Airless Injection Gun Pressure Control for Rapid Crack Filling
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Solution Overview
Problem
Existing manual pumps, such as hand pumps, are inefficient in injecting filler material into cracks or voids in solid structures, resulting in low injection rates, typically ranging from 8 to 10 linear feet per day.
Innovation Solution
An airless injection gun system comprising a filler material injection assembly and a water injection assembly, equipped with a pressure regulator handle, four-way valve, pressure gauge, and pressure release valve, which utilizes two airless pumps to deliver hydrophobic polyurethane materials and water under high pressure for efficient filling of cracks and voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual pumps are used to inject filler material, then the injection process is simple to operate, but the injection rate is low (8-10 linear feet per day)
Solution Approach 1:
The patent employs hydraulic principles through the use of high-pressure hoses and pressure-regulated injection mechanisms. The system uses pressure to force filler material through the injection gun and into cracks, enabling high-speed injection rates up to 120 linear feet per day while maintaining controlled operation through pressure regulation.
Solution Approach 2:
The system changes the pressure parameter of the filler material injection process, operating at high pressures to achieve rapid injection rates. The pressure can be regulated and adjusted according to specific application requirements, allowing the system to maintain both high productivity and operational control.
2Productivity
If high pressure is used to increase injection rate, then productivity improves, but safety risks increase during tool removal
Solution Approach 1:
The system incorporates dynamic pressure regulation capabilities, allowing the pressure to be adjusted during operation. The pressure can be increased to maximum levels during injection to achieve high productivity, then reduced to safe levels before tool removal, adapting to different operational phases to maintain both efficiency and safety.
Solution Approach 2:
The system includes pressure gauges that provide visual feedback on the current pressure level. This allows operators to monitor pressure in real-time and make appropriate adjustments, ensuring pressure is reduced to safe levels before removing injection tools, thereby eliminating safety risks associated with high-pressure residual material.
3Productivity
If filler material is injected at high speed, then productivity increases, but pressure control becomes more difficult
Solution Approach 1:
The system performs preliminary pressure regulation before injection begins. The pressure is set and regulated in advance through pressure-regulated injection mechanisms, allowing the high-speed injection process to proceed with pre-established pressure control, eliminating the need for difficult real-time pressure adjustments during rapid injection.
Solution Approach 2:
The system introduces pressure-regulating mechanisms as intermediaries between the filler material source and the injection point. These intermediaries automatically maintain pressure within desired ranges, simplifying operator control while enabling high-speed injection rates up to 120 linear feet per day.
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 enables rapid filling of cracks and voids, achieving injection rates up to 120 feet per day, with the ability to monitor and control pressure, and reduce pressure safely for tool removal, enhancing the efficiency and effectiveness of crack filling.
Implementation Method 1
utilizes two airless pumps to deliver hydrophobic polyurethane materials and water under high pressure for efficient filling of cracks and voids
Implementation Method 2
regulate a flow of the filler material into the injection gun at a predefined level of pressure
Implementation Method 3
release the predefined level of pressure of the filler material for removal of the airless injection gun
Data Source
AI summary
An injection gun includes a filler material injection assembly. The filler material injection assembly includes a pressure regulator handle to control a flow of filler material, a four-way valve, a pressure gauge, a pressure release valve assembly, and a first output coupling. The four-way valve is connected to the pressure regulator handle. A first port of the four-way valve is connected to the pressure regulator handle to receive the filler material under pressure. The pressure gauge is connected to a second port of the four-way valve to indicate a level of pressure of the filler material under pressure. A pressure release valve assembly is connected to a third port of the four-way valve. The pressure release valve assembly reduces the level of pressure of the filler material under pressure. A first output coupling is connected to a fourth port of the four-way valve to eject the filler material under pressure.