In-situ Foam Curing for Hydraulic Accumulator Separating Layers
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Solution Overview
Problem
The existing methods for producing pressure accumulators with foam bodies are complex, costly, and prone to damage during the introduction of ready-foamed foam materials, which limits their design as disposable components and increases production expenses.
Innovation Solution
A method involving the introduction of a flowable foam material into the pressure accumulator, where it cures in situ, expanding the separating layer to form a finished foam block, avoiding the need for pre-formed blocks and minimizing damage, using a lance-shaped introduction device to ensure targeted and uniform filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-formed foam blocks are inserted into the pressure accumulator, then high storage capacity and damping stiffness are achieved, but damage to the foam and elastomeric separating layer is unavoidable during insertion
Solution Approach 1:
The foam material is introduced in a different physical state (liquid or semi-liquid precursor) rather than pre-formed solid blocks. The material transforms from liquid to solid foam through in-situ foaming and curing processes, changing its physical parameters during insertion to avoid mechanical damage
Solution Approach 2:
The foam material undergoes phase transition from liquid/semi-liquid precursor state to solid foam structure after introduction into the accumulator. This phase change occurs in-situ, allowing the material to flow during insertion and then solidify to provide structural support without damaging other components
2Ease of manufacture
If the storage housing is divided into several segments to facilitate foam insertion, then ease of assembly is improved, but production becomes labor-intensive and costly
Solution Approach 1:
The foam precursor material is introduced using fluid delivery systems (pumps, hoses, injection devices) that can deliver the liquid foam material through existing access openings in the storage housing, eliminating the need to divide the housing into segments
Solution Approach 2:
The foam material self-expands and self-structures after introduction, filling the available space and forming the required foam structure without requiring manual assembly operations or multiple housing segments
3Quantity of substance
If pre-cured foam blocks are used, then storage capacity is maximized, but the manufacturing process is complex and costly
Solution Approach 1:
The foam precursor material is prepared in liquid form before introduction, allowing it to be delivered through simple access openings. The actual foaming and curing actions occur after introduction, eliminating the need for complex pre-foaming and pre-curing operations outside the accumulator
Solution Approach 2:
The mechanical process of inserting pre-formed foam blocks is replaced by a chemical process where liquid precursor material is pumped and injected, then transforms chemically into solid foam in-situ. This substitution eliminates mechanical handling complexity
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 simplifies the production process, reduces costs, and ensures high storage capacity with improved temperature and pressure stability, while avoiding damage to the foam and elastomeric materials, enabling efficient and cost-effective manufacturing of functionally reliable pressure accumulators.
Implementation Method 1
introducing a flowable, preferably liquid, foam material into the pressure accumulator
Implementation Method 2
curing the foam material in the pressure accumulator
Implementation Method 3
the increasingly curing foam material widens the separating layer from an initially partially filled initial state towards a final state
Data Source
Figure 1~3
AI summary
A method for producing a foam body, in particular for a pressure accumulator, such as a hydraulic accumulator, the bubble- or diaphragm-shaped, elastically flexible separating layer (12) of which separates two media chambers from each other within the accumulator housing, in particular a gas working chamber from a liquid chamber (18), with at least the following production method steps: – introducing a flowable, preferably liquid, foam material into the pressure accumulator, said foam material being at least partially surrounded by the separating layer (12), – curing the foam material in the pressure accumulator, and in the process – building up a pressure gradient, in which the visibly curing foam material expands the separating layer (12) from an originally partially filled starting state in the direction of an end state, in which the accumulator is finally filled with the cured foam (38).