Patent ID: 7666341

Claim:
A screed mold method for making gelatinous elastomer gel cushioning articles, the method comprising the steps of: attaching side rails around a perimeter of an open face screed mold, the screed mold including a plurality of crisscrossing slots in a rigid body forming a honeycomb shape defining at least one mold core, providing a separate injection head, the injection head having a plurality of distribution channels therein through which thermoplastic material may flow, and including at least one heating element within it for heating thermoplastic material, positioning the injection head adjacent the screed mold so that thermoplastic material may flow from the distribution channels into at least one of the plurality of crisscrossing slots, utilizing a pumping source to introduce thermoplastic material into the injection head, and using the plurality of distribution channels of the injection head to deliver thermoplastic material into at least one of the plurality of crisscrossing slots in the screed mold, displacing the screed mold and the injection head relative to each other causing the thermoplastic material to be level, and recovering molded and cooled thermoplastic material from the screed mold in a desired geometric shape of a cushioning element.