Method and system for shipping mattresses

Abstract

A method and system for packaging and shipping multiple bedding products. The method includes compressing a stack of compressed and sealed mattresses between an upper shipping support and a lower shipping support and restraining subsequent expansion of the compressed and sealed mattresses with bands enclosing the upper and lower shipping supports and the stack of compressed and sealed mattresses.

1 . A method for preparing mattresses for shipment, the method comprising the steps of:
 inserting a plurality of mattresses into separate protective bags, with at least one of the plurality of mattresses in each protective bag;   compressing individually at least one of the protective bags holding at least one of the plurality of mattresses;   retaining the compression of the at least one of the compressed protective bags holding at least one of the plurality of mattresses;   placing all of the protective bags each holding at least one of the plurality of mattresses on a first support;   placing a second support on top of all of the protective bags each holding at least one of the plurality of mattresses;   compressing all of the protective bags each holding at least one of the plurality of mattresses between the first support and the second support; and   coupling the first support and the second support together, the coupling restraining expansion of all of the protective bags each holding at least one of the plurality of mattresses.   
   
   
       2 . The method of  claim 1  further comprising the step of:
 uncoupling the first support and the second support.   
   
   
       3 . The method of  claim 1  further comprising the step of:
 restoring at least one mattress to its precompression thickness.   
   
   
       4 . The method of  claim 1 , wherein compressing individually the at least one of the protective bags comprises:
 compressing at least one of the protective bags holding at least one of the plurality of mattresses to a predetermined height.   
   
   
       5 . The method of  claim 1  further comprising the step of:
 placing at least one of the protective bags holding at least one of the plurality of mattresses within a bag made from substantially air-impervious material prior to the compressing individually at least one of the protective bags.   
   
   
       6 . The method of  claim 5  wherein the retaining the compression is accomplished by:
 sealing the substantially air-impervious bag.   
   
   
       7 . The method of  claim 6 , wherein sealing the substantially air-impervious bag comprises:
 sealing an open end of the substantially air-impervious bag with a heated element.   
   
   
       8 . The method of  claim 1 , wherein the plurality of mattresses comprises:
 at least ten mattresses.   
   
   
       9 . The method of  claim 8 , wherein the plurality of mattresses comprises:
 twenty-two or fewer mattresses.   
   
   
       10 . The method of  claim 1 , wherein the compressing all of the protective bags comprises:
 compressing all of the protective bags each holding at least one of the plurality of mattresses to a predetermined height.   
   
   
       11 . The method of  claim 1 , wherein the compressing all of the protective bags comprises:
 compressing with a press.   
   
   
       12 . The method of  claim 1 , wherein the first support is a shipping pallet. 
   
   
       13 . The method of  claim 1 , wherein the second support is a shipping pallet. 
   
   
       14 . The method of  claim 1 , wherein the coupling comprises:
 placing at least one band around the first support, the second support, and all of the protective bags each holding at least one of the plurality of mattresses; and   tightening the at least one band.   
   
   
       15 . The method of  claim 1 , wherein at least one protective bag has means to aid in carrying the at least one protective bag. 
   
   
       16 . A plurality of compressed mattresses prepared by a process comprising the steps of:
 inserting a plurality of mattresses into separate protective bags, with at least one of the plurality of mattresses in each protective bag;   compressing individually at least one of the protective bags holding at least one of the plurality of mattresses;   retaining the compression of the at least one of the compressed protective bags holding at least one of the plurality of mattresses;   placing all of the protective bags each holding at least one of the plurality of mattresses on a first support;   placing a second support on top of all of the protective bags each holding at least one of the plurality of mattresses;   compressing all of the protective bags each holding at least one of the plurality of mattresses between the first support and the second support; and   coupling the first support and the second support together, the coupling restraining expansion of all of the protective bags each holding at least one of the plurality of mattresses.   
   
   
       17 . A method for preparing mattresses for shipment, the method comprising the steps of:
 compressing a plurality of mattresses;   inserting at least one of the plurality of compressed mattresses in a protective bag;   retaining the compression of the plurality of compressed mattresses;   placing the plurality of compressed mattresses on a first support;   placing a second support on top of the plurality of compressed mattresses;   compressing the plurality of compressed mattresses between the first support and the second support; and   coupling the first support and the second support together, the coupling restraining expansion of the plurality of further compressed mattresses.   
   
   
       18 . A method for shipping mattresses, the method comprising the steps of:
 compressing a plurality of mattresses;   retaining the compression of the plurality of compressed mattresses;   placing the plurality of compressed mattresses on a first support;   placing a second support on top of the plurality of compressed mattresses;   compressing further the plurality of compressed mattresses between the first support and the second support;   coupling the first support and the second support together, the coupling restraining expansion of the plurality of further compressed mattresses to form a stack assembly; and   shipping the stack assembly from a first location to a second location.   
   
   
       19 . The method of  claim 18  further comprising the step of:
 uncoupling the first support and the second support.   
   
   
       20 . The method of  claim 18  further comprising the step of:
 restoring at least one mattress to its precompression thickness.   
   
   
       21 . The method of  claim 18  further comprising the step of:
 placing at least one of the plurality of mattresses within an air-impervious bag prior to the compressing a plurality of mattresses.   
   
   
       22 . The method of  claim 21  wherein at least one air-impervious bag contains more than one of the plurality of mattresses. 
   
   
       23 . A plurality of compressed mattresses prepared by a process comprising the steps of:
 compressing a plurality of mattresses;   retaining the compression of the plurality of compressed mattresses;   placing the plurality of compressed mattresses on a first support;   placing a second support on top of the plurality of compressed mattresses;   compressing further the plurality of compressed mattresses between the first support and the second support;   coupling the first support and the second support together, the coupling restraining expansion of the plurality of further compressed mattresses to form a stack assembly; and   shipping the stack assembly from a first location to a second location.