Internal Nozzle Cleaner With Misalignment Coupling for Spray Foam
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Solution Overview
Problem
Existing spray foam application systems require significant Personal Protective Equipment (PPE) usage due to the potential for hazardous chemical exposure, particularly with B-side chemicals, necessitating improved safety measures for applicators and adjacent workers.
Innovation Solution
A remote spray foam system with an internal nozzle cleaner system featuring a telescopic chuck, motor, misalignment shaft coupling, and a conical envelope to accommodate misalignment, allowing for automated nozzle cleaning and reduced PPE requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If manual nozzle cleaning is performed, then the nozzle can be cleaned, but the applicator must wear extensive PPE due to chemical exposure risks
Solution Approach 1:
The system performs self-service by automatically cleaning its own nozzle through the robotic manipulator that inserts and operates the cleaning tool within the nozzle, eliminating the need for manual intervention and associated PPE requirements
Solution Approach 2:
The patent replaces the manual mechanical cleaning process with an automated robotic system that uses a motor-driven cleaning tool, substituting human operation with mechanical automation to reduce chemical exposure risks
2Extent of automation
If automated nozzle cleaning is implemented, then PPE requirements are reduced, but the device complexity increases
Solution Approach 1:
The cleaning system is segmented into distinct functional modules: a robotic manipulator for positioning, a motor for rotation, a telescopic chuck for tool holding, and a misalignment shaft coupling for tolerance compensation, allowing independent optimization of each component
Solution Approach 2:
The misalignment shaft coupling allows parameter changes in the form of angular and parallel misalignments (conical envelope with 15° angular and 1/8-inch parallel misalignment), enabling the system to accommodate manufacturing tolerances without increasing overall complexity
3Adaptability or versatility
If the cleaning tool is rigidly mounted, then the structure is simple, but it cannot accommodate nozzle misalignment
Solution Approach 1:
The misalignment shaft coupling enables parameter changes by allowing angular and parallel displacements within a conical envelope, accommodating manufacturing tolerances and nozzle misalignments without requiring complex adaptive mechanisms
Solution Approach 2:
The telescopic chuck with bias member creates a dynamic mounting structure that can adjust its position and orientation to accommodate misalignment, transitioning from a rigid to a flexible connection that adapts to varying nozzle positions
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
Facilitates minimal PPE usage by enabling automated and efficient cleaning of nozzles, ensuring consistent foam application and reducing occupational exposure risks.
Implementation Method 1
The telescopic chuck may include a bias member such as a spring to permit axial movement of the drill bit into the nozzle in response to misalignment that is accommodated by the misalignment shaft coupling.
Data Source
AI summary
An internal nozzle cleaner system for a remote spray foam system for polyurethane insulation foam includes a telescopic chuck along an axis to support a tool; a motor to rotate the telescopic chuck about the axis; and a misalignment shaft coupling between the motor and the telescopic chuck to accommodate a misalignment between the axis and a nozzle of the remote spray foam system.