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In pocket spring mattress production, bonding stability is not a minor issue. It directly determines whether the bed net keeps its structure, whether layers shift during pressing, and whether the finished mattress remains stable during transportation, compression, and long-term use.

Over the years, I have visited many mattress factories. When customers report problems such as loose bed nets, spring rows separating, or bonding failure after pressing, the first reaction is almost always the same. They believe the glue quality is poor or the machine is not good enough. Some even consider replacing the entire production line.

In reality, in most cases, the equipment itself is not the real problem. The real issue is that the glue system has never been fully and correctly adjusted.

This article is written based on real production environments and actual equipment structures used in modern pocket spring assembly lines, including both semi-automatic and fully automatic pocket spring assembly machines. I will explain six critical glue system adjustment points that directly affect bonding stability.

These adjustment points are practical, measurable, and can be implemented on-site. If they are checked and optimized one by one, many bonding problems can be solved without changing glue brands or machines.

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https://mattressmachineryzl.com/

Why Pocket Spring Bonding Fails in Real Production

Before discussing adjustments, one important point must be clarified. Bonding failure is rarely caused by a single factor.

In real factories, instability usually comes from the combined effect of multiple small deviations, such as:
(1) Glue temperature slightly too low
(2) Spray pattern not matching spring diameter
(3) Conveyor speed mismatched with glue open time
(4) Inconsistent pressure during row assembly

Each issue alone may not immediately cause visible defects. But when several occur together, bonding problems become unavoidable. This is why systematic adjustment is essential.

Key Adjustment Point (1): Glue Temperature Control Is Not “Set and Forget”

Hot-melt adhesive is extremely sensitive to temperature. However, many factories treat glue temperature as a fixed value that never needs further attention. This approach often leads to unstable bonding.

In theory, glue temperature is set on the control panel. In practice, temperature fluctuates due to ambient temperature changes, production speed variations, frequent stops and restarts, and the condition of glue hoses and insulation.

When glue temperature is too low, viscosity increases. The glue cannot properly wet the non-woven fabric, and bonding strength drops significantly. When temperature is too high, glue becomes overly fluid, spreads too much, and creates thin glue lines with reduced effective bonding area.

From on-site experience, stable bonding requires a narrow temperature fluctuation range, fast temperature recovery after machine stops, and uniform temperature from the glue tank to the nozzle.

Operators should not rely only on the main tank display. They must also check hose temperature, nozzle temperature, and actual glue flow behavior, especially on high-speed fully automatic pocket spring assembly machines.

Key Adjustment Point (2): Glue Application Pattern Must Match Spring Geometry

Many bonding problems are not caused by insufficient glue quantity. They are caused by incorrect glue placement.

A common misconception is that more glue automatically means stronger bonding. This is not true. Glue sprayed outside the effective contact area between spring rows does not improve bonding strength. It only increases cost and contamination.

Pocket springs differ in spring diameter, spring height, fabric thickness, and bonding layout such as parallel or staggered bonding. The glue spray pattern must be adjusted to match these variables.

In real production, this involves adjusting nozzle angle, spray width, and glue line spacing. Modern pocket spring assembly machines provide these adjustment capabilities, but many factories leave them at default settings, which limits bonding performance.

Key Adjustment Point (3): Glue Quantity Must Be Linked to Production Speed

Glue quantity cannot be adjusted independently. It must be coordinated with production speed.

Hot-melt glue has a limited open time. After spraying, it must contact the adjacent spring row within this time window. If conveyor speed is too fast, glue cools before contact, surface bonding weakens, and rows may separate during pressing.

If conveyor speed is too slow, glue spreads excessively, bonding becomes uneven, and glue consumption increases unnecessarily.

Stable production requires glue output, spray duration, and conveyor speed to work as a coordinated system. When speed changes, glue flow and timing must also change. This is one reason why integrated control systems are increasingly important in modern mattress machinery.

Key Adjustment Point (4): Assembly Pressure Is as Important as Glue

Glue alone does not create bonding strength. Pressure activates the bond.

In many workshops, this factor is underestimated. I have seen production lines where glue temperature, spray pattern, and quantity were all correct, yet bonding was still unstable. The real issue was insufficient or uneven assembly pressure.

Pressure in pocket spring assembly comes from press rollers, compression belts, and assembly platforms. If pressure distribution is uneven, some rows bond well while others remain weak. If pressure duration is too short, glue does not fully penetrate the fabric, resulting in superficial bonding.

Proper pressure adjustment ensures full integration between glue and fabric and significantly improves long-term stability.

Key Adjustment Point (5): Non-Woven Fabric Quality and Tension Cannot Be Ignored

Bonding is a system process, and fabric is a critical part of that system.

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https://mattressmachineryzl.com/