Foam mixing system

Abstract

To provide a mixing system that mixes liquid adhesive and gas to create a solution.SOLUTION: The mixing system includes a manifold (50) defining an adhesive input (54) that receives the liquid adhesive, a gas input that receives the gas, a mixing chamber in fluid communication with the adhesive and gas inputs, an output (58) that outputs the solution, and an output passage extending from the mixing chamber to the output. The mixing system also includes a rotor that rotates within the mixing chamber about a longitudinal axis so as to mix the solution, a motor that rotates the rotor, and a static mixer positioned within the output passage that statically mixes the solution flowing through the output passage.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 62 / 849,228, filed May 17, 2019, and U.S. Provisional Patent Application No. 62 / 860,255, filed June 12, 2019, the entire disclosures of both of which are incorporated herein by reference as if set forth in their entireties.

[0002] The present application relates generally to a mixing system configured to mix a solution including a liquid adhesive and a gas, and more particularly to a mixing system including a rotatable rotor having a plurality of teeth for mixing the solution. [Background technology]

[0003] Hot melt thermoplastic adhesives are used in many applications, including packaging and product assembly. In a traditional hot melt adhesive foam dispensing system, a gear pump delivers a solution containing adhesive and gas to an adhesive dispenser, called a gun. The gun contains a valve at the outlet nozzle through which the solution is dispensed at atmospheric pressure. As the solution is dispensed, gas is released from the solution and trapped in the adhesive, forming a foam on the substrate to which the adhesive is applied.

[0004] During mixing, the gas can form large bubbles within the solution, preventing the gas and adhesive from properly mixing. As a result, foam mixing systems can be utilized to break down the bubbles and create a more homogeneous adhesive and gas solution. Such mixing systems can utilize static and / or dynamic mixers to effectively mix the solution. Dynamic mixers, which include rotating parts, can be effective at mixing the solution, but they can require increased rotational speeds to achieve effective mixing, and certain components, such as seals, often fail and require frequent replacement, leading to increased production downtime and costs. Furthermore, such mixers also require increased power to adequately mix the solution, further increasing production costs.

[0005] As a result, there is a need for a rotary mixer that can effectively mix adhesive and gas solutions at lower rotational speeds. Summary of the Invention [Means for solving the problem]

[0006] An embodiment of the present disclosure is a mixing system configured to mix a liquid adhesive and a gas to generate a solution. The mixing system includes an adhesive input configured to receive the liquid adhesive, a gas input configured to receive the gas, a mixing chamber in fluid communication with the adhesive input and the gas input, an output configured to discharge the solution, and a manifold defining an output passage extending from the mixing chamber to the output. The mixing system also includes a rotor configured to rotate about a longitudinal axis within the mixing chamber to mix the solution, a motor configured to rotate the rotor, and a static mixer disposed within the output passage and configured to statically mix the solution flowing through the output passage.

[0007] Another embodiment of the present disclosure is a mixing system configured to mix a solution comprising a liquid adhesive and a gas. The mixing system includes a manifold defining an input configured to receive the solution, a mixing chamber in fluid communication with the input, and an output in fluid communication with the mixing chamber and configured to discharge the solution. The mixing system also includes a rotor configured to rotate within the mixing chamber to mix the solution, and a motor configured to rotate the rotor at less than 100 revolutions per minute (RPM) such that the rotor mixes the solution at a shear rate greater than 100 double strokes per second.

[0008] The foregoing summary and the following detailed description will be better understood when read in conjunction with the appended drawings. The drawings illustrate exemplary embodiments of the present disclosure. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. [Brief explanation of the drawings]

[0009] [Figure 1A] 1 shows a perspective view of a mixing system according to an embodiment of the present disclosure. [Figure 1B] 1B shows another perspective view of the mixing system of FIG. 1A. [Figure 2A] 2A shows a cross-sectional view of the mixing system shown in FIG. 1A taken along line 2A-2A of FIG. 1A. [Figure 2B] 2B shows a cross-sectional view of the mixing system shown in FIG. 1A taken along line 2B-2B of FIG. 1A. [Figure 3] 2A shows a cross-sectional view of the mixing assembly of the mixing system shown in FIG. 1A taken along line 2A-2A of FIG. 1A. [Figure 4A] FIG. 4 shows a perspective view of the stator of the mixing assembly shown in FIG. 3. [Figure 4B] 4B shows another perspective view of the stator shown in FIG. 4A. [Figure 5] FIG. 4 shows a perspective view of the plate and rotor of the mixing assembly shown in FIG. 3. [Figure 6A] FIG. 4 shows a side view of the rotor shown in FIG. 3. [Figure 6B] FIG. 4 shows a front view of the rotor shown in FIG. 3. [Figure 6C] 6C shows an enlarged portion of the front view of the rotor shown in FIG. 6B. [Figure 7] 4 shows a perspective view of a tooth of the rotor shown in FIG. 3. [Figure 8] FIG. 2C shows a perspective view of a static mixer of the mixing system shown in FIG. 2B. [Figure 9] 9 is a cross-sectional view of the static mixer shown in FIG. 8 taken along line 9-9 of FIG. 8. DETAILED DESCRIPTION OF THE INVENTION

[0010] A mixing system 10 including a mixing assembly 100 for mixing a solution containing a liquid adhesive and a gas is described herein. Certain terms are used in the following description for convenience and not limitation. The terms "right," "left," "bottom," and "top" designate directions in the drawings to which reference is made. The terms "inside" and "outside" refer to directions toward and away from the geometric center of the description, respectively, for describing the mixing system 10 and its associated parts. The terms "upstream" and "downstream" refer to directions along the flow of solution relative to a particular component of the mixing system 10. The terms "forward" and "rearward" refer to directions along the longitudinal direction 2 and opposite the longitudinal direction 2 along the mixing system 10 and its associated parts. The terminology includes the above terms, derivatives thereof, and terms of similar import.

[0011] Unless otherwise specified herein, the terms "longitudinal," "lateral," and "vertical" are used to describe orthogonal components of the various components of the mixing system 10, as designated by the longitudinal direction 2, the lateral direction 4, and the vertical direction 6. While the longitudinal and lateral directions 2, 4 are shown as extending along horizontal planes and the vertical direction 6 is shown as extending along a vertical plane, it should be understood that the planes encompassing the various directions may differ in use.

[0012] 1A-3, a mixing system 10 configured to mix a solution including a liquid adhesive and a gas is shown. The mixing system 10 can be used for a wide variety of applications, such that the liquid adhesive can be a room-temperature vulcanizing (RTV) silicone, a thermoplastic rubber-based hot melt, a thermoplastic hot melt, a polyurethane (PUR) hot melt, a hybrid sealant, or the like, and the gas can be nitrogen, a noble gas, carbon dioxide, or the like. Any combination of these liquid adhesives and gases can be mixed to form a solution capable of forming a foam on a substrate when dispensed from a foam dispenser.

[0013] The mixing system 10 may include a mixer 20 including a manifold 50 and a mixing assembly 100 configured to be received within the manifold 50, the mixing assembly 100 being described further below. The mixing system 10 may further include a motor 24 operably coupled to a rotor 134 of the mixing assembly 100. The motor 24 may be a DC motor, a variable frequency AC motor, a servo motor, a stepper motor, or the like. The mixing system 10 may also include a motor reducer 28 operably connected to the motor 24 and the rotor 134, the motor reducer 28 being configured to reduce the rotational speed imparted to the rotor 134 while increasing the torque imparted to the rotor 134. The motor reducer 28 may produce a 10:1 reduction, although other reductions are contemplated.

[0014] The mixing system 10 may include a controller 32 in wired and / or wireless signal communication with the mixing system 10, particularly the motor 24 and flow meter 70 of the mixing system 10. The controller 32 may be configured to control the operation of the motor 24 and may include any suitable computing device configured to host software applications for monitoring and controlling various operations of the mixing system 10, as described herein. It will be appreciated that the controller 32 may include any suitable computing device, including a processor, a desktop computing device, a server computing device, or a portable computing device such as a laptop, tablet, or smartphone. Specifically, the controller 32 may include memory and a human-machine interface (HMI) device. The memory may be volatile (such as some types of RAM), non-volatile (such as ROM, flash memory, etc.), or a combination thereof. Controller 32 may include additional storage devices (e.g., removable and / or non-removable storage devices) including, but not limited to, tape, flash memory, smart cards, CD-ROMs, digital versatile disks (DVDs) or other optical storage devices, magnetic tape, magnetic disk storage devices or other magnetic storage devices, universal serial bus (USB) compatible memory, or any other medium that can be used to store information and that can be accessed by controller 32. The memory of controller 32 may be configured to store and recall, on demand, the necessary operation of motor 24 required to achieve various mixing operations and corresponding mixing characteristics.

[0015] The HMI device may include inputs that provide the ability to control the controller 32 and, therefore, the motor 24, for example, via buttons, softkeys, a mouse, voice-activated controls, a touchscreen, movement of the controller 32, visual cues (e.g., waving a hand in front of the camera of the controller 32), etc. The HMI device may provide output via a graphical user interface, including visual information such as a visual representation of current conditions within the mixing system 10 and tolerances for these parameters, via a display. Other outputs may include audio information (e.g., via a speaker), mechanical (e.g., via a vibration mechanism), or a combination thereof. In various configurations, the HMI device may include a display, a touchscreen, a keyboard, a mouse, a motion detector, a speaker, a microphone, a camera, or any combination thereof. The HMI device may further include any suitable device for inputting biometric information, such as fingerprint information, retinal information, voice information, and / or facial feature information, so that certain biometric information is required to access the controller 32.

[0016] Continuing with FIGS. 1A-3, the manifold 50 of the mixer 20 may extend along the longitudinal direction 2 from a first end 50a to a second end 50b opposite the first end 50a. The manifold 50 may further define an input 54 at the second end 50b configured to receive adhesive from an adhesive source (not shown). The input 54 is shown disposed at the second end 50b, but may be disposed elsewhere on the manifold 50 as desired. The flow path of the adhesive through the mixing system 10 is indicated by the bold arrows shown in FIGS. 2A and 2B. The manifold 50 may include a passageway 62 extending from the input 54 to the mixing chamber 82. The mixing system 10 may include a flow meter 70 configured to measure the flow rate of adhesive flowing adjacent the input 54. In one example, the flow meter 70 may be disposed upstream of the input 54 as shown. In another example, the flow meter 70 can be configured to measure the flow rate downstream of the input 54, for example, along the passageway 62 between the input 54 and the mixing chamber 82. The flow meter 70 can include a gear flow meter, although other types of flow meters can be used if desired. As shown schematically in FIG. 2A, the flow meter 70 can be in wired and / or wireless communication with the controller 32, such that the flow meter 70 can provide a signal to the controller 32 indicative of the measured adhesive flow rate.

[0017] The mixing chamber 82 is configured to receive the mixing assembly 100, as described further below. Accordingly, the mixing chamber 82 is in fluid communication with the input 54 and receives adhesive from the input 54 and gas from the gas input assembly 92, described below, to form a solution containing adhesive and gas. The mixing chamber 82 may define a cavity extending from the first end 50 a into the manifold 50. The mixing chamber 82 may have a generally circular cross-section, as viewed along a plane defined by the lateral and vertical directions 4, 6, to form a shape complementary to the components of the mixing assembly 100. Consequently, the mixing chamber 82 may define other shapes to accommodate alternative embodiments of the mixing assembly 100. The mixer 20 may include a cap 86 configured to couple to the manifold 50 at the first end 50 a, such that the cap 86 bounds and at least partially defines the mixing chamber 82. The cap 86 can be coupled to the manifold 50 to form a fluid seal between the manifold 50 and the cap 86, thereby preventing leakage of the solution from the mixing chamber 82. The cap 86 can be coupled to the manifold 50 via a detachable fastener, although other methods of attaching the cap 86 to the manifold 50 are contemplated, such as threaded engagement, a clamp, etc. A passageway 90 extends longitudinally through the cap 86, and a rod 150 can extend through the cap 86 from the motor reducer 28 to the rotor 134, as described further below. As shown in FIG. 2B , the manifold 50 can further include an output 58 in fluid communication with the mixing chamber 82 via the output passageway 84 and configured to discharge the mixed solution from the manifold 50. A plurality of static mixers 250 can be disposed within the output passageway 84 for statically mixing the solution; the static mixers 250 are described further below. While the output 58 is shown as being located at the second end 50b of the manifold 50, it is contemplated that the output 58 can be located elsewhere on the manifold 50 as desired.Output 58 can be configured to eject the solution into a dispenser configured to apply the solution as a foam to a substrate, such as a foam gasket or a part requiring pleat stabilization.

[0018] The mixing system 10 may further include a gas input assembly 92 configured to supply pressurized gas to the mixing chamber 82. The gas input assembly 92 may be configured to supply pressurized gas to the mixing chamber 82 from a pressurized gas source (not shown). The gas input assembly 92 may define a hose assembly or other assembly capable of directing a flow of pressurized gas and may be in fluid communication with a gas input 96 defined by the manifold 50. In the illustrated embodiment, the gas input 96 extends from an exterior surface of the manifold 50 to the mixing chamber 82. An input valve 98 may be disposed within the gas input 96, and the input valve 98 may be configured to selectively block the gas input 96. For example, in an open position, the input valve 98 may be configured to place the gas input assembly 92 in fluid communication with the mixing chamber 82, while in a closed position, the input valve 98 may be configured to prevent fluid communication between the mixing chamber 82 and the gas input assembly 92. In the illustrated embodiment, the input valve 98 can be normally in a closed position to prevent solution from exiting the mixing chamber 82 through the gas input assembly 92. The input valve 98 can then open when contacted with a stream of pressurized gas at a sufficient rate, allowing the pressurized gas to enter the mixing chamber 82. The source of pressurized gas supplying the gas input assembly 92 can be activated manually by an operator of the mixing system 10 or automatically by the controller 32.

[0019] During operation, adhesive may be pumped from the adhesive source through the input 54 at a specific rate. The flow meter 70 may measure the adhesive flow rate and communicate that flow rate to the controller 32. Generally, the mixture produced by the mixing system 10 includes an amount of gas that is necessarily related to the amount of adhesive delivered to the mixing chamber 82. As a result, in response to receiving the adhesive flow rate from the flow meter 70, the controller 32 may operate the pressurized gas source to deliver an amount of gas to the mixing chamber 82 through the gas input assembly 92 that corresponds to the amount of adhesive delivered to the mixing chamber from the adhesive source. The relative amounts of adhesive and gas comprising the mixture may vary depending on factors such as the type of solution being produced, the dispensing operation being performed, and the type of adhesive and / or gas. In other embodiments, the controller 32 may operate the pressurized gas source to deliver a fixed amount of gas to the mixing chamber 82 and then operate the adhesive source to deliver the required amount of adhesive to the input 54.

[0020] 2A-3, the mixing assembly 100 will be described in more detail. The mixing assembly 100 may include a rotor 134 operably coupled to a motor 24, the motor 24 being configured to rotate the rotor 134. Specifically, the rotor 134 may define a first end 134a, a second end 134b opposite the first end 134a along the longitudinal direction 2, and an outer surface 135 extending from the first end 134a to the second end 134b. The rotor 134 may be cylindrical, and the outer surface 135 may be a curved outer surface curved about a longitudinal axis A parallel to the longitudinal direction 2. The rotor 134 may be configured to rotate about the longitudinal axis A within the mixing chamber 82 to mix the solution. The rotor 134 may define a passageway 138 extending through the rotor 134 from the first end 134a to the second end 134b along the longitudinal direction 2. The passageway 138 is configured to receive a rod 150, which extends from the rotor 134 to the motor reducer 28 and rotationally couples the rotor 134 to the motor reducer 28. Specifically, the rod 150 extends from a first end 150a, where the rod 150 connects to the motor reducer 28, along the longitudinal direction 2 to a second end 150b opposite the first end 150a, where the rod 150 connects to a fastener 154, as described below. The passageway 138 may have a substantially cylindrical shape that substantially corresponds to the outer shape of the rod 150. However, the passageway 138 may define other shapes as desired to accommodate various other rod embodiments.

[0021] The rod 150 may comprise a solid cylindrical rod configured to transmit torque from the motor reducer 28 to the rotor 134. The rod 150 may define at least one notch extending into the rod 150 from an outer surface, where the at least one notch is configured to receive a portion of a device that rotationally couples the rod 150 to the rotor 134. In the illustrated embodiment, the rod 150 may define a first notch 140a and a second notch 140b spaced apart from the first notch 140a along the longitudinal direction 2. The rotor 134 may define a first channel 142a and a second channel 142b spaced apart from the first channel 142a along the longitudinal direction 2, with each of the first and second channels 142a, 142b extending from the outer surface 135 of the rotor 134 to the passageway 138. Each of the first and second channels 142a, 142b is configured to receive a respective pin 162a, 162b. The first pin 162a is disposed within the first channel 142a and configured to engage with the first notch 140a, while the second pin 162b is disposed within the second channel 142b and configured to engage with the second notch 140b to rotatably couple the rotor 134 to the rod 150. The engagement between the first and second pins 162a, 162b and the rotor 134 and rod 150 functions to rotatably couple the rod 150 to the rotor 134. In the illustrated embodiment, the first and second pins 162a, 162b can define external threads configured to engage corresponding threads in the first and second channels 142a, 142b to lock the first and second pins 162a, 162b within the first and second channels 142a, 142b. However, it is contemplated that other methods of securing the pins 162 a, 162 b may be utilized. Although the first and second notches 140 a, 140 b are shown as being positioned on the rod 150 at specific locations, they may be positioned on the rod 150 in other ways as desired. Similarly, although the first and second channels 142 a, 142 b are shown as being positioned on the rod 150 at specific locations, they may be positioned within the rotor 134 in other ways as desired.However, the locations of the first and second notches 140a, 140b generally coincide with the locations of the first and second channels 142a, 142b.

[0022] 3 and 5, the mixing assembly 100 may include a plate 146 attached to the second end 134b of the rotor 134. Specifically, the rotor 134 may define a recess 188 extending into the rotor 134 from the second end 134b, with the plate 146 configured to be received by the recess 188. The plate 146 may be attached to the rotor 134 via fasteners (not shown), although other means of attaching the plate 146 to the rotor 134 are contemplated, such as welding, integral molding, etc. As a result, the plate 146 may be rotatably coupled to the rotor 134 such that the plate 146 rotates with the rotor 134 upon receiving torque from the motor 24 via the rod 150. The passage 148 may extend through the plate 146 along the longitudinal direction 2, such that the passage 148 is substantially aligned with the passage 138 of the rotor 134 when the plate 146 is attached to the rotor 134. This allows the rod 150 to extend through the passage 138 in the rotor 134 and through the passage 148 in the plate 146 .

[0023] The mixing assembly 100 may further include a stator 104 disposed within the mixing chamber 82. The stator 104 may extend along the longitudinal direction 2 from a first end 104a to a second end 104b opposite the first end 104a. The first end 104a may include a body 108 of the stator 104, the body 108 defining a cross-section having a diameter substantially matching the diameter of the cross-section of the mixing chamber 82. In contrast, the second end 104b may include a protrusion 112 extending from the body 108 along the longitudinal direction 2, the protrusion 112 defining a cross-section having a smaller diameter than the body 108. However, it is contemplated that in other embodiments, the stator 104 may define a body having a substantially constant diameter from the first end 104a to the second end 104b.

[0024] The stator 104 can define a passageway 116 extending through the stator 104 from the first end 104a to the second end 104b along the longitudinal direction 2. The passageway 116 can also extend through the stator 104 from the body 108 to the protrusion 112. The passageway 116 can be in fluid communication with the passageway 62 such that the passageway 116 is configured to receive adhesive from the input 54 and deliver adhesive to the mixing chamber 82. The passageway 116 can be configured to receive a portion of a fastener 154 attached to the second end 150b of the rod 150 and a locking ring 158 attached longitudinally to the stator 104 and configured to secure the fastener 154, and therefore the rod 150, to the stator 104 along the longitudinal direction 2. The engagement between the fastener 154 and the locking ring 158 prevents the rod 150 and rotor 134 from being pulled longitudinally away from the stator 104. The passage 116 may receive a plate 159 defining a plurality of circumferentially spaced holes 160 extending therethrough along the longitudinal direction 2. During operation, adhesive flows through the holes 160 in the plate 159 as it flows through the passage 116. The plate 159 may be integral with a portion of the fastener 154 or may comprise a separate component configured to be disposed about the fastener 154. As shown, the plate 159 may define four circumferentially equally spaced holes 160. However, the plate 159 may define more or less than four holes 160. For example, the plate may define one, two, three, or four or more holes. Additionally, the holes may be spaced unequal distances about the plate 159. The number and spacing of the holes 160 may be defined based on the desired flow characteristics of the adhesive as it enters the mixing chamber 82 .

[0025] The passage 116 may also be configured to receive a valve 166. The valve 166 may be a one-way valve configured to allow adhesive to flow from the passage 62 to the mixing chamber 82 through the passage 116, but to prevent adhesive from flowing from the mixing chamber 82 to the passage 62 through the passage 116. The valve 166 may include a spring 170 and a ball 174, where the spring 170 is biased between the fastener 154 and the ball 174. In operation, when adhesive flows through the passage 62, the force of the adhesive flow presses against the ball 174, compressing the spring 170 toward the fastener 154 along the longitudinal direction 2, thereby opening the passage 116 and placing the passage 62 in fluid communication with the mixing chamber 82. Conversely, when adhesive is not flowing through the passage 62, the spring 170 biases the ball 174 against a portion of the protrusion 112 of the stator 104, closing the passage 116 and interrupting fluid communication between the passage 62 and the mixing chamber 82. As a result, valve 166 prevents adhesive located within mixing chamber 82 from flowing upstream from mixing chamber 82 back into passageway 62. Although valve 166 is specifically shown as including a spring 170 and a ball 174, it is contemplated that other types of valves may be utilized.

[0026] Unlike the rotor 134 and the plate 146, the stator 104 is rotationally coupled to the manifold 50. In other words, the stator 104 is configured to remain stationary during mixing operations, while the motor 24 is configured to rotate the rotor 134 and the plate 146 relative to the stator 104 within the mixing chamber 82. To couple the stator 104 to the manifold 50, the manifold 50 can define an elongated hole 117a (shown in FIG. 2A ) that opens into the mixing chamber 82 and is configured to align with an elongated hole 117b (shown in FIGS. 2A and 4B ) that extends within the body 108 of the stator 104 when the stator 104 is received within the mixing chamber 82. A pin 118 can be disposed within the elongated holes 117a, 117b, and engagement between the pin 118 and the manifold 50 and the stator 104 is configured to rotationally couple the stator 104 to the manifold 50.

[0027] 4A and 4B , mixing of the adhesive and gas to create a solution may be accomplished in large part by teeth defined by various components of the mixing assembly 100 extending into the mixing chamber 82. For example, the stator 104 may define a plurality of teeth 119 extending from the stator 104 along the longitudinal direction 2. When positioned within the mixing chamber 82, the plurality of teeth 119 may extend from the body 108 of the stator 104 toward the rotor 134 along the longitudinal direction 2. With the stator 104 rotationally stationary relative to the manifold 50, the plurality of teeth 119 may statically mix the adhesive and gas into a solution as the adhesive flows out of the passages 116 of the stator 104 through the holes 160 and the gas flows out of the gas input assembly 92 through gaps 132 defined between pairs of adjacent teeth 119.

[0028] The plurality of teeth 119 defined by the stator 104 may define a particular arrangement. For example, the stator 104 may form a first tooth ring 120, a second tooth ring 124, and a third tooth ring 128, each of which defines a plurality of teeth extending in a ring shape from the stator 104. For example, the first tooth ring 120 may define an arrangement of innermost teeth 122 extending from the stator 104 along the longitudinal direction 2. The second tooth ring 124 may define an arrangement of teeth 126 extending from the stator 104 along the longitudinal direction 2 and concentrically positioned radially outward from the teeth 122 of the first tooth ring 120. The third tooth ring 128 may extend radially outward from the stator 104 along the longitudinal direction 2 and define an arrangement of teeth 130 concentrically arranged radially outward from the teeth 126 of the second tooth ring 124. As a result, the second tooth ring 124 may be concentrically arranged between the first tooth ring 120 and the third tooth ring 128. A channel 123 may be defined between adjacent ones of the tooth rings. For example, a channel 123 may be disposed between the first and second tooth rings 120 and 124, and a channel 123 may be disposed between the second and third tooth rings 124 and 128. Each channel 123 may have a ring shape. Each channel 123 may be devoid of teeth. In other embodiments, it is contemplated that the plurality of teeth 119 may define other configurations, such as more or less than three tooth rings, or configurations other than rings.

[0029] In the illustrated embodiment, each of the first, second, and third tooth rings 120, 124, and 128 may define the same number of teeth 122, 126, and 130, respectively. Accordingly, the teeth 122, 126, and 130 of the first, second, and third tooth rings 120, 124, and 128 may define different sizes. The teeth 122, 126, and 130 may have widths along the circumferential direction. In the illustrated embodiment, the teeth 122 of the first tooth ring 120 may define the smallest width of the plurality of teeth 119, the teeth 130 of the third tooth ring 128 may define the largest width of the plurality of teeth 119, and the teeth 126 of the second tooth ring 124 may define a width greater than the width of the teeth 122 but less than the width of the teeth 130. However, it is contemplated that each of the first, second, and third tooth rings 120, 124, 128 can define different relative sizes and numbers of teeth, as desired. Additionally, in other embodiments, the teeth 122 of the first tooth ring 120 can define different widths and / or other dimensions from one another, the teeth 126 of the second tooth ring 124 can define different widths and / or dimensions from one another, and the teeth 130 of the third tooth ring 128 can define different widths and / or other dimensions from one another.

[0030] 4A , gaps 132 can be formed between adjacent ones of the plurality of teeth 119 to allow for flow of solution within the mixing chamber 82. For example, gaps 132 can be defined between adjacent teeth 122 of the first ring of teeth 120, gaps 132 can be defined between adjacent teeth 126 of the second ring of teeth 124, and gaps 132 can be defined between adjacent teeth 130 of the third ring of teeth 128. The respective gaps 132 from each of the rings of teeth 120, 124, 128 can be radially aligned with one another so that the solution has multiple unobstructed paths through the rings of teeth 120, 124, 128 as it exits the holes 160 in the plate 159. However, in other embodiments, it is contemplated that the gaps 132 defined between the teeth 122, 126, 130 of the tooth rings 120, 124, 128 may be at least partially offset or staggered so that the solution encounters a somewhat greater obstruction due solely to the plurality of teeth 119 of the stator 104 as it flows out of the holes 160 in the plate 159.

[0031] 3 and 5 , the plate 146, similar to the stator 104, may define a plurality of teeth 189 extending from the plate 146 along the longitudinal direction 2. When positioned within the mixing chamber 82, the plurality of teeth 189 may extend along the longitudinal direction 2 from the rotor 134 toward the stator 104. Thus, the plurality of teeth 189 extend along the longitudinal direction 2 in an opposite direction to the plurality of teeth 119 of the stator 104. At least some of the teeth 189 of the plate 146 may be disposed between the teeth 119 of the stator 104. Similarly, at least some of the teeth 119 of the stator 104 may be disposed between the teeth 189 of the plate 146. When the plate 146 is rotationally coupled to the rotor 134, the plurality of teeth 189 can dynamically mix the adhesive and gas into solution as gas flows from the passages 116 of the stator 104 through the holes 160 and from the gas input assembly 92 through gaps 191 defined between two adjacent teeth 189. As the plate 146 rotates, at least some of the teeth 189 of the plate 146 can rotate between the teeth of the stator 104.

[0032] The plurality of teeth 189 defined by the plate 146 may define a particular arrangement. For example, the plate 146 may define a first ring of teeth 190, a second ring of teeth 194, and a third ring of teeth 198, where each of the rings of teeth 190, 194, 198 defines a respective plurality of teeth extending from the plate 146 in a ring-like arrangement. For example, the first ring of teeth 190 may define an arrangement of innermost teeth 192 extending from the plate 146 along the longitudinal direction 2. The second ring of teeth 194 may define an arrangement of teeth 196 extending from the plate 146 along the longitudinal direction 2 and concentrically positioned radially outward from the teeth 192 of the first ring of teeth 190. The third tooth ring 198 may extend radially outward from the plate 146 along the longitudinal direction 2 and define an arrangement of teeth 199 concentrically arranged radially outward from the teeth 196 of the second tooth ring 194. As a result, the second tooth ring 194 may be concentrically arranged between the first tooth ring 190 and the third tooth ring 198. A channel 193 may be defined between adjacent ones of the tooth rings. For example, a channel 193 may be arranged between the first and second tooth rings 190 and 194, and a channel 193 may be arranged between the second and third tooth rings 194 and 198. Each channel 193 may have a ring shape. Each channel 193 may be devoid of teeth. In other embodiments, it is contemplated that the plurality of teeth 189 may define other configurations, such as more or less than three tooth rings, or configurations other than rings.

[0033] In the illustrated embodiment, each of the first, second, and third tooth rings 190, 194, and 198 can define the same number of teeth 192, 196, and 199, respectively. Accordingly, the teeth 192, 196, and 199 of the first, second, and third tooth rings 190, 194, and 198 can define different sizes. For example, the teeth 122, 126, and 130 can each have a width along the circumference. In the illustrated embodiment, the teeth 192 of the first tooth ring 190 can define the smallest width of the plurality of teeth 189, the teeth 199 of the third tooth ring 198 can define the largest width of the plurality of teeth 189, and the teeth 196 of the second tooth ring 194 can define a width greater than the width of the teeth 192 but less than the width of the teeth 199. However, it is contemplated that each of the first, second, and third tooth rings 190, 194, 198 can define different relative sizes and numbers of teeth, as desired. Additionally, in other embodiments, the teeth 192 of the first tooth ring 190 can define different widths and / or other dimensions from one another, the teeth 196 of the second tooth ring 194 can define different widths and / or dimensions from one another, and the teeth 199 of the third tooth ring 198 can define different widths and / or other dimensions from one another.

[0034] 5 , gaps 191 can be formed between adjacent ones of the plurality of teeth 189 to allow solution to flow through the mixing chamber 82. For example, gaps 191 can be defined between adjacent teeth 192 of a first ring of teeth 190, gaps 191 can be defined between adjacent teeth 196 of a second ring of teeth 194, and gaps 191 can be defined between each adjacent tooth 199 of a third ring of teeth 198. The respective gaps 191 from each of the rings of teeth 190, 194, 198 can be radially aligned with one another so that solution has multiple unobstructed paths through the rings of teeth 190, 194, 198 as it exits the holes 160 in the plate 159. However, in other embodiments, it is contemplated that the gaps 191 defined between the teeth 192, 196, 199 of the tooth rings 190, 194, 198 may be at least partially offset in a staggered manner so that as the solution flows from the holes 160 in the plate 159, it encounters a greater level of obstruction due solely to the plurality of teeth 189 of the plate 146.

[0035] When the mixing assembly 100 is positioned within the mixing chamber 82, the stator 104 and the plate 146 can be positioned adjacent to one another such that adhesive and gas entering the mixing chamber 82 flow through the passages 116 in the stator 104 and then outward along the plane defined by the lateral and vertical directions 4, 6 to the periphery of the mixing chamber 82, as shown in FIGS. 2A and 2B . As the solution flows between the stator 104 and the plate 146, interaction between the plurality of teeth 119 of the stator 104 and the plurality of teeth 189 of the plate 146 can mix the solution, which can be amplified by the relative positioning of the plurality of teeth 119 and the plurality of teeth 189. When the mixing assembly 100 is positioned within the mixing chamber 82, the plurality of teeth 119 extend from the stator 104 toward the plate 146, while the plurality of teeth 189 extend from the plate 146 toward the stator 104, such that the ring of teeth 120, 124, 128 of the stator 104 can be positioned to be substantially aligned with the ring of teeth 190, 194, 198 of the plate 146 in the plane defined by the lateral and vertical directions 4, 6, i.e., the plane of fluid flow between the stator 104 and the plate 146. This allows the teeth of the stator 104 and the teeth of the plate 146 to be aligned in a plane perpendicular to the longitudinal axis A, such that the plane perpendicular to the longitudinal axis A intersects the teeth of the stator 104 and the teeth of the plate 146.

[0036] Each channel 193 of plate 146 can receive a corresponding tooth ring of stator 104. Similarly, each channel 123 of stator 104 can receive a corresponding tooth ring of plate 146. For example, first tooth ring 120 of stator 104 can be positioned in channel 193 between first and second tooth rings 190 and 194 of plate 146. Second tooth ring 194 of plate 146 can be positioned in channel 123 between first and second tooth rings 120 and 124 of stator 104. Second tooth ring 124 of stator 104 can be positioned in channel 193 between second and third tooth rings 194 and 198 of plate 146. Third tooth ring 198 of plate 146 can be positioned in channel 123 between second and third tooth rings 124 and 128 of stator 104.

[0037] As a result, the first tooth ring 190 of the plate 146 can be positioned radially inward from the first tooth ring 120 of the stator 104. The first tooth ring 120 of the stator 104 can be positioned radially inward from the second tooth ring 194 of the plate 146 and radially outward from the first tooth ring 190 of the plate 146. The second tooth ring 194 of the plate 146 can be positioned radially inward from the second tooth ring 124 of the stator 104 and radially outward from the first tooth ring 120 of the stator 104. The second tooth ring 124 of the stator 104 can be positioned radially inward from the third tooth ring 198 of the plate 146 and radially outward from the second tooth ring 194 of the plate 146. The third tooth ring 198 of the plate 146 can be positioned radially inward from the third tooth ring 128 of the stator 104 and radially outward from the second tooth ring 124 of the stator 104. The third tooth ring 128 of the stator 104 can be positioned radially outward from the tooth rings 190, 194, 198 of the plate 146. Because the stator 104 is rotationally coupled to the manifold 50 while the plate 146 is rotationally coupled to the rotor 134, during operation, the plurality of teeth 189 of the plate 146 is configured to rotate while the plurality of teeth 119 of the stator 104 remains stationary. Providing both dynamic and static mixing can aid in mixing of the solution as it flows between the stator 104 and the plate 146 toward the periphery of the mixing chamber 82.

[0038] Similar to the stator 104 and plate 146, the rotor 134 may define a plurality of teeth 178 configured to aid in mixing of the solution. Referring to FIGS. 6-8 , the plurality of teeth 178 may extend radially outward from the outer surface 135 of the rotor 134. As a result, unlike the teeth 119, 189 of the stator 104 and plate 146, respectively, the plurality of teeth 178 of the rotor 134 extend from the outer surface 135 along a plane defined by the lateral direction 4 and the vertical direction 6. The plurality of teeth 178 may be arranged in columns and rows along the outer surface 135 of the rotor 134, with each column extending substantially along the longitudinal direction 2, while each row may extend circumferentially around the outer surface 135 of the rotor along a plane defined by the lateral and vertical directions 4, 6. However, the rows and columns of the plurality of teeth may be alternatively oriented with respect to the longitudinal, lateral, and vertical directions 2, 4, 6, as desired. Every two adjacent teeth 178 in each row of teeth 178 may define a gap 187 therebetween, with solution configured to flow through each gap 187 along the length of the rotor 134 .

[0039] As shown, the rotor 134 may include a first row 182a of teeth 178, a second row 182b of teeth 178, a third row 182c of teeth 178, ... through an nth row of teeth 178. In one embodiment, the rotor 134 may define between 60 and 130 rows of teeth 178. In another embodiment, the rotor 134 may define between 70 and 120 rows of teeth 178. Furthermore, the rotor 134 may define between 80 and 110 rows of teeth 178. The rotor 134 may also define between 90 and 100 rows of teeth 178.

[0040] Further, as shown, the rotor 134 may include a first row 186a of teeth 178, a second row 186b of teeth 178, a third row 186c of teeth 178, ... through an nth row of teeth 178. In one embodiment, the rotor 134 may define between 10 and 50 rows of teeth 178. In another embodiment, the rotor 134 may define between 15 and 45 rows of teeth 178. Furthermore, the rotor 134 may define between 20 and 40 rows of teeth 178. The rotor 134 may also define between 25 and 35 rows of teeth 178.

[0041] In the illustrated embodiment, the rotor 134 may include 58 rows of teeth 178 and 15 rows of teeth 178. As a result, the illustrated rotor 134 may include 870 teeth 178. However, in other embodiments, it is contemplated that the rotor 134 may include fewer than 870 teeth 178. For example, the rotor 134 may include at least 400 teeth 178. Further, the rotor 134 may include at least 500 teeth 178. Further, the rotor 134 may include at least 600 teeth. The rotor 134 may also include at least 700 teeth 178. In other embodiments, the rotor 134 may include at least 800 teeth 178.

[0042] In other embodiments, it is contemplated that the rotor 134 may include more than 870 teeth 178. For example, the rotor 134 may include at least 1000 teeth 178. Further, the rotor 134 may include at least 1500 teeth 178. Further, the rotor 134 may include at least 2000 teeth. The rotor 134 may also include at least 2500 teeth 178. In other embodiments, the rotor 134 may include at least 3000 teeth 178. In one specific example, the rotor 134 may include 96 columns and 30 rows of teeth 178. As a result, the rotor may include 2880 teeth 178. The number of teeth 178 extending from the rotor 134 represents a greater number of teeth than those included in rotors of conventional mixing assemblies. This creates more parallel paths for the solution to travel between the teeth 178, thereby reducing the pressure drop of the solution as it flows through the mixing chamber 82. Additionally, the number of teeth 178 allows the diameter of rotor 134 to be larger than conventional rotors, thus reducing the rotational speed at which rotor 134 must be rotated to achieve adequate mixing. The speed at which rotor 134 must rotate to achieve adequate mixing of the solution is further described below.

[0043] The inclusion of an increased number of teeth 178 extending from the rotor can be achieved by reducing the size of the individual teeth of the teeth 178. The structure of each tooth 178 will now be described with reference to FIGS. 6-8. Each tooth 178 can define a body 200 extending from a base 200a on the outer surface 135 to a tip 200b opposite the base 200a. The body 200 can define a height H measured from the base 200a to the tip 200b. In one embodiment, the height H is 0.20 inches or less, e.g., 0.19 inches or less, e.g., 0.18 inches or less, 0.17 inches or less, 0.16 inches or less, 0.15 inches or less, 0.14 inches or less, 0.13 inches or less, 0.12 inches or less, 0.11 inches or less, 0.10 inches or less, 0.9 inches or less, 0.8 inches or less, 0.7 inches or less, etc. This relatively short height H of the body 200 of each tooth 178 allows more teeth 178 to extend from the outer surface 135 of the rotor 134, thereby helping to enable the rotor 134 to have a larger diameter.

[0044] The body 200 of each tooth 178 may substantially define a trapezoidal prism. However, it is contemplated that the body may define other shapes, such as a cone, a pyramid, or a rectangular prism. The body 200 may define a front surface 204a, a back surface 204b opposite the front surface 204a along the longitudinal direction 2, a first side surface 204c, and a second side surface 204d opposite the first side surface 204c along the circumferential direction. The first side surface 204c and the second side surface 204d may be offset from one another by an angle Q. In one embodiment, the angle Q may be between 10 and 50 degrees. The angle Q may also be between 10 and 45 degrees. The angle Q may also be between 10 and 40 degrees. Additionally, the angle Q may be between 10 and 35 degrees. The angle Q may also be between 10 and 30 degrees. Additionally, the angle Q may be between 10 and 35 degrees. In one specific example, angle Q may be 20 degrees. In another specific example, angle Q may be 30 degrees.

[0045] In addition to including more teeth 178 than conventional mixing assemblies, the teeth 178 may define a smaller cross-sectional profile than other conventional mixing teeth. As a result, the rotor 134 may maximize the ratio of the surface area AT of the front face 204a of each tooth 178 to the cross-sectional area AG of each gap 187. Both the surface area AT and the cross-sectional area AG may be measured in a plane defined by the lateral and vertical directions 4 and 6. Specifically, the cross-sectional area AG of each gap 187 may be measured from one tooth 178 to the adjacent tooth 178 and from the base 200a of each tooth 178 to the tip 200b of each tooth 178. The surface area AT of the front surface 204a of the tooth 178 can be less than 0.010 square inches, e.g., less than 0.0095 square inches, less than 0.0090 square inches, less than 0.0085 square inches, less than 0.0080 square inches, less than 0.0075 square inches, less than 0.0070 square inches, less than 0.0065 square inches, less than 0.0060 square inches, less than 0.0055 square inches, less than 0.0050 square inches, less than 0.0045 square inches, less than 0.0040 square inches, less than 0.0035 square inches, less than 0.0030 square inches, less than 0.0025 square inches, etc. The cross-sectional area A of each gap 187 can be greater than 0.0035 square inches, e.g., greater than 0.004 square inches, greater than 0.005 square inches, greater than 0.0060 square inches, greater than 0.0070 square inches, greater than 0.0080 square inches, greater than 0.0090 square inches, greater than 0.0100 square inches, greater than 0.011 square inches, greater than 0.012 square inches, greater than 0.013 square inches, greater than 0.014 square inches, greater than 0.015 square inches, greater than 0.016 square inches, etc. The ratio of the surface area A of the front surface 204a to the cross-sectional area A of the gap 187 can be less than 0.60, e.g., less than 0.55, less than 0.50, less than 0.45, etc.

[0046] 2A and 2B, adhesive can enter mixing system 10 through flow meter 70, flow through input 54, and through passage 62 into passage 116 in stator 104. Alternatively, adhesive can enter mixing system 10 through input 54, flow through passage 62, flow through flow meter 70 positioned along passage 62, and into passage 116 in stator 104. When pumped at a sufficient rate, the solution can actuate valve 166, opening passage 116 and allowing solution to flow through passage 116, through holes 160 in plate 159, and into mixing chamber 82. Similarly, gas can flow through gas input assembly 92 and into mixing chamber 82. Once in mixing chamber 82, the solution, including adhesive and gas, flows outward between stator 104 and plate 146 along the plane defined by the lateral and vertical directions 4 and 6. As previously described, motor 24 is configured to rotate rotor 134 and plate 146 within mixing chamber 82 about longitudinal axis A. As a result, as the solution flows between stator 104 and plate 146, it is mixed by interaction with stationary teeth 119 of stator 104, since stator 104 is fixed relative to manifold 50, and movable teeth 189 of plate 146, since plate 146 is rotationally fixed relative to rotor 134. After passing through stator 104 and plate 146, the solution flows in longitudinal direction 2 along outer surface 135 of rotor 134 between teeth 178, particularly between gaps 187 defined between adjacent teeth 178. Motor 24 is configured to rotate rotor 134 at a rotational speed controlled by controller 32 to effectively mix the solution into a homogenous solution free of air bubbles. After flowing the length of the mixing chamber 82 and around the rotor 134, the solution flows through the output passage 84 and a static mixer 250 disposed within the output passage 84, described below, to the output 58, where the solution flows to the dispenser.

[0047] As described above, the rotor 134, and in particular the configuration of the teeth 178 of the rotor 134, maximizes the number of teeth 178 extending from the rotor 134 and minimizes the ratio of the surface area AT of the front surface 204a of the tooth 178 to the cross-sectional area AG of the gap 187 defined between two adjacent teeth 178. The configuration of the teeth 178 also allows the diameter of the rotor 134 to be increased, thus allowing the motor 24 to rotate the rotor 134 at a lower rotational speed and still achieve high shear rates for the solution. For example, the motor 24 can be configured to rotate the rotor 134 at less than 100 revolutions per minute (RPM) so that the rotor 134 mixes the solution at shear rates greater than 100 reciprocating seconds. In one embodiment, the motor 24 can be configured to rotate the rotor 134 at less than 75 RPM so that the rotor 134 mixes the solution at shear rates greater than 100 reciprocating seconds. Additionally, the motor 24 can be configured to rotate the rotor 134 at less than 100 RPM so that the rotor 134 mixes the solution at shear rates greater than 120 reciprocating seconds. The motor 24 can also be configured to rotate the rotor 134 at less than 50 RPM to achieve any of the above shear rates. The motor 24 can also be configured to rotate the rotor 134 at 10 RPM or less to achieve any of the above shear rates. Furthermore, the motor 24 can be configured to rotate the rotor 134 at less than any of the above rotational speeds to achieve shear rates in the solution greater than 140 reciprocating seconds. Shear rate is the velocity gradient measured across the diameter of the fluid flow path, or the rate of change of velocity at which one layer of fluid passes over an adjacent layer. The shear rates listed above are estimated shear rates ignoring the teeth 178. These shear rates are therefore the average shear rates between the outer surface 135 of the rotor 134 and stationary components of the mixing system 10, such as the manifold 50. These shear rates are only estimates, so errors due to the selection of dimensions of the various components of the mixing system 10 are negligible.

[0048] 2B, 8, and 9, multiple static mixers 250 may be disposed within the output passageway 84 to statically mix the solution flowing through the output passageway 84. In the illustrated embodiment, two static mixers 250 are disposed in series within the output passageway 84, such that the solution must flow through each static mixer 250 in sequence after flowing through the mixing chamber 82 before reaching the output 58. However, in other embodiments, more or fewer than two static mixers 250 may be disposed within the output passageway 84. While components of one static mixer 250 are described, the components may be representative of each static mixer included in the mixing system 10. The static mixer 250 may include a base 254 defining a passageway 258 extending therethrough along the longitudinal direction 2, and multiple outlets 262 extending from the passageway 258 to an exterior surface of the base 254. The base 254 may define a portion of the static mixer 250 that engages with the manifold 50 to secure the static mixer 250 within the output passage 84. The cap 266 may be disposed over a portion of the base 254 and may be secured to the base 254 by threaded engagement, a snap fit, a slot and groove engagement, or the like. The cap 266 may define a plurality of inlets 270 extending through a body of the cap 266 to receive a flow of solution therethrough. A cylindrical screen 274 may be disposed between the cap 266 and the base 254 such that the cap 266 secures the screen 274 within the static mixer 250. During operation, when the static mixer 250 is positioned within the output passage 84, the static mixer 250, and particularly the screen 274, may be configured to break up large air bubbles still present in the solution after passing through the mixing chamber 82. Screen 274 may include a mesh cylinder defining a plurality of small holes extending therethrough such that large air bubbles are broken down as the solution flows through screen 274. As shown by the arrows in Figure 9, solution may flow from output passage 84 through inlet 270 in cap 266, through screen 274 into passage 258, and out outlet 262 in base 254 back to output passage 84.

[0049] While various inventive aspects, concepts, and features of the present invention may be described and illustrated herein as embodied in combination in exemplary embodiments, these various aspects, concepts, and features may be used in many alternative embodiments, either individually or in various combinations and subcombinations thereof. Unless expressly excluded herein, all such combinations and subcombinations are intended to be within the scope of the present invention. Furthermore, while various alternative embodiments of various aspects, concepts, and features of the present invention may be described herein, such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, form, fit, and function, such descriptions are not intended to be a complete or comprehensive list of available alternative embodiments, whether currently known or later developed. Furthermore, while some features, concepts, or aspects of the present invention may be described herein as preferred configurations or methods, such descriptions are not intended to imply that such features are required or essential, unless expressly so stated. Additionally, while example or representative values ​​and ranges may be included to aid in understanding the present disclosure, such values ​​and ranges are not intended to be limiting, and are intended to be significant values ​​or ranges only when expressly stated as such. Furthermore, while various aspects, features, and concepts may be expressly identified herein as inventive or forming part of the invention, such identification is not intended to be exclusive; rather, there may be inventive aspects, concepts, and features that are fully described herein, but for which such identification is not expressly stated or expressly stated as part of a particular invention, the scope of which is set forth in the accompanying claims or in the claims of any related or continuing application. The description of an exemplary method or process is not limited to the inclusion of every step required in all cases, nor is the order in which steps are presented intended to be construed as necessary or required unless expressly so stated.While the present invention has been described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the invention as described and claimed herein. The precise arrangement of the various elements and ordering of the articles and method steps described herein should not be considered limiting.

Claims

1. 1. A mixing system configured to mix a solution comprising a liquid adhesive and a gas, the mixing system comprising: a manifold configured to receive the solution; a mixing chamber disposed within the manifold in fluid communication with the solution; and an output in fluid communication with the mixing chamber and configured to discharge the solution. a rotor configured to rotate within the mixing chamber to mix the solution; a motor configured to rotate the rotor at less than 100 revolutions per minute (RPM) such that the rotor mixes the solution at a shear rate greater than 100 double strokes per second; A mixing system comprising:

2. 10. The mixing system of claim 1, wherein the motor is configured to rotate the rotor at less than 75 RPM such that the rotor mixes the solution at a shear rate greater than 100 double strokes per second.

3. 3. The mixing system of claim 2, wherein the motor is configured to rotate the rotor at less than 50 RPM.

4. 4. The mixing system of claim 3, wherein the motor is configured to rotate the rotor at 10 RPM or less.

5. 10. The mixing system of claim 1, wherein the motor is configured to rotate the rotor at less than 100 RPM such that the rotor mixes the solution at a shear rate greater than 120 double strokes per second.

6. 6. The mixing system of claim 5, wherein the rotor mixes the solution at a shear rate greater than 140 double strokes per second.

7. a plate rotatably coupled to an end of the rotor, the plate defining a plurality of teeth extending longitudinally therefrom; a stator disposed within the mixing chamber and defining a plurality of teeth extending therefrom toward the plate, the stator being configured such that at least a portion of the teeth of the plate and stator are disposed between one another; The mixing system of claim 1 further comprising:

8. 1. A method for mixing a liquid adhesive and a solution comprising a gas in a mixing system, comprising: placing the solution in a mixing chamber of the mixing system; rotating the rotor of the mixing system within the mixing chamber at less than 100 revolutions per minute (RPM) such that the rotor mixes the solution at a shear rate greater than 100 double strokes per second; A method comprising:

9. 9. The method of claim 8, wherein the rotating step comprises rotating the rotor at less than 75 RPM such that the rotor mixes the solution at a shear rate greater than 100 double strokes per second.

10. The method of claim 8 , wherein the rotating step includes rotating the rotor at less than 50 RPM.

11. The method of claim 10 , wherein the rotating step includes rotating the rotor at no more than 10 RPM.

12. 9. The method of claim 8, wherein the rotating step comprises rotating the rotor at less than 100 RPM such that the rotor mixes the solution at a shear rate greater than 120 double strokes per second.

13. 13. The method of claim 12, wherein the rotating step comprises rotating the rotor to mix the solution at a shear rate greater than 140 double stroke seconds.

14. 9. The method of claim 8, wherein the mixing device includes a stator having teeth extending therefrom, an end of the rotor includes a plate having teeth extending therefrom toward the stator, and the rotating step includes rotating the plate with the rotor such that at least some of the teeth of the plate rotate between the teeth of the stator.

15. 1. A mixing system configured to mix a liquid adhesive and a gas to form a solution, comprising: a manifold defining an adhesive input configured to receive the liquid adhesive, a gas input configured to receive the gas, a mixing chamber in fluid communication with the adhesive input and the gas input, an output configured to output the solution, and an output passage extending from the mixing chamber to the output; a rotor having an outer surface curved about a longitudinal axis extending in a longitudinal direction, said rotor having a plurality of teeth extending outwardly from said curved outer surface; a motor configured to rotate the rotor about the longitudinal axis within the mixing chamber to mix the solution; a plate rotatably secured to an end of the rotor, the plate defining a plurality of teeth extending longitudinally therefrom; a stator disposed within the mixing chamber and defining a plurality of teeth extending therefrom along the longitudinal direction toward the plate, at least a portion of the teeth of the plate and the stator being disposed between one another; A mixing system comprising:

16. 16. The mixing system of claim 15, wherein each tooth extends from a base to a tip and defines a front surface, a rear surface longitudinally opposite the front surface, a first side surface, and a second side surface circumferentially opposite the first side surface.

17. 17. The mixing system of claim 16, wherein the front surface has a surface area of ​​less than 0.003 square inches.

18. 18. The mixing system of claim 17, wherein gaps are defined between adjacent ones of the teeth along the circumferential direction, the gaps having a cross-sectional area of ​​0.004 square inches or greater measured along a plane perpendicular to the longitudinal axis.

19. 20. The mixing system of claim 18, wherein the ratio of the surface area of ​​the front surface to the cross-sectional area of ​​the gap is less than 0.

5.

20. 17. The mixing system of claim 16, wherein each tooth defines a height from said base to said tip of less than 0.2 inches.

21. 17. The mixing system of claim 16, wherein the first and second sides are offset by an angle between 10 and 50 degrees.

22. 8. The mixing system of claim 7, wherein the angle is between 10 and 40 degrees.

23. 16. The mixing system of claim 15 having at least 1000 teeth extending radially outward from said outer surface.

24. 16. The mixing system of claim 15, wherein the rotor defines at least 1500 teeth extending radially outward from the outer surface.

25. 16. The mixing system of claim 15, wherein the motor is configured to rotate the rotor at less than 100 revolutions per minute (RPM) such that the rotor mixes the solution at a shear rate greater than 100 double strokes per second.

26. 26. The mixing system of claim 25, wherein the motor is configured to rotate the rotor at 10 RPM or less.

27. 16. The mixing system of claim 15, further comprising a static mixer disposed within the output passageway and configured to statically mix the solutions flowing through the output passageway.

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