Foam-in-Bag Mixing Chamber Isolation
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Solution Overview
Problem
Foam-in-bag packaging systems face issues with foam build-up in dispensers, leading to operational disruptions and the need for frequent cleaning, and the use of solvents for cleaning adds complexity and expense, with solvent leakage potentially damaging packaged items.
Innovation Solution
A machine that mixes foam precursors within a bag, using a base and shell that move to isolate a mixing chamber, reducing nozzle clogging and eliminating the need for solvent cleaning by ensuring precursors mix only within the bag, minimizing foam build-up and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If foam precursors are mixed in an internal mixing chamber of the dispenser, then the precursors can be ejected through a discharge outlet, but foam build-up occurs in the mixing chamber and discharge outlet causing operational disruptions
Solution Approach 1:
The invention extracts the mixing process from the dispenser by providing a separate mixing chamber located outside the dispenser. The mixing chamber is positioned such that the mixed foamable composition is delivered directly to the discharge outlet, bypassing the internal mixing chamber. This extraction eliminates foam build-up within the dispenser's internal mixing chamber and discharge outlet, preventing nozzle clogging and operational disruptions.
2Ease of operation
If solvent is supplied to the dispenser for cleaning, then frequent manual cleaning can be avoided, but operational expense and complexity increase
Solution Approach 1:
The invention extracts the mixing function from the dispenser entirely, placing it in a separate external mixing chamber. Since mixing occurs outside the dispenser, there is no foamable composition buildup inside the dispenser to require cleaning. This eliminates the need for solvent supply systems and manual cleaning operations, reducing both operational complexity and expense.
3Reliability
If solvent is used to clean the dispenser, then foam build-up can be removed, but solvent may leak through incomplete seals or vent holes damaging packaged items
Solution Approach 1:
The invention extracts the mixing chamber from the dispenser structure, positioning it externally with direct delivery to the discharge outlet. This configuration prevents foamable composition accumulation inside the dispenser, eliminating the need for solvent cleaning operations. Consequently, there is no solvent leakage risk to packaged items, as the cleaning process is entirely eliminated.
4Device complexity
If the mixing chamber is inside the dispenser, then the structure is compact, but foam build-up disrupts operation requiring frequent cleaning
Solution Approach 1:
The invention segments the foamable composition delivery system into two distinct functional components: an external mixing chamber for mixing the precursors and a dispenser for ejecting the mixed composition. The mixing chamber is positioned separately from the dispenser, with the mixed composition being delivered directly to the discharge outlet. This segmentation prevents foam build-up within the dispenser, eliminating operational disruptions and maintaining continuous productivity.
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
The machine effectively produces foam within bags with reduced disruption from nozzle clogging and cleaning needs, maintaining operational efficiency while avoiding solvent-related issues and damage to packaged items.
Implementation Method 1
Polyurethane foam may be formed by mixing an isocyanate compound with a hydroxyl-containing material, such as a polyol... As the isocyanate and polyol foam precursors react in the presence of the catalyst to form polyurethane
Implementation Method 2
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
Implementation Method 3
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
Implementation Method 4
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
Data Source
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AI summary
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.