Multi-Component Chemical Spray Dispensing System
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Solution Overview
Problem
Existing systems for spray application of multiple component liquid chemicals lack precision in controlling the volume and mass flow rate of each component, leading to environmental and personnel hazards due to uncontrolled temperature and inaccurate measurement, and require frequent container changes, which can expose reactive chemicals to ambient air.
Innovation Solution
A system comprising bulk storage and dispensing units with protective housings, low-pressure transfer pumps, and a central processor that maintains temperature control and precise flow rate management through sensors and heaters, ensuring accurate dispensing and minimizing exposure to ambient air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If reciprocating-type pumps are used to dispense multiple component liquid chemicals, then the system can operate with simple container connections, but the volume and mass flow rate control precision is insufficient
Solution Approach 1:
The patent replaces traditional mechanical reciprocating pumps with a computer-controlled pumping system that uses sensors to detect liquid levels and electronically controlled valves to regulate flow. The central processor coordinates the operation of multiple pumps and valves, substituting mechanical timing and measurement mechanisms with electronic sensing and control, thereby achieving precise volume and mass flow rate measurement while maintaining operational simplicity.
Solution Approach 2:
The system incorporates sensors that continuously monitor the volume and mass of each liquid component being dispensed. These sensors provide real-time feedback to the central processor, which adjusts the pumping and valve operation to maintain precise flow rates. This feedback mechanism enables accurate measurement and control of chemical dispensing quantities without requiring complex manual calibration or measurement devices.
2Ease of operation
If chemical containers are opened for dispensing, then the chemicals can be accessed for spray application, but environmental and personnel hazards increase due to uncontrolled temperature and exposure to ambient air
Solution Approach 1:
The patent maintains an inert atmosphere within the chemical storage and dispensing system by sealing containers and using nitrogen or other inert gases to displace ambient air. This prevents reactive chemicals from degrading through exposure to oxygen and moisture in the air, while still allowing controlled dispensing through automated pumping systems. The inert environment protects both the chemical integrity and reduces hazards to personnel and environment.
Solution Approach 2:
The system incorporates automatic temperature control mechanisms that maintain chemicals at optimal temperatures without manual intervention. Heating or cooling elements regulated by temperature sensors and the central processor ensure chemicals remain in their proper viscosity and reactivity states, eliminating the need for manual temperature management and reducing the risks associated with uncontrolled temperature variations.
3Productivity
If frequent container changes are performed, then empty containers can be replaced with full ones, but the need for container handling increases exposure risk and operational time
Solution Approach 1:
The system is designed with pre-filled chemical containers that are prepared and positioned before the dispensing operation begins. The automated system can quickly connect these pre-prepared containers without requiring manual emptying or cleaning operations. This preliminary preparation of containers significantly reduces the time and risk associated with container changes while maintaining continuous dispensing capability.
Solution Approach 2:
The patent employs a nested container arrangement where smaller dispensing containers are positioned within or adjacent to larger storage containers. This nesting allows for efficient space utilization and enables quick swapping of smaller containers without disrupting the overall system configuration. The nested arrangement facilitates rapid container changes while maintaining system integrity and minimizing exposure time during transitions.
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 achieves precise control over the volume and mass flow rate of each chemical, reducing environmental exposure and personnel hazards by maintaining controlled temperature and accurate measurement, and minimizing the need for frequent container changes.
Implementation Method 1
a first plurality of heaters H in each chemical delivery hose 29
Implementation Method 2
The chemical delivery hoses 29 may each include a plurality of heaters H, for example, electrically operated resistance heaters, disposed at spaced apart locations along the length of each chemical delivery hose 29
Data Source
AI summary
A system for dispensing a plurality of chemicals includes a respective storage tank for each chemical. A respective metering, rotary positive displacement pump is in hydraulic communication at an inlet thereof with an outlet of each tank. An outlet of each pump is connected to a respective discharge hose. At least one heater is in thermal contact with each discharge hose. At least one temperature sensor is provided for measuring a temperature of each chemical in each respective discharge hose. A pressure sensor is provided for measuring pressure at an inlet end and at an outlet end of each discharge hose. A processor is in signal communication with each temperature sensor, each pressure sensor, a metering signal output of each pump and in control communication with each heater. The processor is programmed to operate each heater to maintain a temperature of each chemical such that a selected difference between pressure is measured between the inlet end and the discharge end of each discharge hose when each respective chemical is moved therethrough.