PU Foam Mixing Tube for Precise Air-to-Component Ratio Control
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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 interruption-free conveyance, inaccurate mixing ratios, and difficulty in setting the air-to-component ratio, leading to inconsistent material quality and efficiency.
Innovation Solution
The system introduces a method where all components, including gas, are mixed within an application device featuring a mixing tube with defined sections and injection units. This allows for precise control over the mixing ratio and order of components, ensuring homogeneous mixing and efficient application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If components are pre-mixed with air in tanks before feeding to the mixer, then the mixing process is simplified, but the mixing ratio precision and material quality deteriorate
Solution Approach 1:
The mixing process is segmented into two distinct stages: (1) components are conveyed separately without air mixing, and (2) air mixing occurs only within the mixing tube at the application device. This segmentation allows precise control of component ratios before air introduction, while still achieving the benefit of simplified mixing process.
Solution Approach 2:
Components are pre-conveyed and pre-mixed with each other (but not with air) before the final mixing stage. This preliminary action ensures accurate component ratios are established beforehand, while the actual air mixing is deferred to the precise moment of application.
2Ease of manufacture
If tank-based component storage and feeding is used, then material storage is simplified, but interruption-free conveyance and productivity deteriorate
Solution Approach 1:
The system implements continuous conveyance of components from storage tanks through metering devices to the mixing tube without interruptions. The components flow continuously through the system, enabling uninterrupted foam production and eliminating the need for manual tank replacement or reloading operations.
3Ease of operation
If components are fed in air-displaced state to the mixer, then handling is simplified, but the ability to set precise mixing ratios and air-to-component ratios deteriorates
Solution Approach 1:
Components are pre-mixed with each other in precise ratios before air is introduced. This preliminary mixing action establishes accurate component proportions, while air mixing is deferred to the final stage within the mixing tube, maintaining both handling simplicity and ratio precision.
4Device complexity
If conventional mixer or applicator is used, then application is simplified, but material quality homogeneity and reproducibility deteriorate
Solution Approach 1:
The mixing process is segmented into component mixing (without air) and final air mixing within the mixing tube. This segmentation ensures homogeneous mixing of components before air introduction, while the mixing tube design maintains simple application device structure.
Solution Approach 2:
Components are pre-mixed with each other in precise ratios before air is introduced. This preliminary mixing action ensures homogeneous component distribution, while the actual air mixing occurs at the final stage, improving foam consistency without complicating the application device.
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 solution enables interruption-free production and application of PU foam, improves homogeneity and controllability, and allows for precise setting of the mixing ratio, resulting in enhanced material quality and flexibility in using different components.
Implementation Method 1
a mixer (8) arranged at least partially in the mixing space (5), which is configured to mix the injected components with one another
Implementation Method 2
a pump device (18), in particular a high-pressure pump, which is configured to increase a pressure of the component
Implementation Method 3
a treatment unit (22), in particular a heating unit, which is configured to heat the component in the material container (20)
Implementation Method 4
a vacuum unit (24), in particular a high-vacuum unit, which is configured to actuate a vacuum in the material container (20)
Data Source
AI summary
The disclosure relates to an application system for mixing a plurality of components for producing a multicomponent mixture, in particular a polyurethane foam, and for introducing and/or applying the multicomponent mixture into and/or onto an article, in particular a lithium-ion battery, wherein the application system comprises an application device. Furthermore, 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 article is disclosed.