Roll mattress

from Wikipedia, the free encyclopedia

A roll mattress is under compression wound in roll form mattress . Most of the roll mattresses on the market were packaged in a RollPack machine that rolls the mattress and then pushes it into a relatively small bag. Once unpacked, however, the roll mattress cannot be rolled again by the customer because the machine rolls it with great force. To press a mattress as flat as the machine can roll it, you need between 40,000 and 250,000 Newtons, depending on the mattress. This corresponds to the weight of a mass of 4 to 25 tons. Aside from the advantage in transport, rolling primarily reduces packaging waste.

Types of mattresses

Roll mattresses are mostly foam mattresses , less often latex mattresses . The packaging method can also be used with restrictions for spring mattresses.

Foam mattresses

Foam mattresses make up the majority of roll mattresses, with the foam having to meet certain minimum quality requirements so that the mattress can take up its full volume again after unpacking and its springiness remains unchanged or changes only imperceptibly. As a rule of thumb, a density of 30 to 35 kg / m³ is the lower limit for polyurethane foams. The possible degrees of compression go up to a factor of five, with high-quality foams (high density, the same amount of plastic and less air), however, only up to about a third of the initial volume.

Latex mattresses

Latex mattresses are considerably more sensitive to compression than PU foam, both the compression factor must be selected to be lower and the storage time and storage temperature must be more strictly limited. As a rule of thumb, latex should not be compressed to more than a third of its original volume and should not be stored for too long. The type of latex also plays a major role. A latex foam with a higher percentage of natural latex admixture tolerates compression better. The foaming process also contributes to the compression resistance: Talalay latex recovers better than latices foamed by other processes. High temperatures are extremely dangerous (for the manufacturer who packs their mattresses in this way): a container full of roll-up mattresses made of latex, which is transported over the equator on top of the ship in direct sunlight, is very likely to be returned as a complaint because the mattresses are falling not reaching their full volume after unpacking: the high temperature revulcanises the latex foam when compressed.

Innerspring mattresses

Spring mattresses can also be rolled, but with one preparation: Using the vacuum packaging method, the mattress must first be compressed lying flat and only then can it be rolled. Otherwise there is a risk that the springs of the spring core will get caught. However, even with strong flat compression, there is a certain level of displacement between the top and bottom of the mattress when it is rolled up.

Procedure

RollPack is the type designation for a machine that compresses a mattress into a roll, i.e. produces a roll mattress. The machine was registered for a patent in 1996 by a Mannheim company. The term is increasingly being used for machines from other manufacturers that also compress a mattress and pack it in a roll. Different methods are used for this. The packaging of foam mattresses compressed in a roll has been around for a long time, but has experienced an enormous upswing after the publication of the "RollPack". Large distributors such as Ikea have increasingly been delivering certain mattresses in rolls since then. In all processes, the end result is a mattress that has "exhaled" the air enclosed in it through compression, that is to say has lost a considerable amount of volume. The process differences only affect the way there, but have an impact on the costs and the amount of plastic film in the packaging.

Vacuum packing

With vacuum packaging, the mattress is placed in a plastic bag. Then the pre-packed mattress is placed in a press and pressed with the end of the bag open. The air escapes. Then the open end of the bag is sealed airtight. The resulting vacuum pack is then rolled (by machine or by hand) and pushed into an outer bag. The vacuum pack cannot normally (due to the film used) be permanently sealed, but the mattress cannot expand again because the outer bag keeps it in the roll shape. One variant is that a long, open film tail remains at the airtight welded end of the bag, which is then welded to the roll itself after being rolled up in a machine. Foil consumption for 1 × 2 m mattress: approx. 6 m².

Wrap the mattress with foil

The mattress is pushed against a foil wall that hangs freely below. With this film you push them into an open roller drum, which then closes. The rollers are then driven to spiral up the mattress. The mattress pulls the film from above from a supply roll until it is completely in the roll drum. Then the film is cut off and separated from the supply roll. This creates a role in which the mattress is wrapped in foil. The free end of the film is secured by wrapping the roll with adhesive tape, or glued or welded onto the roll. In a variant of this application, instead of being wound in a roller drum, it is wound around an axis with a strong pressure roller. Foil consumption for 1 × 2 m mattress: approx. 6 m².

Roll packing

The machine pulls the mattress into a roller drum in which it is rolled up in a spiral. The compression of the mattress occurs when it is rolled up without foil. Then a slide pushes this role out in the axial direction. On the way out of the machine, the rolled mattress passes a pipe socket over which the operator has put a bag of the appropriate size beforehand. The mattress pulls the bag off the pipe socket and lands in the bag in roll form. This is closed with a clip, adhesive tape or welding. The mattress is neither wrapped nor pre-compressed. Foil consumption for 1 × 2 m mattress: approx. 1.5 m².

Web links