Inflatable mattress maker: solving seam slow leaks

Customer Background

The customer is an inflatable mattress manufacturer in southern China. Most of its output is exported, so factory airtightness standards are high and after-sales leak complaints translate directly into return and replacement costs.

The Problem

• Occasional slow leaks after high-frequency welding that outgoing inspection could not fully screen out
• The previous film had considerable thickness variation, leaving a narrow welding process window
• The material became stiff at low temperature and showed fine cracks after being folded for storage

What We Did

After reviewing the customer’s high-frequency equipment parameters and service environment, we adjusted the film formulation and the thickness control plan to improve thickness uniformity, and optimised the dielectric response of the material for the welding process. We also proposed a formulation direction with a higher cold-resistance grade to improve low-temperature folding performance.

Results

• Welding process window widened and line set-up time shortened
• Factory airtightness defect rate dropped noticeably
• Low-temperature folding test passed and the customer reported fewer after-sales leak complaints

Note: the figures in this case come from the customer’s interim statistics. Actual values vary with product and process conditions.