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Simmons Beautyrest Mattress Rebuild 12 Jan 2021 13:32 #21

You can purchase a zippered mattress cover directly from purple, just tell them which one you want. I have bought the purple hybrid premier (.4) cover from them. It was $181 in the twin xl size and it fits a 13" thick mattress. You could get the original 9", purple hybrid 11", hybrid premier (.3) 12".

Intellibed makes a topper which is made by edizone llc which is owned by purple so purple sort of does make a topper. I have it, it was $762 but this was the older cal king topper without the 1" serene foam on top. I didn't want the foam on top to maximize breathability. I cut it down w/an electric knife to fit my twin xl bc I didn't all the polyfoam that surrounds the grid. The polyfoam does serve a purpose though it gives the topper edge support. That's why I left a little on both sides. I've been reading up on serene foam & it's supposed to be more open cell than regular polyfoam & more breathable so maybe the new style "luxury toppers" from intellibed don't sleep too hot. I know the new version in twin xl is $699+.

If you want to experiment with the purple grid from purple mattresses you can find many trial returns on eBay for a fraction of the cost of a new one. I decided I wasn't comfortable buying used bedding so I bought 3 new ones (two hybrid. 2's) and one original. You can pull the grid out of a brand new one quite easily & experiment with it.


Fantastic info Mr Yabo, much appreciated! It will at least allow me to experiment with different materials to make sure my design isn't bottlenecking because of the mattress cover.

For others in case they are looking for mattress covers.

Purple replacement covers:
shop-ca.purple.com/products/replacement-mattress-cover?variant=44638360394

Tempurpedic replacement covers:
www.tempurpedic.com/bedding/mattress-replacement-cover/v/3164/

If the intellibed toppers are over $1000 for a king then I'll likely just try to get a used Purple bed and salvage materials so I can see what works best. Any chance you have any photos of inside the topper so I can see how much gel and foam there are in there?

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Last edit: by NikkiTMU.

Simmons Beautyrest Mattress Rebuild 12 Jan 2021 17:05 #22



This is a picture of the foam to gel ratio. Mine has maybe an inch of foam on each side instead of the 6" you see in the picture I found just doing a search for the intellibed topper. Also mine had a layer of fabric on top of yhe grid referred to as scrim. Its like a layer of thin cloth attached to the top of the grid.
Attachments:

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Simmons Beautyrest Mattress Rebuild 12 Jan 2021 17:18 #23

www.google.com/url?sa=t&source=web&rct=j&url=https://www.youtube.com/watch%3Fv%3DsWTXuVfd6wY&ved=2ahUKEwj2juyP3ZfuAhUOZd8KHZPZCdAQwqsBMAV6BAgwEAw&usg=AOvVaw2m8m9I-2Ht6mIjeA8qY2gI


At 4:10 in to the video you can see what the cloth layer looks like on top of the grid but I don't know if they still use it on the new "luxury" intellibed toppers with the serene foam on top. They no longer sell the old style topper that I have without the serene foam on top.

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Simmons Beautyrest Mattress Rebuild 12 Jan 2021 17:23 #24

Mattrebuild wrote:
Fantastic info Mr Yabo, much appreciated! It will at least allow me to experiment with different materials to make sure my design isn't bottlenecking because of the mattress cover.


No problem ☺

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Simmons Beautyrest Mattress Rebuild 12 Jan 2021 18:16 #25

So I went ahead and ordered a replacement King mattress cover from Purple tonight. Can’t wait to give it a try and see what sort of difference it makes in the feel of the comfort layers. I’ll definitely post some photos once I get it all installed.

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Simmons Beautyrest Mattress Rebuild 13 Jan 2021 04:26 #26

Sounds great ☺

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Simmons Beautyrest Mattress Rebuild 14 Jan 2021 10:03 #28

I had assumed the mattress cover coming from Purple was being shipped from within Canada since they had a Canadian specific website to order from, you pay in Canadian dollars and they even included HST on the order. I get a tracking number that says the cover should be here by tomorrow so I think wow, this is great! Then I look at the address and it says Utah which has me a bit worried but shipping still says free on the Purple invoice so what could go wrong. That euphoria quickly changes when Fedex calls and claims I owe $107 in taxes and duties. I explained to them that I already paid the taxes on my order from Purple and that there are no duties on items made in the US (I verified the situation with the CBSA). I also called Purple customer service to ensure the mattress cover was made in the US and they confirmed that all actual mattress components are in fact made in the US (if you call them, the invoice number is a Shopify order number, not an actual Purple invoice number so they will need to look that up to get your details). I was told by Fedex the only way to contest the charges was to email their dispute center and they would get back to me in 4-5 days (while still holding your package hostage in the meantime). This is exactly why I avoid international shipping with Fedex, UPS and DHL (only good one is Canada Post but they are SLOW) like the plague. Anyway just be forewarned if others go the same route. I'll keep folks up to date when/if I finally receive it.

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Simmons Beautyrest Mattress Rebuild 15 Jan 2021 06:45 #29

Well, I finally received the mattress cover but I'm still out the $107 for duties and taxes because Fedex washes it's hands in the process. It looks like the error actually started with someone at Purple when they filled out the shipping invoice wrong (value was done in USD not CAD and they put the HST as a shipping charge when it wasn't) which created a massive ripple effect through the system. It looks like I will have to maybe file with the CBSA to get a refund on the taxes and duties and if that doesn't work I may ask Purple to help cover costs but at least I have the cover to fix my bed. I'll post some pics when I get it all installed and let everyone know how it worked out.

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Simmons Beautyrest Mattress Rebuild 16 Jan 2021 06:36 #30

So I had a chance to get the new mattress cover on last night and all I can say is WOW! I can't believe I was overlooking this component of the mattress design which now seems so obvious. I took a photo of my fist pushing into the bed on both the old and new cover so you all can see how well the new one conforms versus the old pillow top cover. If you are a curvy person then point elasticity is a big problem on most beds (made even worse when they use poor quality foam), you can see what I mean in the video below. The old pillow top style covers seem to rely heavily on the very light foam on the top for pressure relief, but when that breaks down (as it did on mine) you lose that conforming feel very quickly. Also the old cover has very little stretch so that seriously limits what the foam layers below can do (no matter how soft they are) to conform to your specific body shape.

www.youtube.com/watch?v=xsn_nzoJoOg (elasticity demo starts around the 2:13 mark)

Here's my old cover:


Here's the new cover:


Final result looks great too!


I will say the design of the Purple cover is such that the zipper is at the bottom which makes it a major pain to swap out comfort layers (I would look for a stretchy cover with a zipper around the middle or top if you were just getting starting on designing your own bed and adjusting layers often) but the end result was so worth it. The performance of this new cover is absolutely night and day compared to the old one. You can really feel it allow the latex foam layers below do their job much more than before. I always had trouble with the bed supporting my waist while on my side and my lower back while lying face up but with this new setup you can really feel it fill in those areas nicely. Last night I tried the 3" soft (20ILD) and the 3" medium (30ILD) combo and it was just a bit too stiff on the pressure relief while my wife had a soft/soft combo and said hers was absolutely amazing so I may try that combo tonight. I will continue to make a few more layer changes just to get the best pressure relief possible but very happy overall, feels great now. This is definitely a setup I could sleep on for years without issue.

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