Method of manufacturing evaporative cooler pads

A method for manufacturing evaporative cooler pads from a supply of mat material, comprising the steps of:

• forming said supply of mat material into an elongated mat on a first conveyor belt assembly;
• cutting a mat out of said elongated mat;
• forming a gap between said mat and said elongated mat by using a second conveyor belt assembly moving at a higher speed than said first conveyor belt assembly to pull said mat away from said elongated mat;
• placing a mesh netting against said mat and in said gap to enclose said mat and said gap in said netting by applying an upper netting layer against an upper surface of said mat and a lower netting layer against a lower surface of said mat;
• applying one or more rows of stitching to said netting against said mat and in said gap to bind said netting to said mat and to connect said upper netting layer to said lower netting layer in said gap;
• applying an adhesive to said netting and said stitching in said gap to seal said gap;
• and
• cutting said netting and said stitching in said gap.

A method for manufacturing evaporative cooler pads, comprising the steps of:

• placing a plurality of mats of absorbent material on a first conveyor belt assembly, forming a gap between said mats by using a second conveyor belt assembly moving at a higher speed than said first conveyor belt assembly;
• placing a lower netting layer under said plurality of mats and an upper netting layer over said plurality of mats to enclose said mats and said gap between said lower netting layer and said upper netting layer;
• applying one or more rows of stitching to said lower netting layer and said upper netting layer against said mats and in said gap to bind said lower netting layer and said upper netting layer to said mats and to interconnect said lower netting layer and said upper netting layer in said gap;
• pulling said mat, said lower netting and said upper netting layer with a double draw roller;
• and
• cutting said lower netting layer and said upper netting layer in said gap.