Remote Spray Unit With Pneumatic Actuation for Underfloor Insulation
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Solution Overview
Problem
Existing spray apparatuses for thermally insulative materials are primarily designed for manual operation and are not suitable for remote or autonomous use in confined spaces such as underfloor cavities, limiting their effectiveness in providing efficient insulation.
Innovation Solution
A remotely operable spray unit with a mixing chamber and spray orifice, controlled by a pneumatic actuator and a solenoid actuator, which can be mounted on a robotic device to spray thermally insulating materials like polyurethane foam, allowing for compact and autonomous operation in confined spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spray apparatus is designed for manual operation, then ease of operation is improved, but adaptability to confined spaces and remote operation deteriorates
Solution Approach 1:
The patent replaces manual mechanical control with an electric actuator system. The spray component is moved between spraying and non-spraying positions using an electric actuator controlled by a remotely operable switch, eliminating the need for manual mechanical operation while enabling remote control capability.
Solution Approach 2:
The patent introduces an electric actuator as an intermediary mechanism between the control switch and the spray component. This intermediary translates electrical signals into mechanical motion, enabling remote operation while maintaining ease of control through a simple switch interface.
2Adaptability or versatility
If spray apparatus is made compact for confined spaces, then adaptability to underfloor cavities is improved, but device complexity increases
Solution Approach 1:
The spray apparatus is segmented into distinct functional components: a spray component with mixing chamber and spray orifice, a pneumatic actuator for positioning, and a control system. This segmentation allows each component to be optimized independently while maintaining overall compactness for underfloor cavity application.
Solution Approach 2:
The patent employs a nested arrangement where the spray component is positioned within the housing, the pneumatic actuator is integrated into the housing structure, and control elements are embedded within the assembly. This nesting minimizes the overall footprint while containing all necessary functions.
3Productivity
If spray component is continuously open for spraying, then productivity is improved, but loss of material increases when not in use
Solution Approach 1:
The spray component operates in periodic cycles, alternating between spraying position and non-spraying position. The electric actuator moves the spray component to the spraying position only when material application is required, and returns it to the non-spraying position when not in use, eliminating continuous material flow and preventing waste.
Solution Approach 2:
The spray component is designed to be dynamically positionable between two states: spraying and non-spraying. This dynamic positioning controlled by the electric actuator allows the system to adapt material flow to actual application needs, maintaining productivity during spraying while preventing material loss during idle periods.
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
Enables efficient and remote spraying of thermally insulating materials in confined spaces, such as underfloor cavities, improving insulation coverage and reducing manual labor requirements.
Implementation Method 1
a pneumatic actuator operable to move the spray component between the spraying position and the non-spraying position
Implementation Method 2
a remotely operable electric actuator arranged to control operation of the pneumatic actuator
Implementation Method 3
the first and second material components enter the mixing chamber and are sprayed via the spray orifice
Data Source
AI summary
There is provided a spray unit for a remotely operable spray apparatus. The spray unit is configured to spray a material having first and second material components. The spray unit comprises a first material inlet for receiving the first material component, a second material inlet for receiving the second material component, and a spray component comprising a mixing chamber and a spray orifice. The spray component is movable between a spraying position in which the mixing chamber is in communication with the first and second material inlets such that the first and second material components enter the mixing chamber and are sprayed via the spray orifice, and a non-spraying position in which the mixing chamber is closed from the first and second material inlets. The spray unit further includes a pneumatic actuator operable to move the spray component between the spraying position and the non-spraying position, and a remotely operable electric actuator arranged to control operation of the pneumatic actuator.