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MATTRESS ASSEMBLY

The quality of a mattress is determined by its structure, the processed materials, the used adhesive and the related assembly process.

  • Highest efficiency in manufacturing
  • High-performance adhesives for automated processes
  • Easy handling due to hot melt adhesives

 

Adhesives for mattress assembly

 

Apart from quality, efficiency plays an essential role for mattress manufacturers. In this context, efficiency means especially an excellent cost-benefit ratio, high productivity in the assembly of the mattresses and in the following processes, such as filling, packing and shipping.

 

Minimal production costs, short process cycles, easy handling with a low potential for errors in the assembly and downline processing are decisive factors in the global competition. Effectiveness can be increased by reducing and preventing inefficient waiting times and transport routes. The adhesive for mattress assembly has to support the virtually unlimited structure diversity and be characterised by good adhesion also to substrates which are difficult to bond, such as latex, viscose or gel foams. Therefore, different adhesive systems with different application methods may be used for different mattress types depending on the mattress structure. Automated adhesive application by roller or bead (multi bead) has become established in industrial operations.

 

Automated mattress assembly processes can generally be divided into the two main mattress types Bonnell or pocket innerspring mattresses, and foam mattresses. Polyolefin hot melts (applied in beads) are the standard adhesives for innerspring mattresses, and reactive polyurethane hot melt adhesives (applied by roller) are used especially in the manufacture of foam mattresses where they provide excellent advantages compared to the established polychloroprene dispersion adhesives.

 

The fast build-up of strength of hot melt adhesives facilitates faster processing speeds and consequently increased efficiency.

 

Requirements | Efficient manufacturing processes

 

  • High productivity
  • High plant availability
  • Easy handling
  • Short process cycles
  • Fast downline processing
  • Low potential for errors
  • Minimum safety requirements
  • Good environmental compatibility

 

The requirements for a strong and durable bond in the manufacture of foam mattresses are constantly growing. For instance due to new materials and mattress compositions which are difficult to bond with standard adhesive systems. Like in many other applications, reactive polyurethane hot melt adhesives (PUR) provide major benefits for the bonding of foam mattresses due to the special characteristics of this product group. Jowatherm-Reaktant® 609.20 impresses with excellent bonding results on all established materials, especially on materials which are difficult to bond, such as latex, viscose or gel foam.

 

Due to the complex requirements in the assembly of innerspring mattresses, adhesives for this application are high-performance products. In addition to bonding the different substrates, adhesives also help increase comfort and health and therefore support a good night’s sleep. And they frequently have to meet these requirements for 10 years and longer. By developing Jowat-Toptherm® 232.30, Jowat has established a general-purpose hot melt adhesive of the highest standard for the assembly of pocket innerspring and Bonnell mattresses.