Abstract: An apparatus for shaping a slab of compressible or cellular polymer material (80), such as polyurethane foam, shapes such slab by cutting portions of the material from one surface. A moving patterned platform (32), preferably an endless belt or a series of interconnected panels, is interposed between a compression roller (56) and a cooperating surface (18) and defines at least one recess (36) or at least one projection (320) or a combination of recesses and projections. When the slab is compressed between the compression roller and the platform, which is supported by the cooperating surface, a portion of the material fills the recess or recesses in the moving platform.

Abstract: A method for shaping a slab of polyurethane foam (80) cuts portions of the foam material from one surface. A moving patterned platform (32) is interposed in a gap formed between a compression roller (56) and a drive roller (18) and defines at least one recess (36). The slab is introduced into the gap and foam material is compressed into the recess. At least a portion of the compressed material within the recess is then cut from the surface of the slab by a blade (76) just as the slab emerges from the gap to produce a profile-cut surface with a shaped portion corresponding to the shape of the recess in the patterned platform.

Abstract: An apparatus for continuously shaping a compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from a surface of a slab of the material includes a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. The blade then transversely cuts from the surface of the slab a portion of the material within the recesses in the platform just as the slab emerges from between the compression roller and the support surface.

Abstract: A method for shaping a slab of compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from one surface uses a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. At least a portion of the compressed material within the recesses is then cut from the surface of the slab by the blade just as the slab emerges from between the compression roller and the support surface.

Abstract: A machine for rotary cutting of continuous synthetic foam sheets while compressed between two rollers has a roller drive featuring individually adjustable roller speed to allow use of rollers of dissimilar diameter, such as a large diameter pattern roller and a small diameter compression roller. The roller drive may be selectively engaged for driving each roller with a separate drive motor or both rollers with a single motor through a gear train, allowing conversion of the machine to conventional foam convoluting using similar sized rollers.

Abstract: Apparatus for continuously shaping a compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from a surface of one or more slabs of material (180) includes two compression rollers (146, 146a), two moving patterned platforms (132, 132a) interposed between the compression rollers, and one or more cutting blades (76) for transversely cutting the slab or slabs just as the cellular material emerges from between the compression rollers. At least one of the moving patterned platforms, preferably an endless belt, defines a recess or pattern of recesses. When a single slab or multiple slabs of material are fed and compressed between the compression rollers, a portion of the material from one side of the slab or slabs fills the recess or recesses in one of the moving patterned belts. The blade then transversely cuts the cellular material.

Abstract: A resilient material shaped into a bent strand with a preferred length from 1.5 to 7 inches forms a filling element for cushions, pillows and upholstered articles. The strand may be bent so as to have a Z-shape or an S-shape or a V-shape or a C-shape along a portion of its length. The length of the strand is greater than its nominal cross-sectional thickness. A quantity of filling elements (e.g., the filling material), preferably formed from flexible, open cell polyurethane foam, is inserted or blown into a casing for a cushion, pillow or upholstered article. Following compression, the filling elements rebound substantially to their uncompressed state without clumping together or leaving pockets within the casing.

Abstract: Methods for continuously shaping a compressible or cellular polymer material such as polyurethane foam, by cutting portions of the material from a surface of one or more slabs of material (180) include (a) compressing one or more slabs of cellular material between a pair of compression rollers (146, 146a) and two moving patterned platforms (132, 132a) interposed between the compression rollers, and (b) transversely cutting the slab or slabs with a blade or blades (76) just as the cellular material emerges from between the compression rollers. At least one of the moving patterned platforms, preferably an endless belt, defines a recess or pattern of recesses. When a single slab or multiple slabs of material are fed and compressed between the compression rollers, a portion of the material from one side of the slab or slabs fills the recess or recesses in one of the moving patterned belts. The blade then transversely cuts the cellular material.