the present
document
may use other suitable measurements that may vary from those presented here.
Although in some of the embodiments discussed above, the upper and lower
pallets are
constructed in the same or similar way, this is not necessarily the case for
some
alternative embodiments of the invention. An example of such an alternative
embodiment
of an assembly of stacked mattresses is depicted in Figure 10. As shown, the
assembly
790' includes a first pallet 1001, a second pallet 501 and a plurality of
mattresses 302
positioned between the first pallet 401 and the second pallet 501. In this
example, the
first pallet 1001 is a lower pallet and the second pallet 501 is an upper
pallet. The
assembly 790' is similar to the assembly of stacked mattresses 790 depicted in
Figure 1
with the lower (or first) pallet 1001 having a configuration that is different
from the lower
(or first) pallet 401 (shown in Figure 1). More specifically, the lower pallet
1001 in the
example depicted is constructed of an array of wooden planks 1004 held in
position by
another array of wooden crosspieces or crossbars 1002 arranged orthogonally to
the array
of wooden planks 1004. It will be readily appreciated that other variants are
possible and
will become apparent to the person skilled in the art in view of the present
description.
Certain additional elements that may be needed for operation of some
embodiments have
not been described or illustrated as they are assumed to be within the purview
of those of
ordinary skill in the art. Moreover, certain embodiments may be free of, may
lack and/or
may function without any element that is not specifically disclosed herein.
Although various embodiments and examples have been presented, this was for
the
purpose of describing, but not limiting, the invention. For example, although
in the
embodiments discussed above relate to assemblies of stacked mattresses and
method for
preparing such assemblies, similar assemblies (and method of preparing same)
may also
be considered for other types of bedding products such as for example mattress
covers,
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bedding foam, pillows, quilts, comforters. Various other modifications and
enhancements
will become apparent to those of ordinary skill in the art. The invention is
defined more
particularly by the appended claims.
