Apparatus and methods for applying discrete foam coatings

A method for applying a discrete foam coating to a discrete areas of a substrate and comprising the steps of:

• extruding foam coating material from an elongated slot nozzle and in the form of a film;
• impinging air at an angle onto extruding coating material film and from both sides thereof;
• then depositing extruded coating material film onto said substrate;
• and
• starting and stopping the extrusion of coated material and the flow of impinging air at different times to produce said discrete foam coating with even leading and trailing edges on a discrete area of said substrate.

A method of producing discrete foam coatings comprising the steps of:

• intermittently supplying foam material to the slot of a slot nozzle die;
• dividing the foam material in said slot into a plurality of extruding streams of material emanating from said slot nozzle die in separate streams;
• merging the streams together to form an unbroken stream of foam material in the form of a film;
• and
• impinging a flow of air on both sides of said unbroken stream to produce a foam coating in the form of a film for deposition onto said surface and for carrying said foam coating horizontally onto said surface;
• and
• discontinuing the supply of foam material to said slot for thereby producing a discrete foam coating.