Viscous Material Foaming via High-Pressure Gas Injection
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Solution Overview
Problem
Existing methods for foaming viscous materials, such as two-component systems and low-pressure injection methods, face challenges in process reliability and foam quality due to irregular gas bubble distribution and small foaming effects.
Innovation Solution
A device and method that uses a gas injection valve to control the size and quantity of gas bubbles in viscous materials under high pressure, combined with static or dynamic mixing and pressure relief, to produce a uniform foam with improved foaming effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If gas is injected into viscous material under low pressure (1 bar), then the equipment complexity is reduced, but the foaming effect is relatively small and process reliability deteriorates
Solution Approach 1:
The patent changes the pressure parameter from low pressure (1 bar) to high pressure (80-120 bar) for conveying the viscous material. This parameter change enables a stronger foaming effect and improved process reliability while maintaining controlled gas bubble distribution through the gas injection valve.
2Manufacturing precision
If gas bubbles are injected using a gas injection valve under high pressure, then manufacturing precision of gas bubble distribution is improved, but device complexity increases
Solution Approach 1:
The gas injection valve acts as an intermediary device that precisely controls gas bubble injection into the high-pressure viscous material flow. This intermediary component enables precise manufacturing precision for gas bubble distribution while managing the overall device complexity through a dedicated control element.
3Reliability
If viscous material is conveyed at high pressure (80-120 bar), then the foaming effect is enhanced, but the energy consumption increases
Solution Approach 1:
The needle valve is actuated periodically to inject gas bubbles in controlled intervals into the high-pressure viscous material flow. This periodic action allows for controlled gas injection that achieves the desired foaming effect while managing energy consumption through intermittent rather than continuous high-pressure gas supply.
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 achieves a high-quality, uniform foam with enhanced process reliability by ensuring precise control over gas bubble distribution and increased pressure, resulting in a more consistent and effective foaming process.
Implementation Method 1
Due to the pressure relief, the gas bubbles distributed in the viscous material expand due to the pressure difference after the pressure relief and thereby physically foam the viscous material
Implementation Method 2
The gas bubbles are injected under high pressure into the viscous material, which is already under high pressure. According to the invention, the viscous material is conveyed at a conveying pressure of 80 bar to 120 bar
Data Source
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AI summary
The invention relates to a device (01, 19, 23) for foaming a viscous material (02). The viscous material (02) is conveyed by a first conveying means (04) under a first conveying pressure through a first conveying line (05), and a gas (07) is conveyed under a second conveying pressure through a second conveying line (08). The second conveying line (08) opens into the first conveying line (05) at an opening point (15), and an outflow device (17) is provided downstream of the opening point (15) to allow the mixture (14) of viscous material (02) and gas (07) to flow out in a depressurising manner. A gas injection valve (09) is provided at the opening point (15), said gas injection valve (09) being able to inject gas bubbles (25) into the viscous material (02).