Low Pressure Two Component Fluid Metering System
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Solution Overview
Problem
Existing systems for metering, mixing, and dispensing reactive fluids for structural adhesives or sealants often subject the fluids to high pressures, which can lead to inconsistent mixing and potential damage to the materials, particularly when the system is idle or paused, affecting the quality and consistency of the final product.
Innovation Solution
A two-component fluid metering, mixing, and dispensing system that operates at lower average pressures by using an actuator to control the movement of piston rods in double-acting cylinders, reducing pressure on the fluids through electronic control of pumps and valves, allowing for controlled filling and emptying of metering cylinders, and maintaining pressures below 500 psi during idle periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional high pressure pump systems are used to meter and mix reactive fluids, then the fluids can be pumped efficiently, but the average pressure on the fluids becomes too high (above 500 psi), causing inconsistent mixing and potential material damage
Solution Approach 1:
The system divides the fluid delivery function into separate components: low-pressure pumps feed into pressure-accumulation chambers, which then feed into metering cylinders. This segmentation allows efficient fluid transfer without subjecting the reactive mixture to high pressures, resolving the contradiction between pumping efficiency and material protection.
Solution Approach 2:
Pressure-accumulation chambers act as intermediaries between the pumps and metering cylinders. These chambers buffer the pressure fluctuations, allowing high-pressure pumping without transmitting high average pressure to the reactive fluids, thus protecting materials while maintaining pumping efficiency.
2Productivity
If pumps operate continuously to maintain fluid flow, then productivity is improved, but the average pressure on the fluids increases beyond acceptable levels
Solution Approach 1:
The system uses periodic actuation of the metering cylinders rather than continuous pumping. The cylinders are filled during idle periods and then discharged in controlled periodic cycles during dispensing. This periodic action maintains productivity while keeping average pressure low during idle periods.
Solution Approach 2:
The pressure-accumulation chambers are filled in advance during idle periods before dispensing begins. This preliminary action allows the system to be ready for immediate dispensing without requiring continuous high-pressure operation, thereby maintaining productivity while reducing average pressure exposure.
3Speed
If high pressure is used to move pistons in metering cylinders, then fluid delivery speed is improved, but mixing consistency deteriorates due to pressure-induced material damage
Solution Approach 1:
The system replaces direct high-pressure mechanical pumping with an actuated piston system. Electric or pneumatic actuators directly drive the pistons in the metering cylinders at controlled speeds, eliminating the need for high-pressure fluid to move the pistons. This substitution maintains piston speed while preserving mixing consistency by avoiding pressure-induced material damage.
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 ensures a more consistent mixture over time by reducing average fluid pressure, preventing material damage, and enabling the system to handle both higher and lower viscosity fluids, improving the quality and consistency of the dispensed mixture.
Implementation Method 1
the system has an actuator that is coupled to push or pull the rods of a double acting piston cylinder for one of the fluids as well as for the other of the fluids
Implementation Method 2
The controller may electrically control a) speed of the base pump, and b) speed or force of pushing and pulling by the actuator, so as to maintain pressure of the base fluid within a dispensing range
Implementation Method 3
The controller also serves to electrically activate and deactivate the pumps, which are pushing the two fluids from their respective repositories or containers into their respective metering cylinders
Data Source
AI summary
A base valve, a base pump, a catalyst valve, a catalyst pump, a mixing chamber, a base cylinder connected to the base valve, and a catalyst cylinder connected to the catalyst valve. The base and catalyst cylinders are actuated so as to push base and catalyst fluids out of the base and catalyst cylinders, respectively, and into the mixing chamber. An electronic controller has a ready mode and a dispensing mode. In the ready mode, the controller i) activates the base and catalyst pumps and ii) signals the actuator to push or pull, in response to a dispense signal being asserted. In the dispensing mode, the controller a) deactivates the base and catalyst pumps, b) signals the actuator to stop pushing or stop pulling, and maintains a) and b) in response to the dispense signal being de-asserted. Other embodiments are also described.