Packaging system for producing a foam-in-bag and method of mixing foam

Abstract

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.

1 . A packaging system for producing a foam-in bag, comprising:
 a first precursor packet having a first sealed pouch and an encapsulated first precursor solution;   a second precursor packet having a second sealed pouch and an encapsulated second precursor solution;   a paperboard box having an outer shell and a release path for the first and second precursor solution, wherein the first and second sealed pouches are encapsulated in the paperboard box; and   a deformable outer bag having an outer shell and a gas release valve, wherein the paperboard box is encapsulated in the bag,   wherein the first and second precursor packets are disjoined, and where an external pressure is applied to the first and second packets through the paperboard box and the deformable outer bag, and where the first and second precursor solutions are mixed and released into the deformable outer bag through the release path for creation of a foam encased within the deformable outer bag by reaction of the mixed precursor solutions.   
     
     
         2 . The packaging system for producing a foam-in bag of  claim 1 , wherein the first and second precursor packets are sealed using a peelable seal. 
     
     
         3 . The packaging system for producing a foam-in bag of  claim 1 , wherein the first and second precursor packets are partially sealed using a first section of permanent seal and a second section of peelable seal. 
     
     
         4 . The packaging system for producing a foam-in bag of  claim 2 , wherein the precursor solution is encapsulated in the precursor packet by a peelable seal over a periphery of the precursor packet. 
     
     
         5 . The packaging system for producing a foam-in bag of  claim 2 , wherein the precursor solution is encapsulated in the precursor package by a peelable seal over a first portion of the periphery of the precursor packet and by a permanent seal over a second portion of the periphery of the precursor packet. 
     
     
         6 . The packaging system for producing a foam-in bag of  claim 5 , wherein a third portion of the periphery of the precursor packet is not sealed but is closed by a fold in the sealed pouch. 
     
     
         7 . The packaging system for producing a foam-in bag of  claim 1 , wherein a sealed end of the paperboard box is used to form the release path. 
     
     
         8 . The packaging system for producing a foam-in bag of  claim 1 , wherein the paperboard box further comprises score lines as the release path. 
     
     
         9 . The packaging system for producing a foam-in bag of  claim 8 , wherein the score lines are in a shape selected from the group consisting of a star shape, an X shape, a rectangle, an I, a series of ovals, a center line, and an off-set line. 
     
     
         10 . The packaging system for producing a foam-in bag of  claim 1 , wherein the paperboard box is disintegrated by the foam forming process. 
     
     
         11 . A method of mixing foam precursors in a foam-in bag system, the method comprising the steps of:
 sealing a first precursor solution in a first precursor packet;   sealing a second precursor solution in a second precursor packet disjoined from the first precursor packet;   placing inside a paperboard box the first and the second precursor packets;   sealing inside a deformable outer bag the paperboard box; and   applying pressure to the external surface of the deformable outer bag to the paperboard box and to the precursor packets to release a first and a second precursor solutions located in the first and second precursor packets, respectively, into the plastic bag through a release path and ultimately into the deformable outer bag.   
     
     
         12 . A packaging system for producing a foam-in bag, comprising:
 a first precursor packet having a first sealed pouch and an encapsulated first precursor solution;   a second precursor packet having a second sealed pouch and an encapsulated second precursor solution;   a plastic bag with a reclosable opening having an outer shell and a release path for the first and second precursor solution, wherein the first and second sealed pouches are encapsulated in the plastic bag; and   a deformable outer bag having an outer shell and a gas release valve, wherein the plastic bag is encapsulated in the deformable outer bag,   wherein the first and second precursor packets are disjoined, and where an external pressure is applied to the first and second packets through the plastic bag and the deformable outer bag, and where the first and second precursor solutions are mixed and released into the deformable outer bag through the release path for creation of a foam encased within the deformable outer bag by reaction of the mixed precursor solutions.   
     
     
         13 . The packaging system for producing a foam-in bag of  claim 12 , wherein the first and second precursor packets are sealed using a peelable seal. 
     
     
         14 . The packaging system for producing a foam-in bag of  claim 12 , wherein the first and second precursor packets are partially sealed using a first section of permanent seal and a second section of peelable seal. 
     
     
         15 . The packaging system for producing a foam-in bag of  claim 14 , wherein the precursor solution is encapsulated in the precursor packet by a peelable seal over a periphery of the precursor packet. 
     
     
         16 . The packaging system for producing a foam-in bag of  claim 14 , wherein the precursor solution is encapsulated in the precursor package by a peelable seal over a first portion of the periphery of the precursor packet and by a permanent seal over a second portion of the periphery of the precursor packet. 
     
     
         17 . The packaging system for producing a foam-in bag of  claim 16 , wherein a third portion of the periphery of the precursor packet is not sealed but is closed by a fold in the sealed pouch. 
     
     
         18 . The packaging system for producing a foam-in bag of  claim 12 , wherein the reclosable seal is used to form the release path. 
     
     
         19 . The packaging system for producing a foam-in bag of  claim 12 , wherein the plastic bag further comprises a foam guide. 
     
     
         20 . The packaging system for producing a foam-in-bag of  claim 19 , wherein the foam guide in the release path is in a shape selected from the group consisting of a side-sealed segment in the plastic bag, a cut-out portion, a seal with two unsealed portions, bent lateral seals, a folded side with cut-out portions, and small perforated sections. 
     
     
         21 . A packaging system for producing a foam-in bag, comprising:
 a first precursor packet having a first sealed pouch and an encapsulated first precursor solution;   a second precursor solution;   a plastic bag with a reclosable opening having an outer shell and a release path for the first and second precursor solution, wherein the first sealed pouch and the second precursor solution are encapsulated in the plastic bag; and   a deformable outer bag having an outer shell and a gas release valve, wherein the plastic bag is encapsulated in the deformable outer bag,   wherein the first precursor packet and the second precursor solution are inserted in the plastic bag, and where an external pressure is applied to the first packet through the plastic bag and the deformable outer bag, and where the first and second precursor solutions are mixed and released into the deformable outer bag through the release path for creation of a form encased within the deformable outer bag by reaction of the mixed precursor solutions.   
     
     
         22 . The packaging system for producing a foam-in bag of  claim 21 , wherein the first precursor packet is sealed using a peelable seal. 
     
     
         23 . The packaging system for producing a foam-in bag of  claim 21 , wherein the first precursor packet is sealed partially using a first section of permanent seal and a second section of peelable seal. 
     
     
         24 . The packaging system for producing a foam-in bag of  claim 23 , wherein the precursor solution is encapsulated in the precursor packet by a peelable seal over a periphery of the precursor packet. 
     
     
         25 . The packaging system for producing a foam-in bag of  claim 23 , wherein the precursor solution is encapsulated in the precursor package by a peelable seal over a first portion of the periphery of the precursor packet and by a permanent seal over a second portion of the periphery of the precursor packet. 
     
     
         26 . The packaging system for producing a foam-in bag of  claim 25 , wherein a third portion of the periphery of the precursor packet is not sealed but is closed by a fold in the sealed pouch. 
     
     
         27 . The packaging system for producing a foam-in bag of  claim 21 , wherein the reclosable seal is used to form the release path. 
     
     
         28 . The packaging system for producing a foam-in bag of  claim 21 , wherein the plastic bag further comprises a foam guide. 
     
     
         29 . The packaging system for producing a foam-in bag of  claim 28 , wherein the foam guide in the release path is in a shape selected from the group consisting of a side-sealed segment in the plastic bag, a cut-out portion, a seal with two unsealed portions, bent lateral seals, a folded side with cut-out portions, and small perforated sections. 
     
     
         30 . A method of mixing foam precursors in a foam-in bag system, the method comprising the steps of:
 sealing a first precursor solution in a first precursor packet;   sealing a second precursor solution in a second precursor packet disjoined from the first precursor packet;   placing the first and the second precursor packets inside a plastic bag with a reclosable opening;   sealing the plastic bag inside of a deformable outer bag; and   applying pressure from the external surface of the deformable outer bag to the plastic bag and to the precursor packets to release a first and a second precursor solution located in the first and second precursor packets respectively into the plastic bag, through a release path and ultimately into the deformable outer bag.   
     
     
         31 . A method of mixing foam precursors in a foam-in-bag system, the method comprising the steps of:
 sealing a first precursor solution in a first precursor packet;   sealing a second precursor solution in a plastic bag;   placing the first precursor packet and the second precursor solution inside the plastic bag with a reclosable opening;   sealing the plastic bag inside of a deformable outer bag; and   applying pressure from the external surface of the deformable outer bag to the plastic bag and to the precursor packet to release a first precursor solution located in the first precursor packet in the plastic bag, through a release path and ultimately into the deformable outer bag.