Method and apparatus for rolling and packaging convoluted foam pads

Claim 1

In a method of packaging a rollable and compressable foam pad with a continuous flexible sheet material divided into a plurality of sections separated by transverse pre-weakened lines, the sections having a length greater than the circumference of the foam pads when the pad is in a rolled and compressed condition and a width greater than the length of the foam pad when the pad is in a rolled and compressed condition, the steps comprising: a. feeding the continuous flexible sheet material to a set of clutch-brake nip rolls; b. engaging the clutch-brake nip rolls to feed the continuous flexible sheet material into a set of drive nip rolls; c. guiding the flexible sheet material during its travel between the nips of the clutch-brake nip rolls and the drive nip rolls; d. braking the clutch-brake nip rolls while the drive nip rolls are engaged in advancing the continuous flexible sheet material, so that a tension is exerted on the continuous sheet material sufficient to tear the sheet material along the transverse pre-weakened line and separate a single section from the length of the continuous sheet material; e. synchronously feeding the foam pad, in a non-compressed condition, and the separated single section in a predetermined direction and into adhesive contact such that a trailing portion of the pad in said direction of feeding adheres to a leading portion of the separated single section; and f. rolling and compressing the foam pad thereby causing the single section to completely wrap around the exterior of the pad and maintain the pad in a rolled and compressed condition.