Polyurethane (PU) foam is a material derived from petroleum used widely in modern mattresses, pillows, and upholstered furniture. This synthetic material is valued for its durability, flexibility, and ability to conform to the body, particularly in the form of memory foam. Concerns frequently center on the substances used in the manufacturing process and those added to the material to meet performance or safety standards. Understanding the specific chemical factors involved allows for a clearer assessment of the overall safety of sleeping on a PU foam product.
Volatile Organic Compounds and Off-Gassing
The most immediate concern with new polyurethane foam products is the emission of Volatile Organic Compounds (VOCs). VOCs are carbon-containing chemicals that vaporize easily at room temperature, releasing into the surrounding air in a process commonly referred to as off-gassing. This distinctive chemical odor associated with a new mattress results from residual manufacturing components, such as toluene di-isocyanate (TDI) or methylene diphenyl diisocyanate (MDI), which did not fully react during the foaming process.
Specific VOCs detected can include formaldehyde, benzene, and toluene, though concentrations are highest immediately after the product is unsealed. Studies on new memory foam mattresses have shown that VOC emissions peak during the first day of use and then decrease steadily over the following month. For most individuals, the levels of VOCs released fall below established indoor air quality benchmarks and are considered unlikely to cause major health risks.
The initial exposure can still trigger temporary, acute symptoms in individuals who are chemically sensitive or have existing respiratory conditions. These short-term health effects may include irritation of the eyes, nose, or throat, as well as headaches, nausea, or dizziness. To mitigate this initial exposure, the most common strategy is to “air out” the new mattress by removing it from its packaging and placing it in a well-ventilated space for several days or up to a week before using it. This process allows the majority of the residual VOCs to dissipate safely outside of the sleeping environment.
Fire Retardants and Other Additives
A separate set of chemicals in polyurethane foam are those intentionally added to meet specific performance requirements. Federal regulations in the United States, specifically 16 CFR Part 1633, mandate that all mattresses must resist ignition from an open flame to slow the spread of fire. Historically, manufacturers often achieved this compliance by incorporating chemical fire retardants (FRs) directly into the polyurethane foam.
Older classes of FRs, such as Polybrominated Diphenyl Ethers (PBDEs), were phased out due to concerns over neurological and hormonal disruption. Today, the industry has largely shifted away from incorporating FR chemicals into the foam itself. Instead, most mattresses comply with the open-flame standard by using non-chemical fire barriers.
These modern barriers typically involve layers of materials like silica or inherent flame-resistant fibers wrapped around the foam core. This physical barrier method prevents the direct exposure of the combustible polyurethane to a flame, avoiding the need for chemical FRs within the foam layer. Other additives can include antimicrobial treatments, colorants, and phthalates, which may be present in adhesives or fragrances added to mask off-gassing odor.
What Certifications Mean for Safety
To provide consumers with clarity regarding the chemical content of their bedding, several independent, third-party certification programs now exist. These certifications verify that the polyurethane foam meets stringent standards for content and emissions, offering an objective measure of safety. The most widely recognized of these is the CertiPUR-US certification, which specifically applies to the flexible polyurethane foam material used in mattresses and upholstered furniture.
A foam that carries the CertiPUR-US seal is certified to be made without ozone depleters, heavy metals, formaldehyde, or certain phthalates regulated by the Consumer Product Safety Commission. Critically, this certification also requires that the foam meet a strict standard for low VOC emissions, with total emissions limited to less than 0.5 parts per million. This low-emission standard directly addresses the concern of off-gassing and indoor air quality.
Another significant certification is the OEKO-TEX Standard 100, which is often applied to the fabric and other textile components of the mattress, rather than the foam itself. This standard tests every component of a textile product for harmful substances, ensuring the final product is safe for human use. By seeking out mattresses that display these certifications, consumers can make purchasing decisions based on objective testing of the polyurethane foam and surrounding materials.