Three-Gear Foaming Layout for Stable Expansion Ratio
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Solution Overview
Problem
Existing mechanical foaming apparatuses face challenges in maintaining a stable foaming expansion ratio due to high load on downstream gear pumps, leading to fluctuations in the mixture of liquid and gas delivery, which affects the consistency of the foaming process.
Innovation Solution
A foaming apparatus with a configuration of three gear pumps, where the second gear pump operates at a higher speed than the first, and the third gear pump operates at the same speed as the second, stabilizing the suction pressure and load distribution, ensuring consistent mixing of gas and liquid, and a mixer disperses bubbles in the liquid to generate a stable foamable material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the downstream pump is configured to suck both liquid and gas at higher speed, then the gas can be supplied into the flow path, but the load on the downstream pump becomes high causing fluctuations in delivery ratio
Solution Approach 1:
The patent divides the single downstream pump function into two separate pumps: a liquid pump that handles only liquid resin and a gas pump that handles only gas. This segmentation allows each pump to operate independently at optimal speeds without the instability caused by trying to handle both phases simultaneously, thereby maintaining stable delivery ratios while achieving the required mixing performance.
2Adaptability or versatility
If two pumps are installed on the flow path, then the foaming capability is improved, but the device complexity increases
Solution Approach 1:
The patent combines the liquid pump and gas pump into a single integrated mixing chamber where both streams converge and mix. This merging approach allows the system to maintain the functional benefits of having separate liquid and gas handling capabilities while reducing the overall system complexity compared to having completely separate pumping and mixing systems.
3Productivity
If the downstream pump operates at higher speed to supply gas, then gas flow is improved, but the mixture may feed back to upstream side due to fluctuations
Solution Approach 1:
By separating the liquid and gas pumping functions into independent pumps, the system eliminates the pressure fluctuations that occur when a single pump tries to handle both phases at varying speeds. The liquid pump maintains stable upstream pressure while the gas pump independently controls gas supply, preventing feedback and ensuring unidirectional stable flow.
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 apparatus achieves a stable foaming expansion ratio by reducing the load on the second gear pump, ensuring consistent mixing and delivery of gas and liquid, resulting in a uniform foamed product.
Implementation Method 1
the rotation speed of a gear of each gear pump is controlled to generate suction pressure (negative pressure) in the flow path between the gear pumps, such that a desired amount of gas flows into the flow path
Implementation Method 2
a foaming apparatus which discharges a foamable material obtained by mixing gas into a viscous material and dispersing bubbles in a liquid
Data Source
AI summary
According to the present invention, there is provided a foaming apparatus that discharges a foamable material obtained by mixing gas into a viscous material of a resin and dispersing bubbles in a liquid of the viscous material. The foaming apparatus includes: a pipe; a material supply unit; a gas supply unit; a first gear pump; a second gear pump; a third gear pump; a mixer; a discharge unit; and a control unit.