Pocket springs are a popular type of mattress spring system that offers superior support and comfort for sleepers. They are constructed using a series of individual springs that are contained within fabric pockets, which allows for greater flexibility and support compared to traditional mattress springs. If you are interested in learning how pocket springs are manufactured, this article will guide you through the process.
Step 1: Wire Drawing
The first step in manufacturing pocket springs is wire drawing. This involves pulling a large coil of steel wire through a series of dies to reduce the wire’s diameter and increase its strength. The wire is then wound onto spools for use in the next step.
Step 2: Spring Coiling
In the spring coiling process, the steel wire is fed into a machine that shapes it into individual springs. The machine uses a series of rollers to form the wire into a coil, which is then cut to the desired length. The coils are then heated and tempered to give them their final shape and strength.
Step 3: Pocketing
Once the individual springs are formed, they are placed into fabric pockets. The pockets are typically made from non-woven polypropylene or a similar material that is durable and breathable. The pockets are stitched together and arranged in a grid pattern to create a mattress core.
Step 4: Border Support
To provide additional support around the edges of the mattress, a border wire is added. This wire is typically thicker than the individual springs and is shaped to match the perimeter of the mattress. The border wire is attached to the pocketed springs using special clips or staples.
Step 5: Assembly
In the final step, the pocketed spring core is assembled into a complete mattress. This typically involves adding a layer of padding on top of the springs to provide cushioning and support. The padding may be made from a variety of materials, such as foam, latex, or cotton. The cover is then added, which may be made from a range of materials, including cotton, polyester, or a blend of natural and synthetic fibers.
