The production of memory foam is a true marvel of modern chemistry and industry. Memory foam is made by reacting different substances in a process similar to polyurethane, but with additional agents that create the viscous, denser properties inherent to memory foam. Here is the basic process involved in its production:
1.Polyols (alcohols derived from petroleum products or plant oils), isocyanates (organic amine-derived compounds) and reacting agents are mixed together right before production.
2.This mixture is then whipped into a froth and poured into a mold. An exothermic, or heat-releasing, reaction is the result, which causes the mixture to bubble up and produce foam.
3.The foamy mixture may be infused with gas or blowing agents, or vacuum-sealed to create the open-cell matrix. The amount of polymer mixture versus air correlates to the resulting density.
4.At this stage, the large chunk of foam is referred to as a “bun”. The bun is then cooled, and heated again after which it is left to cure, which can take anywhere from 8 hours to a few days.
5.After curing the memory foam is inert (no longer reactive). The material may be washed and dried to remove lingering residues, and can now be inspected for quality.
6.Once the memory foam bun is finished, it is then cut into pieces for use in mattresses and other products. The mattress-sized pieces are now ready to be assembled into a finished bed.
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