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.

A longitudinal sealer includes a housing, an arm, and a heating element. The housing is configured to be installed in a foam-in-bag system. The arm is movably coupled to the housing. The heating element has a leading edge exposed through an exterior surface of the arm. A position of the arm with respect to the housing is controllable so that the arm is movable between a first location where the leading edge of the heating element is not in contact with a film in a film path of the foam-in-bag system and a second location where the leading edge of the heating element is in contact with the film in the film path of the foam-in-bag system.

In a skin integral molded article which is formed by filling the inside of a skin which is formed into a bag shape with a foamed body and molding the foamed body integrally with the skin, an opening through which a foaming raw material is supplied into the skin is formed in the skin, in one side skin and other side skin which are formed with the opening being interposed, the one-side skin is bent into inside the opening, the other-side skin is provided with a part disposed ahead of a part which is bent into inside the opening and is formed to be pliable, and the part which is disposed ahead of the other-side skin part and is formed to be pliable is formed in contact with a leading end part of the one-side skin part which is bent into the opening.

Apparatus for supplying multiple foam machines with foam precursor chemicals. The apparatus comprises first and second totes having a top opening and a bottom drain and containing first and second foam precursor chemicals, first and second supply lines connected to the bottom drains of the first and second totes and in fluid communication with first and second sets of batcher stands, and first and second sets of batcher pumps each of which is positioned in a respective one of the first and second sets of batcher stands. Each batcher pump is adapted to be in fluid communication with a respective one of the foam machines.

Apparatus for supplying multiple foam machines with foam precursor chemicals. The apparatus comprises first and second totes having a top opening and a bottom drain and containing first and second foam precursor chemicals, first and second supply lines connected to the bottom drains of the first and second totes and in fluid communication with first and second sets of batcher stands, and first and second sets of batcher pumps each of which is positioned in a respective one of the first and second sets of batcher stands. Each batcher pump is adapted to be in fluid communication with a respective one of the foam machines.

A material spill prevention system with feed location sensing system to reduce the possibility of material spillage relative to the film being utilized for bag formation. The material spill prevention system monitors whether there is a proper film feed situation and, if not, precludes the release of material from the dispenser as in by precluding a flow controller opening and the release of material to the bag intended to receive the release chemical (e.g., a foam packaging bag). The prevention system is applicable to a variety of film feed arrangements as in a C-fold film drawn by a nip roller arrangement from a roll source with the dispenser mechanism positioned intermediate the nip and film source relative to film travel. An embodiment of the spill prevention system also features an absolute position transducer for monitoring position of a flow controller which controls output of material from the dispenser.

A method for filling a cavity with an expanding insulating foam component includes the following. First, providing a closed cavity comprising at least one elongated wall surface that extends along a first direction and includes first and second opposite sides, a top side and a bottom side. Next, forming a plurality of openings in the elongated wall surface arranged along the first direction and being alternating close to the first or the second opposite sides. Next, inserting a dispense tube through a first opening of the plurality of openings, and injecting a first portion of the expanding insulating foam into the closed cavity. The first opening is located close to the bottom side and close to the first side of the elongated wall surface. The injected foam expands along the bottom side and the first side and forms a first sloped top surface that has a positive slope angle. Next, inserting the dispense tube through a second opening of the plurality of openings located close and above the first opening and close to the opposite second side, and injecting a second portion of the expanding insulating foam into the closed cavity. The injected foam expands along the first sloped top surface and the second side and forms a second sloped top surface that has a negative slope angle.

A process for producing a molded article involves providing a thin-walled, gas-permeable shell; filling the shell with a foamed pelletized material composed of a polymer; and welding the foamed pelletized material to obtain the molded article. Molded articles are obtainable or obtained by such a process, and can be used as a footwear sole, part of a footwear sole, a mattress, a seat cushion, an underlay, a grip, a protective film, a component in automobile interiors and exteriors, a gymnastics mat, a body protector, a trim element in automobile construction, a sound insulator, a vibration damper, a cushion, a bicycle saddle, a toy, a tire or part of a tire, a covering for a track and field surface, a covering for a sports hall or a pathway, a damping layer or a damping core in a sandwich element, or a packaging.

A bag for producing a foam-in-bag dunnage material comprises a closed edge portion and, in a non-sealed state of the bag, an open edge portion, the closed and open edge portions delimiting an inner bag volume. The invention proposes that a bag structure of the bag comprises a mixing chamber which is adapted to receive foam precursor substances, which is arranged within the inner bag volume, which is at least partially and initially delimited against the remainder of the inner bag volume, and which in the non-sealed state of the bag is connected to the open edge portion.