Glossary

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Latex Fabrication Processes
latex fabrication processes

The raw material used to make latex foam is either natural latex, which comes from the rubber tree, or synthetic latex which is made from SBR (styrene butadiene). Many latex foams are made from a blend of the two (such as 70% SBR and 30% Natural latex or NR). Two different processes can be used when manufacturing latex: the Dunlop process and the Talalay process. The Dunlop process has two main variations: one uses a mold and the other is done with a continuous pour method on a moving belt. The mold method is simpler and results in a denser foam. Dunlop mattresses made with foam from the continuous pour method are softer, but still dense and durable, varying little in terms of firmness throughout the material. The Talalay process is more complex than the Dunlop process. It requires less latex as it uses a vacuum to expand the latex in a mold and then it is frozen, preventing the particles from settling before being heated and cured, resulting in a lower density. Despite having less latex in the foamed core, it has a stronger, thicker cell structure, making up for the lower amount of latex in the material in terms of durability.

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