The mattress market already offers an enormous range of designs and materials; however,the demands surrounding the quality, flexibility, and efficiency of the assembly process are constantly on the rise. The adhesives used in the manufacturing processes for foam mattresses have a significant role to play. While most manufacturing processes still rely on dispersions, Jowat has long since been using a solution that not only improves efficiency, but also streamlines production processes in the form of the polyurethane hot melt adhesive (PUR) in the Jowatherm-Reaktant® series.
Standard use of aqueous dispersions requires a time-consuming interim storage period of up to 24 hours during the mattress Assembly process, not to mention the corresponding storage spaces and logistics costs. This is due to the low initial strength of the adhesives and the risk of mould formation as a result of the water introduced while applying the adhesive. Jowatherm-Reaktant® keeps this time-consuming intermediate step to a minimum. According to Falk Potthast, Product Manager at Jowat, “as soon as the Pressing process is complete, the mattress covers can be filled with the mattress core, packed in foil and rolled up after just a few minutes.” The use of PUR not only minimises storage periods and thereby increases cycle rates, it also only requires a significantly lower amount to achieve exceptional adhesive results in comparison to a dispersion, which in turn saves on costs. At the same time, the use of Jowatherm-Reaktant® ensures there are no compromises in terms of comfort; quite the opposite, in fact, since the soft adhesive bonds and minimal tacky adhesive surface residue left behind by PUR prevent any unpleasant noise when lying on mattresses, making for a quiet and healthy sleep.
Proven technology made even better
Jowatherm-Reaktant® 639.20 is part of a new generation of PUR hot melt adhesives that have been successfully used to manufacture foam mattresses for many years. The hot melt is suitable for all conventional materials used in the production of foam mattresses, and – unlike the commonly used polychloroprene dispersions – does not feature any chlorine compounds. As a result, it not only lives up to the high requirements of OEKO-TEX® and the Blue Angel, it also makes a significant contribution in terms of process reliability. Switching to PUR is a relatively straightforward process. As it can be applied using a roller or a spraying process, just like a dispersion, this means only the application unit has to be replaced in most cases. Offering extensive specialist expertise and application proficiency, Jowat is always on hand to offer support every step of the way – even after switching to PUR hot melts.
A wise decision
The dispersion adhesives currently used in mattress production processes are based on polychloroprene rubber, ethylenevinyl acetate (EVA), or polyurethane (PUR). In order to facilitate faster processes, however, they have to be dried out in a phase that requires a great deal of energy. This is where the reactive PUR hot melts are clearly the better choice, as they do not involve any water at all. Jowatherm-Reaktant® 639.20 are therefore ideal when it comes to maximising process efficiency and saving on the costs of adhesives. After all, as the motto goes, better gluing means better sleeping.