Process and apparatus for making air-filled cellular structures for use as resilient cushions

Abstract

A method for fabricating an air-filled cellular structure for use as a resilient cushion. The method includes providing a molding structure including a shelf substantially surrounding a depression, and a platform that fits within the depression and is selectively movable between a plurality of positions relative to the shelf, moving the platform to a preselected position relative to the shelf, wherein the preselected position corresponds to a substantially predetermined amount of air to be contained by the air-filled cellular structure, and using a vacuum device to draw air from within the depression. The method further includes engaging a first portion of a first expanse of generally air-impermeable material with the shelf, whereby the vacuum device draws a second portion of the first expanse of material against the moveable platform, and bonding a first portion of a second expanse of generally air-impermeable material to the first portion of the first expanse, thereby enclosing a volume of air between the first and second expanses. The method may further include bonding a third portion of the first expanse to a second portion of the second expanse, thereby decreasing the volume of the air enclosed between the first and second expanses.

Dependencies are inferred from the claim text.