Foam Injection Shot Timing for Accurate Cavity Filling
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Solution Overview
Problem
Existing insulation foam dispensing systems, particularly those using high-pressure and low-pressure systems attached to external compressors or compressed gas cylinders, suffer from issues such as excessive pressure buildup leading to wall blowout, complexity, high costs, noise, and inefficiency, while self-contained low-pressure systems face challenges with variable flow rates and inaccurate dispense volumes.
Innovation Solution
A self-contained insulation foam dispensing system that uses pre-pressurized precursor vessels not in fluid communication with external pressure regulators, employing monitoring devices to track system parameters like pressure and temperature, and a computing device to calculate and adjust shot times based on established mathematical relationships to ensure accurate and reliable foam injection without positive displacement flow meters or flow control valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-pressure systems with external compressors or compressed gas cylinders are used, then foam dispensing power is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes external compressors and gas cylinders from the system, extracting the pressure-generating components that cause complexity. The precursor vessels are self-contained with internal pressurization, eliminating the need for external pressure sources and their associated regulators and control apparatus.
Solution Approach 2:
The precursor vessels are designed to be self-contained and self-pressurized, containing their own pressurizing mechanism without requiring external assistance. Each vessel independently maintains the pressure needed for foam dispensing, making the system simpler and more autonomous.
2Speed
If high-pressure systems are used, then foam dispensing speed is improved, but wall blowout risk increases
Solution Approach 1:
The system incorporates monitoring devices that detect pressure and temperature conditions in real-time, providing feedback to control the dispensing process. This feedback mechanism allows the system to adjust dispensing parameters to maintain safe pressure levels that prevent wall blowout while achieving adequate dispensing speed.
Solution Approach 2:
The system dynamically adjusts dispensing parameters based on real-time monitoring of pressure and temperature conditions. The dispensing speed is not fixed but adapts to current system conditions, allowing optimal speed while preventing excessive pressure buildup that could cause wall blowout.
3Object-affected harmful factors
If self-contained low-pressure systems are used, then wall blowout risk is reduced, but flow rate accuracy deteriorates
Solution Approach 1:
The patent replaces mechanical flow control apparatus (flow meters, valves, regulators) with a computational approach. A computing device calculates precise dispense volumes based on mathematical relationships between pressure, temperature, and foam expansion characteristics, then uses monitoring devices and counted dispensing cycles to achieve accurate flow measurement without mechanical flow control components.
Solution Approach 2:
Instead of directly measuring flow rate with mechanical instruments, the system creates a computational model (mathematical relationship) that replicates the flow rate behavior based on pressure and temperature data. This virtual copy allows accurate flow rate determination without physical flow meters.
4Stress or pressure
If external compressors and regulators are used, then pressure control is improved, but noise and operational inefficiency increase
Solution Approach 1:
The precursor vessels are self-contained with internal pressurization mechanisms that automatically maintain required pressure levels without external intervention. The system eliminates noisy external compressors and complex regulator assemblies, resulting in quieter operation and improved operational efficiency through simplified maintenance and setup.
Solution Approach 2:
The patent extracts and removes external compressors, regulators, and associated control apparatus from the system. Pressure control is achieved through the self-contained precursor vessels, eliminating the sources of noise and operational inefficiency associated with external pressure control equipment.
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 provides reliable and quantitatively accurate filling of cavities with foam, minimizing wall blowout risk and operational inefficiencies, allowing for easy movement and operation in various building conditions.
Implementation Method 1
the two precursors fully react with each other, and expand to form the foam insulation
Implementation Method 2
Pour foams with gaseous blowing agents often expand 5 times the dispensed volume of liquid precursor. Pour foams with liquid blowing agents can expand 30 to 100 times the volume of liquid precursor
Implementation Method 3
Each precursor vessel is provided with a gas having a gas pressure, and the gas pressure is monitored before and/or during filling of a cavity
Data Source
AI summary
A cavity is filled with a foam-in-place insulation by a self-contained dispensing system for which precursor vessel pressures and precursor flow rates decrease as the precursors are dispensed. Flow rate functions for the precursors are pre-calibrated as a function of vessel pressures and/or related parameters such as vessel weights, precursor levels in the vessels, and total volumes dispensed. The cavity is filled by at least one shot of the precursors, each shot comprising a plurality of counts that are announced to a user during the shot. The length of each count and/or the number of counts is/are adjusted according to the flow rate functions in compensation for the decreasing vessel pressures. Embodiments further adjust the count durations for reduced start-up flow at the start of a shot and/or extended flow at the end of a shot, due to mechanical properties and/or user reaction times.