Patent ID: 7007356

Claim:
A method of forming a cushioning pad comprising the steps of: providing a first web of a first material; a second web of a second material; and a component of a third material; placing the component on the first web; covering the component with the second web; compressing the component to a substantially flattened state between the first web and the second web, as the first web, the component and the second web simultaneously pass through a gap formed between a pair of pressing members; attaching the second web to the first web to form a seam completely surrounding the component, thereby encapsulating the component, as the first web, the component and the second web simultaneously pass through the gap formed between the pair of pressing members; forming an opening in at least one of the first web, the second web, or in a seam between the first web and the second web, which opening passes to the component; and allowing air to pass through the opening into the component, such that the component expands in size from its substantially flattened state.