Method and apparatus for making foam

摘要

An improvement in the manufacture of flexible densified polyurethane foam wherein the partially cured freely risen foam is fed through a crush conveyor to minimize the density gradient throughout the vertical cross section. The crush conveyor includes an upper crushing section which is arcuate and has a radius of a dimension such that the ratio of the radius of the arc to height of the partially cured freely risen foam is 1.1 to 1 or greater. The crush conveyor has a bottom crushing section which may be arcurate with a radius of a dimension such that the ratio of its radius to the height of the partially cured freely risen foam is also 1.1 to 1 or greater. The radius of the bottom arcuate crushing section may be the same or larger than the radius of the top arc. As an alternative, the bottom crushing section may be planar and may be horizontal, or inclined with respect to the horizontal.