Foam Filling Elongated Window Lineals Without Deformation

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Solution Overview

Problem

Existing methods for filling elongated window lineals with foam result in substantial voids and inconsistent filling, as they often deform the cross-sectional profile due to foam expansion, especially in long channels like those found in vinyl and metallic window frames.

Innovation Solution

A frothable polyurethane or polyisocyanurate foam system using low-pressure, high-boiling-point blowing agents, such as HFC-245fa, is introduced into the window lineal from one end, allowing the foam to expand without deforming the channel, ensuring minimal voids and uniform insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If liquid foamable resin is dispensed into the channel using conventional methods, then the channel can be filled with foam insulation, but substantial voids are created throughout the length of the channel

Engineering Contradiction:

Improvefoam filling completenessVSAvoidfilling consistency

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The channel is divided into multiple dispensing zones along its length. Multiple foam dispensing nozzles are positioned at different locations (e.g., first, second, and third nozzles at different distances from the channel end) to sequentially or simultaneously dispense foam into different segments of the channel, ensuring complete filling without voids while maintaining consistent application throughout the entire channel length.

Inventive Principle:

Principle #1Segmentation

2Quantity of substance

If foam is allowed to expand freely in the channel, then complete filling is achieved, but the cross-sectional profile of the channel is deformed

Engineering Contradiction:

Improvechannel filling completenessVSAvoidcross-sectional profile

Core Design Contradiction:

Quantity of substanceVSShape

Solution Approach 1:

Constriction elements are pre-installed within the channel at strategic positions to provide preliminary resistance against foam expansion. These elements create controlled restriction zones that prevent the foam from deforming the channel's cross-sectional profile while still allowing complete filling. The constriction elements counteract the expansion force before it can cause profile deformation.

Inventive Principle:

Principle #9Preliminary anti-action

3Length of stationary object

If the channel length is increased to 16 feet or more for architectural applications, then the insulation coverage is improved, but conventional dispensing methods cannot achieve complete filling

Engineering Contradiction:

Improvechannel lengthVSAvoidfoam filling completeness

Core Design Contradiction:

Length of stationary objectVSQuantity of substance

Solution Approach 1:

For long channels of 16 feet or more, the dispensing system is segmented into multiple nozzles positioned at different locations along the channel length. This segmentation allows each nozzle to effectively fill its designated zone, ensuring complete coverage even in very long channels where a single dispensing point would be insufficient.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Extender rods or positioning mechanisms serve as intermediaries to hold and position the foam dispensing nozzles at precise distances from the channel end and from each other. These intermediaries enable accurate placement of multiple nozzles along long channels, ensuring optimal dispensing geometry and complete filling throughout the entire length.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Volume of moving object

If a metal tubular extension is used to reach into the channel, then foam can be dispensed deeper into the channel, but the method requires two operators and results in inconsistent filling

Engineering Contradiction:

Improvefoam dispensing depthVSAvoidoperational complexity

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

Multiple foam dispensing nozzles are combined into a single integrated dispensing assembly that can be operated by one operator. The nozzles are positioned at different distances from the channel end and are controlled simultaneously through a single operation, merging the function of multiple dispensing points into one coordinated system that eliminates the need for multiple operators while ensuring consistent filling.

Inventive Principle:

Principle #5Merging (Combining)

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 foam effectively fills long window lineals without deforming the original cross-sectional profile, providing uniform insulation and complete filling over distances of up to 20 feet or more, while maintaining dimensional stability and reducing ozone depletion potential.

Implementation Method 1

a two-component polymeric foam system which, upon contact with atmospheric moisture, expands to fill the cavity

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

expanding polymeric foams to fill elongated channels

Methodology Applied

Scientific EffectFoam expansion: Foam

Data Source

PatentUS9593222B2Method and composition for filling elongated channels with expanding foam insulation

Publication Date: 2017.03.14 ICP CONSTRUCTION INC

AI summary

The invention described herein generally pertains to the use of low boiling point, low vapor pressure blowing agents with froth polyurethane or polyisocyanurate foams to fill hollow cavities (particularly window lineals) and which have lowered exotherms, which prevent deformation of the hollow cavity (e.g., window lineal) and additional achieve filling of longer lengths of window lineals by increasing the foaming and gel times of the reaction.