Nov 1

In business, minimizing waste is one of the biggest goals of an organization, whether it’s materials or manpower. Some industries are inherently wasteful, but one area that is shockingly efficient is the foam industry.

With most materials, mistakes, runoff, and scraps are all wasted costs, thrown away in the garbage. With foam, many scrap pieces are able to be made into new products. A chunk of foam sawn off the end of a topper can become multiple keyboard typing pads, or a mis-cut mattress can be diced up into multiple pillows. While these mistakes rarely happen with the automation of manufacturing these days, when they do, it isn’t cause for panic.

What’s more, the smallest pieces and most irregular cuts of foam can be reused, even if they can’t be repurposed into a new product. For these scraps, foam shredders turn what’s left from a foam-cutting job into fluffy, comfortable filling. Shredded foam has enough uses that virgin foam sheets are routinely shredded to meet demand, but foam scraps get added into the batch as well. “Scrap” shouldn’t carry a negative connotation either, since in every case, the chunk being shredded was only a saw blade’s width away from being part of a mattress, pillow, or cushion.

Shredded foam is then turned into pillow stuffing, beanbag chair filler, and carpet padding. With this kind of versatility, foam is one of the most efficient products on the market, in any industry!

Article submitted by The Foam Factory, an online source for a wide range of durable, well-made foam products, from mattresses to shredded foam filling.

Oct 1

When dealing with acoustical foam tiles, there are two varieties of the material that are more popular than other tile designs; wedge and pyramid.

A mixing or listening space is one where people spend a substantial amount of time, and for that reason, aesthetics are an integral part of a room layout, in addition to the sound performance of a space. With its clean lines, sharp angles, and vibrant colors, wedge and pyramid foam tiles can help individuals decorate their room in a fashion that is both pleasing as well as functional. Wedge foam is able to be mounted in linear patterns, or arranged in a perpendicular, alternating pattern to break up the design. Pyramid meanwhile, is uniform side-to-side, so you always know the look you’re getting with that tile design.

Wedge and pyramid foam are not just attractive though, they’re very functional pieces of acoustical treatment, that while similar, each provide their own unique benefit to the room they are installed in, aside from their good looks.

Wedge foam, with its long ridges across the panel, offers a slight advantage in overall absorption of sound. With a greater amount of physical product in wedge foam tiles than pyramid, it is able to stop more sound, along the mid- and high-frequency range.

Pyramid foam is formed with two passes through the machine that creates the wedge foam; one run creates the wedge design, while a second pass with the foam turned 90 degrees results in the pyramid look being created. There is less foam in a pyramid tile than wedge, making it slightly less absorptive. However, the greater surface area created by the individual peaks makes for a slightly more diffusive tile. Going with either style can give you a great-sounding and great-looking room, no matter which pattern you go with.

Sep 10

For DIY fans, foam is incredibly popular due to its versatility, availability, and ability to be cut with tools most of us have in our homes. Because of this, making a DIY cushion, seat pads, or even a foam bed has become a project that’s able to be done at home.

For some projects, the foam you’re working with isn’t large enough to handle the job in a single piece. When you need to combine multiple pieces together to complete a project, spray adhesive is used, and there are a few rules and tips to abide by when bonding two pieces of foam.

The first thing to cross off the checklist is identifying the type of foam you will have to glue. This sounds fairly obvious to most people, but different kinds of foam are composed of different materials that may or may not have different reactions to the chemicals in adhesive. As an example, polystyrene can be melted by certain types of spray adhesive that aren’t formulated for use with EPS. Fortunately, different adhesives are made that work with almost every type of foam, and chances are slim that you wind up working with a material you can’t find a usable adhesive for.

For smaller pieces being glued to a larger cushion, the process is very simple; preparing an area to spray, coating both sides of the foam, squeezing the pieces together, and holding them in place for a couple minutes. Larger pieces may not be as easy to reach around to compress from both ends, so for bonding larger sections like window seats, firmly pinching as you go down the perimeter of the seam will ensure a strong bond for your project.

To mount some varieties of foam acoustic treatment, you can spray the foam with adhesive and apply it directly on the wall. A light layer on only the foam forms temporary bond, while a heavy coating with more on the wall forms a stronger bond.

Aug 20

Adding decorative crown molding to your home is one of the smartest ways to give it an injection of attractiveness and value without an over-the-top approach that comes off as too bold. Crown molding is an architectural trim placed in the joint where wall meets ceiling, giving a space a classic, understated elegance that gently impacts an entire room’s ambiance.

Created in all kinds of styles and sizes, crown molding makes a room feel larger than it actually is by smoothing the transition over the static joint at the top of a room. Molding was traditionally made from wood, but is now manufactured in more user-friendly materials like polyurethane foam. Foam molding is much easier to trim and squeeze into place than traditional materials, while offering a greater margin for error. With wood, the smallest miscalculation or cut can leave you with gaps and bad angles.

Custom molding services make replicating pre-existing patterns in a home simple, especially if you are able to provide foam manufacturers with a sample to pattern-match with. Companies also sell pre-made kits, with stock patterns that guarantee you can add more matching molding down the road if you so choose.

Crown molding isn’t solely for interior applications décor either. Many individuals add architectural designs to the exteriors of their homes for a regal and stately look. Exterior architectural trim is often more labor intensive to install due to the heights and size of external walls, but can also make a significant difference in the appearance of your home, as well as the way you feel about it. Exterior foam molding is typically made from polystyrene, due to its water resistant characteristics and durability once sealed and painted.

Jul 29

Understanding the physical characteristics of a product is necessary to ensuring it possesses the capabilities necessary to perform a task. When dealing with firm foam, soft foam, or any variety between, density is perhaps the most important characteristic to note, just as vital in a mattress as it is in cushions or acoustical foam. Knowing how foam density is found and understanding how to interpret its values in the products you need can help you make sure you select a foam product that meets your needs.

The density of every foam product is measured the same way, so whether you’re looking for back pain mattresses or closed-cell foam for DIY weather stripping your doors, you can know you’ll be comparing apples to apples.

Density is found by measuring a cubic block of a given foam material; there are no formulas required, or calculations needed. If a cubic block of foam weighs two pounds, that batch of polyurethane is two pound density. Because of the different formulas used to manufacture foam, each individual foam-maker supplies their manufacturers and retailers with data sheets that list the values of that particular batch. This means a particular type of foam doesn’t carry universal density figures, since batches can vary. Similar types are often within a similar range, but each batch still needs to undergo its own testing to verify density. 10 companies can offer the same foam, all with slightly different densities.

Foam density is mostly used to assess the quality of a foam material. This does not include the feel or firmness of a material however; a major difference. Because foam is simply a physical cell structure and air, higher densities mean there is more performance product and less air. Knowing what density means, as well as how it is calculated and interpreted will help you make better informed material decisions.

Jul 10

Circulation issues are the root of a restless night’s sleep for millions of people on a nightly basis. For these issues and many more, leg support pillows offer you better comfort and improve circulation, whether sleeping in bed or relaxing around your home.

The most basic comfort product used to combat circulation problems is also the most versatile; the foam mattress wedge. Outstanding for providing a boost to the upper body, a wedge can also be used by the lower body to comfortably lift the legs when placed under the knees for a more comfortable sleeping position.

Rounded body bolsters can be used as targeted foam bed pillows, with their offerings entailing many diameters and lengths to suit an individual’s needs. Smaller bolsters are often used to support the lower back, while larger ones can provide a boost under the knees for people sleeping on their backs. While body wedges may be too great of an adjustment for some people, smaller bolster pillows can offer a more gradual boost that doesn’t change posture too drastically.

There are many support pillows designed specifically for the legs as well, ranging from hybrid wedge cushions that begin with a taper and flatten to scooped pillows that comfortably hold calves and ankles. Yet another option is the use of a full-length, fiber-stuffed body pillow, great for side sleepers. These can support and boost the legs, shoulders, arms, and knees for better alignment while sleeping

Jun 11

For those who make their living rolling down the road, the time logged behind the wheel can take a lot out of a person. Because distracted and tired driving is one of the main causes of accidents among all drivers, not just truckers, safety regulations have been put in place for the freight industry that mandates rest periods after so many hours driven within a certain time frame. These breaks give drivers personal time to relax before having a full night’s sleep. Due to the tight confines of trucks’ sleeper cabins, and the less-than-stellar mattresses that often accompany them, this recuperation period intended to keep drivers refreshed and alert on the road doesn’t always provide the quality of sleep they enjoy at home.

To keep drivers focused and well-rested, a comfortable, quality mattress is vital. Fortunately, with the versatility foam materials offer, luxurious beds can be made in special sizes, making them perfect for a truck’s mattress platform that may not be a standard size. Bunks in rigs and trucks are often non-traditional sizes to maximize what little space there is, so it can be difficult to find a traditional mattress in truck berth dimensions. Fortunately, many foam manufacturers are able to take the recorded berth dimensions from drivers, cut a new foam mattress to size, and mail it to them.

Some drivers move between different rigs owned by their companies, making it impractical to buy a full mattress. To get custom-mattress comfort, even when sharing rigs, foam sleeping toppers offer the ability to be rolled up and moved to your next truck when the trip is over. These can soften even the firmest beds, giving drivers relaxing sleep every night, no matter who owns the truck.

For the safety of everyone on the road, keeping drivers rested and alert should be a priority. To help truckers do that, foam mattresses and mattress toppers are a smart choice.

May 21

Though they’re bound to insist it’s toys and games, the most important thing in a child’s bedroom is the bed itself. Granted, it’ll never be as fun as games or puzzles, but making sure a child has a quality mattress is key to ensuring healthy growth and development.

Often times, children receive hand-me-down mattresses from siblings or other family members. However the fact that somebody else has chosen to replace it should tell you that it wasn’t good enough then and won’t be good enough now. Unless it’s a brand-new mattress that turned out to be completely wrong for the person who bought it, a bed that’s too worn and not supportive enough for an adult will be too worn and not supportive enough for a child. Even if these second-hand mattresses were once top-of-the-line models in their day, that quality isn’t restored when ownership is transferred. Even if you are one of those people who can say, “I used to be able to sleep anywhere when I was a kid,” it doesn’t mean you couldn’t have gotten much better sleep on a quality surface.

One benefit of a quality, comfortable new bed for children is that a comfortable mattress can help make bedtime something that’s enjoyed instead of detested. This can be even more true if the frame holding the mattress is something fun like castles, cars, or another interesting theme. Meanwhile, captain’s beds with drawers can be useful for kids who have more things than places to put them. A teen’s bed needs to have enough room for growth, making full-sized beds increasingly popular. Even if you’re only adding a foam topper to a bed, giving kids the most comfortable and supportive sleeping surface is important to their health and happiness.

May 14

For those who enjoy crafting and sewing, one material that can be supremely useful is polyester fiberfill, also known as polyfill. This light and fluffy material has been used in comfort products and soft toys for ages, and is a standard for filling pillows, cushions, and stuffed animals.

Polyester fill consists of interwoven strands of hypoallergenic polyester fibers that are either spun tightly into sheets or woven into loose, fluffy bunches. Tightly woven sheets called batting are often used to wrap chair and couch cushions for an extra layer of softness that doesn’t diminish support. Loose fiberfill makes great pillow fill for a throw cushion that pads furniture, and offers a visual fullness and physical softness that can be easily added or removed. In clump form, pillow fill can be gently pulled apart by hand to make the filling less dense, or packed in tightly for a more consistent, fuller pillow. Loose fiberfill is also great to have around the home for quick repair projects. Well-loved stuffed animals or torn pet toys can be easily filled back to their original shape and size with the polyester stuffing.

In batting form, polyfill is particularly useful in quilting because it’s light, warm, and holds its shape to give blankets even fullness. It can be sewn through as well, to keep it from sliding around within the covers, showing its versatility as a crafting material.

Apr 30

Treating the sound in a room requires an individual to take many factors into consideration and use different targeted methods to handle each situation. One of the most basic treatments to be considered is diffusion.

Diffusion is the scattering of sound waves that hit and reflect back off of a surface. This is important for attaining clear, crisp sound because without acoustical treatment, delayed reflections of original sound are reaching the listener. Because it’s the same sound arriving split-seconds apart, it is interpreted as distortion and noise, muddling the experience.

If you sit in the middle of a room with speakers in front of you, they aren’t sending a single, straight sound wave. Instead, sound radiates out in a spherical shape, in all possible directions. You hear the original sound, but what you are trying to avoid are the multiple echoing waves of sound that are present in a room that isn’t acoustically treated.

Products that function as diffusors often feature angular patterns that break up sound and scatter it in every direction, reducing standing waves and minimizing the echoes that are a detriment to sound enjoyment. Foam and fiberglass sound diffusors also help absorb some of the waves, eliminating a portion of noise. Even economy acoustical products like wedge foam or eggcrate can deliver performance when dealing with diffusion sound issues. No matter what products are used to create diffusion in a problematic room, always be sure they are fire retardant and rated properly for your use.

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