Foam Cushion Molding System Pneumatic Ejection
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Solution Overview
Problem
Current foam-in-place packaging systems face challenges in automating the molding process for foam cushions, leading to potential distortion and incomplete filling of mold cavities, which can result in defective cushions.
Innovation Solution
A molding system that includes a mold with an air plenum and pneumatic vacuum/blowout system, using vacuum to draw the expanding foam into the mold cavity and pressurized air to expel it once fully expanded, ensuring proper settling and shaping of the foam cushion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If mechanical devices such as rods are used to push molded cushions out of molds, then automation of the molding process is achieved, but the molded cushions are distorted
Solution Approach 1:
The patent replaces mechanical pushing devices (rods) with a pneumatic system that uses air pressure to eject the cured foam cushion from the mold. The mold includes air passages that deliver pressurized air to the cushion, causing it to expand and be pushed out without mechanical contact, thereby eliminating distortion while maintaining automation.
Solution Approach 2:
The invention employs pneumatic pressure through air passages integrated into the mold structure to eject the cushion. Compressed air is delivered through channels in the mold to the cushion surface, using gas pressure instead of mechanical force to achieve cushion ejection, thus preserving cushion shape integrity.
2Productivity
If the cushion is placed into the mold cavity without proper settling, then the molding process can proceed, but the expanding cushion does not completely fill the cavity resulting in defective cushions
Solution Approach 1:
The patent incorporates preliminary action by designing the mold with integrated air passages that deliver air pressure to the cushion during the expansion phase. This preliminary pneumatic assistance ensures the cushion is pushed into all corners and regions of the mold cavity during expansion, guaranteeing complete filling before the cushion cures.
3Reliability
If manual operations are used for molding foam cushions, then cushion quality can be monitored, but the molding process is not automated and efficiency is reduced
Solution Approach 1:
The mold design incorporates self-service features where the air passage system automatically delivers pressurized air to assist cushion settling and ejection without requiring manual intervention. The system uses the cushion's own expansion pressure combined with pneumatic assistance to achieve proper filling and ejection, maintaining quality while enabling automation.
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 system automates the molding process, ensuring that foam cushions are accurately shaped and fully filled within the mold cavity, reducing the likelihood of distortion and defects, and improving the efficiency of foam-in-place packaging.
Implementation Method 1
A vacuum source is provided separate from the mold cavity. A plurality of air passages connect the mold cavity to the air plenum... The vacuum/blowout system comprises a vacuum source... When the vacuum source is connected to the at least one port by the vacuum/blowout valve, air is evacuated from the mold cavity via the air passages and air plenum so as to suck a newly formed cushion into the mold cavity.
Implementation Method 2
an air tank containing pressurized air... Next, the door is opened and the vacuum/blowout valve is operated to connect the air tank to the at least one port. Accordingly, pressurized air is supplied from the air tank to the mold cavity via the air plenum and air passages to expel the cushion from the mold cavity.
Implementation Method 3
The isocyanate and polyol precursors react to form polyurethane. At the same time, the water reacts with the isocyanate compound to produce carbon dioxide. The carbon dioxide causes the polyurethane to expand into a foamed cellular structure, i.e., a polyurethane foam.
Data Source
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AI summary
A molding system (40) for foam-in-bag cushions comprises a mold (90) defining a mold cavity (110), an air plenum (116) separate from the mold cavity, a plurality of air passages (114) that connect the mold cavity to the air plenum, and at least one port (118) connected to the air plenum. The mold cavity has an open side and the mold includes a door (100) that is movable between a closed position closing the open side of the mold cavity and an open position allowing a cushion to enter and exit through the open side. The system further comprises a pneumatic vacuum/blowout system (130) connected with the at least one port. The vacuum/blowout system comprises a vacuum source (136), an air tank (132) containing pressurized air, and a vacuum/blowout valve structured and arranged to alternately couple the at least one port either to the vacuum source or to the air tank.