APAOs for Mattress Assembly
Hot melt adhesives make assembling mattresses quicker and easier. Because they are easy to handle, many manufacturers use adhesives for joining foam around mattress springs, attaching cushioning foam and insulation to the interior of the mattress body and keeping pillow top cushioning and upholstery fabrics in place.
That's important with the more complex mattresses being assembled today. Customers want features like additional comfort layers of gels and foams, which need to be carefully attached to the interior mattress structure using a fastening system that is non-toxic.
You may be using hot melt to assemble mattresses already, and if so, you likely appreciate its non-flammable and non-toxic properties as well as its fast cure time. Now, a new polymer may be able to help you increase your productivity and stretch further than the adhesives you have been using.
What makes APAOs unique?
REXtac APAO polymer adhesives — also known as Amorphous Poly-alpha-olefins — incorporate REXtac's proprietary catalyst and their Liquid Pool production process. This lets you essentially customize an APAO polymer by adding other hot melt adhesive components like plasticizers, tackifiers or waxes to get exactly the features you need for your specific application. In the case of manufacturing mattresses, a REXtac APAO option likely already exists that can be used neat, or you can tweak it to make a custom formulation.
Benefits of REXtac APAOs
If you're currently using a water-based hot melt adhesive system, you'll find that REXtac APAO is simply easier to use. You don't have to mix it up or clean up excess waste, so it's much less messy. That translates to faster line speeds and greater productivity. In addition, REXtac APAOs deliver a more solid adhesive that's dependable — reduce the risk of improperly adhered mattress components.
Using a different type of hot melt system? REXtac is likely to better it in cohesion and in thermal stability. Plus, REXtac APAOs have very low VOCs and no odor so the mattresses won't off-gas or otherwise be unappealing to consumers. This also makes them more environmentally friendly.
REXtac APAOs also offer nearly instant initial tack, so you can quickly assemble mattress pieces and get the finished products out the door and to the customer more quickly. The bond is durable, so your products will hold up under years of typical mattress usage. In most cases, the foam or fabric will tear before the bond will fail.
Specifications of REXtac APAOs
Four main specifications help you to determine whether a specific REXtac APAO product is right for your needs.
1. Melt Viscosity (MV)
This identifies the fluidity of the polymer at a certain temperature, generally 375 degrees Fahrenheit. Melt viscosity is measured in centipoise, or cps.
The lower molecular weights of APAOs means that they generally have lower viscosities, which makes them easier to use. Very low viscosity allows hot melt adhesives to be sprayed, which is becoming the most common method of application in the mattress industry.
2. Ring and Ball Softening Point (RBSP)
This measures heat resistance in the hot melt material. APAOs, like most polymers, soften rather than melt. The RBSP indicates at what temperature the APAO is soft enough to work with. This can have an impact in some industries, where delicate components can't be exposed to high temperatures; in the mattress industry, you can't have such high softening points that the fabrics and foams used will overheat or even catch on fire.
3. Open Time
This tells you how long you can have the adhesive out in the air before it will solidify. Long open times are desirable for many adhesives in the mattress industry, where workers need some time to position elements together.
This measures how hard the polymer is, and indicates durability when cured. All of REXtac's APAO products have a density of 0.85 to 0.88 g/cc (grams per cubic centimeter).
REXtac APAO Product Options
APAO hot melts have unique characteristics that make them extremely useful and adaptable so they work for many applications. Many of them have significantly longer open times than traditional hot melts. They are also known for exceptional temperature resistance, ability to be extruded or sprayed and being relatively low cost. APAOs often replace other expensive adhesives like polyamide hot melt.
Short to Medium Open Time
The shortest open time for the REXtac products we carry is the REXtac 6825. It has a low to medium viscosity and an open time of 20 seconds, it's great for furniture manufacturing and assembly and specialty packaging. For a medium open time of 60 seconds, the REXtac 2535 is a great option. It has a medium to low viscosity and is a favorite for product assembly applications because it has a high initial tack, exceptional strength and thermal stability.
Long and Extra Long Open Time
The REXtac 2730 has a longer open time, up to 5 minutes, depending on the temperature. It's able to bond many substrates, like difficult plastics, fabric, wood, and more, which makes it preferable in a wide range of industrial applications. In some cases, a very long open time is needed and the REXtac E101 is the APAO for your application. It has a very low softening point and medium viscosity. With an open time of up to 15 minutes, it's perfect for nonwoven and product assembly applications that require additional time to set substrates.
Alternative APAO Product for the Mattress Industry
Infinity Bond offers a competitive, low-cost alternative that works for a range of mattress manufacturing, foam bonding, product assembly and spray hot melt applications. The Infinity Bond A6240 offers an open time of 90 to 120 seconds depending on the temperature and spray pattern. It's an incredibly useful hot melt for the increasingly popular 'Bed-in-a-Box' mattress because it is noise free after setting and no cracking noises.
Ready to Get Started?
Ease of use and strong adhesive bonds make using REXtac APAOs a good choice for any application in the mattress industry. Assemble mattresses quickly while increasing productivity, while maintaining confidence that the bonds will last. Contact us for more information about the REXtac APAO products we carry and which one is right for your application.