Mixer with Variable Diameter Sections for Polyurethane Foam
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solutions for producing and applying polyurethane (PU) foam 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.
Innovation Solution
The development of an application device with a mixing tube having sections with different internal diameters and a mixer that can rotate along the mixing tube, allowing for precise control of component injection and mixing, ensuring uniform mixing and adjustable air-to-component ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are fed to the mixer in air-displaced state from tanks, then the mixing ratio of components is difficult to set precisely, but continuous conveyance and production is interrupted by frequent tank replacement
Solution Approach 1:
The patent applies preliminary action by pre-filling a magazine with multiple component cartridges before the mixing process begins. This allows the mixer to continuously draw components from the magazine without interruption, eliminating frequent tank replacements while maintaining precise metering through the cartridge-based delivery system.
Solution Approach 2:
The patent introduces an intermediary component - a magazine storing multiple cartridges - between the component tanks and the mixer. This intermediary system enables continuous component supply to the mixer while allowing precise control of component delivery through the cartridge-based metering mechanism, resolving the contradiction between continuous production and precise mixing ratio control.
2Manufacturing precision
If a constant internal diameter mixing tube is used, then the mixing process is simple, but the mixing homogeneity and adaptability to different component ratios is insufficient
Solution Approach 1:
The patent segments the mixing tube into multiple sections with different internal diameters along its length. This segmentation creates varying flow conditions for the components as they pass through each section, improving mixing homogeneity by preventing channeling and dead zones while maintaining a relatively simple overall tube structure without complex moving parts.
Solution Approach 2:
The patent applies local quality by giving different sections of the mixing tube different internal diameters tailored to specific mixing requirements. The varying diameters create localized flow patterns that enhance mixing efficiency at different stages of the mixing process, allowing optimization of mixing homogeneity without requiring the entire tube to be complex.
3Adaptability or versatility
If the mixer remains stationary, then the device structure is simple, but the application flexibility and adaptability to different objects is limited
Solution Approach 1:
The patent transforms the stationary mixer into a dynamic, movable component that can be positioned at different locations along the mixing tube. This dynamic positioning capability allows the mixer to adapt to different application requirements and objects while the overall device structure remains relatively simple, avoiding the need for complex reconfiguration mechanisms.
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 uninterrupted and precise production and application of PU foam, improving homogeneity, controllability, and precision, while preventing dripping and ensuring clean application.
Implementation Method 1
a mixer (8) arranged at least partially in the mixing chamber (5), which mixer (8) is configured to mix the injected components with one another
Implementation Method 2
The mixing tube (2) has a plurality of sections (2a, 2b, 2c), wherein a wall (19) of the mixing tube (2) of at least two of the plurality of sections (2a, 2b, 2c) has mutually different internal diameters
Data Source
AI summary
The disclosure relates to an application device 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 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 has a mixing chamber and a plurality of sections, wherein a wall of the mixing tube of at least two of the plurality of sections has mutually different internal diameters, further comprising a plurality of injection units, which are each configured to inject a corresponding one of the plurality of components into the mixing chamber, and a mixer arranged in the mixing chamber, which mixer is configured to mix the injected components with one another along the mixing tube. Furthermore disclosed is an application system comprising the application device.