Method for roll packing foam cores

Abstract

A method for roll packing foam mattress cores includes the step of providing a radially collapsible mandrel for winding up the foam material. Compression of the foam material is accomplished during the roll operation via a compression roller associated with the mandrel. After a sufficient amount of foam material has been rolled, the mandrel is collapsed to facilitate easy removal of the roll. In one embodiment of the invention, packing material is applied to a surface of the foam as it is rolled to prevent adhesion of successive layers in the roll.

Having described the invention, what is claimed is:  
     
         1 . A method for packaging compressible foam material in a roll, the method comprising the steps of: 
 providing a radially collapsible mandrel in a radially non-collapsed position;    compressing a foam material and feeding the compressed foam material to the mandrel;    rotating the mandrel to wind the compressed foam material onto the mandrel to form a roll of compressed foam material;    collapsing the mandrel; and    removing the roll of compressed foam material from the mandrel.    
     
     
         2 . The method of  claim 1  further comprising providing a compression roller proximate the mandrel for compressing the foam material and adjusting the spacing between the compression roller and the mandrel to obtain a desired compression of the foam material.  
     
     
         3 . The method of  claim 1  further comprising feeding a packing material to a surface of the foam material while feeding the compressed foam material to the mandrel.  
     
     
         4 . The method of  claim 1  further comprising providing a feed table upstream of the mandrel and directing the foam material from the feed table to between the mandrel and the compression roller for compressing and feeding the foam material to the mandrel.  
     
     
         5 . The method of  claim 1  further including the step of securing the roll of compressed foam material, prior to removal from the mandrel, to prevent unrolling.  
     
     
         6 . The method of  claim 1 , wherein the foam material comprises latex.  
     
     
         7 . The method of  claim 1 , wherein the foam material comprises urethane.  
     
     
         8 . A method for packaging compressible foam material in a roll using an apparatus having a radially collapsible mandrel and a compression roller proximate the mandrel and adjustable to vary the spacing between the mandrel and the roller, the method comprising the steps of: 
 providing the mandrel in a non-collapsed position;    adjusting the spacing between the compression roller and the mandrel to obtain a desired compression of the foam material;    directing the foam material between the mandrel and the compression roller such that compressed foam material can be wound upon an outer surface of the mandrel by rotating the mandrel;    rotating the mandrel to wind the compressed foam material onto the mandrel;    stopping rotation of the mandrel when a desired quantity of compressed foam material has been wound onto the mandrel;    collapsing the mandrel to release the roll from the outer surface of the mandrel; and    removing the roll of compressed foam material from the mandrel.    
     
     
         9 . The method of  claim 8  wherein the apparatus further includes a packing material dispenser, the method further including the step of applying packing material to a surface of the foam material as it is being wound onto the mandrel.  
     
     
         10 . The method of  claim 8  wherein the apparatus further includes a feed table upstream of the mandrel and the step of directing the foam material between the mandrel and the compression roller involves supporting the foam on the feed table and aligning the foam for proper positioning between the mandrel and the compression roller.  
     
     
         11 . The method of  claim 8  further including the step of securing the roll packed foam material, prior to removal from the mandrel, to prevent unrolling.