Process for applying foam material

Claim 1

A process for spreading foam material relatively free of undesirable air bubbles, blisters, or blotches, in the form of large or irregular spots or blemishes, and substantially uniformly in thickness across the full width of continuously advancing sheet material comprising: supplying foam material having a predetermined density of from about 17 pounds per cubic fott to about 22 pounds per cubic foot to a chamber which does not increase in cross-sectional area and does, at least in part, gradually and constantly decrease uniformly at a steady rate to form a delivery nozzle-- filling said chamber substantially completely with said foam material at said predetermined density; pumping said foam material forwardly within said chamber under a relatively low amount of pressure which does not exceed about five pounds per square inch gauge and wherein the pressure drop from the point of entry into said chamber to the point of exit therefrom does not exceed about five pounds per square inch gauge; maintaining the predetermined density of said foam material in said chamber substantially constant from point of entry thereto to point of exit therefrom; delivering said foam material from said chamber and spreading the same substantially uniformly in thickness and relatively free of undesirable air bubbles, blisters, and blotches, in the form of irregular spots or blemishes, across the full width of continuously advancing sheet material; and regulating and controlling the amount and the thickness of said foam material being spread on said continuously advancing sheet material, said regulating and controlling taking place immediately following said delivery of said foam material.