Solvent-Free Plural Component Spraying System
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Solution Overview
Problem
Current plural component spraying systems face challenges in handling wide ranges of viscosities and ratios without solvents, leading to difficulties in mixing and dispensing, and require solvent-based purging, which contradicts environmental and health regulations.
Innovation Solution
A solvent-free spraying system with impingement mixing and static mixing elements, allowing for varying viscosities and ratios, and eliminating the need for solvent purging by incorporating a movable mixing and spraying apparatus with a heating system for temperature control and an air purge mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based purging is used to clean spraying equipment, then equipment cleanliness is improved, but environmental compliance deteriorates due to VOC emissions
Solution Approach 1:
The patent removes the solvent purging function from the system by using a heating element that thermally breaks down residual materials in the spray tip and hoses, eliminating the need for solvent-based cleaning while maintaining equipment cleanliness
Solution Approach 2:
The patent replaces the mechanical/chemical solvent flushing system with a thermal decomposition system using heating elements that bake out residual materials from the equipment, substituting thermal energy for chemical cleaning agents
2Adaptability or versatility
If formulations with wide viscosity ratios are used, then material versatility is improved, but mixing and dispensing difficulty increases
Solution Approach 1:
The patent applies heating to reduce the viscosity of high-viscosity components before mixing and dispensing, allowing formulations with wide viscosity ratios (up to 100:1) to be processed effectively by transforming the physical state of the materials
Solution Approach 2:
The patent separates the mixing and dispensing functions into distinct stages, with pre-heating and initial mixing occurring separately from the final dispensing operation, allowing each stage to be optimized independently for handling materials with wide viscosity variations
3Object-affected harmful factors
If solvent-free formulations are used, then environmental compliance is improved, but equipment purging requirements increase complexity
Solution Approach 1:
The patent extracts the purging function entirely from the system by using thermal decomposition to break down and eliminate residual materials in the equipment, removing the need for separate purging systems while maintaining solvent-free operation
Solution Approach 2:
The heating element enables the equipment to self-clean by thermally decomposing residual materials in the spray tip and hoses, allowing the system to maintain itself without external solvent-based purging operations
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 mixing and dispensing of formulations with wide viscosity and ratio variations, reducing gel and cure times significantly and eliminating the need for solvent-based purging, thus enhancing environmental sustainability and operational efficiency.
Implementation Method 1
a heating system to heat the respective fluid components
Implementation Method 2
an impingement mixing element
Implementation Method 3
a static mixer housing that contains one or more static mixing elements downstream of the point at which the respective fluid components enter
Data Source
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AI summary
Solvent-free spraying system including methods and apparatus for spraying plural component materials without requiring the use of solvents to flush out equipment or as part of the materials being dispensed. Materials sprayed can have simultaneously widely varying viscosities, pressures, temperatures and ratios between two or more respective components being combined by the spraying apparatus. Cure rates and gel times can vary widely from hours to less than 10 seconds for mixing and dispensing various plural component thermoplastic and thermosetting materials including foams, moldings and coatings made from urethanes, ureas, epoxies, polyesters, phenolics and other chemical compositions that react rapidly upon mixing of the components thereof.