Viscous Mixture Distribution Device for Uniform Foam Application
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Solution Overview
Problem
The existing methods for applying viscous mixtures, such as polyurethane foam, to surfaces often result in uneven distribution, air bubbles, clogging, and premature curing due to variations in exit velocity and residence time, leading to inconsistent foam layers and reduced thermal insulation performance in roof elements.
Innovation Solution
A device with a first distribution element connected to a second distribution element via intermediate pipes, where the outlet openings on the second element are staggered and have varying cross-sectional areas to ensure uniform residence time and pressure distribution, minimizing 'dead' spaces and foam contraction, thus achieving a constant and uniform foam application across the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a central supply point with outlet openings along the casting rake is used, then the foam can be applied to the surface, but the exit velocity varies between outlet openings causing uneven mass distribution
Solution Approach 1:
The casting rake is divided into multiple segments (first casting rake portion, second casting rake portion, third casting rake portion) with separate outlet openings in each segment. Each segment receives viscous mixture through individual supply channels, allowing independent control of flow distribution. This segmentation enables uniform exit velocity across all outlet openings by optimizing the number and positioning of outlets in each segment, thereby achieving even mass distribution and consistent foam layer uniformity.
2Productivity
If high exit velocity is used to apply foam quickly, then productivity increases, but air bubbles are introduced into the foam layer
Solution Approach 1:
The outlet openings are designed with specific local characteristics including optimized numbering, positioning, and cross-sectional areas tailored to each segment's requirements. The supply channels are dimensioned to provide appropriate flow rates to each local region. This local optimization ensures that exit velocity remains within an optimal range that maintains high productivity while preventing air bubble entrapment, as each local region's geometry is specifically designed to control flow dynamics and minimize turbulence.
3Productivity
If the casting rake moves quickly to increase productivity, then output increases, but uniform distribution of foam becomes difficult to achieve
Solution Approach 1:
The system is designed to accommodate dynamic operation with the casting rake moving at variable speeds. The outlet openings and supply channels are configured to maintain proper viscous mixture flow rates even at higher pass velocities. The segmented design with multiple outlet openings per segment ensures that inertial effects and flow distribution remain stable across a range of operating speeds, allowing high productivity through increased pass velocity while preserving uniform foam distribution through the inherently stable flow path design.
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 device ensures a consistently uniform mass distribution of the foam layer, reduces the risk of clogging, and maintains an even foam height, enhancing the thermal insulation effect by minimizing air bubbles and premature curing, resulting in a stable and uniform foam application.
Implementation Method 1
a viscous mixture that is reactive towards carbon dioxide or water and that forms a foam
Implementation Method 2
allowing the foam thus applied to cure
Data Source
AI summary
The present invention relates to a device for applying a viscous mixture to a surface via one or more outlet-openings (7), to which device the viscous mixture is supplied via supply means (8). The present invention further relates to a method for manufacturing an insulation element, comprising the steps of applying a viscous mixture that forms a foam to a substrate layer, allowing the foam thus applied to cure and possibly applying a coating to the foam layer.