Abstract: A structure for protectively supporting and spacing rolls of web material in a multi-layer stack. The structure includes an elongated member of expandable polystyrene material having a pair of opposed surfaces. A first of the surfaces has a plurality of spaced parallel generally semi-cylindrical indentations disposed to receive rolls of web material. The radius of each of the semi-cylindrical indentations being greater than the depth of the indentation so that the rolls will be snugly retained within indentations in a pair of members and the members will be out of contact with each other. The member has a plurality of cavities located on the lateral edge surfaces thereof extending transversely of the axis of the semi-cylindrical indentation to render the expanded foam material substantially uniformly thick throughout to enhance uniform curing thereof.

Abstract: A molded sheet of expandable polystyrene material has a generally rectangular shape and a plurality of spaced, parallel openings extending therethrough. The openings are arranged in spaced, parallel rows. In a preferred embodiment, a plurality of cavities are molded into the surface of the sheet to minimize deformation during molding as the sheet cures. A stack of such sheets is placed in a single grid electric wire cutter having a plurality of spaced, parallel, hot wires, and the wires are simultaneously passed through the stack to cut each sheet into plural elongated members, the surface of each of the openings in any given row of openings being substantially bisected into two substantially semicylindrical portions by a respective one of the wires. The elongated members thus obtained are adapted for use in protectively supporting and spacing a plurality of rolls of material such as cellophane in a multi-layer stack for storage or shipping.