Interchangeable Port Inserts for Variable Foam Injection Pressure

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Solution Overview

Problem

Conventional foam injection systems for cementitious slurry production require replacing entire foam blocks to change orifice sizes, which is costly and time-consuming, limiting the ability to vary foam injection pressure efficiently.

Innovation Solution

A foam injection system with interchangeable port inserts of different orifice sizes that can be removably mounted to a foam injection body, allowing for easy adjustment of foam flow conditions without replacing the entire foam block.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If entire foam blocks are replaced to change orifice sizes, then foam injection pressure can be varied, but the process becomes costly and time-consuming

Engineering Contradiction:

Improvefoam injection pressure variationVSAvoidtime to replace foam block

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The foam block is segmented into a reusable foam block body and interchangeable port inserts. Each port insert contains a specific orifice size and can be independently replaced without replacing the entire foam block. This segmentation allows quick switching between different orifice sizes by simply detaching and attaching different port inserts to the same foam block body.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The orifice-containing port insert is extracted as a separate, removable component from the foam block system. This extracted port insert can be independently replaced while the main foam block remains in place, eliminating the need to replace the entire foam block when changing orifice sizes.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If entire foam blocks are replaced to change orifice sizes, then foam flow characteristics can be adjusted, but manufacturing cost increases

Engineering Contradiction:

Improvefoam flow characteristics adjustmentVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The port inserts are designed as lower-cost, replaceable components compared to entire foam blocks. By making the orifice-containing inserts disposable or easily replaceable while keeping the expensive foam block body reusable, the overall manufacturing cost is reduced when changing specifications are needed.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Device complexity

If fixed orifice sizes are used in foam blocks, then system complexity is reduced, but flexibility to vary foam injection parameters is limited

Engineering Contradiction:

Improvefoam injection system structureVSAvoidfoam injection parameter variation

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The foam injection system transitions from a static, fixed-orifice design to a dynamic, interchangeable-orifice design. Port inserts with different orifice sizes can be swapped based on production requirements, allowing the system to adapt its parameters dynamically without increasing overall structural complexity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A single foam block body is designed to accommodate multiple different port inserts, making it a universal component that can perform multiple functions with different orifice sizes. This multi-functionality is achieved through standardized mounting interfaces that accept various port insert configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables efficient variation of foam injection pressure and flow characteristics, improving the flexibility and cost-effectiveness of cementitious product manufacturing by allowing for quick changes in orifice sizes without the need for extensive system modifications.

Implementation Method 1

The first port insert defines a first foam passageway having a first orifice with a first orifice size... adapted to removably mount to the foam injection body such that the first foam passageway is in fluid communication with the slurry passageway

Methodology Applied

Scientific EffectFluid flow through orifice:

Data Source

PatentEP3094459B1Foam injection system with variable port inserts for slurry mixing and dispensing apparatus

Publication Date: 2019.10.02 UNITED STATES GYPSUM CO

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AI summary

A foam injection system (301, 701) for use in the manufacture of cementitious products includes a foam injection body (305, 605) and first and second port inserts (100, 400; 200, 500). The foam injection body (305, 605) defines a slurry passageway (310, 610) and a port passageway (315, 615) having a port opening (317, 617) in fluid communication with the slurry passageway (310, 610). The first and second port inserts (100, 400; 200, 500) respectively define first and second foam passageways (115, 415; 215, 515) having first and second orifice sizes (1, 4; 3, 4, 5) which are different. The first and second port inserts (100, 400; 200, 500) are adapted to removably mount to the foam injection body (305, 605) such that the respective foam passageway (115, 415; 215, 515) is in fluid communication with the slurry passageway (310, 610) via the port opening (317, 617) of the port passageway (315, 615). One port insert (100, 400) can be replaced with another (200, 500) to readily vary the pressure of the foam passing through the particular port insert (100, 400; 200, 500) and injected into a cementitious slurry traveling through the slurry passageway (310, 610).