GUANGZHOU, China—Seven-zone polyurethane mattresses have been commercialized by BNP, a sister company of South Korea-based DUT.
Unlike conventional mattresses, the zones are made inside the block on the conveyor. Although the set up is more expensive than conventional mattresses' manufacturing methods, it is cheaper to make the individual mattresses. This is because there is no need to cut and glue mattress components together, according to DUT CEO Yong Chai Jung.
Jung said his company worked with Dow Polyurethanes on the different formulations needed to make the mattress. The different formulations are poured adjacent to each other in the foaming machine. The process involves four PU formulations—visco, semi-visco and HR foam—dispensed through seven nozzles, one for each comfort zone of the mattresses.
Jung said his firm had been "supported 100 percent by Dow Polyurethanes."
BNP is marketing the mattress directly to consumers under the Healthy Spine bedding range as a bed-in-a-box product. It also is being sold as a layer in conventional hybrid mattresses.