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A-Z of Dunlop Foams Terminology
Allergies
25% of all allergies are due to Dust Mites, with up to 85% of people with Asthma allergic to Dust Mites. This allergy has a significant effect on the development of Asthma and the severity of its symptoms and has also been shown to be a trigger for hay fever, rhinitis and eczema. See Anti-microbial and Ultra-Fresh.
Bedding Accessories
Foam is used to make a variety of bedding accessories including Pillows, Overlays, Chiropractic Wedges, supports, cushions, etc.
Bun
A large block of polyurethane foam, which is cut into different shapes and sizes for various uses.
Coding
All flexible polyurethane foams manufactured by Dunlop Foams are identified with industry coding which have a series of letters and numbers. An example of this coding is: EN36-100, where EN is the foam type, 36 is the density, and 100 is the hrdness.
Comfort
While the spring unit provides support in a mattress, it is the foam and other cushioning layers that add to the comfort of the bed. This is evidenced by the increase in the thickness of mattresses to improve their comfort over the last few years. Comfort is very subjective - some people prefer a softer mattress, some a firmer one. Use of high quality foams helps to ensure that the mattress retains its initial comfort for the whole of its life.
Comfort Factor
A technical measurement that calculates comfort. It is the hardness at 65% compression divided by the hardness at 25% compression. It provides an indication of how supportive the foam will be in use - the higher the number, the more supportive. Ranges from 1.5 to over 2.5 depending on foam type & quality.
Compression Set
A technical measurement that provides an indication of the durability of the foam. It is the percentage of foam height lost after an extended period of compression. Ranges from 5% to over 15% depending on foam type and quality.
Convolusion
The process of cutting foam while it is compressed between two shaped rollers, which produces two "egg-crate" or other shape sheets from one flat sheet of foam.
Density
This is a measure of mass/volume and is expressed in kilograms per cubic metre. Density is the best indicator of durability and quality, and is NOT related to hardness. For a given hardness, a higher density foam will provide better support over a longer period of use than a lower density foam. This is demonstrated by higher density foams losing less height/thickness than lower density foams. Higher density foams will require higher levels of raw materials in their manufacture, will be better quality, and therefore will be more expensive.
Durability
Measured by various tests to give an indication of how long one grade of foam may last in use relative to another. Results depend on foam type and quality.
Dunlop Foams
The largest manufacturer of flexible polyurethane foam in Australia, with branches in all States; a division of Pacific Brands - an Australian owned public company.
Elongation
A research & development department test that measures the percentage stretch of a foam sample before tearing - ranges from 100% to over 200% depending on foam type.
Enduro
A range of High Resilience (HR), Flame Retarded (FR) Dunlop foams with densities of 36 kg/m3 or higher. Enduro foams were introduced by Dunlop Foams in 1986 and are renowned for their comfort and durability. It is the premium Dunlop Foams brand.
Fillers
Powdered materials that are in some cases added to polyurethane and latex foams to increase weight - fillers generally reduce foam quality and durability.
Fire Retarded (FR) Foams
Flame Retarded foams have flame-retardants incorporated in their formulations to control ignition and the spread of flame. Use of FR foams in bedding is mandatory in UK and California.
Firmness
See hardness
Flammability Tests
Various tests which show how foams burn in different simulated situations.
Foam
A light cellular material created from small bubbles of gas in polyurethane plastic or rubber as a result of a chemical reaction.
Foam Type
Part of the industry coding used to identify a grade of foam. Dunlop Foams manufacture many different grades of foam for a multitude of furniture, bedding and industrial uses. Common foam types include:
AA - Utility grades of foam that do not fall into any of the brands/types listed below
HS - Hypersoft foams that are generally suited for use as overlays, soft backs, quilting etc.
MA - Marathon part of a branded range of foams with densities exceeding 23kg/m3
ST - Stamina part of a "premium" branded range with a 10 year Guarantee.
EN - Enduro are our top of the range branded foams, which carry up to a Lifetime Guarantee
Hardness
A measure of the foam's ability to support a load - an indication of the suitability of the foam for various applications and its initial feel - not a measure of Quality. If a foam is too soft, it will bottom out; if it is too firm, it will be uncomfortable. In most instances foam is selected based on its hardness, which is closely related to perceived consumer preference. All foams manufactured by Dunlop Foams are tested for hardness (load bearing) and must be within a set range of tolerance. To find the hardness we compress a standard sized piece of foam to 40% and measure the amount of force required to obtain that compression which is expressed in newtons.
Hardness Loss
Softening of foam in use - an indication of foam Durability. Ranges from 15% to over 40% depending on foam Quality. Most of it occurs within the initial period of use.
High Resilience (HR) Foams
Foams that have resilience above 50% are considered HR - these foams generally offer superior comfort and durability.
IFD
Indentation Force Deflection - see hardness
IFD 25% Recovery
A measure that provides an indication of foam durability. The ratio of the IFD force measured at 25% deflection on return (unloading) cycle to the IFD force at 25% deflection measured on the loading cycle.
Indentation Factor
A term used by the Research & Development team to test foam. It is also sometimes called the Sag Factor or Comfort Factor, and is the ratio of a compression reading at 65%/25%. A high ratio indicates a wider difference between the two readings and this would indicate initial softness and deep down support/firmness. See comfort factor.
Low Resilience (LR) Foam
Low Resilience foams are often called "memory" or "visco-elastic" foams due to their slow recovery after compression force is removed, leaving a temporary imprint. These foams provide superior comfort by reducing pressure points and are often used in chiropractic or pressure-relieving products.
Luxura
A range of Dunlop foams used in furniture and bedding. It provides luxurious soft cushioning with lasting support and exceptional durability. It is made from a combination of LR and Enduro HR foams that provides a soft and yielding feel, with healthy support.
Marathon
A range of quality Dunlop cushioning foams with densities from 24 to 29kg/m3.
Material Safety Data Sheet
Often referred to as MSDS's, these are information sheets about Dunlop foam grades to be used as a reference for handling and working with Dunlop Foams in a safe way. MSDS's can be downloaded from the Dunlop Foams website (via the homepage).
Memory Foam
See low resilience foam
Moulding
The process of producing a finished foam shape by pouring liquid chemicals into a mould, where they react and fill out the inside shape of the mould.
Opulence
Introduced by Dunlop Foams in 2002, its very high density ensures a very plush and supportive feel and excellent durability.
Peel Foam
Thin continuous sheet of foam produced by slicing off or "peeling" a layer from the outside of a cylindrical block of foam. Peel foam is usually supplied in rolls.
Polyurethane
A class of synthetic materials commonly used as foam in a variety of applications including seats, beds, insulation, packaging, etc.
Pressure Points
Areas of the human body (e.g. hips, shoulders, heels, etc.) where, depending on sleeping position, the soft tissue is squashed between the mattress and the bone, preventing blood flow. This causes discomfort and numbness, and results in tossing and turning, which leads to poor quality sleep. In elderly or bed-ridden people, it can lead to pressure sores (also called pressure ulcers or bed sores). Low Resilience foams help to reduce pressure, thus improving comfort and quality of sleep and reducing the risk of pressure sores.
Quality
The quality of the foam is generally related to its density, however use of fillers can increase the density of the foam without improving its quality. Other factors can also affect foam quality, e.g. formulation and manufacturing process consistency.
Quilting
Peeled foam is usually put through a quilting machine between two layers of fabric to create the outer casing of the mattress.
Resilience
This is a measure of the foams "bounce" or springiness, contributing to comfort and support. It is widely agreed that foams with higher resilience are best suited for seating. The resilience of foam is found by dropping a steel ball onto a standard sized test piece and measuring the distance that the ball bounces back. The height the ball was dropped from divided by the bounce height equals the foams resilience percentage. Foams with resilience above 50% are classified as High Resilience and those with resilience below 10% are classified as Low Resilience. An example of superior resilience foam is Dunlop Foams Enduro.
Repol or Rebond
Multi-coloured foam of high density and hardness made by combining shredded foam scrap into blocks using a special adhesive.
Sag Factor
See comfort factor
Slabstock Foam
Foam produced in large blocks to be cut to customers' requirements.
Stamina
A range of high quality Dunlop foams that hold their shape well and provide lasting comfort in furniture and bedding. They usually range in densities from 29 to 35 kg/m3.
Tear Resistance
The resistance of the foam to tearing - can vary from about 100 to over 400 N/m depending on the foam grade.
Tensile Strength
The force required to stretch a standard size foam piece until it breaks - can vary from under 50 to over 100 kPa depending on the foam grade.
Ultra-Fresh
A performance anti-microbial compound added to all Dunlop foams during manufacture to produce a long-lasting, cleaner, and fresher product. Ultra-Fresh helps prevent and control odour-causing bacteria and degradation that can be caused by microbes such as mould and fungi. For more information, visit the Ultra-Fresh website.
Visco-elastic
See low resilience
Viscoflex
A new range of low resilience visco-elastic foams with superior feel and exceptional memory properties over an extended temperature range for enhanced comfort and pressure reduction. It is ideal for mattresses, pillows and overlays.
Weight
See density
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