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Design
Mattresses are manufactured according to a set of standard sizes. Some of which are Twin bed (39 x 74) Double bed ( 54 x 74), Queen bed (60 x 80) and King bed (78 x 80). Most mattresses use an innerspring as the core unit, then a set of upholstery layers called insulators are affixed onto the innerspring. The next layer is cushioning and it can vary from two to eight layers of various thickness sizes. The outward look of the mattress comprises of flanges, which are connecting panels attached to the mattress’s quilt cover with large round staples called hogs rings. The panels seen on the top, side and bottom of the mattress are stitched together with border tape. The four most commonly used coils are the Bonnell, Offset, Continuous, and Pocket System. A normal mattress contains about 250-1000 coil springs
Raw Materials
The mattress consists of various materials, which are natural and synthetic. The innerspring is made of wire, the insulator is made of semi-rigid wire mesh, cushioning layers include natural fiber, polyurethane foam, polyester etc. The flanges are made of fabric and hogs rings are made of metal. The top, bottom and side panels are made of durable fabric cover quilted over foam or fiber along with the binding
The Manufacturing process
Most mattresses manufacture the innerspring as the first layer followed by the insulator and the cushioning layer which determines the feel and comfort of the final product. The decorative cover for the mattress is made on a quilting machine and it covers the entire mattress, acting as a cushion and creating a visually pleasing look. The fabric is then cut into panels to fit on all the sides of the mattress and side handles and vents are also added to complete the look. Flanges are attached to the top and bottom panels and hogs rings on the flanges are stapled. The mattress is closed by a heavy-duty binding tape at the top, bottom and side panels. Some high-quality mattresses feature a pillow top (panel filled with soft upholstery) for a more luxurious feel and appearance. Once the mattress is filled and sealed they are inspected for quality, labeled and tagged. The product when finished is shifted to the packing area and covered with protective plastic or paper covers. Warranty information, safety and care instructions are also included in the packaging.
Quality Control
Quality control is mostly carried out by sight during the manufacturing process. Inspections are held at critical points like after receiving the innerspring, before closing and packing etc. Fire is a potential threat to all conventional mattresses and hence strict instructions on how to care for your mattress is informed in detail along with the product.
The Future
Good sleep is always accompanied by a good mattress and a great sleeping environment. Comfort and sleep are highly subjective; a high-quality mattress may feel uncomfortable for one person and super comfortable for the other. Most companies spend a considerable amount of time and money on research and found that comfort and quality go hand in hand.
