Abstract: A method of forming a spring cushion construction comprising a foamed pad having a generally flat inner surface with a depending peripheral edge, the flat inner surface including a dense outer crust. A spring assembly is disposed so that the terminal face portions thereof contact the outer crust and with the depending edge of the pad confiningly receiving the spring assembly to prevent lateral displacement therebetween. The pad is formed by a method which includes foaming a foamable material in an open top mold while leveling the upper surface of the foamable material in a manner which does not interfere with the formation of a dense outer crust thereon. The depending foam edge may then be formed by adding additional foamable material along the periphery of the pad, or by suitably attaching a preformed foam strip therealong.

Abstract: An apparatus for fabricating foam pads having a generally flat inner surface with a depending peripheral edge, the flat inner surface including a dense outer crust. A spring assembly is adapted to be disposed so that the terminal face portions thereof contact the outer crust and with the depending edge of the pad confiningly receiving the spring assembly to prevent lateral displacement therebetween. The apparatus includes an open top mold, and a mold insert which is adapted to be floatingly positioned on the upper surface of the foaming material to level the same while permitting the formation of a dense outer crust thereon. The depending foam edge may then be formed by adding additional foamable material along the periphery of the pad between the border of the mold and mold insert, or by suitably attaching a preformed foam strip therealong.