Aerosol Sealant Concentration Control for Autonomous Leak Sealing
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Solution Overview
Problem
Existing methods for sealing air leaks in building enclosures are inefficient and lack automation, particularly in inaccessible areas like boilers, hidden ducts, and crawl spaces, leading to reduced energy efficiency and indoor environmental quality.
Innovation Solution
An autonomous concentration control system with injection stations equipped with sensors and controllers that monitor and adjust the flow of aerosolized sealant particles to maintain a specified concentration, using a network of sealant application stations and a main control unit to optimize sealant distribution and prevent excess deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual methods are used to discover and seal leaks, then labor intensity is reduced, but automation and efficiency in inaccessible areas remain insufficient
Solution Approach 1:
The system enables autonomous operation where the sealant application device automatically detects leaks through sensors, navigates to leak locations, and applies sealant without human intervention. The device self-manages the entire sealing process in inaccessible areas including boilers, hidden ducts, and crawl spaces.
Solution Approach 2:
The patent replaces manual mechanical inspection and sealing operations with an automated system that uses sensors to detect leaks and a controlled delivery mechanism to apply sealant. This substitution enables operation in areas that are difficult or impossible to access manually.
2Reliability
If sealant is applied without concentration control, then leak sealing is achieved, but excess deposition and material wastage occur
Solution Approach 1:
The system incorporates sensors that continuously monitor the concentration of aerosolized sealant in the environment and provide feedback to the controller. The controller adjusts the sealant delivery rate in real-time to maintain optimal concentration, ensuring effective leak sealing while preventing excess deposition and material wastage.
Solution Approach 2:
The patent dynamically changes the concentration parameter of the aerosolized sealant based on environmental conditions and sensor feedback. By adjusting the delivery rate to maintain optimal concentration levels, the system achieves reliable sealing while minimizing material wastage.
3Manufacturing precision
If aerosolized sealant is used to seal leaks, then sealing effectiveness is improved, but control over mixture concentration becomes challenging
Solution Approach 1:
The system uses sensors to monitor aerosol concentration and provides feedback to the controller, which adjusts the sealant delivery rate to maintain precise concentration levels. This feedback mechanism enables precise control of aerosolized sealant application despite the complexity of the system.
Solution Approach 2:
The controller integrates multiple functions including sealant delivery control, concentration monitoring, and automatic adjustment into a single device. This multi-functionality manages the complexity of aerosol concentration control while maintaining precise sealant deposition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively seals air leaks by maintaining optimal sealant concentration and distribution, improving energy efficiency and reducing wastage, while allowing for autonomous operation in challenging environments.
Implementation Method 1
a sprayer assembly that aerosolizes the sealant and liquid or gas and releases the sealant and liquid or gas to a surrounding environment
Implementation Method 2
monitor a signal from a sensor or sensors indicative of a concentration level in a surrounding environment of the liquid or gas in which the sealant is suspended or dissolved
Implementation Method 3
a pump that delivers liquid sealant to the compressed air source
Implementation Method 4
a compressed air source that provides compressed air to aerosolize the liquid sealant
Data Source
AI summary
A method of controlling a concentration or range of concentrations of a liquid or gas in an enclosure is provided. The method includes positioning an injection station within the enclosure. the injection station includes a liquid or gas source, a sprayer assembly and a system that delivers the liquid or gas from the liquid or gas source to the sprayer assembly. A concentration level of the liquid or gas in the environment surrounding the injection station is monitored using a sensor and the sensor providing a signal indicative of the concentration level to a controller. The controller controls the flow of the liquid or gas to the sprayer assembly based on the signal.