Stretch Knit Mattress Upholstery

Adjustable and High-End Foam Systems

High stretch knit is mandatory for mattress designs that rely on surface compliance or dynamic movement:

• Adjustable Bases: The fabric must stretch significantly (up to 60%) without stress or structural failure when the bed is articulated.
• Memory Foam/Gel Foam Mattresses: Allows the ticking to move dynamically with the foam, ensuring the body benefits fully from the pressure-relieving qualities.
• Tailored Covers: Used for tight-fitting covers where high elongation is needed to achieve a smooth, wrinkle-free fit over the mattress corners.

It is a key indicator of a technologically advanced sleep system.

Stretch and Performance Metrics

Core Advantages of High Stretch Knit

• Unimpeded Pressure Relief: Allows the user to interact directly with the performance layers of the mattress (foam), maximizing pressure reduction.
• Superior Conformance: Provides a smooth, non-creasing surface appearance, even when the underlying foam structure is compressed or molded around the body.
• Durability on Motion Bases: Withstands the constant stretching and flexing required by adjustable beds without structural fatigue.
• Aesthetic Fit: Enables clean, tight tailoring on mattress corners and borders, enhancing the product's visual appeal.

Frequently Asked Questions (FAQ)

• Q: Can high stretch knit ticking be laminated with a waterproof barrier?
• A: Yes, but the barrier (e.g., TPU film) must also be highly elastic. Our lamination process uses thin, stretch-optimized films and low-tension bonding to preserve the fabric's elongation properties.

• Q: Does the spandex component affect the cost significantly?
• A: Spandex is a specialty component and increases the material cost. However, the enhanced performance and suitability for high-value adjustable systems justify the investment for premium product lines.

• Q: How do you prevent fabric distortion during the heat-setting process?
• A: Our advanced finishing machinery features precise tension control and sequential heat zones, carefully calibrated to stabilize the polyester base while preserving the critical elasticity and recovery properties of the spandex component.

Optimizing Stretch Blend Design

Achieving the right stretch profile is a design process:

• Spandex Percentage: Lower percentages (2% to 4%) provide comfort stretch; higher percentages (5% to 8%) are needed for full adjustable base functionality.
• Knit Gauge: Using a finer gauge (more needles per inch) typically provides a smoother fabric surface and better recovery.
• Yarn Type: Using covered spandex yarn (wrapped in polyester) protects the elastomeric core from chemical damage and improves durability.

Production and Process Control

Manufacturing high-stretch fabric requires specialized machine settings:

• Yarn Feed Control: Highly specialized feeders are used on knitting machines to insert the spandex under controlled tension, which is crucial for determining the final stretch percentage.
• Recovery Testing: Samples are stretched to a set percentage and measured for their return to original length after a defined period, ensuring the 95% recovery rate is achieved.
• Roll Packing: Fabrics are often rolled onto wide-diameter cores to prevent creasing and premature stretching in storage.