U.S. patent application number 13/497152 was filed with the patent office on 2012-10-18 for machine for producing foam within a bag.
This patent application is currently assigned to SEALED AIR CORPORATION (US). Invention is credited to John J. Corrigan, Mark Garceau, William M. Gray.
Application Number | 20120261028 13/497152 |
Document ID | / |
Family ID | 43796221 |
Filed Date | 2012-10-18 |
United States Patent
Application |
20120261028 |
Kind Code |
A1 |
Gray; William M. ; et
al. |
October 18, 2012 |
MACHINE FOR PRODUCING FOAM WITHIN A BAG
Abstract
A machine produces foam-in-bag from foam precursors mixed within
the bag. The machine comprises a base and a shell. The base and
shell are moveable relative each other between a base/shell
disengaged position and a base/shell engaged position. In the
base/shell engaged position, the base and shell divide the bag so
that a mixing chamber is isolated from the remainder portion of the
bag. First and second nozzles inject foam precursors into the
mixing chamber. A mixer engages the mixing chamber to provide
mixing energy to facilitate the foam reaction.
Inventors: |
Gray; William M.; ( Redding,
CT) ; Garceau; Mark; (Bethlehem, CT) ;
Corrigan; John J.; (Washington, CT) |
Assignee: |
SEALED AIR CORPORATION (US)
Elmwood Park
NJ
|
Family ID: |
43796221 |
Appl. No.: |
13/497152 |
Filed: |
September 24, 2010 |
PCT Filed: |
September 24, 2010 |
PCT NO: |
PCT/US10/50177 |
371 Date: |
June 18, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61277411 |
Sep 24, 2009 |
|
|
|
Current U.S.
Class: |
141/9 ;
141/69 |
Current CPC
Class: |
B01F 11/0065 20130101;
B31D 5/0078 20130101; B31D 2205/0023 20130101; B29C 44/3442
20130101; B29C 44/182 20130101; B01F 3/04446 20130101 |
Class at
Publication: |
141/9 ;
141/69 |
International
Class: |
B65B 3/04 20060101
B65B003/04 |
Claims
1. A machine useful for mixing first and second foam precursors to
produce foam within a bag, the machine comprising: a base and a
shell moveable relative each other between: (i) a base/shell
disengaged position, in which the base and shell are spaced apart
to permit insertion of the bag between the base and shell, and (ii)
a base/shell engaged position in which the shell and base press
together to hold the bag between the base and shell and to divide
the bag into (1) a mixing chamber and (2) a remainder portion so
that the mixing chamber is isolated from the remainder portion of
the bag; a first nozzle adapted to inject the first foam precursor
into the mixing chamber within the bag; a second nozzle adapted to
inject the second foam precursor into the mixing chamber within the
bag; and a mixer adapted to engage the mixing chamber of the bag to
provide mixing energy to the first and second foam precursors
within the mixing chamber of the bag when the base and shell are in
the base/shell engaged position, thereby facilitating the foam
reaction between the first and second foam precursors.
2. The machine of claim 1 wherein the shell comprises a bottom jaw
such that when the base and shell are in the base/shell engaged
position, the bottom jaw is adapted to press together with the base
to hold the bag between the base and bottom jaw to divide the bag
into the mixing chamber and the remainder portion.
3. The machine of claim 2 wherein the bottom jaw has a concave
curved bottom region.
4. The machine of claim 3 wherein the bottom jaw has a U-shaped
configuration.
5. The machine of claim 2 further comprising a top jaw movable
relative the bottom jaw and adapted to move to a top jaw engaged
position cooperating with the bottom jaw to form a peripheral
enclosure about the mixing chamber when the base and shell are in
base/shell engaged position.
6. The machine of claim 5 wherein: the bottom jaw has a U-shaped
configuration; and the top jaw is adapted to extend across the open
top of the U-shape configuration of the bottom jaw to form the
peripheral enclosure.
7. The machine of claim 1 wherein the mixer is adapted to
reciprocatingly engage the mixing chamber of the bag to provide the
mixing energy.
8. The machine of claim 1 wherein the mixer is adapted to
rotatively engage the mixing chamber of the bag to provide the
mixing energy.
9. The machine of claim 1 wherein the mixer is mounted to the
shell.
10. The machine of claim 1 wherein the mixer comprises one or more
mixing rollers adapted to engage the mixing chamber of the bag.
11. The machine of claim 10 wherein the mixer is adapted to
circulate the one or more mixing rollers in a plane generally
parallel with the surface of the mixing chamber of the bag.
12. The machine of claim 10 wherein the one or more mixing rollers
are adapted to roll along the surface of the bag.
13. The machine of claim 1 wherein the mixing chamber has a bottom
region and the mixer is adapted to engage the bottom region of the
mixing chamber.
14. The machine of claim 1 wherein: the shell comprises a bottom
jaw such that when the base and shell are in the base/shell engaged
position, the bottom jaw is adapted to press together with the base
to hold the bag between the base and bottom jaw to divide the bag
into the mixing chamber and the remainder portion; the bottom jaw
has a concave curved bottom region so that in the base/shell
engaged position the mixing chamber of the bag has a corresponding
concave curved bottom region; the mixer comprises one or more
mixing rollers adapted to engage the mixing chamber of the bag; and
the mixer is adapted to circulate the one or more mixing rollers
along a path having a portion corresponding to the concaved curved
bottom region of the mixing chamber, whereby the mixer is adapted
to provide mixing energy to liquids that collect in the concave
curved bottom region of the mixing chamber.
15. The machine of claim 1 wherein the first and second nozzles are
fixedly mounted to the base.
16. A method of making a foam-in-bag cushion comprising: inserting
a bag in the machine of claim 1 between the base and shell in the
base/shell disengaged position and beneath the first and second
nozzles; moving the base and shell relative each other to the
base/shell engaged position to divide the bag into a mixing chamber
and a remainder portion, wherein the mixing chamber is isolated
from the remainder portion of the bag; injecting a first foam
precursor from the first nozzle into the mixing chamber within the
bag; injecting a second foam precursor from the second nozzle into
the mixing chamber within the bag; and activating the mixer to
engage the mixing chamber of the bag to provide mixing energy to
the first and second foam precursors within the mixing chamber.
17. The method of claim 16 further comprising subsequently moving
the base and shell to the base/shell disengaged position so that at
least a portion of the reacting first and second foam precursors
move to the remainder portion of the bag.
18. A method of making a foam-in-bag cushion comprising: inserting
a bag in the machine of claim 5 between the base and shell in the
base/shell disengaged position and beneath the first and second
nozzles; moving the base and shell relative each other to the
base/shell engaged position and to hold the bag between the base
and bottom jaw to divide the bag into a mixing chamber and a
remainder portion, wherein the mixing chamber is isolated from the
remainder portion of the bag; injecting a first foam precursor from
the first nozzle into the mixing chamber within the bag; injecting
a second foam precursor from the second nozzle into the mixing
chamber within the bag; subsequently moving the top jaw to an
engaged position cooperating with the bottom jaw to form a
peripheral enclosure about the mixing chamber; and activating the
mixer to engage the mixing chamber of the bag to provide mixing
energy to the first and second foam precursors within the mixing
chamber.
19. The method of claim 18 further comprising subsequently moving
the base and shell to the base/shell disengaged position so that at
least a portion of the reacting first and second foam precursors
move to the remainder portion of the bag.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 61/277,411 filed Sep. 24, 2009, which
is incorporated herein in its entirety by reference.
[0002] The present invention relates to a machine for producing
foam in a bag.
BACKGROUND
[0003] Polyurethane foam may be formed by mixing an isocyanate
compound with a hydroxyl-containing material, such as a polyol
(i.e., a compound that contains multiple hydroxyl groups),
typically in the presence of water and a catalyst. As the
isocyanate and polyol foam precursors react in the presence of the
catalyst to form polyurethane, the water reacts with isocyanate to
produce carbon dioxide gas, which acts as a blowing or foaming
agent to expand the polyurethane into a foamed cellular structure
(i.e., a polyurethane foam).
[0004] With foam-in-bag packaging, the foam precursors may be mixed
and dispensed into flexible plastic bags, for example, as the bags
are formed from plastic film. As the precursors react to form
expanding foam within the bag, the bag may be sealed closed. The
bag may then be placed into a box holding an object to be
cushioned. The foam tends to expand within the bag into the
available space inside the box to form a custom foam cushions
around the packaged object. Machines for producing foam-in-bag
cushions are described, for example, in U.S. Pat. Nos. 4,800,708;
4,854,109; 5,376,219; 5,727,370; 6,003,288; 6,550,229; and
6,675,557; each of which is incorporated herein in its entirety by
reference; and such machines are available, for example, from
Sealed Air Corporation under the Instapak.RTM., SpeedyPacker
Insight.RTM., and Instapacker.RTM. trademarks.
[0005] Machines that produce foam-in-bag packaging may use a
dispenser in which foam precursors enter the dispenser to mix with
one another in an internal mixing chamber of the dispenser to form
a foamable composition. The resultant foamable composition then
exits the dispenser via a discharge outlet. See for example, U.S.
Pat. Nos. 4,898,327 and 5,255,847, each of which is incorporated
herein in its entirety by reference.
[0006] Polyurethane foam tends to stick to objects as it hardens
into foam. This tendency may be problematic inside the dispenser
from which the mixed foam precursors are ejected. Therefore, the
polyol and isocyanate foam precursors may be withheld from mixing
with one another until just before injection from the dispenser.
Nevertheless, over time the foamable composition may build up in
the internal mixing chamber and the discharge outlet of the
dispenser, harden into foam, and disrupt the desired operation.
Foam build-up may also form on the end of the nozzle and protrude
below the nozzle.
[0007] As a result, the mixing chamber and discharge outlet of an
injector may require frequent cleaning. The dispenser may be
cleaned by a solvent capable of dissolving both the foam precursors
and the foamable composition before its fully cured state. To avoid
frequent disassembly and manual cleaning of the dispenser, the
solvent may be supplied to the discharge end of the dispenser to
clean the dispenser on an on-going basis. See, for example, U.S.
Pat. Nos. 6,811,059; 6,929,193; and 6,996,956; and U.S. Patent
Application Publications 2009/0038270 A1 and 2002/0092278 A1, each
of which is incorporated herein in its entirety by reference.
[0008] There are challenges presented by the use of a solvent in
this manner. The supplying of the solvent to the dispenser adds to
the operational expense and complexity of foam-in-bag packaging
systems. Further, excess solvent that may flow from the dispenser
into the next cushion to be formed may also leak through incomplete
seals or vent holes in the bag or film containing the foam. Such
solvent leakage may be detrimental to the surface appearance of
certain types of packaged items, for example, comprising wood.
SUMMARY
[0009] The presently disclosed subject matter may address one or
more of the aforementioned problems.
[0010] An embodiment is directed to a machine useful for mixing
first and second foam precursors to produce foam within a bag
comprises a base and a shell. The base and shell are moveable
relative each other between a base/shell disengaged position and a
base/shell engaged position. In the base/shell disengaged position,
the base and shell are spaced apart to permit insertion of the bag
between the base and shell. In the base/shell engaged position, the
shell and base press together to hold the bag between the base and
shell and to divide the bag into (1) a mixing chamber and (2) a
remainder portion so that the mixing chamber is isolated from the
remainder portion of the bag. A first nozzle is adapted to inject
the first foam precursor into the mixing chamber within the bag. A
second nozzle adapted to inject the second foam precursor into the
mixing chamber within the bag. A mixer is adapted to engage the
mixing chamber of the bag to provide mixing energy to the first and
second foam precursors within the mixing chamber of the bag when
the base and shell are in the base/shell engaged position, thereby
facilitating the foam reaction between the first and second foam
precursors.
[0011] One or more embodiments of the machine may operate to create
foam in bags with reduced disruption of nozzle operation caused by
clogging or foam build-up, and therefore reduce the need and
frequency of nozzle cleaning. Some embodiments of the machine may
be devoid of structure to heat the foam precursors; and/or the
machine may be used to create foam in a bag where without heating
the foam precursors.
[0012] These and other objects, advantages, and features of the
presently disclosed subject matter will be more readily understood
and appreciated by reference to the detailed description and the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a representative perspective view of an embodiment
machine 10 having a roll 104 of series of bags 102 installed;
[0014] FIG. 2 is a front elevation view of the machine of FIG. 1,
but without the installed bags;
[0015] FIG. 3 is a right side elevation view of the machine of FIG.
2, but without illustrating the injector assembly 50 and lift
51;
[0016] FIG. 4 is a right side elevation view of the machine of FIG.
3, but with the base and shell in the base/shell disengaged
position;
[0017] FIG. 5 is a front elevation view of the machine of FIG. 4,
but having the shell further opened for illustration purposes;
[0018] FIG. 6 is a top view of the machine of FIG. 3;
[0019] FIG. 7 is a representative front view of the base 14 and
shell 12 in the base/shell disengaged position and the injector
assembly in the retracted mode;
[0020] FIG. 8 is a representative partial cross-section view taken
along line 8-8 of FIG. 2 showing the divider 40 in the divider
engaged position;
[0021] FIG. 9 is a representative partial cross-sectional view
similar to FIG. 8, but with the divider 40 in the disengaged
position;
[0022] FIG. 10 is a representative partial cross-section view taken
along line 10-10 of FIG. 2;
[0023] FIG. 11 is a representative partial cross-section view taken
along line 11-11 of FIG. 10;
[0024] FIG. 12 is a representative exploded view of the base,
shell, and injector assembly having bag 100 in the fill
position;
[0025] FIG. 13 is a representative sectional side view of the bag
and the injector assembly in the retracted position;
[0026] FIG. 14 is a representative sectional side view of the bag
and the injector assembly in the engaged position;
[0027] FIG. 15 is a representative view of the base, shell, and
injector assembly with the injector assembly in the retracted
position and the base and shell in the base/shell disengaged
position;
[0028] FIG. 16 is a representative view similar to FIG. 15, but
with the base and shell in the base/shell engaged position and the
injector assembly in the engaged position;
[0029] FIG. 17 is a representative view similar to FIG. 16, but
representing the injection of foam precursor;
[0030] FIG. 18 is a representative view similar to FIG. 17, but
with the injector assembly in the retracted position after
injecting the foam precursors into the first and second
compartments of the mixing chamber of the bag;
[0031] FIG. 19 is a representative view similar to FIG. 18, but
having a representation of the divider in the disengaged position
so that the first and second foam precursors may react in the
mixing chamber of the bag;
[0032] FIG. 20 is a representative view similar and subsequent to
FIG. 19, but showing the base and shell in the base/shell
disengaged position and representing the foam expanding into the
remainder portion of the bag;
[0033] FIG. 21 is a representative view of the foam precursor
supply system;
[0034] FIG. 22 is a representative view showing the effect on the
bag held between the base and shell of the machine when in the
base/shell engaged position and the divider engaged position, where
the machine is not shown;
[0035] FIG. 23 is the representative view of the effect on the bag
as in FIG. 22 but showing foam precursor in the first and second
compartments of the bag;
[0036] FIG. 24 is the representative view of the effect on the bag
held between the base and shell of the machine when in the
base/shell engaged position and the divider disengaged position,
where the machine is not shown, showing first and second foam
precursors mixed together;
[0037] FIG. 25 is a representative view of the effect on the bag
where the base and shell are in the base/shell disengaged position
and divider is in the disengaged position, where the machine is not
shown, showing the reacted foam expanded in the bag;
[0038] FIG. 26 is a representative partial cross-section view
similar to FIG. 8, but showing bag 100 installed in the machine
with the base and shell in the base/shell engaged position and the
divider in the divider engaged position;
[0039] FIG. 27 is a representative partial cross-section view
similar to FIG. 26, but showing the first and second foam
precursors in the first and second compartments of the bag;
[0040] FIG. 28 is a representative partial cross-section view
similar to FIG. 8, but showing the machine with the base and shell
in the base/shell engaged position and the divider in the divider
disengaged position;
[0041] FIG. 29 is a representative partial cross-section view
similar to FIG. 27, but of an alternative embodiment showing bag
100 installed in machine 11 with the base and shell in the
base/shell engaged position and the divider in the divider engaged
position;
[0042] FIG. 30 is a representative partial cross-section view
similar to FIG. 29, but showing the machine with the base and shell
in the base/shell engaged position and the divider in the divider
disengaged position;
[0043] FIG. 31 is a representative partial cross-section view
similar to FIG. 30, but showing the machine with the base and shell
in the base/shell engaged position, the divider in the divider
disengaged position, and the mixers 43, 45 engaging the bag to
provide mixing energy;
[0044] FIG. 32 is a representative schematic drawing of the control
system;
[0045] FIG. 33 is a representative perspective view of an
embodiment machine 300 having a roll 404 of series of bags 402
installed and the shell 312 in the base/shell engaged position;
[0046] FIG. 34 is a representative partial perspective view of the
shell 312, base 314, mixer 370, and nozzles 358, 360 of machine
300;
[0047] FIG. 35 is a partial representative side cutaway view of
machine 300 in the base/shell disengaged position and in the top
jaw disengaged position before injection of foam precursors;
[0048] FIG. 36 is a partial representative side cutaway view of
machine 300 in the base/shell engaged position and in the top jaw
disengaged position;
[0049] FIG. 37 is a partial representative side cutaway view of
machine 300 in the base/shell engaged position and in the top jaw
engaged position;
[0050] FIG. 38 is a partial representative side cutaway view of
machine 300 in the base/shell engaged position and in the top jaw
disengaged position after the injected foam precursors have been
mixed; and
[0051] FIG. 39 is a representative perspective view of an
embodiment machine 300 having a roll 404 of series of bags 402
installed and the shell 312 in the base/shell disengaged
position;
[0052] Various aspects of the subject matter disclosed herein are
described with reference to the drawings. For purposes of
simplicity, like numerals may be used to refer to like, similar, or
corresponding elements of the various drawings. The drawings and
detailed description are not intended to limit the claimed subject
matter to the particular form disclosed. Rather, the intention is
to cover all modifications, equivalents, and alternatives falling
within the spirit and scope of the claimed subject matter.
DETAILED DESCRIPTION
[0053] Various embodiments of the machines of the present
invention, for example, machine 10 (FIG. 1), machine 11 (FIG. 29),
and machine 300 (FIG. 33) may be used to produce foam within a bag,
for example, bag 100.
Bag
[0054] Bag 100 may comprise front and rear sheets 128, 130 sealed
together in selected areas. (FIGS. 12-14.) For example, bag 100 may
comprise seals 108 attaching the front and rear sheets together in
selected areas to form and define one or more edge boundaries of
the interior of the bag. (FIGS. 15-20, 22-25.) Seals 108 may be
formed by heat sealing the sheets together or by applying an
adhesive to hold the sheets together in the desired regions. One
edge of the bag may be formed by folding a sheet over upon itself
(e.g., center fold) such that a seal is not required to form the
corresponding edge that in essence forms a demarcation between the
front and rear sheets. (FIGS. 13-14.)
[0055] Bag 100 may comprise trough 110, for example, forming the
top edge of the bag. Trough 110 may be formed, for example, by
attaching the front and rear sheets 128, 130 to each other, for
example by a fin seal to create fin seal region 132. The trough 110
may also be formed without a seal in fin seal region 132 but having
end seals 108 extending to the top of the trough at each end to
"close" the trough at each end.
[0056] The bag 100 may comprise first one-way valve 112 and second
one-way valve 113, for example positioned in the fin seal region
132. Suitable one-way valves (also described in the art as
self-closing valves and self-sealing valves) are known in the art;
for example, as described by one or more of U.S. Pat. Nos.
4,966,197; 4,917,646; 5,348,157; 5,803,263; 5,830,780; each of
which is incorporated herein in its entirety by reference.
[0057] By way of example, the one-way valves 112, 113 may each
comprise a first sheet of thermoplastic material and a second sheet
of thermoplastic material in face-to-face relationship with each
other. To form the one-way valve, the sheets of thermoplastic
material may be secured together along a portion of their
longitudinal edges such that the sheets define a passageway
therebetween. The passageway defines an inlet end and an outlet
end. The longitudinal edges are secured through the portion of the
edges nearest the inlet end with the remainder toward the outlet
end being opened at each longitudinal edge.
[0058] A plurality of bags 100 may be provided as series of bags
102 configured as roll 104. (FIG. 1.) Each of the adjoining bags
100 may be separated form the adjoining bag by seal 108. A line of
weakening 106 may be formed between adjoining bags 100, for
example, formed within seal 108, to facilitate detachment of
adjoining bags. For example, line of weakening 106 may comprise a
plurality of perforations formed in seal 108 (or between adjacent
seals). Additionally, the plurality of bags may be supplied in a
fan-fold stacked arrangement, or may be supplied as independent
singular bags
[0059] Bag 100 may comprise one or more vents, for example, vent
103. (FIGS. 15-25.) A suitable vent is designed and/or positioned
to provide gas or vapor communication between the interior of the
bag and the outside of the bag, while minimizing the communication
of foam (and/or reacting, expanding foam) between the interior of
the bag and the exterior of the bag. The vent, or one or more
vents, may be positioned in bag 100 to facilitate the flow of
by-product gas from the interior of the bag, while minimizing the
flow of foam or reacting or expanding foam from the bag 100 through
the one or more vents. For example, the vent 103 may be located or
positioned at a portion of the bag that is outside of the mixing
chamber 120 of the bag, discussed herein.
[0060] Vent 103 may comprise one or more, for example, a plurality
of, perforations or slits in the sheet. Vent 103 may be formed in
either the front sheet 128 or the rear sheet 130 or both of bag
100. Such vent is described, for example, in U.S. Pat. Nos.
5,899,325 and 6,712,201, each of which is incorporated herein in
its entirety by reference. Another embodiment of the vent comprises
a relatively small opening or gap in an edge seal of the bag, for
example as disclosed in U.S. Pat. No. 6,550,229, previously
incorporated by reference. Further, such opening or gap may be
surrounded by a pattern of partial seals forming a tortuous path
through which gasses may pass, but through which the flow of foam
and liquid is impeded, as set forth for example, in U.S. Pat. Nos.
5,376,219 and 5,699,902, each of which is incorporated herein in
its entirety by reference. In another embodiment of the vent, the
vent may comprise a gas-permeable material such as nonwoven bonded
polyolefin fibers, microporous polytetrafluoroethylene (PTFE),
textile fabrics such as woven polyolefins, porous papers, such as
surgical grade kraft paper, spunbonded polypropylene, and
microporous membranes. The amount and type of the gas-permeable
material is sufficient to allow the gas from the interior of the
bag to escape while impeding the escape of expanding foam or
liquids from the interior of the bag. Such vent is described in WO
1998/046498, which is incorporated herein in its entirety by
reference.
[0061] The sheets 128, 130 may comprise materials useful for
formation into bag 100, such as polymeric films or fibrous sheets
comprising for example paper. Useful polymeric films may comprise
one or more thermoplastic materials selected from polyolefins, for
example, polyethylene homopolymers, such as low density
polyethylene (LDPE) and high density polyethylene (HDPE),
polyethylene copolymers, such as, ionomer, ethylene/vinyl acetate
copolymer (EVA), ethylene/(meth)acrylate copolymer (EMA),
heterogeneous (e.g., Zeigler-Natta catalyzed) ethylene/alpha-olefin
copolymers, homogeneous (e.g., metallocene, single-cite catalyzed)
ethylene/alpha-olefin copolymers (e.g., linear low density
polyethylene (LLDPE), linear medium density polyethylene (LMDPE),
very low density polyethylene (VLDPE), and ultra-low density
polyethylene (ULDPE)), polypropylene homopolymer, polypropylene
copolymer (e.g., propylene/ethylene copolymer); and polyesters,
polystyrenes, polyamides, and polycarbonates. The polymeric film
may be monolayer or multilayer, for example, a three-layer film
having a sealant layer, a core layer, and an outer abuse layer. The
film may be made by film-forming methods known in the art, such as
coextrusion and lamination. Useful sheet material is available, for
example, from Sealed Air Corporation in a centerfolded roll
configuration under the SpeedyPacker.RTM. silver SP19 and SP30
trademarks. Sheet material available as a roll of converted
three-sided bags--having the transverse sides formed by heat seals
with perforations through the seals, one longitudinal side formed
by a centerfold, and the other longitudinal side open--is available
for example from Sealed Air Corporation under the Instapacker.RTM.
Tabletop white IP16 and IP24 trademarks.
Foam Precursor Supply System
[0062] Machine 10 comprises foam precursor supply system 90. (FIG.
21.) The supply system comprises first foam precursor supply tank
20 and second foam precursor supply tank 22, which are containers
suitable for holding a reservoir of first and second foam
precursors 72, 74, respectively. (FIGS. 6 and 21.) Supply tanks 20,
22 may be a bag-in-box container, where the foam precursor is
stored within and supplied from a bag housed within a supporting
box.
[0063] The first foam precursor source tube or hose 84 may be
attached to the first supply tank 20 by a hose quick-connect system
98. Such hose quick-connect systems may include a male end attached
to the hose 84 and a female end attached to the container 20. The
male end of the hose may facilitate puncturing a seal on the
container having the female end of the connect. Similarly, second
foam precursor source tube or hose 86 may be attached to the second
supply tank 22 by a hose quick-connect system 98.
[0064] The hose 84 may also be attached to the inlet end of the
corresponding three-way shuttle valve 88, having the inlet/outlet
end of the three-way shuttle valve attached to first piston 92 and
the outlet end of the three-way shuttle valve attached to first
foam precursor supply tube or hose 80. Similarly, the hose 86 may
also be attached to the inlet end of corresponding three-way
shuttle valve 89, having the inlet/outlet end of the three-way
shuttle valve attached to second piston 94 and the outlet end of
the three-way shuttle valve attached to second foam precursor
supply tube or hose 82. The first and second foam precursor supply
hoses 80, 82 feed the first and second foam precursors to the
injector assembly 50.
[0065] The first and second pistons 92, 94 are driven by drive
mechanism 152 associated with the foam precursor supply system 90,
for example, motor 96, such as a linear stepper motor. (FIGS. 21,
32.) Controller 140 may direct the movement of the pistons 92, 94
by signaling the drive mechanism 152.
[0066] Alternative to a piston-based pump system, the foam
precursor supply system may comprise other types of pumps, such as
one or more diaphragm pumps or bellows pumps, for example, in-line
one or more of the supply hoses. The bellows type pump may be
housed within the box Any of the pumps, for example, the bellows
pump, may be adapted to be manually driven, or alternatively, may
be driven by a motor controlled by controller 140.
[0067] By way of example, the first foam precursor 72 may comprise
one or more: (i) hydroxyl-containing materials, such as polyols
(i.e., compounds that contain multiple hydroxyl groups), (ii)
water, and optionally (iii) one or more catalysts, foam stabilizers
or surfactants, compatibilizers, or other additives (e.g.,
fragrances, flame retardants, colorants, and viscosity-control
agents); and the second foam precursor 74 may comprise one or more
isocyanates, such as toluene diisocyanate (TDI) and methylene
diphenylisocyanate (MDI), all as conventionally used in
foam-in-place/foam-in-bag packaging. Such first and second foam
precurors are described, for example, in U.S. Pat. No. 6,034,197,
which is incorporated herein in its entirety by reference. Useful
polyols include, for example, polyether polyols, diols, such as
aliphatic diols, and triols. It is useful to provide the first and
second foam precursors 72, 74 as a "two-component" system having
the first foam precursor 72 comprising the one or more polyols and
water, and the second foam precursor 74 comprising the one or more
isocyanates. It may also be useful for the first foam precusor 72
to further comprise the one or more suitable catalysts,
surfactants, and any other additives, although one or more of these
could be provided as part of the second foam precursor 74, provided
there are no significant stability issues.
[0068] Useful foam precursors are available having the first foam
precursor and the second foam precursor provided in separate
containers, for example, from Sealed Air Corporation under the
Ultralite.RTM., Instafill.RTM., Instapak.RTM.-40W,
Instapak.RTM.-50W, Instapak.RTM.-75W, Instapak.RTM.-Molding Foam,
Instapak.RTM. FlowRite.TM., GFlex.RTM., GFlex.RTM. QS,
Instaflex.TM., Instapak.RTM. Rigid, and Instapak.RTM. F9401
trademarks.
Injector Assembly
[0069] Machine 10 comprises injector assembly 50. (FIGS. 1-2.)
Injector 50 comprises injector block 52 movably supported by lift
51. For example, the injector block 52 may be slidably attached to
the lift 51 along lift guide channel 53, and may driven up and
down, for example, by a drive mechanism 146, such as a powered
screw drive (not visible) enclosed within lift 51. The drive
mechanism 146, such as a powered lift drive, may be directed by
controller 140. (FIG. 32.) The injector may be moveable between an
injector engaged position (FIGS. 1-2, 11, 14, and 16-17) and an
injector retracted position (FIGS. 13, 15, 18-20).
[0070] First nozzle block 54 extends from the injector block 52 and
supports first nozzle 58, which defines lumen 59. Second nozzle
block 56 extends from the injector block 52 and supports second
nozzle 60, which defines lumen 61. The injector 50 is adapted to
receive the first and second foam precursors 72, 74 from the first
and second foam precursor supply hoses 80, 82, respectively, of the
foam precursor supply system 90, and deliver these precursors
through the lumens 59, 61 respectively of the first and second
nozzles 58, 60.
Base and Shell
[0071] Machine 10 comprises base 14 and shell 12 movable relative
to each other between a base/shell engaged position (e.g., FIGS. 1
and 3) and a base/shell disengaged position (e.g., FIG. 4). The
base and shell are moveable relative each other, for example, by
pivoting about hinge 16. The base and shell may be configured such
that they are biased to return to a position selected from the
base/shell engaged position and the base/shell disengaged position.
For example, the hinge 16 may comprise a spring (e.g., may be
spring loaded) to provide a bias to maintain the base and shell in
either of these positions, for example, may be biased to maintain
the base and shell normally in the base/shell engaged position. The
base and shell may be movable relative to each other, for example,
powered by drive mechanism 142, such as any of a motor, actuator,
piston, and solenoid, which may be directed by controller 140.
(FIG. 32.)
[0072] Base 14 defines cavity 39. (FIG. 9.) Base 14 may define
first channel 63 and second channel 65 extending from the base
cavity 39 to the top of the base. (FIG. 5.)
[0073] Base 14 may moveably support divider 40 within cavity 39.
(FIGS. 5, 7-9, 26-28.) Divider 40 may define first concave section
42 and second concave section 44. The divider 40 is movable
relative to the base and shell between a divider engaged position
(FIGS. 8 and 26-27) and a divider disengaged position (FIGS. 9 and
28). Divider 40 may be moved by drive mechanism 144 associated with
the divider, for example, one or more of a motor, actuator, piston,
and solenoid. For example, divider 40 may comprise rod 49 slidably
received by base 14. Rod 49 may be selectively driven forward and
backward within base cavity 39 by any of the drive mechanisms 144.
The drive mechanism 144 may be directed by controller 140. (FIG.
32.)
[0074] Base 14 may support rear right roller 32 and rear left
roller 36 rotatably mounted at least partially within associated
roller recesses 70 defined within base 14. (FIG. 10.) One or more
of the rollers 30, 32, 34, 36 may be selectively driven by a drive
mechanism 150, such as a motor, directed by controller 140. (FIG.
32.)
[0075] Shell 12 may define first concave section 46 and second
concave section 48. The first concave section 46 of the shell may
correspond to and be aligned with the first concave section 42 of
divider 40 when the base and shell are in the base/shell engaged
position. The second concave section 48 of the shell may correspond
to and be aligned with the second concave section 44 of divider 40
when the base and shell are in the base/shell engaged position.
Shell 12 may support front right roller 30 and front left roller 34
rotatably mounted at least partially within associated roller
recesses 70 defined within shell 12. (FIG. 10.)
[0076] Shell 12 may define first channel 67 extending from the
first concave section 46 to the top of the shell. Shell 12 may also
define second channel 69 extending from the second concave section
48 to the top of the shell. (FIGS. 5-7.) The base 14 and shell 12
may cooperate in the base/shell engaged position to define first
throat 66 and second throat 68. (FIG. 1.) For example, first
channel 63 of the base and first channel 67 of the shell may oppose
each other and cooperate to define first throat 66; and second
channel 65 of the base and second channel 69 of the shell may
oppose each other and cooperate to define second throat 68. The
first throat 66 may surround and engage first nozzle block 54; the
second throat 68 may surround and engage second nozzle block 56.
(FIG. 10.)
Other Structure
[0077] Machine 10 may comprise spindle 38 adapted to support roll
of bags 104. Guide roller 62 may be provided to assist in guiding
the series of bags 102 from the roll location on the spindle to
between the base 14 and shell 12.
[0078] A controller 140 (FIG. 32) and/or one or more of the various
drive mechanisms discussed herein may be housed in cabinet 64.
(FIG. 1.) The controller 140 may receive and send the various
status, activation, and control signals described herein along
various input/output connections and signal transmission lines
between the controller 140 and the various sensors and controlled
devices described herein.
[0079] The controller 140 may comprise one or more of:
[0080] (1) a programmable logic controller ("PLC"),
[0081] (2) a central processing unit ("CPU"), for example,
comprising a microprocessor, to control the functions and
operations of the controller,
[0082] (3) a read only memory ("ROM"), for example, to store data
and program code,
[0083] (4) a random access memory ("RAM"), for example, to provide
a work area and a storage area,
[0084] (5) a printed circuit assembly containing a micro controller
unit (MCU), which stores pre-programmed operating codes,
[0085] (6) a personal computer (PC),
[0086] (7) various input/output (I/O) interfaces for receiving and
sending signals to interface with, direct, or control the operation
of any of such drive mechanisms (e.g., motors, actuators, pistons,
solenoids, and the like) by any of local control (e.g., via an
operator interface), remote control, and/or pre-programmed control,
and
[0087] (8) other interface, storage, display, and peripheral
devices as are known in the art. The controller 140 may also store
and execute software control program code for carrying out the
various control and monitoring functions described herein.
[0088] An interface 154 may provide for human or other interaction
or communication with the controller. Interface 154 may comprise
one or more of display panels (e.g., liquid crystal displays),
monitors, keypads, keyboards, and computer input/output access
ports, for example, to provide for loading or modifying software
that runs on the CPU of a controller.
Second Embodiment
[0089] FIGS. 29-31 illustrate machine 11, which is a second
embodiment of the present invention varying from machine 10 in ways
discussed herein. Machine 11 comprises base 214 and shell 212. Base
214 defines cavity 139. Base 214 and shell 212 are movable relative
to each other as described herein with respect to the first
embodiment.
[0090] Base 214 may moveably support divider 41 within cavity 139.
(FIGS. 29-31.) The divider 41 is movable relative to the base and
shell between a divider engaged position (FIG. 29) and a divider
disengaged position (FIGS. 30-31). Divider 41 may be moved by drive
mechanism 144 associated with the divider, for example, by one or
more of a motor, actuator, piston, and solenoid. For example,
divider 41 may comprise rod 249 slidably received by base 214. Rod
249 may be selectively driven forward and backward within base
cavity 139 by any of the drive mechanisms 144. The drive mechanism
144 may be directed by controller 140. (FIG. 32.) Shell 212 may
define first concave section 246 and second concave section
248.
[0091] Base 214 may movably support first mixer 43 and second mixer
45 within cavity 139. The mixers may comprise rods 250 and 252
slidably received by base 214. The first and second mixers 43, 45
are movable between a mixer disengaged position (FIGS. 29-30) and a
mixer engaged position (FIG. 31). The first and second mixers 43,
45, and/or rods 250, 252 may be selectively driven forward and
backward within base cavity 139 by drive mechanism 148 associated
with the mixers, for example, one or more of a motor, actuator,
piston, and solenoid, which may be directed by controller 140.
Additional Embodiments
[0092] Although, machines 10 and 11 have been described with
respect to first and second foam precursors such that these
embodiments utilize, for example, first and second foam precursor
supply tanks, first and second foam precursor supply lines, first
and second nozzles, first and second concave sections of the base
and shell, and the like, additional embodiments of the machine may
comprise structure to process one or more additional foam
precursors, such as a third foam precursor. These additional
embodiments are useful where, for example, it is desirable to
maintain three distinct compounds or mixtures separate from each
other until near or at the time for creation of a foam. For
example, a third foam precursor may comprise one or more of any of
hydroxyl-containing materials (e.g., polyols), catalysts, or
isocyanates that may react with, degrade in the presence of, or
have a decreased shelf life if mixed or combined with, the first
and second foam precursors described above.
[0093] For example, a third foam precursor supply tank may provide
a third foam precursor to combine with one of the first or second
foam precursors in the corresponding supply line to the injector
assembly. Also by way of example, the third foam precursor may
combine with one of the first or second foam precursors in the
corresponding first or second nozzles. Also, a third foam precursor
may be provided by a third supply line into a third nozzle distinct
from the first and second nozzles described above. The third nozzle
may correspond with third concave sections of the base and shell,
which in combination with a second divider, may compliment each
other to form a third compartment within the bag to maintain the
third foam precursor isolated from the first and second
compartments of the bag until mixing to form the foam is desired.
In such embodiment, it may be useful to incorporate a third one-way
valve in the bag.
[0094] Although the bag has been described as comprising first and
second one-way valves, in some embodiments of the machine the bag
may be provided without one-way valves but with the top edge in an
open configuration so that the first and second nozzles do not have
to align for insertion into the valves of the bag. In such an
arrangement, the top open edge may be sealed closed after injection
of the foam precursors into the bag, for example, by incorporating
a sealing device such as described in U.S. Pat. No. 6,550,229,
previously incorporated by reference. For example, the heat seal
device may comprise a pair of opposing counter-rotating rollers and
an electrically conducting heating element that contacts one sheet
as the front and rear sheets pass between the rollers to press the
heated sheets together to form a longitudinal heat seal across the
top of the bag to "close" the bag. Such heat sealing capability may
be provided in conjunction, for example, with rollers 30, 32
described herein. Further, such sealing devices can be used even
where bags incorporate the one-way valves in order to seal the
valves "permanently" closed after the foam precursors have been
injected. The heat seal device may be located downline from the
injector, for example, downline from the base and shell, for
example, to effect the transverse heat seal to close the top edge
of the bag after the precursors have been mixed together and
expanded into the remainder portion of the bag.
[0095] Although the bags may be provided as a pre-formed series of
bags 102, a portion or all of the bags may be formed by the machine
itself from a roll of sheet material, for example, by incorporating
capability to make any of heat seals, perforations, folds, and/or
cuts, for example, by transverse sealing/severing devices, all as
disclosed for example, by any of U.S. Pat. Nos. 4,800,708;
4,854,109; 5,027,583; 5,376,219; 6,003,288; 6,550,229; and
6,675,557; each of which is incorporated herein in its entirety by
reference.
Operation
[0096] The series of bags 102 may be installed on spindle 38 so
that (i) the edge comprising trough 110 is oriented in the top or
upward position and (ii) the first and second one-way valves 112,
113 in the fin seal region 132 are oriented at the top of the bag.
(FIG. 1.) The base 14 and shell 12 (or base 214, 212) are placed in
the disengaged position, in which the base and shell are spaced
apart to permit insertion of the bag between the base and shell.
(FIGS. 4 and 15.) The series of bags can be installed between
upstream opposing front left roller 34 and rear left roller 36 and
also between downstream opposing front right roller 30 and rear
right roller 32 to set up a bag in the machine.
[0097] The bag may be positioned in the machine such that the first
and second one-way valves 112, 113 are aligned with and/or beneath
throats 66 and 68 formed when the base and shell are placed in the
base/shell engaged position. To assist in this alignment, the bag
may be provided with an indicator such as an printed "eye spot" or
mark (e.g., bar code) that is detectable by a sensor (not
illustrated), which can send a corresponding signal to the
controller. The controller may index the bags by directing one or
more rollers to stop or forward the series of bags until receiving
a confirmation signal that the sensor has detected the indicator
showing that the bag is properly aligned. The sensor may comprise,
for example, one or more of an optical sensing device, such as a
photo-eye, an electric-eye, or a photo-detector. Such sensors and
their operation are known to those of skill in the art; see for
example, U.S. Pat. No. 6,675,557 (column 10), previously
incorporated herein. The opposing pairs of rollers may
counter-rotate to pull the series of bags from the spindle and
between the base and shell.
[0098] The base 14 and shell 12 (or base 214, 212) may be moved
relative each other to be placed in the base/shell engaged position
in which the shell and base press together to hold the bag 100
between the base and shell to divide the bag 100 into a mixing
chamber 120 and a remainder portion 122 such that the mixing
chamber 120 is isolated from the remainder portion 122 of the bag.
(FIGS. 16 and 24.) Compressed region 121 of bag 100 illustrates and
represents the region of bag 100 that is pressed together by the
base 14 and shell 12 so that the mixing chamber 120 is isolated
from the remainder portion 122 of the bag. In this context,
"isolated" means that the mixing chamber and the remainder portion
of the bag are not in liquid communication with each other, such
that foam liquid precursor that may be injected or placed into the
mixing chamber does not transfer or leak into the remainder portion
of the bag. The base and shell may be moved relative each other
into the base/shell engaged position by spring force provided, for
example, at one or more of hinges 16 biased in the base/shell
engaged position.
[0099] In the base/shell engaged position holding the bag, in a
first embodiment divider 40 may be moved relative to the base 14
and shell 12 to the divider engaged position (FIGS. 26-27) and in a
second embodiment divider 41 may be moved relative to the base 214
and shell 212 to the divider engaged position (FIG. 29). In the
divider engaged position, the divider engages the bag to partition
the mixing chamber 120 of the bag into first and second
compartments 124, 126 that are isolated from each other while the
divider is in the engaged position. Compressed region 123 of bag
100 illustrates and represents the region of bag 100 that is
pressed together by the divider 40 as well as base 14 and shell 12,
so that the first and second compartments of the bag are isolated
from each other and the remainder portion 122 of the bag. In this
context, "isolated" means that the first and second compartments of
the bag are not in liquid communication with each other, such that
foam liquid precursor that may be injected or placed into either of
the first and second compartments does not transfer or leak into
the other compartment of the bag. In the divider engaged position,
the first one-way valve 112 corresponding to first compartment 124
of the bag is also isolated from the second one-way valve 113
corresponding to second compartment 126 of the bag.
[0100] Injector assembly 50 may be moved or positioned so that (i)
the first nozzle block 54 is held between or engaged by first
throat 66, which is formed by opposing first channel 63 of base 14
and first channel 67 of shell 12 when the base and shell are moved
to the base/shell engaged position and similarly, (ii) the first
nozzle block 56 is held between or engaged by second throat 68,
which is formed by opposing second channel 65 of base 14 and second
channel 69 of shell 12 when the base and shell are moved to the
base/shell engaged position. (FIG. 10.) In this injector engaged
position the first nozzle 58 pushes and extends into the first
one-way valve 112 of bag 100 (FIG. 14) and the second nozzle 60
extends into the second one-way valve 113 of bag 100. (FIG. 16.) A
small burst of pressurized air may be injected from an air supply
source (not illustrated) to the injector 50 and into the first and
second one-way valves to assist in opening the valves before the
first and second nozzles are extended into the valves.
[0101] Motor 96 may be directed to move first piston 92 to pump a
supply of first foam precursor 72 from the reservoir within piston
92 through first three-way shuttle valve 88 and into first foam
supply hose 80. The desired selected amount of first foam precursor
72 sent into the supply hose 80, and subsequently into the first
compartment of the bag, may be determined by the amount of travel
of the piston 92. (FIG. 21.) The first foam precursor 72 flows
through supply hose 80 into injector 50, through the lumen 59 of
nozzle 58 and thereby through first one-way valve 112 into first
compartment 124 of the bag. (FIGS. 17, 23, and 27.) The motor 96
may then drive the piston 92 in the opposite direction by a
selected distance to draw a selected amount of first foam precursor
from first foam precursor supply tank 20 through the first
three-way shuttle valve 88 and into the piston reservoir.
[0102] Similarly, motor 96 may be directed to move second piston 94
to pump a supply of second foam precursor 74 from the reservoir
within piston 94 through second three-way shuttle valve 89 and into
second foam supply hose 82. The desired selected amount of second
foam precursor 74 sent into the supply hose 82, and subsequently
into the second compartment of the bag, may be determined by the
amount of travel of the piston 94. (FIG. 21.) The second foam
precursor 74 flows through supply hose 82 into injector 50, through
the lumen 61 of nozzle 60 and thereby through second one-way valve
113 into second compartment 126 of the bag. (FIGS. 17, 23 and 27.)
The motor 96 may then drive the piston 94 in the opposite direction
by a selected distance to draw a selected amount of second foam
precursor from second foam precursor supply tank 22 through the
second three-way shuttle valve 89 and into the piston reservoir. A
small burst of pressurized air may be injected from an air supply
source (not illustrated) to the injector 50 and into the first and
second nozzles to clear the remaining first and second foam
precursors from the nozzles into the first and second compartments
to assist in clearing the nozzles.
[0103] The precursors may be supplied to the bag at ambient
temperature, in which case the machine may be devoid of structure
having a primary purpose of heating one or more of the precursors
to above ambient temperature. Alternatively, one or more of the
foam precursors may be heated to a desired temperature above
ambient temperature, for example, before or during supply to and/or
from the injector. Such heating may be accomplished, for example,
by using a heating device such as heating electrical resistance
"tape" wrapped around one or more of the hoses, by heating one or
more portions of the injector through which the precursors pass,
and/or by heating the supply tanks of the precursors.
[0104] After injection of the foam precursors, injector assembly 50
may be moved or positioned in the retracted position so that the
first and second nozzles 58, 60 are withdrawn from the first and
second one-way valves 112, 113, respectively. (FIG. 18.) The
one-way valves are then unencumbered by the nozzles so that the
valves may preclude reverse flow of foam precursor from the first
or second compartments of the bag. In this manner, there is minimal
chance that the first and second foam precursors would encounter
each other in the lumens 59, 61 of nozzles 58, 60, respectively, a
situation which if occurred could initiate a foaming reaction
within the nozzle lumen that might clog the nozzle. Accordingly,
the frequency of nozzle clogging and/or the need for solvent
cleaning of the nozzles is reduced in comparison to the prior art
dispensers discussed in the Background section above.
[0105] In a first embodiment, the divider 40 may then be moved to
the divider disengaged position, in which the divider 40 does not
isolate the first and second compartments of the bag from each
other. (FIG. 28.) Similarly, in a second embodiment, the divider 41
may then be moved to the divider disengaged position, in which the
divider 41 does not isolate the first and second compartments of
the bag from each other. (FIGS. 30-31.) Consequently, the first and
second foam precursors are free to interact and begin the foaming
reaction within the mixing chamber 120 of the bag. (FIGS. 24, 28,
30.)
[0106] In a first embodiment, the mixing of the first and second
foam precursors within the mixing chamber of the bag may be
facilitated by reciprocating movement of the divider to repeatedly
engage the mixing chamber of the bag, for example, as the foam
reaction begins, in order to provide mixing energy to the first and
second precursors within the mixing chamber of the bag to further
the mixing of the first and second precursors thereby enhancing the
foaming reaction.
[0107] In a second embodiment, the mixing of the first and second
foam precursors within the mixing chamber of the bag may be
facilitated by reciprocating movement of the mixers 43, 45 to
repeatedly engage the mixing chamber of the bag, for example, as
the foam reaction begins, in order to provide mixing energy to the
first and second precursors within the mixing chamber of the bag to
further the mixing of the first and second precursors thereby
enhancing the foaming reaction.
[0108] The first and second mixers 43, 45 are movable from a mixer
disengaged position (FIGS. 29-30) to a mixer engaged position (FIG.
31). The first and second mixers 43, 45, and/or rods 250, 252 may
be selectively driven forward and backward within base cavity 139
by drive mechanism 148, which may comprise one or more of a motor,
actuator, piston, and solenoid, which may be directed by controller
140.
[0109] In both embodiments, as the foam reaction progresses, the
foam expands within the mixing chamber of the bag. In one
embodiment, the foam expands to the point of pushing the base and
shell to the base/shell disengaged position, for example, by
pushing against a spring force that is biased to normally position
the base and shell in the base/shell engaged position. The gasses
generated by or resulting from the foaming reaction may control or
may also facilitate the expansion of the mixing chamber to push the
base and shell to the base/shell disengaged position. In another
embodiment, the base and shell may be placed into the base/shell
disengaged position by drive mechanisms discussed herein directed
for example by the controller, rather than relying solely upon, or
partially upon, the foam or reaction gas by-products to place the
base and shell in the base/shell disengaged position.
[0110] When the base and shell are in the base/shell disengaged
position, remaining first and second foam precursors as well as the
reacting or expanding foam and reaction by-products may flow into
the remainder portion 122 of the bag to complete the reaction.
(FIGS. 20 and 25.) The foaming generated excess gasses may flow
from the interior of bag 100 through vent 103 to the exterior of
the bag. The vent may be sized and positioned on the bag to
minimize contact with expanding foam and thereby reduce the
likelihood of foam flow through the vent.
[0111] The opposing front left roller 34 and rear left roller 36
and/or the downstream opposing front right roller 30 and rear right
roller 32 may cooperate to engage the bag and provide a traction
for transmitting a propelling force to the bag. By providing
rotational power to drive one or more of the rollers, for example
by driving rear left roller 36 or rear right roller 32 or both,
then the bag 100 containing the reacted foam may be propelled
forward, for example in an indexed manner, to place a subsequent
bag from the series of bags in position for filling after the foam
has been formed in the previous bag. The bag containing the foam
may be detached from the subsequent bag, for example, by tearing
the bag along the line of weakening 106.
[0112] One or more of the various drive mechanisms described herein
may be directed by controller 140. (FIG. 32.) The controller may be
programmed to direct the operation of machines 10 or 11, for
example, by directing any of the drive mechanisms in a desired
coordinated and sequenced manner to effect the operation as
discussed herein. For example, the controller may direct the
placement of base 14 and shell 12 in the base/shell engaged
position and/or the base/shell disengaged position by signaling
drive mechanism 142 associated with the base and/or shell. The
controller may also direct the movement of divider 40 between the
divider engaged position and the divider disengaged position by
signaling the drive mechanism 144 associated with the divider.
Further, if the divider is to be reciprocated to provide mixing
energy to the mixing chamber of the bag, then the controller 140
can direct the reciprocating movement of divider 40 by signaling
the drive mechanism 144. If the mixing energy is provided by one or
more mixers, for example, mixers 43, 45, then the controller 140
may direct the movement of the mixers by signaling the drive
mechanism 148 associated with the mixers.
[0113] The controller 140 may direct the positioning of the
injector assembly 50 in the injector engaged position or the
injector retracted position by signaling the drive mechanism 146
associated with the injector assembly, for example, lift 51. The
controller 140 may also direct the movement of the pistons 92, 94
by signaling the drive mechanism 152 associated with the foam
precursor supply system 90, for example, motor 96. Further, the
controller 140 may also direct the movement of one or more of the
rollers 30, 32, 34, 36 by signaling the drive mechanisms 150
associated with the rollers.
Third Embodiment
[0114] Machine 300 represents a third embodiment of the machine of
the present invention for producing foam within a bag, for example,
bag 400. (FIG. 33.) The description of bag 400 is similar to that
of bag 100 described herein, and therefore that description is not
repeated here. Machine 300 comprises foam precursor supply system
390. (FIG. 33.) The supply system may be supported by base 314. The
supply system comprises first foam precursor supply tank 320 and
second foam precursor supply tank 322, which are containers
suitable for holding a reservoir of first and second foam
precursors 72, 74, respectively. (FIG. 33.) Supply tanks 320, 322
may comprise a bag-in-box configuration, as described herein. The
supply system comprises supply hoses (not visible) connecting each
of the supply tanks to its respective first nozzle 358 and second
nozzle 360 (FIG. 34). Selected or desired amounts of the first and
second foam precursors may be transferred through the hoses to the
first and second nozzles by use of pistons or pumps (e.g., in-line
bellows pump) such as described herein with respect to other
embodiments. The pistons or pumps of supply system 390 may be
driven by manual energy, for example, utilizing hand lever 352, or
may be motor driven for example as described herein with respect to
other embodiments. The first and second nozzles 358, 360 may be
mounted to or supported by base 314. For example, the first and
second nozzles may be fixedly mounted to the base such that in
operation they are stationary relative to base 314 (FIG. 34), in
which case the nozzles are not adapted for movable retraction and
insertion as described herein. Alternatively, the first and second
injectors may be movably mounted to the base, as described herein
with respect to other embodiments.
[0115] Machine 300 comprises base 314 and shell 312 movable
relative to each other between the base/shell engaged position
(e.g., FIGS. 33 and 36-37) and the base/shell disengaged position
(e.g., FIGS. 35 and 38-39). The base and shell are moveable
relative each other, for example, by pivoting about a hinge as
previously described herein. The base and shell may be movable
relative to each other, for example, powered by drive mechanism
142, such as any of a motor, actuator, piston, and solenoid, which
may be directed by controller 140. (FIG. 32.) Shell 312 may
comprise one or more magnets 362, for example attached to shell
frame 386 or bottom jaw 380, to facilitate the pressing together of
the shell and base in the base/shell engaged position. (FIG.
34.)
[0116] Base 314 may support front right roller 330 and front left
roller 334 rotatably mounted to base 314 (FIGS. 33, 39) with
corresponding opposing rollers (not visible) adapted to move bags
400 within machine 300 from roll 404. One or more of the rollers
may be selectively driven by a drive mechanism 150, such as a
motor, directed by controller 140. (FIG. 32.)
[0117] Shell 312 may comprise bottom jaw 380 and top jaw 382. In
the base/shell engaged position, bottom jaw 380 of shell 312 is
adapted to press together with the base to hold the bag between the
base and bottom jaw 380 to divide the bag into the mixing chamber
320 and the remainder portion 322. The bottom jaw 380 may have a
concave curved bottom region 350. (FIG. 34.) Bottom jaw 380 may
have the letter "U" shape configuration as illustrated for example
in FIG. 34.
[0118] Top jaw 382 is movable relative to bottom jaw 380 to
cooperate with the bottom jaw and be adapted to move to a top jaw
engaged position (FIG. 34, 36-37) cooperating with the bottom jaw
380 to form a peripheral enclosure about the mixing chamber 320
when shell 312 and base 314 are in the base/shell engaged position.
(FIG. 34.) Top jaw 382 may be capable of extending across the open
top of the U-shape configuration of the bottom jaw to form the
peripheral enclosure of the mixing chamber, as illustrated. A drive
mechanism (not illustrated) may be used to move the top jaw; such
drive mechanism may be mounted on frame 386, may comprise one or
more of a motor, actuator, piston, and solenoid, and may be
directed by controller 140. The top and bottom jaws may have a
surface comprising a material to facilitate the isolation of the
mixing chamber from the remainder portion when the base and shell
are in the base/shell engaged position, for example, one or more
relatively resilient materials selected from elastomers, foams, and
plastics.
[0119] Mixer 370 may be mounted to shell 312, for example mounted
to or supported by shell frame 386. The mixer 370 is adapted to
rotatively engage the mixing chamber 320 of the bag. Mixer 370 may
comprise, for example, one or more mixing rollers 372 adapted to
engage the mixing chamber 320. The one or more mixing rollers may
comprise relatively resilient materials, such as one or more
materials selected from elastomers, foam, and plastics. The one or
more mixing rollers 372 may be rotatively attached to drive shaft
374 which is driven by mixing motor 376. Motor 376 may be directed
by controller 140. The mixer 370 is adapted to circulate the one or
more mixing rollers 372 in a plane generally parallel with the
surface of the mixing chamber of the bag. (FIGS. 36-37.) The term
"generally" is used to modify the term "parallel" so that the term
parallel is not interpreted in a rigid mathematical sense, but
rather to indicate the general orientation of the circulating
rollers relative the uneven bag surface of the mixing chamber as
the one or more rollers roll along the surface of the bag.
[0120] The mixing chamber 320 has bottom region 326 in which the
un-reacted and reacting liquid precursors may tend to collect
because of gravity effects. Where the bottom jaw 380 has a concave
curved bottom region 350, then in the base/shell engaged position
the bottom region 326 of the mixing chamber 320 is correspondingly
concave curved. The mixer may be adapted to circulate the one or
more mixing rollers along a path having a portion corresponding to
the concave curved bottom region of he mixing chamber. The mixer
can then provide mixing energy to liquid precursors that collect in
the concave curved bottom region of the mixing chamber.
[0121] Machine 300 may comprise spindle 338 adapted to support roll
of bags 404. (FIGS. 33, 39.) A controller 140 (FIG. 32) and/or one
or more of the various drive mechanisms discussed herein may be
housed in cabinet 364. (FIGS. 33, 39.) The controller 140 may
receive and send the various status, activation, and control
signals described herein along various input/output connections and
signal transmission lines between the controller 140 and the
various sensors and controlled devices described herein. Interface
154 as previously described may provide for human or other
interaction or communication with the controller.
[0122] In operation of the third embodiment, the series of bags 402
may be installed on spindle 338 so that an open edge or trough of
the bag 400 is oriented in the top or upward position. The base 314
and shell 312 are placed in the disengaged position, in which the
base and shell are spaced apart to permit insertion of the bag
between the base and shell. (FIG. 35.) The opposing pairs of
rollers may counter-rotate to pull the series of bags from the
spindle and between the base and shell. The bag 400 is positioned
so that the bag 400 is beneath the first and second nozzles.
Additionally, the first and second nozzles 358, 360 may extend
within the open top edge of bag 400 between the front and rear
sheets 128, 130 of bag 400. (FIG. 35.)
[0123] The base 314 and shell 312 may be moved relative each other
to be placed in the base/shell engaged position in which the shell
and base press together to hold the bag 400 between the base and
shell to divide the bag 400 into a mixing chamber 320 and a
remainder portion 322 such that the mixing chamber 320 is isolated
from the remainder portion 322 of the bag. The mixing chamber is
beneath the first and second nozzles. (FIGS. 36-37.) As previously
described above, in this context, "isolated" means that the mixing
chamber and the remainder portion of the bag are not in liquid
communication with each other, such that foam liquid precursor that
may be injected or placed into the mixing chamber does not transfer
or leak into the remainder portion of the bag. As illustrated in
FIG. 36, mixing chamber 320 is isolated from remainder portion 322
of the bag--even though the top of the bag may be open--because
gravity precludes the injected amount of liquid foam precursor from
spilling out or over the open top of the engaged U-shaped bottom
jaw into the remainder portion of the bag.
[0124] The base and shell may be moved relative each other into the
base/shell engaged position by spring force provided, for example,
at one or more of hinges 16 biased in the base/shell engaged
position, and/or by the drive mechanism 142 as described
herein.
[0125] The supply system is actuated to inject first and second
foam precursors though nozzles 258 and 260 into the mixing chamber
320 of the bag. Because the first and second nozzles may be spaced
apart from each other, there is minimal chance that the first and
second foam precursors would encounter each other within the
nozzles 258, 260 to initiate a foaming reaction within either
nozzle that might clog the nozzle. Accordingly, the frequency of
nozzle clogging and/or the need for solvent cleaning of the nozzles
is reduced in comparison to the prior art dispensers discussed in
the Background section above.
[0126] After injecting the liquid foam precursors into the mixing
chamber, the top jaw 382 is moved relative to the bottom jaw 380
and base 314 from a top jaw disengaged position (FIGS. 35-36) to a
top jaw engaged position (FIG. 37) in which the top jaw 382 and
base 314 press together to hold the top portion of bag 400 between
the top jaw and base to close the top of the mixing chamber 320,
for example, so that shell 312 forms a peripheral enclosure about
the mixing chamber, also by way of example, having top jaw 382
extend across the open top of the bottom jaw 380. The top jaw 382
may engage the bag beneath the first and second nozzles, such that
the first and second nozzles may remain stationary relative the
base, and may not have to be retracted or moved relative the base
in order to move the top jaw to the engaged position. That is, the
first and second nozzles may be fixedly mounted to the base 314. In
such arrangement, bag 400 may not require any one-way valves of the
type described herein, but may have an open top edge, as
illustrated in FIGS. 35-38.
[0127] Upon injection of the first and second foam precursors into
the mixing chamber 320, the first and second foam precursors are
free to interact and begin the foaming reaction within the mixing
chamber 320 of the bag. (FIG. 37.) The mixing of the first and
second foam precursors 272 within the mixing chamber of the bag may
be facilitated by the operation of mixer 370. Mixer 370 is movable
between a mixer disengaged position (FIGS. 35, 38) and a mixer
engaged position (FIGS. 36-37). The mixer engaged and disengaged
positions may correspond with the base/shell engaged and disengaged
positions, respectively, as illustrated in FIGS. 35-39. In the
mixer engaged position, the mixer engages the mixing chamber of the
bag. When activated in the engaged position, the mixer provides
mixing energy to the first and second precursors 272 within the
mixing chamber of the bag to further the mixing of the first and
second precursors thereby enhancing the foaming reaction. For
example, upon activation of mixing motor 376, drive shaft 374
causes the mixing rollers 372 to rotate about drive shaft 374. In
such operation, the one or more mixing rollers 372 circulate in a
plane generally parallel to the surface of the mixing chamber 320
of the bag. As the mixing rollers engage the mixing chamber, they
roll along the surface of the mixing chamber 320 of bag 400 to
provide mixing energy to the precursors within the mixing chamber.
The mixer may circulate the one or more mixing rollers along a path
having a portion corresponding to the concave curved bottom region
350 of the bottom jaw 380 of shell 312. As such, the outer boundary
of the rotational mixing path (e.g., circular rotational path) of
the one or more mixing rollers 372 as they circulate about the
drive shaft 374 may define a mixing path adjacent bottom region of
the mixing chamber. In this configuration, the mixing rollers can
engage the mixing chamber where the reacting foam precursors 272
may collect in the bottom region 326 of the mixing chamber 320.
[0128] As the foam reaction progresses, the foam expands within the
mixing chamber of the bag. The base and shell may be placed into
the base/shell disengaged position (e.g., by drive mechanisms
discussed herein directed for example by the controller) so that
the remaining first and second foam precursors as well as the
reacting or expanding foam and reaction by-products (collectively,
272) may flow or fall into the remainder portion 322 of the bag to
complete the reaction. (FIG. 38.)
[0129] The opposing front left roller 334 and rear left roller
and/or the downstream opposing front right roller 330 and rear
right roller may cooperate to engage the bag and provide a traction
for transmitting a propelling force to the bag. By providing
rotational power to drive one or more of the rollers, for example
by driving rear left roller or rear right roller or both, then the
bag 400 containing the reacted foam may be propelled forward, for
example in an indexed manner, to place a subsequent bag from the
series of bags in position for filling after the foam has been
formed in the previous bag. The bag containing the foam may be
detached from the subsequent bag, for example, by tearing the bag
along the line of weakening.
[0130] As previously mentioned, bag 400 may be provided without
one-way valves but with the top edge in an open configuration so
that the first and second nozzles do not have to align for
insertion into the valves of the bag. In any event, the top of the
bag may be sealed closed after injection of the foam precursors
into the bag, for example, by incorporating a sealing device such
as described in U.S. Pat. No. 6,550,229, previously incorporated by
reference. For example, the heat seal device may comprise a pair of
opposing counter-rotating rollers and an electrically conducting
heating element that contacts one sheet as the front and rear
sheets pass between the rollers to press the heated sheets together
to form a longitudinal heat seal across the top of the bag to
"close" the bag. Such heat sealing capability may be provided in
conjunction, for example, with the opposing right rollers described
herein. The heat seal device may be located downline from the
injector, for example, downline from the base and shell, for
example, to effect the transverse heat seal to close the top edge
of the bag after the precursors have been mixed together and
expanded into the remainder portion of the bag and, for example, as
the bag is propelled forward after the foaming reaction has
begun.
Various Embodiments
[0131] The following sentences describe various embodiments of the
invention.
A. A machine useful for mixing first and second foam precursors to
produce foam within a bag, the machine comprising:
[0132] a base and a shell moveable relative each other between:
[0133] (i) a base/shell disengaged position, in which the base and
shell are spaced apart to permit insertion of the bag between the
base and shell, and [0134] (ii) a base/shell engaged position in
which the shell and base press together to hold the bag between the
base and shell and to divide the bag into (1) a mixing chamber and
(2) a remainder portion so that the mixing chamber is isolated from
the remainder portion of the bag;
[0135] a divider, wherein in the base/shell engaged position the
divider is moveable relative to the base and shell between: [0136]
(a) a divider engaged position in which the divider engages the bag
to partition the mixing chamber of the bag into first and second
compartments that are isolated from each other while the divider is
in the engaged position; and [0137] (b) a divider disengaged
position in which the divider does not isolate the first and second
compartments from each other;
[0138] a first nozzle adapted to inject the first foam precursor
into the first compartment within the bag; and
[0139] a second nozzle adapted to inject the second foam precursor
into the second compartment within the bag.
B. The machine described by sentence A wherein the divider is
adapted to engage the mixing chamber of the bag to provide mixing
energy to the first and second foam precursors within the mixing
chamber of the bag when the base and shell are in the base/shell
engaged position and the divider is in the disengaged position,
thereby facilitating the foam reaction between the first and second
foam precursors. C. The machine described by sentence B wherein the
divider is adapted to reciprocatingly engage the mixing chamber of
the bag to provide the mixing energy. D. The machine described by
any one of sentences A through C wherein the base defines a cavity
in which the divider is moveably received. E. The machine described
by any one of sentences A through D further comprising at least one
mixer adapted to engage the mixing chamber of the bag to provide
mixing energy to the first and second foam precursors within the
mixing chamber of the bag when the base and shell are in the
base/shell engaged position and the divider is in the disengaged
position, thereby facilitating the foam reaction between the first
and second foam precursors. F. The machine described by sentence E
wherein the at least one mixer is adapted to reciprocatingly engage
the mixing chamber of the bag to provide the mixing energy. G. The
machine described by any one of sentences E and F wherein the base
defines a cavity in which the at least one mixer is moveably
received. H. The machine described by any one of sentences E
through G comprising at least two mixers adapted to engage the
mixing chamber of the bag to provide mixing energy to the first and
second foam precursors within the mixing chamber of the bag when
the base and shell are in the base/shell engaged position and the
divider is in the disengaged position, thereby facilitating the
foam reaction between the first and second foam precursors. I. The
machine described by any one of sentences A through H wherein the
divider defines:
[0140] a first concave section adapted to correspond to the first
compartment of the partitioned mixing chamber of the bag; and
[0141] a second concave section adapted to correspond to the second
compartment of the partitioned mixing chamber of the bag.
J. The machine described by any one of sentences A through I
wherein the base defines:
[0142] a first concave section adapted to correspond to the first
compartment of the partitioned mixing chamber of the bag; and
[0143] a second concave section adapted to correspond to the second
compartment of the partitioned mixing chamber of the bag.
K. The machine described by any one of sentences A through J
wherein the shell defines:
[0144] a first concave section adapted to correspond to the first
compartment of the partitioned mixing chamber of the bag; and
[0145] a second concave section adapted to correspond to the second
compartment of the partitioned mixing chamber of the bag.
L. The machine described by any one of sentences A through K
wherein the base defines a roller recess and comprises a roller
rotatably mounted at least partially within the base roller recess
and adapted to engage the bag. M. The machine described by any one
of sentences A through L wherein the shell defines a roller recess
and comprises a roller rotatably mounted at least partially with
the shell roller recess and adapted to engage the bag. N. The
machine described by any one of sentences A through K wherein:
[0146] the base defines a roller recess and comprises a roller
rotatably mounted at least partially within the base roller recess
and adapted to engage the bag;
[0147] the shell defines a roller recess and comprises a roller
rotatably mounted at least partially with the shell roller recess
and adapted to engage the bag; and
[0148] the roller within the base roller recess and the roller
within the shell roller recess oppose each other when the base and
shell are in the base/shell engaged position.
O. A method of making a foam-in-bag cushion comprising:
[0149] inserting a bag in the machine described by any one of
sentences A through N between the base and shell in the base/shell
disengaged position;
[0150] moving the base and shell relative each other to the
base/shell engaged position to divide the bag into a mixing chamber
and a remainder portion, wherein the mixing chamber is isolated
from the remainder portion of the bag;
[0151] moving the divider relative to the base and shell to the
divider engaged position to engage the bag and partition the mixing
chamber of the bag into first and second compartments that are
isolated from each other while the divider is in the engaged
position;
[0152] inserting the first nozzle into the bag to inject a first
foam precursor into the first compartment within the bag;
[0153] inserting the second nozzle into the bag to inject a second
foam precursor into the second compartment within the bag;
[0154] withdrawing the first and second nozzles from the bag;
and
[0155] placing the divider into the disengaged position so that the
first and second foam precursors may contact each other in the
mixing chamber of the bag.
P. The method described by sentence O wherein:
[0156] the bag comprises first and second one-way valves;
[0157] inserting the first nozzle comprises inserting the first
nozzle into the first one-way valve to inject a first foam
precursor into the first compartment within the bag;
[0158] inserting the second nozzle comprises inserting the second
nozzle into the second one-way valve to inject a second foam
precursor into the second compartment within the bag; and
[0159] withdrawing the first and second nozzles from the bag
comprises withdrawing the first and second nozzles from the first
and second one-way valves.
Q. The method described by any one of sentences O and P wherein
subsequent to placing the divider in the disengaged position, the
base and shell are placed in the base/shell disengaged position,
wherein the expanding foam extends into the remainder portion of
the bag. R. The method described by any one of sentences O through
Q wherein mixing energy is applied to the first and second foam
precursors in the mixing chamber of the bag before the base/shell
are placed in the base/shell disengaged position. S. The method
described by sentence R wherein the mixing energy is applied by
reciprocating the divider to repeatedly engage the mixing chamber
of the bag. T. The method described by sentence R wherein the
mixing energy is applied by at least two mixers that repeatedly
engage the mixing chamber of the bag. U. A machine useful for
mixing first and second foam precursors to produce foam within a
bag, the machine comprising:
[0160] a base and a shell moveable relative each other between:
[0161] (i) a base/shell disengaged position, in which the base and
shell are spaced apart to permit insertion of the bag between the
base and shell, and [0162] (ii) a base/shell engaged position in
which the shell and base press together to hold the bag between the
base and shell and to divide the bag into (1) a mixing chamber and
(2) a remainder portion so that the mixing chamber is isolated from
the remainder portion of the bag;
[0163] a first nozzle adapted to inject the first foam precursor
into the mixing chamber within the bag;
[0164] a second nozzle adapted to inject the second foam precursor
into the mixing chamber within the bag; and
[0165] at least one mixer adapted to engage the mixing chamber of
the bag to provide mixing energy to the first and second foam
precursors within the mixing chamber of the bag when the base and
shell are in the base/shell engaged position, thereby facilitating
the foam reaction between the first and second foam precursors.
V. The machine described by sentence U wherein the at least one
mixer is adapted to reciprocatingly engage the mixing chamber of
the bag to provide the mixing energy. W. The machine described by
any one of sentences U and V wherein the base defines a cavity in
which the at least one mixer is moveably received. X. The machine
described by any one of sentences U through W comprising at least
two mixers adapted to engage the mixing chamber of the bag to
provide mixing energy to the first and second foam precursors
within the mixing chamber of the bag when the base and shell are in
the base/shell engaged position, thereby facilitating the foam
reaction between the first and second foam precursors. Y. A method
of making a foam-in-bag cushion comprising:
[0166] inserting a bag in the machine described by any one of
sentences U though W between the base and shell in the base/shell
disengaged position;
[0167] moving the base and shell relative each other to the
base/shell engaged position to divide the bag into a mixing chamber
and a remainder portion, wherein the mixing chamber is isolated
from the remainder portion of the bag;
[0168] inserting the first nozzle into the bag to inject a first
foam precursor into the mixing chamber within the bag;
[0169] inserting the second nozzle into the bag to inject a second
foam precursor into the mixing chamber within the bag;
[0170] withdrawing the first and second nozzles from the bag;
and
[0171] moving the mixer to repeatedly engage the mixing chamber of
the bag to provide mixing energy to the first and second foam
precursors within the mixing chamber.
Z. The method described by sentence Y wherein:
[0172] the bag comprises first and second one-way valves;
[0173] inserting the first nozzle comprises inserting the first
nozzle into the first one-way valve to inject a first foam
precursor into the mixing chamber within the bag;
[0174] inserting the second nozzle comprises inserting the second
nozzle into the second one-way valve to inject a second foam
precursor into the mixing chamber within the bag; and
[0175] withdrawing the first and second nozzles from the bag
comprises withdrawing the first and second nozzles from the first
and second one-way valves.
AA. The method described by any one of sentences Y and Z wherein
subsequent to moving the mixer to repeated engage the mixing
chamber of the bag, the base and shell are placed in the base/shell
disengaged position, wherein the expanding foam extends into the
remainder portion of the bag. BB. The method described by any one
of sentences Y through AA wherein mixing energy is applied to the
first and second foam precursors in the mixing chamber of the bag
before the base/shell are placed in the base/shell disengaged
position. CC. The method described by any one of sentences Y
through BB wherein the mixing energy is applied by at least two
mixers that repeatedly engage the mixing chamber of the bag. DD. A
machine useful for mixing first and second foam precursors to
produce foam within a bag, the machine comprising:
[0176] a base and a shell moveable relative each other between:
[0177] (i) a base/shell disengaged position, in which the base and
shell are spaced apart to permit insertion of the bag between the
base and shell, and [0178] (ii) a base/shell engaged position in
which the shell and base press together to hold the bag between the
base and shell and to divide the bag into (1) a mixing chamber and
(2) a remainder portion so that the mixing chamber is isolated from
the remainder portion of the bag;
[0179] a first nozzle adapted to inject the first foam precursor
into the mixing chamber within the bag;
[0180] a second nozzle adapted to inject the second foam precursor
into the mixing chamber within the bag; and
[0181] at least one of either: [0182] A) a divider, wherein in the
base/shell engaged position the divider is moveable relative to the
base and shell between: [0183] (a) a divider engaged position in
which the divider engages the bag to partition the mixing chamber
of the bag into first and second compartments that are isolated
from each other while the divider is in the engaged position,
wherein the first nozzle is adapted to inject the first foam
precursor into the first compartment within the bag and the second
nozzle is adapted to inject the second foam precursor into the
second compartment within the bag; and [0184] (b) a divider
disengaged position in which the divider does not isolate the first
and second compartments from each other; or [0185] B) at least one
mixer adapted to engage the mixing chamber of the bag to provide
mixing energy to the first and second foam precursors within the
mixing chamber of the bag when the base and shell are in the
base/shell engaged position, thereby facilitating the foam reaction
between the first and second foam precursors. EE. A machine useful
for mixing first and second foam precursors to produce foam within
a bag, the machine comprising:
[0186] a base and a shell moveable relative each other between:
[0187] (i) a base/shell disengaged position, in which the base and
shell are spaced apart to permit insertion of the bag between the
base and shell, and [0188] (ii) a base/shell engaged position in
which the shell and base press together to hold the bag between the
base and shell and to divide the bag into (1) a mixing chamber and
(2) a remainder portion so that the mixing chamber is isolated from
the remainder portion of the bag;
[0189] a first nozzle adapted to inject the first foam precursor
into the mixing chamber within the bag;
[0190] a second nozzle adapted to inject the second foam precursor
into the mixing chamber within the bag; and
[0191] a mixer adapted to engage the mixing chamber of the bag to
provide mixing energy to the first and second foam precursors
within the mixing chamber of the bag when the base and shell are in
the base/shell engaged position, thereby facilitating the foam
reaction between the first and second foam precursors.
FF. The machine of sentence EE wherein the shell comprises a bottom
jaw such that when the base and shell are in the base/shell engaged
position, the bottom jaw is adapted to press together with the base
to hold the bag between the base and bottom jaw to divide the bag
into the mixing chamber and the remainder portion. GG. The machine
of sentence FF wherein the bottom jaw has a concave curved bottom
region. HH. The machine of any one of sentences FF and GG wherein
the bottom jaw has a U-shaped configuration. II. The machine of any
one of sentences FF to HH further comprising a top jaw movable
relative the bottom jaw and adapted to move to an engaged position
cooperating with the bottom jaw to form a peripheral enclosure
about the mixing chamber when the base and shell are in base/shell
engaged position. JJ. The machine of sentence II wherein:
[0192] the bottom jaw has a U-shaped configuration; and
[0193] the top jaw is adapted to extend across the open top of the
U-shape configuration of the bottom jaw to form the peripheral
enclosure.
KK. The machine of any one of sentences EE to JJ wherein the mixer
is adapted to reciprocatingly engage the mixing chamber of the bag
to provide the mixing energy. LL. The machine of any one of
sentences EE to KK wherein the mixer is adapted to rotatively
engage the mixing chamber of the bag to provide the mixing energy.
MM. The machine of any one of sentences EE to LL wherein the mixer
is mounted to the shell. NN. The machine of any one of sentences EE
to MM wherein the mixer comprises one or more mixing rollers
adapted to engage the mixing chamber of the bag. OO. The machine of
any one of sentences EE to NN wherein the mixer is adapted to
circulate the one or more mixing rollers in a plane generally
parallel with the surface of the mixing chamber of the bag. PP. The
machine of any one of sentences NN to OO wherein the one or more
mixing rollers are adapted to roll along the surface of the bag.
QQ. The machine of any one of sentences EE to PP wherein the mixing
chamber has a bottom region and the mixer is adapted to engage the
bottom region of the mixing chamber. RR. The machine of any one of
sentences EE to QQ wherein:
[0194] the shell comprises a bottom jaw such that when the base and
shell are in the base/shell engaged position, the bottom jaw is
adapted to press together with the base to hold the bag between the
base and bottom jaw to divide the bag into the mixing chamber and
the remainder portion;
[0195] the bottom jaw has a concave curved bottom region so that in
the base/shell engaged position the mixing chamber of the bag has a
corresponding concave curved bottom region;
[0196] the mixer comprises one or more mixing rollers adapted to
engage the mixing chamber of the bag; and
[0197] the mixer is adapted to circulate the one or more mixing
rollers along a path having a portion corresponding to the concaved
curved bottom region of the mixing chamber, whereby the mixer is
adapted to provide mixing energy to liquids that collect in the
concave curved bottom region of the mixing chamber.
SS. The machine of any one of sentences EE to RR wherein the first
and second nozzles are fixedly mounted to the base. TT. A method of
making a foam-in-bag cushion comprising:
[0198] inserting a bag in the machine of any one of sentences EE to
SS between the base and shell in the base/shell disengaged position
and beneath the first and second nozzles;
[0199] moving the base and shell relative each other to the
base/shell engaged position to divide the bag into a mixing chamber
and a remainder portion, wherein the mixing chamber is isolated
from the remainder portion of the bag;
[0200] injecting a first foam precursor from the first nozzle into
the mixing chamber within the bag;
[0201] injecting a second foam precursor from the second nozzle
into the mixing chamber within the bag; and
[0202] activating the mixer to engage the mixing chamber of the bag
to provide mixing energy to the first and second foam precursors
within the mixing chamber.
UU. The method of sentence TT further comprising subsequently
moving the base and shell to the base/shell disengaged position so
that at least a portion of the reacting first and second foam
precursors move to the remainder portion of the bag. VV. A method
of making a foam-in-bag cushion comprising:
[0203] inserting a bag in the machine of claim II between the base
and shell in the base/shell disengaged position and beneath the
first and second nozzles;
[0204] moving the base and shell relative each other to the
base/shell engaged position and to hold the bag between the base
and bottom jaw to divide the bag into a mixing chamber and a
remainder portion, wherein the mixing chamber is isolated from the
remainder portion of the bag;
[0205] injecting a first foam precursor from the first nozzle into
the mixing chamber within the bag;
[0206] injecting a second foam precursor from the second nozzle
into the mixing chamber within the bag;
[0207] subsequently moving the top jaw to an engaged position
cooperating with the bottom jaw to form a peripheral enclosure
about the mixing chamber; and
[0208] activating the mixer to engage the mixing chamber of the bag
to provide mixing energy to the first and second foam precursors
within the mixing chamber.
WW. The method of sentence VV further comprising subsequently
moving the base and shell to the base/shell disengaged position so
that at least a portion of the reacting first and second foam
precursors move to the remainder portion of the bag. XX. The
machine of any one of sentences EE to SS further comprising:
[0209] a first tank adapted to supply the first foam precursor to a
first bellows pump, wherein the first bellows pump is adapted to
pump the first foam precursor to the first nozzle; and
[0210] a second tank adapted to supply the second foam precursor to
a second bellows pump, wherein the second bellows pump is adapted
to pump the second foam precursor to the second nozzle.
YY. The machine of any one of sentences EE to SS and XX wherein the
first and second bellows pumps are adapted for manual operation.
ZZ. The machine of any one of sentences EE to SS and XX to YY
wherein the first and second tanks comprise first and second
bag-in-box containers, respectively.
[0211] The descriptions herein are those of various embodiments of
the invention. Various alterations and changes can be made without
departing from the spirit and broader aspects of the invention as
defined in the claims, which are to be interpreted in accordance
with the principles of patent law, including the doctrine of
equivalents. Except in the claims and the specific examples, or
where otherwise expressly indicated, all numerical quantities in
this description indicating amounts of material, reaction
conditions, use conditions, and the like, are to be understood as
modified by the word "about" in describing the broadest scope of
the invention. Any reference to an item in the disclosure or to an
element in the claim in the singular using the articles "a," "an,"
"the," or "said" is not to be construed as limiting the item or
element to the singular unless expressly so stated. The definitions
and disclosures set forth in the present Application control over
any inconsistent definitions and disclosures that may exist in an
incorporated reference.
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