High Loft Quilting Substrates

Integrated Mattress Assembly Use

These substrates are used as the foundational layer beneath the ticking to create an immediate comfort layer:

• Quilted Panel Production: Used universally in quilting lines to provide the necessary padding for decorative stitching.
• Pillow Top and Euro Top Designs: Essential for building up the highly visible, plush layer on top of the mattress core.
• Border Quilting: Utilizing thinner substrates to provide a soft feel to the vertical side panels without excessive bulk.

The choice of loft density directly impacts the firmness perceived at the mattress surface.

Material Density and Dimensional Data

Core Advantages of High Loft Substrates

• Enhanced Surface Softness: Provides an immediate, cushioned feel that contributes significantly to the initial comfort rating of the mattress.
• Aesthetic Appeal: Creates a highly dimensional, luxurious look when combined with decorative stitching patterns.
• Quilting Stability: Engineered for minimal fiber breakage and movement during high-speed multi-needle quilting.
• Lightweight Bulk: Achieves significant thickness (loft) without adding excessive weight or density to the overall mattress.

Frequently Asked Questions (FAQ)

• Q: How is the risk of fiber clumping after extended use addressed?
• A: We utilize conjugated, hollow-core polyester fibers which possess greater resilience and spring-back. Additionally, proper quilting tension ensures the fibers are locked securely into the ticking.

• Q: Does the use of siliconized fiber affect the flammability rating?
• A: No. The siliconization process, which aids in resilience, does not significantly alter the inherent flammability of the polyester. For FR requirements, the ticking layer must incorporate the necessary FR barrier.

• Q: Can these substrates be supplied with a thin scrim backing?
• A: Yes. For easier handling during complex quilting operations, we can provide substrates thermally or chemically bonded to a light non-woven scrim backing to enhance tear resistance and dimensional control.

Fiber Type and Processing Guide

Fiber selection focuses on structure and resilience:

• Hollow Conjugated Fiber: Provides the best balance of loft and resilience (spring-back).
• Blended Denier: Mixing fine and coarse denier fibers can optimize both softness and structural support within the batting.
• Thermal Bonding: Use of low-melt fiber during carding to lightly bond the batting and prevent shedding prior to quilting.

Production and Thickness Control

Production is centered on the carding and lapping process:

• Weight Consistency: Continuous monitoring of the fiber feed rate on the carding machine to ensure uniform GSM across the roll length.
• Loft Measurement: Laser-based systems are used to verify the thickness of the batting layer before it is rolled, ensuring dimensional standards are met.
• Compression Rolling: Batting is lightly compressed during rolling to maximize shipping container efficiency, relying on the fiber's natural resilience to recover loft post-unrolling.