Serenity foam mattress and box spring from Original Mattress Factory

Foam Mattresses

Foam mattresses are becoming increasingly popular in today’s market. Like an innerspring mattress, a foam mattress conforms to and supports your body by allowing your hips and shoulders to penetrate the surface while allowing the back to be supported
in its proper position.

If you are interested in a mattress with a foam core, there are a few different kinds of foam available. It’s important to consider the type of foam as well as its density and Indentation Load Deflection (ILD). ILD is a measure of a foam’s load bearing capacity and is indicative of the foam’s feel (hardness/softness).
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Polyurethane Foam

Polyurethane foam is both durable and lightweight, and makes up the high density foam core of our foam mattresses. It conforms comfortably to an individual’s body shape and is also available in a range of densities. A higher density gives the foam an increased amount of support and durability.

illustration of Serenity foam mattress

This synthetic material is produced by a reaction between two chemicals, a few minor ingredients and water. It is then solidified into foam via one of two processes: the Slabstock Process or the Molded Process. In the former, a chemical mix is poured onto a moving conveyor belt, where it is allowed to react and expand. The slab is then cut, stored and allowed to cure for 24 hours. The Molded Process differs only in that the chemical mix is poured into specially shaped molds as opposed to an open conveyor.

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Latex Foam

Latex literally means “polymers suspended in water” and can be 100% natural, 100% synthetic or a blend of the two. Latex foam can be manufactured via one of two processes: the Dunlop process or the Talalay process.

The Dunlop Process is the most commonly used method of production for latex foam. The four-step process begins by blending natural and synthetic latex with soaps and curing agents. In the second step, the mixture is poured into molds on a conveyor belt. The introduction of sodium silicaflouride (SSF) then gels the mixture into foam. Finally, the foam is sent into a steam chamber, where it sets and cures. This process, although much quicker than the alternative Talalay process, tends to create denser foams that are less consistent with a limited range of firmness.

The Talalay latex foam process is a highly controlled and precise process that produces the highest quality, most resilient and most consistent latex foam. It consists of six steps.

Original Mattress Factory foam mattress process

Step One:A mixture of natural and synthetic latex is blended with soaps and rubber curing agents in a temperature-controlled stainless steel tank.  The soaps stabilize the mix, prevent it from coagulating and helps it “foam” up.  The curing agents strengthen the polymer or rubber bond of the latex particles.

Original Mattress Factory foam mattress process

Step Two:The compound is transferred to the pressroom, where it is whipped into a frothy liquid form.  It is then injected into an aluminum pin core mold by a robotic arm.  The mold, which is fixed, is filled partially to allow for the production of a wider range of ILDs.  More compound is used to create a firmer foam, while less compound results in a plusher feel.

Original Mattress Factory foam mattress process

Step Three:The mold is sealed and a vacuum is used to extract air and evenly distribute the liquid inside.  This gives the latex a consistent, round and open cell structure.

Step Four:The latex is chilled to -20 degrees Fahrenheit. Freezing allows for a more consistent cell structure as it prevents particles from settling.  It also allows for the production of softer ILDs.

Original Mattress Factory foam mattress process

Step Five:Carbon dioxide is introduced to gel or solidify the foam.

Step Six:The mold is heated to 220 degrees Fahrenheit to cure the core as it is baked into a solid state.  The large number of pins in the Talalay mold allow for consistent heat transfer to the entire product.

The resulting product of either process is latex foam, which is a naturally resilient and breathable cushioning foam that instantly conforms to the body to provide comfort and support.

In order to experience the true feel and performance of latex foam or memory foam in a mattress, there should be at least a 2 inch thick foam layer near the sleeping surface(s). Anything thinner or further down in the product will have little to no benefit or value.

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Original Mattress Factory memory foam mattress

Memory Foam

Memory foam (viscoelastic foam) is a type of polyurethane foam and is therefore synthetic. When the foam was originally developed in the late 1960s by NASA, the result was a very dense, open cell variety of polyurethane foam that molded to the weight and shape and temperature of an individual. Unlike latex or standard polyurethane foam, memory foam is a slow-response foam and gradually conforms to your body and temperature. It also takes a certain amount of time to recover and resume its original shape. Due to its high density, it helps to reduce pressure points as well as minimize motion transfer.

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