Angled Opening Application Device for Uniform PU Foam Edge Coverage
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Solution Overview
Problem
Existing methods for producing composite elements, particularly those with metal cover layers and PU foams, face challenges in ensuring uniform application of reaction mixtures, especially when the cover layers have complex profiles, leading to inefficiencies and quality issues due to insufficient edge coverage and potential product loss.
Innovation Solution
The application device features 1 to 4 outer openings above the edge of the cover layer, angled between 1 to 50°, which allows for improved distribution of the liquid reaction mixture, even in complex geometries, by adjusting the angle and arrangement of openings based on the cover layer's profile, enabling better coverage and easier cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the application device is positioned closer to the edges of the cover layer, then edge coverage is improved, but reaction mixture builds up next to the cover layer causing product loss and equipment fouling
Solution Approach 1:
The application device is divided into multiple zones with different opening configurations: central openings for main coverage and peripheral openings angled toward the edges for targeted edge application. This segmentation allows different regions of the device to perform specialized functions, delivering reaction mixture precisely where needed without excessive buildup.
Solution Approach 2:
Different openings are configured with different angles and orientations based on their location. Central openings face downward for general coverage, while peripheral openings are angled toward the edges to specifically address edge coverage needs. This local differentiation optimizes application effectiveness for each zone while minimizing waste.
2Loss of substance
If the application device is positioned at a greater distance above the edges of the cover layer, then product loss is reduced, but insufficient reaction mixture reaches the edges causing quality problems
Solution Approach 1:
The solution adds a directional dimension to the opening configurations. Instead of all openings facing uniformly downward, peripheral openings are angled toward the edges, creating a three-dimensional application pattern that reaches edge areas effectively from a higher position, thus maintaining distance while ensuring coverage.
3Stability of the object's composition
If pipes are used as application devices, then mechanical stability is achieved, but cleaning becomes laborious due to caking of fully reacted polyurethanes
Solution Approach 1:
Instead of trying to clean the complex internal passages of traditional drilled-hole pipes, the invention inverts the approach by using a smooth-walled tube with openings formed by the tube structure itself. The reaction mixture flows through the tube and exits through peripheral openings, allowing cleaning solution to flow easily through the same path without getting trapped in complex geometries.
4Adaptability or versatility
If the cover layer has a complicated profile, then design versatility is improved, but dead spaces are created into which reaction mixture cannot be introduced
Solution Approach 1:
The peripheral openings are asymmetrically angled toward the edges of the cover layer, allowing the reaction mixture to be directed into dead spaces and complex profile areas that would be inaccessible to uniformly oriented openings. This asymmetric configuration adapts to various cover layer profiles while ensuring complete coverage.
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 ensures a more uniform distribution of the reaction mixture, enhancing the quality of composite elements by addressing edge coverage issues and reducing product loss, while also facilitating easier cleaning and wider application versatility.
Implementation Method 1
the liquid components used in the foam, in the production of isocyanate-based foams the polyol and isocyanate components, are mixed, for example in a mixing head, and from there are applied to the top layer by means of an application device, where they Foaming react with each other and harden to foam
Data Source
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AI summary
The invention relates to a device for applying liquid reaction mixtures to a cover layer, the cover layer being moved continuously and the liquid reaction mixture being applied to the cover layer, the device consisting of at least one pipe (a) which is preferably immovably arranged and which is provided with openings (b) in the direction of the cover layer, and which is mounted above the cover layer parallel to the cover layer plane and at a right angle to the direction of motion of the cover layer, the outer openings being located on the side of the pipe that is above the edge of the cover layer, at an angle of 1 to 50° in the direction of the edge of the cover layer. The invention further relates to the use of said device to produce composite elements and to apply liquid reaction mixtures to a cover layer. The invention further relates to a method for producing composite elements, comprising the application of liquid reaction mixtures to a cover layer by means of said device, the cover layer being moved continuously and the liquid reaction mixture being applied to the cover layer.