Process and apparatus for making air-filled cellular structures for use as resilient cushions

Abstract

A method for fabricating an air-filled cellular structure for use as a resilient cushion is disclosed in the present application.

1 .- 16 . (canceled) 
     
     
         17 . A method for fabricating an air-filled cellular structure for use as a resilient cushion, comprising:
 bonding a first portion of a first expanse of generally air-impermeable material to a first portion of a second expanse of generally air-impermeable material, thereby enclosing a volume of air between the first and second expanses; and   bonding a second portion of the first expanse to a second portion of the second expanse, thereby decreasing the volume of the air enclosed between the first and second expanses.   
     
     
         18 . The method of  claim 17 , wherein the step of bonding the second portions of the first and second expanses includes clamping the second portions of the first and second expanses together with opposing clamping members, and heating the second portions of the first and second expanses. 
     
     
         19 . The method of  claim 18 , wherein each of the opposing clamping members includes one of a pair of opposing heat-conductive members and one of a pair of opposing insulating members partially surrounding its corresponding heat-conductive member, wherein the pair of opposing heat-conductive members are adapted to clamp together and heat the second portions of the first and second expanses, and the pair of opposing insulating members are adapted to clamp together selected portions of the first and second expanses adjacent to the second portions of the first and second expanses. 
     
     
         20 . The method of  claim 17 , wherein the step of bonding the second portions of the first and second expanses forms an air-filled cell having a plurality of discrete air chambers. 
     
     
         21 . The method of  claim 20 , wherein the air in at least some of the plurality of air chambers is fluidly associated.