Foam cushion forming apparatus and methods
An apparatus includes a containment member having a containment member interior cavity to contain foam precursor compartments, and a release member to release foam precursor components contained within the foam precursor compartments in response to a specific relative movement produced between the release member and the containment member. The apparatus may form a portion of a foam cushion forming apparatus.
This application claims priority to U.S. Provisional Patent Application No. 60/686,322, filed Jun. 1, 2005, and entitled “Foam Cushion Forming Apparatus and Methods.”
TECHNICAL FIELDThe inventive subject matter relates generally to foam cushion forming apparatus, and methods of making and using such apparatus.
BACKGROUNDIn the packaging industry, “foam-in-place” bag systems have been developed for immobilizing objects within shipping containers. In an un-activated phase, a foam-in-place bag includes an outer bag and a foam precursor pouch, which is located within the outer bag. The foam precursor pouch holds two chemicals in separation from one another. Prior to use, the foam-in-place bag (and thus the foam precursor pouch) is pre-heated within a pre-heating chamber (e.g., an oven) until the foam precursors reach a desired activation temperature. To achieve this temperature, preheating may be recommended for as long as 30 minutes or more. After that time, the foam-in-place bag is removed from the pre-heating chamber, and the foam precursor pouch is popped and kneaded by the user to cause the two chemicals to combine and react with one another. This reaction produces an expansive foam, which is extruded into the outer bag.
Shortly after initiation of the foam production, a user can place the foam-in-place bag within a shipping container in proximity to an object being immobilized. As the expansive foam fills the bag, the bag may contour around the object. After the foam hardens, the object may be completely or partially held in place by the hardened foam.
This packaging technology currently relies on the use of pre-heating equipment (e.g., ovens) and trained users. In part, because the costs for the foam-in-place bags, the pre-heating equipment, and the training can be substantial, this technology is not widely used by the general population. Instead, this technology typically is used by business entities having a significant volume of packaging work.
BRIEF DESCRIPTION OF THE DRAWINGSThe appended claims point out, with particularity, different embodiments of the inventive subject matter described herein. However, the detailed description presents a more complete understanding of various embodiments of the inventive subject matter when considered in connection with the figures, wherein like-reference numbers refer to similar items throughout the figures and:
Flexible carrier 102 is defined by an inner surface 108 and an outer surface 110. The inner surface 108 defines an interior space 112, within which an expansive foam may be substantially retainable, as will be described in more detail later. As the foam expands, the interior space 112 may be capable of expanding to a shape that is defined by expansion limits of the flexible carrier 102. In an embodiment, flexible carrier 102 has expansion limits within the following ranges: a) width (horizontal on page) within a range of about 10-90 centimeters (cm); b) depth (into page) within a range of about 10-90 cm; and c) height (vertical on page) within a range of about 10-90 cm. In alternate embodiments, the width, depth, and/or height may be greater or smaller than the above-given ranges.
In an embodiment, flexible carrier 102 includes one or more panels 118, 120 of flexible material. Panels 118, 120 may be sealed (e.g., via seals 122, 124) on one, two, three, or all edges to form a bag-like structure. In alternate embodiments, flexible carrier 102 may be formed substantially from a flexible material that is pressed and/or blown (e.g., using a blow film extrusion process), rather than sealed, to define the interior space 112.
The flexible material may include a single layer of plastic sheet or film material, and/or multiple, laminated layers of plastic sheet or film material, in various embodiments. The flexible material also or alternatively may include one or more layers of metallic foil, a composite material, or any other flexible material that is capable of substantially retaining a foam during foam formation and expansion.
In an embodiment, foam producing mechanism 104 is located within the interior space 112 of flexible carrier 102. In a further embodiment, foam producing mechanism 104 may be secured to an area of the inner surface 108 of flexible carrier 102, so that mechanism 104 is held in place with respect to the flexible carrier 102.
Foam producing mechanism 104 may be secured to inner surface 108, for example but not by way of limitation, by an adhesive or other securing component 106. In an embodiment, securing component 106 may include one or more bands or beads of adhesive (e.g., hot melt adhesive), which adhere mechanism 104 to inner surface 108. In an embodiment, securing component 106 includes an adhesive of a pressure sensitive type. In an embodiment, the position of the foam producing mechanism 104 may be indicated by markings (not illustrated) on the outer surface 110 of the flexible carrier 102, to make it easier for a user to identify the location of the unit 104.
In another embodiment, the foam producing mechanism 104 may initially not be located within the flexible carrier 102. Instead, the flexible carrier 102 may include an opening (not illustrated), which enables insertion of the foam producing mechanism 104 either before or during activation. Desirably, the opening is sealable, so that it would not allow significant amounts of foam to escape the flexible carrier 102 during foam formation.
In an embodiment, foam producing mechanism 104 includes two or more members, which will be described in detail later. The two or more members may form a chamber within which foam precursor components are mixable when the two or more members have a first orientation relative to each other. Further, in an embodiment, foam producing mechanism 104 may include one or more openings to allow a foam, which results from the foam precursor mixture, to disperse into flexible carrier 102 when the two or more members have a second orientation relative to each other.
In an embodiment, foam precursor components are held in separation within foam producing mechanism 104, prior to activation. A user of foam cushion forming apparatus 100 may provide one or more user inputs to release and combine the foam precursor components. As they react, the foam precursor components may start to form an expansive foam, which disperses out of the foam producing mechanism 104 and into the flexible carrier 102. The expanding foam may force the inner surface 108 outward toward the expansion limits of the foam containment member 102. Further, as the flexible carrier 102 expands under the pressure of the expanding foam, the outer surface 110 may contour around or displace any physical objects located within the expansion limits of the flexible carrier 102. The foam may then harden, producing a rigid structure.
In an embodiment, in which a foam producing mechanism 104 has been activated within the interior space (e.g., interior space 112,
In an embodiment, the foam material 202 includes a polyurethane foam. The foam may have some, all, or none of the characteristics of being rapidly hardening, somewhat flexible, but substantially rigid, and relatively low-density, in an embodiment. In other embodiments, the foam material 202 may include another type of suitable foam material, as would be obvious to one of skill in the art, based on the description herein.
Polyurethane foam may be produced from the combination of two foam precursor components, in an embodiment. In other embodiments, polyurethane foam may be produced from the combination of more than two foam precursor components.
An isocyanate-including foam precursor component, which also may be referred to herein as an “isocyanate foam precursor” or “Part A,” may include one or more isocyanates and zero or more additives, in various embodiments. As used herein, the term “isocyanate” includes, but is not limited to, a group of materials that includes isocyanates, diisocyanates, and/or polyisocyanates. Isocyanates included in Part A may include, for example but not by way of limitation, one or more polymeric methylene diphenyl diisocyanates (MDI) (e.g., Lupranate M20S, sold by BASF, USA), in various embodiments. A polyol-including foam precursor component, which also may be referred to herein as a “polyol foam precursor” or “Part B,” may include one or more polyols and zero or more additives, in various embodiments. Polyols included in Part B may include, for example but not by way of limitation, one or more polyether polyols, in an embodiment.
Various additives may be included in the polyol-including foam precursor component, in an embodiment. In alternate embodiments, additives may be included in the isocyanate-including foam precursor component or in both the polyol-including and isocyanate-including foam precursor components. In an embodiment, additives may be selected from a group of additives that includes one or more surfactants (e.g., cell size control agents), one or more catalysts, one or more blowing agent precursors, one or more cross-linkers, and one or more flame retardants. In other embodiments, more, fewer, or additional additives can be included with either or both of the foam precursor components.
In an embodiment, the polyol-including foam precursor component and the isocyanate-including foam precursor component may be included in the apparatus in a ratio of about 1:1, by volume. By weight, about 100 parts of the isocyanate-including foam precursor component to about 90 parts of the polyol-including foam precursor component, may be included in the apparatus, in an embodiment. In another embodiment, about 100 parts of the isocyanate-including foam precursor component to about 72 parts of the polyol-including foam precursor component, by weight, may be included in the apparatus. In other embodiments, the polyol-including foam precursor component and the isocyanate-including foam precursor component may be included in different volume or weight ratios.
In an embodiment, foam precursors are selected to produce suitable foam for packing purposes without pre-heating the foam precursors. The foam precursors may or may not be preheated prior to activating the apparatus. In an embodiment, the isocyanate-including foam precursor component and the polyol-including foam precursor component, when mixed (e.g., hand mixed by stirring, shaking within a container, or other agitation method), may produce a “suitable foam” at a reaction temperature of about 75 degrees Fahrenheit (F). In another embodiment, the foam precursor components, when mixed, may produce a “suitable foam” at a reaction temperature of less than 75 F. In still another embodiment, the foam precursor components, when mixed, may produce a “suitable foam” at a reaction temperature within a range of about 75 F to 95 F. In still another embodiment, the foam precursor components, when mixed, may produce a “suitable foam” at a reaction temperature within a range of about 95 F to 135 F.
A “suitable foam,” as the term is used herein, may have some, all or none of the following characteristics, in various embodiments:
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- 1) cream time (e.g., time when foam starts to rise) of about 10-15 seconds (+15 seconds or −5 seconds);
- 2) rise time (e.g., time from onset of rise until completion of rise) of about 20-25 seconds (+20 seconds or −10 seconds); and
- 3) tack free time (TF) of about 25-30 seconds (+25 seconds or −15 seconds).
A suitable foam may have a density of about 0.5-0.6 pounds per cubic foot (PCF) (±40%), in an embodiment.
When the polyol-including foam precursor component and the isocyanate-including foam precursor component are combined and mixed, one or more chemical blowing agents, which aid in the production of the foam, may be generated. In an embodiment, a blowing agent may include carbon dioxide (CO2). The CO2 may be generated by the reaction of an isocyanate (e.g., diisocyanate) in the isocyanate-including foam precursor component with a blowing agent precursor (e.g., water (H2O)) in the polyol-including foam precursor component, in an embodiment. In alternate embodiments, other chemical or physical blowing agents may be generated through the reaction of the polyol-including foam precursor component and the isocyanate-including foam precursor component. Alternative physical blowing agents include, but are not limited to, chlorinated fluorocarbons (CFC), hydrogenated chlorofluorocarbons (HCFC), and/or hydrocarbons (e.g., pentane, butane, or other hydrocarbons), for example, but not by way of limitation.
As the above paragraph indicates, gaseous by-products may be produced during foam formation. Referring again to
In still another embodiment, gas venting may be provided by an intermittent seal.
In an embodiment, two panels 304, 306 may be brought together and an “intermittent seal” 302 may be formed between the panels 304, 306. The intermittent seal is a seal that enables gaseous by-products to be vented out of a flexible carrier during foam formation.
In an embodiment, intermittent seal 302 includes alternating sealed sections 308 and open sections 310. Panels 304, 306 may readily part to produce apertures 312 at open sections 310 when the pressure within the interior space (e.g., interior space 112,
Various embodiments of foam producing mechanisms will now be described in more detail, in conjunction with
A foam producing mechanism may be adapted to provide one or more of the following functionalities: 1) storage of foam precursors prior to mixing; 2) provision of a mixing chamber for the foam precursors; and 3) dispersal of the foam produced from the foam precursor mixture into a flexible carrier, in an embodiment. In some embodiments, one or more of the above listed functionalities may be provided by system elements other than the foam producing mechanism.
In several embodiments, a foam producing mechanism may include two or more members. The mechanism may be arranged to form a chamber within which foam precursors are mixable when the two or more members have a first, “chamber-forming” orientation relative to each other. Further, in various embodiments, the mechanism may include one or more openings to allow a foam to disperse into the flexible carrier when the two or more members have a second, “foam-dispersal relative orientation.”
Containment member 402, in an embodiment, may include an interior cavity 416 to contain foam precursor compartments 410, 412. In an embodiment, interior cavity 416 may be defined by containment member sidewalls 418 and a containment member bottom 420. In an embodiment, foam precursor compartments 410, 412 are distinct from containment member 402. In alternate embodiments, some or all foam precursor compartments 410, 412 may be completely or partially integrated with containment member 402.
Interior cavity 416 may me adapted to house two foam precursor compartments 410, 412, in an embodiment. A first compartment 410 may include an isocyanate-including foam precursor component, and a second compartment 412 may include a polyol-including foam precursor component. In alternate embodiments, more than one compartment may be used to contain the isocyanate-including foam precursor component, the polyol-including foam precursor component, or both. In still other alternate embodiments, first compartment 410 and second compartment 412 may be housed by another member of mechanism 400.
Release member 404, in an embodiment, may include an interior cavity 430 and one or more precursor release portions 432. In an embodiment, interior cavity 430 may be defined by release member sidewalls 434 and a release member top 436. As will be described in more detail later, interior cavity 430 may form a portion of a mixing chamber within which released foam precursors 412, 414 may be mixed.
Further, in an embodiment, release member top 436 may include one or more first openings 438, and release member sidewalls 434 may include one or more second openings 440. First openings 438 may enable a foam, which results from the foam precursor mixture, to be released from the mixing chamber, as will be described in more detail later. Second openings 440, which may be referred to herein as “degassing openings,” may enable air and other gasses to escape from the interior cavity 430, as will also be described in more detail later.
Precursor release portion 432 may be distinct from or integrated with release member 404, in various embodiments. Precursor release portion 432 may include a surface having one or more openings, which are adapted to allow precursors 412, 414 to flow into interior chamber 430. For example, but not by way of limitation, precursor release portion 432 may include a mesh or other surface having one or more openings.
In various embodiments, precursor release portion 432 is adapted to cause precursor compartments 408, 410 to be “ruptured,” which includes any or all of crushing open, puncturing, tearing, bursting, popping or cutting, when precursor release portion 432 is compressed toward precursor compartments 408, 410.
Dispersal member 406, in an embodiment, may include an interior cavity 450. Interior cavity 450 may be defined by dispersal member sidewalls 452 and a dispersal member top 454. Dispersal member sidewalls 452 may include one or more first openings 456, and dispersal member top 454 may include one or more second openings 458. First openings 456 and second openings 458 may enable a foam, which results from the foam precursor mixture, to be released from the mechanism 400, as will be described in more detail later.
In an embodiment, the one or more second openings 458 in dispersal member top 454 are positioned so that the one or more second openings 458 are not open to the interior cavity 430 when the openings 458 are spanned by portions of release member top 436 (e.g., when dispersal member top 454 is in contact with release member top 436). Similarly, the one or more first openings 438 in release member top 436 are positioned so that the one or more first openings 438 are not open to the exterior of mechanism 400 when the openings 438 are spanned by portions of dispersal member top 454 (e.g., when dispersal member top 454 is in contact with release member top 436). In other words, the dispersal member 406 and the release member 404 have openings 438, 456, 458, which are non-intersecting when dispersal member 406 and release member 404 are in a pre-activation relative orientation.
In an embodiment, a specific relative movement may be produced (e.g., by a user) to cause release member 404 to release foam precursors 412, 414 contained within the foam precursor compartments 408, 410. The specific relative movement may include a movement to compress release and dispersal members 404, 406 toward containment member 402, in an embodiment. For example, but not by way of limitation, a user could pinch the mechanism to produce the compression, or could place the mechanism on a surface and push down on the top of the mechanism.
In an embodiment, containment member 402, release member 404, and dispersal member 406 are arranged in a nested configuration. As such, an outer diameter of the sidewalls of release member 404 is smaller than an inner diameter of the sidewalls of containment member 402, and an outer diameter of the sidewalls of containment member 402 is smaller than an inner diameter of the sidewalls of dispersal member 406. This configuration enables containment member 402 substantially to encompass release member 402, and enables dispersal member 406 substantially to encompass containment member 402, when the members are in a compressed relative orientation. In other embodiments, the members 402, 404, 406 may be differently nested, allowing the members 402, 404, 406 to encompass each other in different arrangements.
In an embodiment, release member 404 includes one or more projections 460 which slidably engage with one or more depressions 462 (e.g., grooves) located on inside surfaces of containment member 402. In an alternate embodiment, containment member 402 may include one or more projections and release member 404 may include one or more depressions, which provide for slidable engagement of the two members 402, 404. Further, as will be described in more detail later, projections 460 and depressions 462 may include ratcheting elements, which function to allow members 402, 404 readily to be compressed together, but which retain them in a compressed relative state and retard their separation, in an embodiment.
In an embodiment, dispersal member 406 includes one or more projections 470 which slidably engage with one or more depressions 472 (e.g., grooves) located on outside surfaces of containment member 402. In an alternate embodiment, containment member 402 may include one or more projections and dispersal member 406 may include one or more depressions, which provide for slidable engagement of the two members 402, 406.
As they are compressed, such as by providing forces indicated generally by arrows 480, 482, release member 404 causes foam precursor compartments 408, 410 to rupture, thus releasing precursor components 412, 414. Precursor components 412 414 may flow through or around precursor release portion 432 and into interior cavity 430. In addition, air or other gasses within interior cavity 430 may flow out through holes 440, in an embodiment. When they are fully compressed, members 402, 404, 406 may form a chamber, and thus are in a “chamber-forming relative orientation.”
In an embodiment, a user may then shake or otherwise agitate mechanism 400 to cause foam precursors 412, 414 to mix within chamber 502. Foam precursors 412, 414, when mixed, should react and begin to produce an expansive foam.
The expansive foam may cause pressure on the inner surfaces of the chamber 502, and thus may produce forces on the chamber's inner surfaces. These forces may include forces, indicated generally by arrows 504, 506 on portions of the dispersal member top 454 which are exposed to the chamber 502 through holes 438 in release member 404. In an embodiment, these forces 504, 506 may cause dispersal member 406 to move away (e.g., upward) from containment member 402 and release member 404. As discussed previously, release member 404 may have a stopping mechanism to retard its movement out of the compressed orientation, and thus it may not move significantly when the forces produced by the expansive foam act on its surfaces. As dispersal member 406 moves away from containment member 402 and release member 404, the members 402, 404, 406 may assume a “foam-dispersal relative orientation,” which will be described in more detail in conjunction with
In the chamber-forming relative orientation, the members 402, 404, 406 are arranged to form a substantially closed chamber 502. Accordingly, a first member may be considered a “first chamber forming portion,” and a second member may be considered a “second chamber forming portion,” which is engaged with the first chamber portion. The first chamber portion and the second chamber portion form a chamber when the first chamber portion and the second chamber portion have a compressed relative orientation, and foam precursor components are mixable within the chamber. In an embodiment, openings in the chamber are to result when an expansive foam is produced from a mixture of the foam precursor components, and the openings are to enable release of the expansive foam from the chamber.
The next series of Figures will illustrate features of containment members, release members, and dispersal members in more detail, in accordance with various embodiments. Specifically,
In an embodiment, foam precursor compartments (e.g., compartments 410, 412,
In an embodiment, containment member 700 includes one or more depressions 710 (e.g., grooves or depressed portions) located on one or more outside sidewall surfaces 712. Depressions 710 are adapted to receive and slidably engage with one or more projections (e.g., projections 470,
In an embodiment, containment member 700 includes one or more depressions 714 (e.g., grooves) located on one or more inside sidewall surfaces 716. Depressions 714 are adapted to receive and slidably engage with one or more projections (e.g., projections 460,
In an embodiment, containment member 700 has a width 720 in a range of about 5-10 cm, and a height 722 in a range of about 2-5 cm. In other embodiments, the width 720 and/or height 722 may be greater and/or smaller than the above given ranges.
Ratcheted groove 802 may include one or more ratcheting elements 806, which enable projection 804 to be pushed in a downward direction through groove 802, but which retard upward motion of projection 804 within groove 802. The ratcheted groove 802 and projection 804 function to allow the containment and release members readily to be compressed together, and also function to retain them in a compressed relative state and retard their separation, in an embodiment. In other words, ratcheted groove 802 and projection 804 enable one-directional movement (e.g., compression) between the two containment and release members. In alternate embodiments, other ways of retarding two-directional movement may be employed, as will be described in more detail later.
Various embodiments of release members, which may engage with a containment member and/or a dispersal member, will now be described.
Further, in an embodiment, release member top 1206 may include one or more first openings 1212 and second openings 1214. As described previously, first openings 1212 may enable a foam to be released from a mixing chamber, which is partially defined by release member 1200. As also described previously, second openings 1214 may function as degassing openings, thus enabling air and other gasses to escape from the interior cavity 1202 as the release member 1200 is compressed into a containment member.
Precursor release portion 1204 substantially defines a bottom of interior cavity 1202, in an embodiment. Precursor release portion 1204 may be distinct from or integrated with release member 1200, in various embodiments. As described previously, precursor release portion 1204 may include a surface having one or more openings, which are adapted to allow precursors to flow into interior cavity 1202. In various embodiments, precursor release portion 1204 is adapted to cause precursor compartments (e.g., precursor compartments 408, 410,
In an embodiment, release member 1200 includes one or more projections 1216 which slidably engage with one or more depressions (e.g., grooves 462,
In an embodiment, release member 1200 has a width 1220 in a range of about 5-10 cm, and a height 1222 in a range of about 2-5 cm. In other embodiments, the width 1220 and/or height 1222 may be greater and/or smaller than the above given ranges.
In still other embodiments, a release member may alternatively have a centrally-positioned opening, particularly in an embodiment where the corresponding openings within a dispersal member are arranged in non-centralized positions. In other words, the openings of the release member and the dispersal member may be oppositely or differently arranged, so long as they provide a substantially closed surface when the release member top and the dispersal member top are in contact with each other.
In an embodiment, the cross-section of a release member, as indicated in
In an embodiment, a precursor release portion (not illustrated) may be separately formed, and may be attached to the bottom of release member 1500. Accordingly, release member 1500 may include an inner rim 1506, onto which the precursor release portion (not illustrated) may nest or otherwise attach.
Various embodiments of dispersal members, which may engage with a containment member and/or a release member, will now be described.
Dispersal member sidewalls 1902 may include one or more first openings 1910, and dispersal member top 1906 may include one or more second openings 1912. First openings 1910 and second openings 1912 may enable a foam, which results from a foam precursor mixture, to be released from the foam producing mechanism, as was previously described.
In an embodiment, dispersal member 1900 includes one or more projections 1914 which slidably engage with one or more depressions (e.g., grooves 472,
In an embodiment, dispersal member 1900 has a width 1920 in a range of about 5-10 cm, and a height 1922 in a range of about 2-5 cm. In other embodiments, the width 1920 and/or height 1922 may be greater and/or smaller than the above given ranges.
In an embodiment, the cross-section of the dispersal member, as indicated in
Various alternate embodiments for foam producing mechanisms will now be described.
Release member 2204 may include, in an embodiment, one or more protrusions 2214, which are adapted to nest into one or more indentations 2216 within containment member 2202. In an embodiment, protrusion 2214 forms an annular ring, which encircles the outside surface 2218 of release member 2204, and indentations 2216 form cooperatively shaped annular indentations on the inside surface 2220 of containment member 2202. In a further embodiment, the cross-sectional area of protrusion 2214 may be substantially triangular, as illustrated in
In
Containment member 2402 includes integrated or attached walls 2408, which are adapted to form cups 2410 to contain foam precursor components 2412, 2414. In an embodiment, walls 2408 include a top rim 2416, onto which one or more rupturable precursor seals 2420 may be affixed.
Release member 2404 includes a protruding precursor release portion 2422, in an embodiment. When release member 2404 and containment member 2402 are compressed together, protruding precursor release portion 2422 may function to rupture precursor seal 2420 and press into cups 2410, thus releasing foam precursor components 2412, 2414. In an embodiment, protruding precursor release portion 2422 may include one or more bottom openings 2424, which enable foam precursors 2412, 2414, to pass around or through the bottom of protruding precursor release portion 2422. Protruding precursor release portion 2422 may include one or more interior openings 2426, which enable foam precursors 2412, 2414, once released, to be mixed.
Containment member 2602 may house two or more foam precursor compartments 2608, 2610, within which foam precursor components 2612, 2614 are held. In an embodiment, foam precursor compartments 2608, 2610 are formed of a material suitable to be popped or punctured by a sharp object.
Release member 2604 includes one or more protruding precursor release portions 2612, in an embodiment. When release member 2604 and containment member 2602 are compressed together, protruding precursor release portions 2612 may function to pop or puncture foam precursor compartments 2608, 2610, thus releasing foam precursor components 2612, 2614. In an alternate embodiment, one or more protruding precursor release portions may be attached to dispersal member 2606, rather than or in addition to being attached to release member 2604.
The containment member, release member, and dispersal member may be formed from the same, similar, or different materials as each other. In an embodiment, some or all of the members are formed substantially from a plastic material. In various embodiments, the plastic material may include thermoset and/or elastomer materials, and consequently may be relatively rigid. In other embodiments, the plastic material may include thermoplastic material. For example, but not by way of limitation, some or all of the members may include plastics selected from a group of plastics that includes polyethylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyethylene terephthalate (PETE), polypropylene (PP), vinyl/polyvinyl chloride (PVC), polystyrene (PS), polytetrafluoroethylene (PTFE), acrylic, delrin, nylon, glycolized polyesther (PETG), phenolic, polycarbonate, ultra-high molecular weight (UHMW) polymers, other plastic or polymer materials, and combinations thereof. In other embodiments, some or all of the members, or portions thereof may additionally or alternatively be formed from metals, alloys, fiberglass, or other materials.
The members may be formed using one or more of a variety of manufacturing processes. For example, but not by way of limitation, one or more processes used to manufacture the members may include injection molding, reaction injection molding, casting, blow molding, thermoforming, dispersion molding, and compression molding. Other techniques suitable for forming the members may be used, in other embodiments.
Referring again to
In an embodiment, cup 2902 is formed from a material that provides a sufficient moisture and vapor barrier to achieve a reasonable shelf-life for the apparatus. In an embodiment, the material may include a plastic, metal, or other material. Further, in an embodiment, cup 2902 is formed from a material that may be readily crushed (e.g., by a release member of a foam producing mechanism). Sidewalls 2908 may be substantially straight, in an embodiment, or may include one or more ribs, which facilitate crushing in a direction indicated generally by arrow 2914. The cup material may be a homogenous, or may be formed in layers. In an embodiment, cup 2902 is formed from a plastic material using a thermoforming or other manufacturing process.
For example, in an embodiment, one or more first compartments may include about 88 grams of an isocyanate-including foam precursor component, and one or more second compartments may include about 63 grams of a polyol-including foam precursor component. In alternate embodiments, one or more first compartments may include a quantity of an isocyanate-including foam precursor component in a range of about 44 grams to about 176 grams, and one or more second compartments may include a quantity of a polyol-including foam precursor component in a range of about 31 grams to about 126 grams. In still other embodiments, more or less isocyanate-including foam precursor component and/or polyol-including foam precursor component may be included.
In still another alternate embodiment, the ingredients of either or both of the isocyanate-including foam precursor component or the polyol-including foam precursor component may be divided into multiple compartments. For example, but not by way of limitation, if the polyol-including foam precursor component includes two polyols and one or more additives, a first polyol may be included in a first compartment, a second polyol may be included in a second compartment, and one or more of the additives may be included in a third compartment. Other divisions of ingredients may be possible in various embodiments.
In an embodiment, the foam precursor compartments may have roughly a split cylinder shape, so that two foam precursor compartments may fit together somewhat snugly within a containment member.
In alternate embodiments, a foam precursor compartment may have a significantly different shape, particularly when the containment member has a non-circular cross-section, when the relative quantities of foam precursor components are significantly different, when more than two foam precursor compartments are to fit within a containment member, or when the foam precursor compartments are in a nested configuration.
Viewed from the top, the foam precursor compartments, whether they are integrated with or placed within a containment member, may take on any of a variety of configurations.
Referring again to
In alternate embodiments, as described previously, the containment member may include two or more integrated cups (e.g., cups 2410,
In block 2808, the foam producing mechanism may be assembled. In an embodiment, assembly includes inserting the release member into the interior cavity of the containment member, so that the release member is in an uncompressed position (e.g., the release member is not compressing against the foam precursor compartments in a manner that they may rupture). Assembly may further include installing the dispersal member over the release member, and connecting the containment member within the interior cavity of the dispersal member, so that the dispersal member is in an uncompressed position. In an embodiment, the dispersal member top may make contact with the release member top, when the assembly is completed.
In block 2810, the assembled foam producing mechanism may be affixed within the interior space (e.g., interior space 112,
In block 2812, the flexible carrier may be sealed (e.g., heat or pressure sealed). In an embodiment, an intermittent seal may be formed during the sealing process, to enable gasses to escape the apparatus during use.
The flexible carrier may then be folded, and the apparatus may be packaged, in block 2814. In an embodiment, the apparatus is packaged within a container, so that the foam producing mechanism is not likely to be unintentionally compressed, prior to use. An apparatus may be packaged separately, or multiple apparatus may be packaged together. The method then ends.
In block 3604, the user may provide a first user input to release the foam precursors. In an embodiment, the first user input may include the user grabbing the portion of the flexible carrier within which the foam producing mechanism is located (e.g., the user may place his or her thumb on the bottom of the containment member and his or her fingers on the top of the dispersal member), and may pinch the members together into a compressed or chamber-forming relative orientation (e.g., as exemplified in
In block 3606, the user may provide a second user input to mix the foam precursors. For example, in an embodiment, the user may shake the apparatus for a period of time to mix the foam precursors within the mixing chamber. In an embodiment, this initiates formation of a foam.
Before or during foam formation, the user may place the apparatus in a container (e.g., a box or envelope), in block 3608. If a container is not being used to assist in immobilization, or if the apparatus is already incorporated within a container, then this block may be bypassed.
As the foam expands out of the foam producing mechanism and into the flexible carrier, the user may place one or more objects in proximity to the apparatus, in block 3608. For example, if the apparatus is being used to immobilize an object in a shipping container, the user may place the apparatus in the bottom of the shipping container, and as the foam expands, the user may place the object onto the flexible carrier. Alternatively, for example, if the apparatus is being used as a splint to immobilize a body part, the user may place the body part onto the flexible carrier, as the foam expands. In this situation, the apparatus may be further secured to the body part, once the foam has hardened, using an attachment mechanism.
Optionally, the user may then obtain one or more additional unactivated foam cushion forming apparatus, in block 3612, and may repeat the processes described in blocks 3604, 3606, and 3610. For example, a user may activate a second apparatus, and place the apparatus on top of an object within a shipping container. In block 3614, the container, if one is being used, may be closed as the foam is forming. In an embodiment, the additional apparatus may substantially fill portions of the remaining unfilled container, and thus further immobilize the object. The method then ends.
Embodiments of the inventive subject matter could be used in a number of different applications. For example, but not by way of limitation, embodiments could be used within a shipping container (e.g., a box, envelope, or other container) to immobilize objects being shipped. As another example, embodiments could be used as a splint to immobilize a body part. As another example, embodiments could be used to produce a flotation device (e.g., a lifesaving ring, kickboard, raft, buoy, or another type of device), on demand. As another example, embodiments could be used to plug openings, for example, to temporarily plug channels, leaks or ruptures in air handling, liquid handling, or other systems.
Before or during foam formation or thereafter, an object 3704 (in this case a monitor) may be placed on or near the first foam cushion forming apparatus 3706. If the foam has not yet hardened completely, the first foam cushion forming apparatus 3706 may contour around a portion of the object 3704. If the foam has hardened, the object 3704 may rest atop the first foam cushion forming apparatus 3706.
A second foam cushion forming apparatus 3708 may be activated and placed on top of the object 3704. The shipping container 3702 may then be closed. The second foam cushion forming apparatus 3708 may contour around a portion of the object 3704 and may also contact interior surfaces of the shipping container 3702. After the foam has hardened, the object 3704 may be at least partially immobilized within the shipping container 3702.
In the embodiment described in conjunction with
Before or during foam formation or thereafter, an object 3804 may be placed on or near the foam cushion forming apparatus 3806. If the foam has not yet hardened completely, the foam cushion forming apparatus 3806 may contour around a portion of the object 3804. If the foam has hardened, the object 3804 may rest atop the foam cushion forming apparatus 3806.
The envelope 3802 may then be closed. After the foam has hardened, the object 3804 may be at least partially immobilized within the envelope 3802.
In the embodiment described in conjunction with
In an embodiment, a foam cushion forming apparatus 3902 may be activated, as described previously. As the foam is expanding, the apparatus 3902 may be placed in proximity to a body part being immobilized (e.g., a leg (as shown), an arm, a finger, a head/neck, etc.). The expanding foam within the apparatus may cause the apparatus to contour around the body part being immobilized. Once the foam hardens, the body part may be completely or partially immobilized.
In an embodiment, the expansion limits of the flexible carrier are selected with a particular body part in mind. In some cases, the flexible carrier may be designed so that the apparatus will not completely surround the body part, thus making subsequent removal of the apparatus easier, and less likely to cause damaging manipulation to the body part. During foam formation or after the foam has hardened, the apparatus 3902 may then be loosely secured (e.g., using straps 3904 or other securement mechanisms).
Various embodiments of foam cushion forming apparatus and methods have been described. The inventive subject matter is not to be construed as being limited to any particular configuration of its component parts. The inventive subject matter's use is extremely flexible, being readily adaptable to any application in which one or more of its advantages are desired to be achieved. The apparatus and methods depicted in the Figures are merely examples of applications in which the inventive subject matter can be used.
It is to be understood that other embodiments may be utilized, and that process, material, chemical or mechanical changes may be made, without departing from the scope of the inventive subject matter. Various permutations and combinations will be readily apparent to those skilled in the art. In particular, but not by way of limitation, the arrangements and interconnections between various, illustrated functional blocks and method steps can be different, and other and different functional blocks and steps can be used to achieve the same function, in substantially the same way, to achieve substantially the same result.
Further, the arrangements of the various members of the foam producing mechanism can be different (e.g., it can include more, fewer or different components than those illustrated and described, or the components can be interconnected in different ways). The various members also may be engaged using different types of mechanisms than those described, and/or some or all of the members may be integrally connected together. Further, various features illustrated in the Figures may be used in different combinations than the combinations illustrated, in alternate embodiments. In addition, where various components and elements are illustrated singularly in the illustrated configurations, multiple ones of some or all of the components and/or elements may be included in alternate configurations.
Further, the compositions of the foam precursor components may be different. For example, foam precursors other than isocyanate-including and/or polyol-including foam precursors may be used. Accordingly, the terms “isocyanate-including” and “polyol-including” are not meant to limit the inventive subject matter only to these types of foam precursors.
Further, the dimensions also may be changed. For example, the illustrated embodiments depict a foam producing mechanism that has a width (in the horizontal direction) that is greater than its height. In alternate embodiments, the opposite may be the case, and the foam producing mechanism may be substantially tubular in shape. In addition, the various shapes (e.g., substantially circular, rectangular, etc.) may be varied.
The foregoing description of specific embodiments reveals the general nature of the inventive subject matter sufficiently that others can, by applying current knowledge, readily modify and/or adapt it for various applications without departing from the generic concept. Therefore, such adaptations and modifications are within the meaning and range of equivalents of the disclosed embodiments. The phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, it is manifestly intended that the inventive subject matter be limited only by the claims and the equivalents thereof.
It is emphasized that the Abstract is provided to comply with 37 C.F.R. §1.72(b), which requires an Abstract that will allow a reader to ascertain the nature and gist of the technical disclosure. The Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
In the foregoing Detailed Description, various features are occasionally grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the subject matter require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate preferred embodiment.
Claims
1. An apparatus comprising:
- a containment member having a containment member interior cavity to contain foam precursor compartments; and
- a release member to release foam precursor components contained within the foam precursor compartments in response to a specific relative movement produced between the release member and the containment member.
2. The apparatus as claimed in claim 1, wherein the containment member comprises:
- a bottom portion, which defines a bottom of a containment member interior cavity; and
- one or more sidewalls, which define sides of the containment member interior cavity.
3. The apparatus as claimed in claim 1, wherein containment member comprises:
- one or more openings, which are covered during at least a portion of the specific relative movement, and which become uncovered as the foam precursor components released from the foam precursor compartments react to form an expansive foam.
4. The apparatus as claimed in claim 1, wherein the release member comprises:
- one or more precursor release portions;
- one or more release member sidewalls sized to slidably contact one or more containment member sidewalls, wherein the one or more release member sidewalls define sides of a release member interior cavity; and
- a release member top portion, which defines a top of the release member interior cavity.
5. The apparatus as claimed in claim 4, wherein the one or more precursor release portions comprise:
- one or more openings through which the foam precursor components are to move into the release member interior cavity during the specific relative movement.
6. The apparatus as claimed in claim 1, further comprising:
- the foam precursor compartments, which include one or more first foam precursor compartments for containing one or more polyol-including foam precursor components, and one or more second foam precursor compartments for containing one or more isocyanate-including foam precursor components.
7. The apparatus as claimed in claim 6, wherein the foam precursor compartments are separable from the containment member.
8. The apparatus as claimed in claim 6, wherein at least a portion of the foam precursor compartments are fixed to the containment member.
9. The apparatus as claimed in claim 1, wherein the release member comprises:
- one or more release member openings, which are covered during at least a portion of the specific relative movement, and which become uncovered as the foam precursor components released from the one or more foam precursor compartments react to form an expansive foam.
10. The apparatus as claimed in claim 9, further comprising:
- a dispersal member engaged with release member, wherein the dispersal member includes a structure, which substantially covers the one or more release member openings during the specific relative movement, and which is to move away from the one or more release member openings when the expansive foam presses against the structure, and one or more dispersal member openings in the structure, to enable the expansive foam to escape from the apparatus.
11. An apparatus comprising:
- a first chamber portion; and
- a second chamber portion, engaged with the first chamber portion, wherein the first chamber portion and the second chamber portion are to form a chamber when the first chamber portion and the second chamber portion have a compressed relative orientation, and wherein foam precursor components are mixable within the chamber, and wherein openings in the chamber are to result when an expansive foam is produced from a mixture of the foam precursor components, and wherein the openings are to enable release of the expansive foam from the chamber.
12. The apparatus as claimed in claim 11, further comprising:
- two or more foam precursor compartments, which include one or more first foam precursor compartments to contain one or more isocyanate-including foam precursor components, and one or more second foam precursor compartments to contain one or more polyol-including foam precursor components; and
- wherein the second chamber portion includes a precursor compartment opening mechanism to open the one or more precursor compartments as the first chamber portion and the second chamber portion are moved into the compressed relative orientation.
13. The apparatus as claimed in claim 11, wherein the second chamber portion comprises:
- a first structure, which forms a portion of the chamber; and
- first openings in the first structure, to enable release of the resulting foam from the chamber.
14. The apparatus as claimed in claim 13, further comprising:
- a dispersal member engagable with the second chamber portion, wherein the dispersal member includes a second structure, which substantially covers the first openings when the first chamber portion and the second chamber portion are in the compressed relative orientation, and which is to move away from the first openings when the resulting foam presses against the second structure, and second openings in the second structure, to enable release of the resulting foam from the apparatus.
15. A foam cushion forming apparatus comprising:
- a flexible carrier; and
- a mechanism that includes two or more members, wherein the mechanism forms a chamber within which foam precursor components are mixable when the two or more members have a first orientation relative to each other, and the mechanism includes one or more openings to allow a foam to disperse into the flexible carrier when the two or more members have a second orientation relative to each other.
16. The apparatus as claimed in claim 15, further comprising:
- one or more first foam precursor compartments, within the mechanism, to hold one or more isocyanate-including foam precursor components; and
- one or more second foam precursor compartments, within the mechanism, to hold one or more polyol-including foam precursor components.
17. The apparatus as claimed in claim 15, wherein the mechanism comprises:
- a containment member having a containment member interior cavity;
- a release member engaged with the containment member, wherein the release member is to release foam precursor components from two or more foam precursor compartments within the mechanism, in response to a specific relative movement produced between the release member and the containment member; and
- a dispersal member, which is in contact with the release member in the first orientation.
18. The apparatus as claimed in claim 17, wherein the release member comprises:
- one or more release member openings, which are covered by the dispersal member during at least a portion of the specific relative movement, and which become uncovered as the foam precursor components released from the one or more foam precursor compartments react to form the foam.
19. The apparatus as claimed in claim 18, wherein the dispersal member comprises:
- a structure, which substantially covers the one or more release member openings during at least part of the specific relative movement, and which is to move away from the one or more release member openings when the foam presses against the structure; and
- one or more dispersal member openings in the structure, to enable dispersal of the foam into the carrier.
20. The apparatus as claimed in claim 15, further comprising the foam precursor components contained within the mechanism, wherein the foam precursors comprise:
- a polyol-including foam precursor component that includes one or more polyols; and
- an isocyanate-including foam precursor component that includes one or more isocyanates.
21. A packaging apparatus comprising:
- a packaging container; and
- a foam cushion forming apparatus having a flexible carrier, and a mechanism that includes two or more members, wherein the mechanism forms a chamber within which foam precursor components are mixable when the two or more members have a first orientation relative to each other, and the mechanism includes one or more openings to allow a foam to disperse into the flexible carrier when the two or more members have a second orientation relative to each other.
22. The packaging apparatus as claimed in claim 21, wherein the packaging container comprises:
- a box.
23. The packaging apparatus as claimed in claim 21, wherein the packaging container comprises:
- an envelope.
24. A body-part immobilizing apparatus comprising:
- a flexible carrier; and
- a mechanism that includes two or more members, wherein the mechanism forms a chamber within which foam precursor components are mixable when the two or more members have-a first orientation relative to each other, and the mechanism includes one or more openings to allow a foam to disperse into the flexible carrier when the two or more members have a second orientation relative to each other.
25. The apparatus as claimed in claim 24, further comprising:
- a securement apparatus to secure the flexible carrier to a body part.
26. A method of making a foam cushion forming apparatus comprising:
- fabricating two or more members of a mechanism;
- inserting foam precursor components into a containment member of the two or more members;
- engaging the two or more members in a pre-activation orientation with respect to each other; and
- attaching the mechanism to the flexible carrier.
27. The method as claimed in claim 26, wherein inserting the foam precursor components into the containment member comprises:
- dispensing one or more isocyanate-including foam precursor components into one or more first foam precursor compartments;
- dispensing one or more polyol-including foam precursor components into one or more second foam precursor compartments; and
- positioning the one or more first foam precursor compartments and the one or more second foam precursor compartments within the containment member.
28. The method as claimed in claim 26, wherein inserting the foam precursor components into the containment member comprises:
- dispensing one or more isocyanate-including foam precursor components into one or more first foam precursor compartments attached to the containment member;
- dispensing one or more polyol-including foam precursor components into one or more second foam precursor compartments attached to the containment member; and
- sealing the one or more first foam precursor compartments and the one or more second foam precursor compartments.
29. A method of using a foam cushion forming apparatus comprising:
- applying a physical force to a mechanism of the foam cushion forming apparatus, to cause a first chamber portion and a second chamber portion of the mechanism to obtain a first post-activation orientation, with respect to each other, and to form a chamber within the mechanism;
- agitating foam precursor components within the chamber to form a mixture within the chamber; and
- releasing the mechanism to allow openings in the chamber to occur as an expansive foam is produced from the mixture of the foam precursor components, wherein the openings are to enable release of the expansive foam from the chamber and into a flexible carrier.
30. The method as claimed in claim 29, wherein applying the physical force comprises:
- applying a compressive force to the mechanism.
31. The method as claimed in claim 29, further comprising:
- placing the apparatus into a packaging container, after agitating.
32. The method as claimed in claim 29, further comprising:
- securing the apparatus to a body part, after agitating.
33. The method as claimed in claim 29, further comprising:
- preheating the apparatus, prior to applying the physical force.
Type: Application
Filed: Jun 1, 2006
Publication Date: Dec 7, 2006
Inventors: Shay Pausa (Scottsdale, AZ), Sherry Schumm (Scottsdale, AZ), Robert Anders (Phoenix, AZ)
Application Number: 11/445,175
International Classification: B65B 31/00 (20060101);