Patent Publication Number: US-7213383-B2

Title: Bag forming system edge seal

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     Priority under 35 U.S.C. § 119(e) is claimed relative to the Provisional Patent Applications 60/468,988 and 60/468,989 referenced as “I” and “J” in the Table immediately below, each of which was filed on May 9, 2003. The disclosure of each of the 15 provisional applications A to O set forth below is incorporated herein by reference. 
     
       
         
           
               
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                 REF. 
                 SERIAL 
                   
                   
               
               
                 ID. 
                 NUMBER 
                 FILED 
                 TITLE 
               
               
                   
               
             
            
               
                 A 
                 60/468,942 
                 May 9, 2003 
                 Dispenser Assembly With 
               
               
                   
                   
                   
                 Mixing Module Design 
               
               
                 B 
                 60/469,034 
                 May 9, 2003 
                 Bagger With Integrated, 
               
               
                   
                   
                   
                 Inline Chemical Pumps 
               
               
                 C 
                 60/469,035 
                 May 9, 2003 
                 Mixing Module Drive Mechanism 
               
               
                 D 
                 60/469,037 
                 May 9, 2003 
                 Mixing Module Mounting Method 
               
               
                 E 
                 60/469,038 
                 May 9, 2003 
                 Dispenser Tip Management System 
               
               
                 F 
                 60/469,039 
                 May 9, 2003 
                 Hinged Front Access Panel For 
               
               
                   
                   
                   
                 Bag Module Of, For Example, A 
               
               
                   
                   
                   
                 Foam In Bag Dispenser 
               
               
                 G 
                 60/469,040 
                 May 9, 2003 
                 Improved Film Unwind System 
               
               
                   
                   
                   
                 With Hinged Spindle And 
               
               
                   
                   
                   
                 Electronic Control Of Web 
               
               
                   
                   
                   
                 Tension 
               
               
                 H 
                 60/469,042 
                 May 9, 2003 
                 Exterior Configuration Of A 
               
               
                   
                   
                   
                 Foam-In-Bag Dispenser Assembly 
               
               
                 I 
                 60/468,988 
                 May 9, 2003 
                 Bag Forming System Edge Seal 
               
               
                 J 
                 60/468,989 
                 May 9, 2003 
                 Improved Heater Wire 
               
               
                 K 
                 60/468,982 
                 May 9, 2003 
                 Foam-In-Bag Dispenser System 
               
               
                   
                   
                   
                 With Internet Connection 
               
               
                 L 
                 60/468,983 
                 May 9, 2003 
                 Ergonomically Improved Push 
               
               
                   
                   
                   
                 Buttons 
               
               
                 M 
                 TBD 
                 Jun. 18, 2003 
                 Control System For A Foam-In- 
               
               
                   
                   
                   
                 Bag Dispenser 
               
               
                 N 
                 TBD 
                 Jun. 18, 2003 
                 A System And Method For 
               
               
                   
                   
                   
                 Providing Remote Monitoring 
               
               
                   
                   
                   
                 Of A Manufacturing Device 
               
               
                 O 
                 TBD 
                 Jun. 18, 2003 
                 Push Buttons And Control Panels 
               
               
                   
                   
                   
                 Using Same 
               
               
                   
               
            
           
         
       
     
    
    
     FIELD OF THE INVENTION 
     The present invention is directed at a dispensing system and components therefore, with a preferred embodiment featuring a foam-in-bag dispensing apparatus and components having application in the foam-in-bag system and, in some instances, utility alone or in combination with other systems. The present invention is also directed at a method of manufacturing a foam-in-bag apparatus, as well as the above noted components, and a method of using a foam-in-bag system to produce foam filled bags, and a method of using the above noted components. 
     BACKGROUND OF THE INVENTION 
     Over the years a variety of material dispensers have been developed including those directed at dispensing foamable material such as polyurethane foam which involves mixing certain chemicals together to form a polymeric product while at the same time generating gases such as carbon dioxide and water vapor. If those chemicals are selected so that they harden following the generation of the carbon dioxide and water vapor, they can be used to form “hardened” (e.g., a cushionable quality in a proper fully expanded state) polymer foams in which the mechanical foaming action is caused by the gaseous carbon dioxide and water vapor leaving the mixture. 
     In particular techniques, synthetic foams such as polyurethane foam are formed from liquid organic resins and polyisocyanates in a mixing chamber (e.g., a liquid form of isocyanate, which is often referenced in the industry as chemical “A”, and a multi-component liquid blend called polyurethane resin, which is often referenced in the industry as chemical “B”). The mixture can be dispensed into a receptacle, such as a package or a foam-in-place bag (see e.g., U.S. Pat. Nos. 4,674,268, 4,800,708 and 4,854,109), where it reacts to form a polyurethane foam. 
     A particular problem associated with certain foams is that, once mixed, the organic resin and polyisocyanate generally react relatively rapidly so that their foam product tends to accumulate in all openings through which the material passes. Furthermore, some of the more useful polymers that form foamable compositions are adhesive. As a result, the foamable composition, which is often dispensed as a somewhat viscous liquid, tends to adhere to objects that it strikes and then harden in place. Many of these adhesive foamable compositions tenaciously stick to the contact surface making removal particularly difficult. Solvents are often utilized in an effort to remove the hardened foamable composition from surfaces not intended for contact, but even with solvents (particularly when considering the limitations on the type of solvents suited for worker contact or exposure) this can prove to be a difficult task. The undesirable adhesion can take place in the general region where chemicals A and B first come in contact (e.g., a dispenser mixing chamber) or an upstream location, as in individual injection ports, in light of the expansive quality of the mix, or downstream as in the outlet tip of the dispenser or, in actuality, anywhere in the vicinity of the dispensing device upon, for instance, a misaiming, misapplication or leak (e.g., a foam bag with leaking end or edge seals). For example, a “foam-up” in a foam-in-bag dispenser, where the mixed material is not properly confined within a receiving bag, can lead to foam hardening in every nook and cranny of the dispensing system making complete removal not reasonably attainable, particularly when considering the configuration of the prior art systems. 
     Because of this adhesion characteristic, steps have been taken in the prior art to attempt to preclude contact of chemicals A and B at non-desired locations as well as precluding the passage of mixed chemicals A/B from traveling to undesired areas or from dwelling in areas such as the discharge passageway for aiming the A/B chemical mixture. Examples of injection systems for such foamable compositions and their operation are described in U.S. Pat. Nos. 4,568,003 and 4,898,327, and incorporated herein by reference. As set forth in both of these patents, in a typical dispensing cartridge, the mixing chamber for the foam precursors is a cylindrical core having a bore that extends longitudinally there through. The core is typically formed from a fluorinated hydrocarbon polymer such as polytetrafluoroethylene (“PTFE” or “TFE”), fluorinated ethylene propylene (“FEP”) or perfluoroalkoxy (“PFA”). Polymers of this type are widely available from several companies, and one of the most familiar designations for such materials is “Teflon”, the trademark used by DuPont for such materials. For the sake of convenience and familiarity, such materials will be referred to herein as “Teflon”, although it will be understood that materials having the above and below described qualities are available from companies other than DuPont and can be used if otherwise appropriate. 
     While features of the present invention are applicable to single component dispensing systems, the present invention is particularly suited for systems that have a plurality of openings (usually two) arranged in the core in communication with the bore for supplying mixing material such as organic resin and polyisocyanate to the bore, which acts as a mixing chamber. In a preferred embodiment of the invention, there is utilized a combination valving and purge rod positioned to slide in a close tolerance, “interference”, fit within the bore to control the flow of organic resin and polyisocyanate from the openings into the bore and the subsequent discharge of the foam from the cartridge. 
     Teflon material and many of the related polymers have the ability to “cold flow” or “creep”. This cold flow distortion of the Teflon is both beneficial (e.g., allowing for the conformance of material about surfaces intended to be sealed off) and a cause of several problems, including the potential for the loss of the fit between the bore and the valving rod as well as the fit between the openings (e.g., ports) through which the separate precursors enter the bore for mixing and then dispensing. In many of the prior art systems utilizing Teflon, the Teflon core is fitted in the cartridge under a certain degree of compression in order to help prevent leaks in a manner in which a gasket is fitted under stress for the same purpose. This compression also encourages the Teflon to creep into any gaps or other openings that may be adjacent to it which can be either good or bad depending on the movement and what surface is being contacted or discontinued from contact in view of the cold flow. 
     Under these prior art systems, however, over time the sealing quality of the core is lost at least to some extent allowing for an initial build up of the hardenable material which can lead to a cycle of seal degradation and worsening build up of hardened material. This in turn can lead to a variety of problems including the partial blockage of chemical inlet ports so as to alter the desired flow mix and degrade the quality of foam produced. In other words, in typical injection cartridges the separate foam precursors enter the bore through separate entry ports. Polyurethane foam tends to build up at the area at which the precursor exits the port and enters the mixing chamber. Such buildups cause spraying in the output stream, and dispensing of the mixture in an improper ratio. The build up of hardened material can also lead to partial blockage of the dispenser&#39;s exit outlet causing a misaiming of the dispensed flow into contact with an undesirable surface (e.g., the operator or various nooks and crannies in the dispenser). Another source of improper foam output is found in a partially or completely blocked off dispenser outlet tip that, if occurs, can lead the foam spray in undesirable areas or system shutdown if the outlet becomes so blocked as to preclude output. A variety of prior art systems have been developed in an effort avoid tip blockage, particularly in automated systems, as in foam-in-bag systems, which impose additional requirements due to the typical high usage level and the less ready access to the tip as compared to a hand-held dispenser. The prior art systems include, for example, porous tips with solvent flush systems. However, over time these tips tend to load up with hardened foam and eventually become ineffective. 
     The build of hardened/adhesive material over time can lead to additional problems such as the valve rod and even a purge only rod, becoming so adhered within its region of reciprocal travel that either the driver mechanism is unable to move the rod (leading to an oft seen shut down signal generation in many common prior art systems) or a component along the drive train breaks off which is often the annular recessed valve rod engagement location relative to some prior art designs. 
     The above described dispensing device has utility in the packing industry such as hand held dispensers which can be used, for instance, to fill in cavities between an object being packed and a container (e.g., cardboard box) in which the object is positioned. Manufacturers who produce large quantities of a particular product also achieve efficiencies in utilizing automated dispensing devices which provide for automated packaging filling such as by controlled filling of a box conveyed past the dispenser (e.g., spraying into a box having a protective covering over the product), intermediate automated formation of molded foam bodies, or the automatic fabrication of foam filled bags, which can also either be preformed or placed in a desired location prior to full expansion of the foam whereupon the bag conforms in shape to the packed object as it expands out to its final shape. 
     With dispensing devices like the hand held and foam-in-bag dispensing apparatus described above, there is also a need to provide the chemical(s) (e.g., chemicals “A” and “B”) from their respective sources (typically a large container such as a 55 gallon container for each respective chemical) in the desired state (e.g., the desired flow rate, volume, pressure, and temperature). Thus, even with a brand new dispenser, there are additional requirements involved in attempting to achieve a desired foam product. Under the present state of the art a variety of pumping techniques have arisen which feature individual pumps designed for insertion into the chemical source containers coupled with a controller provided in an effort to maintain the desired flow rate characteristics through monitoring pump characteristics. The individual in “barrel” pumps typically feature a tachometer used in association with a controller attempting to maintain the desired flow rate of chemical to the dispenser by adjustment in pump output. The tachometers used in the prior art are relatively sensitive equipment and prone to breakdowns. 
     In an effort to address the injection of chemicals into the mixing chamber at the desired temperature(s) there has been developed heater systems positioned in the chemical conduits extending between the chemical supply and the dispenser, these heaters include temperature sensors (thermisters) and can be adjusted in an effort to achieve the desired temperature in the chemical leaving the feed line or conduit. Reference is made to, for example, U.S. Pat. Nos. 2,890,836 and 3,976,230, which references are incorporated by reference. These chemical conduit heater wires suffer from a variety of drawbacks such as (a) poor sensor (e.g., thermistors) responsiveness due to non head-on flow positioning of the sensor or difficulty in manipulating the sensor without breakage to be in the proper orientation, (b) difficulty in positioning the tip of the heater wire close enough to the dispenser to avoid cold shot formation and associated material stretch limitations in the heater wire conduit needed to avoid stretching and separation of the dispenser from the tip of the heater wire when the other “fixed” end originates from the pump control region, (c) increased pump weight and an increase in the length and cost associated with the leads extending from the heater wire tip to heater wire control and power source locations at the pump end, (d) an associated increase in electromagnetic interference (EMI) due to the longer “umbilical” cords and thermister leads, (e) poor thermister reliability in its heavy flex location within the interior of the heater wire, (f) difficulty in feeding heater elements within the outer protective chemical conduit, and (g) cost and production limitations in the overall heater wire and conduit length requiring relatively close positioning of the chemical driven source to the dispenser location. 
     As noted above, in the packaging industry, a variety of devices have been developed to automatically fabricate foam filled bags for use as protective inserts in packages. Some examples of these foam-in-bag fabrication devices can be seen in U.S. Pat. Nos. 5,376,219; 4,854,109; 4,983,007; 5,139,151; 5,575,435; 5,679,208; 5,727,370 and 6,311,740. In addition to the common occurrence of foam dispenser system lock up, cleaning downtime requirements, poor mix performance in prior art foam-in-bag systems, a dispenser system featuring an apparatus for automatically fabricating foam filled bags introduces some added complexity and operator problems. For example, an automated foam-in-bag system adds additional complexity relative to film supply, film tracking and tensioning, bag sealing/cutting, bag venting, film feed blockage. Thus, in addition to the variety of problems associated with the prior art attempts to provide chemicals to the dispenser in the proper rate, keeping the dispenser cartridge operational, and feeding film properly, the prior art foam-in-bag systems also represent a particular source of additional problems for the operators. These additional problems include, for example, attempting to understand and operate a highly complicated, multi-component assembly for feeding, sealing, tracking and/or supplying film to the bag formation area; high breakdown or misadjustment occurrence due to the number of components and complex arrangement of the components; high service requirements (also due in part to the number of components and high complexity of the arrangement in the components); poor quality bag formation, often associated with poor film tracking performance, difficulty in achieving proper bag seals and cuts, particularly when taking into consideration the degrading and contamination of heater wires due to, for example, foam build up and the inability to accurately monitor current heated wire temperature application, difficulty in formation and maintaining clear bag vent holes, as well as the inevitable foam contamination derivable from a number of sources such as the dispenser and/or bag leakage, and clean up requirements in general and when foam spillage occurs. 
     Another particularly problematic area associated with the prior art foam-in-bag system lies in the area of heated resistance wire replacement, both in regard to edge sealing and in regard to the cross-cutting sealing systems. In the prior art systems, there is often required delicate operator manipulation (see for example U.S. Pat. No. 5,376,219) with certain tools to achieve removal and reinsertion of broken, or worn, heated wires (which is a common occurrence in the thin heated resistance wires used in the industry to form the seals and cuts). 
     In addition, prior art systems suffer from other drawbacks, such as relatively slow bag formation and a slow throughput of completed bags which, in some systems, is partially due to a reverse feed requirement to break an upper, not-yet-completely formed bag from a completed bag adhered together by a bond formed by the earlier melted and presently cooled plastic material on the heated cross-cut wire. 
     The prior art mixing cartridge driven mechanisms for reciprocating valve rods has also shown in the field to be inadequate as they are subject to often breakdowns and often quickly become unable to achieve rod reciprocation after a minor build up of foam in the cartridge. An additional problem associated with the mixing chamber used on fixed dispenser embodiments such as a foam-in-bag dispenser is the difficulty in proper removal and mounting of a mixing module in the support housing. Prior art systems also suffer from hose and cable management (e.g., electronics, chemical supply and solvent supply) difficulties due to their becoming tangled and in a state of disarray so as to present obstacles to operators and potential equipment malfunctions due to cable or hose interference with moving components or the hoses/cables becoming disconnected and/or damaged. 
     The pump equipment of prior art systems are also prone to malfunction including the degrading of seals (e.g., isocyanate forms hardened crystals when exposed to air which can quickly degrade soft seals). The pumping systems currently used in the field are also subject to relatively rapid deterioration as they often operate at high rates during usage due to, for example, general inefficiency in driving the chemical from its source to the dispenser outlet. The common usage of in-barrel pump systems also introduces limitations in chemical source locations (e.g., typically a 20 foot range limitation for standard heater wire conduit and in barrel pump systems), which can make for difficulties in some operator facilities where it is required or preferred to have the chemical source located at a greater distance from the dispenser. The common usage of in-barrel pumps for prior-art dispenser systems also presents a requirement for multiple chemical sources to achieve the required one-to-one chemical source and pump combination, which in particularly problematic for operators running numerous dispenser systems. 
     Prior art foam-in-bag systems, in presumably an effort to accurately dispense foam into the bag, locate the dispenser within the bag being formed (e.g., all dispenser components placed between the film left and right side edges and above the end seal of the bag). These prior art arrangements present problems from the stand point of the placement of the dispenser and its various components such as filters, chemical valving lines, and other components required for accessing a mixing module, all in the bag formation region. This positioning places those components in an area highly prone to chemical contact even with a properly functioning dispenser. Efforts have been made in the prior art to protect the dispenser through the use of covers, but these covers have shown to be highly ineffective in protecting the components. Once foam hardens on the components they are often made even more difficult to access when servicing is desired. Also, the non-smooth, multi-protrusion and edge presentment design of prior art foam dispensers, in addition to making cleaning impractical, have a tendency to create film tracking problems and/or require added guidance members to avoid film/dispenser contact. 
     In addition to the difficulty in achieving proper wire temperature levels in the chemical conduit heater wires, there has also been experienced difficulty in achieving proper end and edge sealing/cutting, and venting wire temperatures in prior art foam-in-bag systems. There is also associated with prior art systems problems in achieving proper positioning and in gaining access for servicing heater wires. The two most common prior art systems take different approaches with a first utilizing a rolling heater wire which presents added complexity in power supply as well as difficulty in removing and re-inserting heater wires. The second approach uses a non-rolling drag technique (e.g., U.S. Pat. No. 6,472,638) that, while being easy to remove and re-insert, has experienced difficulty in the field in maintaining a proper location of the exposed heater wire relative to the film being driven thereby, which is due in part to a tendency for the heated seal wires becoming more and more embedded in the underlying support. 
     Film replenishment in the prior art systems has also proven to be difficult. Accessing prior art systems to remove the emptied roll and to replace it with a new role, which can be relatively heavy as in 25 lbs. or so, is only achieved with great difficulty due to the insertion location being in the rear, intermediate region of a typical foam-in-bag system design. This location is highly straining on the operator. 
     Many prior art foam-in-bag systems and other automated dispending systems have shown in the field to have high service requirements due to, for example, breakdowns and rapid supply usage requirements (e.g., film, solvent, precursor chemicals, etc.). There is thus a great deal of servicing associated with prior art systems as in problem solving and in maintaining adequate supply levels. The prior art systems suffer from the problem of difficult and often non-adequate servicing which can be operator or service representative induced (e.g., failing to monitor own supply levels or anticipating level of usage or difficulty in responding timely to service requests which are often on an emergency or rush basis as any down time can be highly disruptive to an operator in timely meeting orders). 
     As can be seen there are numerous potential areas that can create problems in the field of dispensing. 
     SUMMARY OF THE INVENTION 
     The invention includes an edge seal assembly for use with a nip roller set, comprising an edge wire supported on an edge wire support and a bearing sleeve that receives a driving member of a film driving mechanism such that the edge wire support retains an edge seal position while said driving member rotates within the sleeve. The support preferably includes an insert head and a housing receiving the insert head with the housing preferably including a pair of “shoe” side positioning members between which said insert head is positioned. The shoes are releasably secured to the edge seal housing and are electrically conductive while the edge seal housing is electrically insulating. Preferably the bearing sleeve includes a friction reducing roller bearing on its interior surface and has an intermediate slot for receiving the edge sealer housing. 
     To opposite sides (or just one) of the edge seal housing and roller bearing there is provided first and second roller members (or just one) having means for attachment with a rotating roller component of the nip roller set, and with the first roller member being free to rotate relative to the sleeve which retains its fixed edge seal position relative to a drive shaft rotating within the sleeve (and the interior roller bearing within the sleeve). Also, the edge seal assembly preferably includes a support that has a base block and a housing member releasable secured to the base block, and the block and housing have a cavity for receiving the driving shaft or member of the nip roller set. There is also preferably provided a pair of electrical conductor extensions or conductor pins and wherein the base block and housing are releasably secured by said electrical conductor extensions extending within each of said housing and base block. The aforementioned pair of shoes that are releasably secured to said housing are in an electrical communication with a respective one of said shoes. There is also featured a guide pin which extends into the head insert supporting the heating element (e.g., small section of seal wire as in a 2 inch long piece) which head insert is slidingly supported thereon. The head insert includes an upper wire portion and two conducting side extensions of the upper wire portion are placed in electrical communication with the shoes. In a preferred embodiment the wire or heating element is formed of a material which has a TCR value that increases by at least 0.008 ohm per 10 degree rise in temperature between 350 to 425 degrees. 
     The present invention also includes an edge seal assembly comprising an edge seal assembly comprising an edge seal heater element a support for the edge seal heater element, and a control system in electrical communication with the heater element and the control system including means for comparing resistance levels at a current temperature and comparing with a TCR value reference. A method of sealing an edge of a bag in a foam-in-bag assembly is also featured wherein there is provided an edge sealer which is supported on a moving drive member of a film drive mechanism while retaining a non-rotating edge seal position relative to film being fed past the edge sealer and wherein there is the step of heating a heating element of the edge sealer to form an edge seal in a bag of the foam-in-bag assembly. 
     A foam-in-bag assembly is also featured under the present invention that comprises a film feed mechanism which feeds film with a film driver, a bag forming assembly which includes an edge sealer that contacts film being fed by the film driver and which is supported on a moving member of the film feed mechanism and retains a fixed position relative to the moving member while in sealing engagement with the film being fed by the film driver. There is also featured a dispenser for feeding foam forming material to a bag being formed by the bag forming assembly. The film feed mechanism preferably includes a pair of nip rollers which receive film therebetween, and wherein the film feed mechanism includes a roller support for one of the rollers that is adjustable between a first position and a second position which is further removed from an opposing one of said nip rollers as in a downward rotation of the roller support. Also, the bag forming assembly further comprises cross-cut forming means for forming a cross cut in a bag being formed by the bag forming assembly, and wherein the cross cut forming means is received by the roller support and adjustable therewith. For example, in one embodiment, the cross-cut forming means includes a cross-cut wire and cross cut wire base, with the cross cut wire having pin conductors at opposite ends dimensioned for sliding reception and removal relative to pin reception ports in said cross-cut wire base. There is further featured a pair of cross-seal wires each having pin conductors at opposite ends dimensioned for sliding reception and removal relative to pin reception ports in a cross-cut wire base and the cross-seal wires being positioned to opposite sides of the cross-cut wire. The roller support (or cross-cut base or moving cross cut jaw support only) is preferably a front access door of the foam-in-bag assembly. There is also featured a latch mechanism for retainment of the roller support in a film feed position as well as a door movement controller which prevents free fall of said door upon release of said latch. 
     An additional embodiment of the invention features a foam-in-bag assembly comprising a cross cut wire base, and a cam operated driving system in driving engagement with said cross cut wire base for moving the cross cut wire base between a cross cut and non-cross cut relationship relative to film material. The cam operated driving system further comprises a biasing device which is designed to accommodate for deviation relative to an opposite base block between which the film being pinched is received. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows an embodiment of the dispensing system of the present invention. 
         FIG. 2  shows a rear elevational view of a dispenser system embodiment used in the dispensing system. 
         FIG. 3  shows a front view of the dispenser system. 
         FIG. 4  provides a top plan view of the dispenser system&#39;s coiled conduit feature. 
         FIG. 5  shows a view similar to  FIG. 2 , but with the lifter extended. 
         FIG. 6  shows a base and extendable support assembly of the dispenser system. 
         FIG. 7  shows a front perspective view of a bag forming assembly. 
         FIG. 8  shows a right side elevational view of the bag forming assembly. 
         FIG. 9  shows a rear perspective view of the bag forming assembly. 
         FIG. 9A  shows a bottom perspective view of the sealer shifting assembly mounted on the frame structure. 
         FIG. 9B  shows a top perspective view of the sealer shifting assembly alone. 
         FIG. 9C  shows an alternate perspective view of that in  FIG. 9A . 
         FIG. 9D  shows an alternate perspective view of that in  FIG. 9B . 
         FIG. 9E  shows a cross-sectional view along cross-section line X-Y in  FIG. 9B . 
         FIG. 9F  shows a perspective view of an alternate embodiment of a sealer shifter assembly showing as well a non-sealing mode or retracted position relative to the stationary jaw on which is supported the cross cut and seal wires. 
         FIG. 9G  show a view similar to  FIG. 9F  but with the moving jaw in a seal or film contact mode relative to the fixed jaw. 
         FIG. 9H  shows a cross-sectional view of that which is shown in  FIG. 9F  taken along cross-section line H—H in  FIG. 9F . 
         FIG. 9I  shows a cross-sectional view of that which is shown in  FIG. 9F  taken along cross-section line I—I in  FIG. 9F . 
         FIG. 9J  shows a cross-sectional view of that which is shown in  FIG. 9G  taken along cross-section line J—J in  FIG. 9G . 
         FIG. 9K  shows a cross-sectional view taken along cross-section line K—K in  FIG. 9G . 
         FIG. 10  shows a left side elevational view of that bag forming assembly. 
         FIG. 11  shows a front perspective view of the bag forming assembly mounted on the support base. 
         FIG. 11A  shows an upper perspective view of the spindle lock in position and release mechanism of the present invention. 
         FIG. 11B  shows as alternate perspective view of the mechanism in  FIG. 11A . 
         FIG. 11C  shows an end elevational view of the mechanism in  FIG. 11A . 
         FIG. 11D  shows a cross-sectional view of the mechanism in  FIG. 11A . 
         FIG. 12  shows a rear perspective view of that which is shown in  FIG. 11 . 
         FIG. 13  shows a front perspective view of that which is shown in  FIG. 11  together with a mounted chemical dispenser apparatus (dispenser and bagger assembly combination). 
         FIG. 14A  shows dispenser apparatus separated from its support location. 
         FIG. 14B  shows a portion of the film travel path past that dispenser apparatus and nip rollers. 
         FIG. 15  shows a side elevational view of the dispenser system with spindle roll support in both operational (with the roll supported) and in mounting positions. 
         FIG. 15A  shows a top plan view of the dispenser system with cover housing components in various positions. 
         FIG. 15B  shows a front view of the dispenser system with control panel boards visible. 
         FIG. 16  shown the film support means or film source support of the present invention with a dash line roll mounted thereon. 
         FIG. 17  shows a similar perspective view of that which is shown in  FIG. 16 , but from an opposite end view showing the web tensioning or film source drive system. 
         FIG. 18  shows a top plan view of that which is shown in  FIG. 16 . 
         FIG. 19  shows a front elevational view of the film support means. 
         FIG. 20  shows a free end elevational view of the film support means. 
         FIG. 21  shows a non-free end elevational view of the film support means. 
         FIG. 22  shows a view of dispensing apparatus similar to  FIG. 13 , but from a different perspective operation. 
         FIG. 23  shows an enlarged view of dispenser outlet section. 
         FIG. 24A  shows a view similar to  FIG. 23 , but with the mixing module compression door in an open state and with the mixing module in position. 
         FIG. 24B  shows the same view as  FIG. 24A , but with the mixing module removed. 
         FIG. 25  shows a perspective view of the mixing module showing the mounting face of the same. 
         FIG. 26  shows a similar view as that in  FIG. 25  but from the valving rod end. 
         FIG. 27  shows a cross-sectional view of the mixing module taken along cross-section line A—A in  FIG. 28 . 
         FIG. 28  shows a cross-sectional view of the mixing module taken along cross-section line B to B in  FIG. 27 . 
         FIG. 28A  shown an expanded view of the circled region in  FIG. 28 . 
         FIG. 29  shows an additional cross-sectional view of the mixing module taken along cross-section line C—C in  FIG. 27 . 
         FIG. 29A  shows an enlarged view of the circled region in  FIG. 29 . 
         FIG. 29B  shows a perspective view of the mixing chamber used in the mixing module. 
         FIG. 29C  shows a vertical bi-secting cross-sectional view of the mixing module. 
         FIG. 30  shows another cross-sectional view of the mixing module taken along cross-section line F—F in  FIG. 27 . 
         FIG. 31  shows a cross-sectional view of the mixing module taken along cross-section line G—G in  FIG. 30 . 
         FIG. 32  shows a front end elevational view of the mixing module. 
         FIG. 33  shows a cross-sectional view of the mixing module taken along cross-section line D—D in  FIG. 29 . 
         FIG. 34  shows a cross-sectional view of the mixing module housing taken along cross-section line A—A of  FIG. 37 . 
         FIG. 34A  shows an enlarged view of the circled region at the left end of  FIG. 34 . 
         FIG. 34B  shows an enlarged view of the circled region at the right end of  FIG. 34 . 
         FIG. 35  shows a cross-sectional view taken along cross-section line C—C in  FIG. 36 . 
         FIG. 36  shows a cross-sectional view taken along cross-section line B—B in  FIG. 34 . 
         FIG. 37  shows a cross-sectional view taken along cross-section line D—D in  FIG. 35 . 
         FIG. 38A  shows a perspective view of the mixing module housing and the front opening solvent feed passageway formed therein. 
         FIG. 38B  shows an enlarged row of the front end of  FIG. 38A   
         FIG. 39  shows a cut away view of the front portion of the housing shown in  FIG. 38B . 
         FIG. 40  shows a front or outer perspective view of the inner or interior front cap of the mixing module. 
         FIG. 41  shows a rear or interior perspective view of the inner front cap. 
         FIG. 42  shows an interior elevational view of the inner front cap. 
         FIG. 43  shows a cross-sectional view taken along A—A in  FIG. 42 . 
         FIG. 44  shows a front or outer perspective view of the outer front cap. 
         FIG. 45  shows a rear or inner perspective view of the knurled outer front cap. 
         FIG. 46  shows a perspective cross-sectional view of the outer front cap. 
         FIG. 47  shows an elevational cross-sectional view of the outer front cap. 
         FIG. 48  shows in greater detail a cross-sectional view of the front cap assembly, solvent flow passageways and interlocked mixing chamber of the mixing module. 
         FIG. 49  shows a side elevational of the solvent supply source with the solvent bottle partially removed from the solvent bottle reception sleeve. 
         FIG. 50  shows back end elevational view of the solvent source combination shown in  FIG. 49 . 
         FIG. 51  shows a side elevational view of the solvent supply bottle above. 
         FIG. 52  shows a view similar to  FIG. 49  but with the bottle fully received. 
         FIG. 53  shows a top plan view of  FIG. 52 . 
         FIG. 54  shows the solvent pump used in the solvent supply system of the present invention. 
         FIG. 55  shows a front elevational view of the dispenser apparatus with means for reciprocating the mixing module rod and with a bottom brush cover plate removed. 
         FIG. 55A  provides a perspective view of the dispenser apparatus similar to that of  FIG. 22  but from a different perspective angle. 
         FIG. 56  shows a top plan view of that which is shown in  FIG. 55 . 
         FIG. 57  shows a right end and view of that which is shown in  FIG. 55  (with the brush cover added). 
         FIG. 58  shows a cross-sectional view taken along cross-section view B—B in  FIG. 56 . 
         FIG. 59  shows a cross-sectional view taken along cross-section line A—A in  FIG. 56 . 
         FIG. 60  shows a front elevational view of the dispenser end section of the dispenser apparatus. 
         FIG. 61  shows a rear end view of that which is shown in  FIG. 60 . 
         FIG. 62  shows a cross-sectional view taken along A—A in  FIG. 61 . 
         FIG. 63  shows a cross-sectional view taken along cross-section line C—C in  FIG. 62 . 
         FIG. 64  shows a perspective view of the dispenser (and brush) drive mechanism. 
         FIG. 65  shows a one way clutch for use in the main dispenser drive mechanism. 
         FIG. 66A  shows a perspective view of the main housing of the dispenser apparatus. 
         FIG. 66B  shows a perspective view of the dispenser housing cap (capped end of housing). 
         FIG. 67  shows a perspective view of a first half (larger) of the dispenser crank assembly. 
         FIG. 68  shows a cross-sectional view of that which is shown in  FIG. 67 . 
         FIG. 69  shows a perspective view of a second half (smaller) of the dispenser crank assembly. 
         FIG. 70  shows a left end elevational view of that which is shown in  FIG. 69   
         FIG. 71  shows a right end elevational view of that which is shown in  FIG. 69   
         FIG. 72  shows the rear side of the main housing for use in the dispenser apparatus. 
         FIG. 72A  shows a view similar to  FIG. 72 , but with access panels removed. 
         FIG. 73  shows the main dispenser housing on a side opposite of  FIG. 72 . 
         FIG. 73A  shows a view similar to  FIG. 73 , but with access panels removed. 
         FIG. 74  illustrates the connecting rod used in the dispenser drive mechanism. 
         FIG. 75  shows one of the guide shoes used in the dispenser drive mechanism. 
         FIG. 76  shows the piston or slider that is utilized in the dispenser drive mechanism. 
         FIG. 77  shows the in-line pump assembly of the preferred embodiment of the present invention. 
         FIG. 77A  shows a side elevational view of the in line plump assembly of the present invention. 
         FIG. 78  shows a cross-sectional view of the in-line pump assembly. 
         FIG. 79  shows a cut away bottom view of the pump motor and electrical feed. 
         FIG. 80  shows a perspective view of the pump motor showing the threaded output shaft. 
         FIG. 81  shows a similar view to that of  FIG. 80  with an added connector housing adapter plate. 
         FIG. 82  shows a cross sectional view of the connector housing for connecting the pump motor and outlet manifold of the in-line pump assembly. 
         FIG. 83  shows a cut away view of the magnetic coupling assembly. 
         FIG. 84  provides a perspective view of the outer magnet assembly. 
         FIG. 85  shows a cross-sectional view of the outer magnet assembly. 
         FIG. 86  shows a perspective view of the magnet coupling assembly shroud. 
         FIG. 87  shows a cross-sectional view of the shroud. 
         FIG. 88  shows a perspective view of the outer magnet assembly. 
         FIG. 89A  shows a perspective view of the inner magnet assembly for the in-line pump assembly. 
         FIG. 89B  shows a cross-sectional view of the inner magnet assembly. 
         FIG. 90  shows a cross-sectional view of the output manifold assembly. 
         FIG. 91  shows a bottom plan view of the outlet manifold. 
         FIG. 92  shows the bearing shaft used in the in-line pump assembly. 
         FIG. 93  shows in perspective the geroter pump head. 
         FIG. 93A  shows an exploded view of the geroter pump head. 
         FIG. 94  shows a cross-sectional view of the geroter pump head from a first orientation. 
         FIG. 95  shows a cross-section view of the geroter pump head from a different orientation. 
         FIG. 96  shows the plates of the geroter pump from an inside or interior surface plate perspective. 
         FIG. 97  shows the plates of the geroter pump from an outside surface plate perspective. 
         FIG. 98  illustrates flex coupling for use in the pump assembly. 
         FIG. 99  shows an upper perspective view of the chemical inlet manifold. 
         FIG. 100  shows a lower perspective view of the chemical inlet manifold. 
         FIG. 101  shows a perspective view of a chemical inlet valve manifold. 
         FIG. 102  shows a cross-sectional view of the chemical inlet valve manifold. 
         FIG. 103  illustrates the hose and cable management means of the present invention. 
         FIG. 104  shows a schematic depiction of the heated chemical conduit circuitry. 
         FIG. 105  shows a section of the heated chemical conduit where the thermister or temperature sensor is provided and the bypass return leg for the heater circuit. 
         FIG. 105A  shows an enlarged view of the thermister section of the heater coil. 
         FIG. 106  provides a cross-sectional view of a non-thermister section of the heated chemical conduit taken along cross-section line Y—Y in  FIG. 106 . 
         FIG. 107  shows a front face elevational view of the feed through block of the chemical conduit heating system. 
         FIG. 108  shows a side elevational view of the feed through block. 
         FIG. 109  illustrates the feed through assembly used in the chemical hose heater wire system for introducing electricity to the heater wire across an air/chemical interface. 
         FIG. 109A  shows a cut-away view of the feed through assembly. 
         FIG. 109B  shows a perspective view of the feed through assembly. 
         FIG. 109C  shows a perspective view of the main manifold and heated chemical hose manifolds in combination. 
         FIG. 110  illustrates a preferred embodiment of the chemical temperature sensing unit which includes a thermister in the illustrated embodiment. 
         FIG. 110A  shows the sensing unit of  FIG. 110  encapsulated as part of a chemical conduit sensing device. 
         FIG. 111  shows a cut-away view of the seal-cut-seal or SE-CT-SE sequence provided by the end seal forming jaw set assembly. 
         FIG. 112  shows the free end of the coiled chemical hose heater wire having a crimped “true” ball end for threaded insertion of the heater wire into the chemical hose. 
         FIG. 113  shows the threading tip means of the present invention alone. 
         FIG. 113A  shows an end view of the tip shown in  FIG. 113 . 
         FIG. 114  shows a side view of the tip used on the second tip embodiment. 
         FIG. 115  shows a cross-sectional view of the spindle with spline drive assembly of the present invention taken along cross-section line A—A in  FIG. 116 . 
         FIG. 116  shows a cross-sectional view of the spindle with spline drive assembly taken along cross-section line B—B in  FIG. 115 . 
         FIG. 117  shows a perspective view of the spindle spline drive or engagement member of the spindle spline drive assembly with emphases on the tooth drive side. 
         FIG. 118  shows a perspective view of the spindle spline drive with emphasis on the non-roll contact side. 
         FIG. 119  provides a side elevational view of the spindle spline drive&#39;s engagement member. 
         FIG. 120  shows a cross-sectional view taken along A—A in  FIG. 119 . 
         FIG. 121  provide a front elevational view of the spindle spline drive from the roll facing side. 
         FIG. 122  provides an enlarged view of a section of  FIG. 119 . 
         FIG. 123  shows a cross-sectional view of a compacted version of the spindle or film support means set for handling shorter width films taken along cross-section line A—A in  FIG. 124 . 
         FIG. 124  shows a cross-sectional view taken along cross-section line B—B in  FIG. 123 . 
         FIG. 125  shows a perspective view of the roll latch mechanism in a locked state. 
         FIG. 126  shows the roll latch mechanism in an unlocked state. 
         FIG. 127  shows the roll latch mechanism in operation locking a roll of film. 
         FIG. 128  shows a cross-sectional view of the roll latch mechanism taken along cross-section A—A line in  FIG. 129 . 
         FIG. 129  shows a cross-sectional view of the roll latch mechanism taken along cross-sectional line B—B in  FIG. 128 . 
         FIG. 130  shows a perspective view of a film roll with core and opposite end core plugs or inserts. 
         FIG. 131  show a cross-sectional view of  FIG. 130 . 
         FIGS. 132 ,  133 ,  134  and  134 A provide varying views of the roll film drive core plug. 
         FIGS. 135 ,  136 ,  137  and  138  provide various views of the roll film non-drive support plug. 
         FIG. 139  provides a cut-away, enlarged view of the roller set assembly and door latch assembly for the front access panel. 
         FIG. 140  shows a view of the front access panel in an open state. 
         FIG. 141  shows the heater jaw assembly. 
         FIG. 142  shows the same view of  FIG. 141  but with one of the heater jaw heater wires removed. 
         FIG. 143  shows an enlarged view of the left end of  FIG. 142 . 
         FIG. 144  shows the assembly support by the front panel frame sections. 
         FIG. 145  shows a cross-sectional view of the roller assembly of  FIG. 144 . 
         FIG. 146  shows a first perspective view of a first embodiment of edge sealer assembly from the electrical contact side. 
         146 A shows a first perspective view of a second embodiment of edge sealer assembly from the electrical contact side. 
         FIG. 147  shows a second perspective view of the first embodiment of the edge sealer assembly from the heater wire side. 
         FIG. 147A  shows a second perspective view of the second embodiment of the edge sealer assembly from the heater wire side. 
         FIG. 148  shows an elevational view of the heater wire side of the first embodiment of the edge sealer assembly. 
         FIG. 148A  shows an elevational view of the heater wire side of the second embodiment of the edge sealer assembly. 
         FIG. 149  shows a cross-sectional view taken along cross-section line A—A in  FIG. 148 . 
         FIG. 149A  shows a cross-sectional view taken along cross-section line A—A in  FIG. 148A . 
         FIG. 150  shows a cross-sectional view taken along cross-section line B—B in  FIG. 148 . 
         FIG. 150A  shows a cross-sectional view taken along cross-section line B—B in  FIG. 148A . 
         FIG. 151  shows the interior side of one of the two sub-rollers of the first embodiment of the edge seal assembly. 
         FIG. 151A  shows the interior side of one of the two sub-rollers of the second embodiment of the edge seal assembly. 
         FIG. 152  shows the exterior side of the sub-roller in  FIG. 151 . 
         FIG. 152A  shows the exterior side of the sub-roller in  FIG. 151A . 
         FIG. 153  shows the internal sleeve of the first embodiment of the edge seal assembly. 
         FIG. 154  shows the roller bearing of the first embodiment of the edge seal assembly which is received by the sleeve and receives the driven roller set shaft. 
         FIG. 155  shows a perspective view of the arbor base of the first embodiment of the edge seal assembly. 
         FIG. 155A  shows a perspective view of the arbor base of the second embodiment of the edge seal assembly. 
         FIG. 156  shows a cross-sectional view of the arbor base shown in  FIG. 155 . 
         FIG. 156A  shows a cross-sectional view of the arbor base shown in  FIG. 155A . 
         FIG. 157  shows a perspective view directed at the heater wire side of the arbor mechanism of the first embodiment of the edge seal assembly. 
         FIG. 157A  shows a perspective view directed at the heater wire side of the arbor mechanism of the second embodiment of the edge seal assembly. 
         FIG. 158  shows an elevational view of the heater wire side of the arbor assembly first embodiment of the edge seal assembly. 
         FIG. 158A  shows an elevational view of the heater wire side of the arbor assembly second embodiment of the edge seal assembly. 
         FIG. 159  shows a cross-sectional view taken along A—A in  FIG. 158 . 
         FIG. 159A  shows a cross-sectional view taken along A—A in  FIG. 158A . 
         FIG. 160  shows a side view of the arbor assembly first embodiment of the edge seal assembly. 
         FIG. 160A  shows a side view of the arbor assembly of the second embodiment. 
         FIGS. 161 to 163  show alternate perspective views of the arbor assembly edge seal assembly with  FIGS. 161 and 163  illustrating the seal wire tensioning means. 
         FIGS. 161A to 163A  show alternate perspective views of the arbor assembly edge seal assembly of the second embodiment. 
         FIGS. 164 to 169  show various illustrations of the arbor housing with the edge seal wire and associated tensioning means removed for added clarity as to the receiving housing. 
         FIGS. 164A to 169A  show various illustrations of the arbor housing with the edge seal wire and associated shoes removed for added clearly as to the receiving housing. 
         FIGS. 170 and 172  show perspective views of the wire end connector of the first edge seal embodiment. 
         FIGS. 170A and 172A  show perspective views of a shoe conductors of the second edge seal embodiment. 
         FIGS. 173A and 173B  illustrate the ceramic head insert used in the arbor assembly in the first embodiment of the edge seal assembly. 
         FIGS. 173C and 173D  illustrate the head insert used in the arbor assembly of the second edge seal assembly embodiment. 
         FIGS. 174 to 176  illustrate alternate perspective views of the edge wire tensioner block or moving mounting block. 
         FIG. 177  shows a cross-sectional view of the tensioner block. 
         FIG. 178  shows a heater wire end connector in the wire tensioning assembly. 
         FIG. 179  shows a top plan view of the tip cleaning brush base. 
         FIG. 180  shows a side elevational view of that which is shown in  FIG. 179  with added bristles. 
         FIG. 181  shows a cross-sectional view of the brush base. 
         FIG. 182  shows a bottom perspective view of the brush base. 
         FIG. 183  shows a top plan view of the brush base. 
         FIG. 184  shows a bottom plan view of the brush base. 
         FIG. 185  shows an end view of the brush base. 
         FIG. 186  shows an overall dispenser assembly sub-systems schematic view of the display, controls and power distribution for a preferred foam-in-bag dispenser embodiment. 
         FIG. 186A  provides a legend key for the features shown schematically in  FIG. 186 . 
         FIG. 187  shows a schematic view of the control, interface and power distribution features for the heated cross cut and cross seal wires in the bag forming assembly of the present invention. 
         FIG. 188  shows a schematic view of the control, interface and power distribution features for the heated edge seal wire. 
         FIG. 189  shows a schematic view of the controls, interface and power distribution features for the moving jaw with cross cut and seal wiring. 
         FIG. 190  shows a schematic view of the control, interface and power distribution features for the rod moving mechanism for chemical dispensing and the dispenser tip cleaning system. 
         FIG. 191  shows an illustration of the control, interface and power distribution features for the film advance and tracking system of the present invention. 
         FIG. 192  shows an illustration of the control, interface and power distribution features for the film web tensioning system of the present invention. 
         FIG. 193  shows an illustration of the control, interface and power distribution features for the heated and temperature monitored chemical hoses of the present invention. 
         FIG. 194  shows an illustration of the control, interface and power distribution features for the heaters used in the main manifold and dispenser housing to maintain the chemical flowing therethrough at the desired set temperature through use of heater cartridges in the main manifold and dispenser housing adjacent flow passageways formed in the manifold and housing. 
         FIG. 195  shows an illustration of the control, interface and power distribution features for the pump system feeding chemical to the dispenser. 
         FIG. 196  shows an illustration of the control, interface and power distribution features of the solvent supply system. 
         FIG. 197  shows plotted TCR values based on the temperature and resistance values set forth in Table 1 of the present application. 
         FIG. 198  shows a comparison of ratio value (ratio of accumulated tachometer pulses of film tension motor divided by the accumulated tachometer pulses of film advance motor) versus number of dispenser shots brought about by a control board comparison of the encoder signals from the respective film advance and film tension motors. 
         FIG. 199  shows a testing apparatus for use in testing temperature versus resistance for heater wires. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  illustrates a preferred embodiment of the dispensing system  20  of the present invention which comprises dispenser system  22  in communication with the chemical supply system  23  comprising chemical supply container  24  (supplying chemical component A) and chemical supply container  26  (supplying chemical component B). Chemical hoses  28  (chemical A) and  30  (chemical B) provide fluid communication between respective chemical supply containers  24 ,  26  and in-line pump system  32  mounted on dispenser system  22 . Dispenser system  22  includes in-line pump system  32  that is in communication with chemical supply containers that are either in proximity (40 feet or less) to the dispenser system  22  or remote (e.g., greater than 40 feet) from where the dispenser system  22  is located. This allows the containers to be situated in a more convenient or less busy area of the plant, as it is often not practical to store chemicals in close proximity to the machine (e.g., sometimes 100 to 500 feet separation of dispenser and chemicals is desirable). 
     Thus the present invention has a great deal of versatility as to how the dispenser system is to be set up relative to the chemical source. For example, “in-barrel pumps,” while available for use as a chemical drive component in one chemical supply system  23  of the present invention, are less preferred as they have a limited reach as they have the electric resistance heaters that is positioned between the chemical supply and the dispenser. The normal chemical hose length is 20 feet, but typically at least five feet of this length is required to route the hoses and cables out of the system enclosure and part way down the support stem. This means that the chemical drums for many prior art “in barrel” pump systems can be no more than 15 feet away from the dispenser system, which is not feasible in many plants. The in barrel pumps can to some extent be modified with longer chemical hoses and pump cables (e.g., chemical hose internal electric resistance heater wires), but there is a practical limit on how far these hoses can extend, since they are light duty and susceptible to mechanical damage, kinking, and crushing. Another limitation, for various electrical and electromagnetic interference (EMI) reasons, is the cable length from the drive board in the enclosure to the “in barrel” pumps. Because of these reasons it is estimated that a practical length limit on the pump cable for such systems is 30 to 40 feet without industry unacceptable modifications or enhancements (expensive) to the controls or to the cable construction. As a number of installations require that the containers be stored hundreds of feet (e.g., 100 to 500 feet or more) away from the system, the estimated practical limit of 30 to 40 feet for such hoses is not enough for many requirements. The present invention is designed to accommodate these long length installation requirements. 
       FIG. 1  further illustrates feed pumps  34 , and  36  associated with chemical supply containers  24 , and  26 . Feed pumps  34 , and  36  provide a positive pressure to the in-line pump system so as to provide positive pressure on their input ports to avoid problems like cavitations, or starvation of the pumping means (e.g., a gerotor based pump system) and to reliably suck chemical out of the bottom of the supply containers even if the in-line pumps are far away (e.g., over 100 feet). Short runs of hose length between the containers and the positive pressure feed pumps can be handled by attaching a dip tube to the inlet end of the feed hose, or by simply attaching the feed hose to the bottom of the container via valves and connectors. 
     The positive pressure feed pumps are preferably located in or near the chemical supply containers, are preferably air driven, and preferably produce between 50 and 200 psi of pressure at the input port of each in-line pump. Rather than individual feed pumps, a common feed pump system is provided in a preferred embodiment having an output capacity to supply chemical to multiple systems all dispensing at the same time.  FIG. 1  illustrates a multiple chemical conduit arrangement wherein feed pumps  34  and  36  feed chemical to more than one dispenser system at the same time with lines  28  and  30  feeding dispenser system  22  and lines  38  and  40  feeding a second dispenser system (not shown). A single feed pump with manifold assembly can also be used to distribute chemicals A and B to multiple locations. Under the present invention the feed pumps can have expanded capacity such as a capacity to feed  4  to  5  systems simultaneously. The ability to run multiple systems from a single set of supply containers sets the in-line pump option provided by the present invention apart from in-barrel pump based systems, which can only feed one system per set of containers. 
       FIG. 2  provides a rear elevational view of dispenser system  22  which includes exterior housing  38  supported on telescoping support assembly  40  which in a preferred embodiment comprises a lifter (e.g., electric motor driven gear and rack system with inner and outer telescoping sleeves) and is mounted on base  42  (e.g., a roller platform base to provide some degree of mobility). Further mounted on base  42  is in-line pump system  32  comprising in line chemical A pump  44  and in line chemical B pump  46  housing output or downstream chemical supply conduit sections  43  and  45  that extend into hose manager assembly  48  containing heated coiled hoses and cables set  50 . The rear view shown in  FIG. 2  also illustrates control console  52  and communication links generally represented by communication lines  54 . Film roll reception assembly  56  and film roll driver  58  extends out from support assembly  40 . 
       FIG. 3  provides a front view of dispenser assembly  22  including first and second control panels  61  and  63  having an improved finger contact means as described in co-pending U.S. Provisional Patent Application Ser. No. 60/488,009 filed on Jul. 18, 2003, and entitled Push Buttons And Control Panels Using Same, and which is incorporated herein by reference. 
       FIG. 4  provides a top plan view of dispending system  22  with heated coiled hoses and cables set  50  emphasized relative to the rest of the system  22  shown with dotted lines.  FIG. 5  provides a similar rear elevational view as in  FIG. 2 , except with extendable support assembly  40  being in a maximum extension state (e.g., a 15 to 40 inch extension with a 24 inch extension being well suited ergonomically from a collapsed maximum height of 3 to 5 feet being illustrative for the dispenser). With reference to  FIG. 5  and the front view of  FIG. 1  there is seen solvent container  60  which is fixed to extendable support  40  and rides up and down with the moving component of lifter or extendable support  40 . 
       FIG. 6  illustrates base  42  and lifter or extendable support assembly  40  (e.g., preferably a hydraulic (air pressure) or gear/rack combination or some other telescoping or slide lift arrangement) extending up from base and having bagger and dispenser assembly support mount  62 .  FIG. 6  also illustrates the mobile nature of base  42  which is a wheeled assembly. 
       FIGS. 7–10  shows foam-in-bag assembly or “bagger assembly”  64  (with dispenser removed for added clarity) that is designed to be mounted in cantilever fashion on support mount or bracket  62  as shown in  FIGS. 11 and 12 . Bagger assembly  64  comprises framework  65  having first side frame  66  (shown on the right side relative to a front view in  FIG. 7 ) and second side frame  68  (shown on the left side in the front view  FIG. 7 ). Side frame  66  has means for mounting bagger assembly  64  to support bracket  62  (e.g., a set of bolts  69  as shown in  FIG. 11 ). Framework  65  further includes front pivot rod  70  extending between the two interior sides of side frames  66 , and  68 , as well as front face pivot frame sections  71  and  73  which are pivotally supported by pivot rod  70 . Rod  70  also extends through the lower end of front face pivot frame sections  71  and  73  to provide a rotation support for sections  71 ,  73 . Driver roller shaft  72 , supporting left and right driven or follower nip rollers  74  and  76 , also extends between and is supported by side frames  66  and  68 . While in a latched state the upper ends of pivot frame sections  71 ,  73  are also supported (locked in closed position) by door latch rod  85  with handle latch  87 . 
     First frame structure  66  further includes mounting means  78  for roller shaft drive motor  80  in driving engagement with drive shaft  82  extending between and supported by frame structures  66  and  68 . Drive shaft  82  supports drive nip rollers  84  and  86 . Framework  65  further comprises back frame structure  88  preferably formed as a single piece unit with side frame structures  66  and  68 . Driven roller shaft  72  and driver roller shaft  82  are in parallel relationship and spaced apart so as to place the driven nip rollers  74 ,  76 , and drive nip rollers  84 ,  86  in a film drive relationship with a preferred embodiment featuring a motor driven drive roller set  84 ,  86  formed of a compressible, high friction material such as an elastomeric material (e.g., synthetic rubber) and the opposite, driven roller  74 ,  76  is preferably formed of a knurled aluminum nip roller set (although alternate arrangement are also featured as in both sets being formed of a compressible material like rubber). The roller sets are placed in a state of compressive contact by way of the relative diameters of the nip rollers and rotation axis spacing of shafts  72 , and  82  when pivot frame sections  71 ,  73  are in their roller drive operation state.  FIG. 7  further illustrates door latch rod  85  rotatably supported at its opposite ends by pivot frame sections  71 ,  73  and having door latch (with handle)  87  fixedly secured to the left end of door latch rod  85 . As explained in greater detail below, latch  87  provides for the pivoting open of pivot frame sections  71 ,  73  of the hinged access door means about pivot rod  70  into an opened access mode. While in a latched state, the upper ends of pivot frame sections  71 ,  73  are also supported (locked in closed position) by door latch rod  85 . 
     Drive nip rollers  84  and  86  have slots formed for receiving film pinch preventing means  90  (e.g., canes  90 ) that extend around rod  92  with rod  92  extending between first and second frames  66 ,  68  and parallel to the rotation axes of shafts  72  and  82 .  FIG. 7  further illustrates bag film edge sealer  91  shown received within a slot in roller  76  and positioned to provide edge sealing to a preferred C-fold film supply. Rear frame structure  88  has secured to its rear surface, at opposite ends, idler roller supports  94  and  96  extending up (e.g., 8 to 15 inches or a preferred 11 inches) from the nip roller contact location. Idler roller supports  94 ,  96  include upper ends  98  and  100  each having means for receiving a respective end of upper idler roller  101  (e.g., a roller shaft reception aperture or bearing support). As shown in  FIG. 7 , ends  98 ,  100  present opposing parallel face walls  102 ,  104  and outward flanges  106 ,  108 . Within the confines of flanges  106 , and  108  there is provided first and second idler roller adjustment mechanisms  110 , and  112 . In a preferred embodiment, one of the adjustment mechanisms provides vertical adjustment as to the rotation axis of idler roller  101  while the other provides front to back horizontal adjustment to the same idler roller  101  rotation axis.  FIG. 8  illustrates the horizontal track adjustment means of the present invention which, in combination with the opposite vertical adjustment track plate, helps ensure the film properly tracks through the nip roller (retains a right angle film edge relationship to the roller axis while traveling a pre-set preferably generally centered or intermediate path through the nip roller set). Sliding plate  110  is retained in a frictional slide relationship with surface  100  by way of slide tabs TA extending through elongated horizontal slots SL at opposite corners of the plate. On the front flange  100  FF there is supported adjustment screw SC extending into engagement with tab TA on sliding plate  110  receiving an end of the idle roller  101 . Upon rotation of screw SC, plate  110  is shifted together with the end of the idler roller. The opposite side is just the same but for there being a vertical adjustment relationship as shown in  FIG. 9 . In this way, idler roller  101  can be adjusted to accommodate any roller assembly position deviation that can lead to non-proper tracking and also can be used to avoid wrinkled or non-smooth bag film contact. Also, idler roller  101  is preferably a steel or metal roller and not a plastic roller to avoid static charge build up relative to the preferred plastic film supplied. Idler roller is also preferably of the type having roller bearings positioned at its ends (not shown) for smooth performance and smooth, unwrinkled film feed. 
     With reference particularly to  FIGS. 7 and 9 , second or lower idler roller  114  is shown arranged parallel to drive roller shaft  82  and supported between left and right side frames  66  and  68 . Idler roller  114  preferably has a common roller/bearing design with that of idler roller  101 . Also, these figures show first (preferably fixed in position when locked in its operative position) end or cross-cut seal support block or jaw  116  positioned forward of a vertical plane passing through the nip roller contact location and below the axis of rotation of drive shaft  82 . End seal jaw  116 , which preferably is operationally fixed in position, is shown having a solid block base of a high strength (not easily deformed over an extended length) material that is of sufficient heat wire heat resistance (e.g., a steel block with a zinc and/or chrome exterior plating), and extends between left and right frame structures  66 , and  68 , but again, like driven shaft  72  and rollers  74 ,  76 , is preferably supported on pivot frame sections  71 ,  73  and extends parallel with driven shaft  72 .  FIG. 7  illustrates block  116  rigidly fixed at its ends to the opposing, interior sides of pivot frame sections  71 , and  73  for movement therewith when latch  87  is released. 
     Movable end film sealer and cutter jaw  118  ( FIG. 9 ) is secured to end sealer shifting assembly  120  is positioned adjacent fixed jaw  116  with fixed jaw having sealer and cutter electrical supply means  119  with associated electric connections ( FIG. 8 ) supported on the opposite ends ofjaw  116  positioned closest to the front or closest to the operator. End sealer shifting assembly  120  is positioned rearward and preferably at a common central axis height level relative to end seal contact block  116 . During formation of a bag heater jaw  116  supports a cutter heated wire in-between above and below positioned seal forming wires (e.g., for a total of three vertically spaced apart heater wires) with of, for example ⅛ to ¾ inch equal spacing with ¼ to ½ inch spacing being well suited for providing the seal (SE) cut (CT) seal (SE) sequence in the bag just formed and the bag in the process of being formed. The SE-CT-SE sequence is illustrated in  FIG. 111  which, in conjunction with edge seal ES, forms a complete bag from a preferred C-film source. With the SE-CT-SE arrangement there is provided a more assured bottom bag formation and there is avoided the problems associated with prior art devices that rely on the end or cross-cut only as the means for sealing. For example, if for any reason a perfect end seal is not secured during the cut formation, there can result massive foam spillage and build up as the foam mix is at its most liquid and least foam development stage when the dispenser first shoots the shot into the just formed bag bottom. 
     A preferred embodiment features a combination end film sealer means and cutter means  119  (e.g., see  FIGS. 141 to 143 ) having three independently controlled cross-cut/cross-seal resistance wire mechanisms preferably extending across the full length of the face of block  116 . These wires are connected at their ends with quick release wire end holders. This end seal and cutter on the fixed block  116  (after access panel locked in place) works in conjunction with movable sealer shifting assembly or jaw support assembly  120 . As also explained below, the heater and sealer wires are sensed and thus in communication with a controller such as one associated with a main processor for the system or a dedicated heater wire monitoring sub-processing as illustrated in  FIG. 186 . Venting preferably takes place on the side with the edge seal ES through a temporary lowering of heat below the sealing temperature as the film is fed past or some alternate means as in adjacent mechanical or heat associated slicing or opening techniques. Block  118  also has a forward face positioned rearward (farther away from operator) of the above mentioned nip roller vertical plane when in a stand-by state and is moved into an end seal location when shifting assembly is activated and, in this way, there is provided room for bag film feed past until end sealer shifting assembly  120  is activated. 
     A first embodiment of sealer shifting assembly  120  is shown in  FIGS. 9 , and  9 A to  9 E and comprises first and second sealer support rod assemblies  122 ,  124  each having a front a forward end with reception blocks  121 ,  123  having a recess area securement means for receiving and securing jaw  118 . The securement means is preferably in the form of an elongated (end threaded) rod,  126  ( FIG. 9E ) extending through a respective one of blocks  121 ,  123  and into threaded engagement with a respective jaw extension  141 ,  143  laterally external to the main or contact body of jaw  118 . The supported rod assemblies  122 ,  124  are preferably designed the same, but for their mirror image orientation. Rod  126  has a rear end extending through cylinder extensions  147  ( FIG. 9B ) and out through block  125  and out the rear of block  125  and having blocking member  117  (e.g., threaded cup). Rod  126  is surrounded by cylindrical sleeve SL extending between cap  117  and jaw extension  143 . Spring  130  surrounds sleeve SL and extends into contact with jaw extension  143 , at one end and, at an opposite end, abuts cup  147  as well as threaded low friction sleeve FS received within block  125 . Spring or biasing means  130  is preferably a preloaded spring (e.g., 6″ free state at 80 lb/in spring preloaded to about 110 lbs) to bias block  118  forward against the limiting end of the rod  126  (threaded end and cap  117 ). With the rear end of rod  126  slidingly received within housing block  125  and having blocking protrusion  117  to prevent inadvertent release, there is allowed for absorption of additional compression on the spring during a state of advancement into contact with fixed jaw  116  (e.g., 0.03 to 0.04 inch) which is enough to absorb and deviations in the relative compressing faces of the two jaws and to improve the length consistency of the heated wire seal and cut formation. 
     Each of assemblies  122 ,  124  further comprise cam roller pin support extension  132  secured at a rear end of housing block  125  which respectively receive cam roller  140 . Cam rollers  140  are received within respective cam tracks  136 ,  138  formed in cams  144 ,  146  which are shown in  FIGS. 9A and 9B  to have an indented cylindrical shape or an ear shape with an outer flange wall defining, on its interior surface, a first cam track surface  141 C and an inner wall, defining on its outer surface, a second cam track surface  143 C ( FIG. 9B ). Cams  144 ,  146  are fixed to cam shaft  148  extending between bearing reception ports provided at the rear end of first and second side frames  66 ,  68 . To lock shaft  148  into position on frame structure  68 , there is provided bearing block  145  ( FIG. 9B ). Jaw  118  is confined to reciprocation essentially (as noted above, some degree of play at connection end to provide for flush contact adjustment relative to the operationally fixed jaw  116 ) along a horizontal plane in forward and rearward travel by guide roller sets  133  and  135  each featuring upper and lower guide rollers which are provided and supported on frame structures  66 ,  68  and placed in contact with upper and lower surfaces of housing blocks  125 ,  127 . Second sets of upper and lower guide rollers  137 ,  139  are supported on frame structures  66  and  68  and in contact with the upper and lower surfaces of jaw extensions  141 ,  143 . 
     Cam shaft  148  extends into driving engagement with drive pulley  150  forming part of drive pulley assembly  152  which further includes pulley belt  154  ( FIG. 7 ). As seen from  FIG. 7 , side frame  66  includes cam motor support section  156  to which cam motor  158  is secured. Cam motor drive shaft  160  is secured to drive pulley  162  of drive pulley assembly  152 . Thus, activation of cam motor  158  leads to drive force transmission by transmission means (represented by the drive pulley assembly in the illustrated preferred embodiment) which in turn rotates cam shaft  148  and cams  144 ,  146  fixedly mounted thereon to provide for the pushing forward during the push forward cam rotation mode (cam roller  140  riding on a portion of the interior cam track surface  143  to effectuate a push forward to provide for the end seal and cutting function) and the pulling rearward ofj aw  118  after the sealing function is completed (can include cutting as sole means of sealing or as a component of multiple seals (non-cutting and cutting) or as a weakening for downstream separation in a bag chain embodiment through control of the level of heat and time of contact with film) by way of cam roller  140  riding on the first cam track surface  141 C during a pull back cam rotation mode for cams  140 ,  142 . Alternate transmission means and cam or non-cam push-pull driving means are also featured under the present invention such as a gear based system (e.g., rack and pinion) or hydraulic system for either or both of the drive transmission means or the push-pull driving of the end seal block or jaw  118 . However, the illustrated cam arrangement provides for efficient and accurate push and pull movement with controlled force application to help provide improved seals and/or cuts. Thus, blocks  121 ,  123  and the supported moving jaw  118  are biased forward into a compression sate with jaw  118  which compression is accommodated via compression of spring  130  and sliding of rod  126  if need be in each of assemblies  122 ,  124 . In addition, the spring provides for some degree of play relative to up-down/side-to-side and points in-between. In a preferred embodiment the biasing force is about 75 to 150 lbf with 110 lbf being an illustrative force level. This arrangement provides a non-rigid, compliant system which can accommodates deviations relative to the end seal opposing faces of the jaws in the invention disclosure. 
       FIGS. 7 and 9  also illustrate the preferred external support plates  156  for cam motor  158 , and plate  66  for drive shaft motor  80 . 
       FIG. 9F  shows a perspective view of a second embodiment of a moving jaw assembly  4000  which retracts and pushes forward jaw block  118  against the preferably stationary jaw  116  with heated cross cut and seal wires. The rear end of block  118  is connected at opposite ends to respective casings  4002  and  4004  with these casings forming a part of the cam force transmission devices  4006  and  4008 . Cam force transmission devices  4006  and  4008  are the same except for their mirror image positioning (and below described home positioner) and thus the discussion focuses on transmission device  4006  alone. Casing  4004  is secured to frame structure  66  of bagger assembly  64  at its expanded ends and has an interior reception chamber formed along its inner side. As seen from  FIG. 91 , within this chamber is positioned bearing plates  4010  and  4012  which receive in sliding fashion cam rod  4014 . The rear end of cam rod  4014  includes cam yoke  4015  which supports cam roller  4016  which rides along cam  4018  having a eccentric shape with a minimum contact thickness shown in contact with roller  4016  in  FIG. 9I  and a maximum thickness shown in contact with roller  4016  in  FIG. 9J . 
     The forward end of cam rod  4014  includes a threaded center hole receiving push rod  4020  having a first end extending into threaded contact with the center hole and a second end that extends through an aperture in block  118  and has enlarged head  4022 . Push rod  4020  is encircled by rod sleeve  4024  having a forward end received with a pocket recess in block  118  and a forward end in contact with first (inner) biasing member  4026 , which is preferably a coil spring, compressed between a forward end of push rod  4014  and a rear end of sleeve  4024 . Surrounding inner spring  4026  is a second (outer) biasing member  4028 , also preferably in the form of a coil spring, received by a flanged end of cam follower  4014  at one end and in contact with an outer flanged sleeve  4030  in contact with the forward enlarged end of casing  4004 . Outer spring  4028  is designed to hold the cam follower or cam rod  4014  against the cam, while the inner spring  4026  produces the compression for sealing the jaws at the time of forward extension. In view of these different functions, outer longer spring (e.g., 3.5 inch free length) preferably has a much lower spring constant (e.g., 12 lbs/in) as compared to the inner shorter spring (e.g., 1.75 inch free length) having a higher spring constant (e.g., 750 lbs/in). Cams  4018  and  4018 ′ are interconnected by cylindrical drive sleeve  4032  with annular flanges  4034  and associated fasteners providing a means of securement between the sleeve  4032  and a respective eccentric cam, with the cams being driven by cam motor  158  and associated drive transmission as in the other embodiment. 
       FIG. 9F  illustrates home sensor  4036  which is connected to an extension of casing  4004  and is positioned for monitoring the exact location of the moving jaw  118  at all times and is in communication with the control and monitoring sub-system shown in  FIG. 189  and provides position feedback which is useful, together with the encoder information generated by the cam motor  158  in determining current and historic location data. 
     With reference to  FIGS. 6 , and  11  to  13  there is illustrated a preferred mounting means featuring base  42 , lifter assembly  40  and securement structure  62 . Securement structure  62  comprises curved forward wall  164  and vertical back wall  166  which, together with lifter top plate  168 , define cavity  169 . As shown in  FIGS. 11 and 12  securement structure  62  further comprises curving interior frame member  170 , which has an outer peripheral edge  171  that provides for dispenser hinge bracket support (discussed below) and a back curved flange section  175  extending outward and integral with frame member  170  as well as outer frame wall  174 . Frame wall  174  has a pulley drive assembly reception aperture (e.g., an ellipsoidal slot)  172  formed therein. 
     Further longitudinally (right side-to-left side) outward of frame wall  174  is mounting plate  176  which, in conjunction with open area  169 , provides a convenient location for securement of the electronics such as the system processor(s), interfaces, drive units, and external communication means such as a modem. In this regard, reference is made to co-pending U.S. Provisional Patent Application Ser. No. 60/488,102 “System and Method For Providing Remote Monitoring of a Manufacturing Device” filed on Jul. 18, 2003, and which is incorporated herein by reference describing the remote interfacing of the dispensing system with, among potential recipients, service and supply sources.  FIG. 11  also illustrates the supporting frame work for the hinged front access door assembly shown open in  FIG. 139  which comprises front access door plate  180  (partially shown in  FIG. 13 ) supported at opposite ends by pivot frame sections  71  and  73 . Pivot frame sections  71  and  73  preferably have a first (e.g., lower) end which is pivotally secured to pivot rod  70  and also between which rod  70  extends. 
       FIGS. 11 and 12  further reveal film roll support means  186  shown supporting film roll core  188  about which bag forming film is wrapped (e.g., a roll of C-fold film; not shown in  FIGS. 11 and 12 ). Film roll support means  186  is in driving communication with film roll/web tensioning drive assembly  190  (partially shown  FIG. 11 ) with motor  58  shown supported on the back side of lifter assembly  40 . 
       FIG. 13  provides a perspective view of bagger assembly  64  mounted on mounting means  78  with dispenser apparatus  192  included (e.g., a two component foam mix dispenser apparatus is shown), which is also secured to support assembly  62  in cantilever fashion so as to have, when in its operational position, a vertical central cross-sectional plane generally aligned with the nip roller contact region positioned below it to dispense material between a forward positioned central axis of shaft  72  and a rearward positioned central axis of shaft  82 . As shown in  FIG. 13 , dispenser assembly  192  comprises dispenser housing  194  with main housing section  195 , a dispenser end or outward section  196  of the dispenser housing with the dispenser outlet preferably also being positioned above and centrally axially situated between first and second side frame structures  66 , and  68 . With this positioning, dispensing of material can be carried out in the clearance space defined axially between the two respective nip roller sets  74 ,  76  and  84 ,  86 . 
     Also dispenser assembly  192  is preferably supported a short distance above (e.g., a separation distance of 1 to 5 inches more preferably 2 to 3 inches) the nip contact location or the underlying (preferably horizontal) plane on which both rotation axes of shafts  72 ,  82  fall. This arrangement allows for receipt of chemical in the bag being formed in direct fashion and with a lessening of spray or spillage due to a higher clearance relationship as in the prior art. Dispenser apparatus  192  further includes chemical inlet section  198  positioned preferably on the opposite side of main dispenser housing  194  relative to dispenser and section  196 . The outlet or lower end of dispenser assembly  194  is further shown positioned below idler roller  101  (e.g., a preferred top to bottom distance for housing  194  is 5 to 10 inches with 7 inches preferred, and it is preferable to have only a short distance between the upper curved edge of dispenser housing  194  and the horizontal plane contacting the lower end of upper idler roller  101  (e.g., 1 to 3 inch clearance with 1.5 inches preferred). In this way the upper, smooth curved edge of dispenser housing  194  helps in the initiation of the C-fold film or like film with the edges being separated and opened up as the film passes from idler roller  101  and along the smooth sides of dispenser housing  194  into the nip roller set. Thus, a distance of about 1 foot±3 inch is preferred for the distance between upper idler roller axis and the nip roller contact point. 
       FIG. 13  also illustrates dispenser motor  200  used for dispenser valve rod reciprocation as described below. Inlet end section  198  comprises chemical shut off valves with chemical shut off valve handles  201 ,  203  ( FIG. 14A ) that are large (e.g., a ½ to 1 inch or more in length) because of their placement outside of the film pathway, and thus readily viewed, particularly with color coding (as in blue and red handles) and positioned for easy hand grasping and adjustment without the need for tooling. As shown in  FIG. 14A , chemical shutoff valves  201 ,  203  are supported on manifold housing  205  of main manifold  199  through which the chemicals pass before being forwarded to the manifold housing portion of dispenser housing  194  and are adjustable between chemical pass and chemical blocked settings. The chemical shutoff valves are also positioned well away from the dispenser outlet so as to help avoid the problem associated with the prior art of having foam harden on the valves rendering them difficult to access. There is thus avoided the prior art disadvantages of having valves of relatively small size that are positioned within the confines of the bag being formed and are designed to make it difficult to view the status of the shut off valves and access the valves particularly after a foam coating. 
     Inlet end section  198  further includes pressure transducers  1207  and  1209  adjacent heater chemical hose and hose heater feed through manifolds  1206  and  1208  which feed into main manifolds  205 . Pressure transducers are in electrical communication with the control system of the foam-in-bag dispenser system and used to monitor the general flow state (e.g., monitoring pressure to sense line blockage or chemical run out) as well as to provide pressure signal feedback used by the control system in maintaining the desired chemical characteristics (e.g., pressure level, temperatures, flow rate etc.) for the chemicals in maintaining the desired mix relationship for enhanced foam generation. In this regard, reference is made to  FIG. 194  for an illustration of chemical temperature control means in the main manifold  199  and housing manifold  194 .  FIG. 14A  also illustrates manifold heater H 1  which also is in communication with the control system for maintaining a desired temperature in the manifold  199 . Filter devices  4206  and  4208  seen in  FIG. 13  are placed in fluid communication with the heated chemical passing through the manifold and can be made of a relatively large size and also of a fine mesh (e.g., screen mesh size of 100 or more mesh) and arranged so as to present at least one screen section in contact with the through flow of chemical. In view of the filter device&#39;s location at the inlet end section  148  they too are also far removed from the chemical dispenser&#39;s outlet and thus not prone to hardened chemical coverage (e.g., the inlet end section&#39;s  198  closest surface (e.g., the nearest filter&#39;s central axis and the closure valves are positioned 4 or more inches and more preferably 6–16 inches from the interior edge of film travel off the dispenser housing). This positioning outside of the film edge provides for the filter enlargement and much greater flexibility in the type and configuration of the filter. As seen, filters  4206  and  4208  are readily accessible and preferably retained in a cylindrical cavity such that a cylindrical filter shape can be inserted in cartridge like fashion. Enhanced removal filters can also be inserted like “depth” filters (100 micron or 50 micron removed or less as in a two stage depth filter with first stage soft outer element and more rigid inner element capable of handling the pressures involved and the chemical type passing therethrough without degradation). 
       FIG. 14A  illustrates dispenser apparatus  192  separated from its support location shown in  FIG. 13  and shows main housing  194 , dispenser end  196  as well as additional detail as to inlet end section  198  and dispenser motor  200 . As seen from  FIGS. 13 ,  14 A and  14 B and described in part above, many of the components previously placed in the prior art close to the dispenser outlet and between the left and right edges of the film being fed therepast and thus highly susceptible to foam contact, are moved outside and away from the area between the left and right edges of the film. In  FIG. 13  there is demarcation line FE representing the most interior film edge with the opposite edge traveling forward of the free end of dispenser system  192 . Thus, with a C-fold film the bend edge is free to pass by the cantilevered dispenser system  192  while the interior two sides are joined together with edge sealer  91  while passing along line edge FE. The components which have been moved from the prior art location between the film edges includes the drive motor (and a portion of its transmission), filter screens, electrical wires, chemical hoses and fittings, shut off valves, and pressure sensors. 
     For example, moving the drive motor  200  for the valving rod outside of the bag area facilitates (i) making the shape of the dispenser more streamlined for smooth film contact as in a smooth upper curvature leading to planar side walls (ii) making for use of a larger, more powerful, and more robust motor and gear box than is possible if it had to be inside the bag, (a requirement that demands the miniaturization of any potentially large components or mechanisms), (iii) the motor will stay cleaner of foam, crystallized isocyanate, sticky B chemicals, and solvents for the life of the system, since it is situated out of harms way, (iv) motor is easier to service than on previous dispenser designs, which required some fine work in a sticky environment, with the motor of the present invention being serviceable without having to open any of the chemical passages or touch any components that handle chemical. 
     The aforementioned chemical filter screens for filters  4206 ,  4208  are needed to protect the small orifice ports in the mixing chamber. These screens need to be cleaned out periodically. In the common prior art design, these screens are adjacent to the mixing block. To access these screens you have to work in this area, which can be a sticky and difficult task because of the chemical and foam buildup. A preferred embodiment of the present invention locates the screens of filters  4206  and  4208  in the main dispenser manifold  199 , which is completely outside of the bag. This means that the screens retainers will be cleaner and easier to remove than with the prior art design. The screen retainer caps are also made much larger relative to the above noted prior art design. By moving the filters external to the bag forming area, the screens can be made larger avoiding the situation that the smaller the screen surface area, the more often it has to be cleaned or replaced. The screens in previous foam dispensers were located near the mixing chamber, which were always inside the bag. These screens had to be small because of the miniaturization required to keep everything inside the bag. The filter screens and filters  4206 ,  4208  supporting the screens of a preferred embodiment are located outside of the bag in the main dispenser manifold, where components can be much larger without affecting machine performance in any way. The current design preferably has 10 to 100 times or more the surface area of the screens used in the most common prior art design (e.g., an exposed screens surface area of greater than an inch such as in the 1½ to 3 inch range). Also, with the filter screen area increased capability, the present invention provides for the use of a finer mesh screen without increasing the frequency of required screen cleaning to a noticeable degree. If the screens in the noted prior art design were changed to a finer mesh, it would cause a significant increase in screen clogs and maintenance, because of the increased trapping power of the finer mesh and the undersized screen surface area. Finer mesh screens (e.g., 100 mesh or better) do a better job of protecting the ports in the mixing chamber from particles, debris, and polymeric gunk that sometimes forms in the chemical lines. The mesh size of the screen used in the noted prior art dispenser is roughly the same as the diameter of the port in the mixing chamber. In this situation, the screen is ill suited to provide the recommended level of protection required to keep the ports clean over an extended period. For example, in the hydraulics business, the general rule of thumb is that the size of the hole in the screen mesh should be about 10 times smaller than the size of the orifice that is being protected. The present inventions ratio is about 3 to 1 or more, which is judged adequate for the anticipated needs, but can be increased without significant repercussions as in pressure drop concerns. 
     Heating the chemical manifolds of the dispenser assembly to a proper temperature range prevents the phenomenon called cold shot, which occurs when the chemical temperature drops in proximity to the dispenser, because of the large mass of relatively cold metal in that area. If the idle period between shots is short, less than 10 seconds, for example, the chemical within the manifolds will not have sufficient time to cool below an acceptable range, and no cold shot will be observed. However, if the idle time exceeds 10 seconds, the problem begins to manifest itself as coarse, poorly cured, sticky foam. Cold shot has an impact on foam efficiency, since it is possible that every shot that the user makes will be affected. If an unheated dispenser has been idle for a long time, say 15 minutes or more, it can take in excess of 1 second to purge the cold chemical and dispense at the correct temperatures with chemical that was residing within the chemical lines. If the operator&#39;s average shot length is 4 seconds, then the cold shot phenomenon could potentially affect 25% of the chemical volume that is used. The present invention has the advantageous feature of providing heat sources at strategic locations to provide at least temperature maintenance heating along the entire path of chemical travel starting with a heater in the chemical supply hose initiated within 20 feet or so of the dispenser housing, a heater in the main manifold  205 , and a heater in the dispenser housing  194  which has chemical passageways that exit into the mixing module. In this way, from the initiation point all the way to the outlet tip, the chemical is maintained at the desired temperature (maintained in the sense of not being allowed to drop below a desired temperature 130° F. or with the option of applying additional heat to raise the level at to above an initial chemical hose temperature setting). 
     Manifold heaters to prevent cold shot by maintaining the metal mass temperature in an acceptable zone, which is typically in the 110 to 130° F. range, have been developed in the prior art but not used particularly effectively. The problem is not so noticeable if the manifolds are heated to at least 110 degrees F. At this point, the visual indications of cold shot are reduced to a point where most users will not notice it. In an effort to eliminate cold shot as an issue entirely, the manifolds of the present invention are preferably heated to the same temperature as the chemical lines, which is preferably about 125 to 145 degrees F. The manifold heaters in use in many prior art systems, have a heating power in the 10 to 20 watt range. This is not well suited to do the job as it takes about 15 to 25 minutes for the manifolds to get close to steady state temperature from a cold start. At this low power, the manifolds will only heat up to 110 or 115 degrees F., if the operating environment is not much colder than normal room temperature, and possibly not even get up to that temperature if the room is significantly colder than normal, which is a common occurrence in the manufacturing environment. Under the present invention&#39;s “external to bag” manifold positioning and the way the manifolds and dispenser support are designed, there can be used a larger and much more powerful heater than what was possible in the noted prior art design. A preferred embodiment of the present invention has about 300 watts or more of manifold heating power available. A preferred embodiment of the invention uses two cartridge heaters, one is preferably mounted into a drilled hole in the main manifold  199  (the manifold block designated  205 ) and is represented by H 1  in  FIG. 14A , and the other (H 2 — FIG. 58 ) is preferably installed into an extruded hole in the dispenser support and is of cartridge form meaning it has its own sensors and controls for making adjustments in coordination with a control board processor or with its own processor or reliance can be placed on the control sub-system for the manifold noted above. The cartridge heaters of the present invention can be replaced without having to handle any components that are likely to be in contact with foam, chemicals, or solvents and thus to service one does not have to deal with components that are contaminated with chemicals, solvents, and foam. 
     Common prior art systems use a small PTC heater, which is situated inside the dispenser manifold that is adjacent the mixing block. A PTC is an abbreviation for Positive Temperature Coefficient. Heaters with this designation are based on thermistors with a resistance vs. temperature curve that has a positive slope, meaning that its resistance goes up as the temperature goes up. Most thermistors are NTC, or Negative Temperature Coefficient, and have a resistance vs. temperature curve that has a negative slope. PTC type thermistors are often used in heating applications because of their self-limiting characteristic; as they get hot, they draw less power allowing for a small PTC heater to heat the dispenser manifold. This approach has the advantage of not needing a temperature sensor or a temperature control circuit, since the PTC is self-regulating and self-limiting. One disadvantage, among many, however, with the PTC approach is that there is no practical way to change the temperature setpoint. The resistance vs. temperature curve of the PTC, in conjunction with the thermal conductivity between the PTC and the adjacent materials, determines the final steady state temperature of the manifold. A preferred embodiment of the present invention has two manifolds ( 199  and dispenser housing  194  described below), each with its own independent cartridge heater, thermistor (H 1  and H 2 ), and control circuit; giving it the capability of controlling each manifold independently and at a wide range of setpoints if necessary (e.g., a number of setpoints falling between 3 to 20). The control circuits and thermistor sensors that are used in the manifolds of the present invention are easily capable of maintaining manifold temperatures to an accuracy of 2 or 3° F., even if ambient temperatures in the work environment vary widely. The present invention also preferably uses the feature of having the temperature setpoints of the manifolds H 1  and H 2  follow and match the temperature setpoints of the chemical hoses. For example, if the operator sets the chemical line temperatures (e.g., 130 degrees F.) for chemical hose extensions  28 ′ and  30 ′ (see  FIG. 103 ) feeding from the in-line pumps to the dispenser). Thus, the system controller can automatically make the setpoint temperatures of the manifolds match the set chemical hose temperature (e.g., 130 degrees F.) unless instructed otherwise. If the operator later changes the line temperature setpoints to 140 degrees F., the system controller can automatically make the temperatures of the heaters in the manifolds set for 140 degrees F. in the chemical passing therepast. 
     A preferred embodiment of the present invention also has no exposed electrical wires or cables inside of the bag. All electrical connections are made from the outside, or completely isolated inside the dispenser support  194  (which preferably based on an extruded main body as shown in  FIGS. 72 and 73 ). 
     Common prior art systems have one large multi-conductor electrical (e.g., motor) supply cable that is exposed inside of the bag, often together with a number of single conductor wires inside of the dispenser mechanism that are not protected from the seepage of chemicals and foams. Also, the common prior art designs have chemical hoses that run wide-open right into the middle of the bag, where they are regularly exposed to foam, chemicals, and solvents. These chemical hoses are especially vulnerable because their outer layer is a stainless steel braiding, which presents an obstacle to cleaning when the foam gets into it. Prior art chemical hose fittings, JIC swivel type, are also completely exposed to foam, which can make it more difficult to loosen the fittings, or to re-tighten them. 
     The conventional dispenser systems shutoff valves for chemical flow are located adjacent to the mixing block. They are fully exposed, right in the middle of the bag, where they are regularly contacted by foam. As seen from  FIG. 14A , for example, chemical line shut off valves  201  and  203  are supported by manifold  205  and positioned far off from the bag (e.g., more than 5 and preferably more than 7 inches from the film edge FE). 
       FIG. 14A  further illustrates support bracket assembly  202  comprising main bracket body  204 , having bracket plate  206  secured to an exterior bracket plate  208  by way of cross plate  207  with securement bolts  209  on which motor  200  is mounted, with dispensing system  192  also being secured to bracket assembly  202 . Bracket assembly  202  further comprises dispenser rotation facilitator means  210  such as the hinged bracket support assembly  219  shown in its preferred positioning with the rotation axis being at its rearward most end whereby rotation of the dispenser from the dispense mode (e.g., a vertical orientation with chemical output along a vertical axis preferred) shown in  FIG. 14A  to a servicing mode whereupon both the bracket assembly  202  and rigidly (or also hinged by) attached dispenser system  192  are rotated greater than 60 degrees (e.g., 90° transverse to original position) out toward the operator. Bracket support assembly  219  comprises securement clamp plate assembly  212  with opposing clamp plates  215 ,  217  with bolt fasteners  214  for securement to interior frame member  170  such that support bracket assembly  202  can be hinged (together with the dispenser assembly  192  with driving motor  200  out of the way and forward of the front face  181  of bagger assembly  64  (e.g., a counterclockwise rotation)). 
     Thus, while dispenser apparatus  92  is preferably designed to have its outlet port vertically close to the bag&#39;s end seal location, it is also preferably arranged at a height relative to the upper end of support assembly providing mounting means  78  for the bagger assembly  64  to have freedom of adjustment between the dispensing position and the servicing position (e.g., see the curved forward wall  164  whose curvature provides for added clearance relative to the lower edge of dispenser  192 ). With this arrangement, when servicing is desired, the operator simply rotates the entire dispenser assembly toward the operator (a counterclockwise rotation for the dispenser assembly shown in  FIG. 13  (e.g., a 45–135° rotation with a preferred 90° rotation placing the axis of elongation of housing  194  transverse to the central axis of drive shaft  82 )). Rotation bracket support assembly  202  is preferably made rotatable by way of a hinged connection  219  at the rear end of the support bracket  202 , although other rotation arrangements are also featured under the present invention such as the dispenser  192  having a rotation access at its boundary region of bracket assembly  202  and dispenser housing  194  or inlet end section  198 . 
       FIG. 14B  provides a side elevational view of dispenser system  192  and bracket assembly  202  in relationship to film  216  which in a preferred embodiment is a C-fold film featuring a common fold edge and two free edges at the opposite end of the two fold panel. While a C-fold film is a preferred film choice, a variety of other film types of film or bag material sources are suitable for use of the present invention including gusseted and non-gusseted film, tubular film (preferably with an upstream slit formation means (not shown) for passage past the dispenser) or two separate or independent film sources (in which case an opposite film roll and film path is added together with an added side edge sealer) or a single film roll comprised of two layers with opposite free edges in a stacked and rolled relationship (also requiring a two side edge seal not needed with the preferred C-fold film usage wherein only the non-fold film edging needs to be edge sealed). For example, in a preferred embodiment, in addition to the single fold C-fold film, with planar front and back surfaces, a larger volume bag is provided with the same left to right edge film travel width (e.g., 12 inch or 19 inch) and features a gusseted film such as one having a common fold edge and a V-fold provided at that fold end and on the other, interior side, free edges for both the front and rear film sheets sharing the common fold line. The interior edges each have a V-fold that is preferably less than a third of the overall width of the sheet (e.g., 2½ inch gussets). 
     As shown in  FIG. 14B  after leaving the film roll and traveling past lower idler roller  114  (not shown in FIG.  14 B—See  FIG. 12 ), the film is wrapped around upper idler roller  101  and exits at a position where it is shown to have a vertical film departure tangent vertically aligned with the nip contact edge of the nip roller sets. Because of the C-fold arrangement, the folded edge is free to travel outward of the cantilever supported dispenser system  192 . That is, depending upon film width desired, the folded end of C-fold film  216  travels vertically down to the left side of dispenser end section  196  (from a front view as in relative to  FIG. 13 ) for driving nip engagement with the contacting, left set of nip rollers ( 74 ,  86 ). As further shown in  FIG. 14B  the opposite end of film  216  with free edges travels along the smooth surface of dispenser housing whereupon the free edges are brought together for driving engagement relative to contacting right nip roller set ( 76 ,  84 ) whereupon the contacting free film edges are subject to edge sealer  91  to complete the side edge sealing for the bag being formed. 
       FIGS. 12 ,  15  and  16 – 21  illustrate the film roll spindle loader adjustment means  218  of the present invention that facilitates the loading of a roll of film for use in bagger assembly  64 . Rolls of film vary in weight depending upon the width (e.g., a 12 roll or a 19 inch bag width with weight of, for example, 25 to 35 lbs.) and the amount of film on the roll which is at least partly defined by the radius differential of the rolled film annulus formed between the outer surface of the film roll and the exterior of the roll core  188  (if a core is relied upon), with the preferred outer diameter dimension of the roll being 8 to 12 inches (e.g., 10.5 inches) and the core being 3 to 6 inches with (4 inches being preferred). The film source is preferably a high density polyurethane blend film wrapped about a film core with at thickness of 0.0075 in. times 2 for folded combinations. 
       FIG. 15  provides a left side elevation view of dispenser system  22  with a full bag film roll  220  shown in a ready to use state (ready for film feed or reel out to nip roller set) by way of dashed lines and wrapped about core  188  while being supported on film support means  186 .  FIG. 15  also illustrates (after film roll run-out and core removal) spindle  222  forming a component of film support means  186  and having been adjusted from the reel out mode to a ready to load (unload) state wherein the axis of elongation of spindle  222  extends transversely to the axis of elongation assumed by the spindle when in a reel out state. 
     The ability to adjust the axis of elongation of spindle  222  to a location where an operator can simply slide a bag film roll on to the spindle, which roll can weigh 30 lbs or more, past the free end  224  of the spindle and along its central axis greatly simplifies and speeds up roll film loading as compared to many prior art designs that require the operator to load the film roll into the bottom and/or back of the machine at a very awkward angle. This loading requirement for prior art devices can put a great strain on the back and shoulders muscles and cannot be expected to be performed by some operators. Spindle load adjustment means  218  of the present invention includes an embodiment that allows an operator to rotate an empty film roll (spindle) to a position where the spindle points directly at the operator, whereupon the empty roll core can be readily removed and a new film roll with core can be loaded in a fashion that provides for reduced operator stress through the ability to load from the front of the machine where an operator typically stands during general dispensing operation. 
     Furthermore, in a preferred embodiment spindle load adjustment means  186  operates in conjunction with lock in-position mechanism  226  ( FIG. 11A to 11D ) that locks or engages the film support means in a operational film feed state, and which can be disengaged (e.g., a control signal based on the processing of a button on the control panel shown in  FIG. 15B ) to provide for movement of spindle  222  into a loading position. That is, lock mechanism  226  locks the spindle with loaded roll upon locking activation (e.g., following insertion of a new roller spindle  222  and the return of the roll to a ready to feed mode). Upon release activation, lock-in-position mechanism  226  releases film support means from its fixed or reel out state with the spindle axis parallel to driver roller  72  to enable adjustment to the new film roll load state. In a preferred embodiment, there is further provided a release facilitator  221  ( FIG. 11D ) such as a light load wrapped torsion spring or a compressed helical spring or solenoid driven pusher to initiate the rotation of the spindle toward the load state as illustrated by the rotation arrow in  FIG. 12 . Thus, release facilitator means is provided such as an electrically activated pusher solenoid, a compressible elastomeric block, or some other rotation facilitator. 
     With reference to  FIGS. 16 and 17 , there can be seen pivot support frame structure  227  (or the spindle-to-support connector  218 ) of spindle load adjustment means  218  to which the non-free or base end of the spindle is connected in a bearing portion of frame structure  227 . Spindle locking latch  226  ( FIG. 6 ) locks spindle  222  with film roll  220  in its operational feed mode—automatically upon return rotation from a film load position. In addition, the release mechanism preferably comprises a capture spindle latch mechanism that is solenoid driven (button activated at display panel) into release and has a cam surface which rides over and latches a capture portion of the spindle mechanism when being returned into ready to reel out mode. 
       FIGS. 16–21  illustrate film roll support means  186  comprising spindle  222  with roll latch  228  for locking the film axially on the spindle. These figures also show drive transmission  238  includes spindle base or proximal end roll engagement means  232 . The spindle base end engagement member  232  drives film roll  220  with web tension motor  58  and forms the downstream component of web tension or film source drive transmission  238 , with the film source drive means of web tension assembly  190  comprising driver or web tension motor  58  and film source or web tension drive transmission  238 . 
       FIGS. 20 and 21  further illustrates spindle loading adjustment means  218  having load support structure  240  with hinge section  242  at one side of a first support plate (e.g., a metal casting)  243 , an intermediate support section  244 , aligned with the central axis of spindle  222  and receiving by way of a bearing support the base end of the spindle, and a web tension motor mount support section  246  radially spaced from the noted central spindle axis. As shown in  FIGS. 12 and 19 , web tension motor  58  is supported by motor mount support section  246  on a first side opposite to the spindle location side (relative to an extension of the axis of rotation of the roller) and is spaced rearward of lifter assembly  40 . On the second or spindle location side of motor mount support section  246  and the interconnected intermediate section  244 , there is provided support transmission casing  248  ( FIG. 19 ) which encases a preferred embodiment of web tension drive transmission  238 . As shown, drive transmission  238  features a timing belt  250  (shown in dashed lines in  FIG. 20 ), driving pulley  252  and a driven pulley (not shown) with the latter being in driving engagement with engagement member  232 . 
       FIG. 22  provides a view of dispenser system  192  in similar fashion to that shown in  FIG. 13 , but from a different perspective angle.  FIG. 22  thus shows dispenser housing  194  comprising main housing section  195 , dispenser outlet section  196  and dispenser inlet section  198 . Dispenser drive motor  200  is shown mounted on dispenser housing  194 .  FIG. 22  further partially illustrates chemical mixing module  256  from which mixed chemical is dispensed to an awaiting reception area such as a partially completed bag. 
       FIG. 23  provides an enlarged view of dispenser outlet section  196  and illustrates the outlet port  258  of mixing module  256 .  FIG. 23  further illustrates mixing module retention means  260  which in a preferred embodiment comprises adjustable door  262  comprising a first, outer, upper mixing module enclosure component  263  and a second pivotable base  265  engagement component with the pivot base shown engaged with hinge  538  (e.g., a pair of hinge screws with one shown in  FIG. 23 ) supported by main housing  194 . The first upper component  263  is designed for contact with an upper forward section of main housing section  196  when in a closed mixing module retention and positioning state.  FIG. 23  illustrates door or closure device  262  in a closed state while  FIGS. 24A and 24B  show door  262  in an open state. Door  262  is closed in position relative to a received mixing module  256  sandwiched between the door and the main housing, while providing a biasing function to facilitate a secure compression seal arrangement between the mixing module&#39;s chemical and solvent inlet seals and the corresponding chemical feed outlets of the main housing.  FIG. 24A  illustrates closure device  262  in an open, mixing module access mode with mixing module  256  retained in an uncompressed position relative to main housing  194 , and with the free end of valving rod  264  in an upper position and the mixing module outlet end cap  266  in a lower position which can be seen partially jutting out in the  FIG. 23  door closed state.  FIG. 24B  shows a similar view to that of  FIG. 24A , but with the mixing module removed. 
     The mixing module mounting means of the present invention is designed to be entirely functional in a tool free manner which is unlike the prior art systems requiring tools to access the mixing cartridges for servicing or replacement and require that same tooling to replace a mixing cartridge. Also, the area required for tool insertion in the prior art systems is also prone to foam coverage, making accessing and removal even more difficult. The tool free design of the present invention features toggle clamp  262  having its pivot base  8000  secured to dispenser housing  194  preferably at the forward face of upper housing cap  533  and supports in pivotable fashion, at first pivot pin  8004 , “over center” toggle level handle  8002  which has a second pivot pin  8006  receiving, in pivotable fashion, compression lever  8008  having at its free end abutment member  8010  and which is supported on base  4002  with a third pivot pin  8007  to provide for over center latching which compression lever is preferably a threaded pin with a compressible (e.g., electrometric) tip  8012  at its interior end and its opposite and fixed by nut  8014  (which renders compression pin  8010  adjustable in the level of compression imposed while in the over center latch mode). 
       FIG. 23  illustrates the mixing module closure door pivoted up into its closure state and with toggle clamp  262  in its initial contact immediately preceding being put in the toggle or over center latch state upon pivoting lever  4002  into its final over center state (pointing down and not shown in the drawings) which can be achieved with a simple one finger action (same true for release). Preferably tip  8012  is a hard rubber tip and the compression level is factory set so that the hinged door firmly clamps the mixing module when the toggle clamp is closed. Field adjustments can also be made. Various other mixing module mounting closure means are also featured under the present invention such as a rotating disk or lever with a cam riding surface ramp with temporary holding depression or a sliding wedge in bracket supported by housing  194 . The toggle clamp provides, however, a system taking advantage of the mechanical advantage of the over center latch and housing arrangement. In the over center closed state with pin tip  8012  in compression sate, tip  8012  makes contact with the upper end of the pivoted door. The electrometric seals about the solvent ports and chemical ports sealing off the interchange between the dispenser housing  194  and mixing module are thus compressed into the desired sealing compression state. Thus, there is provided an easy manner for properly and accurately mounting the mixing module in dispenser  192  of the present invention. 
     Mixing module  260  of the present invention shares similarities with the mixing module described in co-pending U.S. patent application Ser. No. 10/623,716, filed on Jul. 22, 2003 and entitled Dispenser Mixing Module and Method of Assembling and Using Same, which application is incorporated herein by reference in its entirety. Through the use of mixing chamber shift prevention means ( 313 ,  FIG. 28A ) there is prevented movement of a mixing chamber within its housing due to rod stick and compression and return of the compression means with the mixing chamber and thus there is avoided a variety of problems associated with the movement of the mixing chamber in the prior art. The present invention also preferably features mixing chamber shift prevention means used together with an additional solvent distribution system that together provide a tip management system with both mixing chamber position maintenance and efficient solvent application to those areas of the mixing module otherwise having the potential for foam build up such as the dispenser outlet tip. 
     With reference to  FIGS. 25 to 48  there is provided a discussion of a preferred embodiment of mixing module  256  of the present invention.  FIG. 25  illustrates the contact side  268  of mixing module housing  257  encompassing mixing chamber  312  with shift prevention means  313  and also, preferably provided with solvent flow distribution means having solvent entrance port  282 . Housing  257  features, first, second and third side walls  270 ,  272  and  274  which together provide housing contact side  268  representing half of the walls of the preferred hexagonal cross-sectioned mixing module. Wall  272  includes main housing positioner  276 , with a preferred embodiment being a positioner recess configured to receive a corresponding positioner projection  277  provided in main housing component  532  ( FIGS. 248 and 66A ). Positioner  276 , when engaged by projection  277 , acts to position first and second mixing module chemical inlet ports  278 ,  280  in proper alignment with chemical outlet feed ports  279 ,  281  of housing module support  532  ( FIG. 24B ). Similarly, the positioning means for the mixing module further aligns the mixing module solvent inlet port  282  in proper position relative to solvent outlet port  275  ( FIG. 24B ) of module support housing  532 . While a two component system is a preferred embodiment of the present invention, the present invention is also suitable for use with single or more than two chemical component systems, particularly where there is a potential stick and move problem in a mixing or dispensing chamber of a dispenser (mixing being used in a broad sense to include multi-source chemical mixing or the spraying into a rod passageway of a chemical through a single, sole inlet source and an internal intermingling of the sole chemical material&#39;s constitution). 
       FIGS. 27 to 33  illustrate mixing module  256  in an assembled state comprising module housing  302  having a “front” (open) end  304  and a “rear” (open) end  306  with associated front end solvent dispensing front cap assembly  308  or cap covering and back cap  310 . Front cap assembly  308  and back (e.g., compression) cap  310  retain in operating position mixing chamber  312 , slotted cup-shaped spacer  314  and Belleville washer stack  316  (the preferred form of compression means). Each of the face cap assembly  308 , mixing chamber  312 , spacer  314 , washer stack  316  and back cap  310  have an axial passageway for receiving valving or purge rod (“rod” hereafter)  264 . Mixing module  256  also preferably has internal solvent chamber  322  with spacer  314  and back cap  310  preferably formed with solvent reception cavities ( 323 , 324 ). The Belleville washers in stack  316  are also shown as having an annular clearance space which facilitates solvent flow along the received portion of rod  318  and provides room for limit ring  332  for limiting axial movement of rod  264 . 
     Solvent cap  326  ( FIG. 29 ), is attached (e.g., threaded) to housing  302  to close off solvent access opening  328  formed in one of the sides (e.g., side wall  272 ) of the multi-sided housing  302 . Solvent cap  326  is preferably positioned to axially overlap part of the internally positioned Belleville washer stack  316  and the spacer  314  positioned between the compression means  316  and Teflon block  312 . The Belleville washer stack  316  is also preferably arranged in opposing pairs (e.g., 8 washer pairs with each pair set having oppositely facing washers) which provides a preferred level of 200 lbf. relative to spacer contact with the mixing chamber. Solvent cap  326  provides an access port for emptying and filling the solvent chamber  322  which provides for a pooling of solvent (continuous replenishment flow pooling under a preferred embodiment of the present invention) at a location which retains fluid contact with an exposed surface of the valving rod as it reciprocates in the mixing chamber. As shown in  FIG. 30 , there is further provided solvent feed port  282  which provides an inlet port for solvent from a separate source (preferably a pumped continuous or periodic flow solvent system as described below) for feeding the flow through dispenser tip cleaning solvent system for the front cap assembly  308  and replenishing solvent chamber  322  after its initial filling via access cap  326 . 
     Valving rod  264  has a reciprocating means capture end  330  (e.g., an enlarged end as in a radially enlarged cylindrical end member) for attachment to a motorized rod reciprocator. Rod  264  axially extends completely through the housing so as to extend out past respective face and back caps  308  and  310 . Rod  264  also comprises annular limit ring  332  ( FIG. 29 ) to avoid a complete pull out of rod  264  from the mixing module. A rod contacting seal  334  is further preferably provided such as an inserted O-ring into an O-ring reception cavity formed in back cap  310 . Housing  302  further includes chemical passage inlet holes  278 ,  280  ( FIG. 27 ) formed at midway points across side walls  270  and  274  which are positioned to opposite sides of intermediate side wall  272  in the preferred hexagonal configured housing  302 . Wall  348  is preferably diametrically opposed to wall  272 . Walls  270  and  274  position chemical inlets  278 ,  280  in the preferred 120° chemical inlet spacing. 
     Reference is made to  FIGS. 28A ,  29 B,  29 C,  30  and  48  for a further discussion of mixing chamber  312  with locking or rod stick movement prevention means  313 .  FIGS. 29B and 29C  provide different perspective views of a preferred embodiment for mixing chamber  312  which is preferably formed of a low friction material such as one having cold flow capability with Teflon being a preferred material. Mixing chamber  312  has first end (e.g., spacer sleeve contact end or rear end)  352  and second (e.g., front) end  354 . As shown in  FIG. 29C , axial rod passageway (or through hole)  356  extends along through the central axis of chamber  312  (and also along the central axis of the mixing module housing  302  as well) so as to open out at the first and second ends. 
       FIG. 29C  shows the preferred configuration for passageway  356  as a continuous diameter passageway of diameter Da (a range of 0.1 to 0.5 inches is illustrative of a suitable diameter range Da with 0.15 to 0.3 inch being a more preferred sub-range and 0.187 being a preferred value for Da). It is noted that any dimensions provided in the present application are for illustrative purposes only and thus are not intended to be limiting relative to the scope of the present invention.  FIGS. 29B ,  29 C and  48  further illustrate locking protrusion  358  forming a part of locking means  313 , and which in a preferred embodiment is an annular extension having a forward edge  360  coinciding with the outer peripheral edge of front face  355 , and rear edge  362  defining an axial inner edge of peripheral surface  364 . Peripheral surface  364  preferably includes a cylindrical section  365  with rear chamfer edge  367 . Locking protrusion  358  is preferably integral with main body portion  366 , with main body  366  extending from the rear end to the front end of mixing chamber  312  (e.g., entire mixing chamber formed as a monolithic body and also preferably of a common material). As illustrated, the radial interior of step down wall ring  368 , extends into main body portion  366  (with the main body being the illustrated cylindrical body extending from the front end to the rear end of mixing chamber  312  with the annular projection  358  extending radially out from a front end region of that main body preferably for 20% or less of the length of main body  312 ). Rear end  352  of main body portion  366  preferably features a chamfered peripheral edge  370  to facilitate insertion of mixing chamber  312  into the front open end of housing  302  prior to front cap assembly  308  securement to the front end  304  of the housing as by finger threading. 
     While the illustrated looking protrusion  358  can take on a variety of configurations (e.g., either peripherally continuous or interrupted with common or different length/height protrusion(s) about the periphery of the mixing chamber  312 ) as well as a variety of axial extension lengths and a variety of radial extension lengths (e.g., a radial distance R ( FIG. 29C ) between surface  364  and the forward most outer, exposed surface  366 ′ of main body  366 , of 0.025 to 0.5 inch with 0.035 to 0.05 inch being suitable). The utilized axial length and radial protrusion for the locking projection  358  is designed to provide a sufficient locking in position function (despite rod stick due to the static friction/adhesion relationship between the rod and mixing chamber) while avoiding an inefficient use of material. 
       FIGS. 29B ,  29 C and  48  illustrate step wall  368  of locking protrusion  358  extending off from main body  366  with the overall locking protrusion diameter Dp being preferably of 0.25 to 1.0 inch with a preferred value of 0.56 of an inch. Diameter Dm is preferably 0.35 to 0.75 inch or more preferably a value of 0.49 of an inch with the difference (Dp−Dm=R) representing about 5 to 15% of Dp. Also, with a preferred diameter Da for rod passageway  358  of 0.1 to 0.4 inch or 0.15 to 0.3 inch with a preferred value of 0.19 inch. The main body portion&#39;s radial thickness of its annular ring “RT” is preferably 0.1 to 0.5 inch with 0.15 inch being preferred. 
     Port holes  374 ,  376  are shown in  FIGS. 29B and 29C  and are formed through the radial thickness of main body portion  366  and are shown circumferentially spaced apart and lying on a common cross-section plane (rather than being axially offset which is a less preferred arrangement). The central axis of each port hole  374 ,  376  is designed to be common with a respective central axis of inlet passage holes  278 ,  280 , in housing  257  and the respective central axis for chemical output ports  279  and  281  feeding the mixing module. The central axis for port holes  374 ,  376  also are preferably arranged to intersect the central axis of passageway  356  at a preferred angle of 120°. 
     Also, port holes  374 ,  376  preferably have a step configuration with an outer large reception cavity  378  and a smaller interior cavity  380 . The step configuration is dimensioned to accommodate ports  382 ,  384  which are preferably stainless steel ports designed to produce streams of chemicals that jet out from the ports to impinge at the central axis, based on, for example, a 120° angle orientation to avoid chemical cross-over problems in the mixing chamber cavity. As shown in  FIG. 29C , diameters Db and Dc are dimensioned in association with the dimensioning of ports  382 ,  384  with a preference to have the inlet end of ports  382  and  384  of a common diameter and aligned relative to the exit end of housing inlets  340 ,  342 . Ports  382 ,  384  are shown to have an upstream conical infeed section and a cylindrical outfeed section each representing about 50% of the ports axial length. 
       FIG. 29C  illustrates length dimension lines L 1  to L 4  for mixing chamber  312  with L 1  representing the full axial length of mixing chamber  312  or the distance from the outer back edge to the forward most front edge. L 2  representing the axial distance from the back end  352  to the peripheral edge  360  of locking protrusion  358  (while taking into consideration the inward slope of the mixing chambers front face). L 3  represents the axial length between the rear edge  352  to locking protrusion interior edge  362  of surface  364 . L 4  represents the distance from the rear edge  352  to the central axis of the closest chemical passageway such as the central axis of smaller interior cavity  380 . Preferred value ranges for L 1  to L 4  are as follows: (0.5 to 2 inch with 1 inch suitable), (0.43 to 1.8 with 0.95 inch suitable), (0.5 to 1.0 inch with 0.74 inch suitable), and (0.1 to 0.3 inch with 0.18 inch suitable), respectively. 
       FIGS. 30 and 48  illustrate front end  304  of mixing module housing  302  having a larger diameter recess  386  which steps down to a lesser diameter housing recess  388 . The different recess diameters define step up wall  390  formed between the larger and smaller diameter housing recess  386 ,  388  which is dimensioned to correspond with step down wall ring  368  of locking protrusion  358 . The abutting relationship between walls  368  and  390  establishes an axial no movement locking relationship between mixing chamber  312  and housing  302  when the mixing module is in an assembled state, despite the establishment of a stick relationship between the reciprocating rod  264  and mixing chamber  312 . Thus, the mixing chamber is not subject to rod stick movement against compressible comparison means, and avoids problems associated with this movement, such as port misalignment. 
     The housing configuration is further illustrated in  FIGS. 34 ,  34 A,  34 B,  35 ,  36  and  37  showing perspective and cross-sectional views of housing  302  alone. These figures illustrate the above noted step up wall  390  formed between larger diameter recess  386  and interior recess  388  which preferably includes a first radially extending (transverse) section  390 ′ and a sloping, chamfered section  390 ″ defining a conical surface bridging the different diameter cylindrical sections  386 ,  288  which facilitates insertion of the mixing chamber. Section  390 ′ preferably extends radially transverse to the central axis of the mixing chamber or oblique or in stepped fashion thereto (e.g., conically converging in a forward to rearward direction) which ensures the locking relationship between the housing and mining chamber. For example, with reference to  FIG. 34B  housing  302  has a radial thickness T 1  defining recess diameter D 1  ( FIG. 35 ) at its forward most end (e.g., 0.10 to 0.20 inch (0.15 inch) for T 1 , and 0.5 to 0.75 (e.g., 0.56 inch) for D 1 , and with a radial thickness increase in going to T 2  (e.g., 0.2 to 0.3 (e.g., 2.25 inch) and preferably a corresponding decrease in D 2  of 0.4 to 0.6 inch with 0.49 inch being preferred). The reduced diameter housing cavity  388  is formed based on the difference in thickness and/or recess depth and defines housing recess diameter D 2  which is bridged by step-up wall  390 . Rearward of the recess  388  defining housing surface there is provided a slight step up  394  ( FIG. 35 , e.g., a 0.007 to 0.01 inch increase in going from D 2  to D 3 ) which leads to the larger diameter recess  389 . This minor step up  394  and the larger diameter recess  389  provides additional clearance space receiving the mixing chamber in direct contact. The Belleville stack  316  is received within enlarged section  389  of the housing providing a degree of radial clearance to allow for compression adjustments in the compression means. Spacer  314  has an outer diameter generally conforming to D 2  and axially bridges step up  394  (See  FIG. 28 ). 
     As seen from  FIGS. 28–30 , mixing chamber  312  is preferably received entirely within housing recess  388  while Belleville washer stack  316  is preferably received entirely in larger diameter recess  386 . Spacer  314  thus extends to opposite sides of step  394 . At the rearward end of housing  302  there is provided back cap main reception recesses  392  of diameter D 4  (e.g., 0.5 to 0.6 inch or 0.58 inch as shown in  FIGS. 34 and 35 ) and thickness T4 (e.g., 0.25 to 0.3 inch or 0.28 inch  FIG. 34A ) which opens even farther out at the rear most end to back cap flange reception recess  395  defining diameter D 5  (0.6 to 0.7 inch or 0.66 inch  FIG. 35 ). Recesses  392  and  395  are designed to receive back cap  310  which is dimensioned to occupy the area of recess as  392  and  395  and to also extend inward into recess  386  into contact with compression means  316 . In this regard reference is made to  FIG. 29  wherein L 5  illustrates axial length from the rear end of the housing into the rear end of compression means  316  (e.g., L 5  is 0.3 to 0.6 inch or 0.45 inch which is about 10 to 30% or more preferably 20% of the full axial length L 9  ( FIG. 28 ) of mixing module  256 ). L 6  illustrates the axial length from rear end  306  of the housing to the central axis of the solvent access opening  328  which also is preferably generally commensurate with the forward end of the compression means  316  and the rear end of spacer compression  314  (e.g., 0.9 to 1.4 inches or 40 to 60%); L 7  represents the contact interface between the front end of spacer sleeve  314  and rear end of the mixing chamber  312  (e.g., 1.1 to 1.5 inches or 50 to 65%); and L 8  ( FIG. 28 ) representing the distance from the rear end  306  of the housing and the central axis of housing chemical inlet  278  (e.g., 1.3 to 1.9 inches or 55 to 85%). 
     Reception recess  392  includes means for axial locking in position back cap  310  which means is preferably one that can be removed without the need for first releasing the compression force. In a preferred embodiment a threaded recess is provided having relatively fine threads TH for facilitating axially locking in position back cap  310  at a desired compression inducing setting. As shown in  FIG. 34A  to opposite axial sides of threads TH there is formed recess  395 , which defines larger diameter D 5  (e.g., 0.67 inch), provides an annular ridge  397  providing an additional seat with the interior most end back cap  310  being placed in contact with housing  302  which preferably is preset relative to compression means  316  to provide the desired level of compression in the cold flow material mixing chamber  312 . 
     Historically, packaging foam mixing cartridges have been assembled using clip rings on the back of the compression cap. In order to install the clip ring, the back cap must be forced into the Belleville washer stack, an action that requires about 200 lbs of force to accomplish. This method of assembly of the prior art mixing cartridges requires the use of machines like arbor presses and some special holding and alignment fixtures to put a mixing cartridge together making the process difficult. Also, assembly of these prior art mixing cartridges cannot be done by hand tools normally found in a tool kit. These prior art designs are difficult to assemble, and even more difficult to disassemble, as the clip rings can be difficult to remove with the heavy spring load on the back cap. In view of this, mixing module  256  of the present invention is designed to be easier to assemble and disassemble. 
     Also, under the Belleville stack compression forces imposed on prior art mixing chambers and mixing cartridges prior art housing tend to deform at their front face when considering the thinness desirability relative to a purge rod front face passageway travel. This deformation can occur in prior art assemblies even after only moderate usage in the field. That is, the front cover of prior art mixing chambers are often swaged onto the housing and the design is not always strong enough to carry the load. This deformation can cause a number of reliability problems for the mixing cartridge. The present invention helps avoid this prior art tendency for the front cap of the housing to deform, or bulge due to the force imposed by the Belleville washer stack on the mixing chamber front face. 
     A preferred embodiment of the present invention includes the feature of having non-permanent, releasable fixation means for back cap  310 , with a preferred embodiment featuring threads TH ( FIG. 34A ) provided in back cap reception recess  392  or some other releasable fixation means as in, for example, a key/slot engagement (e.g., helical), although fine threads are preferred for facilitating small step compression inducement and release in the compression means contacted by the back cap. The interior threads of the back cap reception recess  395  are designed to mate with the exterior threads on the back cap  310 . The opposite front end  304  of housing  302  also preferably is provided with releasable front end closure means as in front cap assembly  308  releasably secured with the exterior of the front end  304  of housing  302  through, for example, exterior threads TH on front end  304  that are designed for threaded engagement with the internal threads of front cap assembly  308  (a preferred embodiment has the front cap assembly in the form of a multicomponent and/or double walled front cap assembly). 
     This releasable securement relationship at both the front and back of the mixing chamber allows a mechanic of minimal skills, without special fixture or exotic tools, to assemble and disassemble mixing module  256 . The assembly technique under the present invention featuring “releasable securement” (e.g., threaded construction) also has a variety of other advantages. For example, the securement construction is much easier to assemble without the prior art clip ring that holds the back cap in place against the pressure of the Belleville stack. The present invention also provides for easier disassembly in a current foam production setting as the securement construction makes the mixing module easier to rework without sending out to a special service location for a rework. In this regard, reference is made to copending application U.S. Provisional Ser. No. 60/488,102, filed on Jul. 18, 2003, and entitled “A System and Method for Providing Remote Monitoring of a Manufacturing Device”, which is incorporated herein by reference, and which describes the automatic or operator requested servicing directly from the dispenser system through use of an internet connection or the like in conjunction with a controller monitoring of sensed information from various dispensing system sub-systems. 
     The manner of attachment and construction of the assembly of front cap covering  308  (particularly inner front cap component  438  shown in  FIG. 43 ) on the front end of housing  302  provides for a more solid construction in the front cap. For example, the means for releasable connection allows for the front cap to be more easily designed so that it is better able to avoid distortion under load. The present invention is thus designed to avoid the aforementioned problems associated with swaged prior art front caps, including difficulty in proper installation, strength parameters that are difficult to predict, and a tendency for deformation under high load. This ease of assembly and disassembly of the mixing module design in the production setting also makes for easy assembly and disassembly in the field and at any service location. 
     With the arrangement of the present invention, it is easier to install the mixing chamber  256  from the front, instead of from the rear of the mixing module housing  302 . The mixing chamber locking means  358  ( FIG. 48 ) in the front end of the mixing chamber  312  and releasable securement face cap assembly  308  provides the advantage of being able to install a mixing chamber from the front of the mixing module housing as compared to the more difficult rear installation in the prior art housing design. For example, the front loading potential makes it much easier to orient the chemical feed ports in the mixing chamber into correct alignment with the through holes in the mixing module housing. Also, to facilitate the assembly and disassembly of the mixing module of the present invention, the outer cap  440  ( FIG. 45 ) of front cap assembly  308  is preferably provided with a circumferential knurled surface for preferred finger contact only tightening into position and release for access. 
     An additional feature of the mixing module  256  is that it can be assembled in its entirely, and access to the solvent port is still made possible based on the relative positional relationship between, for example, the threaded solvent cap access port  328  and the spacer sleeve&#39;s recessed areas (described below in greater detail). This ability to completely assemble mixing module  256  and then introduce the solvent via solvent cap  326  and the coordinated solvent chamber positioning and solvent chamber forming component portions allows, for example, easy solvent filling without the spillage problem and filling level uncertainties of the prior art. It also makes it easy to open the solvent cap for an initial check as to the solvent level (although less preferable the back cap can be removed as well for a solvent check after the mixing module has been fully assembled as it is much easier to remove and reposition compared to prior art designs). A review of multiple mixing modules filled with solvent and sealed, and then set on the shelf for a few days, prior to being opened, indicated there is often significantly less solvent than originally thought to exist. For example, a solvent chamber may appear to be full after the initial filling operation, but a significant quantity of air can be trapped in the solvent chamber as the viscosity of commonly used solvents can be quite high at room temperature. The trapped air precludes a full fill under the prior art systems. The present invention further addresses this under fill problem through heating of the solvent to around 130° F. before filling. This solvent heating during, for example, initial supplying of the module with solvent represents a preferred step as it lowers the viscosity significantly and works well with the improved visibility and access provided under the present invention&#39;s design. During system operation, a similar above 100° F. and more preferably above 120° F. temperature is maintained under the present inventions heated solvent re-supply flushing arrangement which preferably includes passing solvent by manifold and/or dispenser housing heaters placed in line with the solvent flow. 
     Thus, under the present invention with the large diameter (e.g., 0.25 to 0.75 inch) solvent access cap  326  strategically positioned relative to the solvent chamber to provide solvent chamber access means, the invention provides for complete filling of the chamber in a fashion that is easy and achievable without the introduction of air bubbles or overflows or other problems associated with filling prior art solvent chambers. Because the threaded solvent access hole allows for easy filling, there is also less chance that air pockets will be trapped when the chamber is sealed. Since mixing module life is proportional to solvent quantity, eliminating any trapped air in the solvent chamber is beneficial to prolonged life. Also, an easy refill on the solvent chamber without special tools is possible with the threaded solvent filler cap being readily removed with a small screwdriver any time there is a desire to check conditions on the inside of the mixing module. The solvent chamber therefore can easily be refilled with solvent, and the cap re-installed. 
     As shown in  FIG. 29 , O-Ring seal  327  is provided on the solvent cap to help in preventing solvent from leaking as in during shipping. Less leakage means longer life, and the sealed cap can be opened and resealed multiple times with minimal degradation in seal quality. With the solvent access means of the present invention, the mixing module can be initially built and assembled at a manufacturing or assembly site without solvent if long-term storage is required. There are applications that require long-term storage of system mixing modules in warehouses and/or the placement of mixing modules in harsh climates. In these situations, mixing module solvent, and any elastomeric seals in contact with the solvent, can degrade over time if pre-inserted at initial assembly. The present invention provides for either no solvent insertion at the time of assembly or ready access to replace the old solvent and seals after an extended period. This storage feature can be an advantage, for example, in some military applications, as well as in other environments and/or storage needs. Also, solvent cap  326  can be opened and resealed multiple times with minimal degradation in seal quality. 
       FIGS. 29 and 30  illustrate spacer sleeve  114  having solid cylindrical forward section CY, which is integral with its forward compression contact face, a valve rod reception opening and, at its rear end, a spacer separated by one or more spacer slots SL. These slots are formed between sleeve extensions SP as can be seen by the sequence of extensions and adjacent slotted openings in the sleeve which slots are preferably spaced continuously around the sleeve&#39;s circumference. The slots are preferably aligned with solvent housing access opening(s), and in a preferred embodiment, there are multiple spacer extensions SP (e.g., 3–10 with 6 preferred) which provide ready solvent flow access from the capped solvent opening into solvent sleeve reception cavity  322 . 
     Prior to describing the additional upstream components associated with feeding chemical to the dispenser outlet, a discussion of solvent supply system  400  and its in line relationship with the above described mixing module  256  is provided. As described in the background of the present application, the outlet dispenser region or tip area of the mixing module  256  is an area highly prone to hardened foam build up. If not addressed, it can cause problems such as misdirected output shots or spraying into areas external to the intended target. This in turn can further increase build up problems as the misdirected output hardens on other areas of the solvent dispenser system. 
     With reference to  FIG. 3  and  FIGS. 49–53  there is illustrated solvent supply system  400  comprising supply tank  402  having solvent conduit  404  providing flow communication between solvent tank  402  and solvent valve control unit  406 , which is in communication with the control processor. Downstream from valve control unit, the solvent line is in flow communication with main support housing  194  having a solvent conduit which extends through main housing  194  and opens out into the module support housing  532  ( FIG. 66A ). From there the solvent passes via port  275  ( FIG. 24B ) into solvent port  282  ( FIG. 25 ) in mixing module  256  when mixing module  256  is properly positioned in dispenser system  192 . Solvent is preferably supplied based on a preprogrammed sequence such as one which provides heavy flow volumes at completion of a use cycle or periodically, over periods of non-use (e.g., overnight prior to a daytime shift) as well as periodically during use (e.g., after a predetermined number of shots (e.g., after each shot to every 5 shots) and/or based on a time cycle independent of usage. Preferably, the solvent flow control activates valve mechanism  408  based on open or shut off signals, with an opening signal being coordinated with solvent pump operation. The controller sub-system is shown in  FIG. 196 . 
     As seen from a comparison of  FIGS. 25 ,  29  and  30 , housing solvent inlet port  282  ( FIG. 30 ) opens into internal solvent chamber  322  as does the separate access solvent opening  328  blocked off by solvent cap  326 .  FIG. 30  illustrates solvent port  282  having a central axis that is axially positioned on the housing such that its central axis extends through a central region formed between the compression cap  310  and spacer  314 .  FIG. 29  illustrates solvent passage  412  which is in solvent flow communication with solvent chamber  322  and is preferably formed in the annular thickness of housing  302  such as an annular port opening out into chamber  322  at its rear end and extending axially toward the front end of housing  302  through a peripheral central region of one of the illustrated housing walls.  FIGS. 38A ,  38 B and  39  show solvent passageway with front outlet opening  414 . One axial passageway of, for example, 0.04 to 0.08 of an inch (e.g., 0.06 in diameter) is preferred, although alternate embodiments featuring multiple, circumferentially spaced axial solvent passageway (e.g., of the same size or smaller solvent ports diameters can be provided to achieve a desired flushing solvent flow rate through the front of the housing). Outlet opening  414  is formed in recessed front housing surface  416  extending about the circumference of the front end of housing  302 . Recessed front housing surface  416 , in conjunction with the interior surfaces of circumferential (or peripheral if other than circular cross-section) radially internal flange  418  and radially external flange  420 , is formed at the forward end of housing  302 . External flange  420  includes chamfered outer wall  422  which defines the outer surface of front flange projection  420 . Exterior housing wall  424  is preferably threaded on its exterior with threads  425  and extends into annular recess  426  ( FIG. 39 ) positioned axially internally of main body  428  with the latter preferably defining a portion of the above described hexagonal wall configuration for housing  302 . 
       FIGS. 38A and 38B  also provide added detail as to chemical inlet ports  278 ,  280  which are shown as including annular seal recess  430  concentrically extending about the applicable chemical passageway  278 ,  280  which are defined by the illustrated cylindrical projections  434  inward of the remaining surrounding body portion of hexagonal housing main body  428 .  FIG. 38B  further illustrates seal  436  preferably in the form of an O-ring with seal  436  being dimensioned for compression and/or tensioning (stretched about the inner passageway projection  434 ) state retention within seal recess  430  (e.g., seal stays in place during handling and shipping and is thus ensured to be in proper position upon mixing module mounting). Thus, for chemical ports as well as the solvent ports in housing  302 , sealing means can be provided on the mixing module itself which is beneficial in assuring proper, centered seal positioning despite slight tolerance deviations in the mounting of the mixing module in the dispenser (e.g., avoiding partial obstruction of a housing inlet port). 
       FIG. 38A  also shows the relative positioning of solvent housing inlet port  282 , solvent access opening  328  with threads TH, and outlet  414  of solvent passageway  412 . Which opens out as surface  416  formed between flanges  418 ,  420 , and extends axially along a line that bisects the solvent access opening  328  and extends along common side wall  272 , and preferably parallel to the purge rod passageway. 
       FIG. 29A  and  FIGS. 40–43 , and  48  provide additional detail as to the arrangement of front cap assembly  308  which comprises inner front cap  438  and outer front cap  440 . Front inner cap  438  performs the function of providing a rigid support for the Teflon mixing chamber  312  subject to the compressive load of compressions means  316 . This function being similar to that of the front cap described in co-pending application Ser. No. 10/623,716, filed on Jul. 22, 2003 and entitled “Dispenser Mixing Module and Method of Assembling and Using Same,” which is incorporated by reference. Front cap rod aperture  442  also provides an exit for the reacted foam, with slight clearance for the valving rod  264 . As seen from  FIGS. 41 and 43 , cap  438  has forward face wall  444  having a planer exterior surface  446  and a sloped inner surface  448  with a planer radial outer inner surface  450 . Annular projection  452  is shown extending forward and peripherally about forward face wall  444 .  FIG. 43  shows front inner cap  438  having sidewall  454  having exterior threads  456  in a relatively upper region of front inner cap  438  that originate at the bottom end of upper chamfer wall  462 , with wall  462  extending obliquely out from the base of annular projection  452 . On the inner side of annular projection  452  there is located step down annular edge  453  that extends down to planar exterior recessed surface  446  of inner front cap  438 . Sidewall  454  also has interior threads  464  on its inner side and at a level that extends at a height level intermediate the range of outer threads  456  and then down below to the free rim  457  (which also preferably is chamfered on an interior edge). 
     Interior threads  464  are designed for threaded engagement with external threads  425  provided on front projection wall  424  of housing  302  which can involve alternate securement means as described above for the rear cap, but the threaded attachment is preferable to handle the forces involved. The space can also be formed in other ways relative to facing surface portions of the forward and more interior front cap components as in a series of radial channels between opposing outward/interior front cap components. The illustrated double wall with each cap component releasably supported by the front end of the main housing body is preferred as it functions well as providing a full circumferrical solvent wetting of the rod and is easily formed simply by attachment of the preferred releasable outward and interior front cap components. Upon full securement of front inner cap  438  onto the housings front projection wall  424  there is achieved a releasable securement provided by the threaded engagement of the front inner cap&#39;s threads  464  to the housing&#39;s externally threaded front end. In addition, the threaded securement of threaded surfaces  464  and  425  places the planar radial outer surface  450  of front inner cap  438  into abutment with the forward most surface of annular projection  452  of the Teflon mixing chamber  312 . As seen from  FIG. 48 , this abutting relationship forms a double wall, solvent accumulation disk space  472  between the interior surface  466  of outer front cap  440  and recessed surface  446 . Threaded exterior wall  456  of front inner cap  438  provides a threaded attachment location for the outer front cap  440  discussed in greater detail below. 
       FIGS. 40–43  further show a plurality (e.g., 3 to 10 with 6 shown) solvent flow holes  470  that pass through the forward face wall  444  (e.g., are drilled through the face of the inner cap) to allow solvent flow from the ring groove on the face of the housing  302  to the thin disk space  472  that is created between the outer face  446  of the inner cap  438  and the inner face  466  of the outer cap  440 . In a preferred embodiment, there are six solvent cap holes and the preferred hole diameter is 0.015 to 0.03 with 0.020 being preferred. The axial clearance length between the double wall solvent pooling area of the front cap assembly is preferably about 0.01 to 0.05 in with 0.02 in being suitable. 
     In addition, solvent holes  470  are preferably arranged in the radial external portion of forward face wall (e.g., the radial outer quarter region) and just inward (e.g., 0.02 to 0.06 of an inch) of the interior annular wall surface  453 . Thus, as shown in  FIGS. 42 and 48  solvent face holes  470  are circumferentially equally spaced about front wall  444  (e.g., 6 at 60° spacing) and radially positioned to be in fluid communication with annular solvent recess  417  formed by surface  416  ( FIGS. 39 and 48 ), flanges  418 ,  420  and covering wall  468  of outer front cap  440 . As further shown in  FIG. 48 , the axially extending solvent holes  470  are preferably arranged so as to have a radially exterior surface aligned with the interior wall surface of outer flange  420 . 
     Inner front cap  438  is preferably made from a high strength material such as steel (e.g., 17-4 PH steel that is hardened to be strong enough to withstand the compression means pressure on mixing chamber  312  without significant deformation, and to minimize material thickness of the front face at the center hole  442  where the inside diameter of the center hole comes in close proximity with the outside diameter of the valving rod  264 ). That is, the thickness of the central circular edge  442  of the inner front cap in preferably made as thin as possible (e.g., 0.02 inch) as there is lacking the lower friction benefit of Teflon material there. Thus the interior surface  448  of the front inner cap slopes outward while the outer end surface  446  stays planar. As seen from  FIG. 48  the outer front cap  440  can be made relatively thin (e.g., 0.03 to 0.06 inch) as it is not subjected to the forces compression means  316  as is inner front cap  438 . 
       FIGS. 44–47  illustrate in greater detail outer front cap  440  which attaches via threads  476  to the front inner cap  438 . Outer front cap  440  is designed to be readily removable from inner cap  438  for cleaning (although the below described cleaning member (e.g., steel bristle brush) and associated reciprocation is effective in maintaining the cap clean). That is the entire outer cap  440  can easily be removed, cleaned, or replaced without affecting the integrity of the mixing module. The inner cap on the other hand, since its removal can disrupt and possibly damage the Teflon mixing chamber which has its front face conforming to surfaces  448  and  450  formed therein, is typically not removed for cleaning but is releasable for other purposes such as servicing (e.g., mixing chamber replacement). It is therefore more difficult to reattach the inner cap after removal because the Belleville washers relative to outer cap  440  would have to be compressed to get it back on, although, as explained above in the discussion of the ease of assembly as compared to the prior art, the releasable back end cap can be removed to allow the front inner cap to be threaded on, followed by back cap threading and compression of a positioned mixing chamber or vice versa. Outer front cap  440  is, preferably made from stainless steel to withstand abrasion from the tip cleaning brush bristles (described below). Also, the exterior surface  478  of outer cap  440  is preferably knurled to facilitate hand or toolless removable and insertion onto front inner cap  438 . 
     The cross-sectional view of the front end of mixing module  256  in  FIG. 48  shows the solvent path front the ring groove  417  on the front of the housing  302 , through the small drilled holes  470  in the front inner cap  438 , through the thin disk of open space  472  formed between the inner cap  438  and outer cap  440 , and finally out the small gap formed between the radiuses tip  474  of valving rod  264  and the center hole  442  in the outer cap  440 . That is a small gap is formed between the tip of the valving rod and the outer cap that allows solvent to exit. Also, the central aperture  445  in outer cap  440  is preferably slightly larger (e.g., 0.005 to 0.010 inch) than aperture  442  to provide for solvent passages in the opening between the outer surface of the rod and the surface forming aperture  442 . Accordingly, the solvent outlet onto the rod is in a highly effective location as it maintains a fresh solvent supply on the tip location as well as the area immediately adjacent (common boundary wall) the non-Teflon inner cap portion. 
       FIGS. 49 to 53  illustrate a preferred solvent tank supply system  400  which includes tank holder  480  which is shown as a cup-shaped with an open top, base and four side walls at least one and preferably all three exposed side walls being provided with view transparent or translucent slot  482  to allow for direct solvent level viewing. Tank holder  480  also preferably comprises mounting plate  484  formed on the back tank holder wall and having mounting means (e.g., a bolt fastener) for mounting tank holder  480  to lifter  40  ( FIG. 6 ) such that the tank holder and solvent tank  402  rise together thus minimizing the length of solvent tubing involved, although the present invention also includes an embodiment where the solvent tank is retained stationary while the lifter rises with extra solvent conduit length provided to accommodate, for example, a two foot rise. 
       FIG. 49  illustrates the bottle shaped tank  484  partially removed from holder  480  while  FIG. 51  shows tank  402  completely removed from holder  480  with float  486  and sensor line  488  extending down to monitor the solvent level in tank  484 . Sensor line extends together with solvent conduct  404  to the control unit (described below). A two position level detector (e.g., a float and reed type) is provided as tank level sensing means in the illustrated embodiment (e.g., a warning provided at first level and a shut down at a sensed reaching of the second level) with the solvent level detactor being in communication with the control figure system of the present invention as illustrated in  FIGS. 186 and 196 . Tank  402  preferably has a hinged upper lid  490  covering an upper funnel  492  area of bottle and shown closed in  FIG. 50  and open in  FIGS. 49 and 51 . Bottle  402  is preferably vertically elongated (e.g., a height of 15 to 25 inches) with a width generally conforming to the width of lifter  40  (e.g., about 4 to 8 inches) so as to provide a small base footprint and to minimize space usage. Tank  402  is preferably a 2 to 4 gallon containers with 3 gallons being well suited for purposes of the present invention. A fill line is provided at a specific volume to facilitate the monitoring and resupply of solvent usage by the control system shown in  FIG. 196 .  FIG. 51  also illustrates solvent conduit  404  extending down close to the bottom of bottle  402  and fixed in position with an upper clamp  494 . 
       FIG. 54  illustrates a preferred solvent pump  495  which is mounted at any convenient location such as in the exit port regions of the solvent bottle. Pump  495  has an inlet port  496  which is connected to the outlet end of solvent conduit  404 . Pump  495  includes outlet port  497  to which is connected a downstream solvent conduit  498  feeding to the inlet valve  406  feeding manifold  205 . A preferred embodiment of solvent metering pump is a solenoid driven diaphragm metering pump such as a Teflon coated diaphragm driven by a solenoid powered by electronic wiring WI and capable of generating over 140 psi. Pump  495  preferably also includes adjustment means  499  for adjusting the volumetric output per stroke of the diaphragm (e.g., a volume shot of solvent per stroke). A suitable pump source of manufacture is a ProMinent® Concept b pump manufactured by ProMinent Fluid Controls, Inc. of Pittsburgh, Pa., USA. 
     As a means for reciprocating rod  264  and thus controlling the on-off flow of mixed chemicals from the mixing module, reference is now made to the mixing module drive mechanism  500  of a preferred embodiment of the present invention. In this regard, reference is made to, for example,  FIGS. 55 to 76  for an illustration of a preferred embodiment of the means for reciprocating purge/valve rod  264  extending in mixing module  256 . 
       FIG. 55A  provides a perspective view of dispenser system  192  (similar to  FIG. 22  but at a different perspective angle). Dispenser system  192  is shown in these figures to include dispenser housing  194  with main housing  195  section, dispenser end section  196  and chemical inlet section  198 , with at least the main housing and dispenser end sections each having an upper convex or curved upper surface  197  corresponding in configuration with each other so as to provide a smooth, non-interrupted or essentially seamless transitions between the two. The preferably parallel side walls of the main housing  194  and dispenser end section  196  of dispenser apparatus  192  also fall along a common smooth plane and are flush such that corresponding side walls of each provide an uninterrupted or essentially seamless transition from one to the next (the access plates shown being mounted so as to be flush with the surrounding dispenser housing side walls with, for example, countersunk screws). Dispenser apparatus thus provides smooth, continuous contact surfaces on the top and sides of the portion of dispenser apparatus  192  forward of line  191  representing generally the back edge location of the film being fed past dispenser apparatus  192 . 
     With reference particularly to  FIGS. 59 and 64  there is illustrated dispenser drive mechanism  500  which is used to reciprocate rod  264  within mixing module  256  and is housed in dispenser system  192  and, at least, for the most part, is confined within the smoothly contoured housing of dispenser system  192 . Dispenser drive mechanism  500  includes dispenser drive motor system  200  (“motor” for short which entails either a motor by itself or more preferably a motor system having a motor, an encoder means and/or gear reduction means). Motor  200  (the system “driver”) preferably comprises a brushless DC motor  508  with an integral controller  502  mounted to the back section of the motor and encased within the motor housing, and gear reduction assembly  504 . Motor controller  502  provides encoder feedback (e.g., a Hall effect or optically based encoder system) to the controller such as one provided as a component of main system control board which is used to determine speed and position of the various drive components in the drive mechanism  500 .  FIGS. 186 and 190  illustrate the control system for operating, monitoring and interfacing the data concerning the rod drive mechanism. The motor controller input from the main system control board preferably includes a 0 to 5 volt speed signal from the main system controller, a brake signal, a direction signal and an enable signal. Motor  200  further preferably includes a gear reduction front section  504  out from which motor output drive shaft  506  extends ( FIG. 59 ). The motor drive source is located in the central section  508 . 
     As seen from  FIG. 59 , front section  504  of motor  200  is mounted with fasteners  510  (e.g., pins and bolts) to the rear end dispenser housing  194 . As shown by  FIGS. 59 and 64 , output shaft  506  has fixed thereon bevel gear  512  and one-way clutch  514 . One way clutch  514  ( FIG. 65 ) is fixedly attached to drive shaft  506  and has clutch reception section  516  receiving first end  518  of main drive shaft  520 . Clutch reception section  516  includes means for allowing drive transmission during one direction of rotation (e.g., clockwise) such that rod  264  is reciprocated in mixing module  256 , while one way clutch  514  freewheels when drive shaft  506  rotates in an opposite direction (e.g., counter clockwise) such that bevel gear  512  can drive the below described tip brush cleaning system rather then the reciprocating rod. This provides an efficient means of assuring the timing of any dispenser tip brushing and dispenser output avoiding an extension of this cleaning brush described below at a time when chemical is being output.  FIG. 65  further illustrates the interior rollers/cam lock up mechanisms  522  of one way clutch  514  which provide for device lock up to transmit torque when rotating in a first direction with near zero backlash. It is noted that clutch  514  is included in a preferred embodiment of the invention wherein motor  200  is dual functioning and reversible in direction based on the control system&#39;s instructions, (e.g., reciprocation of valving rod and reciprocation of a cleaning brush or some other means for clearing off any material that accumulates at the end of the dispenser). A single function embodiment wherein motor  200  is used for opening and closing the mixing module only with or without another driver for the cleaning brush is also featured, however, under the present invention (e.g., either without a tip cleaning function or a tip cleaning system which derives power from an alternate source). 
     In a preferred embodiment the second end of main drive shaft  520  is connected to flexible coupling  524 , although other arrangements, as in a direct force application without flexible coupling  524 , is also featured under the present invention. Flexible coupling  524  is in driving engagement with dispenser crank assembly  526  ( FIG. 64 ). Dispenser crank assembly  526  is contained in dispenser component housing (see  FIGS. 55 and 66A ). Dispenser component housing  528  is a self contained unit that is connected to the front end of main housing portion  195  as previously discussed and forms forward dispenser end section  196 . The connection is achieved with suitable fasteners such as fasteners  530  shown in  FIG. 59  (three shown in cross-section). Dispenser component housing  528  comprises main crank (and mixing module) support housing component  532  (see  FIG. 66A ) and upper dispenser housing cap  533  ( FIG. 66B ), with support housing  532  having a generally planar interior end  535  for flush engagement with the forward end  193  of support housing  194 . Dispenser component housing  532  includes pivot recesses  534  (one shown- FIG. 66A ) to which is pivotably attached closure door  536  (see  FIGS. 22 and 60  for a closed closure door state and  FIG. 24  for an open closure door state) by way of pivot screws  538  (one shown) or the like. 
     Dispenser housing cap  533 , illustrated in  FIGS. 59 ,  60  and  66 B is secured to the top front of support structure  194  and is shown as having a common axial outline with support structure  194  (such that all potentially film contact surfaces of dispenser  192  are made with a non-interrupted smooth surface).  FIG. 66B  illustrates housing cap  533  having a large crank clearance recess  542  and a bearing recess  544  sized for receipt of a first of two bearings such as the illustrated first (forwardmost) needle bearing  546  shown in  FIGS. 59 and 62 . Housing cap  533  is secured in position on the forward top face of main crank support housing component  532  by suitable fasteners (not shown). Bearing recess  544  is axially aligned with inner bearing recess  548  provided on the forward face of housing component  532  ( FIG. 66A ). Inner bearing device  550  ( FIG. 59 ) represents the second of the two bearings within cap  533  and is received in inner bearing recess  548 . Crank assembly  526  has opposite ends rotatably received within respective inner and outer bearings  545 ,  550  and is preferably formed of two interconnected components with a first crank assembly component  552  being shown in  FIGS. 67 and 68  with key slot shaft extension  553  designed to extend past the innermost surface of main housing component  532  and into driving connection with the forward flexible coupling connector  554 . 
     For added stability and positioning assurance, rear end  534  of housing component  532  further includes annular projection  556  (see  FIG. 61 ), that is dimensioned for friction fit connection with circular recess  558  ( FIG. 72 ) formed in support housing structure  194 . First crank assembly component  552  further includes bearing extension  560  sized for bearing engagement with inner bearing  550  and is positioned between slotted shaft extension  553  and inner crank extension  562 . Inner crank extension is elliptical is shape and has bearing extension  560  having a central axis aligned with a first end (foci) of the ellipsoidal inner crank extension and crank pin  564  extending forward (to an opposite side as extension  560 ) from the opposite end (foci) of inner crank extension  562 . Crank pin  564  has a reduced diameter free end which is dimensioned for reception in pin reception hole  566  formed in outer crank extension  568  of second crank component  570  having a peripheral elliptical or elongated shape conforming to that of the first crank component. At the opposite end of the elliptical extension  568 , and aligned with the central axis of first or inner bearing extension  560 , is provided outer or second bearing extension  572 . Second bearing extension  572  is dimensioned for reception in outer bearing  546 . 
       FIG. 74  illustrates connecting rod  574  having first looped connecting end  576  designed for driving connection with respect to crank pin  564 . This upper connection is shown in cross-section in  FIG. 59  and in perspective in  FIG. 64 .  FIG. 64  shows connecting rod  574  extending down between a parallel set of guide shoes  578 ,  580  (both shown in cross-section in  FIG. 63 ) and into engagement with hinge pin  582  as shown in  FIGS. 59 and 62  (where one of the two sliding plates is removed in cross-section). Hinge pin  582  is received within second looped connecting end  584  of connecting rod  574  and is secured at its opposite ends to slider mechanism  586  which functions in piston like fashion as it slides between and in contact with guide shoes  578 ,  580 . Thus, connecting rod  574  functions as means to connect the crank assembly to the slider mechanism which provides for a translation of the rotation of the main drive shaft  520  into linear motion of the slider within the two guide shoes. 
       FIG. 75  illustrates one of the two guide shoes  578  with the opposite one being the same but for its fixation position to an opposite one of the two main housing component&#39;s shoe support brackets  588  and  590  shown in  FIG. 66A . As seen from  FIGS. 59 and 60 , shoe support brackets  588  and  590  support corresponding shoes  578  and  580  in mirror image fashion with the back wall  592  of each flush against an interior surface of a corresponding bracket and with flange rims  594  and  596  extending out toward each other to define a peripherally closed sliding area. Fastener holes are formed in each bracket and in the flange rims for fastening the shoe assembly together (e.g., four larger corner bolts with two smaller intermediate bolts holes aligned in each as depicted in  FIGS. 60 and 66 ). Thus, the guide shoes provide means for guiding piston  586  ( FIG. 76 ) as it slides linearly in response to the forces transmitted from connecting rod  574 . A preferred material for the guide shoes is “TORLON” material of DuPont, because it has high load bearing properties coupled with low sliding friction, although other materials can be relied upon to provide a sliding piston guiding function under crank and connecting rod loads. 
       FIG. 76  illustrates slider mechanism  586  having upper trunnion end  598  with forward trunnion extension  599  and rearward trunnion extension  597 . In trunnion extensions  597  and  599  there is formed pin reception holes  595  and  593  for receipt of respective ends of hinge pin  582  (e.g., a threaded engagement although threading not shown). As seen from  FIG. 76 , trunnion end  598  has smooth side walls at the base of extensions  597  and  599  which extend into smoothly contoured semi-circular upper trunnion extension portions. Slider mechanism further includes rod capture base  591  having smooth shoe contact side walls  589  and  587  as well as base bottom  585  within which is formed rod capture recess  583  which has an enlarged rod end insert opening that opens out at front face  581  and an elongated base slot  573  that narrows in opening width in its rear portion due to the extension of two opposing rod capture ribs  577  and  575 . At its rear end, slot  573  has a curvature matching the curvature of the enlarged rod head  330  of rod  264  and capture recess extends rearward past the rear end of slot  573  so as to provide a capture reception region relative to the enlarged head of rod  330  shown in  FIG. 25 , for example. Accordingly the connecting rod  574  converts the rotational motion of crank arm or connecting rod  574  into linear motion in the slider mechanism  586  which in turn, based on its releasable capture connection with the enlarged end  330  of rod  264 , reciprocates rod  264  within the mixing chamber to purge and/or perform a valve function relative to the chemical mixing chamber feed ports. 
     The mixing module drive means of the present invention, which derives its power from motor  200  and achieves rod reciprocation, is highly effective in the environment of a mixing module dispenser in that it coordinates its cycle of high force push and pull levels with the ends of travel of slider mechanism  586  which corresponds with the reciprocation end points of the rod  264  between a forward purge extension to a rearward (upward in the illustrated  FIG. 64 ) valve open retracted position. The calculated pulling or pushing force is over 1000 lbf at these two positions. This higher pushing/pulling force will not necessarily be applied to the mixing module as it is only applied when needed (e.g., the drive mechanism will only apply enough force to move whatever is attached to it). If the item does not want to move (e.g., stuck), the drive mechanism can generate its maximum force level attributable to the system at that point to break any resistance to movement. This feature is well suited for the mixing module&#39;s characteristics as the high force is available at the start of the opening stroke, exactly where it is needed, because this is the location where prior art mixing modules have a tendency to bind up if they are left idle for even a few minutes. For example, if urethane is building up on the inside diameter of the mixing chamber, it will bond the valving rod to the chamber. The drive mechanism of the present invention can effectuate rod reciprocation even if there is a lot of urethane buildup, unlike the prior art wherein an increase in “stick” from urethane build up which often occurs at the end of idle periods and/or when the solvent runs out or gets contaminated. In the prior art systems the binding forces can be high enough to stall, for example, the drive mechanism of the prior art mechanisms leading to a shut down signal and/or breakage of a rod or some other component. 
     The placement of the motor  200  external or out away from the film edging and bag forming area allows for a much more robust motor than utilized in the prior art (e.g., a weight difference of, for example, 7 pounds (for drive motor, gearbox and controller) relative to for example 12 ounces for a typical prior art systems motor, gearbox and controller positioned inside or between the film edges). A conventional motor drive system sized for insertion between the bag film edges (e.g., a ball screw motor drive system) has about 200 pounds when operating at optimum performance levels which was not often the case. This difference provides in the present invention, for example, a torque of at least 5 to 10 times greater than the noted prior art motor and the capability to run at peak torque for the full life of the motor. The preferred motor type for the mixing module driver of the present invention is a brushless DC motor (for example, a Bodine Brushless Torque motor with RAM of 100 to 2000 RPM. The built in encoder of the present invention&#39;s brushless motor provides for accurate dispenser use and avoidance of cold shots in that a preferred embodiment of the invention features a built in encoder that generates a position feedback signal to the control means (i.e., a closed loop system unlike the prior art open loop system). Thus unlike the prior art systems that run open loop and have no way of knowing the positioning of the mixing module rod relative to the axial length of the mixing module passageway and direction of travel therein, the present invention&#39;s closed loop arrangement allows the controller to monitor at all times the status of the drive system and hence whether the mixing module is in an opening or closing cycle. This information is valuable in monitoring the drive performance and the early flagging of potential problems (e.g., build up of hardened foam in the mixing chamber) before the potential problems build up to a level causing major problems.  FIGS. 59 and 62  further illustrate drive mechanism home position sensor  515  that identifies the starting position of the drive mechanism so as to provide added feedback for performance monitoring of the mechanism including operation of the encoder itself. If there is sensed a position problem by the home sensor (e.g., a broken crank) a stop signal is generated to prevent additional system damage (similar functions can be provided by the moving jaw home sensor  4036  as well as the cleaning brush reciprocation system home sensor  3056  discussed below).  FIGS. 186 and 190  illustrate the control system and with  FIG. 190  showing the mixing module home sensor in conjunction with the chemical dispensing and tip cleaning control and monitoring sub-system. 
     As described in the background section the outlet tip region of a dispensing mixing module is a particularly problematic area with regard to foam buildup and disruption of the desired foam output characteristics. Once the output nozzle is sufficiently blocked, the foam stream is deflected from its normal path and can easily be deflected 90° if left unattended having negative consequences in the build up of essentially non-removable foam in other areas of the dispensing system. It is believed that left unattended such a build up can happen in as little as 20 shots. The aforementioned features of the present invention&#39;s tip management means including providing a solvent supply system to the front end of the mixing module with a high pressure solvent pump, flow through or flushing/continuous replenishment solvent chamber, heated solvent and directed tip region flow of solvent through the face of the mixing module and around the valving rod is highly effective in precluding build up. However, even with the advantages or arrangement described above, foam can accumulate at the tip of the dispenser in a softened state during solvent flow supply with the potential to harden during periods where the system is shut down and during times in which solvent flow may not be provided. The present inventions tip management means thus preferably includes an auxiliary cleaning component which is directed at physical removal of any chemical build up in the tip region or outlet port region of the mixing module such as in a wiping or brushing fashion. In a preferred embodiment there is provided a brush or a alternate physical chemical build up removal means preferably connected with means for reciprocating or moving that cleaning member (e.g., brush) between cleaning contact and non-contact states relative to the nozzle tip. 
       FIGS. 55 ,  55 A,  59 ,  64  and  179 – 184  illustrate various features of a preferred embodiment of physical nozzle tip cleaning means  3000 . 
       FIG. 55  shows physical nozzle tip cleaning means  3000  (which preferably works in conjunction with the solvent or chemical cleaning means as part of an overall tip management system) with its cover removed while  FIG. 55A  shows cover  3001  (multi or single unit casing) includes at the bottom region of the dispenser  192 . As shown in  FIG. 64  nozzle tip cleaning means  3000  comprises a physical contact with tip cleaning member  3002  preferably formed of a brush having brush base  3004  with a plurality of bristles (e.g., plastic; but more preferably steel). The bristles are arranged and of a height to come in contact with the nozzle outlet tip most proven to foam build up with the amount of contact being preset (or adjusted with height adjustment means as in wedge adjustments (not shown) to have the bristles deflect to some extent to achieve improved wiping, while avoiding an over contact or unnecessary degree of contact with the nozzle end. This relative spacing can be seen from  FIG. 59  unit, for example, an overlap similar to the thickness of the outer and inner front cap components combined.  FIG. 59  illustrate linear slide base  3008  which is secured to the underside of main dispenser having 194 by fasteners  3010 . Slide base  3008  is preferably formed of TORLON 4301 of DuPont, a high performance plastic used in harsh bearing applications and includes V-Shaped grooves extending along its elongated body.  FIG. 59  also illustrates line or slide yoke or brush drive transmission connection means  3012  having an extended forward end  3014  which lies flush on a central axial elongation area of brush base  3002 . Forward end  3014  is fastened to brush base  3002  with fastener  3010 . Yoke  3012  includes a hook section  3020  with a notch which receives flange extension  3022  of the brush base. As its opposite end, yoke  3012  includes U-Shaped connector  3023  with vertically spaced legs having a central aperture in each. One end connecting rod  3024  is received between the legs and held in place by threaded pin  3026  which pivotably receives rod  3024 . First and second linear slide rails  3028  and  3030  are secured the respective sides of yoke  3012  and include projections that ride within the elonged recesses of linear slide base  3008  (or vice versa). Connecting rod  3024  is secured to crank  3032  by way of its pivot extension  3034  extending into the aperture in the looped yoke end  3031 . Crank  3036  is secured to the bottom end of shaft  3038  which extends through a corresponding series of vertically aligned holes in dispenser housing  194  with suitable bearing mounting into one way clutch  3042  which joins crank  3032  for rotation in one direction of shaft rotation  3038  and freewheels when a shaft  3038  rotates in the opposite direction. At the top end of shaft  3038  there is connected bevel gear  3040  which is connected to the previously described bevel gear  512 . 
     Thus, when motor  508  rotates in a first direction (e.g., clockwise) it reciprocates the mixing module rod (e.g., opens and closes the chemical ports to the mixing chamber while purging the same) and when it runs in the opposite direction it drives the cleaning component (e.g., brush). Motor  508  turns main drive shaft  520 , which turns smaller drive shaft  3038 , arranged perpendicular thereto, through the bevel gear connection. One way clutch  3042  at the lower end of drive shaft  3038  only transmits rotation when turning in a predetermined direction. If the shaft  3038  is rotating in the opposite direction, shaft  3038  will free ride in clutch  3042  and not activately reciprocate the cleaning brush (at which time main shaft  520  is activately transmitting reciprocating force to the rod) when the shaft  3038  is rotated in the opposite direction (at which time main shaft  520  is not rotated due to the one way clutch  516  being in a freewheel state relative thereto) shaft  3038  is rotating in a direction which turns crank  3036  driving connecting rod  3024  which translates the rotary motion of the shaft  3038  to liner motion in the brush slide assembly. Brush  3002  is preferably mounted to an aluminum yoke, attached to the TORLON slider centered between the two side bearings  3028 ,  3030 , which support the yoke assembly as it moves back and forth. The brush base is preferably machined of a polypropylene plastic, with the bristles being arranged of a sufficient width to sufficiently clean the nozzle and is arranged in a grid pattern or spiral pattern. The brush can easily be replaced when warn by removal of the fastener. The number of reciprocating strokes is determined by the controller which instructs motor  508  as to which direction to turn as shown by the control arrangement shown in  FIG. 190 . In a preferred embodiment, the brush is reciprocated a multiple number of times sufficient to clean all build up subjected to solvent application, again based on controller input (automatic or operator set). That is, the number of brush reciprocation&#39;s (time motor running in certain direction) and the period between cycles (time between off states or switching from one direction to another direction) is based on the needs of the system (e.g., solvent type, chemical type, length of inactivity etc.). For example, an extra cleaning cycle both with regard to solvent application and brushing is preferably performed when the system has an extended multi-hour period of shut down such as during a nighttime shut down or other long idler periods (servicing). Preferably this cleaning cycle is performed with the solvent above (e.g., 150 to 160° F.) its normal (e.g., 130° F.) heated temperature (a controller interface relationship between reciprocating brush control and solvent pump supply and manifold heaters (see  FIG. 194 )). The higher temperature increases the solvation power of the dispenser cleaning solution and extended brushing period will help remove any preexisting build up from the last dispenser run period. 
       FIG. 64  illustrates some additional features of the physical nozzle tip cleaning means. As shown, the upper, relatively flat side of crank  3032  features groove  3050  of semi-circular cross-section that concentrically encircles the center hole of the crank. Spring loaded plunger  3052  is mounded (e.g., on housing  194 ) so its retractable tip rides in the groove. Plunger  3052  allows the crank to rotate freely in the brush operating direction because of the nature of the groove design with its ramp up arrangement with wall drop off  3054  which does not preclude crank rotation in the noted direction, but will lock up the crank (relative to a free ride state) if the crank moves in the opposite direction. This feature avoids the possibility of the brush being accidentally moved when the valving rod is the one being moved by the motor such as if there is a minor degree of friction drag in the slip clutch or the brush is in some way accidentally hit in a direction that would force it forward, during potential dispensing of foam, although the cover essentially protects against such an event. 
       FIG. 64  further illustrates proximity sensor  3056  for home position determination. Thus, in conjunction with the encoder of motor  508 , the actual position of brush  3006  relative to its reciprocation travel can be monitored at all times in similar fashion to the location of the reciprocating rod with the proximity sensor  515  (e.g., position monitoring means) ensuring proper operation of the encoder based position monitoring system. Either of these sensors can be moved up or downstream relative to the respective transmission lines in which they exist. 
     With reference to  FIGS. 58–63 ,  72  and  73 , there is illustrated the chemical feed housing conduit system  600  passing from the inlet section  198  of dispenser apparatus  192  (via manifold  205 ) to dispenesr housing  194 . Chemical outlets (see  FIGS. 58 and 72 )  602  and  604  corresponding with those in the chemical front end dispenser housing component  528  feeding into the mixing module housing  302 . Chemical conduits  602  and  604  are preferably formed in conjunction with an extrusion process used in forming the basic structure of main housing  194  (e.g., main housing section  195 ). As further shown in  FIG. 58  positioned above conduits  602  and  604  there is a second set of conduits with conduit  606  providing a solvent flow through passageway in main housing  194  and with the adjacent conduit  608  providing a cavity for reception of a heater cartridge  610  (or H 2 ) (e.g., an elongated cylindrical resistance heater element) that is inserted into conduit  608  and has its electrical feed wires (not shown) feeding out the inlet end  198  side to the associated power source and control and monitor systems of the control means of the present invention as shown in  FIG. 194 . Heater cartridge  610  features a heat control sub-component system which interfaces with the control means of the present invention as illustrated in  FIG. 194  and, is preferably positioned immediately adjacent (e.g., within an inch or two or three of the two chemical conduits  602  and  604 ) and runs parallel to the chemical passage to provide a high efficiency heat exchange relationship relative to the main housing preferably formed of extruded aluminum. The heat control sub-system of the present invention preferably is designed to adjust (e.g., automatically and/or by way of a temperature level setting means) the heater to correspond or generally correspond (as in averaging) with the temperature setting(s) set for the chemicals passing through the heater wires associated with the chemical feed lines  28 ′ and  30 ′ so as to maintain a consistent desired temperature level in the chemicals fed to the dispenser. Heater cartridge  610  is also within an inch or two of the solvent flow through passageway and thus is able to heat up the solvent flow being fed to the mixing module (e.g., a common 130° F. temperature). A temperature sensor is associated with the heater cartridge which allows for a controller monitoring of the heat output and the known heat transmissions effect on the chemical passing through the adjacent conduit through the intermediate known material (e.g., extruded aluminum). 
     With reference to  FIG. 57  there is illustrated inlet manifold  199  formed of block  205  with the manifold cavities including one to inlet manifold heater  612  which functions in similar fashion to heater  610  in heating the surrounding region and particularly the chemical flowing through manifold  199  to preferably maintain a consistent chemical temperature level in passing from the heater wire conduit exits to the mixing module. Heater  612  also includes a temperature monitoring and control means associated with the main control board of the present invention to monitor the temperature level in the manifold block and make appropriate heat level adjustments in the manifold block to achieve desired chemical output temperature(s), as shown in  FIG. 194 . 
       FIGS. 57 and 59  also illustrate manifold  199  as having A and B chemical passageways  614 ,  616  which feed into corresponding main housing A and B chemical conduits  602  and  604  also running adjacent the manifold heater  612  to maintain a desired temperature level in the chemical for all points of travel through the main manifold  199 . The cross-section in  FIG. 59  illustrates filter reception cavities  618 ,  620  within which are received filters  4206  and  4208  ( FIG. 55 ) which are readily inserted (e.g., screwed or friction held) into place so as to receive a flow through of respective chemicals A and B. Chemicals A and B passing through manifold  199  are also subject to flow/no flow states by way of chemical shutoff valves  622  and  624  which feature readily hand graspable and turnable handles and are preferably color coded to correspond with the A and B chemicals. Pressure sensing means (e.g., transducers)  1207  and  1209  also sense the chemical pressure of the chemicals passing in manifold  199  and convey the information to the control board where a board processor determines whether the pressure levels are within desired parameters and, if not, sends out a signal for making proper system adjustments as in a reduction or increase in pump output.  FIG. 195  shows the control system schematic for monitoring and adjusting chemical pressure in the dispensing system. 
     With reference to  FIG. 2  there can be seen chemical hose extensions  28 ′ and  30 ′ for chemicals A and B extending into a bottom connection with manifold  199  (not shown if  FIG. 2 ) via threaded plugs  626  and  628  and extend down though extendable support assembly  40  which houses the remaining portions of chemical A and B feed hose extensions extending between the manifold and cable and hose management system  630  shown in  FIG. 103  which retains the coiled hoses and cable assembly  50 . As further shown in  FIG. 2 , chemical hose extensions  28 ′ and  30 ′ have ends  43  and  45  extending down into connection with in-line pump assembly  32  having pumps  44  and  46 . As explained below, chemical hoses are heated chemical hoses, again under control of the control system as illustrated in  FIG. 193 . 
       FIG. 77  provides an enlarged perspective view of in-line pump system  32  shown in  FIG. 2  as being mounted on base  42  and featuring in-line pump assembly  44  for chemical A and in-line pump assembly  46  for chemical B. As shown in  FIG. 77 , pump assemblies  44  and  46  have similar components but have offset extremity extensions that provide for a compact (space minimizing) arrangement for mounting on base  42 . For example, pump motor electrical cables  632  and  634  feeding A chemical pump motor  636  and B chemical pump motor  638  (and preferably part of the cable and coil assembly), are arranged with relatively angled offset supports  640  and  642  attached to the respective motors circumferentially offset but by less than 15 degrees to provide for closer side-by-side pump assembly positioning. Chemical A pump assembly  44  further comprises pump coupling housing  644  which is sandwiched between pump  636  above and the below positioned chemical outlet manifold  646 . Below outlet manifold  646  is positioned chemical inlet manifold  648 . The downstream end of heated chemical conduit  28  is shown connected at angle connector  650  to inlet valve manifold  652  secured to the input section of chemical inlet manifold  648 . Extending out of chemical outlet manifold  646  is another angle connector  654  extending into chemical outlet valve assembly  656  which is connected at its upper connector end  658  to chemical A hose extension  45  leading into hose and cable management system  630  ( FIG. 103 ). The corresponding components in the chemical B pump assembly  46  are designated with common reference numbers with dashes added for differentiation purposes. Also, the following discussion focuses on the chemical A pump assembly  44  only in recognition of the preferred essentially common arrangement of each of the chemical A and B pump assemblies.  FIG. 77A  provides a side elevational view of the pump assembly  46  and thus a different view of the aforementioned pump assembly components. 
       FIGS. 78–81  illustrate in greater detail the preferred embodiment for pump motor  636  for chemical A (same design for chemical B) with  FIG. 78  showing the motor casing being free of an internal motor component for draftsperson&#39;s convenience. In a preferred embodiment a brushless DC motor with internal encoder mechanism is utilized. As shown in  FIGS. 78 and 79 , pump motor  636  features a threaded output shaft  660  having left handed threaded end  662  extending from main shaft section  664 .  FIG. 80  provides a full perspective view of pump motor  636  as well as the strain relief angle connector  642  for electrical cable connection.  FIG. 81  shows a view similar to  FIG. 80  but with added top and bottom adapter plates ( 666 ,  668 ) secured to the motor housing  670 . The top adapter  666  provides a recess for receiving the color and letter coded (A in this instance) identifying plate  667  ( FIG. 77 ) while bottom adaptor plate  668  functions as a positioning means with its reception ring properly centering shaft section  664  when the adapter plate  668  is received by coupling housing  644  shown in  FIG. 82 .  FIGS. 80 and 81  also illustrate housing coupling  644  having a notched portion  672 . Coupling housing  644  has upper and lower stepped shoulders  674  and  676  with upper shoulder  674  designed to frictionally retain the aforementioned adapter plate  668 , while lower stepped shoulder is designed for frictional and/or fastener engagement with a corresponding notched lower end in chemical outlet manifold  646  (the threaded connection of the shaft maintaining to some extent the assembled pump assembly state). 
     Coupling housing  644  houses magnetic coupling assembly  678  shown in position in the cross-sectional view of  FIG. 78 .  FIG. 83  provides a cutaway view of magnetic coupling assembly  678  having outer magnet assembly  680  with drive shaft coupling housing  682  and magnet ring  684  secured to an inner surface of cylindrical coupling housing wall  686 .  FIGS. 84 and 85  provide a perspective and cross-sectional view of outer magnet assembly  680  having an upper wall  687  with a central protrusion  688  with, as shown in  FIG. 85 , a threaded inside diameter  690  designed for threaded engagement with the threaded end  662  of pump motor drive shaft  660  via the left hand threaded end  662 . Thus, drive shaft coupling housing  682  is placed in threaded engagement with drive shaft  660  and positions its supported magnet ring  684  about shroud  692 . Ring  684  is preferably of a magnet material having high magnetic coupling strength such as the rare earth magnet material (e.g., Neodymium). Ring  684  is also preferably magnetized with multiple poles for enhanced coupling power. 
     Shroud  692  is shown in operative position in  FIG. 78  having its based secured to the upper surface of chemical outlet manifold  646 .  FIGS. 86 and 87  further illustrate shroud  692  in perspective and in cross-section, and show shroud  692  having a top hat shape with base flange  694  and cup-shaped top  696  extending upward therefrom and having shroud side wall  698  and top  700  which together define interior chemical chamber  702  (the same chemical being pumped from the respective chemical pumps). Base flange  694  is shown as having a plurality of circumferentially spaced fastener apertures  704  that are positioned for securement to corresponding fastening means  706  on the upper surface  708  of chemical outlet manifold  646  as shown in  FIG. 88 . Preferably there is a static seal relationship between the bottom of the shroud and the receiving upper surface of the outlet manifold  646  as in an O-ring seal relationship (not shown). 
       FIGS. 78 ,  83 ,  89 A and  89 B show inner magnet assembly  710  positioned within the inner chemical chamber  702  of shroud  692  which acts to separate the inner and outer magnet assemblies ( 680  and  710 ) and isolates the chemical. Inner magnet assembly  710  comprises a main housing body  712  which supports along its exterior circumference inner magnet ring  714  and has threaded center hole  716 . Outer magnet assembly  680  positions the threaded inside diameter  690  of the outer magnet assembly  680  in axially alignment with the threaded central hole  716  of inner magnet assembly  710  but to the opposite side of top  700  of the isolating shroud  692 . Also, by way of the illustrated cup shape in outer magnet assembly  680 , its side wall extends down to place outer magnet ring  684  in a generally vertically overlapping and concentric arrangement (to opposite sides of the side wall of the isolating shroud) relative to inner magnet ring  714  supported by inner main housing body  712 . Inner magnet ring  714  is preferably formed of the same magnet material and with multiple poles as its outer counterpart. As seen from  FIG. 78  the central threaded hole in inner magnet assembly  710  connects with bearing shaft  718  (e.g., a left handed thread) which, in turn drives pump shaft  720  by way of the preferred intermediate flexible coupling  722  (components  718 ,  720  and  722  working together to provide inner pump drive transmission means). The magnet coupling achieved under the present invention thus provides means to transmit torque from the motor to the pumping unit without the need for a connecting drive shaft and its problematic drive shaft seal. That is, the pump motor ( 636 ,  638 ) is provided with a magnet (e.g., less than one or two inches, for example) but the pump and motor drive shafts never contact each other although the magnet assemblies generate a magnetic field arrangement that magnetically locks the motor and pump drive shafts together. As noted in the background, this sealed arrangement avoids the problem in the prior art of drive shaft seal degradation such as from iso-crystal build-up which can quickly destroy the softer seal material. 
     Shroud  692  is preferably made of a material (e.g., steel) that does not interfere with the magnetic locking of the inner and outer magnet rings and is relatively thin.  FIGS. 89A and 89B  further illustrate inner magnet assembly  710  having outer encasing layer or covering  722  (e.g., a polymer laminate) that protects inner magnet assembly  710  from adverse chemical reactions from either of the contacting chemicals A or B. Also, as seen by  FIG. 92 , to provide for added stability, bearing shaft  718  has first, enlarged bearing section  724  extending below the smaller diameter uppermost threaded shaft section  726 , and the central through hole  716  of inner magnet assembly  710  has a smaller diameter threaded section  728  which engages with threaded uppermost shaft section  726  and a larger reception recess  730  which receives enlarged bearing section  724  with the step shoulder between sections  724  and  726  contacting the corresponding step shoulder between sections  728  and  730 . 
       FIG. 92  also illustrates shaft  718  having second bearing contact surface  732  spaced from first bearing contact surface  724  by enlarged separation section  734  and intermediate section  719 . Second bearing contact surface  732  extends into shaft flex head connector  736  forming the end of shaft  718  opposite threaded end  726 . 
       FIGS. 88 ,  90  and  91  illustrate bearing shaft  718  received within bearing reception region  738  formed in the upper, central half of outlet manifold assembly  646 . Bearing reception region  738  opens into a smaller diameter shaft end reception region  740  which forms the remaining part of the overall through hole extending through the center of outlet manifold  646 .  FIG. 90  illustrates the compact and stable bearing shaft relationship with outlet manifold  646  wherein first and second ring bearings  742 ,  744  are received in bearing reception region  738  in a stacked arrangement with the lower bearing ring (e.g., a caged ball bearing ring) supported on the step shoulder  746  of outlet manifold  646  and the upper bearing ring supported on a step shoulder defined by enlarged separation section  734  of shaft  718 . This twin bearing support arrangement helps minimize vibration and side load on the below described pump head The relatively short shaft  718  (e.g., less than 3 or 4 inches in length) has its flex connector end  736  received within shaft end reception cavity  740 .  FIG. 88  illustrates chemical outlet port  748  which preferably is threaded for connection with an angle connector as in angle connectors  654  or  654 ′ shown in  FIG. 77 . 
       FIGS. 90 and 91  further illustrate backflow prevention means  750  shown as ball check valve positioned at the pump head side or lower end of outlet manifold  646 .  FIG. 91  illustrates a bottom view of the same which includes an illustration of check valve  750  as well as mounting alignment recesses  752 . In addition rupture disc  754  is threaded into the base of the outlet manifold as protection against over pressure by blowing out at a desired setting (e.g., 1440 psi). Check valve  750  helps avoid backflow and maintain line pressure to minimize the work required from the pumping unit during idle periods. Bearing shaft  718  supports the pump side of the magnetic coupling unit and drives the pump head shaft. 
     In a preferred embodiment, there is attached a gerotor pumping unit to the base of the outlet manifold. In this regard, reference is made to  FIG. 93  providing a rendering of pump head  756  in an assembled condition and  FIG. 93A  showing an exploded view of the same.  FIGS. 94 and 95  provide different cross sectional views of pump head  756  and shows locating pins  760  designed for reception in alignment recesses  752  ( FIG. 91 ) at the base of outlet manifold such that pump head  756 , with its chemical output port  758 , is placed in proper alignment with the input port  750  at the bottom of outlet manifold  646 . As shown in  FIGS. 93-97 , pump head  756  is a multi-stack arrangement comprising a plurality of individual plates with  FIG. 96  showing the unassembled set of plates with a view to the interior surface of each and  FIG. 97  showing the same plates but with an outer or exposed surface presentation (the below described center or intermediate plate  766  and gerotor unit  768  having a common appearance on either side).  FIGS. 94 and 95  illustrate base annular ring  762  which provides a clearance space relative to filter  765  (e.g., a 30 to 40 mesh being deemed sufficient in working with the 100 mesh screens in manifold  199 , for example) sandwiched between ring  762  and bottom or base plate  764  of pump head  756 . Center plate  766  is stacked on base plate  764  and held in radial alignment by way of drive shaft  770  which has an upper connecting end  772 , an intermediate drive pin  774 , and an extension end  776  extending into bottom plate central recess  782  providing a cavity above filter  765 . The solid central region of bottom or base plate  764  defining the base of recess  782  and the chemical access passageway  784  for chemical having just passed through filter screen  765  and into recess  782 . The chemical is then received by gerotor unit  768  comprised of outer gerotor ring  786  and inner gerotor ring  788  each preferably formed of powdered metal. 
     Gerotor unit  768  is received within the eccentric central hole  790  of center plate  766 . As seen from  FIGS. 96 and 97  a preferred arrangement features an inner gerotor section  788  having 6 equally spaced teeth in a convex/concave arrangement. The interior of outer ring  786  also features seven concave cavities extending about a larger inner diameter relative to the outer diameter of the interior positioned gerotor gear with, for example, a 0.05 inch eccentricity. The concave recesses generally conform to the convex projections of the interior gerotor plate with the relative sizing being such that when one interior ring tooth of the interior gerotor pump plate is received to a maximum extent in a receiving concave cavity in outer ring  786 , the diametrically opposite interior tooth of the interior gerotor pump plate just touches one of the outer ring projections along a common diameter point while the adjacent teeth of the inner ring have contact points on the exterior side of the adjacent two projections of the outer ring (e.g., within 15° of the innermost point of those two teeth). The upper (relative to the Figures) left and right teeth of the inner ring extend partially into the cavity adjacent to the one essentially fully receiving the inner ring tooth. The left and right teeth extend into those outer ring reception cavities moreso than the remaining teeth with the exception of the noted essentially fully received tooth. The geometry of the gerotor of the present invention takes into account the characteristics of isocyanate which has a tendency to wear out prior art configured gerotor tips in the A chemical which reduces pump efficiency and negatively effects foam quality. Isocyanate does not provide a good or suitable hydrodynamic boundary layer between the rotating teeth of the gerotor assembly and an associated excessive contact between the inner and outer rotor and rings at specific location on each tooth leading to rapid wear. The illustrated geometry of the gerotor of the present invention takes into account these prior art deficiencies and is directed at providing a minimized degree of pump element wear and loss of pumping efficiency, which if lost can lead poor chemical ratio control and a resultant loss in foam quality. 
       FIGS. 94 and 96  further illustrate top plate  792  which includes outlet port  794  which feeds into the bottom of outlet manifold  646  via conduit  750  with check valve control. As seen from  FIGS. 95 and 97 , there are a plurality of recessed fastener holes  796  formed in the top plate that are designed to receive extended fasteners  798  with one representative bolt type fasteners  798  shown in  FIGS. 93A and 94  as extending through reception holes in each plate with preferably at least a lower plate having threads to interlock all plates into a pump unit with the gerotor unit nested within the same, and pin  774  precluding pull out of drive shaft  770  until unit disassembly. Also, as seen from  FIG. 95  alignment pins  760  are also elongated so as to extend through aligned holes in each plate as in alignment holes  799  and  797  for central plate  766  and top plate  792  ( FIG. 97 ). Alignment pins have enlarged heads  795  that are received as shown in  FIG. 95  and preferably locked in place upon annular ring  762  fixation to bottom plate  764  via fasteners F 5 . 
       FIG. 98  illustrates flex coupling  793  having slotted bearing shaft connection end  791  with slot  699  receiving lower, dual flat sided flex connector end  736  of bearing shaft  718  ( FIG. 92 ) for a torque transmission connection as shown in  FIG. 78 . Flex coupling  793  includes drive shaft connection end  697  having a shaft reception slot  695  rotated 90 degrees relative to slot  699  and designed to fully receive the upper, dual flat sided end  772  of drive shaft  770  ( FIGS. 78 and 95 ). Flex coupling  793  allows for accommodation of some misalignment between the bearing shaft and drive shaft, and helps to avoid premature failure of output manifold bearings or the load bearing surfaces of the pump itself. 
     As seen from  FIGS. 77 ,  78  and  99  and  100 , chemical inlet manifold  648  has a recessed region  693  for receiving the above described gerotor pump assembly as well as fastener reception holes  691  that extend through the inlet manifold to provide for connection with outlet manifold  646  in the stacked arrangement shown in  FIG. 78  (preferably with a compressed O-ring there between as shown in  FIG. 78 ).  FIGS. 99 and 100  also illustrate inlet manifold  648  having flat bottom surface  689  which can be placed on base  42  of the foam-in-bag dispenser. Fastener flange  649  also provides for fastening the pump assembly into a fixed position relative to base  642  (e.g., via fastener holes FA to a suitable flange reception area in base  42 ).  FIGS. 99 and 100  further illustrate chemical inlet port  687  formed in side wall  685  which wall is planar and surrounds port  687  and has fastener holes  683  (e.g., four spaced at corners in the planar wall surface  685 ). Fastener holes  683  and planar surface  685  provide a good mounting surface and means for mounting inlet valve manifold  652  shown in  FIGS. 101 and 102 . Inlet valve manifold is shown to have chemical line angle connector  650  in threaded engagement with housing block  681  having a longitudinal chemical passage  679  with outlet  665  for feeding inlet port  687  of inlet manifold  648  so that chemical can be fed to the gerotor unit. Housing block also has a vertical recess for receiving ball valve insert  677  which is connected at its end to grasping handle  675  (or an alternate handle embodiment as represented in  FIG. 78  with handle  675 ′) which is used to rotate valve insert  677  to either align the ball units passageway with the chemical passageway or block off the same.  FIG. 101  further illustrates mounting face  673  which has a seal ring recess  669  for receiving an O-ring and also illustrates the outlet ends of fastener holes  671  aligned with holes  683  for releasable, sealed mounting of inlet valve assembly  652  on inlet manifold  648 . 
       FIG. 103  illustrates housing  663  forming part of the hose and cable management system of the present invention. As seen from  FIGS. 1–5 , cable management housing  663  has a left to right width that conforms to the combined width of solvent tank  402  and extendable support assembly  40  and is also mounted on base  42  so as to provide a compact assembly that is readily mobile to a desired location. As seen from  FIGS. 1 ,  3  and  4  housing  663  houses chemical A pump assembly  44  and chemical B assembly  46  with the exception of the quick connect inlet valve manifolds  652  and  652 ′ connected to heated chemical hose lines  28  and  30 . As seen from  FIG. 103 , housing  663  includes cable side housing section  661  and pump side housing section  569 . These two sections are designed to mate together to form the overall housing configuration and have fasteners to connect them together. On the pump side section  659  there is provided quick release access cover  653  which covers over an access cut-out  651  provided in housing  663 . In a preferred embodiment, cover  653  is readily removed without fasteners (e.g., a slide/catch arrangement or a hinged door arrangement with flexible tab friction hold closed member (not shown)) and sized so as to provide for direct access to the inlet ports shown in  FIG. 99  for the inlet manifolds  648 ,  648 ′ and the fastener holes  683  and also overlapping valve handles  649 ,  649 ′ ( FIG. 77 ) for shutting off the outlet lines  43 ′ and  45  leading out from outlet manifold  646 . Thus, with the inclusion of inlet valve manifolds  652 ,  652 ′ at the end of the heated chemical hose lines  28 ,  30  an unpacked foam-in-bag system can be rolled into the desired location, and the inlet valve manifolds readily fastened to the inlet pump manifolds  648  and  648 ′, and when the system is ready for operation, inlet manifold valve handles  675  and  675 ′ can be opened with handles  649  and  649 ′ also placed in an open position for allowing chemical flow to the dispenser of the foam-in-bag system. If servicing is desired, the valve handles  649  and  649 ′ are closed off to isolate any downstream chemical, valve handles  675 ,  675 ′ are closed off to avoid any chemical outflow from the heated hoses and the inlet manifold valves  652 ,  652 ′ unfastened and removed. While in this valve closed situation, the flow of isolated chemical out of the pump head unit itself is minimal, there is also preferably provided block off caps  657 ,  657 ′ which are fixed in position close to the inlet manifold ports and can be quickly inserted as by threading or more preferably a soft plastic friction fit. Caps  657  and  657 ′ are also preferably fixed on lines to the pump assembly so as to always be at the desired location and  FIG. 77  shows capture hooks  655  and  655 ′ for mounting the caps in an out of the way position during non-use. 
     Hose and cable management means  663  receives within it portions of the chemical conduit hoses  28 ′ and  30 ′ running from the outlet of the in-line pumps to the dispenser and portions of electrical cables that originate at the dispenser end of the heater hoses. Between the dispenser and the management means  663 , the cables and hoses substantially (e.g., less than 2 feet exposed) or completely extend within the adjustable support  40 . Thus, there are no dangling chemical hoses or umbilical cables outside of the foam-in-bag system&#39;s enclosure areas, with the possible exception of the chemical feed hoses  28  and  30 , which supply chemicals from the remote storage containers, but can be fed directly from the service to the positioned lower pump inlet (e.g., a protected ground positioning and need not be heated, although a manifold type heater or a hose heater can be provided on the upstream side of the in-line pumps (e.g., to avoid situations where the chemical being fed to the in-line pumps is lower than desired) (e.g., below 65° F.)). A feature of the hose and cable management means of the present invention is that it can accommodate the lift of the bagger assembly which is shown in  FIG. 5  in a raised position (e.g., a 24 inch rise from a minimum setting). The ability of the cable management to both enclose and still allow for extension and retraction of the hose and cables provides a protection factor (both from the standpoint of protecting the cables and hoses as well as protecting other components from being damaged by interfering cables and hoses) as well as an overall neatness and avoidance of non-desirable or uncontrolled hose flexing. 
     In a preferred embodiment there is provided a dual-coil assembly  635  for the cable and hose sections enclosed in the housing. This dual-coil assembly includes one static or more stationary hose (and preferably cable) coil loop assembly  633  and one expandable and contractable or “service” coil loop assembly  631 . For clarity, only the chemical coil hoses are shown in the housing in the dual loop configuration although the power cables are preferably looped either together with the hoses or in an independent dual-coil set. In the embodiment shown in  FIG. 103  the hoses are marked at appropriate intervals and tied together (ties  629  shown) at these marks to create a static oval (e.g., a 15″ to 20″ (e.g., 17″) height or loop length L and a 7″ to 12″ (e.g., 10.5″) width) coil loop  633  which has its free hose ends  632  and  634  in connection with the internalized pump assemblies&#39; respective chemical outlets. The downstream or non-free end of static loop  633  merges (a continuous merge) into the upstream end of service coil  631  shown having less coil loops of about the same width when the system is at its lowest setting but longer length coils (e.g., 20–30″ (24″) L×8–12″ (10.5″) width). The length of each hose  28 ′ and  30 ′ is preferably less than 25 feet (e.g., 20 feet) and preferably long enough to accommodate the below described chemical hose/heater of about 18 feet±2 feet in coil assembly with the static loop set having about 3 to 7 coil loops and moving coil  631  preferably having less (but longer length coils) such as 1 to 4 coils with 2 being suitable. Thus, the vertical length of the cable set  631  is vertically longer than the stationary coil set in its most expanded state and the reverse (or equality) is true when the non-stationary coil is in its most contracted state. 
     Housing section  661  further includes cable and hose guide means  3467  which is shown in  FIG. 103  to include separation panel  639  which is fixed in position at an intermediate location relative to the spacing between main panels  647  and  645  of housing sections  569  and  661 . Separation panel  639  is shown with a planar back wall (no lower abutment flange unlike the opposite side) facing main panel  645  and an opposite side having mirror image curved mounts  643  and  641  with curved or sloped upper facing surfaces that are designed to generally conform with the generally static or fixed loop curvature of coil assembly  633 . Service coil  631  is positioned between panel  639  and housing back wall of section  645  and in an extended states extends down below the lower edge of panel  639 . Panel  639  has an upper cut out section  629  which provides space for an overhanging of the fixed loop and service loop merge portion  631  such that the static coil portion is on the opposite side of panel  639  as the service loop. As shown in  FIG. 103  the downstream ends  625  and  627  of the internal chemical A and chemical B conduit extensions  28 ′ and  30 ′ within the hose (and preferably cable) manager are arranged to extend vertically out of an open top of the house and into a reception cavity provided in the hollow support  40  positioned in abutment with housing  663  as shown in  FIG. 2 . 
     With the hose and cable management of the present invention, as the lifter moves up the service coil assembly contracts and gets smaller (tighter coil), while as the lifter moves down the service coil assembly expands back and gets larger or extends down farther. The hose sections in the static coil are arranged so as to avoid any movement as the movement requirement associated with a lifting of the bagger is accommodated by the larger coil loop or loops of the service coil assembly which, because of the larger size, is better able to absorb the degree of coil contraction involved. The number of each coil set depends upon the lifting height capability of the bagger assembly. In addition the arrangement of the housing and the separator panel help in ensuring proper and controlled contraction and expansion. Preferably the hoses and cables are also banded with colored shrink tubing to aid in the manual process of winding the coils within their respective enclosures or housing sections, which typically occurs in the factory before initial ship out and in limited service situations. Lining up the colored guide bands on each hose or cable will help ensure that the coil is wound correctly as a bad winding can cause serious damage to the system when the lifter goes up, as it can lift with over 500 lb. An additional advantage of the cable and hose management means of the present invention is the protection given to the heater wire lines within each of the chemical hoses extending downstream from the pump assemblies. By isolating the chemical lines, and providing limited and controlled motion for everything inside, the hose manager protects the heater wires from excessive bending, pulling, twisting, and/or crushing that could cause the heater wire to fail prematurely (e.g., these forces associated with uncontrolled movement and improper positioning of the hoses also represents a common cause of broken thermistors in the heater wire line representing one of the most common chemical conduit heater system failures). 
       FIG. 103  further illustrates mounting block  623  having a first side mounted to the housing and a second side attached to base  42  so the shorter dimension of the housing&#39;s base hangs off in cantilever fashion off the back flange of the base. The temperature in the two heated coiled chemical source hoses  28 ′ and  30 ′ in the cable and hose managing means preferably have temperature sensors to facilitate maintenance of the chemical at the desired temperature. The coiled hoses  28 ′ and  30 ′ are each provided with an electrical resistant heater wiring and feed through assembly and extend between the in-line pump assemblies  44  and  46  and output to the dispenser (e.g., manifold  199 ) or, if an in-barrel pump is utilized, between the in-barrel pump at the chemical source to the dispenser. Providing the chemical to the dispenser at the proper temperature provides improved foam quality. As an example, chemical precursors for urethane foam usually are heated to about 125 to 145° F. for improved mixing and performance (although various other settings are featured under the present invention such as below 125° F. to room temperature through use of catalyst or alternate chemicals, or higher temperatures above 145 degrees F. (e.g., 160 to 175° F. range) of different characteristic foam in higher density polyurethane foam). 
       FIG. 104  shows the heater conduit electrical circuitry or means for heating the chemical while passing through chemical hose  28 ′ (or  30 ′) provided in the hose management means and coiled for over a majority of their length preferably over 75% of their overall length.  FIG. 104  shows heater element  804  having a lead that extends from a schematically illustrated feed through block  807  providing means for separating a chemical contact side from an air side, with the heater element wiring received within the chemical hose and a feed wire extending externally to the feed through  87  to a control component in electrical connection with a source of power as in a 220 volt standard electrical source connection.  FIGS. 104 to 110A  illustrate various components of the heated chemical hoses  28 ′ and  30 ′ extending for about 20 feet between the outlet of the in-line pumps and manifold  199  mounted on dispenser housing  194 .  FIGS. 186 and 193  illustrate the control system designed to place and maintain the chemical at the desired temperature at the time it reaches the manifold  199 . By increasing or decreasing the amperage level to the below described chemical hose heater the desired temperature can be maintained. Also, with the design of the present invention an 18 foot heater element in the chemical conduit will be sufficient to provide a uniform temperature to the rather viscous and difficult to uniformly heat chemical processors A and B. The electrical heater in the hose extends from its mounting location with the feedthrough (mounted on the dispenser) back down through the coil toward the outlet of the in-line pump (or barrel pump) but need not extend all the way to the pump, as having the control and feedthrough end of the chemical hose heater at the dispenser end allows for the upstream end of the hose heater which first makes contact with chemical in the hose, to be located some length away from the pump source end such as more than 18 inches (which avoids an insulating wrapping of that end of the hose heater). 
       FIG. 104  illustrates feedthrough  807  in electrical connection with the control board with electrical driver and temperature sensor monitoring means by way of a set of wires extending from the air side of feedthrough  807 .  FIG. 109  illustrates electrical cable  801  received within the air side potting AP and the chemical side potting CP, with the potting epoxy utilized being suitable for the temperatures, pressure and chemical type involved such as the chemicals A and B. A suitable epoxy is STYCAST® 2651 epoxy available from Emerson Cumming of Billenca, Mass., USA. 
     The electrical cable set  801  is comprised of four separate leads  801 A,  801 B,  801 C,  801 D with  801 A providing the electrical power required for heating the heater element  804  to the desired temperature and with  801 B in communication with the return leg extending from the end of the heating element that is farthest removed from the feedthrough  807  and with  801 C and  801 D, providing the leads associated with the thermistor (or alternate temperature sensing means). The control schematic of  FIG. 193  shows the chemical hose heater driver circuit and temperature monitoring sub-system of the control system of the present invention.  FIG. 104  also illustrates in schematic fashion the control means  803  which is preferably provided as part of an overall control console or board for other systems of the illustrated foam-in-bag assembly as shown in  FIG. 186 . The driver for the hose heaters preferably receive power from a typical commercial grade wall outlet. When the heater element of the present invention is drawing full power (e.g., at start up to get the chemical up to the desired temperature), the voltage differential from one end of the heater coil to the other is typically the full AC line voltage, which varies depending on local power with a heater coil drawing at about 9 amps at 208 volts AC.  FIGS. 107 and 108  illustrate the feedthrough plate alone while  FIG. 109  illustrates feedthrough connector assembly  810  having feedthrough  807  comprised of an outer feedthrough housing block  812  and an interior insert  814  preferably formed of a material that is both insulating and can be sealed about the terminals (e.g., a molten glass application, although other insulating means as in, for example a material drilled through with an adhesive insulative and sealing injectable material filling in a gap) as shown in  FIGS. 107 and 108  with the illustrated glass insert having extending therethrough to opposite sides terminals T 1  to T 4 . As shown terminals T 1  and T 3  are more robust or larger terminals and are designed to handle a higher amperage than the smaller pins T 2  and T 4  with the larger preferably being 12 amp terminals and the smaller preferably being 1 amp terminals. Terminals T 1  to T 4  extend out to opposite sides of the feedthrough and are embedded in the AC and AP pottings providing casings with casing CP covering all exposed surfaces of the chemical side of terminals T 1  to T 4  and the associated wire connections shown bundled on the chemical side and generally represented by BS. Casing AP or the opposite side also cover all exposed surfaces of terminals T 1  to T 4  as well as the wire lead connections (e.g., solder and exposed wire portions) so as to leave no exposed, non-insulated regions susceptible to human contact (a deficiency in prior art systems). 
       FIGS. 109A ,  109 B, and  109 C illustrate feedthrough connector  810  in combination with dispenser connection manifold DCM. As shown in  FIG. 109B , feedthrough plate  807  is secured (note corner bolt fastener holes) to an end of manifold DCM. As shown in  FIG. 109C , dispenser connection manifold DCM for one of the chemicals (e.g., A) as well as the corresponding dispenser connection manifold DCM′ are secured at their projections PJ having central chemical port CCP (adjacent bolt fastener apertures to each side).  FIG. 104  also illustrates relative to the chemical side of the feedthrough which is received within the chemical hose  28 ′ and  30 ′, the coiled resistance heater  804 .  FIG. 109A  provides a cut away view of the heated chemical hose manifold  1206  (see  FIG. 14A  for an illustration of its mounting on the dispenser together with the other chemical hose manifold  1208 ) which houses feedthrough connector assembly  810 .  FIG. 109A  also shows the coiled heater element  804  received directly in the chemical side potting CP and connected to one of the robust terminals (e.g., T 1 ) while the return leg wire (not shown—included together with the thermistor wires on the chemical side  801 C′ and  801 D′) traveling in the interior of the coil extends through the potting CP and is connected to the other robust terminal (T 3 ). The last 18 to 24 inches of the coiled heater wire extending from the chemical potting is preferably wrapped or coated or covered in some other fashion with an insulative material as the chemical B is somewhat conductive and thus this covering avoids leakage in the area of metal components such as the receiving manifold  1206 . The remained of the coiled heater wire need not be covered (except for perhaps the run out portion of the wires extending out of the heater coil wire to bypass the thermistor head which occupies much of the interior of the coiled heater wire) thus saving the expense and cost associated with prior art heater coils extending from the pump end toward the dispenser. This wrapped end WR is represented in  FIG. 109  but is removed in  FIG. 109A  for added clarity. The opposite cable group  801  on the air side extends a short distance (e.g., less than 2½ fee such as 2 feet) to the controller thus reducing umbilical line cost for the heater element.  FIG. 109A  further illustrates O-ring or some alternate seal received with an annular recess ORR in the feedthrough contacting end of manifold  1206  and placed in sealing compression against feedthrough upon fastening the two together. Thus chemical being fed through chemical hose  28 ′ exits the end of the hose  28 ′ at the enlarged head HE with manifold engagement means (e.g., a threaded connection of a male/female connector—not shown). Also, although not shown in  FIG. 109A , the solvent entering the chamber in manifold  1206  is fed out of the chemical port CCP shown in  FIG. 109B  and into the main manifold  199 . 
       FIG. 106  provides a cross-sectional view taken along line H—H in  FIG. 109  showing the wires  801 B′,  801 C′ and  801 D′ and heater coil  804  received within hose casing HC which is a flexible and includes a Teflon interior TI and a strengthening sheath SS and outer covering OC. Although not shown for added flexibility the outer housing preferably has a coiled or convoluted configuration which extends to the interior conduit surface and which improves flexibility despite the fairly high pressures involved. The convolutions form a non-smooth, corrugated or ridged interior surface in the liner TI&#39;s interior surface (see below regarding the modified coiled heater element free end insert to facilitate the feed in of the coil into the hose conduit). 
     Teflon inner lining has a preferred ½ inch of open clearance for chemical flow and reception of the thermistor and heater wires. The illustrated hose  28 ′ is designed for handling the aforementioned pressures for the pumped chemicals (e.g., 200 to 600 psi) together with the flexibility required associated with the described environment including pressurization and bending requirements. Stainless steel swivel fittings (JIC or SAE type) are preferably provided on each end of any fittings between a chemical hose and any inlet manifold or other receiving component of the chemical pump assembly. The illustrated internal heater  804  is designed to be able to heat the chemical derived from the source which is typically at room temperature (which can vary quite a bit (e.g., −30 to 120° F. depending on the location of use) and needs to be heated to the desired temperature (e.g., 130° F.) before reaching the dispenser mixing chamber—with a length of 20 feet for the chemical hose being common in many prior art systems. In a preferred embodiment, an internal resistance heater wire  804  is snaked through the chemical hose conduit and is not physically attached to the inside diameter of the hose and the heater element of the heater wire is formed of uninsulated wire with a coil configuration being preferred and with a round or rectangular wire configuration (e.g., a ribbon wire) also being preferred. A preferred material is Nichrome material for the chemical hose heater wires. 
     The coiled heater element section of the heater wire received in the hose has a length which is sufficient to achieve the desired heat build up in the chemical but unlike the prior art arrangements (wherein the electrical connections are at the pump end and the heater wire had to extend for about the same length of the chemical hose to avoid cold shot potential), the present invention does not have to match the length of the chemical hose as there can be an unheated upstream section in the chemical hose leading up to the closest, first chemical end tip of the heater wire. The outside diameter ODW ( FIG. 106 ) for the heater coil (e.g., 0.35 inches) is made smaller than the hose fittings which the heater coil must be passed through. 
     As shown by  FIGS. 110 and 110A , the feed out leads  801 C and  801 D′ extend out from terminals T 2  and T 4  (less robust terminals) within the chemical conduit out to a chemical temperature sensor  828  assembly, which in a preferred embodiment includes a thermistor sensor THM glass rod thermistor device  830  encapsulated within thermistor casing  832 . Glass rod thermistor device preferably comprises a 0.055 to 0.060 diameter glass rod thermistor device  830  of a length about 0.25 inches with less than a half of its overall length exposed (e.g., a ¼ length exposure or 0.09 of a 0.25 inch long rod) by extending axially out from the central axis of the illustrated cylindrical casing  832 . Running internally within glass rod  830  is a pair of platinum iridium alloy leads (PI) leading to the thermistor sensing bead BE which is positioned at (and encompassed by) the end of the glass rod. The thermistor device is preferably rated at 2000 ohms at room temperature with a +/−0.5° F. accuracy and is designed for operating at high efficiency within a 125 to 165° F. range. The glass bead BE is provided within the thermistors glass casing which is designed free of cracks and bubbles to avoid undesirable chemical leakage to affect the bead. The thermistor device is further rated for a liquid environment of up to 1000 psi and designed to withstand the potential contact chemicals as in water, glycols and polyols, surfactants, and urethane catalysts and being able to operate within an overall temperature environment of 32 to 212 degrees F. 
     Thermistor casing  832  is preferably formed of epoxy (e.g., an inch long with a diameter which allows of insertion in the heater element coil—such as a 0.190 inch diameter) which encapsulates the leads  801 C′,  801 D′ (e.g., two foot long wires with 24 AWG solid nickel conductor with triple wrap TFE tape and with etched end insulation for improved bonding to epoxy). Inside casing  832  is also the noted portion of the thermistor glass rod  830  and stripped nickel leads  834  bowed for strain relief and welded or silver soldered to the platinum thermistor leads  836  with the latter extending both through the cylindrical casing and having a preferred thickness of 0.002 to 0.004 inch diameter and preferably welded or soldered to the nickel leads. The epoxy forming the casing is preferably transparent or translucent and should be thermal expansion compatible with the glass rod so as to avoid cracking of the same under thermal shock. As depicted in  FIG. 193 , the hose temperature control system senses the chemical temperature by measuring the resistance of the thermistor bead centered in the heater coil. The thermistor is designed to change resistance with temperature change, with a preferred design featuring one that has 2000 ohms at room temperature (e.g., 70° F.), and about 400 ohms at 130 degrees F.). 
       FIGS. 105 and 105A  illustrate in greater detail a section of heater wire  28 ′ (or  30 ′ as they are preferably made in universal fashion) with outer hose conduit casings removed to illustrate the heater means received within that casing along having coiled heater wire  804  and associated wiring having a thermistor sensing means  828  ( FIG. 110 ).  FIG. 105  illustrates the section of chemical hose  28 ′ in which the thermistor extends and thus includes a heater element return leg detour wherein the return leg  838  extends from its travel within the conduit to run for a period out of the coiled heater wire  804  so as to run parallel for a period and then and extends into connection with a corresponding (unoccupied) one of the heavy duty terminals T 1  or T 3 . Return leg  838  is preferably made from an insulated piece of round Nichrome or Nickel wire in a non-coiled form with suitable insulation as in PTFE of PFA insulation, in extruded or wrapped tape form. The return leg  838  that is opposite the one attached to the feedthrough terminal is attached to the end of the heater coil that terminates as coil. The heater coil and the return leg combine to close the heater circuit, so the same current that flows through the heater coil will also flow through the return leg. 
     As shown by  FIG. 105 , since the thermistor and leads for it extend from electrical connections at the dispenser end of the heated conduit the thermistor sensor&#39;s bead BE is placed in direct contact with the incoming flow of chemical. This provides for a fast response to changes in chemical temperature. That is, if the thermistor bead on the end face of the epoxy cylinder faces away from the flow as it is in prior art systems, its thermal response time will be increased, and accuracy of the temperature control will suffer. In other words prior art systems that extend the thermistor from the in barrel pump toward the dispenser instead of the opposite direction of the present invention fail to place the temperature sensor in contact with the incoming chemical flow direction unless an effort is made to reverse the direction in a prior art system which is a difficult and time consuming job that that can readily result in breakage of the delicate thermistor rod. In addition, the arrangement of the present invention is unlike prior art systems where the thermistor leads have to be taken outside the potted thermistor assembly and changed in direction by 180° as they exit the coil and run along together with the return leg. This 180° redirectioning was difficult to accomplish without damaging the coil or the thermistor leads. The prior art also featured Teflon shrink tubing in this difficult to manufacture section of the heater wire with Teflon shrink tubing being a material difficult to work with from the standpoint of high temperature requirements (in excess of 600° F.), requirements for adequate ventilation to remove toxic fumes, and uneven shrink qualities which can necessitate reworking. 
     As seen from  FIG. 105 , only the return leg for the heater coil runs outside of the hose around the thermistor assembly and the thermistor leads never have to leave the inside diameter of the heater coil and do not have to be looped 180 degrees to face the thermistor into the direction of chemical flow. In the transition zones ( 840 ,  842 ), where the return leg  838  exits and re-enters, the chemical hose and exiting or entering portion of the wrapped return leg is covered with ordinary (non-shrink) tubing as in Teflon tubing. Also, because of the positioning of the thermistor assembly (e.g., exact location within two feet of the in-line pump assembly if utilized or the dispenser if an alternate pump system is utilized which is a location positioned internally within the chemical hose and at a location not normally flexed or bent). 
     Accordingly, under the present invention, the thermistor is not as easily subject to mechanical damage when the chemical hose is flexed in its vicinity. This enhanced thermistor reliability is advantageous since flexing is a leading cause of thermistor failure, which is the foremost cause of heater wire failure, and changing heater wires is a difficult, time consuming, and messy job, so avoiding such failures is highly desirable. Also, there are advantages provided under the design of the present invention of having the heater wire connections (e.g., heater wire feedthrough) of the present invention positioned close to the electronics control (e.g., control board) to preferably within 4 feet and more preferably within 2 feet. In this way, the length of the electrical umbilical therebetween can be significantly reduced downfrom a standard 20 foot length in the industry to about 2 feet for example. Also, the umbilical cables are contained in the above described cable and hose management system, which avoids added complications such as having to use robust (SJO rated) wiring, because of the protective inclusion of the cable within the enclosure. An added benefit in the ability to place the shorter length umbilical connection within the housing  636  (e.g., formed of sheet metal) provides protection of the same from electro-magnetic interference (EMI) from the outside world and emits less EMI to the outside world such as other controlled systems in the foam-in-bag system. This feature enhances reliability and provides for easier certification as under the European CE certification program concerning EMI levels. A reduction down in the length from, for example an 18 foot long prior art umbilical cord with thermistor leads down to, for example a 2 foot length umbilical with significant cost savings relative to the often custom engineered, triple insulated wire, with nickel conductor. 
       FIGS. 112 and 113  illustrate an additional feature of the present invention associated with the heated chemical hoses  28 ′ and  30 ′ which have convolved interior surfaces.  FIG. 112  illustrates an alternate free-end chemical hose insertion facilitator  844 .  FIG. 112  shows a generally spherical tip  844  (e.g., referenced as the “true ball” embodiment) which is preferably comprised of Teflon body which is machined or otherwise formed. As seen from  FIG. 113 , tip  844  has a heater coil insertion facilitator end  846  and a chemical hose insertion end  848 . In the illustrated embodiment end  846  has a cylindrical configuration with sloped insertion edge  850  and a spherical or ball shaped end  848  connected to it. This arrangement provides for a rapid connection of end  846  in the free end of the heater coil as in, for example, a crimping operation wherein the insertion end  846  is crimped within the confines of a portion of the free end of the coiled heater element  804 . This design also avoids a requirement for shrink Teflon tubing or any type of tubing or wrap as the ball tip end is positioned far enough away from the end of the chemical hose so that leakage currents are negligible. The relative sizing is such that the ball tip diameter has a diameter that is larger than that of the heater coil diameter but smaller than the inside diameter of the hose conduit  28  and any hose fittings to provide for threading the heater coil within the protective sheathing. For example a size relationship wherein the inside diameter of the hose conduit lining (e.g., Teflon)  802  is about ½ inch, the ball diameter is made less than 0.5 inch and sufficient to allow for chemical flow (e.g., 0.2 to 0.30 inch, which generally corresponds to its axial length (e.g., a less than 20% slice in the true ball configuration and placed flush with the front end cylindrical extension). The cylindrical extension  846  preferably has a ½ inch axial length and a 0.20 inch diameter. The thermistor cylinder described above preferably has a 0.22 inch diameter. Other means of attachment than crimping include, for example, mechanical fasteners and/or adhesives or threading inserts, wrappings, formations, etc. The insertion facilitator  844  of the present invention provides for enhanced heater wire sliding or insertion through the braided flex cable  28  (or  30 ) relative to prior art designs such as the ones where the coil end is provided with a potted cylindrical block with a non-bulbous, generally pointed end. The present invention&#39;s design avoids the tendency to have the inserted pointed end of the prior art tip to catch along the hose convolutions. 
       FIG. 114  shows an alternate embodiment of a chemical hose insertion end  844 ′ (corresponding components being similarly referenced label with an added dash) formed from a rod of Teflon material. As in the earlier embodiment the axial length of the coil insertion end (which extends away from the bulbous insertion end) is preferably between a ½ inch to one inch (V 1 ) to provide sufficient crimping or securement connection surface area. The maximum diameter V 3  of the bulbous hose insertion smoothly contoured end  848 ′ is preferably about 0.260 inch, while the smoothly contoured head (half oval cross-section) has an axial length V 2  of abut a ¼ inch with V 4  for extension  844 ′ being about 0.20 inches to provide for a tight fit in the heater coil  804  before being crimped. 
     With reference back to the earlier described FIGS.  2  and  16 – 21  and the below described  FIGS. 115 to 138 , there is described a preferred embodiment of a film unwind system of the present invention.  FIGS. 115 and 116  provide a cross sectional view of the film support means  186  with spindle  222  supporting film roll  220  locked in position thereon and with spindle supported engagement member  232  providing driving communication from the web tension drive transmission  238  directly to film roll via a film roll core insert. Under the present invention web tension is monitored and controlled with the controller sub-system illustrated in  FIG. 192  (preferably in conjunction with the controller sub-system  191  used for film advance and web tracking). Web tension motor  58  is mounted on spindle load adjustment means  218  ( FIG. 16 ) that includes hinge section  242  or a support-to-spindle connector for achieving the previously described spindle load rotation between a load and film unwind state.  FIGS. 115 and 116  illustrate in greater detail the rotation drive arrangement for the spindle which includes web tension drive transmission  238  with main gear  900  encircling stationary support shaft extension  906  extending axially in and is received by hub pocket HP ( FIG. 15 ) formed in load support structure  240  and is fixed there with fastener  908 . Attached to main gear (e.g., see fastener  911  in  FIG. 115 ) is stub shaft  910  which rotates together with main gear  900 . Between fixed axial shaft  906  and the rotating stub shaft there is located first roller bearing  912 . Stub shaft  910  includes a free end minor step down over which is slid and fixed in position the illustrated radially interior cylindrical extension sleeve  914 . At the free end of fixed axial shaft  906  there is located a second roller bearing  915  which is in bearing contact with the rotating interior cylindrical extension sleeve  914 . 
       FIGS. 115 and 116  further illustrate spindle spline drive  917  which includes engagement member  232  and outer sleeve  918 . Engagement member  232  is shown independently in  FIGS. 117 to 122  while  FIGS. 115 and 116  show spindle spline drive  917  received by fixed interior cylinder  914  in a rotation transmission manner when the sliding or telescoping sleeve  918  is locked in position via locking fastener  934 , but with the capability to axial slide along sleeve  914  when locking fastener  934  is released. The interior annular surface  924  of outer cylindrical sleeve  918  is mounted over and onto the outer flange extension  920  of engagement member  232  of spindle spline drive  917 , and fixed in position through use of fasteners  921  extending through fastener holes  922  shown formed in a thickened base region  926  of engagement member  232  as best shown in  FIG. 120 . Fasteners  921  are threaded through fastener holes  922  into threaded reception holes formed in the abutting edge of outer cylindrical shaft  918 . Radial extension flange  928  extends radially off base region  926  out for a distance sufficient for film roll contact retention as shown in  FIGS. 115 and 116 . Thus, when fastener  934  locks cylindrical sleeves  914  and  918  together, the connection of engagement member  232  to outer sleeve  918  provides for transmission of the rotation gear  900  and stub shaft rotation to roll  20 . Intermediate cylindrical shaft  932  has an inner surface which is concentrically spaced relative to the outer surface of interior cylindrical sleeve  914  and has an open forward end into which is inserted the base of roll lock assembly  228 . The free end of the outer cylindrical sleeve  918  has a radially inward extending annular bearing ring BR in contact with sleeve  932 . 
       FIGS. 115 and 116  illustrate a relatively short (e.g., 12 inch roll) extension state in the roll support wherein there is spacing “SP” between the interior end of stub shaft  910  and the engagement member of spline drive  917  (e.g., 6 to 10 inches). Upon detaching locking fastener  934  (one or a plurality of circumferentially spaced fasteners), the combination of engagement member  232  and outer sleeve  918  can be slid to reduce spacing SP while annular ring BR slides on sleeve  932 . When SP is reduced down a sufficient amount, drive spline  917  is sufficiently placed away from the opposite core plug  977  location to handle a larger axial length roll, (e.g., a 19 inch roll). For example, with spacing SP down to 0 to 6 inches, there is a provided a more elongated roll length support arrangement. In a preferred arrangement SP is reduced by 7 inches to switch from a 12 inch roll to and 19 inch roll. Upon such a reduction of SP empty fastener hole  934 ′ becomes aligned with empty thread hole  934 ′ and fastener  934  inserted to lock into the mode. 
     Thus, spindle  222  is comprised of a plurality of cylindrical sleeves that fit tightly into a telescoping assembly, either extending or contracting to provide for different film width usage on the same support spindle. The ability to adjust for different film width provides the overall system with much greater versatility then prior art systems, with the ability to drive the roll adding web tensioning capability having the below described advantage. While only two roll film widths (e.g., 12 inch and 19 inch) are illustrated in the preferred embodiment, variations are featured under the present invention including the number of adjustment options (e.g., three, four, five or more) or limiting the device to one size whereupon the telescoping arrangement can be removed, or various other roll width support adjustment means being provided as in a helical groove having a series of holes with a spring electronically controlled latch or with a geared or hydraulic telescope arrangement as means for adjusting spindle roll reception length as a few examples. 
     As noted  FIGS. 117 to 121 , engagement member  232  of spline drive  917  (which is preferably a plastic or metal molded member as in a casting or plastic injection mold product) features a plurality of locking members  952  which are shown in the referenced figures as being a plurality of protrusions spaced (preferably equally) about the circumference of base region  926 . In a preferred embodiment the protrusions or means for engaging are teeth shaped and feature a sloped lead in section  964  and a tooth base  962  presenting a straight line side contact surface extending parallel to the axis of rotation. Also in a preferred embodiment the lead in sections  964  are provided by a triangular extension with the apex positioned at a location spaced farthest from the base, with the apex shown being one that is circumferentially centered relative to the opposite straight side walls of the base presenting a “house profile” plan configuration. The base is preferably at least about 50% and more preferably about 60–80% of the total axial length of the tooth to ensure good rotational engagement with the corresponding roll plug  977  described below, which in a preferred embodiment features similar shaped teeth pointed in the opposite direction such that the triangular, sloped or divergent apex portion are less than the total base axial length. In this way, there is a portion of base side wall to base side wall contact between the teeth of the roll core plug and the teeth of the spline drive engagement member. Also, there is preferably a friction fit contact between the adjacent base portion of the roll film drive plug received within the roll film core and the base of the spindle spline drive or engagement member  232  (a minimum of circumferential play, as in less than a ⅛ inch play, between adjacent most different source teeth enhances web tension control is preferred). For example, in a preferred embodiment there are 12 teeth on each of the roll drive plug ( 997 ,  FIG. 12 ) and the spindle drive spline engager each occupying about 15° of the supporting base surface for the radially protruding teeth and each spaced by about 15° so as to provide a no play circumferential engagement that is preferred for good web tension control relative to the offset but similarly spaced teeth of the below described roll insert. A variety of alternate roll film drive plug and spindle drive spline engagement means are also featured under the present invention such as a set of deflectable tabs that preferably have curved or cammed surfaces designed for receipt within reception cavities in one or the other of the interengaging members with the deflectable cam surfaced tabs being adjustable in the axial direction with sufficient separation force but arranged for non-adjustable rotational drive engagement. Alternate engagement means includes, for example, axially extending pins or fasteners in one that are received in corresponding recesses in the other for rotational drive engagement. 
     The mate and lock means of the present invention, illustrated by the intermeshing protrusions for each of the spindle drive spline and roll drive spline ( 997 ,  FIG. 132 ), with the web tension motor  58 , facilitates providing a positive drag or drive to the film  216  ( FIG. 14B ) of the film source roll  20 . For if the core  188  ( FIG. 12 ) were allowed to slip on the outside diameter of roll spindle  222 , web tensioning at the preferred level of control would be made more difficult to achieve. Spindle spline drive engager  232  is thus sized to properly mate both axially and radially with roll film drive  997  which in turn is preferably sized to provide a no slip interrelationship relative to the core  188  having the film wrapped thereon. 
       FIGS. 117 to 121  illustrate engagement member  232  (monolithic preferred but can be multi-component as well) of spline drive  917  well suited for providing accurate web tensioning and having a cylindrical section  938  extending the full axial length from radial base  926  out to the rim  940  with a smooth interior surface  924  which provides for the axial adjustment shown in  FIGS. 123 and 124  when the locking fastener  934  is disengaged. As seen from  FIG. 118 , radial extension flange  928  extends radially out from the base end of cylindrical section  938  and has a roll side surface out from which extends thickened base region  926  (forming teeth  952 ) that extends toward rim  940  but ends axially short of rim  940  so as to define step down wall  942  ( FIG. 120 ). Step down wall  942  extends radially inward into the thinner cylindrical free extension portion  920  of cylindrical section  938  (while the preferred embodiment features a cylindrical configuration for the spindle and roll drives, various other configurations are also featured under the present invention which are compatible with a supported film source as well as various other meshing arrangements which provide for rotational drive transmission while preferably also allowing for axial sliding off and on of rolls when roll latch  228  is released). 
       FIGS. 118 ,  120  and  121  further illustrate fastener holes  922  being aligned so as to open out at open ends  948  ( FIG. 120 ) close to the radial inner edge of step down wall  942  where, upon insertion of outer cylindrical shaft  918  with its rim thread apertures ( FIG. 116 ), fasteners  921  can be inserted through the four holes (with enlarged fastener head end recesses  950  as shown in  FIG. 120 ) and threaded into aligned holes in the rim of outer cylindrical shaft  918 . The fastener holes are shown in  FIGS. 120 and 121  as being aligned with the thickest regions of the thickened base region where the teeth  952  are formed. With reference to  FIG. 122  there can be seen teeth  952  and the parallel straight edges  954 ,  956  at their base and the sloping mating initiation edges  958 ,  960 . As seen from  FIG. 122 , thickened base region  926  preferably represents about ⅔ of the entire length of cylindrical section  938  with a ⅓ of that length represented by free extension portion  920  with exterior surface  944 . Within the exterior surface of thickened base region  926 , the tooth base  962  represents about ⅔ of the axial length of thickened base region  926 , with the remaining ⅓ occupied by the sloped mating tooth portion  964  (shown separated by an imaginary dashed line in  FIG. 122 ). 
       FIGS. 125 to 129  provide additional views of embodiments of roll latch  228  with the cross sectional view of  FIG. 128  illustrating its mounting on the end of cylindrical shaft  932 . Roll latch  228  includes outer housing  966  having a handle adjustment slot  983 , an upper handle reception recess  963 , an interior central recess  969  for receiving axial adjusting and biased pivot ball contact plate  968 . Plate  968  is shown attached to housing  966  by way of a plurality of springs  990  ( FIG. 129 ) and slidingly received within cylindrical recess  972  formed in insert plug  974 . Insert plug is attached (e.g., screw(s)  975 ) to the open end of tubular shaft  932  and has a Z-shaped cross section so as to share a common peripheral surface with that of shaft  932  at its outer end and to provide a stop or limit to plate  968 . Housing  966  is fastened to plug  974  by way of fasteners  976 . Ball end securement means  978  receives and captures the pivotable ball  980  of lever  982 . Lever  982  has an opposite end section extending into an axial cavity in the handle  984 . Handle  984  further includes a curved lower end  986  which functions in cam fashion to facilitate movement between a lock mode wherein the handle is in contact and fixed in position on a peripheral edge of the housing&#39;s cavity  963  and slot  983  and plate  968  is pulled axially within housing  966  so as to compress biasing springs  990 . This positioning causes sliders SL to move causing an outward rotation of the catch levers  988  in to a roll lock position as shown in  FIG. 127 . 
     Upon on operator adjusting the handle so as to have the handle cam surface move from the periphery of the housing into handle catch recess  963  the springs are free to axially move the plate away from the housing causing the sliding pins to draw in the locking levers upon contact with the pivotable lever ends and counterclockwise rotation of the levers. Thus upon adjustment of the handle, catch levers  988  (preferably three or four equally circumferentially spaced about the housing) are moved between the above noted lock location and into an unlocked location wherein the handle lever is generally aligned axially with the central axis of shaft  932  and received within handle cavity  963  with the latches  988  in a retracted state allowing for the removal or insertion of roll core  220 . As shown in  FIG. 126  a spherical ball  984  without surface extension  986  is suitable as well for the handle. A comparison of plate  968  in  FIGS. 125 and 126  illustrates the sliding axial adjustment that is relayed by slider pins  992  into radial adjustement of catch levers  988 .  FIG. 126  also illustrates three catch levers in operation. 
       FIGS. 130 and 131  provide a perspective and a cross-sectional view of roll assembly  994  (a 12 inch version illustrated although a, for example, 19 inch version would have the same features but for an axially longer core and film roll) comprising core  996  (e.g., a 4″ outer diameter core) with roll film drive or core plug  997  and roll support core plug  998  positioned at the opposite open ends of core  996 . 
       FIGS. 132 to 134A  illustrate roll film drive core plug  997  designed for mounting and rotation transmission with spindle spline drive  917  as described above. As shown in the cross sectional view of  FIG. 134 , roll film drive core plug  997  includes a peripheral flange  995  having a core plug rim contact surface  996 ′ for limiting the degree of insertion of core plug in core  996 . The core plugs at each end are preferably sized for tight frictional fit with the interior surface of the core which are preferably formed of a cardboard material, although friction enhancing serrations or some other more permanent position retention means as in fasteners or sharpened catches, spring biased tabs are also featured under the present invention. Alternatively, non-disposable cores can be manufactured out of plastic or the like combining the core and core insert compounds into a single monolithic device. 
     As with the spindle spline drive  917 , the illustrated roll film drive core plug  997  is preferably an injected molded monolithic element that is designed to mate with spindle spline drive at the base of the roll spindle  222 . As shown at  FIG. 132 , plug  997  includes interior teeth  991  formed as thickened portions formed on an interior surface of a continuous cylindrical extension  989  which extension further includes a free cylidrical extension  987  shown stepped in by  FIG. 134  and having an edge rim  985 .  FIG. 132  illustrates that the teeth can be formed by radially extending depressions corresponding with the inwardly radially extending teeth  991  which are separated by the adjacent non-radially extending or neutral sections  981  formed between and at the base of the teeth. This relationship provides for the above described mating with the spindle spline drive engagement member  232 . Also as shown in  FIG. 132  there is a common base band BB which is the interior surface of edge rim  985  and extends about the roots of the teeth  991 . The sizing of the teeth are similar to those described above for engagement member  232 . Also the interior surface of band  985  is generally commensurate with the interior planar surface of teeth  991  and thus represents the portion slid along spline until meshes in supported fashion with the base of the spindle drive assembly. 
       FIGS. 135 to 138  illustrate roll support core insert  977  which is preferably formed with a double walled cylindrical section  975  having an outwardly extending flange at a first end  973  which provides an insertion limitation means relative to the core as it is slid into position into the open end of the roll film core. In addition, double walled cylindrical section preferably has a plurality of strengthening spokes  971  circumferentially spaced about the circumference of the core plug and in between the respective walls of the double wall cylinder. Also, radial protrusions PT extend out and enhance fixation of roll core insert  977  within core  996  upon the forward transverse edge TE embedding in the softer material of the core. The combination of the two roll film core plugs provide sufficient axial support relative to the preferably cardboard or plastic roll core either in a suspended state relative to the outer cylindrical sleeve  918  or in frictional contact over the length of the outer spindle cylinder. 
     With reference to  FIGS. 9 ,  12  and  14 B, there is illustrated the path of film exiting the film roll supported on the spindle extends tangentially off the top of the film roll and into contact with the forward side of idler roller  114 , and then up as shown in  FIG. 14B  into engagement with the rear side of upper idler roller  101  where it is redirected downward. From idler roller  101 , film  216 , in its preferred C-fold form, is separated over a portion of its non-fold side (the fold side passing externally and in front of the front end  196  of the dispenser  192 ) and then brought back together as both sides of the film enter the nip roller assembly comprised of drive nip roller pair  84  and  86  supported on shaft  82  and driven nip roller pair  74 , 76  on shaft  72  (in a preferred embodiment a pair of rollers is supported on each shaft with a preferred intermediate spacing although alternate arrangements are also featured under the present invention such as single, full length rollers provided on each shaft). Reference is again made for  FIGS. 17–21  following the above explanation as to how the roll core is locked in place and is rotated and (electronically) controlled based on its relationship with the spline drive driven by web tension motor in communication with a controller preferably with a general or web tension dedicated processor.  FIG. 192  illustrates the control and interfacing features of the film tensioning sub-system (as well as the spindle latch release sub-system). This ability to control film tension and to counteract film slacking events provides advantages over the prior art devices relying on braking for example, in an effort to avoid film slacking. 
     The present invention thus features electronic (e.g., digital signal) web tension control that provides for film tensioning and tracking. Film tension and tracking relates to how the film is handled once it is loaded into the machine. Any film handling or bag making system is only as good as its ability to control tension and to provide proper tracking for the moving web. Poor control of web tension has a negative effect on web tracking, which can cause all sorts of problems with bag quality. The preferred present invention features means for providing active, digital control of web tension, provided by, for example, the illustrated DC motor/encoder  58  driver (motor), which is mounted directly to the film roll spindle and the transmission line from the motor to the roll as explained above. The motor torque, hence web tension, is accurately controlled by the system processors, and based on algorithms installed in the system processors to carry out the below described web tensioning functions. 
     Under the arrangement of the present invention, the active control capability allows the present invention to adjust tension in the web in response to the rapidly changing dynamics of the bag making process. This type of active web tension control is beneficial with this application, because it can even move the roll backwards, unlike prior art passive or braking web tensioning systems wherein web tension may be lost if the film drive rollers run in reverse, which such prior art devices do at the end of every bag making cycle to pull the film away from the cross-cut wire. For example, the web tensioner on a commonly used prior art device provides web tension via a set of spring loaded drag plates that are positioned to drag on the ends of the film roll. This has proven to be a system with significant room for improvement. 
     Under the present invention tension control is available while the system is in an idle mode. During idle mode, the web tension torque motor of the present invention pulls back on the film (being fed through the system by the nip rollers and associated nip roller driver) with a slight torque, just enough to keep the film from going slack. The motor torque for the web tension driver, hence the web tension, are controlled by the main system control board in conjunction with a correspondingly designed motor control circuit (e.g., tach motor encoder EN— FIGS. 17 and 192 ) that allows the system to control torque via the control of current through the motor windings. 
     The present web tensioning means is also active in controlling tension while dispensing film. For example, while running, the web tensioning control takes into consideration dynamic changes, such as inertia and roll momentum changes based on the continuous decrease in mass of roll film. For example, in a preferred embodiment, film level monitoring is achieved through a continuous monitoring of the DC motor on the film unwind shaft (film roll support) and compared to the film advance motor. For instance, the rotational momentum of the film roll is considered in the calculation of motor torque when the roll is starting or stopping. When starting film drawing, the torque on the motor will be rapidly reduced so as not to over tension the web. When stopping film drawing, the torque on the motor will be rapidly increased so that the film roll&#39;s own momentum does not overrun and cause the web to become slack. The web tensioning device thus works in association with the film feed rollers and other sensors such as system shut down triggering. 
     In a preferred embodiment of the invention, tension calculation includes consideration of film roll diameter by way of knowledge of the tach sate of the film advance motor and web tensioning motor. The control system of the present invention and the web tensioning device of the present invention provide for adjustment in the torque in the web tension motor based on, for example, the amount of film left on the spindle. Motor torque will generally be higher when there is less film on the roll, to make up for the loss of moment arm due to the smaller radius film roll. The encoder on the back of the web tension motor, in conjunction with data on speed of the film drive motor on the nip rollers, provides the information that the control system uses to calculate film roll diameter using standard formulation. 
     An additional advantage of the web tension system of the present invention is in the ability of the system to sense when out of film as well as when approaching a film run out state (roll diameter sensed at a minimum level and signal generated as in an audible sound—so as to facilitate preparation for roll replacement when the roll does run out as described below). Encoder EN on the back of the web tension motor  58  provides the system controller with the ability to sense a run out of film on the film roll. If the roll runs out of film, the web tension motor will have nothing to resist the torque that it is generating, so it will start to spin, more rapidly than normal, in the reverse direction. This speed change is sensed by the encoder, which is monitored by the system control board, which will quickly shut the system down as soon as it occurs. This provides an efficient out-of-film sensing mechanism, and uses no extra components. Thus the present system can be run until it completely runs out of film, and then safely shuts down. An added benefit with such a system is that there are no wasted feet of film left on the roll, and the audible or some other signaling means indicating running low allows the operator to be in a ready to replace state when the system does indeed shut down upon completion of a film roll. 
     In addition to the web tension system rapidly detecting an out-of-film situation, the web tension system of the present invention also provides a film jam or the like safety check and shut down. For example, if there is a film jam somewhere in the system, and the film can no longer move forward in response to the turning of the drive and driver rollers  74 ,  76  and  84 ,  86  or nip rollers (a likely occurrence in response to a major foam-up), the nip rollers keep turning, but the web tension motor stops turning as there is sensed no film feed occurring. In other words, the system controller sees that the encoder pulses from the web tension motor are not keeping up with the speed of the film as determined by the speed of the film drive motor on the nip rolls. The discrepancy causes a quick shutdown, and can save the system from further damage. Once again, no additional components are required for this feature illustrating the multifaceted benefits associated with the web tensioning and monitoring film unwinding means of the present invention. 
     By utilizing, for example, the control and monitoring system of the present invention with the film tension and film advance/tracking sub-systems of the present invention, there can be achieved high performance web tensioning under the present invention. The web tensioning, control and monitoring involves, in one technique, the calculation of film roll size to determine motor torque. That is, the film drive motor (that drives the aluminum nip roller) has an encoder signal that allows the central processing unit to monitor its speed of rotation, by counting the number of pulses received during a known time. The motor produces about 200 encoder pulses per revolution. 
     Since the film does not slip between the two nip rollers, if you know the diameter of the driven nip roller and its speed of rotation, you can easily calculate the web velocity.
 
Web Velocity=(Roller RPM)×(Roller Circumference)
 
     Where:
         Web Velocity is measured in inches per minute   Roller RPM is the revolutions per minute of the film drive roller   Roller Circumference is the circumference of the film drive roller measured in inches. Calculated as (Π×Roller Diameter)       

     The other motor on the web path is located on the film unwind spindle. Its purpose is to provide web tension so that the web does not become slack during operation. Slackness in the web will usually lead to film tracking problems, which are highly problematic to the foam-in-bag process. 
     The web tension motor must not be allowed to over-tension the web, as this can create serious problems like film stretching, tearing, or slippage in the nip rolls. 
     This motor also has an encoder output, which, for example, provides 500 pulses per revolution. This encoder output is used, in conjunction with the encoder signal on the film drive motor, to calculate the diameter of the film roll on the unwind spindle. The film roll diameter gets smaller as the film is used, and suddenly gets larger when a roll is replaced. 
     The roll diameter can easily be calculated, when the film is moving at a steady speed, by comparing the web velocity to the angular velocity of the film roll as it unwinds. 
     Roll Diameter can be calculated as follows:
 
Roll Diameter=(Web Velocity)/[Π×(RPM of Web Tension Motor)]
 
     Where web velocity is calculated by the formula shown above, and the RPM of the Web Tension Motor is measured by the encoder on the output shaft of the web tension motor. For instance, RPM of the web tension motor can be calculated by dividing the number of encoder pulses received per minute by the number of encoder pulses in a complete revolution. 
     The film roll diameter is informative because the torque output of the web tension motor is preferably adjusted as a function of the diameter, to maintain web tension, as measured in pounds per inch of web width, at a constant level. The tension motor torque will track armature current very closely, with a response time measured in milliseconds. 
     Motor Torque is related to Web Tension in the following equation. This equation applies to the greatest extent if the motor and the web are moving at a constant velocity, or are stationary. If the motor and the web are accelerating or decelerating, the equation relating these two variables involves further adjustment which takes into consideration the acceleration of deceleration with associated acceleration/deceleration formulas.
 
Motor Torque=Desired Web Tension×Web Width×Film Roll Diameter/2
 
     Where: 
     a) Web Tension is measured in Pounds per Inch of Web Width 
     b) Web Width is measured in inches 
     c) Roll Diameter is measured in inches 
     d) Motor Torque is measured in Inch-Pounds 
     The central processor controls the torque output of the web tension motor by, for example, measuring and controlling the current flow through the armature coil of the motor. In a preferred embodiment, the web tension motor is a Permanent Magnet DC Brush Motor. In this type of motor, output torque is directly proportional to armature current. The intention of this control system is to maintain within the parameters involved a constant web tension. 
     As noted above, the web tension motor can be used in other situations to help keep web tension constant, or to change it as desired. 
     For long idle periods, where the system is left idle for long periods, the web tension can be reduced to a lower level than what is normally used during operation. This will extend the life of the motor, by reducing current flow through the brushes. 
     For a starting of web motion, during the start of the bag making cycle, the web has to be accelerated to its final velocity. This means that the web has to yank the film roll to get it moving, an act that inherently increases the web tension because the film roll has rotational inertia. During these acceleration periods, the web motor torque can be reduced to compensate for the increase in tension that is inherent to accelerating the film roll. This reduction is preferably based on trial runs and a monitoring of performance of the web tensioner forgiven roll settings. 
     At the end of the web motion, or the end of the bag making cycle, the film roll has to stop, or a lot of slack will be induced into the web. Since the rotational inertia of the film roll is quite high, the web tension motor torque must be increased to prevent the roll from overrunning the web as it comes to a stop. As with the start of motion, this torque profile is typically determined through trial runs. 
     The encoder output on the web tension motor also provides shutdown information that is useful to machine operation. For example, if the nip rolls are turning, and the web tension motor is not turning, then something has jammed the web. An immediate machine shutdown is required. If this happens at the end of a film roll, it probably means that the tape holding the film to the core is too strong, and the film cannot pull off the paper core. This appears to be a jam as far as the machine control system is concerned. 
     Also, if the web tension motor turns in reverse of its direction of rotation when the film is unwinding, then the roll is out of film. When the film pulls off the core, at the end of a roll, this is the expected shutdown mode. 
     Another problem with film feed in prior art systems is poor web tracking. Web tracking refers to the direction of the film as it runs through the machine. If tracking is good, the film runs straight and true through the machine, with the centerline of the web path being very close to the centerline of the nip rollers. If web tracking is poor, the film will track to the left or to the right, with the centerline of the web shifted from the centerline of the nip rolls. Tracking becomes an issue when the film tracks away from the edge seal wire. This results in a bag without an edge seal, which can easily become a bag that leaks foam on the operator, the product that the operator is trying to package, or simply onto the factory floor. In the present invention there is provided a web tracking adjustment means represented by the adjustment mechanisms  98  and  100  (earlier described with reference to  FIG. 7 ) which feature screw adjustable plates that the upper shift idler roller either horizontally, vertically or both. The means is preferably used at the factory for offsetting any tolerance deviations that might lead to off line tracking, and locked in place prior to shipment. However, the adjustment mechanism can also be adjusted by the operator such that field adjustment is possible if needed. 
     A comparison of  FIG. 7  with the film advance/tracking controller sub-system shown in  FIG. 191  illustrates the control systems arrangement for carrying out the film advance and monitored. As shown, the control board comprises, for example, the central processing unit working in conjunction with a field programmable gate array (“FPGA”) and control circuitry receiving signals and sending data on the real time characteristic of the film advance. The FPGA can receive programmed data input from the memory stored in the processor upon machine start up, for example.  FIG. 7  illustrates the drive roller shaft  82  being driven by driver  80  whose output shaft is in direct engagement with the roller shaft via step down gearing  1000  of driver  80 , with driver  80  also preferably comprising a brushless DC motor  1002  with encoder sensor  1004  as in the previous discussed motor  200  for the mixing module drive assembly. As described above, the control board film advance sub-system shown in  FIG. 191  can thus monitor, via the encoder sensor, the status of the drive roller shaft  82  with fixed roller set  84  and  86 . As shown in  FIG. 7 , for example, each roller ( 84 ,  86 ) includes slots for receiving canes  90  supported on fixed rod  92  to help avoid undesirable film back travel. This monitoring is useful for monitoring general tracking of film feed and, as noted above, can be used in conjunction with the web tension driver encoder to monitor system conditions like the above noted film out condition. 
       FIG. 198  provides an illustration of a film advance versus tension motor ratio and its use in monitoring the relationship between roll usage and the interrelationship between the film advance and web tension tachometer feed to the control system. The “shot number” along the X-axis illustrates a history line of the number of dispensed shots for a given bag volume and foam output volume (useful in comparison from one roll to the next as to film usage). This information is useful in the monitoring of film re-supply needs as described in the above noted provisional application entitled “System and Method For Providing Remote Monitoring of a Manufacturing Device”. As described in that application, the remote monitoring, and re-supply of material capabilities facilitated with the control system of the present invention. 
     For example, three main supply requirements for a foam-in-bag dispenser are film (for bags), chemicals (for foam) and solvent (to prevent foam build up in the valving/purge rod and a tip of dispenser). To monitor solvent, there is provided a certain volume solvent container (e.g., 3 gallons) that is in line with a metering pump (e.g., a pump that dispensers a fixed volume of fluid with every cycle (e.g., 0.57 ml based on a preferred 3 pump pulses of 0.19 ml per bag cycle). The controller thus receives signals from the pump as to cycles and/or correlates with bag cycle history such that by monitoring the number of cycles of known solvent volume usage there can be determined usage of solvent and when re-supply is needed. The solvent container also has a float valve or the like which signals when a first low level is reached and sends out a warning via controller interfacing. There is also provided an even lower level sensor that when triggered shuts down system to prevent purge rod binding and other problems involved with no solvent flow is provided. With the monitoring of solvent level based on usage and/or container levels, a new supply of solvent can be automatically sent out from a supplier when there is reached either a certain level of closed amounts or a container level signal following a review of history of usage for machine (re-supply could be triggered by the first low signal or at a higher level depending on re-supply time etc.). 
     A somewhat similar arrangement is provided to monitor the chemical usage for re-supply, for example. The preferred gerotor pump system used to pump the chemical to the dispenser is not a fixed volume pump per se so there is monitored with the controller the chemical mass of each bag produced is maintained in the database. This is a calculated field based on the ‘dispenser open time’ and the respective flow rate standard with the know source supply (e.g., a 55 gallon drum) a monitoring of usage and re-supply needs can be actively made by the controller. 
     One way to monitor the film usage is to use the encoder on the nip roller set to determine number of rotations and with estimated film passage length per rotation can compare against overall length on a roll of film or film source. Under the present invention there is an alternate way to monitor film usage and that is to utilize facets of the above noted web tensioning comparison wherein the output of the film tensioning system (e.g., the encoder of a web tension torque motor having a torque drive transmission system in direct engagement with a roll core drive insert) and the output of a motor driving the nip roller set are used with the controller to compare the interrelationship, and with a review of roll unwinding charcteristics a determination can be made as to how much film has been fed out from the roller. The comparison of motor torque method is the preferred method since it is independent of the machine keeping track of when a roll of film is changed and how much film is on the roll. The DC motor on the film unwind shaft is constantly being monitored and compared to the film advance motor to compensate for the continual decrease in mass of a roll of film. 
     Operator servicing under the present invention is also greatly facilitated. For example,  FIG. 139  provides an enlarged view of the roller set assembly shown in  FIG. 7  as well as a close up view of the front door latch handle  87  which is a component of the adjustable front panel access means  1006  for gaining access to the below described components as depicted in  FIG. 140 . As shown in  FIGS. 139 and 140 , door access latch handle  87  is fixed to door latch rod  85  which has opposite end cam latches  1008  and  1010  non-rotatably attached to latch rod  85 . Cam latches  1008  and  1010  are shown in  FIGS. 139 and 140  as having hook or engagement means designed to engage with the stub pin supports  1012  and  1014  ( FIG. 7 ) supported on upper forward regions of first and second side frames  66  and  68 . Front face pivot frame sections  71  and  73  also have a top end connected with door latch rod  85  and are positioned inward and in abutting relationship with respective cam latches  1008  and  1010 . The opposite ends of front face frame sections  71  and  73  are pivotably attached to front pivot rod  70  secured at its ends to the left and right side frames  66  and  68 . 
     As seen from  FIG. 140 , front face frame sections  71  and  73  feature bearing support platforms  1016  and  1018  receiving in free roll fashion the opposite ends of shaft  72 . Bearing support platforms are shown as being releasably attached to the interior side of front face frame sections  71  and  73  to facilitate servicing or replacement of the preferably knurled aluminum driven nip rollers  74 ,  76  as well as edge seal  91  shown in  FIG. 140  sandwiched between its bearing mount  1022  also supported on shaft  72 . Unlike rotating rollers  74  and  76 , however, edge seal  91  remains stationary as the shaft rotates internally within bearing mount  1022 . For opposite free edge film or non-C fold film embodiments a similar edge seal as  91  can be positioned at the opposite end of shaft  72 . 
       FIG. 140  also illustrates heater jaw  1024  with its sealing face  1026  exposed upon adjustment of the access panel into the panels exposed, service facilitating state (rotated down in the illustrated preferred embodiment).  FIG. 139  illustrates the front of heaterjaw assembly  1024  in its operational position aligned with the aforementioned moving jaw  118 . The preferred embodiment features having the heating wires (cutting as well as sealing in the preferred embodiment shown) used to cut and seal the end of one bag from the next on the heated jaw  1024  and to have the heated jaw  1024  fixed in position relative to moving jaw  118 . A reversal or sharing as to heat wire support and/or wire backing support movement are also considered alternate embodiments of the present invention. Having the moving mechanism positioned out of the way under the bagger assembly is, however, preferable from the standpoint of stability and compactness. Also, having the heater wires on the accessible door facilitates wire servicing as described below. Heater jaw assembly  1024  is shown rigidly fixed at its ends to the front face pivot frame sections to provide a stable compression backing relative to the moving jaw  118  and is positioned, relative to the direction of elongation of frame sections  71  and  73  between the aforementioned driven roller set and the pivot bar  70  to which the bottom bearing ends  1028  and  1030  of frame sections  71  and  73  are secured. 
     With the cam latches and handle in the front face closed mode (shown in  FIG. 139  and  FIG. 7  with latches  1008  and  1010  engaged with pin stubs  1012 ,  1014 ), the driven rollers are positioned in proper nip location in relationship to the drive rollers  84  and  86  that are preferably of a softer high friction material as in an elastomer (e.g., natural or synthetic rubber) to facilitate sufficient driving contact with the film being driven by the rollers. In addition to proper film drive positioning brought about by the latched front access door arrangement, the heater jaw is also appropriately positioned to achieve a proper cut and/or seal relationship relative to the opposite jaw. As shown by  FIGS. 2 ,  15  and  15 A, front access door is preferably enclosed or covered over with front access panel  1032 , which is shown in  FIG. 15A  to be pivotable about a vertical access and then slideable back along side frame  68  as shown by the same door referenced  1032 A in  FIG. 15A  to provide for rotation down of the frame sections  71  and  73  (which can also be provided with an integrated outer cover facings supported, for example, as the exterior of heater jar  124 ).  FIG. 15B  shows a side elevational view of front access door  181  in a flipped down state ready for servicing ( FIG. 15B  also shows the spindle in the replace roll mode—although to avoid contact between the spindle and front access door it is preferable to carry out the roll servicing and front access door component servicing at separate times as it provides for a more compact overall system). As shown in  FIG. 15A  face plate  1034  is secured at its opposite ends to the frame sections  66  and  68 , and supports touch pad button set  1036  for operator manipulation (e.g., a set of bag size control panel buttons). The buttons are connected by electrical wires to the aforementioned control board in a fashion which does not interfere with the pivoting open of the front face plate  181  and supported front panel  1034 . The control board is in communication with a modem or the like for remote data exchange as described in Provisional Patent Application Ser. No. 60/488,102, filed on Jul. 18, 2003 and entitled “A System And Method For Providing Remote Monitoring of a Manufacturing Device” which is incorporated herein by reference.  FIG. 15B  provides a front view of the bagger assembly similar to  FIG. 3  but with a ghost line outline of the interior components and of a possible conveyor line CL for automated or supported feeding of boxes or the like to receive a foam filled bag. As seen, main front panel  1032  extends from the top of the bagger assembly down past the upper edge of the front face panel  1034  supporting button set  1036  when the assembly is in an ready for operation mode. As seen from  FIG. 15A , following a pivoting and sliding away of main face panel  1032  into a service mode position, access can be had to the dispenser and other components of the bagger assembly, as front face panel  1034  is exposed and free to rotate about its lower horizontal pivot axis to provide access to the components supported by pivot frame sections  171  and  173  as shown in  FIG. 140 . 
       FIG. 140  also illustrates the ease of accessibility to either the drive or the driven roller set provided by the flip open feature of the present invention. Whether it be access for cleaning where the rollers need not be removed or freedom to remove any of the rollers for replacement or roller servicing, the flip open access feature of the present invention renders such activity easy to achieve.  FIGS. 139 and 140  also illustrate removable drive shaft exterior bearing retention block  1038  and interior bearing extension block  1040  with the former having releasable fasteners which upon removal allow for the larger sized exterior bearing block to be removed and the entire drive roller assembly axial slid out form the bagger assembly. 
     The flip open front door access means of the present invention provides easy access to the sealing jaws, seal wires, cut wires, and the various substrates and tapes that cover the jaw face(s). Opening the door provides full visibility, greatly easing the task of servicing the sealing jaws to provide the inevitably required periodic maintenance (e.g., cleaning of melted plastic build up and/or foam build up). 
     With reference to  FIGS. 140 to 144 , there is provided a discussion of the heated wire supporting jaw  1024  and the easily accessible and serviceable supported cut and sealing wires.  FIG. 141  shows the complete heater jaw assembly  1024  and  FIG. 143  shows an enlarged view of the left end of heater jaw assembly  1024 . As shown, heater jaw assembly  1024  includes base block  1042  which is a solid bar formed of, for example, nickel chromium plated steel having good heat resistance and heat dissipation qualities as well as minimal load deflection and thermal expansion qualities. For enhanced heat resistance and avoiding heat build up in the base block, there is preferably provided a high heat resistance thermal barrier layer  1044  (shown in cut away in  FIG. 141 ) between the heated resistance wires  1046 ,  1048  and  1050  (preferably in a seal/cut/seal wire sequence). Barrier  1044  is preferably a removal barrier to avoid degradation of a more expensive and less easily replaced component of the system. An adhesive Teflon tape is well suited for this purpose. Base block  1042  features opposite end indented sections  1052  and  1054  forming underlying projection supports for electric contact housings  1056  and  1058  formed of an insulating material (e.g., plastic) and having internal electrical connectors which are designed to transfer current between the fixed electrical wire connectors  1060  extending out from the housing&#39;s bottom and the housing&#39;s interior plug reception contacts (not shown) and to provide information to the controllers heat wire control and monitoring sub-systems as shown in  FIG. 187 . As a preferred embodiment provides both sealing and cutting means together relative to the just formed and just being formed bag border, there is featured seal wires  1046  and  1050  positioned to opposite sides of the intermediate cut wire  1048 . Because of their different functions, seal wires are preferably flat or ribbon wires that provide for a strip area seal (SE 1 ,  FIG. 111 ) at the bottom of a just being formed bag and the top (SE 2 ) of a just formed bag. As the intermediate wire  1048  is providing a cutting function a circular cross section wire is utilized. 
       FIGS. 142 and 143  show that each seal and cut wire has opposite ends fixedly secured (weld or solder preferred) to one of the illustrated support plates  1062  which are flat metal conductive plates having an enlarged conductor pin securement base leading to a converging extension to which the ends of the seal and cut wires are secured (see  FIGS. 142 and 143 ). Conductor pins  1064  are provided at each end of the heater wires and each features grasping pin head  1066  with cylindrical base  1064  which receives and secures in position conductor pin extension  1068  and an upper recessed section for easy grasping. Leaf type spring members can also be provided in either the male or female portions of the pin connection. Pin extension  1068  preferably has a threaded base or upper end to which threaded nut  1070  is secured to compress plate  1062  into a fixed level relative to the bottom of grasping pin head  1066 . The portion of pin extension to be received in the electrical contact housing  1058  is elongated and thus is fixed in position by way of a sliding friction fit in one of the conductive reception ports  1072  provided in contact housing  1058 , although an optional expansion leaf spring  1074  embodiment such as illustrated in dashed lines in  FIG. 143  is also featured under the present invention. Each reception port  172  is maintained insulated at the plate  1062  level by barriers  1076  (e.g., a plastic flange extension in the injection molded reception housing block  1056 ). Also, the upper end of each reception port is recessed relative to the upper exposed surface of the heating jaw base block (or upper surface of layer  1044  when utilized) such that the thickness of the fully threaded and plate compressing nut  1070  places plate  1062  at the desired suspension height level away from the base block&#39;s upper surface. To achieve the desired seal versus cut differential, there can be implemented, for example, variations in relative height of the wires  1046 ,  1048  and  1050  from the block as noted above and/or, differences in wire material or form (e.g., as in the illustrated ribbon versus circular cross-section wire forms) and/or electrical power supply via the control. As seen from  FIG. 143  a significant portion of the ends of the wires extend over at least a third of the upper surface of the plates  1062  so as to provide secure engagement and to facilitate the maintenance of high tension and minimal intermediate “droop” deflection. 
     In addition to the access door opening providing easy access to the heater wires, the heater wire conductor pairs connection in the heater jaw assembly is such that they can be quickly removed and replaced without tool requirements and there positioning, upon return relative to the underlying support, is ensured at a precise location. Heater wires generally last for over 100,000 bag cycles, although a cleaning at every 5000 or so cycles is likely to be required for good performance. The access door allows for quick and easy periodic checks (e.g., operator determined or based on a prompt from the control means to the display panel described in greater detail below). Also the ease of access allows for a quick check as to the condition of the covering layer on the moving and fixed jaws which is usually a Teflon tape that typically requires replacement after every 20,000 to 30,000 bag cycles. The moving jaw also preferably has a silicone rubber pad SR supported by the jaw base (See  FIG. 140 ) which typically requires replacement in prior art systems at about 100,000 bag cycles. This too is made easy to accomplish as the jaws can be readily accessed and readily removed, if desired. Also, the control means preferably monitors the number of bag cycles and can prompt the operator when the number of bag cycles suggests cleaning or replacement is in order as with the other components made more easily accessible by the flip open door, or induce an automatic order as described in Provisional Patent Application filed on Jul. 18, 2003 and entitled “Control System For A Foam-In-Bag Dispenser,” which is incorporated by reference. 
       FIGS. 139 and 140  also illustrate door movement limitation means or door stop  1078  which comprises connection rod  1080  extending through fixed reception member  1082  having a passage through which the rod extends and a base secured to the fixed frame  68 . At the free end of rod  1080  there is provided clip  1084  to prevent a release of the rod from member  1082  and a stop means to limit the downward rotation of the fixed jaw and front access door. The opposite end of connector rod  1080  is connected to part of the flip open access door such as front face pivot frame structure  71 . Thus, the hinged access door is precluded from rotating freely down into contact with fixed frame structure of the bagger assembly. Additional damping means DA is preferably also provided as illustrated in  FIGS. 9 ,  139  and  140  featuring a pair of constant force negator springs arranged in mirror image fashion to counteract forces generated by the springs at their fixed positing on the support extending up from frame structure  88 . The negator springs are held in a bracket support BT and connected by way of a cable past the two illustrated redirection pulleys to connection to hinged front door. The coil spring damper thus allows for controlled opening of the relatively heavy front access door with supported roller set, fixed jaw and other noted components. Damping means other than the illustrated coil arrangement or also featured in the present invention, such as a hydraulic dampening device and/or helical spring member to provide greater control during the rotation undertaken by the hinged access door. 
     An additional advantage provided by hinged access door is the ease in which the film can be threaded through the nip rolls (or released as, for example, when a change in film size is desired). The threading of film through the rolls is simplified, as the operator now has an easy way to separate the nip rolls as opposed to the difficult threading or pushing and drawing of film between the fixed roller sets of the prior art which prior art technique leads to a significant amount of film being wasted before a smooth and hopefully properly aligned/tracking film threading is achieved (e.g., it is estimated that on average 5 to 10 feet of film is wasted in the threading procedure before the film straightens and smoothes). Under the present invention, the access door can be opened to further separate apart the nip roller sets and the film played out into position (e.g. by hand or by using a feed button on the control panel) between the nip rollers and the film tends to naturally stay flat or, if not flat, a quick wiping action will achieve the same whereupon the operator merely needs to close the access door (using the handle  87  to lift up and then rotate the access door&#39;s cam latch into locking position). The only film wasted is the length of film that extends beyond the cutting wire, prior to the first cut being made. 
     An addition advantage of the access door flip open feature is easy access to the edge sealer assembly  91 AS. Edge sealer assembly  91 AS is described in greater detail below and comprises replaceable edge seal arbor mechanism  1104  featuring arbor base  1108  and a heater wire supporting arbor assembly  1106  with, for example, plug in ends similar in fashion to those described above for the end sealer and cutter wires. Thus the access provided by the door allows for either replacement, servicing or cleaning of the entire edge sealer assembly  91 AS or individual components thereof such as the arbor or just the double pin and heater wire combination or the below described high temperature heater wire under support. One of the standard prior art edge sealers typically requires cutter wire servicing about every 20,000 to 30,000 bag cycles or less. As noted above, the prior art are considered to have a high service requirement as compared to the present invention, and thus under the present invention, the service cycle can be set greater than 30,000 for this service feature, again preferably with prompting by the control system which monitors the number of bags formed and can either visually and/or audibly provide the operator with such prompting (e.g., menu screen as described in U.S. Provisional Application No. 60/488,009, filed Jul. 18, 2003 and entitled “Push Buttons And Control Panels Using The Same,” which is incorporated by reference. 
     An additional not easily accessed and difficult to service component of the dispenser system is the roller canes  90  ( FIG. 7 ) used to prevent undesired extended retention of the film on the driving nip roller. With the access made available by the access means of the present invention, an operator or service representative can readily clean or replace a cane  90 . As seen from  FIG. 140 , and the view of the driven roller assembly shown in  FIG. 144  with driven shaft  72  and driven rollers  74  and  76 , as well as the cross-sectional view of the same in  FIG. 145 , edge seal assembly  91  is mounted on shaft  72  which is preferably a precision ground steel support shaft supporting aluminum (knurled) driven rollers  74  and  76 . Edge seal assembly  91  is shown as well in  FIG. 7  on the right side of driven shaft  72  (viewing from the front of the bagger) in a side abutment relationship with driven roller  76 . The cross sectional view of  FIG. 145  shows driven roller  76  preferably being formed of multiple sub-roller section with driven roller  76  having three individual sub-roller sections  76   a  and  76   b  which are included with edge. Edge seal assembly  91 AS includes edge seal  91  and roll segments  1100  and  1102 . 
     Thus with this positioning, edge seal  91  is the sealer that seals the open edge side of the folded bag. The open edge side is produced by folding the film during windup of the film on core  188  ( FIG. 11 ), so the folded side does not need to be sealed and can run external to the free end of the suspended dispenser. The present invention features other bag forming techniques such as bringing two independent films together and sealing both side edges which can be readily achieved under the design of the present invention by including of an additional edge sealer assembly on the opposite driven roller such as the addition of a seal assembly as a component of roller  74   a . The open side edge side of the film is open for accommodating suspended dispenser insertion and is sealed both along a direction parallel to the roller rotation axis via the aforementioned heated jaw assembly and also transversely thereto via edge sealer assembly  91 AS. 
       FIGS. 146 to 152  illustrate in greater detail a preferred embodiment for edge seal assembly  91  AS featuring first and second sub-rollers  1100  and  1102  and edge seal arbor mechanism  1104  having arbor assembly  1106  on the film contact side of the driven roller and arbor base  1108  on the opposite side.  FIG. 149  illustrates each sub-roller  1100  and  1102  has a pocket cavity  1110  and  1112 .  FIGS. 151 and 152  illustrate sub-roller  1102  with pocket cavity and with the cavity interior surface  1114  having a pair of screw holes  1116  spaced circumferentially (diametrically) around it, that open out at the other end as shown in  FIG. 151 . Thus, edge seal roller  1102 , which is positioned on the side of the edge seal  91  that is closest to the center of elongation of shaft  72 , is attached to adjacent driven sub-roller  76   b  by insertion of screws SC ( FIG. 145 ) through screw or fastener holes  1116  and into receiving thread holes formed in driven sub-roller section  76   b . This arrangement thus ensures that the sub-roller  1102  will not drag with the edge seal unit, causing it to rotate more slowly than the rest of the driven nip rollers. Sub rollers  76   a  and  76   b  are each secured to shaft  72  with a fastener as shown in  FIG. 145  as is roller  74 . The edge seal sub-roller  1100  positioned on the outer side closest to the adjacent most end of driven shaft  72  is attached to the closest of the shaft collars (in  FIG. 145 )  1120  positioned at the end of driven shaft  72  and secured to the shaft to rotate together with it. Shaft collar  1120  forces edge seal sub roller  1100  to also rotate as a unit with the shaft  72  in unison with sub-roller  1102  but is independent of that sub-roller except for the common connection to shaft  72 . 
       FIG. 149  shows that extending within and between pocket cavities  1110  and  1112  is edge seal sleeve  1122  which is shown alone in  FIG. 153  and functions as a means for providing a site of attachment for the edge seal base  1108  and a positioner for arbor assembly. Sleeve  1122  includes a cylindrical housing having an axially centrally positioned slot  1124  that extends circumferentially around for ½ of the circumference of the sleeve  1122  and occupies about a third of the entire axially length of sleeve  1122 . Sleeve  1122  further includes fastener hole  1125  positioned on the solid side of sleeve  122  diametrically opposite to slot  1124 . In addition to locating arbor base  1108 , sleeve  1122  further functions as means for supporting cylindrical roller bearing  1126  which is preferably secured by way of a press fit into the sleeve and arranged so that the driven shaft  72  runs through the center of the bearing  1126  and the large radius on the bottom surface of the arbor assembly rests on the exposed (slot location) surface of the bearing&#39;s outside diameter. Rollers  1128  or other bearing friction reduction means are arranged around the interior or inside diameter of the roller bearing and protect the surface of the bottom surface of arbor assembly so that the arbor assembly is unaffected by the rotating shaft and thus not worn down by that rotation. This provides for the feature of precision positioning and maintenance of the compression depth of the below described edge seal wire into the surface of the elastomeric or compressible material of the opposite drive roller  84  ( FIG. 7 ) to be maintained which provides for high quality seals to be formed and extends the life of arbor assembly  1106 . In other words, the seal compression depth, which controls the length of the sealing zone (and venting zone) and the pressure of the sealing wire on the film has a significant influence in the quality of the edge seal.  FIG. 149  further illustrates seal rings  1130 ,  1133  positioned around the opposite axial ends of bearing  1126 . 
       FIGS. 155 and 156  illustrate arbor base  1108  of edge seal arbor mechanism  1104  with  FIG. 156  showing a cross section taken along cross section vertically bisecting the arbor base shown in  FIG. 155 . Arbor base  1108  functions as an edge seal base unit to provide a mounting base for arbor assembly  1106 . As shown in  FIG. 150  arbor base  1108  has a central semi-circular recess that has radius Ra which is the same as the radius Rs of the exterior of sleeve ( FIG. 150 ). The interior radius RB of sleeve  1122  conforms to the exterior radius of bearing  1126  and with the interior radius of bearing  1126 RC conforms to the exterior radius of shaft  72  such that the edge seal unit is able to stay in place as the roller bearings accommodate the rotation of shaft  72  and as the adjacent sub-rollers  1100  and  1102  rotate. Arbor base  1108  is formed of an insulative material such as Acetyl plastic which is machined to have the illustrated configuration. Fastener hole  1125  in sleeve  1122  is also in line with fastener passage  1132  formed in arbor base  1108  such that sleeve can be mounted to the arbor base  1108  with a small flat head screw, for example.  FIG. 156  also shows electrical pin reception passageways  1134 ,  1136  formed in the enlarged side wings of arbor base  1108  with each having an enlarged upper passageway section  1138  ( FIG. 156 ) which opens into an intermediate diameter inner passageway  1140  which in turn opens into a smaller diameter lower passageway section  1142 . The lower passageway section  1142  opens out at the bottom into notch recesses  1144  and  1146 . 
       FIG. 150  further illustrates elongated cylindrical, electrically conductive contact socket sleeves  1148  and  1150  nested in intermediate passageway  1140  for each of the passageways  1134  and  1136 . Socket sleeves  1148  and  1150  are dimensioned for mating with bottom electrical contact pins  1152  and  1154  having enlarged heads  1156 ,  1158  for sandwiching electrical contact leads  1160 ,  1162  and  160 ′,  1162 ′ to the base edge of the arbor base provided within a respective one of notched recesses  1144  and  1146 . Thus the electrical contact leads  1160 ,  1160 ′ and  1162 ,  1162 ′ are held in position and placed into electrical communication (e.g., power and/or sensing electrical lines) with the interior of sleeves  1148  and  1150  via respective contact pins  1152  and  1154 .  FIG. 188  illustrates the control sub-system for controlling and monitoring the performance of edge seal  91 . 
       FIGS. 157 to 178  provide illustrations of a preferred embodiment of edge seal arbor mechanism  1104  which functions to position an edge seal wire  1182  in a stationary and contact state relative to film being fed therepast and which is designed to provide a high quality edge seal in the bag being formed. Edge seal arbor mechanism  1104  comprises arbor assembly  1106  and the aforementioned arbor base  1108 .  FIGS. 157 to 163  illustrate arbor assembly  1106  having arbor housing  1168  having an outer convex upper surface  1170 , central bottom concave recessed area  1172  conforming in curvature to the exterior diameter of bearing  1126  and outer extensions  1174  and  1176  which extend out to a common extent or slightly past the wing extensions of arbor base  1108 .  FIG. 168  illustrates a preferred arrangement for the intermediate portion of upper convex surface or profile for housing  1170  (between the straight slope sections as in  1188 ″ described below) and concave lower surface  1172  which share a common center of circle and with  FIG. 168  illustrating in part concentric circles by way of concentric sections C 1  and C 2  (e.g., diameters for example, of 1.25 inch for C 1  and 2.5 for C 2  partially shown in  FIG. 168  with dashed lines). 
     As shown in the cross-sectional view of  FIG. 159 , arbor assembly  1106  further comprises contact pins  1178  and  1180  extending down from respective outer sections  1174  and  1176 , and sized to provide a friction fit connection in the arbor base  1108  in making electrical connection with respective electrical contact sleeves  1148  and  1150 . Pins  1178  and  1180  are preferably very low in resistance so as to minimize alterations in the below described sensed parameters associated with the edge seal heater wire  1182  being powered via the connector pins  1178  and  1180 , which are preferably of similar design as the plugs  1068  ( FIG. 143 ) used in the end seals/cutter wires. A suitable connector features the gold sided flex pin connectors available from the Swiss Company “Multicontact” having a very low ohm characteristic. Thus, as shown by  FIGS. 146 and 150 , two lead wires extend out from each of the insertion holes for pins  1178  and  1180  powering the heater wire. Lead lines  1160  and  1160 ′ are preferably the power source lines and more robust than parallel sensor lines  1162 ,  1162 ′ which are less robust as they are designed merely as a sensor wire leading to the control center for determination of the temperature of the edge seal heater wire. A similar arrangement is utilized for each of the seal/cut bag end heater wires  1046 ,  1048 ,  1050 . 
     The edge seal system of the present invention provides for the measurement and control of the temperature of the seal wire (e.g., the edge seal wire and cross-cut/seal wire(s)). This is achieved through a combination of metallurgic characteristics and electronic control features as described below and provides numerous advantages over the prior art which are devoid of any direct temperature control of the sealing element. The arrangement of the present invention provides edge sealing that is more consistent, shorter system warm-up times, more accurate sizing of the gas vents (e.g., a heating to melt an opening or a discontinuance of or lowering of temperature during edge seal formation, longer sealing element life, and longer life for the wire substrates and cover tapes). 
     Under a preferred embodiment of the present invention control is achieved by calculating the resistance of the sealing wire, by precisely measuring the voltage across the wire and the current flowing through the wire. Once the current and the voltage are known, one can calculate wire resistance by the application of Ohm&#39;s law:
 
Resistance≈Voltage/Current or  R=V/I 
 
     Voltage is preferably measured by using the four-wire approach used in conventional systems, which separates the two power leads that carry the high current to the seal wire, from the two sensing wires that are principally used to measure the voltage. In this regard, reference is made to the above disclosure regarding the use of low ohm connector plugs to avoid interference with sensed voltage and current readings and the discussion above concerns leads  1060 ,  1060 ′,  1062  and  1062 ′, two of which provide the wires for sensing. 
     This technique of using finer sensor wires eliminates the voltage loss caused by the added resistance of the power leads, and allows a much more accurate measurement of voltage between the two sensing wire contact points. This feature of avoiding potentially measurement interfering added resistance is taken into consideration under the present invention as the measurements involve very small resistance changes, in the milliohm range, across the sealing wire (e.g., 0.005 Ω). While this discussion is directed at the monitoring and controlling of the edge seal wire, the same technique is utilized for the cross-cut and cross-seal wires. 
     Under a preferred embodiment, current is calculated by measuring the voltage drop across a very precise and stable resistor on the control board and using Ohm&#39;s law one more time. The voltage and current data is used by the system controls to calculate the wire resistance in accordance with Ohm&#39;s law. Resistance is preferably calculated by the ultra fast DSP chips (Digital Signal Processing) on the main control board, which are capable of calculating resistance for a sealing wire thousands of times per second. 
     To determine and control temperature (e.g., changes in duty cycle in the supplied current), the measured resistance values must be correlated to wire temperatures. This involves the field of metallurgy, and a preferred use of the temperature coefficient of resistance (“TCR”) value for the seal wire utilized. 
     TCR concerns the characteristic of a metallic substance involving the notion that electrical resistance of a metal conductor increases slightly as its temperature increases. That is, the electrical resistance of a conductor wire is dependant upon collisional process within the wire, and the resistance thus increases with an increase in temperature as there are more collisions. A fractional change in resistance is therefore proportional to the temperature change or 
                 Δ   ⁢           ⁢   R       R   0       =     α   ⁢           ⁢   Δ   ⁢           ⁢   T           
with “α” equal to the temperature coefficient of resistance or “TCR” for that metal.
 
     The relationship between temperature and resistance is almost (but not exactly) linear in the temperature range of consequences as represented by  FIG. 197  (e.g., 350 to 400° F. sealing temperature range and 380 to 425° F. cutting temperature range for typical film material). The control system of the present invention is able to monitor and control wire temperature because it receives information as to three things about every seal wire involved in the dispenser system (edge seal and end seal/cut wires). 
     (1) The electrical resistance of the wire involved at the desired sealing temperature (this is achieved by choosing wires that provide a common resistance level at a desired heating wire temperature set point (with adjustment possible with exceptence of some minor deviations due to the non-exact linear TCR relationship)). 
     (2) Approximate slope of the resistance vs. temperature curve at sealing temperature; and 
     (3) The measured resistance of the wire at its current conditions. 
     Thus, in controlling the edge seal wire under the present invention there is utilized a technique designed to maintain the seal wire at its desired resistance during the sealing cycle. This in turn maintains the wire at its desired temperature since its temperature is correlated with resistance. The slope of the R vs. T curve or data mapping of the same can also be referenced if there is a desire to adjust the setpoint up or down from the previous calibration point calibrated for a wire at the set point temperature (e.g., an averaged straight line of a jagged slope line). Initial wire determination (e.g., checking whether wire meets desired Resistance versus Temperature correlation) preferably involves heating the wires in an oven and checking to see whether resistance level meets desired value. Having all wires being used of the same resistance at the desired sealing temperature setpoint greatly facilitates the monitoring and control features but is not essential with added complexity to the controller processing (keeping in mind that a set of wires sharing a common resistance value at a first set point temperature may not have the same resistance among them at a different set point temperature due to potentially different TCR plots). In this regard, reference is made to  FIG. 199  illustrating a testing system for determining temperature versus resistance values for various wires. The test system shown in  FIG. 199  is designed to determine the resistance of the wires at three temperatures, Ambient, 200 F and 350 F. This test was performed on wires in a “Tenney” thermal chamber (from Tenney Environmental Corp.) at the desired temperature. The instrumentation used to measure the resistance was an Agilent 34401A Digital multimeter using 4-Wire configuration. Temperature measurements were taken with a thermocouple attached to the wire under test. Temperature measurement was taken using the Omega HH509R instrument. Ambient temperature was set at 74.6 F. (The Fluke measurement device being replaceable with the same Omega model). 
     As can be seen from the forgoing and the fact that different metals and alloys have different TCR&#39;s, the proper choice of metal alloy for the sealing element can greatly facilitate the controlling and monitoring of sealing wire temperature. For a desired level of accuracy, the wire must deliver a significant resistance change so that the control circuits can detect and measure something. The above described controller circuit design can detect changes as small as a few milliohms. Thus, there can successfully be used wires with TCR&#39;s in the 10 milliohm/ohm/degF range. 
     Some currently commonly used wire alloys, like Nichrome, are not well suited for the wire temperature control means and monitoring means of the present invention because they have a very small TCR, which means that their resistance change per degree F. of temperature change is very small and they do not give the preferred resolution which facilitates accurate temperature control. On the other hand, wires having two large TCR jumps in relation to their power requirements (also associated with resistance and having units ohms/CMF) can lead to too rapid a burn out due to the avalanching of hot spots along the length of the wire which is a problem more pronounced with longer cross-cut wires as compared to the shorter edge seal wires used under the present invention. For the edge seal of the present invention, an alloy called “Alloy 42” having a chemical composition of 42 Ni, balance Fe with (for resistivity at 20° C.) an OHMS/CMF value of 390 and a TCR value 0.0010 Ω/Ω/° C. Alloy 42 represents one preferred wire material because it has a relatively high, (yet stable) TCR characteristic. The edge seal wire has improved effectiveness when length is ½ inch or less in preferred embodiments. Another requirement of the chosen edge seal wire is consistency despite numerous temperature cycle deviations, which the Alloy 42 provides. 
     For lower seal heat requirements, there is the potential for alternate wire types such as MWS 294R (which has shown to have avalanche problems when heated to too high a level) and thus has limited usage potential and thus is less preferred compared to Alloy 42 despite its higher TCR value as seen from Table II. As an example of determining TCR wire characteristics, Table I below illustrates the results of tests conducted on a one inch piece of MWS 294R wire. The testing results are shown plotted in  FIG. 199 . 
     
       
         
           
               
             
               
                 TABLE I 
               
             
            
               
                   
               
               
                 EDGE SEAL WIRE MWS 294R 
               
            
           
           
               
               
               
            
               
                   
                 TEMP 
                 RES 
               
               
                   
                   
               
               
                   
                 AMB. 
                 .383 
               
               
                   
                 110 F. 
                 .325 
               
               
                   
                 120 F. 
                 .320 
               
               
                   
                 130 F. 
                 .305 
               
               
                   
                 140 F. 
                 .278 
               
               
                   
                 150 F. 
                 .269 
               
               
                   
                 160 F. 
                 .262 
               
               
                   
                 170 F. 
                 .263 
               
               
                   
                 180 F. 
                 .264 
               
               
                   
                 190 F. 
                 .279 
               
               
                   
                 200 F. 
                 .297 
               
               
                   
                 210 F. 
                 .316 
               
               
                   
                 220 F. 
                 .350 
               
               
                   
                 230 F. 
                 .350 
               
               
                   
                 240 F. 
                 .365 
               
               
                   
                 250 F. 
                 .380 
               
               
                   
                 260 F. 
                 .392 
               
               
                   
                 270 F. 
                 .396 
               
               
                   
                 280 F. 
                 .418 
               
               
                   
                 290 F. 
                 .430 
               
               
                   
                 300 F. 
                 .422 
               
               
                   
                 310 F. 
                 .440 
               
               
                   
                 320 F. 
                 .425 
               
               
                   
                 330 F. 
                 .430 
               
               
                   
                 340 F. 
                 .426 
               
               
                   
                 350 F. 
                 .428 
               
               
                   
                   
               
            
           
         
       
     
     As seen from the above table for the typical heater wire levels, the MWS 294R wire (29 Ni, 17Co., balance Fe) shows a relatively large resistance jump per 110° F. temperature increases (with an increase of about 0.012 ohms per 10° F. being common in the plots set forth above and illustrated in  FIG. 197 ) and features an OHMS/CMF value of 294 as seen from Table II below setting forth some wire characteristics from the MWS® Wire Industry source. Using the testing device shown in  FIG. 199 , a TCR plotting can be made and an X-axis to Y-axis correlation between desired temperature set point and associated resistance level can be made for use by the controller as it monitors the current resistance level of the wire and makes appropriate current adjustments to seek the desired resistance (temperature set point level). While Alloy 42 can be used for the cross-cut seal in certain settings, in a preferred embodiment a stainless steel (“SST 302”) wire also available for MWS® Wire Industries is well suited to use as the cross-cut wire in providing sufficient TCR increases (TCR of 0.00017—toward the lower end of the overall preferred range of 0.00015 to 0.0035, with a more preferred range, at least for the edge seals being 0.0008 to 0.0030, and with the preferred OHMS/CMF range being 350 to 500 or more preferably 375 to 400). 
     
       
         
           
               
               
               
               
               
               
             
               
                   
                 TABLE II 
               
             
            
               
                   
                   
               
               
                   
                   
                 COEFFICIENT 
                   
                 POUNDS 
                 APPROX. 
               
               
                   
                 RESISTIVITY 
                 OF LINEAR 
                 TENSILE 
                 PER 
                 MELTING 
               
               
                   
                 AT 20° C. 
                 EXPANSION 
                 STRENGTH 
                 CUBIC 
                 POINT 
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 MATERIAL 
                 COMPOSITION 
                 OHMS/CMF 
                 TCR 0–100° C. 
                 BETWEEN 20–100° C. 
                 MIN. 
                 MAX. 
                 INCH 
                 (° C.) 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 MWS-875 
                 22.5 Cr, 5.5 Al, 
                 875 
                 .00002 
                 .000012 
                 105,000 
                 175,000 
                 .256 
                 1520 
               
               
                   
                 5 Si, .1 C, bal. 
               
               
                   
                 Fe 
               
               
                 MWS-800 
                 75 Ni, 20 Cr, 
                 800 
                 .00002 
                 .000014 
                 100,000 
                 200,000 
                 .293 
                 1350 
               
               
                   
                 2.5 Al, 2.5 Cu 
               
               
                 MWS-675 
                 61 Ni, 15 Cr, 
                 675 
                 .00013 
                 .0000137 
                 95,000 
                 175,000 
                 .2979 
                 1350 
               
               
                   
                 bal. Fe 
               
               
                 MWS-650 
                 80 Ni, 20 Cr 
                 650 
                 .00010 
                 .0000132 
                 100,000 
                 200,000 
                 .3039 
                 1400 
               
               
                 Stainless 
                 18 Cr, 8 Ni, bal. 
                 438 
                 .00017 
                 .000017 
                 100,000 
                 300,000 
                 .286 
                 1399 
               
               
                 Steel 
                 Fe 
               
               
                 ALLOY 42 
                 42 Ni, bal. Fe 
                 390 
                 .0010 
                 .0000029 
                 70,000 
                 150,000 
                 .295 
                 1425 
               
               
                 MWS-294 
                 55 Cu, 45 Ni 
                 294 
                 .0002* 
                 .0000149 
                 60,000 
                 135,000 
                 .321 
                 1210 
               
               
                 MWS-294R 
                 29 Ni, 17 Co, 
                 294 
                 .0033 
                 .0000033 
                 65,000 
                 150,000 
                 .302 
                 1450 
               
               
                   
                 bal. Fe 
               
               
                 Manganin 
                 13 Mn, 4 Ni, 
                 290 
                 .000015** 
                 .0000187 
                 40,000 
                 90,000 
                 .296 
                 1020 
               
               
                   
                 bal. Cu 
               
               
                 ALLOY 52 
                 50.5 Ni, bal. Fe 
                 260 
                 .0029 
                 .0000049 
                 70,000 
                 150,000 
                 .301 
                 1425 
               
               
                 MWS-180 
                 22 Ni, bal. Cu 
                 180 
                 .00018 
                 .0000159 
                 50,000 
                 100,000 
                 .321 
                 1100 
               
               
                 MWS-120 
                 70 Ni, 30 Fe 
                 120 
                 .0045 
                 .000015 
                 70,000 
                 150,000 
                 .305 
                 1425 
               
               
                 MWS-90 
                 12 Ni, bal. Cu 
                 90 
                 .0004 
                 .0000161 
                 35,000 
                 75,000 
                 .321 
                 1100 
               
               
                 MWS-60 
                 6 Ni, bal. Cu 
                 60 
                 .0005 
                 .0000163 
                 35,000 
                 70,000 
                 .321 
                 1100 
               
               
                 MWS-30 
                 2 Ni, bal. Cu 
                 30 
                 .0013 
                 .0000165 
                 30,000 
                 60,000 
                 .321 
                 1100 
               
               
                 Nickel 205 
                 99 Ni 
                 57 
                 .0048 
                 .000013 
                 60,000 
                 135,000 
                 .321 
                 1450 
               
               
                 Nickel 270 
                 99.98 Ni 
                 45 
                 .0067 
                 .000013 
                 48,000 
                 95,000 
                 .321 
                 1452 
               
               
                   
               
               
                 *TCR at 25–105° C. 
               
               
                 **TCR at 25–105° C. 
               
               
                 Note: 
               
               
                 Available in bare or Insulated 
               
            
           
         
       
     
     The temperature of the seal wire can be readily changed under the current invention by changing the duty cycle pulses of the supplied current within the range of 0 to 100%. 
     Maintaining the sealing wire at the correct temperature helps improve the consistency of the seals, since wire temperature is the main factor in producing seal in the plastic film. Other advantages of the present invention includes: 
     (A) Temperature controlling of the edge seal will not only improve sealing performance, it will also improve reliability since the present design can avoid the prior art problem of thermally stressing the components of the seal mechanism; 
     (B) The seal wire avoids overheating and damaging the substrates, cover tapes, or the wire itself, a problem which exists in prior art designs; 
     (C) The response time of the sensing circuit is extremely fast because the temperature sensor is the heater itself. The heater element and the temperature sensor are at the same temperature, which is ideal for accurate control. 
     (D) Thermal Lags and Overshoots are avoided. Even the smallest thermocouples, RTD&#39;s, or thermistors have longer response times than the response time available under the present invention. 
     (E) It no longer matters if the system is located in a hot factory or a cold factory. The seal wire temperature can be easily maintained consistent regardless, and the resultant seals will correspondly be the same. The ambient temperature was a significant problem with the prior art seal wire system designs that lack temperature control. 
     (F) Duty cycle will no longer be an issue, unlike prior art designs, wherein the higher the duty cycle the hotter the seal wire becomes noting that the seal wires run the coolest when they are first used after a long idle period leading to temperature variations in use which can have a noticeable affect on seal quality. 
     (G) A temperature-controlled wire will not overheat and produce the phenomenon called ribbon cutting. Ribbon cutting occurs when the wire gets so hot that it cuts right through the film instead of sealing the two layers together. Ribbon Cutting is quite common in the prior art designs and can be a cause of leaky bags. 
     (H) Vent sizing can be more accurate. 
     As described above, the thickness of arbor housing  1168  for the edge seal supporting the desired wire (e.g., one having resistance increase of 0.005 (more preferably 0.008) or more per 110° F. jump in temperature in the typical seal/cut temperature range of the film like that described above) is designed for insertion within slot  1124  in sleeve  1122 .  FIGS. 164 to 169  illustrate arbor housing  1168  with its bridge-like configuration having opposite side walls  1184  and  1186  with upper rims  1188  and  1190 . As seen from  FIG. 169  each rim has a circular intermediate section represented by  1188 ′ and straight edge sloping sections (opposite sides) represented by  1188 ″ which place the arbor assembly components not involved in the compression edge seal wire function removed from the elastomeric drive roller. Between rims  1188  and  1190  there is provided a series of arbor assembly reception cavities. The illustrated reception cavities include non-moving end connector reception cavity  1192  having horizontal base  1194  with pin aperture  1196 , and with cavity  1192  ( FIG. 164 ) being defined at its upper edge with enlarged base horse-shoe shaped rim  1198  being bordered on opposite sides by rails  1199  and  1197 . Rim  1198  opens into intermediate reception cavity  1195  which is preferably a horizontal planar mount surface bordered by thicker side rail sections  1193  and  1191 . Centrally positioned within intermediate cavity there is located central cavity  1189  which extends deeper into arbor housing  1168  than intermediate reception cavity  1195 . As shown in  FIG. 164 , to the opposite side of intermediate section, there is provided moving end connector reception cavity  1187  which includes sliding slope surface  1185  extending out from a transverse wall  1183  having an upper edge forming the outer edge of smaller based horse-shoe shaped rim surface  1181  having notched side walls bordered by sloped outer contact surfaces  1179 ,  1177  ( FIG. 164 ,  165 ). Further provided is second horizontal base surface  1175  with second pin aperture  1173  formed therein. 
     As shown in  FIG. 159 , pin connectors  1178 , have threaded upper ends with pin  1178  having its upper threaded end receiving nut  1169  below horizontal base  1194  and extended through house cavity  1167 ′ and fixed in position with nut NU. Pin  1180  has it upper end threaded into a threaded cavity  1167  formed in non-moving connection block  1165  having a bottom flush with horizontal base  1194 . Non-moving connector block  1165  has a configuration that generally conforms to the profile of cavity  1192  so that block  1165  slides either vertically or horizontally into and out of cavity  1192  but  1192  during installation, and after that is prevented from any appreciable movement in a side to side, inward or rotational direction. 
       FIGS. 170 to 172  illustrate in perspective and in cross-section non-moving connector or mounting block  1165  and is preferably formed of a brass material. There is additionally formed in block  1165  sloping (down and in from an upper outward corner) reception hole  1163  having a central axis of elongation that extends transverse to the planar sloped surface  1161 . As seen from  FIG. 171 , the side edge from which reception hole  1163  opens is a multi-sided side edge MS. 
     Arbor assembly  1106  further includes ceramic plug  1159  which is illustrated by itself in  FIGS. 173A and 173B , and has insertion projection  1157  and head  1155 . Ceramic plug  1159  has side walls  1153 ,  1151  (includes coplanar or co-extensive surfaces for both head end plug) which are separated apart a distance that generally conforms to the opposing inner walls of thick-end rail sections  1191 ,  1193  for a slight friction sliding fit. Similarly, central cavity  1189  has a generally oval configuration that conforms to that of projection  1157  for a snug fit. Head  1155  has underside extension surfaces extending out from opposite sides of the top of projection  1157  and defines a surface designed to lie flush on intermediate planer surface defining intermediate cavity  1195  such as a common flush horizontal surface arrangement. Ceramic plug  1159  has an upper convex surface  1149  which, as shown in  FIG. 159 , matches the curvature of  1170  of arbor housing  1168  and terminates out its ends at the outer edges of intermediate cavity  1195 . 
     Arbor assembly  1106  further comprises moving mounting block  1147  illustrated in position within arbor housing  1168  and alone in  FIGS. 174 to 177 . As shown in  FIGS. 174 to 177 , moving mounting block  1147  has an electrical plug reception hole  1145  that extends transversely into moving mounting block  1147  from upper planar surface  1143 . Electrical plug reception hole  1145  is preferably threaded and is designed to receive and hold an electrical connection  1117 ′ with lead connector  1145 ′ clamped down ( FIG. 150 ). In similar fashion lead connector  1145  is clamped down by nut NU″. Block  1147  further includes planar bottom surface  1141  which is placed flush on sloping upper surface  1161 , and planar side walls  1139  and  1137  spaced apart to generally coincide with the side walls defined by arbor housing  1168 . Block  1147  further includes convex (three sloping flat sides forming a general curvature) end walls  1135  and  1133 . Interior passageway  1131  ( FIG. 177 ) extends between end walls  1135  and  1133  and opens out at a central vertical location in the middle sub-wall of the convex end walls. At the end closest to the central plug  1159  there is formed notch  1129  which extends from end  1133  inward with an upper level commensurate with an upper level of passageway  1131  and downwardly to open out at bottom surface  1141 . The interior end of notch  1129  includes transverse enlargements to form a T-shaped cross-section TC as shown in  FIG. 175 . 
       FIG. 159  further illustrates slide shaft  1127  received within housing  1168  at one end and designed to extend into interior passageway  1131  so as to provide a means for guiding slide movement along guide shaft  1127  in said moving mounting block  1147 . Between the end surface  1183  of the arbor housing and the convex end surface  1135  of the adjacent moving mount block, there is positioned outward biasing means  1125  which in a preferred embodiment comprises conical spring which biases moving mounting block  1147  outward along slope surface  1179 . The T-shaped slot facilitates adding the conical spring on to the system (i.e., allows for finger grasping in holding its position as the guide is passed through the center of the spring).  FIG. 159  further shows upper nut NU which fixes conducting pin  1178  in position and sandwiches first arbor conductor lead  1145 ′ between the planar surface  1175  and nut NU. Threaded fastener  1117 ′ is threaded within threaded part  1145 ″ in the moving block and through the base region of end connector plate  1113  ( 1111 ) in  FIG. 178  and also through the looped end of electrical lead  1145 ′ so as to compress them into electrical communication. Moving block  1147  is preferably formed of the same material as non-moving block  1165  as in electrically conducting base. Moving block  1147  is also sized as to have an operative position inward from the end of the conducting pin extending upward from planar surface  1175 . 
     Heater wire assembly  1119  comprises the aforementioned heater wire  1182  connected at its ends to respective arbor assembly wire plates  1113  and  1111  shown in  FIG. 128 , which are similar to those described above for the heater wire end seal wire support plates  1062  ( FIG. 143 ). Plates  1111  and  1113  have an enlarged portion with conductor screw aperture and a tapering, elongated end for welded, soldered or alternate securement means to fix edge seal heater wire  1182  to the plates at opposite ends of the heater wire. Heater wire insert plugs  1117  and  1115 , are preferably of a screw type for threaded attachment to the respective mounting blocks. Thus, the screws are extended through the central apertures formed in plates  1113  and  1111  so as to hold the plates and the connected wires in fixed position relative to the mounting blocks  1147  and  1165 . Thus moving mounting block  1147  acts as a tensioner device in the edge seal heater wire as soon as the heater wire and plates combination are secured by the threaded screws to the respective blocks and the blocks are received within the respective arbor housing cavities. Since the tensioner means of the present invention maintains edge seal heater wire  1182  under tension at all time (the biasing means is preferably a relatively small spring as to avoid over tensioning and stretching the heater wire)  1182 . The moving block is under spring tension and moves in a linear fashion as it is guided by the guide shaft  1127  to keep the edge seal wire taught. The movement makes up for the normal variations in wire length and for the thermal expansion of the wire while the moving block moves along the loosely fitting, preferably stainless steel guide shaft  1127  (to avoid binding). 
     The edge seal heater wire  1182  is centered on the curved upper head surface of plug  1159  which is formed of a high heat resistant material such as a ceramic plug. Plug  1159  is preferably able to withstand over 450° F. and more preferably over 650° F. (e.g., up to 1500° F. available in conventional ceramics) without ablation or melting of the underlying face of the plug coming into contact with the heater wire and without any Teflon taping. 
     Thus, as the film is driven by driven roller set through the nip region, the film is compressed against the compressible material roller and heated to a level which will bond and seal together an edge seal (or seals if more than one involved). The present invention, provides a stationary support and accurate positioning of the edge seal heater wire, both initially and over prolonged usage as in over 20,000 cycles, as the core precludes any underlying heater wire or support backing material melting or softening which can cause deviations in the location of the edge seal and degrade edge seal quality. The deviation in positioning over time as the heater wire sank into the backing material was one of the problems leading to poor edge seal quality in prior art designing. 
       FIGS. 146 to 172  illustrate one embodiment of the edge seal support means ES′ ( FIG. 150 ) of edge seal assembly  91 AS with its arbor mechanism and bar with edge seal heated wire and associated connectors. A second embodiment the edge seal means support (ES— FIG. 150A ) is represented by the “A” versions of  146  to  172  together with  FIGS. 173C and 173D . As seen there are general similarities between embodiments and thus the emphasis below are the differences. 
       FIG. 146A to 149A  illustrate the alternate embodiment of edge seal support ES′ in position relative to edge seal  91 A (“A” added for the same or related components relative to the first embodiment). As seen from  FIGS. 146A and 149A  support ES′ features a modified sleeve to roller segments clamping means featuring components which include annular wedge ring P 1 , threaded block P 2 , and threaded cylinder P 3  with threaded fastener FS is associated with external block P 2  and internally threaded with cylinder P 3  and with annular wedge ring P 1  completing the connection due to sleeve  122 A being fixed in position thereunder with fastener  1132 A received in the opposite, internal end of threaded cylinder  3 . 
     As further seen from  FIGS. 149A ,  150 A, and  159 A, the support ES′ represents a new preferred embodiment from, for example, the standpoint of symmetry in design to the left and right of ceramic insert head CH of the same ceramic described above or of, for example, VESPEL brand high temperature plastic of DuPont received within the central reception cavity CS defined by main housing MH having pin connectors  1178 A and  1180 A as shown in  FIG. 159A . Shoes SH 1  and SH 2 , together with fasteners F 1  and F 2 , are used to secure in position head CH (e.g., a sliding friction positioning is suitable between the interior most ends of the shoes and thus represent positioners or positioning means). Shoes SH 1  and SH 2  are thus designed to sandwich head CH within slot CS with fasteners F 1  and F 2  being utilized to secure shoes SH 1  and SH 2  to housing MH Head CH supports heater wire segment W with upper end UE conforming to the head&#39;s CH convex curvature. The shoes are formed of a conductive material so as to provide for an electrical conduction of current from the pins,  1178 A and  1180 A to head CH. Head CH preferably has, in addition to upper wire segment ω, two side wire extensions EX that are placed in contact with the interior ends of the shoes to complete the circuit. Because rollers  1100  and  1102  are of a non-conducting material together with the arbor housing unit supporting the shoes, there is sufficient electrical insulation provided relative to the conductive shoes when the edge seal assembly is assembled. 
       FIG. 186  shows an overall schematic view of the display, controls and power distribution for a preferred foam-in-bag dispenser embodiment which provides for coordinated activity amongst the various sub-assemblies like that for the foam-in-bag dispenser system described above (and for which component reference numbers are provided in addition to the key legend of  FIG. 186A ). The present invention preferably comprises an electrical package comprised of two board assemblies, the main control board and an operator interface. The boards are interlinked via a single shielded cable, which can be separated up to 8 feet. 
     The operator interface includes an LCD display, keypad, control board and enclosure. It can be separated from the bag machine via a single shielded umbilical cord. Because the operator interface is a separate item from the rest of the machine, different interfaces can be either separate or integrated. For example, the display panel with button control  63  in  FIG. 3  is preferably pivotably attached to the front of the dispenser and provides for both control of dispenser system and initiating other functions such as remote access via a modem or the like to a service provider Provided below are some preferred electrical specifications for a display system. 
     
       
         
           
               
               
             
               
                   
               
             
            
               
                 Display: 
                 240 by 128 pixel graphic LCD display 
               
               
                 Keypad: 
                 4 keys, 1 optical dial, 16 positions with push button for 
               
               
                   
                 selection On main cover, 8 keys, 1 LED 
               
               
                 PCB Size: 
                 7.5″ × 4.5″ × 1.5″ W × H × D 
               
               
                 Connectors: 
                 1) 9 pin Amp connector to main control box 
               
               
                   
                 2) 9 pin RS232 D-sub connector for PC connections 
               
               
                   
               
            
           
         
       
     
     Software or programmed hardware for monitoring, for example, chemical parameters is preferably included with examples provided below (noting the processor and FPGA exchange described above as one ex ample of a preferred processor/sub-system interrelationship): 
     
       
         
           
               
               
               
             
               
                   
                   
               
             
            
               
                   
                 Recorded Shot 
                 1) A and B temperatures 
               
               
                   
                 (dispensed 
                 2) A and B pressures 
               
               
                   
                 chemical) Data: 
                 3) Time and date 
               
               
                   
                   
                 4) A and B amounts dispensed 
               
               
                   
                 PC Programmable 
                 1) A and B ratio 
               
               
                   
                 Variables: 
                 2) A and B specific gravities 
               
               
                   
                   
                 3) User interface menus on/off 
               
               
                   
                 Shot History: 
                 Last 300 shots, download via PC 
               
               
                   
                   
               
            
           
         
       
     
     The shot history allows the operator to monitor and keep track of usage of the noted sub-system (with similar possibilities for other sub-systems such as those illustrated in  FIG. 186 ). In addition to the software programming the personal computer interface for parameters like those outlined below is utilized.
     Real Time Data:
       1) A and B temperatures   2) A and B pressures   3) A and B pump RPM&#39;s   4) Update rate: 2/second   
       System Options:
       1) Menus On/Off   2) Set time and date   3) System options   
       Download Code: Download new operating system stored on PC hard drive   

     A preferred embodiment of the invention places all electrical controls, power supplies, and associated equipment into one main control box which mounts on the side on the bag machine. Provided below are some illustrative examples of electrical control and power supplies for a preferred embodiment of the invention.
     Preferred Power  180  to  255  VAC 30 Amp   Chemical Pumps:
       1) Pressure transducer:
           a) 5VDC supply   b) Pressure range: 0 to 1000 PSI   c) Output voltage: 0.5 to 4.5 VDC   
           2) Tachometer: Signal comes from brushless motor driver   3) Pump motor:
           a) Brushless motor   b) Speed 20 to 3000 RPM&#39;s   c) Power requirements: 230VAC, 3 amps max   d) Direction: Forward   
           4) One pump will operate at max RPM, the other specified by ratio and specific gravity   
       Chemical Heaters:
       1) Supply voltage 230 VAC   2) Heater wattage: 2200 watts, continuous duty A &amp; B   3) Temperature sensor: 2000 ohm NTC thermistor   
       Emergency Stop: Automatically shuts off all high power (pumps, hose heaters, etc.) and low power (cross cut and seal, film advance motors, etc.). Leaves power to user interface and some of the control box. Currently one switch mounted to cover hinge (activates when cover is raised).   Film drive motor:
       1) Type   a) Power requirements: 24VDC, 5 amps   b) Source: 24VDC switching power supply   c) Control: built into motor   d) Direction: Forward and reverse   2) Signals
           a) Tachometer from motor, 216 pulses per revolution (logic)   b) Speed: 0–5VDC speed voltage input   c) Direction: Logic level, 0 to 5VDC   d) Brake: Logic level, 0 to 5 VDC   e) Enable: Logic level, 0 to 5 VDC   f) Fault: Input from motor; logic level, 0 to 5 VDC   
           
       Dispenser drive motor:
       1) Type
           a) Power requirements: 24VDC, 5 amps   b) Source: 24vdc switching power supply   c) Control: built into motor   d) Direction: Forward   
           2) Signals
           a) Tachometer from motor, 216 pulses per revolution (logic)   b) Speed: 0–5vdc speed voltage input   c) Direction: N/A   d) Brake: Logic level, 0 to 5 VDC   e) Enable: Logic level, 0 to 5 VDC   f) Fault: Input from motor; logic level, 0 to 5 VDC   
           
       Cross Cut Jaw Drive Motor:
       1) Type
           a) Power requirements: 24VDC, 5 amps   b) Source: 24VDC switching power supply   c) Control: built into motor   d) Direction: Forward   
           2) Signals
           a) Tachometer from motor, 216 pulses per revolution (logic)   b) Speed: 0–5vdc speed voltage input   c) Direction: N/A   d) Brake: Logic level, 0 to 5 VDC   e) Enable: Logic level, 0 to 5 VDC   f) Fault: Input from motor; logic level, 0 to 5 VDC   
           
       Film Tension Motor:
       1) Type:
           a) Power requirements: 24VDC, 5 amps,   b) Control: Constant current   c) Direction: reverse   
           2) Tachometer
           a) 5VDC supply   b) Speed range: 0 to 500 RPM   c) Resolution: 100 pulses per revolution   d) Output voltage: square wave, 0 to 5 VDC   
           
       Solvent System:
       1) Solvent pump
           a) Type: ProMinent Concept b metering pump   b) Power requirements: 230VAC   c) Control: contact closure   
           2) Pressure transducer
           a) 5VDC supply   b) Pressure range: 0 to 300 PSI   c) Output voltage: 0.5 to 4.5 VDC   
           3) Solvent level sensor
           a) Contact closure, qty:2   
           
       Top and Bottom Seal Wire:
       1) Power requirements: 300 watts   2) Material: Stainless steel 304 band, TOSS 2 mm×0.1 mm tapered band   3) Control: Resistive measurement to derive temperature   4) Cycle time: 0.8 seconds   5) Temperature control: overall wire +/−15° F.   
       Cross Cut:
       1) Power requirements: 200 watts   2) Material: Stainless steal 304 wire 0.3 mm diameter   3) Control: Resistive measurement to derive temperature   4) Cycle time: 0.8 seconds   5) Temperature control: overall wire +/−15° F.   
       Edge Seal:
       1) Power requirements: 15 watts   2) Material: 0.0025×0.018 Alloy 42 wire   3) Control: Resistive measurement to derive temperature   
       Discrete Inputs:
       1) Rating: 24VDC 100 mA max   2) Inputs: 5 programmable inputs   
       Discrete Outputs:
       1) Rating: 24VDC 100 mA max   2) Outputs: 5 programmable outputs   
       Roll Film Sol: 1) 24VDC 1.5 amps   Intelligent I/O 1) One port, protocol TBD   Manifold Heater:
       1) Power rating: 100 watts max each, 200 watts total   2) Power requirements: 32 VAC   3) Temperature sensor: 2000 ohm NTC thermistor   4) Temperature range: 90 to 130° F.   5) Qty: 2 sensors, 2 heaters   
       Alarm: 1) Buzzer, piezoelectric mounted on control board, qty: 1   Main Contactor: 1) 30 amp double pole single toggle contactor. Controls power to all high voltage devices and motors   Machine Lifter:
       1) Power requirements: 24 VDC, 120 watts max   2) Controlled via switches located on user interface   
       Tip Cleaning:
       1) Power requirements: 24 VDC, 148 watts max   2) Solenoid operates only when all bag making module motors are off   
       

     System Integration and Remote Access 
     An addition preferred feature of the invention is to provide an intelligent interface between the bag machine and the customer packaging operation. To allow remote access by the bag machine supplier via standard telephone service or some other convenient connection.
     Data Interface: Built into each machine, discrete I/O along with an intelligent data port for bar code data entry.   Remote Interface: Dial up interface for bag machine manufacturer (and/or service provider) personnel (real time data, shot history, etc) or automated data gathering.