Bed Mattresses and Polyurethane Foam
Polyurethane foam has been used in the furniture industry since the late 1940s. It was introduced as a material for bedding in the 1950s, both as an upholstery material for coil spring mattresses and a core material for foam mattresses. We will be discussing polyurethane foam in this particular article, but keep in mind we won't necessarily be talking about memory foam. That's because memory foam, while it is polyurethane, has other compounds added to it to make a distinct and different product.
In addition, latex polyurethane foam is not the same as natural latex foam. Polyurethane is a man-made substance while natural latex is made from the sap of rubber trees. For this reason, individuals and groups who prefer to promote natural bedding and construction materials often suggest consumers stay away from polyurethane and instead purchase natural latex foam.
Manufacture of Polyurethane Foam
Polyurethane foam is manufactured by combining various types of alcohols, diisocyanates, and compounds that will excite the mixture and cause the foaming action. There are different recipes depending on the rigidity of the foam needed and what that foam will be used for. More flexible foams are used for mattresses, upholstery, and furniture cushions while more rigid foam is used as insulation in refrigerators and car doors. These are just a few examples, by the way. Polyurethane foam has literally thousands of uses in today's modern world.
To construct a mattress the various chemicals are mixed together into a polyurethane "batter" and poured into a preformed mold. Once the mold is a sealed catalyst chemicals are added to excite the mixture so that it foams and expands to completely fill the mold cavity. Once the foaming process has reached the specific density the manufacturer is after, the filling process ceases and the foam is left to set. Once set the mold is removed and the foam mattress is ready for finishing.
Some manufacturers make very large sheets of polyurethane foam and then cut them into various mattress sizes, rather than making individual mattresses. The difference in cost is minimal, making this manufacturing choice a matter of preference in most cases. Manufacturers who do prefer this process have the added benefit of being able to custom cut mattresses for odd-sized beds.
Benefits of Polyurethane Foam in Bed Mattresses
There are quite a few advantages of using polyurethane foam as the core material for a bed mattress. The primary advantage, and the one that caused manufacturers to start using it to begin with, is the fact that any loss of firmness usually occurs very early in the life of the mattress. This is beneficial for customers on several fronts.
First of all, most other bedding materials constructed with fibrous substances will compact with use. As those materials compact a mattress becomes firmer and more uncomfortable. This often leads to complaints of back and hip pain. Polyurethane foam, on the other hand, does not compact over time. Rather, it softens gradually throughout its lifetime, thus providing less firmness rather than more.
Secondly, because most of the loss of firmness occurs in the early stages of mattress use, most consumers would barely recognize anything has occurred. The remaining softness the mattress will experience is so gradual over time that it is difficult to notice. This means that a polyurethane foam mattress tends to have a longer life before the consumer starts complaining of discomfort. This can be seen in statistical data comparing the breakdown of polyurethane foam versus latex foam and inner spring mattresses.
Other benefits of polyurethane foam mattresses include:
- more consistent and even support
- lack of pressure points associated with coil springs
- a cooler sleeping experience when compared to memory foam
High-Performance Polyurethane Foam
While the vast majority of polyurethane foam mattresses are categorized as standard construction, it is possible to purchase high-performance mattresses for special needs. High-performance polyurethane foam is manufactured to a higher density in order to slow down material breakdown and provide a firmer support. High-performance polyurethane foam is ideal for heavier weight individuals, consumers with moderate to severe back issues, and those with other physical disabilities which require greater support to get in and out of bed.
High-performance polyurethane is sometimes compared with natural latex foam in terms of overall performance and durability. Natural latex foam has a reputation for being one of the most durable foams used in the betting industry, yet high-performance polyurethane seems to be a close second. Between the two, high-performance polyurethane and natural latex foam make up the bulk of high-end foam mattresses. As such they also tend to be the most expensive.
Downsides of Polyurethane Foam Mattresses
The biggest downside of using polyurethane foam in a bed mattress is the fact that it is a highly flammable material. Therefore it must be treated with certain chemicals that act as flame retardants. Such chemicals have been known to be toxic to human beings in certain amounts, but keep in mind that mattress manufacturers don't use nearly enough in their manufacturing process to be hazardous to humans. Despite the warnings often issued by natural bedding advocates, polyurethane foam mattresses must pass stringent government standards in order to be considered safe.
Additionally, there is some concern among natural bedding advocates that chemicals in polyurethane foam can either leach into bed linens or create toxic fumes. These concerns have never been scientifically proven to be legitimate. They seem to be the concerns of individuals with genuine motives but a lack of any real knowledge.
The other downside of polyurethane foam is that it does have a very unique odor that some people might find offensive. The odor is not as strong as the odor associated with memory foam, but it is present nonetheless. Individuals with sensitivities to specific odors might find they cannot sleep on a polyurethane mattress. In that case they may switch to a natural latex foam, coil spring, water bed, or air mattress.
Polyurethane foam has been a popular core material for bed mattresses for the better part of 60 years. Its popularity has never waned despite the introduction of other options. If you choose a polyurethane foam mattress for your bed you will be in the company of millions of others who have made the same choice. As long as you purchase a quality product from a quality manufacturer your polyurethane foam mattress should give you many years of reliable and comfortable service.