Process for packaging a polyurethane foam filled article of furniture

Abstract

A process for packaging a polyurethane foam filled article of furniture, comprising the steps of: (a) providing a polyurethane foam filled article of furniture having an initial volume; (b) reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume, comprising at least one of the steps of: (1) decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and (2) compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and (c) associating the polyurethane foam filled article of furniture with a package.

What is claimed is:  
     
         1 . A process for packaging a polyurethane foam filled article of furniture, comprising the steps of: 
 providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume;    associating the polyurethane foam filled article of furniture with a bag, wherein the bag has an aperture;    reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and    associating the polyurethane foam filled article of furniture with a package.    
     
     
         2 . The process according to  claim 1 , wherein the step of providing a polyurethane foam filled article of furniture includes the step of providing a polyurethane foam filled article of furniture having a density of polyurethane foam ranging from between approximately 1.0 and approximately 4.0 pounds per cubic foot.  
     
     
         3 . The process according to  claim 1 , wherein the step of providing a polyurethane foam filled article of furniture includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner, wherein the outer liner is flexible and at least partially gas permeable.  
     
     
         4 . The process according to  claim 3 , wherein the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner which is substantially spherical.  
     
     
         5 . The process according to  claim 1 , wherein the step of associating the polyurethane foam filled article of furniture with a bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, through the aperture.  
     
     
         6 . The process according to  claim 5 , wherein the step of placing the polyurethane foam filled article of furniture inside of the bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, wherein the bag is fabricated from a substantially airtight material.  
     
     
         7 . The process according to  claim 1 , wherein the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume comprises the steps of: 
 providing a vacuum source, wherein the vacuum source is capable of decreasing air pressure within a confined area;    associating the vacuum source with the aperture of the bag, wherein a substantially airtight seal is formed between the vacuum source and the aperture of the bag;    decreasing air pressure within the confined area of the bag via the vacuum source and, in turn, the polyurethane foam filled article of furniture; and    reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.    
     
     
         8 . The process according to  claim 1 , wherein the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately two-thirds of the initial volume.  
     
     
         9 . The process according to  claim 1 , wherein the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-half of the initial volume.  
     
     
         10 . The process according to  claim 1 , wherein the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-third of the initial volume.  
     
     
         11 . The process according to  claim 1 , further comprising the step of sealing the bag to substantially preserve the reduced volume of the polyurethane foam filled article of furniture after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.  
     
     
         12 . The process according to  claim 1 , wherein the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume less than the initial volume of the polyurethane foam filled article of furniture.  
     
     
         13 . The process according to  claim 1 , wherein the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume greater than the reduced volume of the polyurethane foam filled article of furniture.  
     
     
         14 . A process for packaging a polyurethane foam filled article of furniture, comprising the steps of: 
 providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume;    compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and    associating the polyurethane foam filled article of furniture with a package.    
     
     
         15 . The process according to  claim 14 , wherein the step of providing a polyurethane foam filled article of furniture includes the step of providing a polyurethane foam filled article of furniture wherein the polyurethane foam has a density of polyurethane foam ranging from between approximately 1.0 and approximately 4.0 pounds per cubic foot.  
     
     
         16 . The process according to  claim 14 , wherein the step of providing a polyurethane foam filled article of furniture includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner, wherein the outer liner is flexible and at least partially gas permeable.  
     
     
         17 . The process according to  claim 16 , wherein the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner includes the step of providing a frameless polyurethane foam filled article of furniture comprising an outer liner which is substantially spherical.  
     
     
         18 . The process according to  claim 14 , further comprising the step of associating the polyurethane foam filled article of furniture with a mold before the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.  
     
     
         19 . The process according to  claim 18 , wherein the step of associating the polyurethane foam filled article of furniture with a mold includes the step of providing a mold having at least one binding agent therein.  
     
     
         20 . The process according to  claim 18 , further comprising the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent after the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.  
     
     
         21 . The process according to  claim 14 , further comprising the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent after the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.  
     
     
         22 . The process according to  claim 21 , wherein the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least two binding agents, wherein two of the at least two binding agents are perpendicular to each other.  
     
     
         23 . The process according to  claim 21 , wherein the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least two binding agents, wherein two of the at least two binding agents are parallel to each other.  
     
     
         24 . The process according to  claim 21 , wherein the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least three binding agents, wherein two of the at least three binding agents are parallel to each other, and wherein one of the at least three binding agents is perpendicular to two of the at least three binding agents.  
     
     
         25 . The process according to  claim 21 , wherein the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least one binding agent includes the step of binding the reduced volume of the polyurethane foam filled article of furniture with at least four binding agents, wherein at least two of the at least four binding agents are parallel to each other, and wherein at least two of the at least four binding agents are perpendicular to each other.  
     
     
         26 . The process according to  claim 14 , further comprising the step of associating the polyurethane foam filled article of furniture with a bag, wherein the bag has an aperture, before the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.  
     
     
         27 . The process according to  claim 26 , wherein the step of associating the polyurethane foam filled article of furniture with a bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, through the aperture.  
     
     
         28 . The process according to  claim 27 , wherein the step of placing the polyurethane foam filled article of furniture inside of the bag includes the step of placing the polyurethane foam filled article of furniture inside of the bag, wherein the bag is fabricated from a substantially airtight material.  
     
     
         29 . The process according to  claim 26 , further comprising the step of sealing the bag to substantially preserve the reduced volume of the polyurethane foam filled article of furniture after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.  
     
     
         30 . The process according to  claim 14 , wherein the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately two-thirds of the initial volume.  
     
     
         31 . The process according to  claim 14 , wherein the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-half of the initial volume.  
     
     
         32 . The process according to  claim 14 , wherein the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume includes the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume which is approximately one-third of the initial volume.  
     
     
         33 . The process according to  claim 14 , wherein the step of compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume is repeated at least once.  
     
     
         34 . The process according to  claim 14 , wherein the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume less than the initial volume of the polyurethane foam filled article of furniture.  
     
     
         35 . The process according to  claim 14 , wherein the step of associating the polyurethane foam filled article of furniture with a package includes the step of associating the polyurethane foam filled article of furniture with a package which has a volume greater than the reduced volume of the polyurethane foam filled article of furniture.  
     
     
         36 . A process for packaging a polyurethane foam filled article of furniture, comprising the steps of: 
 providing a polyurethane foam filled article of furniture having a first initial length and a second initial length;    associating the polyurethane foam filled article of furniture with a mold and at least two binding agents;    compressing the first initial length of the polyurethane foam filled article of furniture to a first reduced length;    binding at least one of the at least two binding agents parallel to the first reduced length of the polyurethane foam filled article of furniture;    compressing the second initial length of the polyurethane foam filled article of furniture to a second reduced length;    binding at least one of the at least two binding agents parallel to the second reduced length of the polyurethane foam filled article of furniture; and    associating the polyurethane foam filled article of furniture with a package.    
     
     
         37 . The process according to  claim 36 , wherein the step of associating the polyurethane foam filled article of furniture with a mold and at least two binding agents includes the step of associating the polyurethane foam filled article of furniture with a mold having at least four binding agents therein.  
     
     
         38 . The process according to  claim 37 , wherein the step of binding at least one of the at least two binding agents parallel to the first reduced length of the polyurethane foam filled article of furniture includes the step of binding at least two of the at least four binding agents parallel to the first reduced length of the polyurethane foam filled article of furniture.  
     
     
         39 . The process according to  claim 38 , wherein the step of binding at least one of the at least two binding agents parallel to the second reduced length of the polyurethane foam filled article of furniture includes the step of binding at least two of the at least four binding agents parallel to the second reduced length of the polyurethane foam filled article of furniture.  
     
     
         40 . A process for packaging a polyurethane foam filled article of furniture, comprising the steps of: 
 providing a polyurethane foam filled article of furniture having an initial volume;    reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume, comprising at least one of the steps of: 
 decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and  
 compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume; and  
   associating the polyurethane foam filled article of furniture with a package.    
     
     
         41 . The process according to  claim 40 , further comprising the step of associating the polyurethane foam filled article of furniture with at least one binding agent after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.  
     
     
         42 . The process according to  claim 40 , further comprising the steps of: 
 associating the polyurethane foam filled article of furniture with a bag having an aperture before the step of decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and    sealing the bag to substantially preserve the reduced volume of the polyurethane foam filled article of furniture after the step of reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume.    
     
     
         43 . A process for packaging a polyurethane foam filled article of furniture, comprising the steps of: 
 providing a polyurethane foam filled article of furniture, wherein the polyurethane foam filled article of furniture has an initial volume;    associating the polyurethane foam filled article of furniture with a bag, wherein the bag has an aperture;    associating the polyurethane foam filled article of furniture and the bag with an at least partially unassembled package having at least one binding agent therein;    reducing the initial volume of the polyurethane foam filled article of furniture to a reduced volume, comprising at least one of the steps of: 
 decreasing air pressure within the polyurethane foam filled article of furniture via a vacuum source; and  
 compressing the initial volume of the polyurethane foam filled article of furniture to a reduced volume;  
   binding the reduced volume of the polyurethane foam filled article of furniture with the at least one binding agent; and    assembling the unassembled package around the reduced volume of the polyurethane foam filled article of furniture.    
     
     
         44 . A polyurethane foam filled article of furniture packaged according to at least one of claims  1 - 43 .