Apparatus and method for inspecting quality of molded foam parts

Abstract

Apparatus and method is provided for reliably testing a quality level of bead fusion in molded foam parts. Such apparatus may be portable and hand-held, and the test procedure will not destroy or damage tested products. In a useful embodiment comprising apparatus for monitoring quality of a molded foam part, an insertion device introduces a stream of selected gas under pressure into the interior of the molded foam part. The insertion device may include a thin nozzle to be inserted into the part. Poorly fused beads allow a faster flow rate of the gas than well fused beads, since the poor fusion will provide more openings for the gas to escape. Accordingly, the embodiment includes a sensor for measuring the flow rate of the stream of gas, as the stream is introduced into the part interior. An indicator mechanism, responsive to operation of the flow sensor, provides notice to a user of the apparatus that the gas flow rate does or does not exceed a pre-specified level, which indicates a corresponding level of part quality.