Spray Foam Pressure Differential Control System

Abstract

The present disclosure discloses a system for minimizing pressure differentials between multiple components in an applicator while maintaining a temperature of a mixture of a multi-component spray, the system comprising at least one first component temperature sensor and at least one second component temperature sensor, at least one first component pressure sensor and at least one second component pressure sensor, at least one first component heating element, an applicator where the pressure differential between each of the multiple components is minimized by adjusting the temperature of the at least one first component, and a control system including an interface configured to receive at least one temperature set point from a user, the interface also configured to receive at least one pressure set point from the user.

Description

[Background technology]

[0001] Disclosed is a spray foam pressure differential control system, more specifically a system configured to spray a plurality of components onto a target, the components mixing by impingement to form a mixture, the system comprising at least one temperature sensor of a first component and at least one temperature sensor of a second component, at least one pressure sensor of the first component and at least one pressure sensor of the second component, a heating element for at least one first component, an applicator, where a pressure differential between each of the plurality of components is minimized by adjusting a temperature of the at least one first component, and a control system including an interface configured to receive at least one temperature set point from a user, the interface also configured to receive at least one pressure set point from the user.

[0002] In some prior art embodiments, the pressure setpoint is related to the pressure of either the first or second component material at the point where each fluid is delivered, which may be at the fluid pump or at a point near the spray gun or at the spray gun. The pressure of the other fluid is the result of proportion control. For example, the non-specific fluid pressure is the result of the proportioning system driving the pressure matching between the two fluids. Thus, the pressures may be very different at or near the spray gun. Also, in some prior art embodiments, the system requires the user to enter two separate temperature setpoints, and the resulting mixture temperature is entirely the result of proportion control.

[0003] This embodiment has several advantages. First, it can provide automatic dynamic pressure compensation. This results in improved fluid mixing, more consistent patterns, and reduced transport of higher pressure fluid at the applicator to lower pressure fluid lines. Second, it reduces user input to just the temperature of the mixture at or near the gun. This reduction in set point avoids confusion and errors in control. Summary of the Invention

[0004] The present embodiment discloses a system for maintaining the temperature of a mixture of a multi-component spray while minimizing the pressure difference between the components at an applicator. A spray foam pressure difference control system is disclosed, more specifically, a system configured to spray a plurality of components that are mixed by impingement to form a mixture on a target, the system comprising at least one first component temperature sensor and at least one second component temperature sensor, at least one first component pressure sensor and at least one second component pressure sensor, at least one first component heating element, an applicator, where the pressure difference between each of the plurality of components is minimized by adjusting the temperature of the at least one first component, and a control system including an interface configured to receive at least one temperature setpoint from a user, the interface also configured to receive at least one pressure setpoint from a user. [Brief description of the drawings]

[0005] [Figure 1] FIG. 1 is an exemplary, non-limiting diagram of an embodiment described herein. [Diagram 2] FIG. 2 is an exemplary, non-limiting cross-sectional view of a line of components of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] The embodiments of the present invention will be described in more detail below with reference to the above drawings. Please note that the present invention is not limited to the following description. Those skilled in the art can easily understand that the form and details of the present invention can be modified in various ways without departing from the spirit and scope of the present invention. Therefore, the present invention should not be construed as being limited to the following description of the embodiments. Please note that in the structures described below, the same parts or parts having similar functions are indicated by the same reference numerals in different drawings, and their description will be omitted.

[0007] In some embodiments, a system 10 configured to spray a plurality of components onto a target 14, the components mixing by collision to form a mixture 12, comprises at least one first component temperature sensor 16 and at least one second component temperature sensor 18, at least one first component pressure sensor 20 and at least one second component pressure sensor 22, at least one first component heating element 24, an applicator 38, where a pressure difference between each of the plurality of components is minimized by adjusting the temperature of the at least one first component, and a control system 44 including an interface 36 configured to receive at least one temperature set point from a user, where the interface 36 is also configured to receive at least one pressure set point from the user. In some embodiments, the control system 44 includes a non-transitory computer readable medium having stored thereon instructions that, when executed by a processor, cause the control system 44 to perform the following functions: receive a temperature setpoint from a user, receive a pressure setpoint from a user, receive a first component temperature signal, receive a second component temperature signal, receive a first component pressure signal, receive a second component pressure signal, calculate a pressure differential, adjust the first component temperature and second component temperature to achieve a temperature of the mixture 12 corresponding to the temperature setpoint, and adjust the first component temperature and second component temperature to minimize a pressure differential between the first and second components at the applicator 38. According to an embodiment, the temperature setpoint corresponds to the temperature of the first and second component mixture 12. In some embodiments, the first component temperature signal corresponds to the temperature of the first component at the applicator 38 and the second component temperature signal corresponds to the temperature of the second component at the applicator 38. According to an embodiment, receiving the temperature set point from the user and receiving the pressure set point from the user occurs via the graphical interface 36.In some embodiments, the graphical interface 36 is configured to be controlled by a mobile device using a wireless connection to the control system 44. According to an embodiment, the temperature setpoint corresponds to a temperature at the applicator 38. According to an embodiment, the temperature setpoint corresponds to a temperature of the mixture 12 of the multiple components. The temperature of the mixture 12 is calculated based on the known pre-determined fluid ratio, the first component temperature sensor 16, and the second component temperature sensor 18. In some embodiments, the pressure setpoint corresponds to a pressure of the mixture 12 at the spray gun 38. In an embodiment, the pressure setpoint corresponds to a pressure of each of the multiple components at the applicator 38. The pressure and temperature sensors may be measured at the applicator 38, inside the hose, or any combination thereof. When measured upstream of the applicator 38, the control system 44 can calculate the pressure and temperature corresponding to the temperature and pressure at the applicator 38 based on the location of the sensors. According to an embodiment, the interface 36 only requires a single temperature setpoint and a single pressure setpoint from the user. In some embodiments, the system 10 further comprises a first component line 40 and a second component line 42, where the first component line 40 is in fluid communication with a polyol source and the second component line 42 is in fluid communication with a multi-isocyanate source or a urethane prepolymer source. According to an embodiment, the first component line 40 and the first component heating element 24 are heated hoses, and the second component line 42 and the second component heating element 26 are heated hoses. In some embodiments, the heating elements may also include a preheater in the control system 44, which may be a proportioner configured to deliver a predetermined proportion of each component. In some embodiments, the mixture 12 reacts to form a polyurethane foam. In some embodiments, the control system 44 is configured to increase the temperature of each heated hose to achieve a minimum pressure difference between each of the multiple components. In some embodiments, the temperature may be controlled using cooling elements, such as first component cooling element 32 and second component cooling element 34.The cooling element can be a conductive tube with a refrigerant, an electrothermal cooler using the Peltier effect, or a combination thereof. In an embodiment, the applicator 38 is a spray gun 38. In some embodiments, the at least two temperature sensing elements are selected from the group consisting of a heat sensing element and a resistance measurement of a heating element.

[0008] According to an embodiment, the goal may be to match the pressures of the fluids corresponding to the first and second components at the spray gun 38. This also simplifies the input required from the user. With this approach, the user only needs to input a single pressure and temperature setpoint, as opposed to multiple temperature and pressure setpoints. In this configuration, the dynamic pressure of each fluid may be measured at or near the spray gun 38. Due to differences in the viscosities of the fluids, the pressures of the first and second components are generally not equal at or near the gun (or anywhere along the flow path). The viscosity of the first component is usually temperature dependent and is not similar in viscosity vs. temperature characteristics. By raising or lowering the temperature of the fluid using heating and cooling elements of the first and second components, the viscosity may be adjusted to provide more equal pressures at or near the spray gun 38.

[0009] In some embodiments, the system 10 can automatically adjust the temperature of the first and second components to minimize the pressure differential while maintaining the temperature of the fluid mixture 12 at a user setpoint. When the thermal properties and fluid densities are similar between the two materials, the system 10 will increase the temperature of the low pressure side and decrease the temperature of the high pressure side by an equal amount until the dynamic pressure differential is minimized. This can maintain the temperature of the fluid mixture 12. If the thermal properties and / or densities of the two fluids are different, the system 10 can also adjust for those differences in the control system 44. Deviations of the temperatures of the first and second components from the user setpoints can be limited by manufacturer recommendations. The control system 44 can include instructions to not adjust the temperature difference beyond a user-defined recommendation.

[0010] While the above describes specific embodiments of the present invention, it should be understood that these embodiments are exemplary. Reference in the specification to a given embodiment indicates that the described embodiment may include a particular part, structure, or feature, but each embodiment need not necessarily include that particular part, structure, or feature. Finally, although given components are described separately, one skilled in the art will understand that some of the components may be combined or shared in other combinations.

Claims

1. 1. A system configured to spray a plurality of components onto a target, the components mixing by impact to form a mixture, the system comprising: at least one first component temperature sensor and at least one second component temperature sensor; at least one first component pressure sensor and at least one second component pressure sensor; at least one first component heating element; an applicator, wherein a pressure differential between each of the plurality of components is minimized by adjusting a temperature of at least one of the first components; a control system including an interface configured to receive at least one temperature setpoint from a user, the interface also configured to receive at least one pressure setpoint from the user.

2. The system of claim 1 , wherein the temperature setpoint corresponds to a temperature at the applicator.

3. The system of claim 2 , wherein the temperature setpoint corresponds to a temperature of the mixture of the plurality of components.

4. The system of claim 1 , wherein the pressure setpoint corresponds to a pressure at a spray gun.

5. The system of claim 4 , wherein the pressure setpoint corresponds to the pressure of each of the plurality of components at the applicator.

6. The system of claim 1 , wherein the interface requests a single temperature setpoint and a single pressure setpoint from the user.

7. 10. The system of claim 1, further comprising a first component line and a second component line, the first component line being in fluid communication with a polyol source and the second component line being in fluid communication with a multi-isocyanate source or a urethane prepolymer source.

8. 8. The system of claim 7, further comprising a second component heating element, wherein the first component line and the first component heating element are heated hoses, and the second component line and the second component heating element are heated hoses, and wherein a pressure differential between each of the plurality of components is minimized by adjusting the temperature of at least one of the second components.

9. The system of claim 8 , wherein the mixture is a polyurethane foam.

10. 10. The system of claim 9, wherein the control system is configured to increase the temperature of each heated hose to achieve a minimum pressure differential between each of the plurality of components.

11. The system of claim 1 , wherein the applicator is a spray gun.

12. The system of claim 1 , wherein the at least two temperature sensing elements are selected from the group consisting of a heat sensing element and a resistance measurement of the heat sensing element.

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