Abstract: A cushion includes a core, a shell surrounding the core, and a flexible membrane interposed between the core and the shell. Both the core and shell are formed from foam material, with the foam material of the core being substantially stiffer upon initial loading than the foam material of the shell. The membrane is also formed from foam material, but is quite a bit denser than the foam material of either the core or shell. The overall effect of the membrane and the different load bearing characteristics for the two foam materials is a cushion which is quite soft to touch, but nevertheless capable of supporting heavy loading without excessive deflection. The cushion is produced by placing the core, which is cut from slab foam, into a mold cavity and then molding the shell about it.

Abstract: A fabric backed cellular cushioning material is produced in a mold by introducing a liquid reaction mixture into a mold cavity and then covering the mold cavity with a coposite material consisting of a fabric backing and a thin layer of preformed cellular material attached to the backing. The preformed cellular material is presented toward the mold cavity. The reaction mixture expands into a cellular cushioning material, which assumes the shape of the cavity, the expansion being sufficient to enable the molded cellular material to completely fill the cavity and diffuse partially into as well as adhere to the preformed cellular material. The air displaced by the expanding reaction mixture passes out of the mold cavity through the preformed layer of cellular material, but once the expanding cellular material reaches the preformed layer, the mold cavity is sealed.

Abstract: A liquid reaction mixture from which soft cellular material is derived is poured into a moving mold where it begins to expand. Beyond the point at which the reaction mixture is poured, the bottom wall of the mold is deformed between its sides and this causes the expanding mixture to flow laterally so that the mixture expands into a desired configuration. The foregoing process is carried out on a conveyor having an endless belt and rollers for deforming the upper pass of the belt between the sides thereof. The mold is a flexible film material which is supported on and propelled by the belt.