Patent Publication Number: US-2012024895-A1

Title: Mobile foam dispenser

Description:
RELATED APPLICATIONS 
     This application is a non-provisional patent application that claims the benefit of and the priority from U.S. Provisional Patent Application No. 61/386,878, filed Sep. 27, 2010, titled FOAM DISPENSER and is a continuation-in-part patent application that claims the benefit of and the priority from U.S. patent application Ser. No. 13/160,327, filed Jun. 14, 2011, titled FOAM DISPENSER, which is a non-provisional patent application that claims the benefit of and priority from U.S. Provisional Patent Application No. 61/354,540, filed Jun. 14, 2010, titled FOAM DISPENSER, all of which are expressly incorporated herein by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure generally relates to foam dispensers, and more particularly, to a mobile self-contained foam dispensing assembly. 
     BACKGROUND 
     It is commonly understood and known that mixing A and B components (i.e., isocyanate is commonly referred to as the “A component” and or just the “iso” and the blend of polyols and other additives is commonly referred to as the “B component” or as the “poly”) will generate a polyurethane foam product that may be used advantageously in packaging and other industries. For example, the foam products may function as packing material to protect items during transportation. 
     In many cases, a foam dispensing device, such as a gun, may be used to generate the foam at packaging sites. For example, the shipped item may be placed inside a box that is larger than the item and the empty volume between the interior surfaces of the box and the exterior surfaces of the item may be filled with the expanding foam which is preferably confined by a barrier, such as a plastic bag, or vice verse with the item. This foam packaging technology may be used as an alternate to other known packaging technologies such as small packing chips, a sheet of bubble wrap, or other lose packing material. Conventional foam dispensing devices may use a foam guns to produce the packaging foam. Such devices may also generally include pumps, one to control the flow of each of the two chemical components to precise and required amounts to achieve the proper mix. The storage containers for the A and B components may also be heated using heating coils to achieve a better mix or to change the time for hardening of the foam. However, one disadvantage with heating the A and B components is that conventional methods adjust the temperature of the components at the bulk container for the components. Also, heating of the container is inefficient, which is why conventional foam dispensing devices use heated hoses which are very expensive. Additionally, in those foam dispensing devices that heat the container and use a flexible bag, there is considerable inefficiencies because the heat source warms a metal plate that is in contact with the aluminum foil bag. As a result, there is considerable resistance and convective losses. Moreover, when heating the contents of the entire container, any adjustments to the temperature will be slow due to the considerable mass versus the heat source energy that can be provided. As a result, disadvantageous solutions have been developed, such as for example, a specific container must be used, an additional device must be inserted into the container or the warming apparatus must be adapted to be used in connection with the container. Another disadvantage, is the inability to extract or use nearly or virtually all of the A or B component in the container, especially in the instance where a flexible container is used that often collapses before a substantial majority of the applicable component has been extracted. 
     The hardening foam for packing has a plurality of commercial application, one of which is packaging and shipping of fragile items. In one embodiment, two flexible plastic bags are used to confine the solidifying foam as it expands and hardens. In an empty box, a first bag is filled with a pre-determined volume of expanding foam. The bag is rested in the bottom of the box and the fragile item is placed in the foam as it hardens. To complete protection, a second bag may be used cover the upper portion of the fragile item not covered by the expanding foam of the first bag. 
     In other foam producing devices, instead of using a pump driven by a motor, the device may use pressurized air or gas in the storage containers for the A and B components. However, using the pressurized container technology to produce the foam product results in difficulties of control for the proportion of each of the chemicals at the mixing point. 
     Therefore, it is desirous to have a new and non-obvious foam dispenser assembly including a warming apparatus remote from the A and B component containers yet very close to the dispensing nozzle that warms smaller volumes accurately and flexible-walled A and B component vessels that can be nearly or virtually completely emptied, among other things. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following disclosure as a whole may be best understood by reference to the provided detailed description when read in conjunction with the accompanying drawings, drawing description, abstract, background, field of the disclosure, and associated headings. Identical reference numerals when found on different figures identify the same elements or a functionally equivalent element. The elements listed in the abstract are not referenced but nevertheless refer by association to the elements of the detailed description and associated disclosure. Certain embodiments are shown in the drawings. However, it is understood that the present disclosure is not limited to the arrangements and instrumentality shown in the attached drawings. 
         FIG. 1  is a rear isometric view of the mobile foam dispensing assembly in accordance with one embodiment of the present disclosure. 
         FIG. 2  is a side view of the mobile foam dispensing assembly as shown in  FIG. 1 . 
         FIG. 3  is a front view of the mobile foam dispensing as shown in  FIG. 1 . 
       FIG.  4 A 1  is a front isometric view of one embodiment of a base attachment assembly useful in connection with the mobile foam dispensing assembly as shown in  FIG. 1 . 
       FIG.  4 A 2  is an exploded view of the base attachment assembly embodiment of FIG.  4 A 1 . 
       FIG.  4 B 1  is a front isometric view of another embodiment of a base attachment assembly useful in connection with the mobile foam dispensing assembly as shown in  FIG. 1 . 
       FIG.  4 B 2  is an exploded view of the base attachment assembly embodiment of FIG.  4 B 1 . 
       FIG.  4 C 1  is a front isometric view of yet another embodiment of a base attachment assembly useful in connection with the mobile foam dispensing assembly as shown in  FIG. 1 . 
       FIG.  4 C 2  is an exploded view of the base attachment assembly embodiment of FIG.  4 C 1 . 
         FIG. 5  is a partial cross-sectional view of one embodiment of one of the flexible component containers useful in connection with the mobile foam dispensing assembly as shown in  FIG. 1 . 
         FIG. 6  is a partially exploded and cross-sectional view of one embodiment of one of the tanks useful in connection with the mobile foam dispensing assembly as shown in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For the purposes of promoting and understanding the principles disclosed herein, reference is now made to the preferred embodiments illustrated in the drawings, and specific language is used to describe the same. It is nevertheless understood that no limitation of the scope of the invention is hereby intended. Such alterations and further modifications in the illustrated devices and such further applications of the principles disclosed and illustrated herein are contemplated as would normally occur to one skilled in the art to which this disclosure relates. 
     In one aspect of the present disclosure, a foam dispenser assembly may include a base portion including a support, a flexible-walled vessels for A and B components on the support, and the A and B components each disposed in one of the respective flexible-walled vessels. One of the flexible-walled vessels may include walls that define a volume and an opening, an insert within the volume that may separate the walls and maintain the opening unobstructed when the volume is under a negative pressure, and a dry disconnect coupling connected to the walls about the opening. A head portion may be connected to the base portion and associated with each of the flexible-walled vessels that includes a tank and a nozzle assembly to mix the A and B components and dispense a foam product. The tank may be disposed adjacent to the nozzle assembly and connected to one of the flexible-walled vessels and the nozzle assembly. The tank may include a warming assembly. 
     In another aspect of the present disclosure, the insert may have a thickness of approximately 0.005 inches to approximately 0.100 inches, or may include a plurality of enlarged portions connected by links, an enlarged portion disposed adjacent the opening, or a main link having an enlarged portion disposed at each end of the main link, a first arm link connected to the main link having an enlarged portion at its end, and a second arm link connected to each main link enlarged portion having an enlarged portion disposed at its end, or may define a pathway through the volume when the walls are in contact over nearly all of a surface area of the walls as a result of the negative pressure so that nearly 100% of the contents of the flexible-walled vessel are withdrawn through the opening. 
     In another aspect of the present disclosure, the warming assembly may include a heat sink in direct contact with the contents of one of the flexible-walled containers and a heat source or may include a baffle next to the heat sink to define a warming volume between the baffle and the heat sink with a remainder of the interior volume above the baffle that facilitates movement of the contents from the interior volume to the warming volume and retention of heat generated by the heat source within the warming volume for quicker temperature adjustment of the contents disposed in the warming volume. 
       FIG. 1  is a rear isometric view of the mobile foam dispensing assembly  100  in accordance with one embodiment of the present disclosure.  FIGS. 2 and 3 , are, respectively, side and front views of the mobile foam dispensing assembly  100  as shown in  FIG. 1 . In one embodiment, the foam dispensing assembly  100  may include two main elements: a head portion  100  and a base portion  104  (that may include, among other things, a vertically adjustable stand  106 ), both of which are similar to the corresponding parts as described in U.S. Provisional Application Nos. 61/354,540 and 61/386,878 and U.S. patent application Ser. No. 13/160,327, each of which is incorporated herein fully by reference, and for the sake of brevity will not be further repeated herein except to the extent necessary for further explanation of the subject disclosure or that there are differences applicable to the subject disclosure. 
     Various embodiments of the base potion  104  are shown in  FIGS. 1 through 4 . The base portion  104  provides support to hold the other portions of the foam dispensing assembly  100  and mobility of the foam dispensing assembly  100 . In one embodiment, the base portion  104  may include casters or wheels  122  as shown or any other suitable apparatus or device that provide the intended functionality, such as moving the foam dispensing assembly  100  by an operator. In one embodiment, the base portion  104  may include a base unit  124  that may be configured from suitable components, such as metal or plastic tubing or channel, with an “H” shape, but any structure capable of supporting the other portions of the foam dispensing assembly  100  and providing mobility therefor is within the teachings of this disclosure. 
     The base portion  104  may also include a support  108 , as shown in  FIGS. 1-4 , that may be configured as a shelf  126  (see FIGS.  1 - 4 A 2 ) or a workstation  150  (see FIGS.  4 B 1 - 4 C 2 ), both of which are preferably connected to the base unit  124 . Preferably, a flexible-walled vessel  130  for each of the A and B components is disposed on the support  108 . In one embodiment, the contents disposed in the respective flexible-walled vessels  130  includes the A component and the B component. The shelf  126  may have any suitable configuration or construction in order to support containers  128  to store the A and B component vessels  130  (see FIGS.  4 A 2 ,  4 B 2  and  4 C 2  and  5  with respect to the vessels  130 ). The workstation  150  provides the same functionality as the shelf  126 , however in a different manner, namely, doors or drawers that are openable to store the A and B component vessels  130  (see FIGS.  4 A 2 ,  4 B 2  and  4 C 2  and  5  with respect to the vessels  130 ). In one embodiment, the workstation  150  may include a housing  152 , a work surface  154 , and multiple access doors or drawers  156  (the doors may open to provide access to a shelf or the drawers may slide in and out of housing  152 ). The work surface  154  may have any suitable surface but preferably has non-slip surface that is also friendly to a work environment that may include spills of fluids or other substances. 
     The housing  152  may be configured from walls defining an inner chamber. A variety of objects could be located within the inner chamber. Packaging supplies such as bags, packaging tools, or replacement components of the foam dispensing assembly (such as a nozzle) could be stored within the inner chamber. A warming element or recharge packages of chemical products for the foam dispenser could be located there as well. Alternatively, storage vessels for A and B component chemicals could be located in the inner chamber of housing  152 . These storage vessels  130  could be associated, fluidly connected and in fluidic communication with the head portion  102  (and the tanks  118  as described herein) via hoses (such as  218  in  FIG. 6 ) located either along the rectangular channel  134  or via hoses located inside rectangular channel  134 . In order to facilitate the flow of the A and B components from the vessels  130  to the head portion  102 , a pump or a motor could be located on or in the foam dispenser assembly  100  as described in the incorporated applications or herein. 
     In another embodiment, the workstation  150  may also include a work table  160 , a plurality of storage bins  162  and extended compartments  164 . The worktable  160  extends to the left and right lateral sides of the support  108  and the base portion  104  generally overlying and replacing the work station  150  with an increased size and raising it closer to the head portion  102 . The storage bins  162  may be located beneath the work table  160  and are movable to allow access by the user of the foam dispensing unit. In FIGS.  4 C 1  and  4 C 2 , the storage bins  162  are shown with open fronts to allow further access by the user. Extended compartments  164  are open containers that are movably connected to the workstation  150  via rails so as to allow the extended compartments to slide forward and backward relative to the base portion to allow access to the inside of the compartments. One of ordinary skill in the art will recognize that the storage bins and extended compartments provide additional functionality as described with respect to similar structure in the subject disclosure. 
     The stand  106  may include a motor for moving the two part stand up and down so as to adjust the height of the head portion  102  with respect to the base portion  104 . Handles may be provided to assist movement or manually move the head portion  102  relative to the base portion  104 . User inputs  105  may be located on the stand  106  within easy access for the user in order to control of the operations of the foam dispensing assembly  100 , such as movement of the stand as discussed earlier or for control of the flow or temperature of chemicals. The stand  106  may also include gauges, other instruments, feedback, etc. that could provide the user with information regarding the operation of the foam dispenser assembly  100 . A control unit  136  may house the electronic components of the mobile foam dispensing assembly  100  and electrically connect the other components of the foam dispensing assembly  100  requiring electrical control and power such as the head portion  102 , the motor, and the control panel. The electrical controls located in the control unit  136  may also include a CPU, transformer, or other similar devices. Alternatively, the control unit  136  may also house other components of the pumping system such as a motor or a pump to fluidly connect (in fluidic communication) to facilitate movement of the A and B components from the vessels  130  to the tanks  118  and ultimately, the nozzle assembly. A motor or pump located in control unit  136  (or anywhere else on the foam dispenser assembly  100 , even on or adjacent to the head portion  102 ) could then be fluidly connected to the A and B components and the head portion  102  (e.g., tanks  118 , nozzle assembly, etc.). It is within the teachings of the present disclosure that any suitable conventional structure, apparatus, device or assembly including any electrical or mechanical connections or couplings necessary to support or facilitate the structure and functionality of the present disclosure may be incorporated or provided to achieve the described conventional functionality. 
     In one embodiment, at least one flexible-walled vessel  130  may include walls  140  (that may be formed of multiple layers, such as low density polyethylene, nylon, aluminum, polyethylene, and the like, etc.) connected about a perimeter  142  (in any suitable manner such as sealing, folds, lamination, or the like, etc. and may include a handle defined therein for handling by an operator) to define a volume  144  (within the perimeter) and an opening  146  (defined through the perimeter from the volume), an insert  148  disposed within the volume  144  to separate the walls  140  from one another in an area  149  adjacent to the insert  148  and to maintain the opening  146  unobstructed when the volume  144  is under a negative pressure (such as, when a pump is activated to draw the A or B component out of the respective vessel in order to move such component to the tank  118 ), and a dry disconnect coupling  170  (such as, for example only, a female shut-off fitment from Kent Systems, part number 4BX-220-006, a fry-break connection, that is liquid tight to prohibit leaks or the like, etc.) connected to the walls  140  about the opening  146  to seal the walls  140  to the coupling  170  for a leak-proof connection. Preferably, the insert  148  includes a plurality of enlarged portions  172  connected by links  174 . In one embodiment, the insert  148  may include an enlarged portion  172  disposed adjacent the opening  146 . In another embodiment, the insert  148  may include a main link  176  having an enlarged portion  172  disposed at each distal end  178  of the main link  176 , a first arm link  180  connected to and extending from the main link  176  having an enlarged portion  172  disposed at a distal end  182  of the first arm link  180 , and a second arm link  184  connected to and extending from each main link enlarged portion  172  having an enlarged portion  172  disposed at a distal end  186  of each second arm link  184 . In one embodiment, the insert  148  may have a thickness of approximately 0.005 inches to approximately 0.100 inches. Preferably, the insert  148  thickness may be approximately 0.010 inches to approximately 0.030 inches. More preferably, the insert  148  thickness may be approximately 0.015 inches to approximately 0.025 inches. In one embodiment, an insert  148  thickness of approximately 0.020 inches is advantageous. The links and enlarged portions may have any suitable configuration in order to provide the intended functionality. 
     In operation, the insert  148  defines a pathway  188  through the volume  144  when the walls  140  are disposed in contact over nearly all of a plan view surface area of the walls  140  as a result of the negative pressure applied by the pump that removes the contents of the vessel (i.e., the pump is pulling or drawing the contents to another location after the pump output, but the vessel is sealed, so removal of the contents causes the walls  140  to collapse until they are in contact with one another) so that nearly 100% of the contents of the flexible-walled vessel  130  are withdrawn through the dry disconnect coupling  170 . This overcomes the problem observed with similar constructions where the walls  140  collapse near the opening  146  (for the reasons set forth herein) and the remainder of the contents of the vessel  130  cannot be withdrawn by the pump without the operator jostling or manipulating the vessel  130  to re-open the collapsed walls  140  near the opening  146 . 
     The head portion  102  may include a nozzle assembly (not shown, but fully described in incorporated applications) disposed within a nozzle housing  190  that may have a front panel  112  and a back panel  114  pivotally connected at the top at hinge  116 , a control panel  120  that may have an LCD screen or other suitable user interface that can deliver information regarding operation of the foam dispensing assembly  100 , stand  106 , vessels  130  or nozzle assembly as well as provide user input for controlling various aspects of the foam dispensing assembly  100 , and tanks  118 , as shown on  FIGS. 1 ,  2  and  6 . In one embodiment, the tanks  118  may be disposed near or immediately adjacent the nozzle assembly and may be connected to the nozzle assembly by hoses or other suitable conduit for the contents that are moved from the vessels  130  by a pump disposed in the control unit  136  through similar hoses or other suitable conduits. A shield  192  may be connected to a rearmost portion of the tanks  118  for protection against impact and damage. In one embodiment, the channel  134  may be formed of links  194 , similar to a chain, that form an enclosed or partially open chase or raceway in order to route the electrical power and control wires and hoses from the control unit  136  to the head portion  102  for the control panel  120 , nozzle assembly and tanks  118 , as applicable. 
     As shown in  FIG. 6 , the tanks  118  may include a housing  200  that defines an interior volume  196 , warming assembly  198 , inlet port  202 , outlet port  204 , cover  214  and fasteners  216  (to connected all the elements as shown into an integral unit). As described above, the inlet port  202  may be associated with the vessels  130  by connection to the pump disposed in the control unit  136  by a hose  218  or any other suitable structure that may provide the intended functionality. The outlet port  204 , as described above, may be connected to the nozzle assembly by a hose  218  or any other suitable structure that may provide the intended functionality. Preferably, the hose  218  between the outlet port  204  and the nozzle assembly is as short as possible so that precise temperature control of the contents may be maintained. The warming assembly  198  may include a baffle  206 , seal  208 , heat sink  210  and heat source  212 . In one embodiment, the heat sink  210  may have an upper side  220  in direct contact or contiguous with the contents of one of the flexible-walled vessels  130  when the contents are disposed in the interior volume  196  and a lower side  222  contiguous with a heat source  212 . The heat sink  210  may be formed from any suitable heat conducting material. Preferably, such material will have a very high heat transfer coefficient. In one embodiment, the heat sink  210  may be formed from aluminum or a like material and may include a plurality of fins that extend into the interior volume  196  so as to increase the surface area of the heat sink  210  and the heat transfer capability or potential. In one embodiment, the baffle  206  may be disposed in spaced relation to the heat sink  210  to define a warming volume  224  between the baffle  206  and the heat sink  210  such that a remainder of the interior volume  196  is disposed above the baffle  206 . Preferably, the baffle  206  facilitates movement of the contents from the interior volume  196  to the warming volume  224  and retention of heat generated by the heat source  212  within the warming volume  224  for quick temperature adjustment of the contents disposed in the warming volume  224 . The baffle  206  may be configured with a plurality of apertures or openings in any specific or non-specific pattern or any other suitable configuration to provide the intended functionality and may be formed from metal, plastic, composite, hybrid, 2 component or any other suitable material to provide the intended functionality. In one embodiment, the heat source  212  may be configured as a cartridge heater, pair of cartridge heaters, or other suitable electrical, liquid or similar conventional apparatus, device or assembly capable of providing heat energy to the heat sink  210 . Level switches  226  may be provided that may be associated with the control panel  120  or control unit  136  to facilitate control of the pumps for the contents of the vessels  130 . 
     In operation, the vessels  130  are disposed into the containers  128 , hoses  218  that are connected to the intake side of the pump in the control unit  136  may then be connected to the disconnect coupling  170  with a complimentary configured fitting for leak-proof operation disposed at a distal end of the hoses  208  (hoses connected to the outlet side of the pump are connected to the inlet port  202  on the tank  118  and hoses connected to the outlet port  204  on the tank are connected to the nozzle assembly). A preselected amount of the contents is moved from the vessels  130  to the tank  118  as determined by the level switches  226  by the pump in the control unit  136 . The warming assembly  198  raises the temperature of the contents in the warming volume  224  to the desired set point and maintains such contents temperature around such predetermined by conventional control algorithms. Now, the foam dispensing assembly  100  is ready for operation as based on the indication output from the control panel  120  to the operator that all systems are ready. The operator may select the desired output from the nozzle assembly from the control panel  120 , which signals the control unit  136  to perform the necessary steps in order to carry out the desired action. The assembly  100  may remain idle until another foam dispensing request is made from the control panel  120 . 
     It is understood that the preceding detailed description of some examples and embodiments of the present invention may allow numerous changes to the disclosed embodiments in accordance with the disclosure made herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden.