TOTAL BEDROOM IN A BOX

Abstract

A bedding package includes a container, a body support product disposed in the container, and a support foundation disposed in the container. The support foundation is configured to support the body support product. The bedding package also includes a fire retardant coverlet for use with the support foundation. The body support product and the support foundation are shipped in the container.

Claims

1. A bedding package, comprising: a container; a body support product disposed in the container; a support foundation disposed in the container, the support foundation configured to support the body support product; and a fire retardant coverlet for use with the support foundation.

2. The bedding package of claim 1, wherein the support foundation comprises one or more of wood, plastic, fiber composite, metal, paper-based material, or a combination thereof.

3. The bedding package of claim 1, wherein the body support product comprises a foam body.

4. The bedding package of claim 3, wherein the foam body of the body support product comprises a fire retardant material.

5. The bedding package of claim 1, wherein the container has a combined length and girth dimensions of 130 inches or less.

6. The bedding package of claim 1, wherein the bedding package has a weight of 150 pounds or less.

7. The bedding package of claim 1, wherein the support foundation comprises a frame and a filler core.

8. The bedding package of claim 7, wherein the frame comprises a plurality of siding pieces and corner pieces.

9. The bedding package of claim 7, wherein the filler core comprises an expandable configuration configured to support the body support product.

10. The bedding package of claim 1, wherein the coverlet comprises a halogenated chemical group, silica chemical group, phenolic chemical group, or any combination thereof.

11. A bedding package, comprising: a container; a foam body support product disposed in the container, the foam body support product in a compressed configuration; a support foundation disposed in the container, the support foundation in an unassembled configuration and configured to support the body support product; and a fire retardant coverlet for use with the support foundation in an assembled configuration.

12. The bedding package of claim 11, wherein the support foundation comprises one or more of wood, plastic, fiber composite, metal, paper-based material, or a combination thereof.

13. The bedding package of claim 11, wherein a foam body of the foam body support product comprises a fire retardant material.

14. The bedding package of claim 11, wherein the container has a combined length and girth dimensions of 130 inches or less.

15. The bedding package of claim 11, wherein the bedding package has a weight of 150 pounds or less.

16. The bedding package of claim 11, wherein the support foundation comprises a frame and a filler core.

17. The bedding package of claim 16, wherein the frame comprises a plurality of siding pieces and corner pieces.

18. The bedding package of claim 16, wherein the filler core comprises an expandable configuration configured to support the body support product.

19. A method of shipping a bedding package, comprising: providing a container; disposing a foam body support in the container, wherein the foam body support is in a compressed configuration; disposing a support foundation in the container, wherein the support foundation is in an unassembled configuration and configured to support the body support; disposing a fire retardant coverlet for use with the support foundation in the container; and shipping the container including the foam body support, the support foundation, and the coverlet.

20. The method of claim 19, wherein the support foundation comprises a frame and a filler core, wherein the frame comprises a plurality of siding pieces and corner pieces.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] So that the manner in which the above recited features can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

[0014] FIG. 1 illustrates an exemplary package including a container having a body support and a support foundation disposed therein, according to some embodiments.

[0015] FIG. 2 illustrates an exemplary embodiment of a support body in a compressed and rolled up configuration, according to some embodiments.

[0016] FIG. 3 illustrates an exemplary foundation with its components in an unassembled configuration, according to some embodiments.

[0017] FIG. 4 illustrates the foundation of FIG. 3 with its components in an assembled configuration.

[0018] FIG. 4a illustrates an exemplary embodiment of a filler core of the foundation of FIG. 4.

[0019] FIG. 5 illustrates the support body of FIG. 2 in an uncompressed configuration disposed on top of the foundation of FIG. 3, both of which are provided with a fire retardant coverlet, according to some embodiments.

[0020] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one implementation may be beneficially utilized on other implementations without specific recitation.

DETAILED DESCRIPTION

[0021] Embodiments described herein relate to a package include a container having a body support and a support foundation. The body support may comprise a foam material. The support foundation may comprise a frame and a filler core. The package beneficially includes a foam body support and a support foundation and may be advantageously transported as a single package. The foam body support and support foundation are configured to pass burning testing set out by federal regulations. In some embodiments, the package includes a weight that is 130 pounds or less. In some embodiments, the package has a combined length and girth dimensions of 130 inches or less.

[0022] FIG. 1 illustrates an exemplary package 100 including a bedding product 101 disposed in a bedding container 111. The bedding product 101 includes a body support 210 and a support foundation 110. FIGS. 1 and 2 illustrate an exemplary embodiment of the body support 210 in a rolled up configuration. In this example, the body support 210 is a mattress. FIGS. 3 and 4 illustrate an exemplary embodiment of the support foundation 110 in an unassembled configuration and an assembled configuration, respectively. In this example, the support foundation 110 is a foundation configured to support the mattress of FIG. 2.

[0023] In some embodiments, the body support 210 may be made from any suitable foam material for use as a body support. Exemplary foam materials include polyurethane, polyester, and latex. In one example, the foam material is a polyurethane having visco-elastic properties, which polyurethane may be referred to as memory foam. The foam body support 210 may have an indention load deflection (ILD) rating from 1 lb. to 25 lbs. For example, the foam body support 210 may have an ILD rating from 1 lb. to 25 lbs, such as from 1 lb. to 4 lbs., from 1 lb. to 15 lbs., from 4 lbs. to 20 lbs, or from 10 lbs. to 25 lbs. In some embodiments, the foam body support 210 may have a density from 1 lb/ft.sup.3 to 9 lb/ft.sup.3. For example, the foam body support 210 may have a density from 1 lb/ft.sup.3 to 3.5 lb/ft.sup.3, from 3 lb/ft.sup.3 to 5 lb/ft.sup.3, from 5 lb/ft.sup.3 to 8 lb/ft.sup.3, or from 3 lb/ft.sup.3 to 6 lb/ft.sup.3. The density and ILD values are measured using ASTM standard D-3574-05, including Test A for density value and Test B for ILD value. In some embodiments, the foam body can be a foam slab, a foam block, or a foam sheet.

[0024] In some embodiments, the body support 210 is made from a polyurethane foam. In some examples, the polyurethane foam is formed by reacting an isocyanate with a polyol. The polyol is generally reacted with a slight excess of isocyanate to produce a soft flexible foam product. For example, the hydroxyl OH groups to isocyanate NCO groups ratio may range from 1:0.85 to 1:1.40. Typically, a higher ratio will produced a harder foam.

[0025] Isocyanates suitable for use in the present disclosure include any isocyanate used in the production of flexible polyurethane foams. These isocyanates are well known components of polyurethane foams and polyurethane foam formulations and include any compounds which possess at least one free cyanate reactive group, and most preferably two, although more may be utilized. Such compounds may also be aliphatic or aromatic in nature. Non-limiting examples of isocyanates suitable for use include aromatic, aliphatic, and cycloaliphatic polyisocyanates and combinations thereof such as m-phenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4- and 2,6-toluene diisocyanate, hexamethylene diisocyanate, tetramethylene diisocyanate, cyclohexane-1,4-diisocyanate, hexahydrotoluene diisocyanate (and isomers), naphthalene-1,5-diisocyanate, 1-methoxyphenyl-2,4-diisocyanate, 4,4-diphenylmethane diisocyanate, 4,4-biphenylene diisocyanate, 3,3-dimethoxy-4,4-biphenyl diisocyanate, 3,3-dimethyl-4,4-biphenyl diisocyanate and 3,3-dimethyldiphenylmethane-4,4-diisocyanate; the triisocyanates such as 4,4,4-triphenylmethane triisocyanate, and toluene 2,4,6-triisocyanate; and the tetraisocyanates such as 4,4-dimethyldiphenylmethane-2,2,5,5-tetraisocyanate and polymeric polyisocyanates such as polymethylene polyphenylene polyisocyanate. The most commonly used isocyanates are toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI) or methylene diisocyanate.

[0026] Polyols suitable for use in forming the polyurethane foam include polyether or polyester diols. Suitable diols include diols having primary OH groups present in a range from 50% to 95% of the OH groups in the diol, preferably in a range from 65% to 90%. In some embodiments, the diols are polyoxyalkylene diols. Exemplary polyoxyalkylene diols includes Propylene Oxide (PO)-based homopolymers, block Ethylene Oxide (EO)-PO copolymers, random EO/PO copolymers, PO-based polyols that are capped or tipped with a mixture EO and PO to achieve a desired primary hydroxyl content, or any other desired configuration.

[0027] In some embodiments, the reaction for forming the polyurethane foam includes a blowing agent, a catalyst, or both. Blowing agents suitable for use include water, a volatile hydrocarbon, halocarbon, or halohydrocarbon, or mixtures of two or more such blowing agents. Catalysts suitable for use can be categorized as gel catalysts (e.g. stannous or tin salts), blow catalysts (e.g. amine catalysts), or balanced gel/blow catalysts. Gel catalysts promote the reaction between the reactive hydrogen atoms, particularly of the hydroxyl groups, and the isocyanates. Blow catalysts promote the reaction of the reactive hydrogen of water and the pluri-isocyanate. Non-limiting examples of suitable catalysts include amine catalysts, tin-based catalysts, bismuth-based catalysts or other organometallic catalysts, and the like. Examples of suitable tertiary amines as blowing catalyst include, e.g., bis(dimethylaminoethyl) ether and pentamethyldiethylentriamine. Examples of gel catalysts include 1,4-diaza(2,2,2)bicyclooctane; tetramethyldipropylentriamine; and tris(dimethylaminopropyl)hydrotriazine.

[0028] Before being packaged, the foam body support 210 undergoes a compression process, in which the foam body support 210 is compressed to a fraction of the original size of the foam body support 210. For example, the foam body support 210 is compressed to 10% to 50% by volume of an original volume of the foam body. In some examples, the foam body support 210 is compressed using a vacuum device. In some examples, in addition to or alternatively to vacuum compression, the foam body support 210 can be compressed using a mechanical pressing device. In one example, the mechanical pressing device includes two compression plates for compressing the foam body support 210. In some examples, after compression, the foam body support 210 is rolled to a size sufficient for inclusion into the bedding container 111, as shown in FIGS. 1 and 2. This process is applicable for all sizes of the foam body support that is being compressed. The compressed and rolled configuration of the foam body support 210 facilitates inclusion into the container 111 to be transported.

[0029] In some embodiments, the foam body support 210 is provided with a fire retardant material in the form of a coverlet 505, as shown in the example of FIG. 5. This coverlet 505 is applied during or after the foam body support 210 has changed to an expanded configuration. The coverlet 505 is configured to cover the entire top surface of the foam body support 210. In some embodiments, the coverlet 505 is configured to fit around the four corners and the four side surfaces of the foam body support 210 while leaving a portion of the bottom surface exposed. In some embodiments, the coverlet 505 is configured to cover all of the surfaces of the foam body support 210.

[0030] Additionally or alternatively to a coverlet 505, the foam body support 210 described above may include a fire retardant material. For example, the foam body supports 210 may include a fire retardant chemical such as a halogenated chemical group, silica chemical group, phenolic chemical group, or any combination thereof. These chemical groups may be combined in the formation process of the foam body support 210.

[0031] In some embodiments, the foundation 110 is configured to be disposed inside the container 111 of FIG. 1. In the example of FIG. 4, the foundation 110 includes a frame 310 and a filler core 314. FIG. 4 shows the foundation 110 in an assembled configuration. FIG. 3 shows the foundation 110 in an unassembled configuration to facilitate packaging and shipping. In one embodiment, the frame 310 includes four side walls 311 that are interconnected by corner pieces 312. Each of the sidewalls 311 is formed by connecting a plurality of siding pieces 313. The quantity and dimensions of the siding pieces 313 are based on the size of the foam body support 210 with which it is configured to support. For example, the siding pieces 313 may be sized to support a king size mattress when the siding pieces 313 are assembled. The siding pieces 313 and the corner pieces 312, when disassembled, are arranged to fit within a predetermined volume for placement within the bedding container 111. In some embodiments, the siding pieces 313 and the corner pieces 312 can be disposed within a foundation container 102 (shown in FIG. 1) before being placed within the bedding container 111. In some embodiments, the containers 102, 111 are made of cardboard.

[0032] The siding pieces 313 and the corner pieces 312 of the frame 110 may be composed of wood, plastic, fiber composite, metal, paper-based material, or a combination thereof. The siding pieces 313 and the corner pieces 312 may be attached using bolts, screws, glue, tape, or other suitable connectors. In some embodiments, the frame 110 may include attachment hardware 315 to provide additional structural support. The attachment hardware 315 may include bolts, hook and loop connectors, straps, glue, brackets, or a combination thereof to affix the sidewalls 311 forming the frame 110. In this example, straps are used to provide additional structural support of the frame 110.

[0033] As shown in FIG. 4, the foundation 110 includes one or more filler cores 314 disposed within the frame 110 constructed using the siding pieces 313 and the corner pieces 312. The filler core 314 is configured to support at least a majority portion of the foam body support 210. The filler core 314 may be composed of wood, plastic, fiber composite, metal, paper-based material, or a combination thereof. In some examples, the filler core 314 includes a paper-based material such as corrugated boards, paperboards, other suitable paper-based boards, or combinations thereof. In one embodiment, the filler core 314 is constructed to fold flat or to a substantially flat position 314 as shown in FIG. 3. The flat position facilitates storage and transportation within the bedding container 111 or the foundation container 102 of FIG. 1. During assembly of the foundation 110, the filler core 314 may be expanded and disposed inside the frame 110, as shown in FIG. 4. In some examples, the filler core 314 may attach to the siding pieces 313 or the corner pieces 312 of the foundation 110. In the example of FIG. 3, the filler cores 314, the siding pieces 313, and the corner pieces 312 include a connector 323 such as tape or Velcro for attachment.

[0034] In one embodiment, the filler core 314 displays a plurality of hexagonal openings when expanded, as shown in FIG. 4a. The hexagonal openings may be uniform or irregular in geometry. In some embodiments, the expanded filler core 314 may display other suitable openings such as squares, rectangles, triangles, non-polygonal shapes or combinations thereof. The openings in the filler core 314 reduce the weight of the filler core 314 while having sufficient strength to support the body support 210.

[0035] In some embodiments, the total weight of the package 100 including the bedding product 101 is 150 lbs. or less, or from 30 lbs. to 150 lbs. In some embodiments, the package 100 has a combined length and girth dimensions of 130 inches or less, or from 50 inches to 130 inches. In this respect, the package 100 advantageously qualifies for shipping as a small parcel freight class by certain shipping companies, e.g., UPS and FedEx. In some examples, the container 111 of the package 100 has a length from 25 inches to 80 inches or from 25 inches to 60 inches. In some examples, the container 111 has a girth from 40 inches to 110 inches or from 50 inches to 100 inches. In one example, the container 111 has a length from 30 inches to 50 inches and a girth from 65 inches to 95 inches. In some examples, the container 111 of the package 100 has a cuboid shape. However, the container 111 may have any suitable shape that meets the dimension requirements for shipping as a small parcel freight class, such as a combined length and girth dimensions of 130 inches or less. In some examples, the container 111 has a length from 25 inches to 60 inches, a width from 10 inches to 30 inches, and a depth from 10 inches to 30 inches. It is contemplated the total weight of the package 100 including the bedding product 101 can be from 30 lbs. to 350 lbs. or from 50 lbs. to 250 lbs. In some embodiments, it is also contemplated the package 100 has a combined length and girth dimensions of from 50 inches to 300 inches.

[0036] In some embodiments, the package 100 includes a foundation coverlet 504 that covers the exposed faces of the foundation 110. The foundation coverlet 504 possesses fire retardant properties, thereby increasing the fire resistance properties of the foundation 100. In some examples, the foundation coverlet 504 and the mattress coverlet 505, if present, in the package 100, include fibers having fire retardant properties, such as fibers treated with fire retardant chemicals. Suitable fire retardant fibers used to make the coverlet 504, 505 include rayon fibers, modacrylic fibers, or combinations thereof. In some examples, the coverlet 504, 505 includes from 60% to 95% rayon or modacrylic by content of the coverlet 504, 505. In some embodiments, the coverlet 504, 505 further includes other fibers, such as polyester, nylon, cotton, spandex, natural fiber, or combinations thereof. Each of these fibers may be present in an amount from 2% to 25% by content in the coverlet 504, 505.

[0037] In one embodiment, the foundation coverlet 504 may be disposed in the smaller box 102. In another embodiment, the foundation coverlet 504 may be disposed in the container 111. The size of the foundation coverlet 504 depends upon the size of the foundation 110. This coverlet 504 can be applied after the foundation 110 has been assembled. The coverlet 504 is configured to cover the entire top surface of the foundation 110. In some embodiments, the coverlet 504 is configured to fit around the four corners and the four side surfaces of foundation 110 while leaving a portion of the bottom surface exposed. In some embodiments, the coverlet 504 is configured to cover all of the surfaces of foundation 110.

[0038] Embodiments of the present disclosure provide a package 100 containing bedding product 101 having a body support 210 and a foundation 110 that can be advantageously shipped together in a single container. In some embodiments, the package 100 has a size and weight that beneficially qualifies the package 100 for a small parcel freight class for shipping. The bedding product 101 is in compliance with present burn testing requirements.

[0039] In one embodiment, a bedding package includes a container, a body support product disposed in the container, and a support foundation disposed in the container. The support foundation is configured to support the body support product. The bedding package also includes a fire retardant coverlet for use with the support foundation.

[0040] In some embodiments, a bedding package includes a container, a foam body support product disposed in the container, and a support foundation disposed in the container. The foam body support is in a compressed configuration, and the support foundation is in an unassembled configuration. The support foundation is configured to support the body support product. The bedding package also includes a fire retardant coverlet for use with the support foundation in an assembled configuration.

[0041] In some embodiments, a method of shipping a bedding package includes providing a container and disposing a foam body support in the container, wherein the foam body support is in a compressed configuration. The method also includes disposing a support foundation in the container, wherein the support foundation is in an unassembled configuration and configured to support the body support. Further, the method includes disposing a fire retardant coverlet for use with the support foundation in the container. The container including the foam body support, the support foundation, and the coverlet is shipped.

[0042] In one or more of the embodiments described herein, the container has a combined length and girth dimensions of 130 inches or less.

[0043] In one or more of the embodiments described herein, the bedding package has a weight of 150 pounds or less.

[0044] In one or more of the embodiments described herein, the support foundation includes a frame and a filler core.

[0045] In one or more of the embodiments described herein, the frame comprises a plurality of siding pieces and corner pieces.

[0046] In one or more of the embodiments described herein, the filler core comprises an expandable configuration configured to support the body support product.

[0047] In one or more of the embodiments described herein, the filler core comprises a paper-based material.

[0048] In one or more of the embodiments described herein, the support foundation comprises one or more of wood, plastic, fiber composite, metal, paper-based material, or a combination thereof.

[0049] In one or more of the embodiments described herein, the foam body of the body support product comprises a fire retardant material.

[0050] In one or more of the embodiments described herein, the bedding package includes a second coverlet for use with the body support product.

[0051] In one or more of the embodiments described herein, the container has a cuboid shape.

[0052] In one or more of the embodiments described herein, the container has a combined length and girth dimensions from 50 inches to 130 inches.

[0053] In one or more of the embodiments described herein, the container has a length from 25 inches to 80 inches.

[0054] In one or more of the embodiments described herein, the container has a girth from 40 inches to 110 inches.

[0055] In one or more of the embodiments described herein, the container has a length from 25 inches to 60 inches, a width from 10 inches to 30 inches, and a depth from 10 inches to 30 inches.

[0056] In one or more of the embodiments described herein, the fire retardant coverlet comprises a fire retardant fiber.

[0057] In one or more of the embodiments described herein, the fire retardant fiber comprises rayon, modacrylic, or combinations thereof.

[0058] In one or more of the embodiments described herein, the fire retardant coverlet further comprises one or more of polyester, nylon, cotton, spandex, natural fiber, or combinations thereof.

[0059] While the foregoing is directed to embodiments of the present disclosure, other and further embodiments may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.