Natural latex mattress manufacturing tells you about the production process of natural latex mattresses.

　　Natural latex mattress manufacturingTelling you about the production process of natural latex mattresses

　　Natural latex mattress manufacturing tells you that there are mainly three processes for latex mattresses: Dunlop and Talalay. The latest Talalay process uses the principle of physical foaming (i.e., vacuum suction), while Dunlop uses the principle of chemical foaming. The Talalay method is much more expensive and difficult than the Dunlop method. Additionally, there is a process that combines both.

　　Natural latex mattress manufacturing tells you that natural latex and synthetic latex are mixed, along with vulcanizing agents, gelling agents, antioxidants, and all necessary additives, and filled into molds. However, it only partially fills the mold, with the filling amount varying according to the hardness requirements of the latex block. The molds are specially made aluminum molds with a large number of needles, with about 20,000 needles in each mold cover and base. The needles serve a dual purpose: they help transfer heat to the center of the block, as foam rubber is not a good conductor of heat, and they create 'pinholes' that assist in the drying process afterward. There are rubber sealing rings around the mold, with hollow channels inside that allow for heat transfer through liquids like ethylene glycol/water. After the liquid foam partially fills the mold, the mold is closed, cooled, and vacuum processed. The foam expands under vacuum, completely filling the mold. In this case, an internal auxiliary semi-permeable water-washing machine removes air from the mold to prevent liquid foam from flowing into the vacuum pipeline. After this, the mold is cooled, freezing the foam to about -30°C, with carbon dioxide gas passing through the frozen block, causing the foam to 'set' or 'gel'. At this point, individual bubbles begin to connect with each other. Once gelling is complete, the mold is heated to 110°C and left for a few minutes. Heating causes the rubber to 'harden' or 'vulcanize', giving the product normal elasticity. The product is then demolded, cleaned, and residual soap is removed. Finally, it is dried and tested.

　　The process combining these two techniques: The main difference between the Talalay foaming process and the Dunlop foaming process is that the former injects latex liquid directly into the mold, using low-temperature and other physical processes for foaming and fixing; the latter involves chemical foaming before the latex liquid enters the mold for high-temperature shaping. The latex mattress formed by the two will have a porous structure with interconnected holes. The former has a higher natural component, while the latter has a larger proportion of synthetic latex. The former is better than the latter.