Method and apparatus for making foam-in-place cushions with selective distribution of foam

An apparatus for making foam-in-place cushions, comprising:

• a film supply and guide system for supplying a pair of continuous polymer film portions extending along a longitudinal direction and for positioning the film portions in parallel opposing relation to each other;
• a dispenser disposed between the film portions and operable for dispensing a foam-forming composition between the film portions, the foam-forming composition being operable to react to form an expanded polymer foam material;
• a film drive mechanism structured and arranged for advancing the film portions in the longitudinal direction, the film drive mechanism including a drive roller rotatable about an axis and positioned to contact one of the advancing film portions, and a pair of transversely spaced driven rollers that form nips with the drive roller, opposite longitudinal edges of the film portions passing through the nips and being frictionally engaged and advanced by the drive roller;
• and
• a dispersion member extending along an axis spaced from the axis of the drive roller and spaced from an axis about which the driven rollers rotate, the dispersion member being structured and arranged to apply pressure on predetermined areas of one of the advancing film portions towards the other so as to cause the foam-forming composition to be redistributed while the foam-forming composition is in a less than fully expanded state.