Patent ID: 7641459

Claim:
A molding system for molding foam-in-bag cushions each formed by dispensing a foam-forming composition into a bag of flexible film material, the molding system comprising: a mold defining a mold cavity configured for receiving a cushion placed in the mold cavity and allowed to expand to substantially fill the mold cavity, an air plenum separate from the mold cavity, a plurality of air passages that connect the mold cavity to the air plenum, and at least one port connected to the air plenum, the mold cavity having an open side to permit a cushion to enter the mold cavity and subsequently to exit the mold cavity after expansion of the cushion, the mold further comprising a door that is movable between a closed position closing the open side of the mold cavity and an open position allowing a cushion to enter and exit through the open side; and a pneumatic vacuum/blowout system connected with the at least one port, the vacuum/blowout system comprising a vacuum source, an air tank containing pressurized air, an air compressor coupled with the air tank for pressurizing the air tank, and a vacuum/blowout valve structured and arranged to alternately couple the at least one port either to the vacuum source such that air is evacuated from the mold cavity via the air passages and air plenum so as to suck a newly formed cushion into the mold cavity whereupon the door is closed and the cushion is allowed to expand to substantially fill the mold cavity, or to the air tank such that pressurized air is supplied from the air tank to the mold cavity via the air plenum and air passages to expel an expanded cushion from the mold cavity after the door is opened, wherein the vacuum/blowout valve is operable to open in response to pressure in the air tank reaching a predetermined value so as to couple the air tank to the at least one port of the mold.