When it comes to getting a good night’s sleep, having a comfortable mattress is crucial. In recent years, the rise of “mattress in a box” companies has provided consumers with a convenient and affordable way to purchase a new mattress. However, not all mattresses are created equal, and one company that stands out from the rest is Purple.
Purple mattresses are made using a unique technology called the Hyper-Elastic Polymer Grid. This material was originally designed for medical beds and seat cushions for wheelchairs, but has since been adapted to create an innovative and comfortable mattress. In this article, we will explore the history of Purple mattresses, the science behind the hyper-elastic polymer grid, the manufacturing process, and the customer experience. We will also answer some frequently asked questions to help you decide if a Purple mattress is right for you.
The History of Purple Mattresses
Purple mattresses have an interesting history that dates back to the 1980s. Two brothers, Tony and Terry Pearce, were working in the aerospace industry, with Terry as a rocket scientist and Tony as a manufacturing expert. A company that specialized in medical beds and seat cushions for wheelchairs approached them and asked them to create a new material that would be supportive and comfortable for patients who were sitting for extended periods of time.
The Pearce brothers set to work and eventually came up with a material that was unlike anything on the market. It was made from a proprietary blend of hyper-elastic polymers, which provided a unique combination of support and pressure relief. The material was also highly durable and easy to clean, making it ideal for use in medical settings.
Later, when Tony’s daughter complained that her mattress was too hard, he came up with the idea for the hyper-elastic polymer grid. Tony realized that the same material they had made for medical use could also be used to make a comfortable and supportive mattress. The Hyper-Elastic Polymer Grid was born, and the first Purple mattress was launched in 2016.
Since then, Purple has become one of the most popular “mattress in a box” companies on the market. Their mattresses are known for their unique feel and innovative technology, and they have received numerous awards and accolades for their products. However, it all started with the invention of a material that was specifically designed for medical use.
The Science Behind Purple Mattresses
The hyper-elastic polymer grid is the key technology that sets Purple mattresses apart from other mattresses on the market. This special material is made to offer a unique mix of support and pressure relief, as well as to be durable and easy to clean.
At its core, the Hyper-Elastic Polymer Grid is a series of hexagonal-shaped columns that are arranged in a grid pattern. These columns are made from a proprietary blend of hyper-elastic polymers, which allows them to compress and expand as pressure is applied. This gives the mattress a unique feel that is both supportive and comfortable.
One of the benefits of the hyper-elastic polymer grid is that it adapts to different body types and sleep positions. As pressure is applied to the mattress, the columns compress in a way that is specific to the individual’s body. This helps spread weight evenly across the surface of the mattress, which reduces pressure points and helps keep the spine in the right place.
Another benefit of the hyper-elastic polymer grid is that it allows for airflow throughout the mattress. The columns are made to be open and free-flowing. This lets air move through the mattress and keeps it from getting too hot. This can help regulate body temperature and promote a cooler, more comfortable sleeping environment.
Overall, the Hyper-Elastic Polymer Grid is a very new and different material that makes Purple mattresses stand out from the rest. It is a top choice for anyone who wants a comfortable and supportive mattress because it can adapt to different body types and sleeping positions and has great airflow.
The Manufacturing Process of Purple Mattresses
The process of making Purple mattresses is very innovative and efficient. It uses cutting-edge technology and eco-friendly methods. Let’s take a closer look at how Purple mattresses are made.
Tour of the Purple Mattress Factory
The Purple Mattress Factory is an impressive facility that spans seven football fields in size. This state-of-the-art factory is where all Purple mattresses are manufactured and assembled.
The use of purple dust in the manufacturing process
The first step in the manufacturing process is the use of purple dust. This is a proprietary material that is used to create the hyper-elastic polymer grid. The Purple Dust feels like a combination of kinetic sand and powdered sugar, and it is the key ingredient that sets Purple mattresses apart from other mattresses on the market.
How the hyper-elastic polymer grid is made using injection molding
The purple dust is melted down and then injected into a massive injection molding machine. This machine pumps out massive sheets of the Purple Grid, which are then cut down into specific mattress sizes, such as twin, queen, king, and California king.
Zero waste manufacturing process
The fact that Purple wants to make no waste is one of the most impressive things about how they make their products. In the process of making mattresses, any extra materials are ground up and saved to be used in future mattresses. This ensures that there is no waste and that the production process is as sustainable as possible.
Overall, making Purple mattresses is a very efficient and environmentally friendly process that uses new technology and environmentally friendly methods. This makes sure that each mattress is of the best quality and has as little effect on the environment as possible.
Putting the mattress together
Once the Purple Grid has been created through the injection molding process, it is time to combine it with the hybrid base to create a complete mattress. Let’s take a closer look at how this process works.
How the Purple Grid is combined with the Hybrid Base
The first step in putting the mattress together is to combine the Purple Grid with the hybrid base. This is done by sending the coils in the base through a machine that adds adhesive to the top layer. The adhesive is then cooked through a red-hot conveyor belt oven, which helps to create a strong bond between the Purple Grid and the base.
The use of adhesive and foam borders
Foam borders are then set around the outside of the mattress on top, where the Purple Grid can then ride up a conveyor belt and be placed inside. These foam borders help to create a smooth transition between the Purple Grid and the base, and they also provide additional support and stability to the mattress.
The Giant Smasher
Once the Purple Grid is all spread out, the machine goes into a giant smasher, which smashes the Purple Grid into the bottom layer and creates a solid bond. This process ensures that the mattress is stable and durable, and it also helps to prevent any sagging or dipping over time.
Overall, the process of putting the Purple mattress together is a highly precise and efficient process that utilizes advanced technology and sustainable practices. The Purple Grid and the hybrid base, along with the use of adhesive and foam borders, make sure that each mattress is of the highest quality and gives the right amount of comfort and support.
Shipping the Mattress
Once the Purple mattress has been manufactured and assembled, it is time to package it up and prepare it for shipping. Let’s take a closer look at the shipping process for Purple mattresses.
packaging process and compression
The first step in the shipping process is to package the mattress. This is done by compressing the mattress down to a small size and rolling it up into a tight bundle. This helps reduce the size of the mattress and makes it easier to ship and handle.
Use of a suction machine to lift and ship the mattresses
Once the mattress has been compressed and rolled up, it is time to ship it out. This is done by using a suction machine to lift the mattress and place it on two giant pallets. The suction machine is capable of lifting up to 240 pounds, which makes it easy to handle even the heaviest mattresses.
The Power Base and its features
In addition to the mattress itself, Purple also offers a power base that can be used with the mattress. This base has motors that allow it to raise the feet and the head, making it easy to find the perfect sleeping position. It is also adjustable, so it can be set to the perfect height for easy transfers in and out of bed.
Overall, the way Purple mattresses are shipped is very efficient and makes sure that each one arrives in perfect shape. The use of a suction machine to handle and ship the mattresses, along with the optional Power Base, makes it easy to customize and personalize each mattress to meet the needs of each individual sleeper.
Purple mattresses are made to give each sleeper a unique and comfortable experience that adapts to his or her own needs. Let’s take a closer look at some of the key features of the Purple Mattress customer experience.
Thickness options for the mattress
Purple mattresses come in a range of thickness options, including 2″, 3″, and 4″. This allows customers to choose the perfect level of comfort and support for their individual needs.
How the Purple Grid provides a balance between softness and firmness
One of the key features of Purple mattresses is the hyper-elastic polymer grid. This grid is designed to provide a balance between softness and firmness, allowing it to dynamically adapt to the needs of each individual sleeper. This means that the mattress will conform to the shape of the body, providing the perfect level of support and comfort for each person.
The 100-day trial and 10-year warranty
Purple offers a 100-day trial period for all of their mattresses. This allows customers to try out the mattress in the comfort of their own home and see if it meets their needs. If for any reason the customer is not satisfied with the mattress, Purple will come and take it away for free and provide a full refund.
In addition to the 100-night trial period, Purple also backs their mattresses for 10 years. This warranty takes care of any problems or flaws with the mattress and gives customers peace of mind.
Overall, Purple mattresses are made to make the customer’s life simple, easy, and comfortable. The range of thickness options, the unique design of the Purple Grid, the trial period, and the warranty all work together to provide a top-quality sleeping experience that is tailored to the needs of each individual customer.
In this article, we looked at Purple mattresses’ history, science, how they are made, and how customers feel about them. We have seen how Purple mattresses began as medical beds and seat cushions for wheelchairs and how the invention of the Hyper-Elastic Polymer Grid has revolutionized the mattress industry.
We have also looked into how Purple mattresses are made, including how Purple Dust, injection molding, and a process with no waste are used. We have seen how the Purple Grid is combined with the hybrid base to create a durable and comfortable mattress.
We’ve also talked about how Purple mattresses work for customers, such as the different thickness options, the unique design of the Purple Grid, the 100-day trial, and the 10-year warranty.
Final thoughts on Purple mattresses
Overall, Purple mattresses are a high-quality and innovative product that makes sleeping in a unique and comfortable way. The combination of the Hyper-Elastic Polymer Grid with the hybrid base, along with the sustainable manufacturing process and customer-focused approach, make Purple mattresses a great choice for anyone in search of a comfortable and supportive sleeping surface.
If you are in the market for a new mattress, we highly recommend checking out Purple mattresses and experiencing the comfort and support for yourself.
Can the hyper-elastic polymer grid be customized for individual needs?
Unfortunately, the hyper-elastic polymer grid cannot be customized for individual needs because it is manufactured in a specific way. However, the Grid is designed to adapt to different body types and sleep positions, providing a comfortable sleep experience for most people.
Are purple mattresses suitable for people with back pain?
Yes, purple mattresses can be suitable for people with back pain. The hyper-elastic polymer grid provides a balance between softness and firmness, which can support the spine and alleviate pressure points. However, it is always recommended to consult with a healthcare professional before purchasing a mattress for back pain.
How long do Purple mattresses typically last?
Purple mattresses are designed to last for a long time. They come with a 10-year warranty, which shows that the company stands behind their product. With proper care and maintenance, a Purple mattress can last even longer.
How does the Power Base work?
The Power Base is a motorized base that can be adjusted to raise the feet and head of the bed. It also has an adjustable height feature, which can make it easier for people to transfer in and out of the bed. The Power Base is controlled using a remote, making it easy to adjust the bed to the desired position.
Are Purple mattresses eco-friendly?
Purple mattresses are eco-friendly in the sense that they have a zero waste manufacturing process. The excess material from the manufacturing process is ground up and preserved to be used in future mattresses, which reduces waste. Additionally, Purple mattresses are CertiPUR-US certified, which means that they are made without harmful chemicals such as formaldehyde and heavy metals.