Convoluted Foam - Egg Crate Foam

What is convoluted foam?

Convoluted foam was designed as an inexpensive method of doubling foam production. By splitting the foam in half and carving points into it (like an egg crate), you get two 4 inch thick sheets of foam out of one 4 inch thick sheet of foam. This is great for acoustic reasons, or to lower cost of packaging in crates, cases or to use as a mattress topper... but this type of modified foam does not belong "inside" a mattress.

In recent years, mattress manufacturers have been looking for way to cut costs. So along comes the use of acoustic foam. Since they can double their foam production by making convoluted foam, they began to use egg crate foam inside the core of their mattresses. This is great, as they get the same mattress thickness, while saving money! The only problem is that you are paying for air, because half the original foam is missing! Everyone agrees that you need a minimum 2 lb density poly-foam for a durable support core. Convoluted foam removes half the weight of the foam, so you are left resting on small foam spikes (egg crates). In our opinion this weakens the support core and is insufficient for proper orthopedic support because the egg crates eventually collapse as a result of excessive body weight.

Marketing
In order to promote the convoluted foam layer as a good thing,  they give it a fancy name like an airflow system. However it's simple to see how this system fails. Since there is no way for the warmer air from the memory foam sleeping surface to reach the convoluted foam layer in the center core of the mattress. Plus there is no air left inside the mattress anyway, because the foam egg crates are crushed by your body weight and pressure.

Here is an example of this marketing hype and the actual customer comments Under SLEEPS HOT  and more here....

Experience
We have been selling mattress toppers for over 15 years. Our biggest complaint from customers, is that their mattresses are just not as comfortable as they used to be. Customers are trying to fix a mattress that is sinking and offering less support than it used to. The most common cause for this weakness is the use of low density foam (1.5LB or less), or a layer of convoluted foam (or both) in the support core. Unfortunately we cannot solve this problem, as the source of the dilemma lies in the mattress support core. The only option left for the disappointed customer, is to live with this issue, or buy a new mattress!

The proper way to build a mattress, is to use solid, non altered, high density foams in the core and transition layers of the mattress. This method is unpopular as it results in more expensive mattresses. However, the outcome is increased durability and proper support, because the integrity of the mattress has not been compromised by convoluted or lower quality (density) foams inside the mattress.

Suggested use for egg crate foam:

A high density (HD) convoluted foam is often used as a mattress topper or padding to add extra cushioning to a mattress, making it more comfortable to sleep on. It can also be used in other applications, such as in seat cushions, packaging materials, and soundproofing.

The main benefit of egg crate foam is its ability to distribute weight and pressure evenly across the mattress surface surface, which can help reduce pressure points and improve circulation and is a popular choice for those seeking to add comfort to their mattresses or other seating surfaces.

Shop egg crate foam here