Foam-in-Bag Packaging System with Segmented Outer Pouch
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Solution Overview
Problem
Existing foam-in-bag packaging systems face challenges in controlling the mixing and expansion of precursor liquids, leading to suboptimal foam formation due to uncontrolled pressure and confinement issues, particularly in containers of simple geometry.
Innovation Solution
A flexible, multilayered packaging system with a vented, deformable outer bag and an inner confinement structure featuring reclosable openings, score lines, and calibrated frangible seals to facilitate controlled mixing and expansion of foam precursors, ensuring optimal foam production without pressure buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If precursors are placed within sealed pouches and mixed by rupturing with external force, then foam expansion can occur within a confined volume, but uncontrolled pressure waves cause the outer pouch to burst along uncontrolled paths
Solution Approach 1:
The outer pouch is divided into multiple compartments by fold lines, creating a segmented structure that guides foam expansion along predetermined paths. This segmentation prevents uncontrolled bursting while maintaining confined volume expansion.
Solution Approach 2:
The fold lines and compartments are pre-formed in the outer pouch before foam expansion occurs. This preliminary structuring ensures that when foam expands, it follows the predetermined paths rather than causing uncontrolled bursting.
2Ease of operation
If frangible seals are used to join precursor packets, then mixing can be initiated by external force, but the external seals break before the internal seal between precursor zones
Solution Approach 1:
The frangible seals have different local qualities - external seals are designed with lower fracture strength than the internal seal between precursor zones. This ensures that when external force is applied, the external seals break first while the internal seal remains intact until precursors begin mixing.
3Ease of manufacture
If precursors are injected directly into non-airtight containers, then foam can form in the container, but leaks occur and gaseous byproducts evacuate freely
Solution Approach 1:
A sealed outer pouch serves as an intermediary between the precursor packets and the final container. This intermediary maintains airtight containment during foam formation, preventing leaks and controlling byproduct evacuation while still allowing the process to occur within a simple container.
4Adaptability or versatility
If plastic bags are used to allow shape-change during expansion, then foam can adapt to container geometry, but operator manipulation is required and timing must be managed
Solution Approach 1:
The system is designed to be self-activating - applying external force to the outer pouch simultaneously breaks the external frangible seals and initiates precursor mixing and foam expansion without requiring operator manipulation of individual components or timing management.
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 system ensures homogeneous foam expansion and controlled hardening, preventing pressure-induced issues and allowing for efficient packaging of articles with complex geometries, even in containers of simple geometry, by using individually sealed pouches and a deformable outer bag with preferential release paths.
Implementation Method 1
Two liquids, called precursors, are mixed in controlled quantities when foam is needed in low volume. The liquids react chemically to form a polymer-based foam and gas byproducts.
Implementation Method 2
The formation of byproducts is both necessary and unavoidable and must be controlled to obtain the desired foam density and strength since the polyurethane foam is a three-dimensional matrix of gas bubbles held in place by polyurethane.
Implementation Method 3
the precursors are placed within sealed pouches and can be mixed when adjacent pouches are ruptured with an external force, such as hand pressure or foot pressure
Data Source
AI summary
The present disclosure relates to a packaging system for producing a foam-in bag and method of mixing foam for the packaging of articles for shipment and storage, and in particular, to an improved, flexible, multilayered packaging system with a vented, deformable outer bag and an inner confinement structure made of paperboard box or a plastic bag with reclosable opening for optimal mixing and controlled release of the foam using preferential paths, score lines, weakness points, and/or obstacles to flow. In addition, the precursor fluids are placed in individually sealed pouches with calibrated and aptly positioned frangible seals to facilitate mixing after rupture inside of the inner confinement structure. In another embodiment, one of the precursor fluids is placed directly in the inner confinement structure, and in yet another embodiment, both sealed pouches are adhesively joined to the inner confinement structure. What is also disclosed is a method of mixing foam precursors in the different embodiments of the foam-in-bag packaging system.