How Are Mattress Made Of

Home   /   How Are Mattress Made Of

How Are Air Mattresses Made?

Air mattresses offer an affordable bedding solution for millions of people all over the world. From camping to other outdoor activities, lots of people are able to enjoy nature thanks to these mattresses.

They are equally great for sleeping indoors whether you have kids coming over or family on their way. even if you have the worst inflatable mattress in the world.

This is why these types of mattresses inevitably pop up in the minds of consumers as soon as they think of temporary bedding.

So, how are inflatable mattresses made? What kind of materials go into the manufacture of these units?

If you have been getting quality use out of your mattress then you’d probably want to know how they are manufactured.

Even if you have never owned one of these mattresses, it still pays to know.

Stick around as we go through some of the materials that go into the manufacture of these portable mattresses.

Who knows? This may help point you in the right direction the next time you decide to shop for an air mattress.

Polyvinyl chloride (PVC) is one of the most popular materials in the airbed industry. If you have been doing a little bit of research on these units then you may have come across some popular models manufactured from this material.

While lots of affordable mattresses are manufactured with PVC, it is not uncommon to find some high-end models made from it too.

Advantages of PVC Air Beds​

There are lots of advantages you stand to gain from mattresses manufactured by PVC. Here are a few of them.

Waterproof

One of the main reasons for the popularity of PVC the waterproof capabilities. Mattresses made with this material give you a waterproof surface to enjoy your sleep.

The fact that inflatable mattresses are waterproof unlike regular ones makes it suitable for the needs of many consumers. While regular beds can get wet when water or another liquid spills on it, inflatable ones have been traditionally different.

Waterproofing comes in handy in blowup medical mattresses and those relied upon by the bed-ridden.

Low Maintenance

When shopping for an airbed, it is important to choose one that is low maintenance. We live in an era where everyone is extremely busy so you wouldn’t want to waste time keeping your mattress in good shape.

This is what gives PVC an edge over the other materials used in the airbed manufacturing industry. It requires no need for washing, drying, and any of those tedious activities.

However, if you insist oncleaning your mattressperiodically then you can simply get it done with a piece of washcloth and water.

This is another advantage these mattresses have over regular ones.

​Fire Resistant

While most regular mattresses are unable to withstand fires, this is a problem PVC airbeds do not have. Manufacturers apply specific chemicals on the surface of these airbeds to ensure their ability to stay in their original physical condition even when exposed to fire.

This feature is especially handy because non-PVC air mattresses are mostly manufactured from plastic or other materials which crumble when exposed to fire.

Cheap Manufacturing Process

One of the reasons why air mattresses have become so popular is the fact that they are significantly inexpensive. Industry experts have revealed that manufacturing them with PVC comes at significantly lower costs when compared to the others.

Industry players are therefore able to make their product lines available to consumers at affordable prices. You definitely do not have to break the bank in order to get a quality inflatable mattress.

Disadvantages

As expected, there are some drawbacks that come with inflatable mattresses manufactured from PVC. Here are a few of those:

Toxic Material

PVC is far from the cleanest material in the inflatable mattress manufacturing industry. In fact, this plastic has been found to be toxic and harmful to the environment in so many ways.

Vinyl chloride, a sub-component of the material results from the combination of plastic and petroleum.

Production causes the release of toxic chemicals into the environment. If you are green-conscious then you may have to look for one manufactured from alternative materials.

Less Comfortable

It is no secret that PVC is a plastic material. It is quite hard in its basic form meaning it doesn’t make the most suitable sleeping surface. Some additional chemicals are added during the manufacturing process to soften and make it more comfortable.

Phtalates are the most popular chemical added to PVC to make it soft during the manufacturing process.

This chemical can be absorbed into the skin while you are sleeping. It has been linked with severe medical conditions such including cancer and asthma.

Other Manufacturing Materials Used in Air Mattresses

Textile-reinforced urethane and rubber are alternate materials used in the manufacturing of airbeds. They are quite popular and usually found in some of the high-end models available for sale.

Advantages

Here are a few advantages of going in for an airbed manufactured from rubber and textile-reinforced urethane.

Thicker and Puncture-Resistant

The advantage of textile reinforced urethane is they are more puncture-resistant and thicker than PVC. This means that buying a mattress made from one of these gives you more comfort and durability.

The advantage of textile reinforced urethane is they are more puncture-resistant and thicker than PVC. This means that buying a mattress made from one of these gives you more comfort and durability.

True, there may be lots of ways to fix punctures in your mattress. However, how would you feel about having a mattress with minimal risk of puncturing in the first place?

Absence of Phtalates

Thermoplastic urethane airbeds contain no phthalates. You can therefore sleep on them without risk of developing any medical issues. These mattresses typically come with no odors, which is another problem arising out of phthalates.

Disadvantages

The main disadvantage of choosing an airbed manufactured from thermoplastic urethane is the expense. The high cost of manufacture means they are relatively more expensive than models from PVC.

The Verdict

We hope you have learned a few things about the manufacturing process of air mattresses and are in a better position to make a sound choice.

If you want something environmentally friendly and willing to pay the full cost then thermo urethane is a good choice. Rubber is another great choice if your budget is not too tight.

On the other hand, PVC mattresses hit you less in the wallet and are great for consumers with low budgets.

How Mattresses Are Made

This content was created by the National Sleep Foundation

Mattress construction from the inside-out

If reading about mattress construction sounds like a real, ahem, snooze, know this: The way a mattress is made determines how it feels. And how a mattress feels may be the difference between a fitful night and peaceful slumber!

The Big Picture

Two basic types of mattress make up the vast majority of the market: They’re called innerspring and memory foam. Made of steel coils, innerspring is, by far, the most common type. Memory foam, on the other hand, is made from polyurethane or latex foam, and is very dense foam. Memory foam is usually more expensive than innerspring.

Inside an Innerspring Mattress

Coils determine how much support (suspension versus springiness) the mattress will give. Manufacturers may use different types of coil shapes and structures, as well as different amounts of spacing and patterns to affect comfort. The next layer, top padding, isusually made from polyurethane foam. The outer layer (or ticking) is the material bound to the top padding with stitching. The way that ticking and top padding are attached influences the mattress’s overall feel. Large, wide patterns will create a cushioned feel, which smaller patterns feel tighter and firmer. Generally, the more coils an innerspring mattress contains, the more comfortable it’s bound to be—but if the number of coils is over 390, then you’re not likely to notice the difference, so don’t bother paying extra.

Inside a Memory Foam Mattress

Especially attractive to people with chronic pain conditions, memory foam mattresses consist of, essentially, very dense foam. When you lie on a foam mattress, your body heat softens the material, allowing it to “mold” to your body. One big advantage: In bigger beds, a memory foam mattress won’t shift as much as an innerspring when one partner turns or moves. So if you’re often disturbed by your partner’s tossing and turning in the middle of the night, it might be time to invest in a memory foam mattress. But one con: Because these mattresses mold to your body, they can absorb a lot of heat and make you feel hotter while you sleep. Some people also complain that they have a chemical smell.

What’s in a Mattress Anyway? Peeling Back the Layers of Quality Sleep

Have you ever wondered what a mattress is made of? Or how memory foam is made? Or the difference between a quilted mattress vs. spring mattress? As your mom always said, it’s what’s on the inside that counts.

When considering your mattress options, you may wonder what’s going on beneath the fabric that makes it feel like you’re sleeping on clouds. Below is a thorough overview of the various materials that go into making a mattress so the next time you walk into a mattress store you can tell the salesperson exactly what you’re looking for, down to the foam type! The following materials found in many different types of mattresses are some of the key ingredients to a good night’s sleep.

The Most Common Materials In All Mattresses

A soft, movement-absorbing material that helps with temperature regulation and pressure point relief. Some common types of foam include memory foam, gel memory foam, polyurethane foam, and viscoelastic foam (also known as "rebounded foam").

Polyester Batting

Used as a filling in pillowtop mattresses and mattress covers.

Can be found in some mattresses for extra padding and temperature regulation.

Cotton

A breathable material used both inside and outside of the mattress.

Adhesives

Used in mattresses to bond layers, materials and seams together for the perfect fit. Quilting is often used in combination with adhesives to further strengthen the bond between layers.

Flame Retardants

Found in all mattresses sold in the United States due to flammability laws for fire resistance.

Steel Coils

Either formed as open coils or individually wrapped coils (also called pocketed coils), these are a key structural component that establish firm support at the base of the mattress.

Now that you know the most common mattress materials, let’s get more specific about what goes into the three most popular mattress types: innerspring, memory foam, and hybrid mattresses.

What is a Memory Foam Mattress made of?

These mattresses are known for lush layers of memory foam and polyurethane material which conform to your body. A newer addition to the memory foam family is gel memory foam which acts as a phase changing material (PCM).

On a spectrum from hard to soft, specialty foam layers work together to relieve pressure points from your joints and balance your body temperature. These layers conform to your body shape and absorb movement so you sleep undisturbed.

Memory Foam Mattress Cover Materials

Covers used on memory foam mattresses are typically stretch knit covers that allow you to settle comfortably into the foam. With the cover working its magic on top, higher density foams are used as the core layer of the bed to provide support. These beds do not have coils in them! This benefit is great for those who prefer to settle into the mattress with less of a bounce factor because the firmer core layer of foam helps provide a balanced support system.

What is this high-density foam core made of exactly? They are usually made of polyurethane, but can sometimes be made of more natural materials like soy-based foams or latex.

Since they don’t have coils, memory foam mattresses don’t need a foam encasement for edge support to hold the bed together. Some foam mattresses have firmer foam near the edge of the bed, but this is not necessary for support since the high-density foam offers even support throughout.

What is an Innerspring Mattress made of?

Innerspring mattresses come in two different systems: open coil or individually pocketed springs. The outer quilting is typically made of traditional cotton fabric blends that give each mattress a unique look, fitted with steel coil springs for a firm base support.

It’s important to remember that the number of coils doesn’t always amount to the same level of comfort from one mattress to the next, but plays a role in reducing motion transfer and offering support.

Each manufacturer uses different designs and support techniques to achieve this result, often including layers of polyurethane foam and filling inside the mattress. However, more luxurious innerspring mattresses will use other kinds of foam, including memory foam, gel memory foam and latex materials.

Innerspring Mattress Cover Materials

Cover materials can range from polyester to cotton or stretch knit, each one specifically designed to be soft and breathable. Fun fact: the tighter the cover, the firmer the bed will feel.

When you wake up and get ready for the day, edge support materials are important — especially if you prefer to put your shoes on while sitting at the edge of the bed! These materials range from thick metal rods to foam inserts and encasements. The more edge support you have, the more sleep (and sitting!) surface available.

What is a Hybrid Mattress made of?

Hybrid beds are among the latest and greatest options on the market for better sleep thanks to the many unique benefits hybrid mattresses offer. Specifically, they combine a 50/50 ratio of individually wrapped coils with memory foam to offer the best of both.

The coils offer support, while memory foam and gel memory foam layers conform to posture and regulate body temperature. Cotton fabric blends are added to protect the bed. You get the best of both mattress types above in the hybrid, plus personalized materials that are going to work together to help you get a good night’s sleep.

Hybrid Mattress Cover Materials

Hybrids tend to have a more elastic mattress cover so as not to interfere with the conforming benefits of the memory foam layers. Further enhancements to hybrid collections showcase foam encasements, made from high-density foam, which supports the edges of the mattress.

Knowing the basic building blocks of your mattress can help you ensure that your next bed has all your favorite ingredients for good night’s sleep.

Related Posts

You Might Also Like

The sheets are crisp and cool, the pillows fluffed and fresh, the lights are dim or off. But if you haven’t covered your mattress with a protector, you’re not 100 percent in the healthy sleep zone.

Finding a mattress can be a struggle, especially when there are so many bed options to choose from. To simplify your mattress search, we’ve put together a list of the top consumer rated mattresses. Ranked in terms of value, quality and of course, comfort, these beds have been praised highly by real Mattress Firm customers.

The best leggings for yogis. The best gift for a new mom. Everyone wants the best in life, and mattresses are no exception. It’s time to put the debate over the best mattress for back sleepers to rest. Although back sleepers can typically sleep on any mattress, many complain of back pain or a lack of conformance. Contrary to popular belief, firm mattresses aren’t necessarily the best type of mattress for back sleepers. In fact, sleeping on surfaces that are too hard can lead to concentrated areas of pressure, which causes discomfort.

How to Find the Best Rated Mattress for You

To help you make the right choice for your friends and family, regardless of sleep-style, we are here to take the guess-work out of guest room mattresses.

When it comes to mattresses, there’s a lot of choice. Luckily, we at Mattress Firm can help you narrow it down to your perfect match. One brand that we love for its ability to deliver the ultimate sleep experience is Tempur-Pedic®. Their mattresses are proven to provide an incredible amount of pressure relief and motion isolation for a great night’s sleep, every night. Tempur-Pedic® + Mattress Firm = a match made in sleep heaven? We think so—here’s why.

Back pain can be debilitating, turning what would otherwise be a full night’s rest into a night of tossing and turning. And, what’s worse is a night of restless sleeping makes it nearly impossible to get comfortable and catch the Zzz’s you need.

From tossing and turning to bad dreams and racing thoughts, there’s a lot that can get in the way of the perfect night’s sleep — especially when your stress and anxiety levels are at an all time high. Sometimes, no matter how tired we can get, our bodies and our minds can keep us from getting the sleep we so desperately need.

If you’re in the market to buy a new mattress, but are on a budget, you may be worried that finding an affordable mattress may limit your selection. Rest assured, there are many different mattresses that are suited to fit any budget and sleep style.

MattressFirm.com is wholly owned and operated by Mattress Firm, Inc., 10201 S. Main St. Houston, TX 77025 – Copyright 2018 by MattressFirm.com, a Mattress Firm, Inc. Company All rights reserved.

1 Offer valid 3/11/20 – 4/28/20. Savings applied to our low price. Savings vary by mattress and model (max savings up to $400). Product selection may vary by store. Offer not valid on previous purchases, floor models, clearance items, final markdown, Purple, tulo, iComfort, Tempur-Pedic, Stearns & Foster or Sealy Hybrid. Other exclusions may apply. Cannot be combined with any other offers. Limited quantities available; offer valid while supplies last. Visit a store, call (877) 348-1012 or chat online for complete details.

2 Extra 25% off sitewide on qualifying items. Additional savings is applied to listed sale price. Offer not valid on previous purchases, Purple, iComfort, Tempur-Pedic, Stearns & Foster, Sealy Hybrid, Nectar or DreamCloud. Other exclusions may apply. Products & offer may vary by location. No cash value. Visit a store, call (877) 348-1012 or chat online for complete details.

3 Offer valid 3/27/20 – 4/28/20. Receive a free Head Up 50 adjustable base (up to a $499.99 value) with select mattress purchases with minimum $999 purchase. Free adjustable base offer valid on same size mattress purchased. Split king or split California king base purchases consist of 2 bases. For split king or split California king purchases, consumer will receive one free adjustable base with promotion, with second base at regular price. Free adjustable base offer valid to complete mattress set, has no cash value and cannot be used as credit. Offer not valid on previous purchases, floor models, clearance items, final markdown, weekly deals, daily deals, Purple, tulo, iComfort, Tempur-Pedic, Stearns & Foster, Sealy Hybrid, Nectar or DreamCloud. Other exclusions may apply. Adjustable bases not eligible for returns price of adjustable base (up to $499.99) will be deducted from refund if mattress is returned. Adjustable base may be pictured with furniture bed frame and headboard not included with offer. Limited quantities available offer valid while supplies last at participating locations. Visit a store, call (877) 348-1012 or chat online for complete details.

4 Receive a $300 Instant Gift with purchase of select mattresses in store or online. Purchase select Tempur-Pedic mattresses and receive a $300 Instant Gift or purchase select Stearns & Foster or Sealy mattresses and receive a $200 Instant Gift. Select your Instant Gift from your choice of sleep accessories. Sleep accessories must be added to the same transaction as the qualifying mattress purchase. Offer has no cash value and value cannot be carried over any value not used at time of transaction will be surrendered. Offer not valid on previous purchases, floor models, clearance items or final markdown. Other exclusions may apply. Value of accessories received (up to $300) will be deducted from refund if mattress is returned. Offer valid while supplies last at participating locations. Visit a store, call (877) 348-1012 or chat online for complete details.

5 Offer valid 3/22/20 – 4/19/20 at participating locations only. Save 10% on any size 2019 Stearns & Foster® mattress. Selection may vary by retail location. Certain offers may not be combined. Not valid on prior purchases. Visit a store, call (877) 348-1012 or chat online for complete details.

0% APR: 5 years* with a minimum purchase of $2799, 4 years* with a minimum purchase of $1999, 3 years* with a minimum purchase of $1299, 2 years* with a minimum purchase of $999 on your Mattress Firm credit card 60, 48, 36 or 24 equal monthly payments required. *Offer valid 3/11/20 – 4/28/20. Qualifying purchase amount must be on one receipt. No interest will be charged and equal monthly payments are required on promo purchase until it is paid in full. These payments equal the total promo purchase amount divided by the number of months in the promo period and rounded up to the next whole dollar. These payments may be higher than the payments that would be required if this purchase was a non-promo purchase. Regular account terms apply to non-promo purchases. Down payment equal to sales tax and delivery may be required at point of purchase. For new accounts: Purchase APR is 29.99%. Minimum interest charge is $2. Existing cardholders: See your credit card agreement terms. Subject to credit approval.View payment options.

The advertised service is a rental or lease purchase agreement provided by Prog Leasing, LLC, or its affiliates. It is not a loan, credit or financing. While no credit history is required, Progressive obtains information from consumer reporting agencies in connection with lease application. Acquiring ownership by leasing costs more than retailer’s cash price. Not available in MN, NJ, VT, WI, or WY. Merchant participating locations only. Leasing available on select items. Not all applicants are approved. See lease for details.

Mattress Firm is proud to support both current and veteran military members as well as first responders. Save 10% off purchases with valid military/first responder ID. Savings applied to listed sale prices. Offer not valid on previous purchases, floor models, clearance items, final markdown, Purple, tulo, iComfort, Tempur-Pedic, Stearns & Foster or Sealy. Offer valid at participating locations only. Visit a store, call (877) 349-1012 or chat online for complete details.

*Among traditional mattress brands based on 2017-2019 Tempur Sealy Brand Tracker Report

How Mattresses Are Made

This content was created by the National Sleep Foundation

Mattress construction from the inside-out

If reading about mattress construction sounds like a real, ahem, snooze, know this: The way a mattress is made determines how it feels. And how a mattress feels may be the difference between a fitful night and peaceful slumber!

The Big Picture

Two basic types of mattress make up the vast majority of the market: They’re called innerspring and memory foam. Made of steel coils, innerspring is, by far, the most common type. Memory foam, on the other hand, is made from polyurethane or latex foam, and is very dense foam. Memory foam is usually more expensive than innerspring.

Inside an Innerspring Mattress

Coils determine how much support (suspension versus springiness) the mattress will give. Manufacturers may use different types of coil shapes and structures, as well as different amounts of spacing and patterns to affect comfort. The next layer, top padding, isusually made from polyurethane foam. The outer layer (or ticking) is the material bound to the top padding with stitching. The way that ticking and top padding are attached influences the mattress’s overall feel. Large, wide patterns will create a cushioned feel, which smaller patterns feel tighter and firmer. Generally, the more coils an innerspring mattress contains, the more comfortable it’s bound to be—but if the number of coils is over 390, then you’re not likely to notice the difference, so don’t bother paying extra.

Inside a Memory Foam Mattress

Especially attractive to people with chronic pain conditions, memory foam mattresses consist of, essentially, very dense foam. When you lie on a foam mattress, your body heat softens the material, allowing it to “mold” to your body. One big advantage: In bigger beds, a memory foam mattress won’t shift as much as an innerspring when one partner turns or moves. So if you’re often disturbed by your partner’s tossing and turning in the middle of the night, it might be time to invest in a memory foam mattress. But one con: Because these mattresses mold to your body, they can absorb a lot of heat and make you feel hotter while you sleep. Some people also complain that they have a chemical smell.

How Is Memory Foam Made?

Memory Foam Developed by NASA

The very first memory foam material was developed by NASA in the 1970s. Their intention was to try to improve seat cushioning and crash protection for airline pilots and passengers. Memory foam has widespread commercial applications, in addition to the popular mattresses and pillows you are familiar with today.

Anybody who has gone shopping for a bed, a new pillow, or even a new bicycle seat or mouse pad wrist rest in the last two decades will have encountered memory foam. This new material has been applied to a huge range of uses since its introduction to the US in 1991—from revolutionary medical uses to gimmicky new product designs. But what is it, who came up with it, and how does it work?

Though it is a relatively recent phenomenon in the US, memory foam has been around in various forms since the midpoint of the century—the first work on the polyurethane polymers that go into memory foam was actually begun in 1937 by Otto Bayer and his coworkers In 1965 the nursing staff at Lankenau Hospital tested “inert polyurethane porous foam” pads for use as bedding material, and found that they prevented “decubitus ulcers” (also known as pressure ulcers, sustained by patients who spend long amounts of time lying down), and found them to be hypoallergenic and resistant to bacteria (Kraus 1965). In the 1960s, NASA did work on materials that would serve as better cushions, and would also keep astronauts comfortable and protected from the extreme g-forces of lift off. It was then that memory foam as we know it came into being.

Memory Foam vs. Polyurethane Foam

Memory foam starts its life as polyurethane foam—a material first manufactured in the 1950s by adding water, halocarbons, or hydrocarbons to a polyurethane mix. Depending on the chemicals added and the way it is processed, polyurethane can form anything from car parts to spray liner, or in this case, one of the most comfortable sleeping surfaces the world has ever seen.

In the modern production of memory foam, a polyol is mixed with a diisocyanate and water. The foam rises like bread, with an open cell structure that helps give it its unique ability to spring back slowly from pressure. The introduction of gases into the initial solution creates a bubble matrix; vary the application of chemicals, and the size of the bubbles changes. A more open cell structure will have more give, and allow more airflow through the material.

Memory Foam Firmness

The firmness of memory foam is rated by the IFD (Indention Force Deflection), also known as ILD (Indentation Load Deflection) measuring the force in pounds required to make a 25% indentation in a 4 inch thick foam square. Also important in measuring the “softness” of a foam is the density. Foam densities range from 1-7 lbs, but a good-quality foam will usually be at least 4 and usually 5 lbs. A foam with a high density, but low ILD may still feel firm when compressed, especially in a lower room temperature. The density together with the IFD/ILD and the resilience will determine the softness, firmness, and life-span of the foam. Foam that is lower density will more readily conform to pressure, whereas higher density foam (usually 5-lb. or above) molds itself to contours when warmed by body heat.

Major production of memory foam did not begin until NASA released it into the public domain in the 1980s.Fagerdala World Foamstook up the challenge of producing this somewhat difficult product, and in 1991 produced the “Tempur-Pedic Swedish Mattress.” Today numerous companies around the world produce visco-elastic memory foam, which gives consumers increased variety and price range. Unfortunately, it also increases the risk of purchasing cheaply-made foams that may deteriorate over time. Not all memory foam is made equal, as many of the overseas manufacturers work at reducing the cost of memory foam by adding in other “filler” type ingredients that reduce the quality and potentially add toxicity to the formulation. The real problem with overseas foam is the lack of quality standards that have been created in the United States.

Add a Comment: