Modular Spray System with Independent Hydraulic Pumps
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Solution Overview
Problem
Current spray foam and polyurea/urethane elastomeric coating systems are complex, prone to failure, and difficult to troubleshoot, with issues including incorrect component ratios, overheating, and the use of pneumatic drive systems that are noisy and inefficient, leading to costly downtime and suboptimal performance.
Innovation Solution
A modular plural component spray system with independent hydraulic reciprocating piston pumps for each flow line, eliminating transfer pumps and heating components outside the drums to prevent premature expansion and ensure accurate mixing, while using check valves and a bleed line to prevent pulsation and cavitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If heating components inside the drum before pumping, then component viscosity is reduced for easier pumping, but premature expansion and striation occur making the foam impractical to pump
Solution Approach 1:
The system performs preliminary heating of components outside the drum in a controlled manner before pumping, rather than heating inside the drum. This preliminary action reduces viscosity for easier pumping while maintaining foam stability by avoiding premature expansion that occurs with inside-drum heating.
2Productivity
If using pneumatic drive systems for pumps, then pumping action is achieved, but the system becomes noisy, dirty and requires larger air compressors
Solution Approach 1:
The patent replaces pneumatic drive systems with an electric motor-driven hydraulic pump system. This substitution eliminates the need for large air compressors and pneumatic infrastructure, reducing noise and dirt while maintaining pumping capability through hydraulic actuation of the pump mechanism.
3Ease of operation
If using transfer pumps to transport components, then component transport is achieved, but the system becomes complex and prone to failure
Solution Approach 1:
The patent merges the component transport function into the main pump system by having each pump draw directly from its component drum and deliver to the spray gun. This eliminates separate transfer pumps and reduces system complexity while maintaining ease of operation through direct component flow paths.
4Productivity
If delivering components at incorrect ratios, then spray application continues, but the mixture lacks proper stoichiometry and physical properties
Solution Approach 1:
The system incorporates feedback mechanisms through proportional control systems that monitor and adjust component delivery ratios. Each pump is controlled to deliver components at the correct stoichiometric ratio, ensuring proper mixture properties while maintaining continuous spray output productivity.
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 simplifies operation, reduces downtime, and achieves consistent component ratios, improving the quality and efficiency of the spraying process by eliminating pulsations and overheating issues, and allowing for remote drafting with enhanced siphoning capabilities.
Implementation Method 1
independent hydraulic reciprocating piston pumps
Implementation Method 2
reciprocating piston pumps
Implementation Method 3
using check valves and a bleed line to prevent pulsation and cavitation
Implementation Method 4
heating components outside the drums to prevent premature expansion
Implementation Method 5
allowing for remote drafting with enhanced siphoning capabilities
Data Source
AI summary
A modular plural component spray system configured for drawing at least two components, each stored in a discrete drum and sending the at least two components to a spray gun. The spray system comprises at least two flow lines. Each flow line includes a pump, a counter configured to measure the work performed by the pump and a heater disposed outside of each discrete drum downstream from the pump, where each of the two flow lines is configured to be connected at a first end to the spray gun and a second end to each discrete drum and each of the at least two components is drawn from each discrete drum and heated with the heater before arriving at the spray gun to be mixed and dispensed.