Foam in bag packaging system and method for producing the same

A packaging system for producing a foam-in-bag cushion upon demand comprising:

• a bag formed of flexible plastic film material and defining therein an enclosed space of a volume corresponding to the size of the foam cushion to be produced, said enclosed space being vented to the outside of said bag to permit the escape of gases generated during the formation of the foam cushion while preventing the escape of foam therefrom;
• a foam precursor packet positioned at a predetermined location within said enclosed space in said bag and being formed of a barrier material capable of maintaining foam precursor components in a relatively stable and unreacted state, said packet including a first compartment and a second compartment with a first frangible seal separating said first and second compartments and adapted to be raptured when it is desired to form the foam cushion, said packet also including a second frangible seal between one of said compartments and said enclosed space in said bag;
• a first foam precursor component contained in said first compartment of said packet;
• a second foam precursor component contained in said second compartment of said packet;
• said first and second foam precursor components being adapted to be mixed upon rupture of said first frangible seal and to react to form foam which will rupture said second frangible seal and expand from said packet into said enclosed space in said bag until said enclosed space is substantially filled with foam and said foam cushion is formed;
• and
• said frangible seals having a peel strength of at least about one-half pound per inch and less than about twelve rounds per inch, wherein said frangible seals are each formed by a band of printing extending along one of the contiguous surfaces of said packet, said band of printing comprising a pattern of spaced apart printed areas separated by a grid of spaced apart seal lines in orthogonal or non-orthogonal fashion throughout the length of said frangible seals.