Made of 100% Pure Natural Talalay Latex which has the
industry's #1 Highest Overall Ratings for Quality,
Pressure-Relief,
Durability, Breathability, Toxin Free, Support, Bouyancy and Resiliency,
Customer Satisfaction, Craftsmanship and Warranty;
The Whole Mattress by Latexpedic is simply the highest quality, most durable and
most comfortable mattress in the World!
3-separate zippers, 3-separate chambers, 3-separate organic cotton socks,
3-separate layers of Latex
completely reversible and quilted on both sides with cotton and wool
available in (4) four firmnesses: Soft, Regular Firm, Extra Firm and Ultra
Firm;
with different 6" center latex core and two 2" cushioning layers on top and
bottom
FACTORY DIRECT. This mattress is a little expensive, but if it weren't
Factory Direct you would be paying twice as much.
No one in America or the World makes a better mattress. We make it one at
a time: Hand-made and crafted.
Latex Bedding Material.
What actually is it?
Latex is defined as: Any of several natural or synthetic colloidal polymers
suspended in an aqueous solution.
Basically: rubber particles in water
WHAT IS NATURAL LATEX?
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.
WHAT IS SYNTHETIC LATEX?
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.
WHAT IS BLENDED LATEX?
Blended latex is just what it sounds like, a combination of Natural latex and
Synthetic latex mixed together.
WHICH LATEX IS BEST FOR ME?
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
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
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.
BLENDED 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.
How Latex is Made
Making Latex – Manufacturing Processes
Latex Manufacturing Processes
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.
MAKING LATEX - LATEX FORMULAS
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.
Latex Processes
TALALAY
1. Liquid latex formulation is poured into a mold and sealed closed
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
DUNLOP
1. Liquid latex formulation is poured onto a long conveyor belt
2. Liquid latex is slowly heated to “gel” into permanent solid form
3. Cooled solid latex is removed from conveyor belt
The difference in processing are the two additional steps that occur with
Talalay Process - #2 vacuum & #3 freeze .
#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.
Quality
CRAFTING
EXCELLENCE
WHAT MAKES LATEX INTERNATIONAL'S TALALAY SO SPECIAL?
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.
Please visit our product finder
page to locate products and companies in your area.
Earth
Friendly
Oeko-Tex
Certified
LATEX
INTERNATIONAL TALALAY - ENVIRONMENTALLY CONSCIOUS
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*
OEKO-TEX
CERTIFIED
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.
Responsible
·
ENERGY:
Our control systems and state of the art automation allow us to optimize energy
usage at every step of the Talalay process.
·
EMISSIONS:
Our manufacturing facility does not emit any harmful elements into the air.
Because of our clean process, we are not required to use any exhaust scrubbers
or filtration. Our finished products don't emit harmful vapors either! Latex
International Talalay Latex rubber, unlike memory foam, does not off-gas any
harmful chemicals.
·
SUSTAINABILITY:
Latex International uses millions of gallons of natural latex each year. Natural
latex is harvested from trees that help “scrub” excess carbon from our air.
*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.)
PRODUCT
TESTING & RESEARCH
-
Muscle
Relief - Pressure Mapping
-
Durability – ASTM Testing
-
Sleeping
Temperature – Breathability & Surface Heat
-
Bedding
Allergens – Mold, Mildew, Bacteria & Dust Mites
-
Toxicity
– Off Gassing
-
Latex
Allergens
-
Consistency Testing – Mattress & Pillows
-
Posture
Support
-
What is
rubber?
PRESSURE
MAPPING
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.
DURABILITY
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.
BREATHABILITY
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.
TOXIN
FREE
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.
-
Tetrachhloroethane
-
Acetone
-
Dimethylformamide
-
Methyl
Benzene
(tolunlene)
-
Methyl
Dianiline
-
Tolune-diisocynanate
-
Vinilideine Chloride
Latex International Talalay Latex contains none of these.
LATEX
ALLERGENS
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.
CONSISTENCY TESTING- MATTRESSES & PILLOW
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.
Talalay
Latex vs Memory Foam
Most
people have heard of and/or seen advertising for Memory Foam mattresses but you
may not be as familiar with Latex International’s Talalay Latex. Here’s why…
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.
OUR
TALALAY LATEX DOESN’T SLEEP HOT
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.
LATEX
INTERNATIONAL TALALAY LATEX IS MULTI-DIMENSIONAL (33% MORE RELIEF)
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.
OUR
TALALAY LATEX PROVIDES BOUYANT LUXURY
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 IS HEALTHIER
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.
OUR
TALALAY LATEX LASTS LONGER
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.
Mattress
Components
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.
ILD Scale
TalalayClassic (Talatech)
Our most popular and widely used Talalay Latex. Available in all standard
mattress sizes.
Pressure Relief Layers: ILD’s 14, 19, 24, 28, 32
Support Cores : ILDʼs 36, 40, 44
Talalay
Natural (100% natural)
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
Talalay
GL Fast Response/Slow Response
Our proprietary phase change temperature regulating material cools you when
youʼre warm and warms when youʼre cool to keep you in the ideal temperate zone
while you sleep.
Fast Response feels just like our Talalay Classic while Slow Response offers a
unique feel that doesnʼt “crater” like Memory Foam.
Available in all standard mattress sizes.
Pressure Relief Layers: ILD’s 15, 21, 27
Evercloud
Quiltable Latex
Evercloud is Dunlop latex processed as a continuous roll sheet than can be
quilted to the cover panel of a mattress instead of using polyurethane foam
(Talalay can’t be used in this manner). We produce Evercloud to specifications
no more than 2” thick to avoid settling of the latex particles during gelling.
It is a higher quality alternative to polyurethane foam if a quilted mattress
cover is utilized.
Pillow
and Topper Components
In conjunction with our own Rejuvenite pillow and topper brand, Latex
International also produces these items for other retail, manufacturer and
distributor brands.
LI has the capability of making pillows in 25 different sizes/profiles with 3
different firmness levels. All of which can be made using any of our Talalay
formulations.
Toppers can be made using any Talalay formulation in any firmness (ILD)
currently available.
TECHNICAL BLOG
TalaWiki / TalaBlog / TalaTalk / Talalay Down the Truth / TalaTruth
FROM THE DESK OF DR. JOHN LEAN, PH.D., CHEMIST
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 RUBBER BASICS
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.
THE TALALAY PROCESS
-
1. Latex compound is injected with air and frothed to form foam.
-
2. The foam is poured into an aluminum mold. The mold is only partially
filled with foam.
-
3. The mold is closed. The pressure inside the mold is reduced to create a
pressure differential between the cavity of the mold and the air in the foam
bubbles. Since the air in the foam bubbles is at atmospheric pressure and
the mold pressure is lower than atmospheric, the air inside the bubbles
expands causing the bubbles to increase in size expanding the foam. The foam
expands and fills the mold. At the same time the foam redistributes itself
evenly in the mold since the pressure inside the bubbles is driven to
equalize over the entire block. Equalization of pressure in all the bubbles
leads to a very uniform density throughout the foam block.
-
4. The water in the foam is then frozen.
-
5. After freezing, carbon dioxide is injected. The carbon dioxide reduces
the pH of the foam and reduces the effectiveness of the soap at stabilizing
the rubber in the latex. The rubber particles coalescence forming a
continuous, open cell, solid block of foam rubber.
-
6. The foam is heated to vulcanize the rubber.
-
7. The foam is cooled and demolded.
-
8. The foam block is washed and dried.
STANDARD (DUNLOP) PROCESS
-
1. Latex compound is injected with air, a gelling agent, and frothed to form
foam. The gelling agent reduces the pH of the foam and reduces the
effectiveness of the soap at stabilizing the rubber in the latex.
-
2. The foam is poured into a mold until it completely fills the mold making
it critical that the foaming process in well controlled to achieve an even
density throughout the block.
-
3. The mold is closed. The mold is allowed to rest until the gelling agent
has enough time to destabilize the rubber in the latex. The rubber particles
coalescence forming a continuous, open cell, solid block of foam rubber.
-
4. The foam is heated to vulcanize the rubber.
-
5. The foam is cooled and demolded.
-
6. The foam block is washed and dried.
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.
Talalay Comfort Zone
By: John Lean, Ph.D.
Director of Research and Development
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.
The increased compressibility of Talalay Latex Rubber is what allows the
material to shape itself and comform to the human body. The human body’s profile
is not flat and its weight distribution is not even. A coil spring is only able
to respond to a body’s weight and not its shape. Talalay Latex Rubber with its
non-linear compression curve can respond to a body’s weight and shape. A person
may have similar weight distribution between the shoulders and hips, but the
body parts have very different shapes.
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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