WO2018165709A1

WO2018165709A1 - Mattress loading apparatus

Info

Publication number: WO2018165709A1
Application number: PCT/AU2018/050232
Authority: WO
Inventors: Ashley MCIVER
Original assignee: Community Resources Limited
Priority date: 2017-03-14
Filing date: 2018-03-14
Publication date: 2018-09-20

Abstract

A mattress loading apparatus for loading a mattress onto a conveyor line includes an actuating element for moving a mattress toward the conveyor line and a lifting platform for lifting a mattress into a path of the actuating element.

Description

Title of Invention

Mattress loading apparatus

Cross Reference

[0001 ] The present application claims priority from Australian provisional application 2017900889 filed 14 March 2017, the disclosure of which will be taken to be incorporated into this specification.

Technical Field

[0002] The present invention relates to the field of mattress recycling. The present invention has been developed for use with a mattress recycling apparatus and will be hereinafter generally described in this context. However, it is to be appreciated that the invention is not necessarily limited to this application. Whilst the present invention has been developed for use in the field of mattress recycling, it will be appreciated that the present invention may also find application in the fields of mattress transport or mattress manufacture.

Background of Invention

[0003] The following discussion of the background to the invention is intended to facilitate an understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application.

[0004] The Applicant has previously co-developed a method and equipment for the disassembly of mattresses as described in International Patent publication WO2015080580 (filed in the name of Joint Venture between the Applicant and a Partner entity), the contents of which will be understood to be incorporated into this specification by this reference.

[0005] The mattress recycling process generally involves collecting used mattresses from a variety of sources, transporting of the mattresses to a recycling facility and then introducing the mattresses into a recycling apparatus such as that which is disclosed in WO2015080580. The step of introducing the mattresses into the recycling apparatus can involve relocating the mattresses from a stockpile within the recycling facility or, alternatively, relocating the mattresses directly from a transport vehicle such as a truck to the recycling apparatus. It is desirable for mattresses to be fed, introduced or loaded into the recycling apparatus in a particular orientation and at a particular rate so as to enable proper processing by the automated mattress- dissecting portion of the recycling apparatus.

[0006] One method of introducing mattresses into the recycling apparatus involves mattresses being manually carried by facility operators, typically one at a time, and introduced into the automated portion of the process by manually loading the mattresses onto a conveyor line leading to a mattress-dissecting portion of the apparatus. The manual labour involved in this procedure is undesirable in terms of both safety and efficiency.

[0007] As discussed in WO2015080580, an alternative method of introducing mattresses into the recycling apparatus is the provision of a metering conveyor having a hook which periodically engages with a mattress from a supply bunker and permits the feed of mattresses into the conveyor line to be consistently spaced apart. This system does not, however, control the orientation of mattresses and necessitates a further processing step to correctly orientate the mattresses on the conveyor.

[0008] It is therefore desirable to provide an improved or alternative system for loading or introducing mattresses into the conveyor line of a mattress recycling apparatus.

Summary of Invention

[0009] According to the present invention there is provided a mattress loading apparatus for loading a mattress onto a conveyor line including an actuating element for moving a mattress toward the conveyor line and a lifting platform for lifting a mattress into a path of the actuating element.

[0010] The present invention advantageously eliminates the need for operators to manually lift a mattress from the ground onto a conveyor line thereby providing a significant benefit in terms of worker health and safety. Furthermore, the present invention enables mattresses to be located in a desired orientation on the lifting platform thereby reducing the extent of orientation corrections required downstream in a mattress recycling process.

[001 1 ] The lifting platform of this invention can be configured in a variety of ways however, in a particular form of the invention, the lifting platform is configured to move along a generally vertical path between a lower position adjacent to the ground and an upper position in which the lifting platform is adjacent to (but not in the path of) the actuating element. The actuating element can similarly be configured in a variety of ways and, according to a particular form of the invention, is configured to move along a generally horizontal path located above the lifting platform. The actuating element's horizontal path can, in some forms of the invention, extend from one side of the lifting platform to the opposing side of the lifting platform. It will be appreciated that in alternative forms of the invention the lifting platform may be configured to shift along a non-vertical path and the actuating element may be configured to shift along a non- horizontal path.

[0012] In a particularly advantageous form of the present invention, the loading apparatus is automated so as to reduce manual intervention from operators and providing a further increase in efficiency and safety. In a particular form of the invention, the apparatus includes a sensor for detecting the arrival of a mattress in the path of the actuating element. The sensor can be connected to a lifting platform controller which is configured to terminate movement of the lifting platform when a mattress arrives in the path of the actuating element. The sensor may be ultrasonic or optical or any other suitable sensor.

[0013] In this manner, the present invention can perform an automated process which commences with the lifting platform being activated and rising upward to position a mattress in the path of the actuating element, ready for actuating element activation. In the next stage of an automated process the actuating element is activated, for example by the same electronic controller responsible for controlling activation of the lifting platform. Upon activation of the actuating element, the mattress in the path of the actuating element is contacted by the actuating element and thereby actuated to move toward the conveyor line and away from the lifting platform. [0014] A mattress loading apparatus according to the present invention can be located such that the actuating element, in its extended position, is generally adjacent to a conveyor line enabling the actuating element to move the mattress directly onto a conveyor line. Alternatively, the lifting platform and actuating element can be spaced apart from the conveyor line and the apparatus can further include a guide conveyor for guiding the mattress toward the conveyor line. The guide conveyor can, for example, comprise a plurality of rollers. In a particular form of the invention the guide conveyor is sloped downwardly so as to define an upper end and a lower end. The upper end can be positioned at an elevation slightly beneath the elevation of the actuating element. The lower end of the guide conveyor can be positioned adjacent to the conveyor line such that mattresses ejected from the lifting platform by the actuating element can travel down the sloped guide roller and be introduced to the beginning of the conveyor line. In either instance it will be appreciated that the actuating element operates to move the mattresses toward the conveyor line.

[0015] In a particular form of the invention, the mattress loading apparatus is sized to receive a plurality of mattresses arranged in a mattress stack i.e. piled atop one another. This form of the invention is particularly advantageous in that a pre-arranged stack of mattresses can be transported, for example by forklift or similar means, from a storage location to the lifting platform thereby eliminating the need for operators to perform this task manually. Locating a stack of mattresses on the lifting platform may preferably be performed with the lifting platform in its lowermost position such that the maximum number of mattresses can be located without the uppermost mattress contacting the overhead actuating element. In a particular embodiment of the invention, the apparatus can receive up to fifteen mattresses, more particularly ten mattresses and even more particularly eight mattresses. It will be appreciated that the present invention can be scaled, as necessary, to receive and load mattress stacks of various sizes.

[0016] According to this form of the invention, the lifting platform can be configured to position the uppermost mattress of the mattress stack into the path of the actuating element. Once positioned in the path of the actuating element, lifting movement of the lifting platform is terminated and the actuating element is activated so as to actuate movement of the uppermost mattress. The actuating element applies a force to the uppermost mattress until the friction between uppermost (i.e. the highest) mattress in the stack and the second-highest mattress in the stack is overcome and the uppermost mattress begins to move. A particular embodiment of the invention includes a retaining member to retain the second-highest mattress against movement due to friction with the uppermost mattress. The retaining member can be located beneath, and proximate to, the path of the actuating element. The retaining member therefore ensures that the actuating element actuates movement of a single mattress at a time. It may be generally desirable that the supply or feed of mattresses is metered one at a time and that mattresses are consistently spaced apart facilitating downstream processing by, for example, a mattress recycling apparatus.

[0017] As will be appreciated from the above discussion, the lifting platform and actuating element can be configured to cooperatively perform a mattress loading sequence in which a mattress is moved from the mattress stack toward a conveyor line. This sequence can generally comprise activating the lifting platform to lift the uppermost mattress atop the mattress stack into the path of the actuating element and then activating the actuating element to actuate movement of the uppermost mattress from the mattress stack toward the conveyor line. The sequence may be repeated as necessary to continue the feed of mattresses being loaded onto the conveyor line until there are no more mattresses remaining on the lifting platform. It will be appreciated that loading the final mattress (or lowermost mattress in the mattress stack) may involve moving the lifting platform to its upper position and for the actuating element to overcome friction between the mattress and the lifting platform.

[0018] Whilst the actuating element can be configured in a variety of ways, a particular form of the invention provides an actuating element having a path which is linear. The path can extend between a retracted position in which the actuating element is located toward one side of the lifting platform and an extended position in which the actuating element is located toward the opposing side of the lifting platform. The apparatus can include a track for guiding movement of the actuating element. The track could comprise any elongate guide means. In a particular form of the invention the track consists of an elongate rail positioned above the lifting platform and engaged with the actuating element to permit movement of the actuating element between opposing sides of the loading apparatus.

[0019] The actuating element can be configured to engage the mattress in a number of ways. In some forms of the invention the actuating element is configured to pull the mattress and can include one or more hooking elements to hook and drag an upper surface of the mattress. In an alternative, and preferred, form of the invention the actuating element is configured to push the mattress toward the conveyor line. In this form of the invention the actuating element therefore defines a pushing element. The pushing element can include a pushing surface for engagement with a mattress surface to actuate movement of the mattress. In a particular embodiment of the invention, the pushing surface is defined by an elongate pushing member. With the pushing member in the retracted position, the lifting platform can operate to lift a mattress into the path of the pushing member such that movement of the pushing member to the extended position results in the mattress being pushed from its position on the mattress stack (or on the lifting platform) to the conveyor line. The mattress can be pushed either directly to the conveyor line or pushed onto a guiding conveyor leading to the conveyor line.

[0020] According to a particular form of the invention, the pushing surface is generally planar such that the mattress is squared up when pushed toward the conveyor line. Advantageously, this form of the invention can automatically reorientate mattresses to a desired orientation. For example, if a mattress may be stacked askew such that a perimeter surface of the mattress is not parallel with the plane of the pushing surface. Contact between the mattress perimeter surface and the planar pushing surface may therefore advantageously correct the reorientation of the mattress such that the perimeter surface becomes parallel with the pushing surface. In this manner, the present invention may facilitate mattresses being loaded onto the conveyor line in a predetermined (and desirable) orientation which facilitates subsequent processing. Whilst it is possible that some downstream reorientation may still be required in order to permit optimal processing, it will be appreciated that the present invention nonetheless enables a more desirable and consistent orientation as compared to the metering conveyor defined in WO2015080580 in which mattresses are pulled from a supply bunker at random orientations by the hooks of the metering conveyor.

[0021 ] Positioning the mattress in the path of the pushing element may involve, for example, aligning an upper surface of the mattress with an upper edge of the pushing element. In an alternative (and preferred) form of the invention, the apparatus is configured to halt movement of the lifting platform when the upper surface of the mattress is approximately aligned with the vertical midpoint of the pushing element. This configuration advantageously maintains a spacing between the upper surface of the mattress and the top of the loading apparatus and therefore provides a margin of error to prevent undesirable contact between the mattress and the top of the apparatus (for example, contact between the mattress and the overhead actuating element guide track).

[0022] In a particular form of the invention the actuating element includes an upper frame extending outwardly and generally horizontally from an upper edge of the pushing surface. The upper frame provides spacing means preventing contact between an upper surface of the mattress and any upper static portions of the apparatus (for example the apparatus frame).

[0023] The actuating element and lifting platform may be operated by any suitable mechanical system for example pneumatically, hydraulically, electrically. In a particular form of the invention the actuating arrangement is pneumatically operated and the lifting platform is hydraulically operated.

[0024] The lifting platform can be activated by a control panel adjacent to the lifting platform, for example a push button or switch located on one of upright frame members. In a particular form of the invention (in addition to or as an alternative to controls located adjacent the lifting platform) the apparatus can include a remote control system which enables the lifting platform to be activated by a forklift operator. In this form of the invention, lifting platform can be activated by control panel remotely from the apparatus and at a location accessible from a forklift cabin. This form of the invention advantageously allows a forklift operator to unload a mattress stack onto lifting platform, reverse away from the lifting platform and then activate the apparatus via the remote control system without the need to exit the forklift. The remote control system may comprise a free-standing remote control panel positioned, for example, several meters away from the lifting platform.

[0025] As discussed above, activation of the apparatus and loading of the topmost mattress in the mattress stack onto the conveyor line may be triggered by an operator via a control panel positioned either adjacent to the lifting platform and/or via a remote control panel positioned remotely from the lifting platform. In a particular form of the invention, an apparatus-activation sensor (for example an ultrasonic, infrared, laser or optical sensor) is provided to trigger loading of subsequent mattresses onto to the conveyor line. By way of example, a downstream sensor may be positioned on the conveyor line for detecting passage of a first mattress. Upon detection of the first mattress the downstream sensor may trigger the loading apparatus to deploy the next mattress in the mattress stack. This form of the invention enables mattresses to be sequentially deployed from the mattress loader onto the conveyor line at a desirable rate. Furthermore, this form of the invention reduces the possibility of an undesirable mattress build-up in the event a downstream obstruction, for example, if a mattress were to become jammed the downstream sensor would not be triggered and the autoloader would not deploy further mattresses until the obstruction is cleared.

[0026] It will be appreciated that the present invention therefore provides a mattress loading apparatus which may be used in conjunction with a mattress recycling apparatus. Another aspect of the present invention may therefore include a mattress recycling apparatus including a mattress loading apparatus as discussed above.

[0027] The present invention may also include a method of loading a mattress onto a conveyor line. This method includes the steps of a) locating a stack of mattresses on a lifting platform; b) activating the lifting platform to lift an uppermost mattress atop the mattress stack into the path of an actuating element; c) activating the actuating element to actuate movement of the uppermost mattress from the mattress stack toward the conveyor line; d) returning the actuating element to the retracted position; and e) repeating steps b) to d) for each of the remaining mattresses in the mattress stack. [0028] As discussed in the forgoing, initial activation of the lifting platform can be controlled by a manually operated control panel such as a control panel proximate the lifting platform or by a remote control panel located remotely from the lifting platform. After initial operation of the loading apparatus, subsequent timing of mattress deployment can be automated. According to a particular embodiment of the invention, said automated deployment is controlled by a sensor positioned downstream the conveyor line from the lifting platform. In this manner, after initial operator input, the timing of subsequently mattress loading is automatically controlled thereby improving operational efficiency.

Brief Description of Drawings

[0029] Figure 1 exemplifies a mattress recycling process and illustrates a prior mattress loading apparatus.

[0030] Figures 2 to 7 show a mattress loading apparatus according to the present invention and illustrate a sequence of operation in which a mattress is loaded onto a conveyor line.

[0031 ] Figures 8 to 10 illustrate a remote control panel for controlling operation of the loading apparatus from a forklift cabin.

[0032] Figures 1 1 and 12 illustrate a sensor for triggering continuing activation of the mattress loading apparatus.

Detailed Description

[0033] By way of contextual background to the present invention, Figure 1 illustrates a mattress recycling process 14 described in the WO2015080580. At the first stage of the illustrated process, a supply of mattresses 2 is transferred to a supply bunker 14-1 which is fed via a conveyor to a metering conveyor 14-2. In the illustrated example, the metering conveyor 14-2 is sloped steeply such that mattresses 2 are not capable of being conveyed up the slope by conveyor friction alone. To assist in conveying mattresses 2, a hook element is embedded into metering conveyor 14-2 which periodically grasps a unitary mattress 2 and conveys the mattress 2 up the slope of the metering conveyor 14-2. In this way, the feed of mattresses from the plurality of mattresses 2 at supply bunker 14-1 is metered and each mattress 2 is consistently spaced apart on the conveyor line.

[0034] The present invention provides an alternative mattress loading apparatus to metering conveyor 14-2 which can be used for the same general purpose, namely, transferring mattresses to a conveyor line leading to the next stage of the recycling process.

[0035] Figures 2 to 7 illustrate a particular embodiment of the present invention. More particularly, Figures 2 to 7 illustrate an operation sequence of the present invention. Figure 2 illustrates a mattress loading apparatus 10 including a lifting platform 12 and an actuating element comprising a pushing element 16. A plurality of seven mattresses labelled (from top to bottom) 18-1 to 18-7 are stacked upon lifting platform 12. The illustrated embodiment of the invention is shown with seven mattresses although apparatus 10 is, in fact, sized to receive a stack of up to eight mattresses.

[0036] As best illustrated in Figure 5, pushing element 16 comprises an elongate member having a generally rectangular pushing face 20. Returning to Figure 2, lifting platform 12 and pushing element 16 are located within an apparatus frame comprising four upright frame members 24 connected at their upper ends by four horizontal frame members 26. Apparatus 10 further includes a track comprising a guide rail 22 for guiding movement of the pushing element 16. Guide rail 22 is supported from a guide rail frame member 28 connected to the approximate midpoints of a pair of opposing horizontal frame members 26.

[0037] Figure 5 also best illustrates actuating element including an upper frame 44 extending outwardly and generally horizontally from an upper edge of the pushing face 20. Upper frame 44 provides a spacing means preventing contact between an upper surface of a mattress and any upper static portions of the apparatus (for example in instances where the mattress has a particularly thick section or in the event that the lifting platform is raised too higher than desired before sensor detection occurs.

[0038] As best illustrated in Figure 4, apparatus 10 includes a guide conveyor 30 comprising a plurality of rollers 32. Guide conveyor 30 is sloped downwardly from a rectangular mattress outlet 25 bounded, at its sides by an upper portion of upright fame members 24a and 24b, at its upper edge, by one of horizontal frame members 26 and, at its lower edge, by a retaining member 34 which is partially obscured by guide conveyor 30. Guide conveyor 30 includes an upper end 36 generally aligned with retaining member 34 and, as illustrated in Figure 5, a lower end 38 positioned to overlapping the edge of conveyor 40 which defines the beginning of a mattress recycling conveyor line. This arrangements provides that mattresses ejected through outlet 25 travel along guide conveyor 30 and are loaded onto the beginning of the conveyor line at conveyor 40.

[0039] Returning to Figure 2, pushing element 16 is movable along a linear path along guide rail 22 between a retracted position illustrated in Figure 2 and an extended position illustrated in Figure 5. As illustrated in Figure 2, in the retracted position, the pushing element is located on the opposite side of the lifting platform 16 relative to the mattress outlet 25. As illustrated in Figure 5, in the extended position, the pushing element 16 is located overhead the upper end 36 of guide conveyor 30.

[0040] Apparatus 10 further includes an optical sensor 42 in approximate alignment with the pushing element 16 to detect mattresses entering the path of the pushing element.

[0041 ] With the componentry of apparatus 10 having been generally described above, the operation of the present invention can be described in further detail with reference to the process illustrated in sequential Figures 2-7.

[0042] Figure 2 illustrates seven mattresses 18 having been forklifted onto lifting platform 12. As illustrated in Figure 2, the seven-high mattress stack does not reach the elevation of pushing element 16 and therefore can be conveniently located upon the lifting platform without contacting the pushing element 16 overhead. Lifting platform 12 is activated and is raised upwards using a hydraulic hoisting arrangement such as a hydraulic car hoist or similar mechanical lifting means. Uppermost mattress 18-1 atop the mattress stack is lifted toward the path of pushing element 16 which is defined by the guide rail 22.

[0043] Turning to Figure 3, uppermost mattress 18-1 has entered the path of pushing element 16 and triggers sensor 42 which provides a signal to a controller (not shown) to stop movement of lifting platform 12. The upper surface of mattress 18-1 is approximately aligned with the vertical midpoint of pushing element 16.

[0044] The next stage of the process is illustrated in Figure 4, in which activation of the pushing element 16 has occurred pushing element 16 is pneumatically driven from its retracted position toward its extended position and toward outlet 25. Rectangular and planar pushing face 20 contacts a perimeter surface of mattress 18-

1 and actuates movement of mattress 18-1 toward mattress outlet 25 and therefore toward guide conveyor 30 and the conveyor line defined by conveyor 40.

[0045] During movement of mattress 18-1 , the second-to-uppermost mattress 18-

2 is urged in a similar direction toward guide conveyor 30 via frictional engagement with uppermost mattress 18-1 . Mattress 18-2 is retained in position via abutment with retaining member 34 such that mattress 18-2 and the other remaining mattresses are maintained in their stacked formation during movement of uppermost mattress 18-1 . In this regard, apparatus 10 is therefore configured to desirably meter a single mattress at a time through mattress outlet 25.

[0046] In Figure 5, pushing element 16 has arrived at its extended position located above guide conveyor 30 and mattress 18-1 has been pushed from the mattress stack out of mattress outlet 25 and onto the rollers 32 of guide conveyor 30. As illustrated in Figure 6, mattress 18-1 continues to travel under the influence of gravity on rollers 32 over the lower end 38 of guide conveyor 30 onto conveyor 40 and thus is loaded onto the conveyor line of the mattress recycling process to which conveyor 40 leads.

[0047] Turning to Figure 7, after ejection of mattress 18-1 from opening 25, pushing element 16 is returned to its retracted position. The sequence is then repeated with lifting platform 12 rising upwards until mattress 18-2 enters the path of pushing element 16 at which point sensor 42 detects mattress 18-2 and a controller (not shown) triggers a halt to hydraulic movement of platform 12 and the activation of pneumatic pushing element 16.

[0048] Apparatus 10 can be activated by a control panel adjacent to the lifting platform 12, for example a push button or switch located on one of upright frame members 24. A particular embodiment of the invention is illustrated in Figures 8 to 10 in which apparatus 10 includes a duplicate control panel 50 facilitating operation of apparatus 10 from a forklift cabin. Duplicate control panel 50 is mounted to support structure 52 and is elevated for convenient accessibility from the cabin of a forklift 54 (illustrated in Figure 9). As best illustrated in Figure 8, duplicate control panel 50 is free-standing and is remotely positioned several metres from the lifting platform 12. Figure 10 provides a front perspective of control panel 50 which includes a plurality of push-buttons 51 for controlling operation of mattress loading apparatus 10.

[0049] Figures 8 and 9 illustrate a mattress stack 56 of seven mattresses which, in use, is collected by forklift 54 and relocated to lifting platform 12. The operator of forklift 54 then reverses back to duplicate push button 50 and can activate loading apparatus 10 from a seated position in the cabin of forklift 54. The provision of duplicate control panel 50 thereby avoids the need for the operator to exit the forklift providing an improvement in safety and operational efficiency.

[0050] Upon activation of apparatus 10 by either the forklift operator (via duplicate control panel 50) or by an operator standing adjacent to the lifting platform 12 (via a control panel installed adjacent to lifting platform 12) the apparatus 10 operates to deploy a first mattress from stack 56 down guide conveyor 30 and onto the conveyor line, in the manner discussed above. Subsequent activation of apparatus 10 to deploy a second, third etc. mattresses from stack 56 onto the conveyor line may be controlled via a timer or by manually operated push-button or by another triggering means.

[0051 ] However in a particularly preferable form of the invention the deployment of subsequent mattresses is controlled by a downstream apparatus-activation sensor 70 in the conveyor line which is triggered by a mattress travelling along the conveyor line. In this form of the invention after a first mattress is deployed from loading apparatus 10, a second mattress is not deployed until the first mattress has reached a particular downstream location along the conveyor line. Figure 1 1 illustrates sensor 70 installed at the edge of a conveyor 72 and Figure 12 illustrates a sensor reflector 74 installed opposite sensor 70 on the opposing edge of conveyor 72. Sensor 70 and sensor reflector 74 cooperatively provide a sensor beam which, when obstructed by a passing mattress on conveyor 72, signals loading apparatus 10 to load the next mattress onto the conveyor line. [0052] In a particular form of the invention, sensor 70 and sensor reflector 74 are positioned downstream of a preliminary cutting station for applying preliminary cuts to at least two sides of a mattress. According to this embodiment of the invention a mattress exiting the loading apparatus 10 is loaded onto the conveyor line and passes through the preliminary cutting station whereupon exiting the preliminary cutting station the mattress passes sensor 70 and triggers loading of the next mattress onto the conveyor and through the preliminary cutting station.

[0053] It will be appreciated that whilst duplicate push button 50, downstream sensor 70 and sensor reflector 74 are located remotely from lifting platform 12 and pushing element 16, the duplicate push button 50, sensor 70 and sensor reflector 74 are functionally and electronically connected thereto and nonetheless form part of the mattress loading apparatus 10. It will be also appreciated that duplicate push button and the downstream sensor could be electrically connected (for example via wiring) to an electronic controller on apparatus 10 but, in other embodiments, could also be wirelessly connected to the electronic controller via existing wireless technology.

[0054] Where the terms "comprise", "comprises", "comprised" or "comprising" are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other feature, integer, step, component or group thereof.

[0055] The invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be understood that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the present disclosure.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS

1 . A mattress loading apparatus for loading a mattress onto a conveyor line including an actuating element for moving a mattress toward the conveyor line and a lifting platform for lifting a mattress into a path of the actuating element.

2. A mattress loading apparatus according to claim 1 including a sensor for detecting the arrival of a mattress in the path of the actuating element.

3. A mattress loading apparatus according to claim 2, the sensor being connected to a lifting platform controller for terminating movement of the lifting platform when a mattress arrives in the path of the actuating element.

4. A mattress loading apparatus according to any one of the preceding claims, the apparatus being sized to receive a plurality of mattresses arranged in a mattress stack.

5. A mattress loading apparatus according to claim 4, the lifting platform being configured to position the uppermost mattress of the mattress stack into the path of the actuating element.

6. A mattress loading apparatus according to claims 4 or 5 wherein the lifting platform and actuating element are configured to cooperatively perform a mattress loading sequence in which a mattress is moved from the mattress stack toward a conveyor line.

7. A mattress loading apparatus according to claim 6, the mattress loading sequence comprising activating the lifting platform to lift an uppermost mattress atop the mattress stack into the path of the actuating element; and activating the actuating element to actuate movement of the uppermost mattress from the mattress stack toward the conveyor line.

8. A mattress loading apparatus according to any one of the preceding claims, the path of the actuating element being linear.

9. A mattress loading apparatus according to any one of the preceding claims, including a track for guiding movement of the actuating element.

10. A mattress loading apparatus according to any one of the preceding claims, the actuating element being configured to push the mattress toward the conveyor line.

1 1 . A mattress loading apparatus according to claim 10, the actuating element including a pushing surface for engaging with a mattress surface to actuate movement of the mattress.

12. A mattress loading apparatus according to claim 1 1 , the pushing surface being defined by an elongate pushing member.

13. A mattress loading apparatus according to any one of the preceding claims wherein the path of the actuating element extends between a retracted position and an extended position.

14. A mattress loading apparatus according to any one of the preceding claims, the actuating element being configured to pull the mattress toward the conveyor line.

15. A mattress loading apparatus according to claim 14, the actuating element including a hooking element for engaging with a mattress surface.

16. A mattress loading apparatus according to any one of the preceding claims including a guide conveyor for guiding the mattress toward the conveyor line.

17. A mattress loading apparatus according to claim 16 the guide conveyor sloping downwardly from the loading apparatus.

18. A mattress loading apparatus according to claims 16 or 17, the guide conveyor including a plurality of rollers.

19. A mattress loading apparatus according to any one of the preceding claims including a control switch located remotely from the lifting platform.

20. A mattress loading apparatus according to claim 19, the remotely located control switch positioned on a free-standing control panel spaced from the lifting platform to facilitate operation of the loading apparatus from a forklift cabin.

21 . A mattress loading apparatus according to any one of the preceding claims including an apparatus-activation sensor for triggering operation of the loading apparatus upon detecting a mattress at a position of the conveyor line downstream of the lifting platform.

22. A mattress loading apparatus according to any one of the preceding claims, the actuating element being pneumatically operated.

23. A mattress loading apparatus according to any one of the preceding claims, the lifting platform being hydraulically operated.

24. A mattress recycling apparatus including a mattress loading apparatus according to any one of the preceding claims.

25. A method of loading a mattress onto a conveyor line including the steps of: a) locating a stack of mattresses on a lifting platform; b) activating the lifting platform to lift an uppermost mattress atop the mattress stack into the path of an actuating element; c) activating the actuating element to actuate movement of the uppermost mattress from the mattress stack toward the conveyor line; d) returning the actuating element to the retracted position; and e) repeating steps b) to d) for each of the remaining mattresses in the stack of mattresses.

26. A method according to claim 25 wherein initial activation of the lifting platform is triggered by an operator and subsequent activation of the lifting platform is automated.

27. A method according to claim 26 wherein automated activation of the lifting platform is triggered by an apparatus-activation sensor positioned downstream the conveyor line from the lifting platform.