Residential mattresses

Polyurethane foam mattresses are the largest single-volume segment of the global PU industry. A typical mattress is composed of layers of different types of flexible foam stacked together: an upper comfort layer (often viscoelastic or soft), an intermediate support layer (HR or high-density), and a structural base layer of higher density. Hybrid models combine foam with pocket springs.

Flexible foams for mattresses are predominantly manufactured via continuous slabstock — a process in which the PU reaction occurs in a long continuous line, producing a foam bun that is then cut into slabs and profiled according to the mattress design. Typical densities range from 18 to 50 kg/m³, with most residential mattresses in the 28 to 38 kg/m³ range. Viscoelastic foams have unique behavior — slow recovery, body pressure distribution, "hugging" sensation.

The technology has evolved significantly over recent decades with the introduction of HR foams (high resilience, with special polyols and polymer polyols), viscoelastic foams (with lower NCO index and specific formulation that reduces resilience), foams with infused gel for thermal regulation, and increasingly formulations with bio-based polyols.