Foam-in-place cushion selective distribution method
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Solution Overview
Problem
Conventional foam-in-place cushions often have uneven distribution of the foam-forming composition, leading to compromised foam density and protective properties due to the foam expanding before redistribution, which disturbs the cellular structure and results in non-uniform thickness.
Innovation Solution
A method and apparatus that control the dispensing and redistribution of the foam-forming composition between polymer film portions using a dispersion device to achieve uniform or varied thickness before significant expansion, ensuring the foam expands as designed and maintains desired density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the foam-forming composition is dispensed into the bottom of the bag and allowed to expand immediately, then the cushion is formed quickly, but the foam density becomes non-uniform and protective properties are compromised
Solution Approach 1:
The foam-forming composition is redistributed to a uniform layer before significant expansion occurs. This preliminary redistribution action ensures even distribution of the composition across the bag bottom, preventing density non-uniformity while maintaining quick cushion formation. The system performs the redistribution action at the optimal time point before the expansion process significantly alters the composition distribution.
2Manufacturing precision
If manual redistribution of the foam-forming composition is performed after discharge, then uniform thickness can be achieved, but the cellular structure is disturbed and foam density changes
Solution Approach 1:
The system performs redistribution of the foam-forming composition before significant expansion occurs, while the composition is still in a more manageable state. This preliminary action achieves uniform thickness distribution without the need for subsequent manual intervention that would disturb the cellular structure. The timing of the redistribution action is critical - it occurs at the point when the composition has been deposited but before expansion significantly alters its properties.
3Speed
If the foam expands before redistribution, then the cushion formation process is faster, but the foam density becomes higher than desired and uniformity is compromised
Solution Approach 1:
The system redistributes the foam-forming composition to a uniform layer before the expansion process significantly progresses. This preliminary redistribution ensures that when expansion does occur at high speed, the composition is already evenly distributed, preventing localized density variations. The system maintains the desired expansion speed while controlling the final foam density uniformity through the timing and method of redistribution.
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 solution allows for the production of foam-in-place cushions with consistent foam density and protective properties, reducing the need for manual redistribution and minimizing foam density changes, resulting in improved packaging efficiency and protection.
Implementation Method 1
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
Implementation Method 2
The carbon dioxide causes the polyurethane to expand into a foamed cellular structure, i.e., a polyurethane foam
Implementation Method 3
A method and apparatus that control the dispensing and redistribution of the foam-forming composition between polymer film portions using a dispersion device to achieve uniform or varied thickness before significant expansion
Data Source
AI summary
A method for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.