MAKE YOUR OWN BED
907 Hollywood Way
Burbank, CA 91505
WHAT IS BEAUTIFUL ABOUT LATEX FOAM IS THAT YOU CAN CHOOSE:
BLENDED, NATURAL OR ORGANIC LATEX;
BAMBOO, NATURAL OR CERTIFIED ORGANIC QUILTING;
ZIPPERED COVER; HANDLES, ETC . . .
TO MAKE THE PERFECT MATTRESS FOR YOURSELF. PLEASE CALL 800-233-7382 FOR FACTORY DIRECT PRICES ON LATEX FOAM AND HOW TO MAKE THE BEST MATTRESS FOR YOUR BODY. WE'VE MADE "YOUR COMFORT IS EVERYTHING!" OUR ONLY BUSINESS IN BURBANK CA - FOR 50 YEARS NOW - AND ARE PRETTY GOOD AT IT!
"What is a good night's sleep? How my mattress changed my life- from aaaahhhhh! to zzzzzzzzzzzzz."
When you walk into a mattress store what do you see?
20 to 50 white rectangles, right? Ranging in price from hundreds to thousands of dollars.
How are you supposed to know the real differences, if you’re spending too much or too little, and which one is right for YOU?
Most consumers say they want a “good mattress for their back” or something “more comfortable” than they have at home. Both of these are important characteristics in a new mattress, but asking a sales person to help is no guarantee you’ll find the right one, you need to make that decision for yourself.
Simply stated, good sleep is when we wake refreshed & energized, physiologically there’s a process that occurs to accomplish this. This process rotates through a sequence of 5 sleep stages multiple times per night.
If this process is interrupted it has to “reset”, when this happens over and over, we wake feeling exhausted, like we didn’t sleep at all, because we really didn’t!
What causes interruptions to our sleep process? PRESSURE.
Pressure on our muscles prevents our body from relaxing and beginning the sleep process.
Pressure on our circulation causes us to move, constantly “resetting” our sleep process.
So, how can you tell what mattress provides the best pressure relief?
As you travel through the store you’ll quickly determine what beds work for you body and what beds don’t.
When you’ve narrowed down which beds relieve pressure the best, revisit them and go through the process again. This time ask a friend or a salesperson to view your profile from the side of the bed, looking to see if your spine appears relaxed and comfortable.
Most new beds provide adequate support, but you want to be sure the bed you choose properly maintains optimal spinal posture too.
Ask you partner or sales person to look at the alignment of your body when lying on each bed. You’re looking for the spine to be parallel with the mattress. Hips & shoulders should sink deeper but the line of your spine should be straight.
If your spine curls into a U shape then the mattress is not supporting you properly.
If your spine is straight then you have proper support even if the mattress feels softer than you expected.
Many people think a “hard” or “firm” mattress is better for their back. With today’s bedding materials this is not necessarily true. In fact a mattress that is too “hard “ or “firm” will actually create excessive pressure on your muscles and circulation preventing you from getting a good nights’ sleep.
If you follow these simple steps you will find the best bed for your body which will in turn give you the “better sleep tonight” you are looking for.
The first thing to be aware of is that Talalay Latex is utilized by mattress manufacturers in three distinct ways.
There are three options available to get the uplifting benefits of LI Talalay Latex:
Talalay Latex Mattress: The GOLD standard. These beds are built using Talalay Latex for pressure the relief layer(s) in the top of the mattress and firmer Talalay Latex for the support layer(s) below. There are no other materials between the latex and your body. This construction provides for deepest muscle relaxation with maximum dynamic support.
Talalay Latex Hybrid Mattress: These bed design use at least three inches of Talalay Latex in the very top pressure relief layer against your body. Other foam based pressure relief layers might also be included below the latex. Hybrid designs utilize a non-Talalay Latex support system or layer below. Common support materials include metal coils, polyurethane foam or Dunlop latex. These beds provide many but not all Talalay Latex benefits and can be less costly than a full Talalay Latex Mattress.
Beds with Talalay Latex: Some mattresses use less than 3 inches of Talalay Latex and/or create their pressure relieving layer with memory foam/polyurethane foam on top of the Talalay Latex. While these may be high quality mattresses your Talalay Latex experience will be diluted. The more Talalay Latex is covered with foam or fiber, the less benefit you receive.
To get maximum uplifting benefits from Talalay Latex, it needs to be in direct contact with your body. Conventional mattresses frequently have very thick pressure relief layers or “pillow tops” filled with polyester fiber and/or foam. Think about it, Latex is the highest quality ingredient you can have in any mattress. Why would you place inferior layers on top of it? That would be like putting ketchup on your steak.
Talalay latex mattresses have a light, buoyant feel that gently lifts your body, to relax your muscles and relieving tension. It instantly responds to the shape of your body relieving pressure 33% better then memory foam while offering perfectly calibrated support. It is naturally breathable, hypoallergenic, mold & mildew proof and dust mite resistant, making it one of the healthiest sleep materials in the world. Sound interesting? Read on to learn more...
|Uplifting & Bottomless||Floats your body while never bottoming out||Reduce tossing & turning for better / deeper sleep|
Latex is rubber, not plastic like foam
3x more durable than foam
Increases the useful life of your bed
|Latex stretches and responds||Instantly conforms to your natural shape while simultaneously maintaining spinal posture||Sleep deeper and wake free from pain|
|Latex uniform "open cell" structure||Independently proven to be 4x more breathable than other latexes or foam||DOES NOT SLEEP HOT|
|Made from natural ingredients||Toxin free, hypoallergenic, dust mite resistant, mod and mildew proof||Sleep Healthy. Reduce respiratory reactions from mattress build up and off-gassing|
Where do you carry muscle tension? In your back? Your shoulders? Your neck? Our bodies have three times as many muscles as bones. When selecting a mattress, relaxing muscles and relieving tension are the most important contributors to a good nights’ sleep. Everyday stress, poor posture, or sleeping on an ordinary mattress can aggravate muscle tension, leaving you tired and sore. The pressure-free feel of Talalay Latex relieves tension by completely relaxing your muscles so you sleep better.
Talalay latex is derived from natural material that is inherently hypoallergenic, dust-mite resistant, and breathable, making it ideal for allergy sufferers or anyone wanting a cleaner sleep environment. Memory foam and polyurethane foams use chemicals such as acetone and Methyl benzene in the manufacturing process and are not inherently resistant to dust-mites, mold, or microbes. Click here to learn more
If you read the law tag attached on any bed you’re considering, it will list the materials and their origin. Our Talalay Latex is the only one made in the USA. We never use any fillers or additives as they degrade the feel, durability and benefits of the finished product.
Retail sales people should be able to provide details of what materials are inside any particular mattress. Most people only buy a bed every decade. This purchase is a long term investment in your health. Following the basic guidelines above, will ensure years of enjoyment and uplifting comfort.
The terms “Talalay” and “Dunlop” refer to the two different methods of manufacturing Latex Rubber for sleep products. The Dunlop process was developed in 1929. It was the first method used to produce latex material for bedding.
As technology progressed, the Talalay process was developed by the Talalay family during World War II. The Talalay process for producing latex is significantly more complex and costly, resulting in softer, more buoyant and luxurious finished products.
Both Talalay and Dunlop processes start with a formula mixture of liquid latex. These formulas can be any of the following:
100% natural latex rubber (harvested
from rubber tree plants)
100% synthetic latex rubber (a man-made molecular copy of natural latex rubber)
Blended natural & synthetic latex rubbers (specific blend ratios are proprietary)
Note: there are small amounts of other materials required for processing liquid latex into solid form which are necessary for all latex production. (ingredients & amounts are proprietary)
Latex International Talalay is produced using only 100% Natural or Blended formulations to meet optimum quality standards.
1. Liquid latex formulation is poured into a mold and sealed
2. Vacuum is created to disperse liquid latex throughout mold
3. Liquid latex is flash frozen
4. Frozen latex is flash heated to “gel” into permanent solid form
5. Cooled solid latex is removed from mold
1. Liquid latex formulation is poured onto a long conveyor
2. Liquid latex is slowly heated to “gel” into permanent solid form
3. Cooled solid latex is removed from conveyor belt
#2 Vacuum – This allows any amount of latex to be evenly distributed throughout the mold creating precise and varied firmness with the finished latex. The more liquid latex that’s poured into the mold the firmer the resulting solid latex. Therefore, if less liquid latex is used, a softer more supple piece of latex results.
This differs from Dunlop in that Dunlop process has very little ability to vary the firmness or feel of the finished solid product while maintaining its structural integrity. The liquid formula is poured onto a belt and you get the same, dense piece of latex every time. The only way to soften the feel of Dunlop latex is to add “fillers” into the liquid latex formula which result in solid latex that is flaky and breaks down quickly.
#3 Flash Freeze – This provides Talalay with its uniquely consistent characteristic. Liquid latex is a suspension of rubber particles in water, like a shaken snow globe. Flash freezing prevents the latex particles from settling to the bottom while gelling into a solid product. This means that the resulting piece of solid Talalay latex has the same consistent feel from top to bottom.
This differs from Dunlop because Dunlop process does not utilize a freeze step. Therefore, the rubber particles settle to the bottom while the liquid latex is gelling into a solid form, like a snow globe, resulting in a variation of feel from top to bottom. This is not recognizable if the Dunlop latex is used as a bottom layer of a mattress but can cause problems if Dunlop pieces are used for pillows or as top layers of a mattress.
CONCLUSION - The Talalay process takes four times longer than Dunlop with two additional process steps that improve the consistency, quality and feel of the finished latex.
A simple analogy: Talalay latex is like a chocolate soufflé; although the process is long, your end product is a buoyant, airy, complex delight. Dunlop latex is more like a tray of brownies; tasty, but dense and flat in comparison.
Natural Latex is a milky substance harvested from rubber tree plants (Havea brasiliensis) which are grown in tropical climate plantations around the world. Most are located in Africa, Malaysia, South America, and Indonesia. Natural Latex is bio-degradable and naturally resistant to mold, mildew & bacteria.
Harvesting the liquid latex is similar to tapping trees for maple syrup. The trees are not harmed, providing a sustainable resource. The latex is collected in buckets and shipped to large rubber factories such as B.F Goodrich, Dupont, etc. for processing. Natural liquid latex is a commodity that’s publicly traded in stock markets around the world similar to corn, pork bellies, orange juice etc.
Synthetic latex is a man-made molecular copy of natural latex. The scientific name for this compound is Styrene-Butadiene (SBR).
Styrene is named for “styrax”, the resin from a Turkish tree. Low levels of styrene occur naturally in many kinds of plants as well as a variety of foods such as fruits, vegetables & nuts.
Butadiene is produced by dehydration of butane obtained from petroleum. Butadiene is also used in the manufacture of latex paints and nylon fibers used in rope and clothing.
Blended latex is just what it sounds like, a combination of Natural latex and Synthetic latex mixed together.
This is a question that’s answer can depend on your perspective. All latex formulas offer numerous benefits to consumers that far outweigh the benefits of conventional foam bedding materials. Keep in mind that while latex formulations are contrasted with each other below, all latex rubber significantly outperforms foams such as memory foam or traditional polyurethane foam for durability, pressure relief and sleep benefits.
Natural latex, as its name implies, is “natural” which offers many benefits for use in sleep products. Consumers that have an organic lifestyle and have made numerous changes to remove most synthetic chemicals from their household tend to purchase 100% natural formulations. The elasticity, healthiness, and ability of Natural Latex to conform to your body, reducing pressure on your muscles and circulation is unsurpassed. The resulting benefits and luxurious comfort simply can’t be matched by synthetic latex. However, because it is a “natural” product there are inconsistencies at the molecular level which cause Natural Latex products to wear at a faster rate than Synthetic Latex.
Synthetic Latex is extremely uniform at the molecular level, so sleep products will have greater durability than those made solely with Natural Latex. However, what you gain in durability you lose in feel and sleep benefits as compared to Natural Latex.
When consumers want to know a product is natural and good for the environment while also looking for a product that will help them sleep better with optimum value for their money- they purchase blended latex. By combining Natural Latex and Synthetic Latex together you get the best of both worlds. Natural components, elasticity, conformity, health benefits and luxurious feel from Natural Latex combine with extended durability from Synthetic Latex- to make a product that the Earth provided and we perfected.
Blended latex can be compared to a gold wedding band. No one has a 24 karat (100% gold) wedding band because it would be too soft and bend if gripped too hard. The solution is an 18 karat gold ring where the gold is mixed with another, more durable metal. The result is a ring that has the look and feel of pure gold but is less vulnerable to damage or wear.
Our commitment to perfection: From the selection and mixing of raw materials to final product testing and assembly, our entire manufacturing facility utilizes the latest technology to create the most supple, resilient and comfortable Talalay Latex sleep products in the world.
But of course, all this technology won’t get you anywhere without smart, talented professionals to bring all the elements together assuring great finished products are delivered to your home every time.
Talalay latex is the premier material in bedding, LI Talalay delivers a unique buoyant quality which relaxes muscles and relieves tension, lifting away the pressures of the day while you sleep. Careful attention to detail at every step makes certain this amazing feel comes through in the finished product.
To help understand what makes our Talalay Latex so exceptional, think of an artisan chef creating a light and airy chocolate soufflé!
Start with the best ingredients - We utilize only the highest quality natural and synthetic latex and never introduce fillers that can degrade the feel and durability of our products. Unlike other latex manufacturers, Latex International filters the liquid latex to remove any large particles that might affect the consistency and durability of our end products. It you think of Talalay latex like a soufflé, it’s pretty clear that using powdered eggs isn’t going to suffice- you need real, farm fresh eggs!
Use the best recipe – Next, we mix our premium ingredients into a liquid latex formula or “batter”. Creating different formulas of liquid latex “batter”, we meet specific customer requests for 100% natural or more commonly used blended natural/synthetic latex recipes. Think dark chocolate vs, milk chocolate- it’s a matter of personal taste and desired product attributes.
Measure Carefully- As any great baker knows, if you don’t measure correctly the soufflé will fail. Our advanced, state of the art automated systems control both the mix of the batter and the precise amount poured into each mold to attain specific results every time.
Test for Perfection - Once the process is complete, every mattress core is robotically tested in 9 areas to assure a consistent feel from head to toe. Each pillow is individually weighed and hand inspected.
Share the Results - Even the best ingredients and the finest materials can be used poorly. To assure great finished products, we follow through by sharing knowledge with our retail and manufacturing partners. Together, we design and deliver finished pillows, mattress toppers and mattresses that bring the uplifting benefits of Talalay Latex to the surface.
All of our Talalay products are made with Natural Talalay Latex Rubber, which starts as sap from the Havea brasiliensis tree. These rubber trees have a 25 year productive life and a strong positive effect on the environment as they quickly absorb carbon dioxide from the atmosphere and help reduce greenhouse emissions.
Our Talalay process features natural, biodegradable ingredients that come from renewable resources and water-based raw materials: natural latex, air, and water. Our process does not use solvents and does not damage the ozone layer. Our clean and green approach carries through to our end products: Talalay latex contains no toxic chemicals while standard Poly Foam and Memory Foam (visco) can contain as many as seven toxic chemicals*
The Oeko-Tex Standard 100 (link to oeko website) is the leading global testing and certification process that ensures textile materials and home furnishing products do not contain harmful substances or pose a health risk to consumers. Very few latex or foam producers in the world meet the standards of this independent, third-party certification.Click here to view our OEKO-TEX Standard Certification.
All Latex International Talalay Latex products are certified OEKO-TEX Class 100; the healthiest classification.
This means that our products do not contain allergenic materials that form carcinogenic arylamines of the MAK-groups III A1 and III A2 (see the Oeko-Tex website for a list of chemicals included in these groups,link to oeko), pesticides and chlorinated phenoles, heavy metals or formaldehyde. Our Talalay also meets the standard for skin friendly pH and is free from chloro-organic carriers and biologically active finishes.
In other words, Latex International Talalay is the healthiest material you can sleep on.
*Poly Foam and Visco Foam may contain up to seven toxic chemicals: Tetrachoroethane, acetone, and dimethylformamide, Methyl benzene, Methylene dianiline, toluene-neoprene and Vinilideine chloride, one non-toxic chemical - diphenyl diisocyanate, and one natural material (water.) Synthetic Latex has 5 non-toxic chemicals (2-chloro-1–3-butadiene, diphenyl diisocyanate, metallic oxides, Phenol-melamine resins, sulfur, Tellerium) and 1 natural material (water.) 100% Natural Latex has 6 non-toxic chemicals (acrylate resins, diphenyl diisocyanate, Phenol-melamine resins, Phenol-urea, Polyvinyl acetate and waxes styrene- butadiene copolymer) and 3 natural materials (fats, hevea brasiliensis milk, and water.)
LI Talalay Latex provides 33% more Pressure Relief than leading Memory foam.
Pressure mapping tests the amount of pressure your body registers on a selected surface. This technology is widely used throughout the bedding industry to determine the quantity of pressure that a mattress or pillow creates on your body.
Pressure from your mattress and/or pillow prevents your muscles from relaxing which makes it difficult to fall asleep and impairs circulation causing you to toss & turn which makes it difficult to stay asleep.
Therefore, the less pressure your mattress and pillow produce on your body the easier it is to fall asleep and the more complete sleep you achieve throughout the night which leads to more energetic and productive days.
Latex International Talalay Latex is 4x more durable than other latex and 20x more durable than traditional bedding foams.
At Latex International, we continually ensure that our formulas will last the test of time. Using the standardized ASTM Cornell Indentation test we prove that our Talalay outlasts any other material used for bedding today.
This is the most rigorous and material damaging ASTM standardized test that exists for bedding components. While Latex International Talalay performs flawlessly over a period of 12 hours representing decades of use, other latex’s break down much more quickly and foams such as memory foam and polyurethane foam actually tear apart within minutes.
The strength of our material allows LI to match any warranty that retail stores choose to offer on their products and assures maximum value for consumers.
Latex International Talalay Latex breathes up to 7x better than other latex or foams for cooler sleep.
One of the fastest growing concerns with bedding today is sleeping hot. This is a legitimate concern because not only is it uncomfortable, sleeping too hot interrupts the quality of our sleep as we continuously move to find a cooler spot. This can occur from both mattresses and pillows.
The heightened awareness of sleeping hot is primarily due to increased use of Memory Foam in mattresses. Memory Foam has a collapsible cell structure that traps body heat and radiates it back at us resulting in uncomfortable perspiration.
Talalay Latex is sometimes confused with Memory Foam because of extensive Memory Foam advertising. Nothing could be farther from the truth. The Talalay Latex rubber cell structure resists collapsing and allows air to circulate. This breathability whisks away our body heat preventing mattresses and pillows from becoming an oven.
Latex International has gone one step further and developed Talalay GL which is a unique formulation of Talalay Latex with special phase change properties. Talalay GL actually helps regulate the consistency of body temperature for a temperature neutral sleeping experience.
Bedding Allergens BEDDING ALLERGENS
Mold, Mildew, Bacteria & Dust Mites
LI Talalay Latex is Mold, Mildew & Bacteria proof and Dust Mite resistant
Most people don’t consider their mattress as a contributing source for respiratory problems and allergic reactions. We think of our bed as a “safe haven”. The reality can be much more yucky.
Mold, mildew, bacteria and dust mites love our beds & pillows. We shed millions of microscopic skin cells and perspire nearly 1 pint of water every night. The microscopic skin cells and water vapor fall through the weave of our linens and mattress cover landing on the cushioning layers below where they become a food and water source for mold, mildew, bacteria and dust mites- it can’t be avoided, and it's gross.
Whether your “landing pad” cushion layer is hospitable to these infestations is the controlling factor to the amount of hazardous dust created from your mattress & pillow.
Foams such as Memory Foam & Polyurethane Foam are environments where these contaminants thrive, so if they compose the top cushion layers of your mattress you may have a problem.
Independent testing shows that Latex International Talalay Latex is mold, mildew & bacteria proof- these organisms simply won’t grow on it. Furthermore, it’s dust mite resistant so these critters will prefer to be elsewhere, not right next to your face as you sleep.
Try to find a healthier bedding material, we dare you.
In a perfect world all bedding products would be as safe as Latex International's Talalay Latex. The reality is that today’s technology for producing foams like Memory Foam or Polyurethane Foam simply aren't.
Today’s foams may contain any or all of the following, each are known carcinogens.
Latex International Talalay Latex contains none of these.
Zero cases of allergic reactions to LI products have been reported.
Latex International has been making Talalay pillows and mattress components for over 35 years. Every year millions of products are sold using Latex International Talalay.
The FDA tracks allergic reactions to latex products in the USA. Not once has there been a report of an allergic reaction attributed to any of our Talalay products.
Latex International is the only latex producer that tests every block of mattress material in 9 separate areas to insure consistency throughout each piece. This means that retailers and consumers can be sure that products delivered or brought home will match the products experienced in the showroom every single time.
Because pillows are not able to be measured in the same way as block mattress material, we electronically weigh and then hand inspect every pillow for quality and consistency. This is an extra time consuming step in our process, but it’s the only way to be completely sure that consumers receive the very highest quality pillows every single time.
Of the top four mattress companies in the US, one spends more on annual advertising than the other three combined. This company makes only Memory Foam beds. They spend tens of millions every year advertising Memory Foam to consumers. To counter this, the remaining top three US mattress companies (who make metal coil mattresses) also make Memory Foam beds and advertise theirs to stay competitive.
Hence, the circle of abundant advertising for Memory Foam.
Due to this advertising, many people assume that all non-coil beds are made with Memory Foam or that Latex and Memory Foam are the same thing. This couldn’t be farther from the truth.
In fact, the two materials are actually polar opposites and the sleeping experience could not be more different! Latex International Talalay Latex actually outperforms Memory Foam in every way.
Sleeping hot is the #1 complaint from Memory Foam owners. This is because Memory Foam requires body heat to collapse the Foam cell structure in order to conform to your curves, the collapsing of these cells restricts air flow trapping body heat and radiating it back at you.
Latex International Talalay Latex is 7x more breathable than memory foam. The rubber cell structure doesn’t collapse. Its natural resistance lifts your body preventing collapse and allows air to flow through, creating an escape path for body heat.
You won’t have to continuously flip your Latex International Talalay Latex pillow or search for a cooler spot on your LI Talalay Latex bed.
Our Talalay Latex is a two-dimensional material; it’s simultaneously supportive and pressure relieving, where memory foam is a one-dimensional- pressure reliever only.
Your body sinks into and through Memory Foam until you hit a separate support layer below. Memory Foam simply can’t accomplish both pressure relief and support on its own. Hitting the support layer below Memory Foam increases pressure on your body.
Latex International Talalay Latex is different and testing proves it.
Our Talalay Latex provides 33% more pressure relief while simultaneously creating support because of the buoyant nature of latex. Latex International's Talalay Latex material accomplishes both functions (pressure relief & support) on its own so you don’t bottom out on hard layers below.
Our Talalay Latex is the best pressure relieving material used in bedding today. It provides the ultimate in pressure relief so your muscles relax to fall asleep quickly and your circulation can flow to stay asleep soundly.
Memory Foam, even so called “soft” memory foam has a hard dense feel that is unappealing to many. Some call it “getting stuck in the mud” because after a few minutes your body heat collapses the cells and you sink into a hole molded to your body. It soon becomes very difficult to move or get out of bed, you become trapped in a temporary crater.
Latex International Talalay Latex contains naturally based rubber material that gently lifts your body for a light & bouyant experience. Our Talalay Latex instantly conforms and moves with your body, providing postural support and exceptional muscle relief no matter what sleeping position you maintain.
Latex International Talalay Latex is like floating- truly luxurious.
Our Talalay Latex uses naturally derived material harvested from rubber trees that create an inherently hypoallergenic, dust-mite resistant, mold & mildew proof sleeping environment, making it ideal for allergy sufferers or anyone wanting a cleaner bed. In addition our Talalay Latex doesn’t off gas harmful compounds that may be present in Memory Foam.
Cornell Indentation testing proves Latex International Talalay Latex is 20x more durable than leading Memory Foam. While leading Memory Foam tears apart during this industry standard ASTM quality test, our Talalay Latex passes with flying colors.
Latex International manufactures Talalay Latex Support Cores and Pressure relief layers used by top mattress manufacturers around the world. The Talalay process and our advanced technologies allow us to create a wide range of firmnesses (ILDs) from ultra plush to extra firm.
Our most popular and widely used Talalay Latex. Available in all standard
Pressure Relief Layers: ILD’s 14, 19, 24, 28, 32
Support Cores : ILDʼs 36, 40, 44
Unlike so called natural “soy based foams” that have a maximum of 10%
natural content, Talalay 100% Natural utilizes 100% natural liquid latex for a
true eco-friendly solution.
Available in all standard mattress sizes.
Pressure Relief Layers: N1, N2, N3
Support Cores : N4, N5
Sometimes we find that we just have to go to the doctor and get some straightforward information about the facts and science behind latex.
Block latex foam rubber is the general term used to describe latex foam rubber produced with a large enough cross section to be used for mattresses, pillows, and cushions. Block latex foam rubber is produced by two different processes: the Talalay Process and the Standard (Dunlop) Process. Both processes use the same basic ingredients: natural rubber latex (NR), polystyrene-‐butadiene rubber latex (SBR), soap, reinforcing filler, sulfur, and vulcanization agents.
Natural Rubber Latex – Naturally occurring polyisoprene polymer produced by rubber trees and extruded in the sap. The rubber tree sap is collected, concentrated, and preserved with ammonia before being sold.
Polystyrene-butadiene Rubber Latex – Polymer produced from styrene and butadiene designed to mimic and improve upon natural rubber. The polymer is produced in water on both batch and continuous production lines. After polymerization, the latex is stripped of residual reactants and concentrated before being sold.
Soap – Natural soaps are used to stabilize the various components in the mixture.
Reinforcing Filler – Hard materials are added to the mixture to increase firmness.
Reinforcing fillers are of two general types; mineral or plastic. Mineral fillers are generally aluminosilicates such as Feldspar or calcium carbonate (talc). The most commonly used plastic filler is polystyrene resin. Mineral fillers incorporate well into the rubber matrix and tend to be well dispersed. Plastic fillers are typically introduced as a latex and tend to form clusters in the rubber matrix. The plastic clusters are prone to breaking apart under use leading to softening.
Sulfur – Elemental sulfur forms crosslinks between polymer chains when heated giving the latex rubber foam strength and structure.
Vulcanization Agents – Agents used to increase the crosslinking rate and effectiveness of sulfur. The agents are typically consumed in the process. The above components are mixed together in a water based system to form what is termed compound for both processes.
Advantages of the Talalay Process: the resulting feel, the uniformity, and the ability to reach low densities of the foam block as a result of the expansion of the foam to fill the mold under reduced pressure (rather than the complete filling of the mold as in the Standard (Dunlop) Process).Advantages of the Dunlop Process: shorter production times and ease of manufacture.
Latex International - Shelton, Connecticut
Talalay Latex Rubber rubber has superior feel and comfort in bedding materials because of its unique compression profile. Compression is how a material responds to a weight or load being placed on it. A material will resist the load and push back in proportion to the load and the material’s ability to carry the load. The manner in which a material responds to a load defines how the material feels to the touch and how it supports the load. Below is a graph showing the amount of force needed to compress a piece of latex Rubber rubber and a coil spring a percentage of the original height.
As shown in the above graph, a coil spring has avery linear response to the applied load. The linear response of a spring is an inherent property. Talalay Latex Rubber on the other hand responds to the applied load in a non-linear fashion. Initially Talalay Latex Rubber increases in firmness in response to the load, but as the load increases Talalay Latex Rubber compresses to a greater extent. Talalay Latex Rubber will support just as much weight at the coil spring, but it has more give keeping the material from having the feeling of bottoming out.
Talalay Latex Rubber has the ability to allow for more compression without a proportional increase in weight to conform to various body shapes and weights.
Also contributing to Talalay Latex Rubber’s unique feel and support is the material’s resiliency. Resiliency is the amount of energy returned by a material after compression. Resiliency in a Rubber material is important for support. Below is a graph of showing the compression and decompression of Talalay Latex Rubber and a Dunlop latex Rubber. The arrows indicate compression and decompression.
Dunlop latex Rubber behaves more like a coil spring on compression with a fairly linear increase in compression with load until the material cannot be compressed much more. Talalay Latex Rubber once again has an initial increase in firmness followed by increased compressibility under load. Upon decompression, Talalay Latex Rubber is much more resilient than Dunlop latex Rubber providing more support to thebody. Talalay Latex Rubber is able to compress more at a given load while at the same time return more energy and provide increased support.
The unique, non-linear compression profile of Talalay Latex Rubber is the result of the material’s large, open cell structure. Every cell of Talalay Latex Rubber behaves as a micro-spring.
The initial increase in firmness upon compression is the result of the latex Rubber cells resisting the compression until the cells buckle. Cell buckling results in the non-linear response of Talalay Latex Rubber to compression. Talalay Latex Rubber has a more non- linear response than Dunlop latex Rubber because of its larger cell size.
￼￼￼Buckling latex Rubber cells are nothing to worry about since there are hundreds of other cells backing them up. Talalay Latex Rubber cells are also made of one of the most durable materials around, rubber, so they bounce back into shape. The millions of Talalay Latex Rubber cells work together to provide just the right amount of support and comfort.
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