Polyurethane Foam Applicator With Segmented Injection Units
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Solution Overview
Problem
Existing solutions for producing and applying polyurethane (PU) foam in applications like battery production face challenges such as interrupted production, inaccurate mixing ratios, and difficulty in setting the air-to-component ratio, leading to inconsistencies in foam quality and application efficiency.
Innovation Solution
The development of an application device with a mixing tube and injection units that allow for precise control over the injection order and ratio of components, including air, within the mixing space, ensuring continuous and efficient production and application of PU foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If components are pre-conditioned in tanks and fed to mixer in air-displaced state, then storage and handling is simplified, but metering accuracy and mixing ratio control deteriorates
Solution Approach 1:
The system performs preliminary action by pre-mixing components with air in storage tanks before use. The mixing device in the tank ensures components are pre-conditioned with the correct air content, so that when fed to the application device, they maintain consistent properties without requiring precise metering at the application point.
Solution Approach 2:
The patent introduces an intermediary mixing device that acts as a mediator between storage and application. This device preconditioned the components by mixing them with air in the tank, serving as an intermediate step that resolves the contradiction between easy handling and precise metering.
2Ease of manufacture
If components are mixed with air in storage tanks, then production preparation is simplified, but mixing ratio control and foam quality consistency deteriorates
Solution Approach 1:
The system performs preliminary mixing action in the storage tank using a dedicated mixing device. Components are pre-mixed with air to the correct ratio before storage, ensuring that when used, the mixing ratio is already optimized without requiring complex control at the application stage.
3Ease of operation
If conventional mixer/applicator is used, then application is straightforward, but production must be interrupted for tank replacement and dripping occurs after stop
Solution Approach 1:
The system segments the foam production process into separate functions: storage/pre-mixing in tanks, precise metering through injection units with individual meters, and application through the mixing tube. This segmentation allows each component to be independently controlled and replaced without interrupting the overall process.
Solution Approach 2:
The patent achieves continuous production by implementing a system where components are pre-prepared in tanks, then fed continuously through injection units with individual meters to the mixing tube. The decoupled architecture allows uninterrupted flow of materials without tank replacement interruptions or dripping issues.
4Device complexity
If single mixing chamber is used, then device structure is simple, but homogeneity and controllability of multicomponent mixture deteriorates
Solution Approach 1:
The mixing process is segmented into multiple stages: pre-mixing in storage tanks, individual component metering through separate injection units, and final mixing in the mixing tube. This segmentation of the mixing function into distributed stages achieves superior homogeneity while maintaining reasonable device complexity.
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 solution enables interruption-free production and application of PU foam, improves homogeneity and controllability, allows for precise setting of the mixing ratio, and enhances the cleanliness and flexibility of the application process.
Implementation Method 1
a mixer arranged at least partially in the mixing space, which mixer is configured to mix the injected components with one another
Implementation Method 2
a plurality of injection units, which are each configured to inject a corresponding one of the plurality of components into the mixing space at a corresponding position along the mixing section
Data Source
AI summary
The disclosure relates to an application device for mixing a plurality of components for producing a multicomponent mixture, a polyurethane foam, and for introducing and/or applying the multicomponent mixture into and/or onto an object, in particular a lithium-ion battery, comprising: a mixing tube with a first closed end and a second end for discharging the multicomponent mixture from the mixing tube, wherein the mixing tube comprises a mixing space, a plurality of injection units, which are each configured to inject one of the plurality of components into the mixing space at a corresponding position, and a mixer arranged in the mixing space, which mixer is configured to mix the injected components with one another. An application system comprising the application device and a method for mixing a plurality of components for producing a multicomponent mixture and for introducing and/or applying the multicomponent mixture into and/or onto an object is disclosed.