High Durability Woven Polyester Fabric

Foundation and Structural Applications

This fabric is essential for components that hold the structure of the bedding:

• Box Spring Covers (Woven): Provides a durable, low-stretch aesthetic wrap for the mattress foundation.
• Mattress Border Fabric: Used on the vertical sides to provide structure and prevent bulging of internal layers.
• Internal Protective Wraps: Used within the mattress core to separate spring systems from foam or padding layers.

It is chosen over knit options when zero stretch and high tensile strength are non-negotiable.

Strength and Weave Specifications

Core Advantages of Woven Durability

• Exceptional Mechanical Strength: Provides verified resistance to pulling, tearing, and piercing, ideal for structural applications.
• Dimensional Stability: The woven construction ensures virtually zero stretch, maintaining the exact dimensions of the finished product.
• Moisture and Mildew Resistance: The synthetic composition naturally resists water absorption, suitable for use close to flooring or in humid environments.
• Cost-Effective Volume: Polyester provides the required strength at a competitive price point for high-volume structural components.

Frequently Asked Questions (FAQ)

• Q: How is the tear resistance of the fabric measured?
• A: Tear resistance (or Tear Strength) is typically measured using the Trapezoid Method (ASTM D5587), where the force required to propagate an existing tear is quantified in Newtons (N).

• Q: Can this fabric be supplied with a water-repellent finish?
• A: Yes. Being polyester, it readily accepts durable water-repellent (DWR) finishes, which cause liquids to bead up and run off the surface, further enhancing its suitability for foundation covers.

• Q: Is this fabric suitable for use as a structural lining inside a sofa?
• A: Yes. Its high tensile strength and low elongation make it an ideal lining for the internal frame or decking of a sofa, providing necessary support for cushions and preventing sagging.

Yarn Count and Fray Control

Focus areas for maximum durability:

• Filament vs. Spun: Filament yarns provide higher strength and smoothness; spun yarns provide a softer, more fabric-like feel but are slightly less strong.
• Yarn Sizing: Applying a starch or polymer sizing agent to the warp yarns before weaving reduces friction and breakage, increasing weave density.
• Anti-Fray Finish: Applying a light chemical or thermal coating to the cut edges to prevent raveling, particularly important for fast automated cutting.

Production and Consistency Service

Manufacturing ensures repeatable strength:

• Tension Audit: Continuous monitoring of warp and weft tension during weaving to ensure the final fabric is taut and consistently strong.
• Breaking Strength Test: Routine use of a universal testing machine to verify the fabric's tensile strength in both directions against client specifications.
• Roll Labeling: Clear labeling of lot numbers and test results on every roll for complete supply chain traceability.