Manufacturing Techniques for Mattress Protectors

Ultrasonic Lamination

• Ultrasonic lamination is a method of joining fabrics together using spot welding. In this technique, acoustic energy converted into heat provides precisely located fabric welds. This type of lamination is non-contact and creates uniformly bonded fabric layers. Generally, these include cotton or polyester with a fluid-repellent fabric inserted closest to the mattress side. Mattress protectors produced from ultrasonic-laminated fabrics help keep mattresses clean longer by preventing perspiration, urine, blood and bodily fluids from damaging sleeping surfaces.

Hot Melt Gravure

• Hot melt gravure is a form of lamination that depends on dots of hot adhesive to bond several layers of fabrics together. The adhesive is applied in very precise patterns as the fabrics are rolled between two rolling cylinders. Specific heat and pressure are used to secure all layers tightly together. This type of bonding allows for precise bonding and high-frequency application. These high-production volumes help to meet the increased mattress protector needs of medical providers.

Eco-Friendly Plant Production

• Some mattress protectors are made by green manufacturers that work to create products using predominantly natural fibers such as cotton and eco-friendly bamboo. Harvesting and processing methods for these products focus on pesticide-free hand-picked fibers. Manufacturers strive to certify their companies to international standards for organically grown plants, including chemical-free processing. Once the raw materials are harvested, the mattress pads are hand-constructed and sewn using organic threads.

Hand-Produced Organic Wool

• Organic wool mattress pads are famous for their ability to comfort infants and the elderly with highly absorbent wool fibers. Raw wool is removed from the sheep in the spring, hand washed with organic soaps, and then carded and made into batting material by hand. Once prepared into usable wool fabric, the wool is stored in allergen-free areas until it can be assembled into pads. The high lanolin content in the wool produces protectors that are naturally moisture resistant and soft.