Expandable web with in-situ combination of expansion material components

A method for making an expansion-wall web, comprising:

• applying, by depositing with a matrix applicator, a matrix to a first ply;
• applying an expansion element to a surface of the matrix after the matrix is dispensed from the matrix applicator and before the matrix is deposited on the first ply to provide an expansion material;
• and
• applying a second ply over the first ply to trap the matrix and expansion element therebetween,
• wherein the matrix is selected such that, after activation of the expansion material, the matrix expands and the expanded matrix solidifies to provide padding between the first and second plies.

A device for producing an expansion-wall web, the device comprising:

• a matrix applicator for applying a matrix to a first ply;
• an expansion element applicator to apply an expansion element onto the surface of the matrix;
• and
• an entrainment device for inserting the applied expansion element into the matrix, such that activation of the expansion element will cause the matrix to expand to and solidify in, an expanded condition.