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Product Assembly Mattress manufacture adhesives (including hot melt PSA) |
We provide a high performance range of hot
melt adhesives for the mattress industry globally.
Wake up to
Intercol
hot melt adhesives
Our superior range
of adhesives enables
manufacturers to improve
product quality and
product appearance.
Fantastic performance:-
Low odour
-
Non-toxic
-
Non-fuming
-
Tough and resilient
-
Trouble free – consistent performance
-
Cleaner running
-
Safe to handle and use
-
Ability to reduce cost – no need for emission
recovery systems.
Hot melt adhesive
applications.
There are essentially two different methods:
1.Manual assembly.
Hot melt applied with a spray
gun and the mattress is then man-handled to the next
stage of the process. A high tack pressure sensitive (PSA-adhesive) is
needed – high tack to ensure the components do not
come apart during the subsequent handling; pressure
sensitive to give sufficient time between application
by spray and positioning of the covering layers.
2.Automated assembly.
Automatic in-line bonding
allows a shorter open time for the adhesive than
manual assembly; mattresses are moved to the
next stage on conveyors etc. In this instance a
range of adhesives including semi-pressure
sensitive adhesives can be used.
Mattress
types.
Our adhesives have the ability to bond all mattress types
including open coil, pocket sprung and solid foam.
The mattress production process can involve a range
of substrates – including foams, textiles, non-woven
materials, metals and plastics – and a variety of
applications, all with different adhesive requirements.
While others play catch up,
we are already there.
Original thought may be rare, but it’s something we
have built our business on. Much of our success has
come from our unique ability to develop innovative,
quality-assured hot melts that are matched to the
specific needs of our customers. The initial challenge
may seem daunting, but we have the people, the
resources and the capabilities to deliver time after time;
developing clever, bespoke hot melt adhesives.
Adhesive products
Historically, solvent based (PSA) adhesives were the main glue used. Depending on the country, these may have
been flammable (F) or non
-
flammable (NF)
However, in many parts of the world, the industry is facing tougher health and safety regulations as well as
insurance issues due to the health and fire risks that solvents present.
This is driving change to either water based contact adhesives or hot melts
–
and with new capital
investment in manufacturing, hot melt adhesives tend to be preferred:
•
Investment costs for solvent based systems are much higher because of the solvent recovery system
requirement. (The downside is that to maintain market share, solvent adhesives have reduced in price,
in turn reducing margins.)
•
Water borne has two main disadvantages: the capital equipment costs of drying systems and the time to
remove water
–
and drying is critical as residual water trapped in the mattress during manufacture
cannot
escape prior to wrapping in plastic. This results in an unpleasant smell developing which is
released when the packaging is removed
–
water based adhesives are not deemed acceptable.
•
In comparison, hot melt systems have a low capital investment and low
odour
retention.
The majority of hot melt adhesives used in the construction of mattresses are pressure sensitive or semi
-
pressure sensitive (long open time) adhesives.
Hot melt adhesive applications
There are essentially two different situations:
1. Manual assembly
. Hot melt applied with a spray gun and mattresses man
-
handled to the next stage of
the process. A high tack pressure sensitive is needed
–
high tack to ensure the components do not come
apart during the subsequent handling; pressure sensitive to give sufficient time between application by
spray and positioning of the covering layers.
2. Semi automatic assembly
. Automatic in
-
line bonding requires a shorter open time than manual
assembly; mattresses are moved to the next stage on conveyors etc. In this instance, semi
-
pressure
sensitives
can be used |
