Foam-in-Bag Mixing Chamber Integrated Into Bag Structure
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Solution Overview
Problem
Existing foam-in-bag dunnage material production technologies are complex and costly, requiring a movable base and shell structure for the mixing chamber, which complicates the manufacturing process.
Innovation Solution
The mixing chamber is integrated into the bag structure itself, allowing for a simpler machine design that uses a plastic film bag with a preconfigured mixing chamber, which is formed by connecting adjacent side walls during production, and a mechanical or manual mixing action to mix chemical foam precursors within the bag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a movable base and shell structure is used for the mixing chamber, then the mixing chamber can be formed externally, but the machine structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The mixing chamber is merged with the bag structure itself. The bag includes a mixing chamber formed by regionally connecting adjacent side walls during bag production, eliminating the need for a separate external mixing chamber structure. This integration simplifies the machine design while maintaining the mixing function.
Solution Approach 2:
The mixing chamber function is extracted from the machine structure and transferred to the bag structure. By forming the mixing chamber as part of the bag during bag production, the machine no longer requires complex movable base and shell structures, thereby reducing device complexity.
2Ease of manufacture
If the mixing chamber is formed by external machine structures, then mixing can be performed, but the machine requires complex movable components increasing cost
Solution Approach 1:
The mixing chamber is combined with the bag structure by regionally connecting adjacent side walls during bag production. This integration allows the bag itself to serve as the mixing chamber, eliminating complex external machine structures while maintaining mixing capability.
3Quantity of substance
If liquid chemical foam precursor substances are injected into the bag, then foam expansion occurs, but the precursors must be thoroughly mixed first
Solution Approach 1:
The mixing chamber is prepared in advance within the bag structure, with mixing elements already in place. Liquid chemical foam precursor substances are injected into this pre-configured mixing chamber, ensuring thorough mixing occurs before the expansion reaction begins, thereby maintaining manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the production process, reduces costs, and enables efficient mixing and expansion of the foam precursors to form a low-density dunnage material that fits snugly into container voids, providing shock protection for articles.
Implementation Method 1
a plurality of liquid chemical foam precursor substances is injected into a plastic bag. The liquid chemical foam precursor substances react with each other by expanding and building a rather low density foam
Implementation Method 2
The liquid chemical foam precursor substances react with each other by expanding and building a rather low density foam which, after expansion, hardens
Implementation Method 3
This hardened foam may fill a void volume in a container between the container walls and an article placed inside the container, thus blocking the articles inside the container from moving around and also providing a protecting function against shocks movements
Data Source
AI summary
A bag for producing a foam-in-bag dunnage material comprises a closed edge portion and, in a non-sealed state of the bag, an open edge portion, the closed and open edge portions delimiting an inner bag volume. The invention proposes that a bag structure of the bag comprises a mixing chamber which is adapted to receive foam precursor substances, which is arranged within the inner bag volume, which is at least partially and initially delimited against the remainder of the inner bag volume, and which in the non-sealed state of the bag is connected to the open edge portion.