Plural Component Dispensing With Independent Pumps for Ratio Control
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Solution Overview
Problem
Existing foam spray systems struggle to maintain a precise ratio between constituent materials, leading to inconsistent properties in the resultant plural component material, and often require mechanically linked pumps and compressed gas for mixing and application.
Innovation Solution
A system with independent first and second pumps, each driven by an electric motor, controlled by a controller that dynamically assigns one as a lead and the other as a follower based on operating parameters, ensuring the desired mix ratio without mechanical linkage or downstream proportioners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanically linked pumps are used to maintain material ratio, then the mix ratio consistency is improved, but the device complexity increases
Solution Approach 1:
The patent replaces the mechanical linkage system between pumps with an electronic control system. The controller receives feedback from sensors monitoring material flow and pump operating conditions, then dynamically adjusts pump motor speeds to maintain the desired mix ratio. This substitution of mechanical coupling with electronic control achieves precise ratio management while eliminating the complexity of mechanical synchronization mechanisms.
2Manufacturing precision
If downstream proportioners are used to control material mixing, then the mix ratio precision is improved, but the device complexity increases
Solution Approach 1:
The patent extracts and eliminates the downstream proportioner component from the system. Instead of using a separate proportioning device downstream of the pumps, the control system is integrated directly into the pump control architecture. The controller monitors material flow rates and pump parameters upstream and adjusts pumping speeds accordingly, achieving precise mixing ratio control without requiring additional downstream proportioning equipment.
3Productivity
If compressed gas is used for mixing and propelling material, then the application performance is improved, but the device complexity increases
Solution Approach 1:
The patent removes the compressed gas system from the material mixing and delivery mechanism. The system achieves material mixing and propulsion through the controlled pumping action of the variable speed pumps alone. By eliminating the compressed gas component, the system maintains effective material application performance while reducing overall system complexity and removing the need for gas storage tanks, regulators, and delivery manifolds.
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 achieves precise control over the constituent material ratio, allowing for consistent application of plural component materials like foam, adhesive, or coatings, without the need for mechanical linkage or additional pumps, enhancing application accuracy and efficiency.
Implementation Method 1
a first pump for pumping a first constituent material, the first pump having a first electric motor; a second pump for pumping a second constituent material, the second pump having a second electric motor
Data Source
AI summary
A plural component system includes a first pump configured to pump a first constituent material to an applicator and a second pump configured to pump a second constituent material to the applicator. A controller is operatively connected to the first pump and the second pump to control operation of the first pump and the second pump to pump the first and second constituent materials to the applicator at a desired ratio.