Mattress manufacturing process and process

Author: Synwin–Mattress Suppliers

The mattress is mainly composed of three parts: frame, filler and fabric. (1) The frame constitutes the main structure and basic shape of the mattress. The frame materials are mainly wood, steel, wood-based panels, medium density fiberboard, etc. Currently, medium density fiberboard is the main material.

The frame mainly needs to meet the modeling requirements and strength requirements. (2) The filler plays a decisive role in the comfort of the mattress. The traditional fillers are brown silk and springs. Now, various functional foamed plastics, sponges, and synthetic materials are commonly used.

The filler should have good elasticity, fatigue resistance and long life. Different parts of the mattress have different load-bearing and comfort requirements. The performance and price of fillers vary greatly.

(3) The texture and color of the fabric determine the quality of the mattress. At present, the variety of fabrics is really dazzling. With the advancement of science and technology, the variety of fabrics will become more and more abundant. The general structure of traditional mattresses (from bottom to top): frame - wooden strips - springs - bottom gauze - brown pads - sponge - inner bag - outer cover. The general structure of modern mattresses (bottom-up): frame - elastic band - bottom gauze - sponge - inner bag - outer cover.

It can be seen that the production process of modern mattresses omits the time-consuming and labor-intensive processes of fixing springs and laying brown pads compared with traditional mattresses. The characteristics of mattress production are the variety of materials used and the large differences in materials, such as wood, steel, wood-based panels, paint, decorative parts, etc. for making frames; sponge, foam plastic, elastic belt, non-woven fabric, spring, brown pad for filling etc.; fabrics for outerwear, genuine leather, composite materials, etc. The processing technology spans a wide range, from woodworking, lacquer work, sewing work to hairpin work.

According to the principle of professional division of labor and improving work efficiency, the mattress processing is divided into 5 sections: the frame section, which mainly produces mattress frames; the outer decoration section, which mainly produces the exposed components of the mattress; the inner lining section, which prepares various types of sponges. Core; coat section, cutting and sewing coats; final assembly (skin) section, assembling the semi-finished products of each previous section with accessories to assemble a complete mattress product. Different mattress manufacturers have different technological processes. Small enterprises have thicker process division lines, while large and medium-sized enterprises have more detailed process division. Specialized division of labor is conducive to improving work efficiency and ensuring the stability of product quality. Batching process Most of the materials used for mattress frame are boards, which are cut with a slitting saw, while small enterprises use a circular saw and a band saw to cut curved boards.

Mattress frame material can be medium density fiberboard, because medium density fiberboard has the advantages of large format and high yield, especially for curved parts. At present, the performance of various fasteners and connectors for MDF is very good. In the market, there are many chemical products with formaldehyde sealing and formaldehyde capture spraying on the surface of the MDF frame, which can get rid of the trouble of formaldehyde.

For frames, armrests, and decorative parts made of solid wood, these parts have high surface quality requirements and complex processes. Some require solid wood bending, and some require special processing. These parts are basically the same as the processing of solid wood furniture, so there is no need to do so. Discussed. Clear and correct ingredient list, layout diagram, and template of curved parts are the main measures to rationally use materials and improve work efficiency. Assembling the frame Assemble the prepared plates, bent pieces, and square materials into a frame, and seal the bottom plate.

It is necessary to frequently collect and summarize the fasteners used for the mattress frame, and select the fastener information skillfully, which can achieve a multiplier effect on the assembly of the frame. The quality of the manufactured mattress frame should be paid attention to, and the size of the mass-produced frame should meet the requirements, and the size error will cause trouble to the final assembly (skin) process. The strength of the frame must meet the requirements. At present, the frame structure of the mattress is based on experience. In fact, the frame material can be reduced or the strength can be further improved by optimizing the treatment.

The craftsmanship of the frame structure should also be paid attention to to facilitate the operation of subsequent processes. The surface of the frame should be smoothed to remove burrs and sharp angles to avoid leaving hidden dangers for subsequent processes. Sponge preparation According to the specifications and dimensions required by the bill of materials, scribe and cut sponges. For sponges with complex shapes that need to be nested, a nesting list and template should be attached to facilitate construction.

Paste the frame Nail elastic tape on the frame - nail gauze - glue thin or thick sponge to prepare for the peeling process and reduce the workload of the peeling process. In this process, there must be corresponding requirements for the specification, quantity, tension value and cross sequence of the elastic band, and these parameters will affect the comfort and durability of the mattress. Coat cutting According to the requirements of the ingredient list, cut according to the model.

The natural leather should be checked one by one to avoid scars and defects. Synthetic materials can be cut into stacks with electric shears, and the precious natural hides can be rationally used. Coat cutting is a control point for production costs.

Assembly (Skin) Assemble the pasted frame, processed inner and outer cover, various trims and accessories into a mattress. The general process is to nail the inner sleeve on the frame with the sponge, then put the outer sleeve and fix it, then install the decorative parts, nail the bottom cloth, and install the feet. Inspection and storage The products can be packaged and put into storage after passing the inspection.

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