Kluft mattress dissection

This particular model from American firm E.S Kluft and Co is interesting for the build technique used to produce such a model. Looking at the cutaway, it seems to go slightly against the grain of Gradual Support theory with the use of several layers of latex sandwiching softer layers.

If we start at the springs and work our way up, we will be able to see what happens as you lay on this particular mattress.

KLUFT MATTRESS DISECTION

Note: We do not have the actual specification of this particular mattress and the breakdown below is pretty much-educated guesswork.

Springs: We can see that these are calico encased and individually sewn and laced looks like a six turn cylindrical unit in the region of 1800 springs.

First layer: The insulating layer is a layer of latex  looks about 2cm deep. Perfect material to work with the slightest movement on the springs.

Second layer: This looks like cotton felt, probably 600 GSM, going by the depth.  We are assuming this is to provide a cushioning layer to the forthcoming foam layer.

Third layer: Not too sure what this product is. It looks like a soft low-density foam. Estimate 2cm in height.

Fourth layer: A wool blend of sorts. probably blended with mohair and silk. Estimate 600 GSM.

Fifth layer: Latex Estimate 2cm

Sixth layer: Wool blend. Looks like a wool and cotton blend. Estimate 600 GSM.

Seventh layer: Latex – Estimate 2cm

Eighth layer: Biofoam (Soft) estimate 3cm. The convolutions are supposed to encourage airflow. Read our thoughts on this below.

Ninth layer: Latex -Estimate 2cm

Tenth and eleventh layers: The description states that more than 10lbs (4.5kg) of blended cashmere, mohair, silk and New Zealand wool is used as the comfort layers. Going by the visual it looks like a combined weight of all fibre usage.

Conclusion of Kluft dissection

This is quite an impressive build which for around £22000 it would have to be. The use of soft fibres between the latex layers is a very interesting concept enabling the latex layers to remain independent.

The one thing which we don’t understand fully is that this mattress comes in at a depth of just over 19 inches before tufting. If we estimate the height of the spring unit and base support layer (not visible on image) as being 6 inches (spring) and one inch (base support) that leaves around 13 inches (33cm) of upholstery.

The finished mattress height is just over 14 inches (36cm) which mean that after being tufted (by hand) the upholstery is condensed by about 5 inches (13cm).

Looking at the Biofoam layer, the description states that this arrangement will improve airflow – However, surely this will be completely negated as the crowns on the foam will be completely compacted after tufting (thoughts please).

Taking that the mattress is 19 inches in height (pre tufting) we can estimate that seven (18cm) of those is Spring and Base Support leaving approx 12 inches (30cm) for all these upholstery layers which give rise to our estimates of 13cm of latex and foam and around 17cm of high loft fibres. As the finished mattress is 36cm we think that the compression of upholstery from 30cm to 18cm  (5 inches) will give a mattress that will be on the firmer side.

Summary

As we said at the beginning of this post, this is an extremely interesting design concept. Over the next few months, we are going to try and replicate this particular mattress to see what the end result will be.  Like the Kluft image above we give the exact components used in all of our mattresses giving cutaways in every product description in our Shop.  If you need more help, because lets be honest, its a very confusing world with beds, give our small expert team a call for assistance.

Comments

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  • Lee Prebble says:

    The foam crowns compressing could behave as a progressive spring but as you say the degree of compression after tufting would appear to make the unit compacted beyond subtle sensitivity.

    Hi Lee. Yes, I can’t fathom any particular overall benefit of this. The use of foam in the highest region of the mattress seems to detract from the use of higher grade component used in the lower regions. When time allows I am going to construct a recreation of this to see what happens when all this upholstery is stitched together. John and Ryan.

  • Earl Kluft says:

    Hi there,
    This was brought to my attention today by our customer service dept. Are you aware we are now partners with Vi Spring? Or is this just a coincidence? I noticed you compare your mattress to them I have never seen your factory so have no way to compare, but I have seen VI and many of the blends and coil tensions including vanadium steel, are very special with proprietary designs and components not available to any other mattress manufactures.

    The quality and attention to detail is peerless. Anyway… to help you with the process of dissection, our coil system is a hand stitched Calico 2000. the cotton is certified pure organic staple cotton, all the latex (including layer 3 which is not reg foam as you state) is talalay, made in the USA. There are several different firmness of latex in this bed not necessarily in the order one would think.There are over 20 pounds of New Zealand JOMA wool with some cashmere and other exotic natural fibers blended in the top layer. the single layer of convoluted foam for airflow is BIOfoam.

    I have been in the mattress business over 50 years and my family 100 just like Vi Spring, it took us 2 years to get this build ready for market based on trial and error until we got it absolutely perfect, and we have been extremely successful with it at Bloomingdales Department Store. As with the latex firmnesses, the wool and cotton are where they are for several reasons. I do not believe in the progressive firmness theory as a catch all, although for some beds it works the best. UK has some very unusual Fire retardant laws or this product would already be there. Not to say it is not FR… This product has passed the US 30 minute open flame test. EARL KLUFT.

    Hi Earl. Such a great pleasure to have you add your own personal comment to the site. We are indeed aware of your partnership with VS and of course aware of your own history and placement within the luxury beds market. Our comments above are in no way to be taken as negative or derogatory but as a source of discussion of this particular construction method. In the UK there is absolutely nothing available that has a similar style of construction to The Palais Royale, and it was precisely this that piqued our interest.

    Apology for assuming layer three was foam – we do not hold any specific literature on this model and was all pretty much done on guesswork. I am intrigued by the composition of the latex – which as you point out are of different densities ‘not in the order one would think’. My thoughts would be that the softest densities would be within the higher levels of the mattress – if this is not the case I would be incredibly obliged for a more thorough explanatory dissection.

    The use of natural fiber cushioning the latex layers is genius, and I am surprised none of the top five latex mattress specialists in this country have cottoned on to this method of construction. I hope you will be able to give a fuller account of the hows and whys of this particular method – I’m sure the two years R+D gave a particular insight of what the best combinations of fiber and latex densities were.

    Finally Earl, I am especially intrigued by your views of Progressive Firmness and welcome you to provide your own personal thoughts on this subject. Kindest and sincere regards, John and Ryan.

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