Angled Casting Rake for Uniform Foaming Mixture Distribution
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Solution Overview
Problem
Existing methods for applying foaming reaction mixtures to composite elements with complex geometries or profiles, such as facade elements and roof profiles, often result in uneven distribution of the foam, particularly in side areas and beads, leading to suboptimal material application and insulation performance.
Innovation Solution
A method utilizing two casting rakes with tubular hollow bodies and outlet openings arranged at an angle of ≤80° relative to the movement axis, ensuring improved distribution of the foaming reaction mixture across the cover layer, including the use of a mixing head for component mixing and a feed system that maintains a consistent mass flow and inner diameter reduction for uniform discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional pouring rakes with outlet openings perpendicular to the cover layer are used, then the application process is simple, but uniform distribution of the foaming reaction mixture is not achieved in side areas and around fastening elements
Solution Approach 1:
The outlet openings are arranged asymmetrically at angles between 10° and 70° relative to the plane of the cover layer, rather than perpendicular. This asymmetric arrangement allows the foaming reaction mixture to be directed toward side areas and around fastening elements, achieving uniform distribution across the entire surface including previously problematic zones.
Solution Approach 2:
The outlet openings are oriented in three-dimensional space at specific angles rather than flat against the cover layer plane. This spatial reorientation enables the foam to reach side areas and penetrate around fastening elements, adding a dimensional aspect to the distribution pattern that eliminates dead zones.
2Manufacturing precision
If the pouring rake is moved in oscillating motion or the surface layer is moved beneath it, then distribution along the longitudinal length is optimized, but the side areas and fastening element areas still receive uneven distribution
Solution Approach 1:
The angular orientation of outlet openings creates asymmetric flow patterns that naturally direct foam toward side areas and around fastening elements during the movement process, eliminating the need for complex oscillating motions to achieve side area coverage.
Solution Approach 2:
By changing the orientation parameter of the outlet openings from perpendicular to angled (10°-70°), the distribution characteristics are fundamentally altered to improve side area and fastening element coverage without requiring changes in movement complexity.
3Manufacturing precision
If outlet openings are distributed along the longitudinal length of the pouring rake, then longitudinal distribution is improved, but side areas and bead areas remain poorly covered
Solution Approach 1:
The outlet openings are oriented at angles (10°-70°) relative to the cover layer plane, projecting foam in a directional pattern that reaches side areas and bead regions. This angular orientation adds a dimensional component to the distribution that complements the longitudinal arrangement.
Solution Approach 2:
The angled outlet openings create localized foam distribution patterns tailored to specific zones. The angular orientation ensures that foam is directed toward side areas and bead regions where it is most needed, providing locally optimized distribution rather than uniform radial dispersal.
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
This approach enables uniform foam application even on complex geometries, enhancing material distribution in side areas and beads, leading to improved insulation performance and production efficiency for composite elements.
Implementation Method 1
a foaming reaction mixture is applied to a prepared top layer using an application device... where they foam up and harden
Data Source
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AI summary
The invention relates to a device (100) for applying a foaming reaction mixture (600) onto a top layer (500), in particular for producing a composite element, comprising at least one casting rake (200, 260) with a tubular hollow body (210), said hollow body (210) extending along a central axis (250) and having at least two outlet openings (220) for discharging the foaming reaction mixture (600). The casting rake (200, 260) and the top layer (500) can be moved relative to each other along a longitudinal axis (510). According to the invention, the central axis (250) of the at least one casting rake (200, 260) and the longitudinal axis (510) of the movement form an angle (400, 410) of ≤ 80° relative to each other.