Method of manufacturing a zero base convolute pad

Abstract

A foam mattress pad of adjustable size has an initial predetermined length, width and thickness. The pad is provided with punched areas or holes, preferably in rows or columns forming a guide for cutting or tearing away strips of foam material to decrease the size dimensions of the pad. In a preferred embodiment, the holes are formed in rows or columns in the base of troughs between peaks of a convoluted surface of the mattress pad. The holes in the troughs may be separately punched or cut before or after the foam is convoluted. Preferably, the holes in the troughs are formed as the foam is cut by the band knife blade during one pass between convolute rollers. Longer projecting fingers are applied to some portions of the convolute roller to achieve the holes in the bases of the troughs. The mattress pad so formed may be sold in a large size, such as queen or king, and reduced by the consumer to a desired smaller size, such as twin or full, by tearing or cutting away strips of foam material along the punched area guide.

Dependencies are inferred from the claim text.