Systems and methods for fluid heating and control

Abstract

A multi-component fluid delivery system includes a heater system. The heater system includes an improved fluid pre-heat system based on a high thermal conductivity fluid-based heat exchange manifold coupled to an external heater element (e.g., an externally powered heater element via electrical power). These techniques can provide more surface area for heating the fluid and outside of the fluid channel, making servicing or replacement easier. These techniques can utilize etched foil or wire-wound heater elements that operate at lower internal temperatures than cartridge-style heaters and thus can be intrinsically more reliable.

Description

[0001] Cross-reference to related applications

[0002] This application is a continuation and claims the benefit of U.S. Provisional Patent Application Serial No. 62 / 975749 entitled “SYSTEMS ANDMETHODS FOR FLUID HEATING AND CONTROL”, filed on February 12, 2020, which is assigned to the assignee of this application and is incorporated herein by reference.

[0003] In multi-component fluid delivery systems, where two or more fluid components or compounds are delivered to an output device or container (e.g., spray gun, mixing chamber, tank, reaction site), a predetermined ratio of fluid component delivery can be used to control the process output to a desired standard. An example of a desired ratio can be found in a two-part spray polyurethane foam (SPF) system, where the chemical and mixing processes can specify the controlled delivery of two fluid components or compounds (A) and (B) in a 1:1 ratio (by weight or volume). This can be useful for improving the heating of fluids A and / or B. Summary of the Invention

[0004] The following outlines certain embodiments that are equivalent in scope to the original claimed invention. These embodiments are not intended to limit the scope of the claimed invention; rather, they are merely intended to provide a brief overview of the possible forms of the invention. In practice, the invention can encompass a variety of forms that may be similar to or different from the embodiments set forth below. Attached Figure Description

[0005] These and other features, aspects, and advantages of the invention will be better understood when the following detailed description is read with reference to the accompanying drawings, in which the same reference numerals denote the same parts.

[0006] Figure 1 This is a block diagram of an embodiment of a spray application system, such as a multi-component fluid delivery system (e.g., an SPF system), which includes a heating system;

[0007] Figure 2 Is included Figure 1 A block diagram of an embodiment of a heating system in a spray application system;

[0008] Figure 3 This is a perspective view showing an embodiment of the heater;

[0009] Figure 4 This is an exploded perspective view showing an embodiment of the heater;

[0010] Figure 5is a perspective view showing further details of an embodiment of the manifold assembly component of the heater in the above figure;

[0011] Figure 6 is a front view of an embodiment of the manifold assembly component showing two parallel rows of conduits;

[0012] Figure 7 is an exploded perspective view of an embodiment of the heater showing the passage(s) in the cap component;

[0013] Figure 8 is a front view of an embodiment of the cap component showing further details of the passages Figure 7 ; and

[0014] Figure 9 is a rear view showing an embodiment of the side component showing the inlets and outlets fluidly coupled to certain passages. DETAILED DESCRIPTION

[0015] One or more specific embodiments of the present application will be described below. To provide a context for the description, FIG. 1 shows a diagrammatic representation of a machine in the exemplary form of a computer system 100 within which a set of instructions, for causing the machine to perform any one of the methodologies discussed herein, can be executed. The computer system 100 can be used to implement any of the devices described herein, such as the heater 10, the manifold assembly 20, the cap component 30, the side component 40, and / or the like. In alternative embodiments, the machine can be connected, e.g., networked, to other machines in a LAN, an intranet, an extranet, and / or the Internet. The machine can operate in the capacity of a server or a client machine in client-server network environment, as a peer machine in a peer-to-peer (or distributed) network environment, or as a server or a client machine in a cloud computing infrastructure.

[0016] The terms "a," "an," and "the" are intended to denote one or more of the specified elements. The terms "including" and "comprising" are intended to be open and permitting of any subsequent determination of equivalents. The terms "coupled," "connected," and "responsive" are intended to mean directly or indirectly connected.

[0017] Embodiments of the present disclosure relate to systems and methods that can improve heating of multi-component fluid delivery systems, for example, by pre-heating certain fluids. In multi-component fluid delivery, multiple components or compounds, such as chemical compounds, can be delivered to an output device or vessel (e.g., spray gun, mixing chamber, tank, reaction site) at specified temperatures. For example, for a two-part spray polyurethane foam (SPF) system, the chemical and mixing process can specify controlled delivery and / or pre-heating of two fluid components (Compound A) and (Compound B) at desired temperature(s) (e.g., one temperature for A and another temperature for B). Variations in the desired temperature(s) can result in lower yield (lower insulation value per pound of foam), uncured foam, brittle foam, excessive shrinkage, and other issues. It would be beneficial to maintain Compound A and / or Compound B at certain temperatures, for example, between 50°F and 200°F.

[0018] Certain techniques provided for multiple fluids that can be used in SPF systems can utilize a pre-heat system to maintain A fluid and B fluid. In some fluid delivery systems, heating of the fluid can be used to reduce the viscous effects that impede material flow. Fluid heating can also be used to get more optimized process results. Fluid heating can also be used to better match the viscosities between two or more fluids when the fluids are mixed at a reaction and / or dispensing device to improve pressure uniformity. An example of heating is in a two-part spray polyurethane foam (SPF) system, which can employ material heaters for both A fluid and B fluid to reduce viscosity and viscosity differential, initiate kinetic reactions, and improve mixing of materials in the spray gun mixing chamber.

[0019] Current means of fluid pre-heating include: 1) electric heaters (e.g., cartridge heaters, tube heaters) that are inserted into the flow path within a “heat sink” in direct contact with the fluid. 2) cartridge or tube heaters that are enclosed in a high thermal conductive heat sink (e.g., aluminum) that contains the flow path, but not in direct contact with the fluid. 3) fluid-to-fluid heat exchangers that use hot coolant from an on-board generating engine. 4) electric heating cables that are immersed in the fluid hose or manifold.

[0020] The techniques described herein include improved fluid pre-heat systems for high thermal conductive fluid-based heat exchange manifolds that are coupled to external heater elements (e.g., externally powered heater elements). These techniques can provide more surface area for heating the fluid and are external to the fluid path, making servicing or replacement easier. These techniques can utilize etched foil or wire-wound heater elements that operate at lower internal temperatures than cartridge heaters and thus can be intrinsically more reliable.

[0021] It can be useful to describe systems in which the heating techniques described herein can be applied. Accordingly, turning now to the drawings Figure 1 The figure is a block diagram illustrating an embodiment of a spray application system 10 that can include one or more liquid pumps 12, 14. The spray application system 10 can be suitable for mixing and dispensing various chemicals, such as those used to apply spray foam insulation. In the depicted embodiment, compounds A and B can be stored in tanks 16 and 18, respectively. The tanks 16 and 18 can be fluidly coupled to the pumps 12 and 14 via conduits or hoses 20 and 22. It should be understood that while the depicted embodiment of the spray application system 10 shows two compounds for mixing and spraying, other embodiments can use a single compound or 3, 4, 5, 6, 7, 8, or more compounds. The pumps 12 and 14 can be independently controlled.

[0022] During operation of the spray application system 10, the pumps 12, 14 can be mechanically powered by motors 24, 26, respectively. In preferred embodiments, the motors can be electric motors. However, internal combustion engines (e.g., diesel engines), pneumatic motors, or combinations thereof. Motor controllers 27 and 29 can be used to provide motor start / stop, loading, and control based on, for example, signals sent from a processor 40. The motor 24 can be the same or a different type as the motor 26. Likewise, the pump 12 can be the same or a different type as the pump 14. Indeed, the techniques described herein can be used with multiple pumps 12, 14 and multiple motors 24, 26, which can be different types.

[0023] The pumps 12, 14 provide fluid power suitable for moving the compounds A, B into a spray gun system 28. More specifically, the compound A can pass through the pump 12 through the conduit 20 and then through a heated conduit 30 into the spray gun system 28. Likewise, the compound B can pass through the pump 14 through the conduit 22 and then through a heated conduit 32 into the spray gun system 28. To heat the heated conduits 30, 32, a heating system 34 can be provided. The heating system 34 can provide thermal energy suitable for pre-heating the compounds A and B prior to mixing and spraying and for heating the compounds A and B during mixing and spraying. In certain embodiments, the heating system 34 can include a pre-heater using laminated heat foil heating elements outside of a fluid manifold (heat exchanger) system. Accordingly, as described further below, lower temperature heaters can be used over larger surface areas and flow lengths.

[0024] The spray gun system 28 can include a mixing chamber for mixing compounds A and B. For a spray foam insulation application, compound A can include an isocyanate, while compound B can include a polyol, a flame retardant, a blowing agent, an amine or metal catalyst, a surfactant, and other chemicals. When mixed, an exothermic chemical reaction occurs, and a foam 35 is sprayed onto an object. The foam then provides insulation properties at various thermal resistances (i.e., R-values) based on the chemicals found in compounds A and B.

[0025] Control of the spray application system 10 can be provided by a control system 36. The control system 36 can include an industrial controller, and thus include a memory 38 and a processor 40. The processor 40 can include multiple microprocessors, one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, one or more application specific integrated circuits (ASICS), and / or one or more reduced instruction set (RISC) processors, or some combination thereof. The memory 38 can include volatile memory (such as random access memory (RAM)), and / or non-volatile memory (such as ROM, hard disk drive, memory card, memory stick (e.g., USB stick), etc.). The memory 38 can include computer programs or instructions executable by the processor 40 and suitable for controlling the spray application system 10. The memory 38 can further include computer programs or instructions executable by the processor 40 and suitable for detecting a slip of the pumps 12, 14, and providing a ratio control action to continue to provide compounds A and B at a desired ratio (e.g., 1 : 1) in the presence of a slip, as further described below.

[0026] The control system 36 can be communicatively coupled to one or more sensors 42, and operatively coupled to one or more actuators 44. The sensors 42 can include pressure sensors, flow sensors, temperature sensors, chemical composition sensors, speed (e.g., rotational speed, linear speed) sensors, electrical measurement sensors (e.g., voltage, amperage, resistance, capacitance, inductance), level (e.g., fluid level) sensors, limit switches, etc. The actuators 44 can include valves, actuatable switches (e.g., solenoids), positioners, heating elements, etc.

[0027] One or more users can interact with the control system 36 via an input / output (I / O) system 38, which can include a touchscreen, a display, a keyboard, a mouse, an augmented reality / virtual reality system, and a tablet computer, a smartphone, a notebook computer, etc. The users can input a desired pressure, flow rate, temperature, ratio of compound A to compound B (e.g., 1 : 1), alarm thresholds (e.g., threshold fluid levels of compounds A, B in tanks 16, 18), etc. The users can then spray via the spray gun system 28, and the control system 36 can execute one or more programs stored in the memory 38 using the processor 40, which are adapted to sense conditions of the system 10 via the sensors 42 and adjust various parameters of the system 10 via the actuators 44 based on the user input. The I / O system 38 can then display several sensed conditions and adjusted parameters. Certain components of the spray application system 10 can be contained in or interface with a proportioning system 41. The proportioning system 41 can “proportion” or deliver compounds A, B at a specified ratio (e.g., 1 : 1) to achieve the spray 35. In this way, the user(s) can mix and spray chemicals (such as compounds A and B) to provide certain coatings (such as insulating spray foam).

[0028] Turning now to Figure 2 the figure is a block diagram of an embodiment of a heater system 34 included within the proportioning system 41. In the illustrated embodiment, the heater system 34 can include preheaters / heat exchangers 100, 102, 104, and 106. In other embodiments, more or fewer preheaters can be used. For example, the preheaters / heat exchangers 100, 102 upstream of the pumps (12, 14) can not be used, so only the preheaters 104, 106 are used. Likewise, the preheaters 104, 106 downstream of the pumps (12, 14) can not be used, so only the preheaters / heat exchangers 100, 102 are used. Also shown is a heating control system 108 that can be operably coupled to the preheaters / heat exchangers 100, 102, 104, and / or 106. In some embodiments, the heating control system 108 can be included in the controller system 36. In other embodiments, the heating control system 108 can be separate from the control system 36, and thus can include one or more processors adapted to execute code or instructions, and a memory adapted to store the code or instructions. In embodiments where the heating control system 108 is separate from the control system 36, the heating control system 108 can be communicatively and / or operably coupled to the control system 36. It should also be understood that, in some embodiments, a single pump can be used, which is adapted to pump both fluids through both inlets and corresponding outlets.

[0029] During operation, the heating control system 108 can sense temperature via sensors disposed in or on the tanks 16, 18, in or on the fluid conduits (e.g., hoses) 110, 118, in or on the heaters / heat exchangers 100, 102, 104, and 106, and / or in or on the pumps 12, 14. The heating control system 108 can then adjust the temperature of the heaters / heat exchangers 100, 102, 104, and / or 106 to maintain a desired temperature profile. For example, the temperature profile can be a ramp-up profile, where heat is increased until a plateau is reached and maintained (e.g., between 50°F to 200°F). Further, the internal wiring of the heaters / heat exchangers 100, 102, 104, and / or 106 can be used as additional temperature sensors. For example, the resistance (e.g., measured in ohms) of each of the heaters / heat exchangers 100, 102, 104, and / or 106 can provide a measure of temperature. That is, for a given resistance, a temperature can be derived. Accordingly, the resistance of each of the heaters / heat exchangers 100, 102, 104, and / or 106 can be used as a redundant sensor. If a primary sensor fails, the resistance can be used by the heating or backup system to shut off the heaters / heat exchangers 100, 102, 104, and / or 106. The heaters / heat exchangers 100, 102, 104, and / or 106 can provide more surface area for heating the fluid and are external to the fluid passageway, making servicing or replacement easier. The heaters / heat exchangers 100, 102, 104, and / or 106 can utilize etched foil or wire-wound heater elements that operate at lower internal temperatures than cartridge heaters, and thus can be intrinsically more reliable.

[0030] Turning now to Figure 3The figure is a perspective view illustrating embodiments of heaters / heat exchangers 100, 102, 104, and / or 106. In the illustrated embodiments, the heater includes a top heating element 200, which may utilize etched foil and / or wire-wound heater elements. When power is delivered, the heating element 200 can then generate heat, which can then heat the fluid (e.g., compounds A, B) entering the heater via inlet 210. An outlet 212 is then shown, which is used to transfer the currently heated fluid to another conduit (e.g., a hose), or, in the case of a heater "stacked arrangement," such as heaters arranged in series or parallel one after another, to directly transfer the currently heated fluid to another heater 100, 102, 104, and / or 106. It should be noted that inlet 210 and outlet 212 can be switched; that is, inlet 210 can become outlet, and outlet 212 can become inlet. Inlet 210 and outlet 212 are shown as being disposed on side member 214, which is fluidly connected to manifold member 216. Manifold member 216 is shown as being fluidly connected to cap member 218. In use, fluid enters through inlet 210, passes through various openings into manifold member 216, and is heated via one or more heating elements (e.g., heating element 200). The fluid can then touch cap member 218 and return through other conduits in manifold member 216 to exit via outlet 212.

[0031] Figure 4 This is an exploded perspective view showing embodiments of heaters / heat exchangers 100, 102, 104, and / or 106. Because this view includes... Figure 3The same elements are shown in the same manner, and thus the same elements have the same element reference numbers. As in the previous figure, the illustrated embodiment depicts a heater including a top heating element 200, which can utilize etched foil and / or wire-wound heater elements. Also shown is a bottom heating element 250, which can also utilize etched foil and / or wire-wound heater elements. In certain embodiments, the heating elements 200, 250 can comprise polyimide Thermofoil™ flexible heaters available from Minco in St. Paul, MN. The heating elements 200, 250 can be heated via techniques such as pulse width modulation (PWM) that turn the heating elements on and off at a desired time period (e.g., time frequency). Thus, the heater / heat exchanger 100, 102, 104, and / or 106 can minimize or eliminate the possibility of material carbonization, charring, buildup on the heater or interior surfaces. The heater / heat exchanger 100, 102, 104, and / or 106 does not require opening of the fluid path to service or replace the heater. Due to the large area heating and many parallel channels, the heater / heat exchanger 100, 102, 104, and / or 106 provides more precise thermal control of the fluid. When the resistive heater elements 200, 250 contain interleaved resistive zones (e.g., high and low resistance zones in each heater blanket), the total heat output of each heater assembly can be easily adjusted by individually controlling each zone or wiring the zones in various series / parallel electrical combinations. This allows adjustment of each heater 100, 102, 104, and / or 106 to match the available input power. Thus, the low mass nature of the heater / heat exchanger 100, 102, 104, and / or 106 of these heater assemblies can allow for faster heating and shorter warm-up times. When used on the low pressure side of a fluid delivery system, the heat sink mass can be significantly reduced to further increase the heat transfer rate and reduce warm-up times.

[0032] The system 10 can include a spray gun 28 configured to spray a mixture of a first component fluid and a second component fluid, a first component fluid source 16 configured to supply the first component fluid, a second component fluid source 18 configured to supply the second component fluid, a first heat exchanger 100 configured to supply heat to the first component fluid, and a second heat exchanger 102 configured to supply heat to the second component fluid, wherein the first heat exchanger 100 is configured to supply heat to the first component fluid by providing heat to a first conduit 110, wherein the first conduit 110 is located between the first component fluid source 16 and the spray gun 28, wherein the first conduit 110 is in fluid communication with the first component fluid source 16, wherein the system 10 is configured to mix the first component fluid and the second component fluid. The system 10 can further provide that the second heat exchanger 102 is configured to supply heat to the second component fluid by providing heat to a second conduit 118, wherein the second conduit 118 is located between the first component fluid source 16 and the spray gun 28, wherein the second conduit 118 is in fluid communication with the second component fluid source 18. In some embodiments, the system 10 can provide that the first heat exchanger 100 is in thermal conduction with the first conduit 110 and is mechanically isolated from the fluid component fluid by the first conduit 110, and wherein the second heat exchanger 102 is in thermal conduction with the second conduit 118 and is mechanically isolated from the second component fluid by the second conduit 118. In some embodiments, the system 10 can provide that the first heat exchanger 100 and the second heat exchanger 102 are independently controlled by a control system 36. In some embodiments, the system 10 can provide that the control system 36 is configured to independently control the first pump 12, 14 and the second pump 12, 14. In some embodiments, the system 10 can provide that the control system 36 is configured to control the first pump 12, 14 by being in electrical communication with a motor controller of the first pump 12, 14, wherein the control system 36 is configured to control the second pump 12, 14 by being in electrical communication with a motor controller 29 of the second pump 12, 14. In some embodiments, the system 10 can provide that the control system 36 is configured to detect a slip of the first pump 12, 14 and a slip of the second pump 12, 14. In some embodiments, the system 10 can provide that the control system 36 is configured to maintain a ratio of the first component fluid and the second component fluid, wherein the ratio of the first component fluid and the second component fluid is preset at an interface of the control system 36. In some embodiments, the system 10 can provide that the ratio of the first component fluid and the second component fluid can be selectively maintained based on weight or volume. In some embodiments, the system 10 can include a third heat exchanger and a fourth heat exchanger, wherein the first pump 12 is between the first heat exchanger 100 and the third heat exchanger 104, and the second pump 14 is between the second heat exchanger 102 and the fourth heat exchanger 106.In some embodiments, the system 10 can incorporate that the first heat exchanger 100 and the second heat exchanger 102 are electric heat exchangers. In some embodiments, the system 10 can incorporate that the first heat exchanger 100 includes at least one of an etched foil or wire in thermal conduction with at least one first heating element, and wherein the second heat exchanger 102 includes at least one of an etched foil or wire in thermal conduction with at least one second heating element. In some embodiments, the system 10 can incorporate that the component of the first component fluid includes an isocyanate, and wherein the component of the second component fluid includes at least one of a polyol, a flame retardant, a blowing agent, an amine, a metal catalyst, or a surfactant. The first or any previous or subsequent embodiments can incorporate two or more fluid pumps 12, 14, a first component fluid pump 12, 14 of the two or more fluid pumps 12, 14; a second component fluid pump 12, 14 of the two or more fluid pumps 12, 14, wherein the first component fluid pump 12 and the second component fluid pump 14 are not mechanically coupled to one another; and a control system 36 including a processor 40 configured to: derive a slip ratio of the first component fluid pump 12, 14 and the second component fluid pump 12, 14; and apply master slave motor control to deliver a specified fluid ratio via the first component fluid pump 12 and the second component fluid pump 14 based on the slip ratio. In some embodiments, the system 10 can incorporate that the slip ratio includes a differential slip ratio having a certain slip differential between the first component fluid pump 12, 14 and the second component fluid pump 12, 14. In some embodiments, the system 10 can incorporate that the processor 40 is configured to derive the slip ratio via an indirect measurement, a direct measurement, or a combination of the indirect measurement and the direct measurement. In some embodiments, the system 10 can incorporate that the indirect measurement includes a fluid pressure measurement, and wherein the direct measurement includes a fluid flow measurement. In some embodiments, the system 10 can incorporate that the slip ratio includes a slip volume Q, wherein Q(t) = Pf x Ff x ∫ΔP. 1 / 2dt, where t comprises a sampling time period, Pf = experimentally determined pump factor, Ff = experimentally determined fluid factor, ΔP = Po - Pi, Po = outlet pressure, Pi = inlet pressure. In some embodiments, system 10 can provide that the slip ratio comprises a slip volume Q determined via displacement of the first component fluid pump 12 and the second component fluid pump 14 at zero flow pressurization. In some embodiments, system 10 can provide that the processor 40 is configured to apply master-slave motor control to provide the same fluid pressure at a first outlet of the first component fluid pump 12, 14 and at a second outlet of the second component fluid pump 12, 14. In some embodiments, system 10 can provide that the first component fluid pump 12, 14 is configured to be fluidically connected to a foam 35 dispensing gun via a first hose at a first hose inlet of the foam 35 dispensing gun, and wherein the second component fluid pump 12, 14 is configured to be fluidically connected to the foam 35 dispensing gun via a second hose at a second hose inlet of the foam 35 dispensing gun, and wherein the processor 40 is configured to apply master-slave motor control to provide equal fluid pressure between the first hose and the second hose, between the first hose inlet and the second hose inlet, between the first hose and the second hose inlet, between the second hose and the first hose inlet, or a combination thereof. In some embodiments, system 10 can include a first motor controller 27 configured to control the first component fluid pump 12, 14 and a second motor controller 29 configured to control the second component fluid pump 12, 14, wherein the processor 40 is configured to apply master-slave motor control by selecting one of the first motor controller or the second motor controller 29 as a master controller and selecting the other of the first master controller or the second master controller as a slave controller. In some embodiments, system 10 can provide that the slave motor controller is configured to control a slave speed of a motor driver of the slave controller by multiplying a master speed of a motor driver of the master controller by a factor of the slip ratio. In some embodiments, system 10 can include a first pressure sensor 42 disposed on or near the spray gun 28 and configured to monitor the first component fluid, a second pressure sensor 42 disposed on or near the spray gun 28 and configured to monitor the second component fluid, a control system 36 including a processor 40 configured to: receive a first signal from the first pressure sensor 42; receive a second signal from the second pressure sensor 42; derive a pressure difference between the first pressure sensor and the second pressure sensor 42, the pressure difference representing a fluid pressure difference between the first component fluid and the second component fluid; and control one or more pumps 12, 14 based on the pressure difference to obtain a desired pressure difference. In some embodiments, system 10 can provide that the first pressure sensor 42 is disposed on an inlet of the spray gun 28.In some embodiments, the system 10 can propose that the first pressure sensor 42 is disposed on a hose coupling or on a hose portion of the hose fluidically coupling the one or more pumps 12, 14 to the spray gun 28. In some embodiments, the system 10 can propose that the first pressure sensor 42 is disposed on an outlet of the one or more pumps 12, 14. In some embodiments, the system 10 can include a first temperature sensor 42 disposed on or near the spray gun 28 and configured to monitor a first temperature of the first component fluid. In some embodiments, the system 10 can propose that the processor 40 is configured to derive the fluid pressure differential by including the first temperature in the derivation. In some embodiments, the system 10 can propose that the processor 40 is configured to apply the ideal gas law when including the first temperature in the derivation. In some embodiments, the system 10 can propose that the processor 40 is configured to heat the first component fluid based on the first temperature to obtain the desired pressure differential. In some embodiments, the system 10 can include a second temperature sensor 42 disposed on or near the spray gun 28 and configured to monitor a second temperature of the second component fluid. In some embodiments, the system 10 can propose that the processor 40 is configured to derive the fluid pressure differential by including the first temperature and the second temperature in the derivation.

[0033] Figure 5 is a perspective view showing further details of an embodiment of the manifold assembly member 216. For example, a plurality of parallel conduits 300 are shown through which fluid (e.g., compound A or B) can flow through the member 216 to be heated via the heating elements 200, 250. It is also noted that heating elements, such as elements 200, 250, can be disposed on the sides of the manifold assembly member 216 in addition to the top and bottom of the manifold assembly member 216. It is also noted that a plurality of heating elements can be disposed on the top and bottom of the manifold assembly member 216. That is, the top surface area can include two or more heating elements, the bottom surface area can include two or more heating elements, the sides can each include two or more heating elements, etc. The use of multiple heating elements can provide zone control, where multiple zones provide different temperatures to more evenly heat the fluid via the manifold assembly member 216.

[0034] Figure 6is a front (or back) view of an embodiment of the manifold assembly member 216, showing two rows of parallel conduits 300. More specifically, a top row 350 and a bottom row 352 are shown. In the depicted embodiment, each row includes the same number of openings (e.g., 22 conduits 300). In other embodiments, 3 or more rows, or a single row, can be provided, each row having more than 22 conduits or fewer than 22 conduits. In the depicted embodiment, the conduits 300 are parallel to each other and can pass completely through the manifold assembly member 216. The inlet 210 can be fluidly coupled to the top row 350, and the cap member can include one or more channels to divert fluid from the top row 350 into the bottom row 352 for exit from the heater / heat exchanger 100, 102, 104, and / or 106 via the outlet 212.

[0035] Figure 7 is an exploded perspective view of an embodiment of the heater / heat exchanger 100, 102, 104, and / or 106, showing the (multiple) channels 400 in the cap member 218 that can be used to move fluid from conduits of the top row 350 into conduits of the bottom row 352. Figure 8 is a front view showing an embodiment of the cap member 218, where further details of the channels 400 are shown that can be used to move fluid from conduits of the top row 350 into conduits of the bottom row 352. Figure 9 is a back view showing an embodiment of the member 214, showing the inlet 210 fluidly coupled to the channel 500 and the outlet 212 fluidly coupled to the channel 502. Fluid can flow via the channel 500 into conduits of the top row 350, back via conduits of the bottom row 352, into the channel 502, and then into the outlet 212. Accordingly, a method of manufacturing can include manufacturing the member 214, 216, 218 with the features shown and described (e.g., conduits, channels). A control process can include using PID techniques to set a temperature setpoint, and then maintaining a desired temperature by heating the heating elements (e.g., elements 200, 250).

[0036] In a first embodiment, a system is provided, the system comprising: a spray gun configured to spray a mixture of a first component fluid and a second component fluid; a first component fluid source configured to supply the first component fluid; a second component fluid source configured to supply the second component fluid; a first heat exchanger configured to supply heat to the first component fluid; and a second heat exchanger configured to supply heat to the second component fluid, wherein the first heat exchanger is configured to supply heat to the first component fluid by providing heat to a first conduit, wherein the first conduit is located between the first component fluid source and the spray gun, wherein the first conduit is in fluid communication with the first component fluid source, wherein the system is configured to mix the first component fluid and the second component fluid.

[0037] The first embodiment can further provide that the second heat exchanger is configured to supply heat to the second component fluid by providing heat to a second conduit, wherein the second conduit is located between the first component fluid source and the spray gun, wherein the second conduit is in fluid communication with the second component fluid source.

[0038] The first or any previous or subsequent embodiment can further provide that the first heat exchanger is in thermal conduction with the first conduit and is mechanically isolated from the fluid component fluid by the first conduit, and wherein the second heat exchanger is in thermal conduction with the second conduit and is mechanically isolated from the second component fluid by the second conduit.

[0039] The first or any previous or subsequent embodiment can further provide that the first heat exchanger and the second heat exchanger are independently controlled by a control system.

[0040] The first or any previous or subsequent embodiment can further provide that the control system is configured to independently control the first pump and the second pump.

[0041] The first or any previous or subsequent embodiment can further provide that the control system is configured to control the first pump by being in electrical communication with a motor controller of the first pump, wherein the control system is configured to control the second pump by being in electrical communication with a motor controller of the second pump.

[0042] The first or any previous or subsequent embodiment can further provide that the control system is configured to detect a slip of the first pump and a slip of the second pump.

[0043] The first or any previous or subsequent embodiment can further provide that the control system is configured to maintain a ratio of the first component fluid and the second component fluid, wherein the ratio of the first component fluid and the second component fluid is preset at an interface of the control system.

[0044] The first or any prior or subsequent embodiment can further provide that the ratio of the first component fluid and the second component fluid is selectively maintained based on weight or volume.

[0045] The first or any prior or subsequent embodiment can further include a third heat exchanger and a fourth heat exchanger, wherein the first pump is between the first heat exchanger and the third heat exchanger, and the second pump is between the second heat exchanger and the fourth heat exchanger.

[0046] The first or any prior or subsequent embodiment can further provide that the first heat exchanger and the second heat exchanger are electric heat exchangers.

[0047] The first or any prior or subsequent embodiment can further provide that the first heat exchanger includes at least one of an etched foil or wire in thermal conduction with at least one first heating element, and wherein the second heat exchanger includes at least one of an etched foil or wire in thermal conduction with at least one second heating element.

[0048] The first or any prior or subsequent embodiment can further provide that the component of the first component fluid includes isocyanate, and wherein the component of the second component fluid includes at least one of a polyol, a flame retardant, a blowing agent, an amine, a metal catalyst, or a surfactant.

[0049] The first or any prior or subsequent embodiment can include two or more fluid pumps, a first component fluid pump of the two or more fluid pumps; a second component fluid pump of the two or more fluid pumps, wherein the first component fluid pump and the second component fluid pump are not mechanically coupled to one another; and a control system including a processor configured to: derive a slip ratio of the first component fluid pump and the second component fluid pump; and apply master slave motor control to deliver a specified fluid ratio via the first component fluid pump and the second component fluid pump based on the slip ratio.

[0050] The first or any prior or subsequent embodiment can further provide that the slip ratio includes a differential slip ratio having a slip differential between the first component fluid pump and the second component fluid pump.

[0051] The first or any prior or subsequent embodiment can further provide that the processor is configured to derive the slip ratio via an indirect measurement, a direct measurement, or a combination of the indirect measurement and the direct measurement.

[0052] The first or any prior or subsequent embodiment can further provide that the indirect measurement includes a fluid pressure measurement, and wherein the direct measurement includes a fluid flow measurement.

[0053] The first or any prior or subsequent embodiment can further provide that the slip ratio includes a slip volume Q, wherein Q(t) = Pf x Ff x ∫ΔP 1 / 2dt, where t comprises a sampling time period, Pf = experimentally determined pump factor, Ff = experimentally determined fluid factor, ΔP = Po - Pi, Po = outlet pressure, Pi = inlet pressure.

[0054] The first or any previous or subsequent embodiment can further provide that the slip ratio comprises a slip volume Q determined via displacement of the first component fluid pump and the second component fluid pump at zero flow pressurization.

[0055] The first or any previous or subsequent embodiment can further provide that the processor is configured to apply master-slave motor control to provide the same fluid pressure at the first outlet of the first component fluid pump and at the second outlet of the second component fluid pump.

[0056] The first or any previous or subsequent embodiment can further provide that the first component fluid pump is configured to be fluidically connected to the foam dispensing gun via a first hose at a first hose inlet of the foam dispensing gun, and wherein the second component fluid pump is configured to be fluidically connected to the foam dispensing gun via a second hose at a second hose inlet of the foam dispensing gun, and wherein the processor is configured to apply master-slave motor control to provide equal fluid pressure between the first hose and the second hose, between the first hose inlet and the second hose inlet, between the first hose and the second hose inlet, between the second hose and the first hose inlet, or a combination thereof.

[0057] The first or any previous or subsequent embodiment can further comprise a first motor controller configured to control the first component fluid pump and a second motor controller configured to control the second component fluid pump, wherein the processor is configured to apply master-slave motor control by selecting one of the first motor controller or the second motor controller as a master controller and selecting the other of the first master controller or the second master controller as a slave controller.

[0058] The first or any previous or subsequent embodiment can further provide that the slave motor controller is configured to control a slave speed of a motor driver of the slave controller by multiplying a master speed of a motor driver of the master controller by a factor of the slip ratio.

[0059] The first or any prior or subsequent embodiment can further include: a first pressure sensor disposed on or near the lance and configured to monitor the first component fluid; a second pressure sensor disposed on or near the lance and configured to monitor the second component fluid; a control system including a processor configured to: receive a first signal from the first pressure sensor; receive a second signal from the second pressure sensor; derive a pressure differential between the first pressure sensor and the second pressure sensor, the pressure differential representing a fluid pressure differential between the first component fluid and the second component fluid; and control the one or more pumps based on the pressure differential to obtain a desired pressure differential.

[0060] The first or any prior or subsequent embodiment can further provide that the first pressure sensor is disposed on an inlet of the lance.

[0061] The first or any prior or subsequent embodiment can further provide that the first pressure sensor is disposed on a hose coupling or on a hose portion of the hose fluidically coupling the one or more pumps to the lance.

[0062] The first or any prior or subsequent embodiment can further provide that the first pressure sensor is disposed on an outlet of the one or more pumps.

[0063] The first or any prior or subsequent embodiment can further include a first temperature sensor disposed on or near the lance and configured to monitor a first temperature of the first component fluid.

[0064] The first or any prior or subsequent embodiment can further provide that the processor is configured to derive the fluid pressure differential by including the first temperature in the derivation.

[0065] The first or any prior or subsequent embodiment can further provide that the processor is configured to apply an ideal gas law when including the first temperature in the derivation.

[0066] The first or any prior or subsequent embodiment can further provide that the processor is configured to heat the first component fluid based on the first temperature to obtain the desired pressure differential.

[0067] The first or any prior or subsequent embodiment can further include a second temperature sensor disposed on or near the lance and configured to monitor a second temperature of the second component fluid.

[0068] The first or any prior or subsequent embodiment can further provide that the processor is configured to derive the fluid pressure differential by including the first temperature and the second temperature in the derivation.

[0069] The written description of the application uses examples to disclose the application, including the best mode, and also to enable any person skilled in the art to practice the application, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the application is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements in common with the words of the claims or if they do not differ from the words of the claims materially.

Claims

1. A system comprising: a spray gun configured to spray a mixture of a first component fluid and a second component fluid; a first component fluid source configured to supply the first component fluid; a second component fluid source configured to supply the second component fluid; a first heat exchanger configured to supply heat to the first component fluid; a second heat exchanger configured to supply heat to the second component fluid; and a first fluid pressure detection component consisting of a first pressure sensor, wherein the first heat exchanger is configured to supply heat to the first component fluid by providing heat to a first conduit, wherein the first conduit is located between the first component fluid source and the spray gun, wherein the first conduit is in fluid communication with the first component fluid source, wherein the system is configured to mix the first component fluid and the second component fluid, wherein the second heat exchanger is configured to supply heat to the second component fluid by providing heat to a second conduit, wherein the second conduit is located between the second component fluid source and the spray gun, wherein the second conduit is in fluid communication with the second component fluid source, wherein the first heat exchanger and the second heat exchanger are electric heat exchangers, wherein the first heat exchanger comprises at least one first heating element, wherein the at least one first heating element comprises at least one of an etched foil or a wire, wherein the second heat exchanger comprises at least one second heating element, wherein the at least one second heating element comprises at least one of an etched foil or a wire, wherein the first heat exchanger comprises a side member and a manifold member, wherein the side member comprises a fluid inlet and a fluid outlet, wherein the side member is fluidly coupled to the manifold member, and wherein the manifold member comprises a plurality of parallel conduits extending along the manifold member; and wherein the at least one first heating element is disposed on at least one of a top or a bottom of the manifold member, and the first component fluid flowing through the plurality of parallel conduits of the manifold member is heated via the at least one first heating element. the first heat exchanger is in thermal conduction with the first conduit and is mechanically isolated from the first component fluid by the first conduit, and wherein the second heat exchanger is in thermal conduction with the second conduit and is mechanically isolated from the second component fluid by the second conduit; and / or 2. The system of claim 1, wherein, wherein the first component fluid enters the first heat exchanger via the fluid inlet, and the heated first component fluid exits the first heat exchanger from the fluid outlet; and / or wherein the plurality of parallel conduits are arranged in at least two rows, the fluid inlet is fluidly coupled to conduits of a top row, and the fluid outlet is fluidly coupled to conduits of a bottom row. the first heat exchanger and the second heat exchanger are independently controlled by a control system.

3. The system of claim 1, wherein, ​ 4. The system of claim 3, wherein, The control system is configured to independently control the first pump and the second pump.

5. The system of claim 4, wherein, The control system is configured to control the first pump by being in electrical communication with a motor controller of the first pump, wherein the control system is configured to control the second pump by being in electrical communication with a motor controller of the second pump.

6. The system of claim 4, wherein, The control system is configured to detect slippage of the first pump and slippage of the second pump.

7. The system of claim 6, wherein, The control system is configured to maintain a ratio of the first component fluid and the second component fluid, wherein the ratio of the first component fluid and the second component fluid is pre-set at an interface of the control system.

8. The system of claim 7, wherein, The ratio of the first component fluid and the second component fluid can be maintained selectively based on weight or volume.

9. The system of claim 4, further comprising a third heat exchanger and a fourth heat exchanger, wherein, The first pump is between the first heat exchanger and the third heat exchanger, and the second pump is between the second heat exchanger and the fourth heat exchanger.

10. The system of claim 1, wherein, The component of the first component fluid includes isocyanate, and wherein the second component fluid includes at least one of a polyol, a flame retardant, a blowing agent, an amine, a metal catalyst, or a surfactant.

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