Patent ID: 8501061

Claim:
A method for making foam-in-place cushions, comprising the steps of: providing a pair of continuous polymer film portions extending along a longitudinal direction and positioning the film portions in generally parallel opposing relation to each other; advancing the film portions along the longitudinal direction; dispensing a foam-forming composition between the film portions using a foam dispenser, the foam-forming composition being operable to react to form an expanded polymer foam material, the dispenser being controllable to be either in an “on” state wherein foam-forming composition is dispensed from the dispenser or in an “off” state wherein dispensing of the foam-forming composition is stopped; while making a given cushion, controlling the distribution of the foam-forming composition in a thickness direction, which is generally orthogonal to the longitudinal and transverse directions, by regulating a position of a dispersion device along the thickness direction, the dispersion device being structured and arranged to apply pressure on predetermined areas of the film portions in the thickness direction while the foam-forming composition is in a less than fully expanded state, wherein the dispersion device defines a gap between first and second film-engaging members through which the advancing film portions pass with the foam-forming composition therebetween, and wherein the position of the dispersion device is regulated so as to regulate a width of the gap in the thickness direction; and additionally performing at least one of the following operations while making a given cushion: (i) controlling the distribution of the foam-forming composition in a transverse direction, which extends widthwise of the film portions, by moving the dispenser in a predetermined manner along the transverse direction and dispensing foam-forming composition while the dispenser is located at two or more locations differing in position along the transverse direction; and (ii) controlling the distribution of the foam-forming composition in the longitudinal direction by advancing the film portions in the longitudinal direction and dispensing foam-forming composition from the dispenser while the dispenser is located in two or more locations differing in position along the longitudinal direction relative to the film portions.