The core of a spring mattress is the springs, making their manufacturing process crucial. First, high-carbon steel or alloy steel wire is selected and wound into helical springs, then heat-treated to enhance elasticity and durability. Different types of springs (individually pocketed or interconnected) differ slightly in their winding, shaping, and processing to ensure support and resilience meet design requirements.
After the springs are manufactured, they are combined with the comfort layer material. The comfort layer commonly uses latex, memory foam, sponge, or fibers, processed through cutting, layering, and compression to achieve the required size and thickness for the mattress. Some high-end mattresses incorporate zoned support designs in the comfort layer, providing different levels of firmness for the shoulders, waist, and hips, enhancing sleep comfort.
The mattress then enters the assembly stage. The spring system, comfort layer, and bottom layer materials are stacked according to the design sequence, secured with quilting to prevent shifting. A durable fabric is then applied, and the edges are reinforced and shaped. The finished mattress undergoes rigorous testing, including resilience, pressure resistance, and surface flatness, ensuring each mattress meets usage standards.