Note: Descriptions are shown in the official language in which they were submitted.
CA 02713643 2010-08-24
Client File Number: BASF 12440
TWO COMPONENT FOAM DISPENSING APPARATUS
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The subject invention generally relates to a foam dispensing
apparatus for dispensing a mixture of a first fluid and a second fluid. More
specifically,
the subject invention relates to a manifold assembly for supplying the first
fluid, the
second fluid, a gas and a cleansing fluid to a dispensing head of the foam
dispensing
apparatus.
2. Description of the Related Art
[0002] Expanding chemical foam compositions, such as curable
polyurethane foams, are presently well known and used in a number of different
applications. Expanding chemical foam compositions are useful in such
applications as
thermal insulation, floatation, coatings and packaging. The curable foam
compositions
comprise a two-part composition, and in the case of polyurethane foams, one
part of the
composition includes a resin component and the other part includes an
isocyanate
component. The resin component typically includes a polyol component. Chemical
foaming agents, curing agents catalysts or accelerators, as well as other
modifying
additives, may be incorporated into one or both of the foam components. These
two-
components of the foaming composition are separately stored in different
containers until
use.
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[0003] In use, the two components of the foam composition are rapidly
mixed together. A rapid cross-linking reaction and foam expansion commences,
which
ultimately yields a low density, but relatively high load bearing urethane
rigid foam. The
mixing of the resin component and the isocyanate component must occur at a
proper flow
ratio and mix under rapid and sufficient impingement mixing conditions to
obtain a final
acceptable product.
[0004] The urethane components, including the resin component and the
isocyanate component, are stored under pressure in containers, which are
attached to
hand held dispensing assemblies (guns) by means of various hoses and
couplings. The
guns include a trigger operated dispensing head designed to permit the two-
components
of the foam composition to flow into a mixing chamber wherein the two
components are
rapidly mixed to form a reactive and expanding chemical foam composition,
which exits
through a foam discharge nozzle or opening. The trigger operated dispensing
head may
be manually controlled or electronically controlled.
[0005] The two components of the foam composition are highly
chemically reactive and begin to form a cured polymeric product within a
matter of
seconds. Premature leaking and mixing of the two foam components within the
dispensing assembly is a serious and major concern because leakage results in
undesirable curing in the dispensing assembly, causing blockage and damage to
dispensing assembly.
[0006] Referring to Prior Art Figure 1, an example of a prior art
dispensing assembly (gun) is shown. The dispensing assembly comprises a
dispensing
head, which dispenses the mixed foam composition. The dispensing assembly
further
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comprises various pipe fittings and tubing to provide the two foam components
to the
dispensing head. Additionally, the dispensing assembly further comprises
various pipe
fittings to provide a flow of a gas, preferably but not limited to nitrogen,
and a flow of a
cleansing fluid, preferably but not limited to water, to the dispensing head.
The gas is
entrained within the foam components to assist in the formation of the
expanded foam
product and may be utilized to flush or clean the dispensing head. The
cleansing fluid is
also utilized to flush the remnants of the foam components from the dispensing
head at
the end of each use. The gas may be combined with the cleansing fluid to
assist in
cleansing the dispensing head. The various pipe fittings and components
include on/off
control valves, check valves, flow control valves, couplings, T-connectors,
etc. Each of
the connections between the various components is susceptible to leakage.
Additionally,
dispensing assemblies such as shown in Prior Art Figure 1 are heavy and
awkward to
handle.
SUMMARY OF THE INVENTION AND ADVANTAGES
[0007] The subject invention provides a foam dispensing apparatus. The
foam dispensing apparatus dispenses a mixture of a first fluid and a second
fluid. The
apparatus comprises a dispensing head. The dispensing head mixes the first
fluid and the
second fluid and dispenses the mixture onto a substrate. A handle extends from
the
dispensing head. The handle permits a user to grasp and manipulate the
dispensing head
for operating the dispensing head. A manifold assembly is mounted to the
dispensing
head. The manifold assembly comprises a purge portion, a first supply portion
and a
second supply portion. The purge portion of the manifold assembly defines a
gas inlet, a
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cleansing fluid inlet, an outlet in fluid communication with the dispensing
head, and a
plurality of passageways interconnecting the gas inlet, the cleansing fluid
inlet and the
outlet. The purge portion of the manifold assembly supplies a cleansing
mixture to the
dispensing head. The first supply portion of the manifold assembly is mounted
to the
purge portion. The first supply portion defines a first material inlet for
receiving the first
fluid, a first material outlet coupled to the dispensing head for supplying
the dispensing
head with the first fluid and a first fluid passageway interconnecting the
first material
inlet and the first material outlet. The second supply portion of the manifold
assembly is
mounted to the purge portion. The second supply portion defines a second
material inlet
for receiving the second fluid, a second material outlet coupled to the
dispensing head for
supplying the dispensing head with the second fluid and a second fluid
passageway
interconnecting the second material inlet and the second material outlet.
[0008] Accordingly, the foam dispensing assembly of the subject
invention includes the manifold assembly, which consolidates the supply feeds,
e.g., the
gas inlet, the cleansing fluid inlet, the first fluid inlet and the second
fluid inlet, to the
dispensing head. By consolidating the various supply feeds into the manifold
assembly,
the number of pipe connections in the dispensing assembly is greatly reduced,
which
significantly reduces the likelihood of developing a leak between connections.
Additionally, by consolidating all of the supply feeds into the manifold
assembly, the
maneuverability of the foam dispensing assembly is greatly increased.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other advantages of the present invention will be readily
appreciated, as the same becomes better understood by reference to the
following detailed
description when considered in connection with the accompanying drawings
wherein:
[0010] Prior Art Figure 1 is a perspective view of an example of a prior art
foam dispensing assembly;
[0011] Figure 2 is a schematic diagram of a pressurized two component
foam dispensing system;
[0012] Figure 3 is a perspective view of a foam dispensing apparatus in
accordance with the subject invention;
[0013] Figure 4 is a perspective view of a purge portion of a manifold
assembly of the foam dispensing apparatus;
[0014] Figure 5 is a top cross sectional view of the purge portion of the
manifold assembly;
[0015] Figure 6 is a perspective view of a first supply portion of the
manifold assembly of the foam dispensing apparatus;
[0016] Figure 7 is a side cross sectional view of the first supply portion of
the manifold assembly;
[0017] Figure 8 is a perspective view of a second supply portion of the
manifold assembly of the foam dispensing apparatus; and
[0018] Figure 9 is a side cross sectional view of the second supply portion
of the manifold assembly.
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DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring to the Figures, wherein like numerals indicate
corresponding parts throughout the several views, a foam dispensing apparatus
is shown
generally at 20.
[0020] The foam dispensing apparatus 20 is part of a foam dispensing
system shown generally at 22 in Figure 2. Referring to Figure 2, the foam
dispensing
system 22 includes a two component system 22 comprising a first fluid and a
second
fluid. As described herein, the first fluid includes an isocyanate component
and the
second fluid includes a resin component. However, it should be appreciated
that the first
fluid may alternatively include the resin component and the second fluid may
alternatively include the isocyanate component. The resin component reacts
with the
isocyanate component to form a polyurethane foam. It should be appreciated
that the
resin component and the isocyanate component may include foaming agents,
curing
agents, catalysts, accelerators, as well as other modifying additives. It
should also be
appreciated that the first fluid and the second fluid may include materials
other than the
resin component and the isocyanate component described herein. For example,
the first
fluid may include an adhesive and the second fluid may include water.
[0021] The isocyanate component may include, but is not limited to,
isocyanates, diisocyanates, polyisocyanates, biurets of isocyanates and
polyisocyanates,
isocyanurates of isocyanates and polyisocyanates, and combinations thereof. In
one
embodiment, the isocyanate component includes an n-functional isocyanate,
wherein "n"
may be a number from 2 to 5, from 2 to 4, or from 3 to 4. It is to be
understood that "n"
may be an integer or may have intermediate values from 2 to 5. The isocyanate
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component may include an isocyanate selected from the group of aromatic
isocyanates,
aliphatic isocyanates, and combinations thereof. In another embodiment, the
isocyanate
component includes an aliphatic isocyanate such as hexamethylene diisocyanate,
H12MDI, and combinations thereof. If the isocyanate component includes an
aliphatic
isocyanate, the isocyanate component may also include a modified multivalent
aliphatic
isocyanate, i.e., a product which is obtained through chemical reactions of
aliphatic
diisocyanates and/or aliphatic polyisocyanates. Examples include, but are not
limited to,
ureas, biurets, allophanates, carbodiimides, uretonimines, isocyanurates,
urethane groups,
dimers, trimers, and combinations thereof. The isocyanate component may also
include,
but is not limited to, modified diisocyanates employed individually or in
reaction
products with polyoxyalkyleneglycols, diethylene glycols, dipropylene glycols,
polyoxyethylene glycols, polyoxypropylene glycols,
polyoxypropylenepolyoxethylene
glycols, polyesterols, polycaprolactones, and combinations thereof.
[0022] Alternatively, the isocyanate component may include an aromatic
isocyanate. If the isocyanate component includes an aromatic isocyanate, the
aromatic
isocyanate may correspond to the formula R' (NCO), wherein R' is aromatic and
z is an
integer that corresponds to the valence of R'. Preferably, z is at least two.
Suitable
examples of aromatic isocyanates include, but are not limited to,
tetramethylxylylene
diisocyanate (TMXDI), 1,4-diisocyanatobenzene, 1,3-diisocyanato-o-xylene, 1,3-
diisocyanato-p-xylene, 1,3-diisocyanato-m-xylene, 2,4-diisocyanato-l-
chlorobenzene,
2,4-diisocyanato- l -nitro-benzene, 2,5-diisocyanato- l -nitrobenzene, m-
phenylene
diisocyanate, p-phenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene
diisocyanate, mixtures of 2,4- and 2,6-toluene diisocyanate, 1,5-naphthalene
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diisocyanate, 1-methoxy-2,4-phenylene diisocyanate, 4,4'-diphenylmethane
diisocyanate,
2,4'-diphenylmethane diisocyanate, 4,4'-biphenylene diisocyanate, 3,3'-
dimethyl-4,4'-
diphenylmethane diisocyanate, 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate,
triisocyanates such as 4,4',4"-triphenylmethane triisocyanate polymethylene
polyphenylene polyisocyanate and 2,4,6-toluene triisocyanate, tetraisocyanates
such as
4,4'-dimethyl-2,2'-5,5'-diphenylmethane tetraisocyanate, toluene diisocyanate,
2,2'-
diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 4,4'-
diphenylmethane
diisocyanate, polymethylene polyphenylene polyisocyanate, corresponding
isomeric
mixtures thereof, and combinations thereof. Alternatively, the aromatic
isocyanate may
include a triisocyanate product of m-TMXDI and 1,1,1-trimethylolpropane, a
reaction
product of toluene diisocyanate and 1,1,1-trimethyolpropane, and combinations
thereof.
In one embodiment, the isocyanate component includes a diisocyanate selected
from the
group of methylene diphenyl diisocyanates, toluene diisocyanates,
hexamethylene
diisocyanates, H12MDIs, and combinations thereof.
[0023] The isocyanate component may have any % NCO content and any
viscosity. The isocyanate component may also react with the polyol and/or
chain
extender in any amount, as determined by one skilled in the art. Preferably,
the
isocyanate component and the polyol and/or chain extender are reacted at an
isocyanate
index from 15 to 900, more preferably from 95 to 130, and alternatively from
105 to 130.
[0024] The resin component of the subject invention may include a polyol
component. More specifically, the polyol component may include one or more of
a
polyether polyol, a polyester polyol, and combinations thereof. As is known in
the art,
polyether polyols are typically formed from a reaction of an initiator and an
alkylene
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oxide. Preferably, the initiator is selected from the group of aliphatic
initiators, aromatic
initiators, and combinations thereof. In one embodiment, the initiator is
selected from the
group of ethylene glycol, propylene glycol, dipropylene glycol, butylene
glycol,
trimethylene glycol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 1,2-
pentanediol, 1,4-
pentanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, butenediol,
butynediol,
xylylene glycols, amylene glycols, 1,4-phenylene-bis-beta-hydroxy ethyl ether,
1,3-
phenylene-bis-beta-hydroxy ethyl ether, bis-(hydroxy-methyl-cyclohexane),
thiodiglycol,
glycerol, 1,1,1-trimethylolpropane, 1,1,1-trimethylolethane, 1,2,6-
hexanetriol, a-methyl
glucoside, pentaerythritol, sorbitol, aniline, o-chloroaniline, p-
aminoaniline, 1,5-
diaminonaphthalene, methylene dianiline, the condensation products of aniline
and
formaldehyde, 2,3-, 2,6-, 3,4-, 2,5-, and 2,4-diaminotoluene and isomeric
mixtures,
methylamine, triisopropanolamine, ethylenediamine, 1,3-diaminopropane, 1,3-
diaminobutane, 1,4-diaminobutane, propylene diamine, butylene diamine,
hexamethylene
diamine, cyclohexalene diamine, phenylene diamine, tolylene diamine, xylylene
diamine,
3,3'-dichlorobenzidine, 3,3'-and dinitrobenzidine, alkanol amines including
ethanol
amine, aminopropyl alcohol, 2,2-dimethyl propanol amine, 3-aminocyclohexyl
alcohol,
and p-aminobenzyl alcohol, and combinations thereof. It is contemplated that
any
suitable initiator known in the art may be used in the present invention.
[0025] Preferably, the alkylene oxide that reacts with the initiator to form
the polyether polyol is selected from the group of ethylene oxide, propylene
oxide,
butylene oxide, amylene oxide, tetrahydrofuran, alkylene oxide-tetrahydrofuran
mixtures,
epihalohydrins, aralkylene oxides, and combinations thereof. More preferably,
the
alkylene oxide is selected from the group of ethylene oxide, propylene oxide,
and
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combinations thereof. Most preferably, the alkylene oxide includes ethylene
oxide.
However, it is also contemplated that any suitable alkylene oxide that is
known in the art
may be used in the present invention.
[0026] The polyether polyol may include an ethylene oxide cap of from 5
to 20% by weight based on the total weight of the polyester polyol. It is to
be understood
that the terminology "cap" refers to a terminal portion of the polyether
polyol. Without
intending to be bound by any particular theory, it is believed that the
ethylene oxide cap
promotes an increase in a rate of the reaction of the polyether polyol and the
isocyanate.
[0027] The polyether polyol may also have a number average molecular
weight of from 18 to 10,000 g/mol. Further, the polyether polyol may have a
hydroxyl
number of from 15 to 6,250 mg KOH/g. The polyether polyol may also have a
nominal
functionality of from 2 to 8. Further, the polyether polyol may also include
an organic
functional group selected from the group of a carboxyl group, an amine group,
a
carbamate group, an amide group, and an epoxy group.
[0028] Referring now to the polyester polyols introduced above, the
polyester polyols may be produced from a reaction of a dicarboxylic acid and a
glycol
having at least one primary hydroxyl group. Suitable dicarboxylic acids may be
selected
from the group of, but are not limited to, adipic acid, methyl adipic acid,
succinic acid,
suberic acid, sebacic acid, oxalic acid, glutaric acid, pimelic acid, azelaic
acid, phthalic
acid, terephthalic acid, isophthalic acid, and combinations thereof. Suitable
glycols
include, but are not limited to, those described above.
[0029] The polyester polyol may also have a number average molecular
weight of from 80 to 1,500 g/mol. Further, the polyester polyol may have a
hydroxyl
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number of from 40 to 600 mg KOH/g. The polyester polyol may also have a
nominal
functionality of from 2 to 8. Further, the polyester polyol may also include
an organic
functional group selected from the group of a carboxyl group, an amine group,
a
carbamate group, an amide group, and an epoxy group.
[0030] As shown in Figure 2, the first fluid is stored in a first tank 24 and
the second fluid is stored in a second tank 26. The first tank 24 and the
second tank 26
are connected to a pressurized gas source 28 containing a pressurized gas. As
discussed
herein, the pressurized gas includes nitrogen. However, it should be
appreciated that the
pressurized gas may include a gas other than nitrogen. Accordingly, the
pressurized gas
pressurizes the first tank 24 and the second tank 26.
[0031] The foam dispensing apparatus 20 is connected to the first tank 24
and the second tank 26 by a series of hoses, pipes, pipefittings and/or
connections. More
specifically, the foam dispensing apparatus 20 includes a manifold assembly 30
mounted
to a dispensing head 32, with the first tank 24 and the second tank 26
connected to and
supplying the manifold assembly 30. The manifold assembly 30 is connected to
and
supplies the dispensing head 32 with the first fluid and the second fluid. The
dispensing
head 32 mixes the first fluid and the second fluid together to form a mixture
of the first
fluid and the second fluid, and dispenses the mixture of the first fluid and
the second fluid
onto a substrate 34 to form a polyurethane foam.
[0032] The manifold assembly 30 may further be connected to the
pressurized gas source 28. Alternatively, the manifold assembly 30 may be
connected to
a different source of pressured gas other than the pressurized gas source 28,
such as
pressurized plant air. The manifold assembly 30 supplies the pressurized gas
to the
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dispensing head 32 to entrain the gas within the mixture of the first fluid
and the second
fluid to assist in the formation of the polyurethane foam. Additionally, the
pressurized
gas is utilized to expel, i.e., flush or blow out, any residual of the first
fluid and/or the
second fluid from within the dispensing head 32.
[0033] A cleansing fluid source 36 containing a cleansing fluid is further
connected to the manifold assembly 30. As discussed herein, the cleansing
fluid includes
water. However, it should be appreciated that the cleansing fluid may include
some other
material. The manifold assembly 30 supplies the cleansing fluid to the
dispensing head
32 for purging, i.e., flushing, any of the first fluid and the second fluid
from the
dispensing head 32 after use, thereby cleaning the dispensing head 32 and
ensuring
proper functioning of the dispensing head 32 during future uses.
[0034] Referring to Figure 3, the foam dispensing apparatus is shown
generally at 20. As described above, the foam dispensing apparatus 20 includes
the
dispensing head 32. The dispensing head 32 mixes the first fluid and the
second fluid
and dispenses the mixture onto the substrate 34 via a nozzle 38 and a mix tube
39. There
are many suitable dispensing heads 32 known in the art suitable for use in a
two
component foam dispensing system 22 which may be utilized in accordance with
the
subject invention. Preferably, the dispensing head 32 includes a handle 40.
The handle
40 extends from the dispensing head 32 for a user to grasp. The handle 40
permits the
user to conveniently and easily manipulate and operate the dispensing head 32.
[0035] As described above, the manifold assembly 30 is mounted to the
dispensing head 32. Referring to Figures 4 and 5, the manifold assembly 30
comprises a
purge portion 42, a first supply portion 44 and a second supply portion 46. As
shown in
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the Figures, the purge portion 42 of the manifold assembly 30, the first
supply portion 44
of the manifold assembly 30 and the second supply portion 46 of the manifold
assembly
30 are separable from each other. However, it should be appreciated that the
purge
portion 42, the first supply portion 44 and the second supply portion 46 may
be integrally
formed together as a single unit.
[0036] The purge portion 42 defines a gas inlet 48, a cleansing fluid inlet
50 and an outlet 52. The gas inlet 48 is in fluid communication with the
pressurized gas
source 28. The cleansing fluid inlet 50 is in fluid communication with the
cleansing fluid
source 36. The outlet 52 is in fluid communication with the dispensing head
32. As
shown, the gas inlet 48 and the cleansing fluid inlet 50 each include a single
inlet,
whereas the outlet 52 includes a first outlet 52A and a second outlet 52B.
However, it
should be appreciated that the gas inlet 48 and the cleansing fluid inlet 50
may each
include multiple inlets, and the outlet 52 may alternatively only include a
single outlet.
The purge portion 42 further defines a plurality of passageways 58, 60, 62
interconnecting the gas inlet 48, the cleansing fluid inlet 50 and the outlet
52. The gas
inlet 48, the cleansing fluid inlet 50, the outlet 52 and the plurality of
passageways 58, 60,
62 interconnecting the gas inlet 48, the cleansing fluid inlet 50 and the
outlet 52 supply
the pressurized gas to the dispensing head 32 for entrainment into the mixture
of the first
fluid and the second fluid, and supply the cleansing fluid to the dispensing
head 32 for
purging the dispensing head 32.
[0037] The plurality of passageways 58, 60, 62 defined by the purge
portion 42 includes a gas passageway 58, a cleansing fluid passageway 60 and a
combined passageway 62. The gas passageway 58 interconnects the gas inlet 48
and the
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outlet 52. The cleansing fluid passageway 60 interconnects the cleansing fluid
inlet 50
and the outlet 52. The combined passageway 62 interconnects the gas passageway
58
and the cleansing fluid passageway 60 with the outlet 52. It should be
appreciated that
the shape, configuration and orientation of the purge portion 42 and the
plurality of
passageways 58, 60, 62 defined by the purge portion 42 may vary from that
shown and
described herein.
[0038] A gas control valve 68 is mounted to the purge portion 42. The
gas control valve 68 partially defines the gas passageway 58, and controls a
fluid flow
rate between the gas inlet 48 and the outlet 52. The gas control valve 68 is
operable
between an "ON" position and an "OFF" position. The ON position permits fluid
communication between the gas inlet 48 and the outlet 52, and the OFF position
prevents
fluid communication between the gas inlet 48 and the outlet 52. Accordingly,
the flow of
the pressurized gas to the dispensing head 32 is completely disrupted, i.e.,
stopped, when
the gas control valve 68 is in the OFF position.
[0039] A gas regulator valve 70 is mounted to the purge portion 42. The
gas regulator valve 70 partially defines the gas passageway 58 and regulates
the fluid
flow rate between the gas inlet 48 and the outlet 52. The gas regulator valve
70 is
operable between an "ON" position and an "OFF' position. The gas regulator
valve 70
includes a continuous flow orifice 72 permitting fluid communication at a pre-
determined
flow rate through the gas regulator valve 70 when the gas regulator valve 70
is in the
OFF position, i.e., in a closed position. Accordingly, even when the gas
regulator valve
70 is in the OFF position, a continuous flow of the pressurized gas flows
through the
continuous flow orifice 72 into the gas passageway 58. The gas regulator valve
70 is
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disposed along the gas passageway 58 nearer the gas inlet 48 than the gas
control valve
68. As such, the pressurized gas enters the gas inlet 48 and flows through the
gas
regulator valve 70 prior to encountering the gas control valve 68.
[0040] A gas check valve 74 is mounted to the purge portion 42. The gas
check valve 74 partially defines the gas passageway 58. The gas check valve 74
permits
fluid communication from the gas inlet 48 to the outlet 52, and prevents fluid
communication from the outlet 52 to the gas inlet 48. The gas check valve 74
is disposed
along the gas passageway 58 between the outlet 52 and the gas control valve
68, thereby
preventing backflow into the gas passageway 58.
[0041] A cleansing fluid control valve 76 is mounted to the purge portion
42. The cleansing fluid control valve 76 partially defines the cleansing fluid
passageway
60 and controls a fluid flow rate between the cleansing fluid inlet 50 and the
outlet 52.
The cleansing fluid control valve 76 is operable between an "ON" position and
an "OFF"
position. The ON position permits fluid communication between the cleansing
fluid inlet
50 and the outlet 52 and the OFF position prevents fluid communication between
the
cleansing fluid inlet 50 and the outlet 52. Accordingly, the flow of the
cleansing fluid to
the dispensing head 32 is completely disrupted, i.e., stopped, when the
cleansing fluid
control valve 76 is in the OFF position.
[0042] A cleansing fluid check valve 78 is mounted to the purge portion
42. The cleansing fluid check valve 78 partially defines the cleansing fluid
passageway
60. The cleansing fluid check valve 78 permits fluid communication from the
cleansing
fluid inlet 50 to the outlet 52, and prevents fluid communication from the
outlet 52 to the
cleansing fluid inlet 50. The cleansing fluid check valve 78 is disposed along
the
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cleansing fluid passageway 60 between the outlet 52 and the cleansing fluid
control valve
76, thereby preventing backflow into the cleansing fluid passageway 60.
[0043] An outlet check valve 80 is mounted to the purge portion 42. The
outlet check valve 80 is disposed adjacent the outlet 52. The outlet check
valve 80
partially defines the combined passageway 62. The combined passageway 62
interconnects the gas passageway 58 and the cleansing fluid passageway 60.
Accordingly, the combined passageway 62 connects the outlet 52 with both the
gas
passageway 58 and the cleansing fluid passageway 60. The combined passageway
62 is
disposed between the outlet 52, the gas check valve 74 and the cleansing fluid
check
valve 78. Accordingly, in this orientation, no cross contamination between the
pressurized gas and the cleansing fluid is allowed. The outlet check valve 80
permits
fluid communication from the plurality of passageways 58, 60, 62 to the outlet
52, and
prevents fluid communication from the outlet 52 into the plurality of
passageways 58, 60,
62 and more specifically prevents fluid communication from the outlet 52 to
the
combined passageway 62.
[0044] As shown, the outlet check valve 80 includes a first outlet check
valve 80A disposed adjacent the first outlet 52A and a second outlet check
valve 80B
disposed adjacent the second outlet 52B. However, it should be appreciated
that there
will be an outlet check valve 80 disposed adjacent each outlet 52, regardless
of the total
number of outlets 52.
[0045] A hanger 82 is attached to the purge portion 42. The hanger 82
supports the foam dispensing apparatus 20. As shown, the hanger 82 includes an
eyebolt
attached to the purge portion 42 of the manifold assembly 30. However, it
should be
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appreciated that the hanger 82 may include other devices capable of supporting
the foam
dispensing apparatus 20.
[0046] Referring to Figures 6 and 7, the first supply portion 44 is mounted
to the purge portion 42. The first supply portion 44 defines a first material
inlet 54, a first
material outlet 88 and a first fluid passageway 64. The first material inlet
54 is in fluid
communication with the first tank 24 and receives the first fluid from the
first tank 24.
The first material outlet 88 is coupled to the dispensing head 32 and supplies
the
dispensing head 32 with the first fluid. The first fluid passageway 64
interconnects the
first material inlet 54 and the first material outlet 88.
[0047] A first fluid control valve 90 is mounted to the first supply portion
44. The first fluid control valve 90 partially defines the first fluid
passageway 64, and
controls a fluid flow rate between the first material inlet 54 and the first
material outlet
88. The first fluid control valve 90 is operable between and "ON" position and
an "OFF"
position. The ON position permits fluid communication between the first
material inlet
54 and the first material outlet 88. The OFF position prevents fluid
communication
between the first material inlet 54 and the first material outlet 88.
Accordingly, the flow
of the first fluid to the dispensing head 32 is completely disrupted, i.e.,
stopped, when the
first fluid control valve 90 is in the OFF position. It should be appreciated
that the first
fluid control valve 90 may be omitted from the first supply portion 44.
[0048] A first fluid check valve 92 is mounted to the first supply portion
44. The first fluid check valve 92 partially defines the first fluid
passageway 64. The
first fluid check valve 92 permits fluid communication from the first material
inlet 54 to
the first material outlet 88, and prevents fluid communication from the first
material
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outlet 88 to the first material inlet 54. Accordingly, the first fluid check
valve 92
prevents backflow from the foam dispensing apparatus 20 back to the first tank
24.
[0049] A first thermometer 94 is mounted to the first supply portion 44.
The first thermometer 94 extends into the first fluid passageway 64 for
sensing a
temperature of the first fluid. The first thermometer 94 includes a gauge
portion 96 and a
probe portion 98. The gauge portion 96 of the first thermometer 94 is disposed
on an
exterior surface of the first supply portion 44 to permit viewing thereof. The
probe
portion 98 of the first thermometer 94 extends from the gauge portion 96
through a
channel 100 defined by the first supply portion 44 into the first fluid
passageway 64.
[0050] The first supply portion 44 defines a first opening 102 and a first
bore 104 extending from the first opening 102. The first bore 104 partially
defines the
first fluid passageway 64. A first flow control device 84 is disposed within
the first bore
104 of the first supply portion 44. The first flow control device 84,
described in greater
detail below, regulates a fluid flow rate between the first material inlet 54
and the first
material outlet 88.
[0051] The second supply portion 46 of the manifold assembly 30 is a
mirror image of the first supply portion 44. Referring to Figures 8 and 9, the
second
supply portion 46 is mounted to the purge portion 42. The second supply
portion 46
defines a second material inlet 56, a second material outlet 106 and a second
fluid
passageway 66. The second material inlet 56 is in fluid communication with the
second
tank 26 and receives the second fluid from the second tank 26. The second
material
outlet 106 is coupled to the dispensing head 32 and supplies the dispensing
head 32 with
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the second fluid. The second fluid passageway 66 interconnects the second
material inlet
56 and the second material outlet 106.
[0052] A second fluid control valve 108 is mounted to the second supply
portion 46. The second fluid control valve 108 partially defines the second
fluid
passageway 66, and controls a fluid flow rate between the second material
inlet 56 and
the second material outlet 106. The second fluid control valve 108 is operable
between
an "ON" position and an "OFF" position. The ON position permits fluid
communication
between the second material inlet 56 and the second material outlet 106. The
OFF
position prevents fluid communication between the second material inlet 56 and
the
second material outlet 106. Accordingly, the flow of the second fluid to the
dispensing
head 32 is completely disrupted, i.e., stopped, when the second fluid control
valve 108 is
in the OFF position. It should be appreciated that the second fluid control
valve 108 may
be omitted from the second supply portion 46.
[0053] A second fluid check valve 110 is mounted to the second supply
portion 46. The second fluid check valve 110 partially defines the second
fluid
passageway 66. The second fluid check valve 110 permits fluid communication
from the
second material inlet 56 to the second material outlet 106, and prevents fluid
communication from the second material outlet 106 to the second material inlet
56.
Accordingly, the second fluid check valve 110 prevents backflow from the foam
dispensing apparatus 20 back to the second tank 26.
[0054] A second thermometer 112 is mounted to the second supply
portion 46. The second thermometer 112 extends into the second fluid
passageway 66
for sensing a temperature of the second fluid. The second thermometer 112
includes a
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gauge portion 96 and a probe portion 98. The gauge portion 96 of the second
thermometer 112 is disposed on an exterior surface of the second supply
portion 46 to
permit viewing thereof. The probe portion 98 of the second thermometer 112
extends
from the gauge portion 96 through a channel 100 defined by the second supply
portion 46
into the second fluid passageway 66.
[0055] The second supply portion 46 defines a second opening 114 and a
second bore 116 extending from the second opening 114. The second bore 116
partially
defines the second fluid passageway 66. A second flow control device 86 is
disposed
within the second bore 116 of the second supply portion 46. The second flow
control
device 86, described in greater detail below, regulates a fluid flow rate
between the
second material inlet 56 and the second material outlet 106.
[0056] The first flow control device 84 and the second flow control device
86 are identical and will now be defined simultaneously with reference to
Figures 7 and
9, with the first flow control device 84 being shown in Figure 7 and the
second flow
control device 86 being shown in Figure 9. The first flow control device 84
and the
second flow control device 86 each include a piston 118 disposed and moveable
within
the first bore 104 and the second bore 116 respectively. The pistons 118 are
moveable
along a control axis 120. The pistons 118 include a first end 122 defining an
aperture 124
and a second end 126 defining at least one orifice 128 in fluid communication
with the
aperture 124.
[0057] The first ends 122 of the pistons 118 are disposed adjacent the first
material inlet 54 and the second material inlet 56 respectively. The second
ends 126 of
the pistons 118 are disposed opposite the first ends 122 along the control
axis 120. The
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apertures 124 of the pistons 118 include a pre-determined cross-sectional area
for
regulating the fluid flow rate of the first fluid and the second fluid.
Preferably, the
apertures 124 include a circular cross section having a pre-determined
diameter.
However, it should be appreciated that the cross sectional shape of the
apertures 124 may
vary, and that it is the cross sectional area, the depth and the contour of
the leading and
lagging edges that determines the fluid flow rate through the pistons 118 of
the first flow
control device 84 and the second flow control device 86.
[0058] The first fluid passageway 64 defines a first port 130 in fluid
communication with the at least one orifice 128 of the piston 118 disposed
within the first
bore 104. The second fluid passageway 66 defines a second port 132 in fluid
communication with the at least one orifice 128, but normally all of the
orifices 128, of
the piston 118 disposed within the second bore 116. The interface between an
annular
flow path 129 around all of the orifices 128 relative to the first port 130
and the second
port 132, respectively, defines a variable valve orifice 129. The variable
valve orifice
129 created by the position of the annular flow path 127 relative to the first
port 130 and
the second port 132, respectively, in the first flow control device 84 and the
second flow
control device 86 respectively, may be defined by a complete an uninterrupted
ring
whereas other devices typically utilize at least one partially blocked orifice
usually placed
radially around the circumference. Utilizing the complete ring shaped variable
orifice
129 maximizes the flow area for a give stroke, decreases the travel required
to adjust the
variable valve orifice 129 and therefore increases the sensitivity of the
first flow control
deice 84 and the second flow control device 86. Accordingly, the first fluid
and the
second fluid flow through the apertures 124 and the orifices 128 of the
pistons 118 within
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the first bore 104 and the second bore 116 respectively a through the variable
valve
orifice 129 and through the first port 130 and the second port 132 of the
first fluid
passageway 64 and the second fluid passageway 66 respectively.
[0059] The first flow control device 84 and the second flow control device
86 each include a spring 134 disposed within the first bore 104 and the second
bore 116
respectively. The springs 134 abut the pistons 118 disposed within the first
bore 104 and
the second bore 116 respectively. The springs 134 apply a force to the pistons
118 and
therefore across the aperture 124 of the pistons 118 thus creating a fixed
controlled
pressure drop across aperture 124 while the variable valve orifice 129 adjusts
to maintain
a constant fluid flow rate therebetween. As the fluid flow rate tries to
increase, the
pressure drop across aperture 124 increases thus creating a force against the
piston 118.
The increased fore compresses the spring 134 and closes off the variable valve
orifice
129 by minute movement of the piston 118 thus creating additional restriction
and
maintaining a constant flow rate.
[0060] The first flow control device 84 and the second flow control device
86 each include a head 136 in threaded engagement with the first bore 104 and
the second
bore 116 respectively. The heads 136 compress the spring 134 disposed within
the first
bore 104 and the second bore 116 respectively in response to threaded movement
of the
heads 136 within the first bore 104 and the second bore 116 respectively.
Accordingly,
adjustment of the springs 134 adjusts the force against the pistons 118 and
proportionally
the pressure drop across the apertures 124. Moving, i.e., realigning, the
pistons 118
relative to the first port 130 and the second port 132 through which the first
fluid and the
second fluid flow respectively, alters the cross sectional area between the
variable valve
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orifice 129. Altering the cross sectional area of the variable valve orifice
129 thereby
adjusts the pressure drop across the variable valve orifice 129. It should be
appreciated
that the first flow control device 84 and the second flow control device 86
are adjustable,
i.e., tunable, through the first opening 102 and the second opening 114
respectively, by
threading the heads 136 into and out of the first bore 104 and the second bore
116
respectively.
[0061] The first flow control device 84 is removable from within the first
bore 104 of the first supply portion 44 through the first opening 102.
Likewise, the
second flow control device 86 is removable from within the second bore 116 of
the
second supply portion 46 through the second opening 114. Accordingly, the
pistons 118
and the springs 134 of the first flow control device 84 and the second flow
control device
86 are replaceable or serviceable without disconnecting the foam dispensing
apparatus 20
from any of the pipe fittings connecting the manifold assembly 30 to the first
tank 130,
the second tank 26 or the dispensing head 32. Similarly, the flow rate of the
first flow
control device 84 and the second flow control device 86 may be significantly
altered by
replacing the pistons 118 with a different piston 118 having a differently
sized aperture
124, without disconnecting the manifold assembly 30 from the first tank 24,
the second
tank 26 or the dispensing head 32.
[0062] The invention has been described in an illustrative manner, and it
is to be understood that the terminology which has been used is intended to be
in the
nature of words of description rather than of limitation. As is now apparent
to those
skilled in the art, many modifications and variations of the present invention
are possible
in light of the above teachings. It is, therefore, to be understood that
within the scope of
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the appended claims, wherein reference numerals are merely for convenience and
are not
to be in any way limiting, the invention may be practiced otherwise than as
specifically
described.
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