Do you wish to know what a convoluted mattress is? Convoluted foam was created as a low-cost means of tripling foam output.
Splitting the foam in half and cutting points into it (similar to an egg crate) yields two 4-inch thick sheets of foam from a single 4-inch thick sheet of foam.
The convoluted foam mattress offers one of the most economical ways to enhance the comfort of your bed.
The convoluted or egg-crate design reduces stress on common pressure points, supporting your body as you sleep.
This article will explain what convoluted foam is, how it is created, and its benefits in terms of comfort and support.
Also read: Why mattress sag in the middle?
Let us go.
What Is Convoluted Foam?
Convoluted foam is a polyethylene-based synthetic textile used as protective packaging and liner material for various items.
Then, flat sheets of thermosetting resin like trimethylol melamine or benzoguanamine are soaked. Die cutters create an egg crate pattern on one sheet.
After splitting the sheets, they can be nested in pairs.
Cross-linking copolymers like ethylene-acrylic acid or butene-maleic anhydride react with the thermosetting resin to stiffen the nested pairs, which lets the foam stand on its own.
This patterned foam goes by many names because it has so many uses. Because it absorbs sound, it is usually called acoustic convoluted foam.
When attached to walls and other surfaces, the machined pattern’s distinctive hills and valleys trap sound waves in the low-to-mid frequency range up to four times more efficiently than regular flat foam.
It makes convoluted foam highly beneficial to noise reduction or privacy. This foam is commonly seen lining the inside of music studios, machine shops, offices, and computer laboratories.
The coned peaks absorb tension and distribute weight better than flat foam, providing improved cushioning.
The medical-grade convoluted foam prevents bedsores by improving air circulation.
Convoluted Foam – Egg Crate Foam
Convoluted foam is an excellent packaging material. Products can be entirely encased when wrapped for shipping to assist in withstanding movement during transport because of their cone-shaped design and tendency to nest.
As packing material for computers and other electronic components, confident makers of convoluted polyethylene foam provide an anti-static type.
The foam may be trimmed to fit any product and comes in various densities and colors.
Convoluted foam was created as a low-cost means of tripling foam output.
Splitting the foam in half and cutting points into it (similar to an egg crate) yields two 4-inch-thick sheets of foam from a single 4-inch-thick sheet of foam.
It is fantastic for acoustic reasons; however, this customized foam does not belong “inside” a mattress.
Mattress producers have been seeking ways to lower costs in recent years. As a result, acoustic foam is used.
They started using egg crate foam inside the core of their mattresses because it allowed them to increase their foam production by manufacturing convoluted foam.
It is fantastic since they receive the same thickness mattress while saving money! The only issue is that you are paying for air because half of the original foam has been removed!
Everyone agrees that a robust support core requires at least 2 lb density poly-foam. Convoluted foam reduces half of the foam’s weight, leaving you sitting on little foam spikes (egg crates).
Because the egg crates ultimately collapse due to high body weight, we believe this weakens the support core and is insufficient for good orthopedic support.
Marketing
They give the convoluted foam layer a fancy term like an airflow system to sell it as desirable. However, it is clear how this system fails.
Because there is no route for warmer air from the memory foam sleeping surface to reach the convoluted foam layer in the mattress’s central core.
Plus, your body weight and pressure crush the foam egg crates, leaving no air inside the mattress.
Here’s an example of marketing hype versus genuine consumer feedback:
Experience
For over 15 years, we have been selling mattress toppers. Customers’ most common complaint is that their mattresses are no longer as comfy as they once were.
Customers are attempting to repair a sinking mattress and providing less support than it once did.
Low-density foam (1.5LB or less) or a layer of convoluted foam (or both) in the support core is the most typical source of this weakness.
Unfortunately, we cannot resolve this issue because the root of the matter is located in the mattress support core. The only alternative for the dissatisfied consumer is to live with the problem or buy a new mattress!
Properly constructing a mattress employs solid, unaltered, high-density foams in the core and transition layers.
This procedure is controversial since it results in higher-priced mattresses.
However, because the integrity of the mattress has not been damaged by convoluted or lesser quality (density) foams inside the bed, the result is more excellent durability and correct support.
Uses for egg crate foam include:
A mattress topper or padding made of high-density (HD) convoluted foam is commonly used to give extra cushioning to a mattress, making it more pleasant to sleep on.
It’s also valuable for various applications, including seat cushions, packing materials, and soundproofing.
The primary advantage of egg crate foam is its ability to equally distribute weight and pressure over the mattress surface, which may help relieve pressure spots and promote circulation.
It is a popular choice for individuals looking to enhance the comfort of their beds or other seating surfaces.
What Are The Benefits Of Convoluted Foam?
The responsive structure of convoluted foam toppers provides better weight distribution than a flat foam mattress topper.
The egg-crate shape’s peaks and dips relieve strain on the shoulders and hips, making it an ideal, supportive alternative for side sleepers.
However, the strong support of this mattress topper can help both back and front sleepers.
Is Convoluted Foam The Same As Memory Foam?
Egg crate foam is also known as convoluted foam. It gets its name from the material’s ridges that allow your body to sink into it to relieve minor aches and pains.
This foam might be formed of polyfoam or memory foam. It is most commonly used in mattress toppers.
Conclusion
Now that you know what a convoluted mattress is, remember that the material also allows for better air circulation.
Many hospitals employ medical-grade convoluted foam as bedding to prevent the danger of decubitus ulcers, often known as bedsores.
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