The idea of a mattress first appeared in primordial times. Early humans were able to sleep more soundly and comfortably on mounds of leaves, straw, and animal skins than they could have on hard surfaces. Primitive furnishings, such as the bed, started to emerge when more people switched from a nomadic, hunting lifestyle to a stable, agrarian one. The transformation of the mattress is intricately bound the development of the bed. The bed was considered to be the most significant piece of furniture in many ancient societies. Mattresses with stabilizing interior springs were first developed in the mid-1800s, and are widely regarded as the single most significant advancement in mattress design. However, the marketing strategy's effectiveness has only grown over time, as subsequent research has confirmed that adequate; high-quality sleep is a critical component of good health. Modern mattresses improve sleeping comfort in a variety of ways. First, modern mattresses distribute body weight over a wide area due to a variety of improved innerspring designs; this also helps to prevent differential wear on the mattress.
Design
The majority of mattresses are now produced in standard sizes. The industry started this standardization to eliminate any potential dimensions differences between companies that manufacture beds and firms that produce mattresses. The dimensions of the beds are as follows: 39 inches wide by 74 inches long for twin beds; 54 inches wide by 74 inches long for double beds; 60 inches wide by 80 inches long for queen beds; and 78 inches wide by 80 inches long for king beds.
Raw Material
Various natural and synthetic materials, as well as leather, are now used to make mattresses. Wire is used to make the innerspring, helical, and box spring components; the innerspring wire is often of a lighter gauge than the box spring wire. The cushioning layers can be made of a variety of materials, such as natural fiber, polyester, and polyurethane foam, while the insulator is made of semi-rigid netting or wire mesh. The hogs rings are made of metal, while the flanges are made of fabric. A strong fabric cover is quilted over a foam or fiber backing for the top, bottom, and side panels, and the binding tape that holds the panels together is composed of a strong, fibrous & synthetic material.
The Manufacturing Process
1.
The majority of mattress manufacturers hire an outside company that specializes in spring manufacturing to produce the innerspring unit under contract. The workers manually apply the insulator after receiving and inspecting the finished spring unit. The ultimate product's feel and comfort will be determined by the cushioning layers that are applied next.
2.
While the mattress is being "built up" in one area of the plant, another area of the same facility is producing the ornamental cover that will serve as the exterior of the top, bottom, and sides of the mattress. Typically, a huge quilting machine is used to create this cover, which is attached to a layer of backing fabric by a multiplicity of needles. The stitching pattern chosen needs to be both functional and aesthetically beautiful and it must prevent the mattress cover from sliding or crawling over the layers of padding.
3.
The cloth is cut into panels that will fit the top and bottom of the mattress after it has been quilted. The side panels are frequently manufactured independently on a border machine or cut from the same composite. Before the side panels are placed to the mattress, any additional side handles or vents are fixed to them on the side panels.
Quality Control
The majority of quality control methods are performed visually during the manufacturing phase. The majority of producers do inspections after receiving the innerspring, before closing, and before packing—three crucial stages in the production process. All standard mattresses provide a very serious risk of fire, and both the industry and the government have long searched for ways to reduce that risk. The Mattress Industry voluntarily started adding warning labels on mattresses in 1987, alerting consumers to potential fire hazards.
The Future
Numerous studies have been conducted recently on the connection between quality sleep and the environment wherein one rests. Although sleep and comfort are very subjective, it is frequently challenging to put numbers on the outcomes of such investigations. However, many of the larger businesses continue to invest a sizable sum of money in research, particularly with regard to the development of the innerspring. Quality and comfort are important factors in this research.
