Foam Mixing System Gas Pulsing Control

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Solution Overview

Problem

Existing systems for producing and dispensing foamed materials face challenges in accurately controlling gas content and density reduction, leading to inconsistencies in foam quality due to pressure equalization and gas bubble formation.

Innovation Solution

A foam dispensing system with a dynamic mixer, pressurized gas supply, and a gas injection cycle timer, along with check valves and pressure regulators, is used to control the pulsing of pressurized gas into the mixer, ensuring consistent process material and foamed material pressures, and a mass flow controller adjusts gas flow based on process material flow rates to achieve desired density reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If gas is continuously supplied to the dynamic mixer, then the foam production continues, but pressure equalization occurs leading to gas bubble formation and inconsistent foam quality

Engineering Contradiction:

Improvefoam production continuityVSAvoidfoam quality consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The gas supply to the dynamic mixer is converted from continuous to periodic through the gas injection cycle timer. The timer pulses the gas injection valve open and closed at predetermined intervals, creating periodic gas injection cycles. This periodic action prevents pressure equalization between the gas supply line and mixer while maintaining continuous foam production, thereby resolving the contradiction between productivity and manufacturing precision.

Inventive Principle:

Principle #19Periodic action

2Manufacturing precision

If the gas injection valve is pulsed open and closed, then gas bubble formation is prevented and foam quality improves, but the system complexity increases

Engineering Contradiction:

Improvefoam quality consistencyVSAvoidsystem component count

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A gas injection cycle timer is introduced as an intermediary control device between the gas supply and the dynamic mixer. This timer automatically pulses the gas injection valve according to predetermined cycles, eliminating the need for manual control while maintaining foam quality consistency. The intermediary timer simplifies the overall control system by automating what would otherwise require complex manual coordination.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If the mass flow controller adjusts gas flow based on process material flow rates, then density reduction accuracy improves, but the device complexity increases

Engineering Contradiction:

Improvedensity reduction accuracyVSAvoidcontrol system components

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

A mass flow controller is implemented with feedback control based on process material flow rates. The controller receives input about the process material flow rate and automatically adjusts the gas flow rate accordingly to maintain precise density reduction. This feedback mechanism eliminates the need for manual calculation and adjustment, improving measurement precision while the automated control reduces operational complexity.

Inventive Principle:

Principle #23Feedback

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 ensures accurate and consistent foam dispensing by preventing backflow and maintaining pressure balance, reducing large bubbles and improving foam quality by pulsing gas injection and adjusting gas flow according to process material flow rates.

Implementation Method 1

a dynamic mixer having a gas input, a process material input and a foamed material output

Methodology Applied

Scientific EffectMixing:

Implementation Method 2

ensuring consistent process material and foamed material pressures

Methodology Applied

Scientific EffectPressure balance: Pascal's Law

Implementation Method 3

A pump is provided with an output coupled in fluid communication with the process material input of the dynamic mixer for supplying process material to the dynamic mixer

Methodology Applied

Scientific EffectPumping: Pump

Implementation Method 4

The gas injection cycle timer causes the gas injection valve to pulse open and closed to send pulses of pressurized gas into the dynamic mixer through the gas input

Methodology Applied

Scientific EffectGas pulsing:

Implementation Method 5

a mass flow controller adjusts gas flow based on process material flow rates to achieve desired density reduction

Methodology Applied

Scientific EffectFlow measurement and control:

Data Source

PatentUS10589233B2Foam mixing system and methods

Publication Date: 2020.03.17 NORDSON CORP

AI summary

Foam dispensing systems and methods are disclosed. Such systems and methods may include a foamed material dispenser, a dynamic mixer having a gas input, a process material input, and a foamed material output. The foamed material output may be in fluid communication with the foamed material dispenser. A pump having an output may be in fluid communication with the process material input of the dynamic mixer, and a gas injection valve may be in fluid communication with the gas input of the dynamic mixer. A gas pressure regulator may be coupled between the pressurized gas supply and the gas injection valve, and a gas injection cycle timer may be operatively connected to the gas injection valve, the gas injection cycle timer causing the gas injection valve to pulse open and closed to send pulses of pressurized gas into the dynamic mixer through the gas input.