Bedding product packaging and process

Abstract

Packaged bedding products and processes for forming the packaged bedding product generally include a first plastic film, a second plastic film, a first seam joining the first plastic film to the second plastic film, wherein the first seam is disposed about a periphery of the bedding product; at least one second seam joining an end of the first plastic film to an end of the second plastic film, wherein the at least one second seam is spaced apart from the first seam to define excess plastic film material therebetween, and wherein the at least one second seam and excess plastic film material is provided at one or more of the opposed end surfaces and/or one or more of the opposed side surfaces of the bedding product; and one or more gripper openings disposed in the excess plastic film material.

What is claimed is: 
     
         1 . A packaged bedding product having a depth defined between opposed first and second surfaces, a length defined between a pair of opposed end surfaces and a width defined between a pair of opposed side surfaces, said bedding product being encased in a plastic film package, said plastic film package comprising:
 a first plastic film;   a second plastic film;   a first seam joining the first plastic film to the second plastic film, wherein the first seam is disposed about a periphery of the bedding product;   at least one second seam joining an end of the first plastic film to an end of the second plastic film, wherein the at least one second seam is spaced apart from the first seam to define excess plastic film material therebetween, and wherein the at least one second seam and excess plastic film material is provided at one or more of the opposed end surfaces and/or one or more of the opposed side surfaces of the bedding product; and   one or more gripper openings disposed in the excess plastic film material.   
     
     
         2 . The packaged bedding product of  claim 1 , wherein said length is greater than said width. 
     
     
         3 . The packaged bedding product of  claim 1 , wherein the first and second seams are thermal welds. 
     
     
         4 . The packaged bedding product of  claim 1 , wherein the bedding product is a mattress. 
     
     
         5 . The packaged bedding product of  claim 1 , further comprising a third seam joining the first plastic film to the second plastic film about each one of the gripper openings. 
     
     
         6 . The packaged bedding product of  claim 1 , wherein the first plastic film and the second plastic film have a variable thickness. 
     
     
         7 . The packaged bedding product of  claim 1 , wherein the excess plastic film material defined by the second seams is provided at the pair of opposed end surfaces defining the length of the bedding product. 
     
     
         8 . The packaged bedding product of  claim 1 , wherein the excess plastic film material defined by the second seams is provided at pair of opposed side surfaces defining the width of the bedding product. 
     
     
         9 . A process of forming a packaged bedding product having a generally planar first surface and a parallel generally planar second surface, the process comprising:
 simultaneously passing a first web and a second web of plastic film past the first and second surfaces on opposite sides of the bedding product;   cutting the first and second webs so as to create first and second pieces of the plastic film about the bedding product;   joining the first and second pieces of plastic film together about a periphery of the bedding product to form a first seam enclosing the bedding product in a plastic film package;   joining an end of the first piece to an end of the second piece to form at least one second seam, wherein the at least one second seam is spaced apart from the first seam to define excess plastic film material therebetween; and   forming hand-hold openings in the excess material.   
     
     
         10 . The process of  claim 9 , wherein forming the hand-hold openings in the excess material further comprises joining the first and second pieces of plastic film about a perimeter defining the hand-hold opening. 
     
     
         11 . The process of  claim 9 , wherein joining the first and second pieces of plastic film to form the first seam and at least one second seam comprises thermally welding the first piece to the second piece. 
     
     
         12 . The process of  claim 10 , wherein joining the first and second pieces of plastic film about the perimeter defining the hand-hold opening comprises thermally welding the first piece to the second piece. 
     
     
         13 . The process of  claim 9 , wherein the first and second pieces of plastic film have a variable thickness. 
     
     
         14 . The process of  claim 9 , wherein the first and second pieces of plastic film is a polyethylene material.