FOAM MOLDING SYSTEM AND METHOD OF OPERATION

1 . A foam molding machine comprising:

a molding assembly configured to mix a plurality of constituent materials to form a molding material;

a dispenser operably coupled to receive the molding material;

a carrier positioned to receive the molding material from the dispenser, the carrier being removably coupled to the foam molding machine;

an RFID module coupled to the carrier;

an RFID reader arranged to receive a signal from the RFID module when the carrier is arranged in the foam molding machine; and

a controller operably coupled to the RFID reader and the molding assembly, wherein the controller includes a processor that is responsive to executable computer instructions for changing molding parameters in response to the RFID reader receiving the signal from the RFID module.

2 . The foam molding machine of claim 1 wherein the parameters include at least one of a ratio of the constituent materials, a dispensing time and a molding material flow rate.

3 . The foam molding machine of claim 2 wherein the signal includes parameter values that define the parameters.

4 . The foam molding machine of claim 2 wherein the signal includes an identification value.

5 . The foam molding machine of claim 4 wherein the processor is further responsive to executable instructions for retrieving parameter values that define the parameters from a look-up table based at least in part on the identification value in response to receiving the signal.

6 . The foam molding machine of claim 4 wherein the processor is further responsive to executable instructions for retrieving parameter values that define the parameters from a remote server based at least in part on the identification value in response to receiving the signal.

7 . A method of forming an object comprising:

placing a carrier in a foam molding machine, the carrier including an RFID module, the carrier further having a first portion movably coupled to a second portion;

activating the RFID module with an operating field transmitted by an RFID reader operably coupled to the foam molding machine;

transmitting a signal from the RFID module to the RFID reader;

changing molding parameters in the foam molding machine in response to receiving the signal;

dispensing a foam material into the carrier;

closing the first portion and second portion to define the object;

expanding the foam material within the carrier; and

removing the object from the carrier.

8 . The method of claim 7 wherein the signal includes parameter values and the molding parameters are changed based at least in part on the parameter values.

9 . The method of claim 8 wherein the parameter values include at least one of a ratio of the constituent materials, a dispensing time and a molding material flow rate.

10 . The method of claim 7 wherein the signal includes an identification value.

11 . The method of claim 10 further comprising:

retrieving parameter values from a look-up table based at least in part on the identification value; and

wherein the step of changing the molding parameters is based at least in part on the parameter values.

12 . The method of claim 10 further comprising:

retrieving parameter values from a remote server based at least in part on the identification value; and

wherein the step of changing the molding parameters is based at least in part on the parameter values.

13 . The method of claim 7 wherein:

the step of activating the RFID module includes lowering an end of a boom of the foam molding machine; and

the RFID reader is operably coupled to the end of the boom.

14 . A foam molding machine comprising:

a molding assembly configured to mix a plurality of constituent materials to form a molding material;

a boom coupled to the molding assembly and movable between at least a first position and a second position;

a dispenser coupled to an end of the boom opposite the molding assembly, the dispenser configured to receive the molding material;

a carrier positioned to receive the molding material from the dispenser, the carrier being removably coupled to the foam molding machine;

an RFID module coupled to the carrier;

an RFID reader arranged to receive a signal from the RFID module when the carrier is arranged in the foam molding machine; and

a controller operably coupled to the RFID reader and the molding assembly, wherein the controller includes a processor that is responsive to executable computer instructions for changing molding parameters in response to the RFID reader receiving the signal from the RFID module.

15 . The foam molding machine of claim 14 wherein the parameters include at least one of a ratio of the constituent materials, a dispensing time and a molding material flow rate.

16 . The foam molding machine of claim 15 wherein the signal includes parameter values that define the parameters.

17 . The foam molding machine of claim 15 wherein the signal includes an identification value.

18 . The foam molding machine of claim 17 wherein the processor is further responsive to executable instructions for retrieving parameter values that define the parameters from a look-up table based at least in part on the identification value in response to receiving the signal.

19 . The foam molding machine of claim 17 wherein the processor is further responsive to executable instructions for retrieving parameter values that define the parameters from a remote server based at least in part on the identification value in response to receiving the signal.