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.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    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 an intermediate level of confinement, peelable seals, folds, release paths, or score lines, and a method of mixing precursor packets within a confined volume. 
       BACKGROUND 
       [0002]    With the growth of online purchasing, shipment of articles of trade having complex geometries is increasing. One of the known methods often used by large retail chains is packing equipment using specially designed Styrofoam inserts, but these inserts are unavailable to stores with limited series of fragile items or with items customized for each end user. Other packaging methods include the use of air cushions, cardboard inserts, or Styrofoam chips. All these methods require storage of bulky packing materials in an area dedicated to packaging within a shipment room. These methods also suffer from human error; for example, Styrofoam chips may be omitted on one side of an object or may migrate within a box during transportation due to low-frequency vibration. 
         [0003]    Foam-in-bag packaging techniques offer a possible solution to this storage problem. Two liquids, called precursors, are mixed in controlled quantities when foam is needed in low volume. The liquids react chemically to form a polymer-based foam and gas byproducts. One of the most commonly used pairs of precursors is the isocyanate-based precursor and the polyol-based precursor. These two compounds react to form a urethane polymer called polyurethane. Byproducts of this reaction include steam (water and heat), fluorocarbons, and carbon dioxide. The formation of byproducts is both necessary and unavoidable and must be controlled to obtain the desired foam density and strength since the polyurethane foam is a three-dimensional matrix of gas bubbles held in place by polyurethane. 
         [0004]    In the best of conditions, the precursors are mixed instantly and expand fully within an infinite volume. After about ten seconds of mixing, foaming begins, the mixture expands for about fifteen to twenty seconds, and it hardens after about one minute. In less than optimal conditions, the precursors are partly mixed, are partly constrained by storage packaging, and are warped into shape around objects. 
         [0005]    In a first generation of foam-in packaging devices, the foam precursors are injected directly into containers, such as corrugated boxes or molds. Because these containers are not airtight, leaks are frequently observed and gaseous byproducts can evacuate the volume freely. In later generations, precursors were injected in plastic bags that allow for shape-change during expansion. The bags could be placed in boxes, and as the foam expanded, the bag would fill in. If timing is managed properly, the item to be packaged, if not too heavy, could rest on the viscous, unsolidified foam. Such bags must include vents for releasing excess gaseous byproducts into the surrounding space. These technologies require the management and manipulation by an operator of the two liquid precursors, along with the plastic bags. If operators place too much liquid in the bag or do not mix the precursors in the correct proportions, the resulting foam can be less than optimal. 
         [0006]    In new foam-in-bag inventions, the precursors are placed within sealed pouches and can be mixed when adjacent pouches are ruptured with an external force, such as hand pressure or foot pressure. To create a homogeneous foam within a volume to be packaged, the foam must be allowed to expand continuously during the expansion period and not be subject to pressure waves in the container, where expanding foam must defeat confinement barriers. For example, a first prior art reference discloses how inner pouches can be placed within an outer pouch, which is in turn placed inside the shipping container to be filled with foam. Under this early configuration, the liquid from the bags did not mix absent manipulation by the user. The outer pouch, once filled with partly expanded foam, increases in size and pressure until it bursts, often following an uncontrolled path. A second prior art reference discloses the use of two precursor packets joined and sealed within the pouches by frangible seals. Since no preferred path of release is contemplated, external frangible seals break before the frangible seal located between both precursor zones breaks. Finally, a last prior art reference teaches how an external bag can be formed with fixed internal pockets having frangible seals to draw the precursor liquids into a mixing zone. This technology requires the engineering, use, and testing of multicompartment bags with complex technology requiring manipulation of the precursor fluids during manufacture. 
         [0007]    What is needed is a foam-in-bag packaging system that enhances the mixing of the precursor liquids, controls the flow of the foam during expansion and hardening, prevents the formation of pressure walls that overly compress the foam, and can be implemented in containers of simple geometry. 
       SUMMARY 
       [0008]    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 a reclosable opening for optimal mixing and release of the foam using preferential paths, score lines, weakness points, and/or obstacles to flow and expansion. In addition, the precursor fluids are placed in individually sealed pouches with calibrated and aptly positioned frangible seals to facilitate mixture after rupturing the pouches within the inner confinement structure. In another embodiment, one of the precursor fluids is placed directly in the inner confinement structure. 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 above-disclosed embodiments of the foam-in-bag packaging system. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Certain embodiments are shown in the drawings. However, it is understood that the present disclosure is not limited to the arrangements and instrumentality shown in the attached drawings, wherein: 
           [0010]      FIG. 1  is a perspective view of the packaging system for producing a foam-in bag with a plastic bag having a reclosable opening according to a first embodiment of the present disclosure. 
           [0011]      FIG. 2  is a perspective view of the packaging system for producing a foam-in bag with a paperboard box according to another embodiment of the present disclosure. 
           [0012]      FIG. 3  is a perspective view of the plastic bag having a reclosable opening as shown in  FIG. 1  according to an embodiment of the present disclosure. 
           [0013]      FIG. 4  is an elevation view of the plastic bag having a reclosable opening of  FIG. 3  as viewed along line  4 - 4 . 
           [0014]      FIG. 5  is an elevation view of the plastic bag having a reclosable opening of  FIG. 3  as viewed along line  5 - 5 . 
           [0015]      FIG. 6  is a detail view of the plastic bag having a reclosable opening of  FIG. 3  as shown by the zone numbered  6  illustrating the side portion of the reclosable locking mechanism according to an embodiment of the present disclosure. 
           [0016]      FIG. 6A  is a detailed elevation view of the reclosable locking mechanism as shown in  FIG. 6  as viewed along line  6 A- 6 A. 
           [0017]      FIG. 7  is an elevation view of the plastic bag having a reclosable opening of  FIG. 3  as viewed along line  7 - 7 . 
           [0018]      FIG. 8  is top view of a precursor packet with a top and lateral sides closed using a peelable seal and a bottom side closed by a fold in the plastic sheet according to an embodiment of the precursor packet of the present disclosure. 
           [0019]      FIG. 8A  is a side elevation view of the precursor packet of  FIG. 8  viewed along line  8 A- 8 A illustrating the precursor fluid. 
           [0020]      FIG. 9  is a top view of a precursor packet with a top and a lateral seal, a right lateral peelable seal, and a bottom side closed by a fold in the plastic sheet according to another embodiment of the precursor packet of the present disclosure. 
           [0021]      FIG. 10  is a top view of a precursor packet with a top, a bottom, and two lateral peelable seals according to another embodiment of the precursor packet of the present disclosure. 
           [0022]      FIG. 11  is a top view of a precursor packet with a top, a bottom, and a right lateral peelable seal according to another embodiment of the precursor packet of the present disclosure. 
           [0023]      FIG. 12  is a top schematic representation of the plastic bag having a reclosable opening of  FIG. 3  with two lateral sealed segments as foam guides according to an embodiment of the plastic bag of the present disclosure. 
           [0024]      FIG. 13  is a top schematic representation of the plastic bag having a reclosable opening of  FIG. 3  with two cut-out portions as foam guides according to another embodiment of the plastic bag of the present disclosure. 
           [0025]      FIG. 14  is a top schematic representation of the plastic bag having a reclosable opening of  FIG. 3  with two lateral sealed segments and one central sealed segment as foam guides according to another embodiment of the plastic bag of the present disclosure. 
           [0026]      FIG. 15  is a top schematic representation of the plastic bag having a reclosable opening of  FIG. 3  with two bent lateral seals as foam guides according to another embodiment of the plastic bag of the present disclosure. 
           [0027]      FIG. 15A  is a top schematic representation of the plastic bag having a frangible opening with two bent lateral seals as foam guides according to another embodiment of the plastic bag of the present disclosure. 
           [0028]      FIG. 16  is a top schematic representation of a plastic bag with small, perforated sections as foam guides according to another embodiment of the plastic bag of the present disclosure. 
           [0029]      FIG. 17  is an elevation view of the packaging system for producing a foam-in bag with a paperboard box of  FIG. 2  as viewed along line  17 - 17  according to an embodiment of the present disclosure. 
           [0030]      FIG. 18  is a front schematic representation of the paperboard box as shown in  FIG. 2  where the two precursor packets are positioned vertically according to an embodiment of the present disclosure. 
           [0031]      FIG. 19  is a top schematic view of the paperboard box as shown in  FIG. 2  where the two precursor packets are positioned horizontally according to another embodiment of the present disclosure. 
           [0032]      FIG. 20  is a top schematic view of the paperboard box as shown in  FIG. 2  where the two precursor packets are positioned horizontally and side-by-side according to another embodiment of the present disclosure. 
           [0033]      FIG. 21  is a top view of the paperboard box as shown in  FIG. 2  with score lines forming two parallel rectangles on the upper surface of the box according to an embodiment of the paperboard box of the present disclosure. 
           [0034]      FIG. 22  is a top view of the paperboard box as shown in  FIG. 2  with score lines forming two side-by-side rectangles on the upper surface of the box according to another embodiment of the paperboard box of the present disclosure. 
           [0035]      FIG. 23  is a top view of the paperboard box as shown in  FIG. 2  with star-shaped score lines on the upper surface of the box according to another embodiment of the paperboard box of the present disclosure. 
           [0036]      FIG. 24  is a top view of the paperboard box as shown in  FIG. 2  with X-shaped score lines on the upper surface of the box according to another embodiment of the paperboard box of the present disclosure. 
           [0037]      FIG. 25  is a top view of the paperboard box as shown in  FIG. 2  with an I-shaped score line on the upper surface of the box according to another embodiment of the paperboard box of the present disclosure. 
           [0038]      FIG. 26  is a top view of the paperboard box as shown in  FIG. 2  with oval score lines on the upper surface of the box according to another embodiment of the paperboard box of the present disclosure. 
           [0039]      FIG. 27  is a top view of the paperboard box as shown in  FIG. 2  with an off-set longitudinal score line on the upper surface of the box according to another embodiment of the paperboard box of the present disclosure. 
           [0040]      FIG. 28  is a top view of the paperboard box as shown in  FIG. 2  with a central longitudinal score line on the upper surface of the box according to another embodiment of the paperboard box of the present disclosure. 
           [0041]      FIG. 29  is a perspective view of the packaging system for producing a foam-in bag having a plastic bag with a reclosable opening and secured precursor packets according to another embodiment of the present disclosure. 
           [0042]      FIG. 30  is an elevation view of the plastic bag having a reclosable opening and secured precursor packets of  FIG. 29  as viewed along line  30 - 30 . 
           [0043]      FIG. 31  is a perspective view of the packaging system for producing a foam-in bag with a plastic bag with a reclosable opening, a precursor packet, and a second precursor solution in the plastic bag according to another embodiment of the present disclosure. 
           [0044]      FIG. 32  is an elevation view of the plastic bag with a reclosable opening and secured precursor packets of  FIG. 31  as viewed along line  32 - 32 . 
           [0045]      FIG. 33  is a diagrammatic representation of a method of mixing foam precursors in a foam-in-bag packaging system according to an embodiment of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0046]    The present invention is not limited to the particular details of the device depicted and other modifications and applications may be contemplated. Further changes may be made in the above-described device without departing from the true spirit of the scope of the disclosure herein involved. It is intended, therefore, that the subject matter of the above depictions should be interpreted as illustrative, not in a limiting sense. 
         [0047]      FIGS. 1-2 ,  29 , and  31  illustrate four perspective views of the packaging system  1  for producing a foam-in bag having a plastic bag with a reclosable opening according to four of the numerous different contemplated embodiments. For each embodiment, a closed, deformable outer bag  200  holds an inner container, such as a plastic bag with a reclosable opening  100 , a paperboard box  60 , or other container. In one embodiment, the deformable outer bag  200  is made of a single-thickness, transparent plastic bag, which includes a gas release valve  127  or vent on the outer surface of the deformable bag  200  to release any gas formed or present inside the deformable bag  200  to the outside of the deformable bag  200 . Gas located inside the deformable outer bag  200  is released to facilitate folding and storage of an airtight bag  200  of the packaging system  1  or to prevent the accumulation of gaseous byproduct resulting from the chemical reaction from mixing a first precursor solution  25  with a second precursor solution  35  during the formation of foam inside the bag  200 . 
         [0048]    While a single valve  127  is shown, what is contemplated is the use of any gas release system, such as a lip, a reclosable opening, a tube, a calibrated spring valve, pinholes or any combination thereof capable of controlling the flow of gas from inside of the deformable outer bag  200  to the exterior of the deformable outer bag  200 . A valve is used essentially to retain the foam produced inside the deformable bag  200  while the gas produced as a byproduct, if produced in excess of the needed quantity, is released. The valve  127  can be calibrated at a fixed release pressure to accumulate an initial volume of gaseous byproduct to serve to expand the deformable outer bag  200  in position before the foam is fully expanded. 
         [0049]    Within the scope of this disclosure, the area shown with a hashed surface with lines along one direction corresponds to a permanent seal  2  created between two juxtaposed layers of material in a bag  200 ,  100 , as sealed by known sealing technologies as a result of folding of a layer of plastic. Alternatively, what is shown as an area with a hashed surface with angled hash lines along two perpendicular orientation (cross-hashed), such as is shown on the periphery of the precursor packet  30  of  FIG. 10 , is a peelable seal or a type of frangible seal. Peelable seals, in one embodiment, correspond to the union of two adjacent layers of material, partially bonded or secured to each other using a myriad of technologies, capable of releasing from each other once a sheer force is present, such as a pull or internal pressure in a closed volume. 
         [0050]    In one embodiment shown in  FIG. 1 , a plastic bag with a reclosable opening  100  is confined within the deformable outer bag  200 . Details of the different elements of the plastic bag with a reclosable opening  100  are shown in  FIG. 3 . The deformable outer bag  200  and the plastic bag with a reclosable opening  100  have been illustrated with internal elements shown by dashed lines in an effort to illustrate their internal position. While in a preferred embodiment, the use of transparent or partly transparent bags  100 ,  200  is contemplated as the preferred embodiment to provide visual guidance to a user where pressure is to be applied to the internal elements of the packaging system  1 , what is contemplated is the use of any bag, made of any deformable material, having any geometry, shape, surface finish, transparency, or color, such as but not limited to deformable polymers including plastic or vinyl. By way of nonlimiting example, markings could be made on the external surface of the deformable outer bag  200  such as “push here” to guide a user using a nontransparent bag. In another nonlimiting example, the deformable outer bag  200  and plastic bag with a reclosable opening  100  could be folded in such a way that the entire surface of the packaging system  1  must be pressed to release the precursor materials from the precursor packets  20 ,  30  in an effort to provide users with operating guidance. 
         [0051]    What is disclosed is a first precursor packet  20  having a first sealed pouch  21  and an encapsulated first precursor solution  25  as shown in  FIG. 3 . In an embodiment, the plastic bag  100  also includes a second precursor packet  30  having a second sealed pouch  31  and an encapsulated second precursor solution  35 . In another embodiment as shown in  FIGS. 31-32 , the packaging system  1  includes only a first precursor packet  20 , which has a first sealed pouch  21  and an encapsulated first precursor solution  25 , and a second precursor solution  35  free from any second precursor packet  30  to be inserted in the plastic bag  100  before it is sealed. While small, flat packets  20 ,  30  are shown, what is contemplated is the use of any enclosed volume capable of holding a quantity of precursor solution  25 ,  35  and capable of modification to release the precursor solutions  25 ,  35  to mix and initiate a chemical reaction to create foaming. 
         [0052]    In an embodiment shown in  FIG. 3 , a plastic bag with a reclosable opening  100  includes an outer shell  15  and a release path  12  for the first and second precursor solutions  25 ,  35 . A notch  13  on one layer of the plastic bag  100  illustrates both adjacent layers and shows one contemplated variability in bag geometry. The first and second sealed pouches  21 ,  31  forming the first and second precursor packets  20 ,  30  are held in the plastic bag  100  and the deformable outer bag  200  in the outer shell  2 . As shown, the outer shell is made of a first layer  11 , a second layer  12  attached at one end by a reclosable locking mechanism  10 , and a plurality of seals  14 ,  15 ,  16  on the other sides.  FIG. 4  illustrates how the first layer  111  and the second layer  12  may be sealed using a bonded region  17  at the seal  15 .  FIG. 5  illustrates how the first layer  11  and the second layer  12  are also include lateral bonded regions  17  at both sides of the deformable bag  200  at seals  14  and  16 .  FIG. 7  illustrates the same configuration but from another position on the plastic bag  100 . The plastic bag  100  as shown has a reclosable opening  10 , such as reclosable male/female lock lips, is encapsulated in the deformable outer bag  200  and the first and second precursor packets  20 ,  30  are disjoined. In yet another embodiment shown in  FIGS. 29-30 , the first and second precursor packets  20 ,  30  are individual pouches joined by an adhesive  209  at a junction surface between the two packets  20 ,  30 . In another embodiment, the two packets  20 ,  30  united by adhesive  209  are further connected to the plastic bag  100  by a second adhesive  208 . While  FIG. 30  illustrates the packets  20 ,  30  stacked vertically, what is contemplated is the stacking of the packets  20 ,  30  in any configuration that allows a user of the packaging system  1  to apply pressure to both packets  20 ,  30  through the plastic bag  100  and the deformable outer bag  200  in a single operation. For example, if the packets  20 ,  30  are long, cylindrical tubes (not shown), such as sticks used for underwater diving lights, the packets  20 ,  30  may be attached in such way to facilitate the rupture of both sticks in a single operation by the user of the packaging system  1 . Once again, while a single geometric configuration is shown, what is disclosed is the use of the described general principle in conjunction with the described technology as applied to any structure known and contemplated by one of ordinary skill in the art. 
         [0053]    Functionally, the foam-in bag is produced as a result of an external pressure applied to the first and second packets  20 ,  30  through the plastic bag  100  and the deformable outer bag  200  and where the first and second precursor solutions  25 ,  35  are mixed. As the foam expands into place, it is released into the deformable outer bag  200  through a preferential release path. The packaging system  1  is designed to improve and facilitate the mixing of the precursor solutions  25 ,  35  in a tailored volume and further allow the foam to expand into a fixed and controlled volume defined by the deformable outer bag  200  using release paths. One of ordinary skill in the art recognizes that while two packets  20 ,  30  of generally similar geometry are shown, what is contemplated is the use of packets  20 ,  30  with different geometries, different surfaces, different sizes, and different volumes of precursor solutions  25 ,  35  based on the different types of foam to be created within the deformable outer bag  200 . 
         [0054]    In one embodiment, the first and second precursor packets  20 ,  30  are sealed using a peelable seal as defined hereabove. Packets may be closed partially or fully by peelable seals  31  or by permanent seals  3  as shown in a plurality of configurations in  FIGS. 8-11 . In  FIG. 9 , the first and second precursor packets  20 ,  30  are partially sealed using a first section of permanent seal  3  and a second section of peelable seal  31 . In  FIG. 10 , the precursor solution  35  is encapsulated in the precursor packet  30  by a peelable seal  31  over the entire periphery of the precursor packet  30 . In yet another embodiment shown in  FIG. 8 , the precursor solution  35  is encapsulated in the precursor package  30  by a peelable seal  31  over a first portion of the periphery of the precursor packet, a permanent seal  3  over a second portion of the periphery of the precursor packet, and not sealed but merely closed by a fold in the sealed pouch  30  as shown in  FIG. 8A . In  FIG. 11 , the reclosable seal  31  is used to form a preferential release path; if pressure is applied to the sealed pouch  30 , it is more probable that the reclosable seal  31  will open before the permanent seal portion  3 . While  FIG. 1  shows a configuration where the first and second precursor packets  20 ,  30  are of similar geometry and have the same configuration, what is contemplated is the use of two precursor packets of similar or dissimilar type based on user needs. For example, in a packaging system  1  where one of the precursor packets is small compared to a second precursor packet, a seal configuration as shown in  FIG. 10  may be required to ensure that the first precursor solution is properly mixed with the second precursor solution. 
         [0055]    In addition to using seal technology as a first control mechanism of the precursor solutions  25 ,  35 , what is also shown in  FIGS. 12-16  is the use of controlled release openings made in the plastic bag  100  to channel the expanding foam into the deformable outer bag  200  in preferential flow. Dynamic flow resulting from foam release enhances local mixing and makes sure that an optimal quantity of foam but not precursor solution is released from the plastic bag  100 . In  FIGS. 12-16 , arrows are used to illustrate the preferential flow path of the foam along the release path. Once the precursor solutions  25 ,  35  mixes, the foam inside the plastic bag  100  slowly expands and eventually pulls apart the reclosable locking mechanism  10  because of the resulting pressure within the plastic bag  100 . 
         [0056]      FIGS. 6 ,  6 A show in greater detail a possible embodiment of the reclosable locking mechanism  10  as generally known in the marketplace. The reclosable locking mechanism  10  includes a head  42  with retention lips at a distance from a first layer of the bag  12 . The second layer of the bag  11  is equipped with a female lock  41  with an opening for receiving the head  42  and holding the lips within the female lock  41  as shown in  FIG. 6A .  FIG. 6  shows how the reclosable locking mechanism  10  may be welded in place  40  using a tack point. What is also contemplated is the use of a frangible seal or a peelable seal  31  instead of a female and male locking mechanism  10 . In a preferred embodiment, the reclosable locking mechanism  10  is made of to adjacent locks in the form of parallel heads  42  that interlocks with parallel female locks  41  on the adjacent layer of the bag  11 ,  12 . 
         [0057]    Absent any release path, the foam simply migrates to the deformable outer bag  200  through the entire opening created by the opening of the reclosable locking mechanism  10 .  FIG. 12  shows a configuration having two lateral sealed segments  51  functioning as foam guides,  FIG. 13  shows a configuration having two cut-out portions functioning as foam guides,  FIG. 14  shows a configuration having two lateral sealed segments and one central sealed segment functioning as foam guides,  FIG. 15  shows a configuration having two bent lateral seals functioning as foam guides,  FIG. 15A  shows the above configuration with as a reclosable locking mechanism  10  a frangible  31 , and  FIG. 16  shows a configuration having small, perforated sections functioning as foam guides according to another embodiment of the plastic bag of the present disclosure. While five possible embodiments are shown, what is contemplated is the use of any foam guide configuration as would be obvious to one of ordinary skill in the art. 
         [0058]    In one alternate embodiment shown as  FIGS. 2 and 17 , a paperboard box  60  shown having folded ends is used in lieu of a plastic bag  100 . The paperboard box  60  has several unique advantages, the first being its capacity to dissolve during the process of foam making when in contact with the precursor solutions  25 ,  35 . The paperboard box  60  also has inherent strength that allows for a better protection of the first and second precursor packets  20 ,  30 .  FIG. 18  shows a configuration where precursors packets  20 ,  30  are positioned vertically in the paperboard box  60 .  FIG. 20  shows a configuration where the two precursor packets are positioned horizontally and side-by-side in the paperboard box  60 . Another advantage of the use of paperboard boxes over a plastic bag  100  includes the capacity to stack the boxes during manufacture for better manipulation and accountability. 
         [0059]    In the paperboard box configuration shown in  FIG. 2 , the packaging system  1  for producing a foam-in bag includes a first precursor packet  20 , which has a first sealed pouch  21  and an encapsulated first precursor solution  25 , and a second precursor packet  30 , which has a second sealed pouch  31  and an encapsulated second precursor solution  35 . The paperboard box  60  has an outer shell made of paperboard in one embodiment (as shown) and a release path for the first and second precursor solutions  25 ,  35 . The first and second sealed pouches  21 ,  31  are encapsulated in the paperboard box  60 , and a deformable outer bag  200  having an outer shell  2 , a gas release valve  127 , and the paperboard box  60  is held in the bag  200 . In addition, the first and second precursor packets  20 ,  30  are disjoined in the paperboard box  60 , and an external pressure is applied to the first and second packets  20 ,  30  through the paperboard box  60  and the deformable outer bag  200 , and the first and second precursor solutions  25 ,  35  are mixed and released into the deformable outer bag  200  through the release path for creation of a foam encased within the deformable outer bag by reaction of the mixed precursor solutions  25 ,  35 . 
         [0060]    Much like possible release paths for the plastic bag  100  illustrated in  FIGS. 12-16 ,  FIGS. 21-28  illustrate possible configurations of release paths for the paperboard box  60 . In one contemplated embodiment (not shown), a sealed end of the paperboard box is used to form the release path. What is contemplated is the use of score lines  70 ,  71  to create a local weakness in the paperboard box to create a preferential release path. In one embodiment, the local weakness score line  71  is placed at the seam or edge of the paperboard box  60  to enhance natural weakness created during bending operations when the paperboard box  60  is formed.  FIG. 21  contemplates the use of score lines forming two parallel rectangles  70  on the upper surface of the paperboard box  60 ,  FIG. 22  contemplates the use of score lines forming two side-by-side rectangles  70  on the upper surface of the paperboard box  60 ,  FIG. 23  contemplates the use of star-shaped score lines  71  on the upper surface of the paperboard box  60 ,  FIG. 24  contemplates the use of X-shaped score lines  70  on the upper surface of the paperboard box  60 ,  FIG. 25  contemplates the use of an I-shaped score line  71  on the upper surface of the paperboard box  60 ,  FIG. 26  contemplates the use of over score lines  71  on the upper surface of the paperboard box  60 ,  FIG. 27  contemplates the use of an off-set longitudinal score line  71  on the upper surface of the paperboard box  60 , and  FIG. 28  contemplates the use of a central longitudinal score line  71  on the upper surface of the paperboard box  60 . While a plurality of possible preferential release paths  70 ,  71  in the form of score lines is shown, what is contemplated is the use of any weakening structure, fold, variable thickness, or variation in material to create a preferential release path in the paperboard box  60 . 
         [0061]    Finally, what is also contemplated and shown diagrammatically in  FIG. 33  is a method of mixing foam precursors in a foam-in-bag packaging system  1  as described hereabove according to an embodiment of the present disclosure. The method of mixing foam precursors  25 ,  35  in a foam-in-bag system  1  includes the steps of sealing  301  a first precursor solution  25  in a first precursor packet  20 , sealing a second precursor solution  35  in a second precursor packet  30  disjoined from the first precursor packet  20 , and in an alternate embodiment measuring  303  a fixed volume of second precursor solution  35  and sealing  305  the first packet  20  and the second precursor solution  35  in the plastic bag  100 . In a subsequent step, the plastic bag  100  is sealed  307  inside of a deformable outer bag  200 , and finally, applying pressure  309  from the external surface of the deformable outer bag  200  to the precursor solution causes mixture and release of a first and a second precursor solutions  25 ,  35  located in the first and second precursor packets  20 ,  30 , or located in the first precursor packet  20  and the plastic bag  100 , respectively, to the deformable outer bag  200  through a release path. In one alternate embodiment, the first and second precursor packets  20 ,  30 , are placed  304  in the paperboard box  60  before sealing  306  the paperboard box and applying pressure  308  from the outer bag  200  to the paperboard box  60  to rupture the precursor packets  20 ,  30  and mix the precursor solutions  25 ,  35 . 
         [0062]    It is understood that the preceding is merely a detailed description of some examples and embodiments of the present invention and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden.