Patent ID: 12226791

DETAILED DESCRIPTION

This disclosure is related to systems, methods, and apparatuses for dispensing plural component materials, such as foams, among other options. Multiple constituent materials are combined at a dispenser to form a heterogenous mixture that is subsequently aerated by the introduction of air within the spray nozzle. As will be described subsequently, the systems, methods, and apparatuses disclosed herein introduce air within the spray nozzle such that the air is capable of creating, aerating, and spraying a plural component material from multiple component materials and air. The systems, methods, and apparatuses disclosed herein are able to produce a plural component material with superior foam characteristics, such as improved cell homogeneity, reduced cell size, reduced presence of voids in the cell structure, etc., over existing systems, methods, and apparatuses for producing foam. The systems, methods, and apparatuses disclosed herein are also less complex than existing systems, methods, and apparatus and accordingly are able to produce high-quality foams at lower cost than existing systems, methods, and apparatuses.

FIG.1is a schematic diagram of plural component dispense system10. Plural component dispense system10includes material pumps12a,12b; pump drive14; controller16; material supplies18a,18b; air source19; feed lines20a,20b; output lines22a,22b; air line23; and dispenser28. Controller16includes memory44, control circuitry46, and user interface48.

Plural component dispense system10is a plural component dispensing system configured to combine constituent components to form a resultant plural component material. For example, the plural component material can be an insulator, such as foam, or can be paint, sealant, coating, adhesive, etc. In some examples, plural component dispense system10is configured to combine a first constituent material, such as a resin (e.g., polyol resin), and a second constituent material, such as a catalyst (e.g., isocyanate), that combine to form a spray foam. While plural component dispense system10is shown and described as a system that combines two constituent materials to form the plural component material, it is understood that plural component dispense system10can be configured to combine more than two constituent materials to form the plural component material.

Material supplies18a,18bstore the individual constituent materials. For example, each material supply18a,18bcan be formed as a tank, drum, etc. Material pumps12a,12breceive the constituent materials from material supplies18a,18bthrough feed lines20a,20band pump the constituent materials downstream through output lines22a,22b. Each output line22a,22bconnects to dispenser28, discussed in more detail subsequently. In the example shown, material pumps12a,12bare disposed to receive the first and second constituent materials from material supplies18a,18b, respectively. Feed lines20a,20bextend to material pumps12a,12bfrom material supplies18a,18b. Output lines22a,22bextend downstream from material pumps12a,12b, respectively, to dispenser28.

The material pumps12a,12bpressurize the constituent materials and drive the constituent materials through output lines22a,22b. In some examples, the constituent materials are pressurized to an upstream pressure level greater than ambient prior to being received by material pumps12a,12b. The material pumps12a,12bthen increase the pressures of the constituent materials to a downstream pressure level greater than the upstream pressure level and drive the constituent materials downstream through the output lines22a,22baccording to the downstream pressure level. For example, the material supplies18a,18bcan be pressurized tanks that output the pressurized constituent materials or plural component dispense system10can include upstream pumps that draw the constituent materials from the material supplies18a,18band drive the constituent materials through the feed lines20a,20band to the material pumps12a,12b, among other options. Such upstream pumps can also be referred to as transfer pumps. Material pumps12a,12bcan also be referred to as metering pumps because material pumps12a,12boutput the constituent materials at a metered flow rate to generate a desired mix at dispenser28. Output lines22a,22bcan also each include one or more valves for controlling the flow of each constituent material to dispenser28.

In the example shown, material pumps12a,12bare linked for simultaneous reciprocation. Linking material pumps12a,12bfor simultaneous reciprocation causes pumps to output the constituent materials according to a desired ratio for mixing and generating the plural component material. More specifically, material pumps12a,12bare connected to pump drive14to be reciprocated by pump drive14. Material pumps12a,12band pump drive14can be considered to form a pump assembly of the plural component dispense system10. The material pumps12a,12brespectively include fluid displacers40a,40b, such as pistons or diaphragms, among other options, that are reciprocated to pump the constituent materials. Pump drive14can be of any desired configuration suitable for driving reciprocation of the fluid displacers40a,40b. For example, pump drive14can be an electric motor, pneumatically drive, hydraulically drive, etc. Controller16is operatively connected, electrically and/or communicatively, to pump drive14to control the speeds of material pumps12a,12b. For example, controller16can be operatively connected to a motor controller of the electric motor or to a fluid supply configured to route driving fluid (e.g., compressed air or hydraulic oil) to drive linear displacement, etc.

In the example shown, material pumps12a,12bare configured as piston pumps such that fluid displacers40a,40bare formed as pistons that reciprocate within cylinders42a,42b, respectively. In the example shown, material pumps12a,12bare configured as double displacement pumps that output the constituent materials during both a stroke in a first axial direction AD1and a stroke in an opposite, second axial direction AD2.

Air source19is a source of air for creating an aerated mixture, such as a foam, at dispenser28. Air line23fluidly connects air source19to dispenser28. The air supplied by air line23can be pressurized air, such that the air provided via air line23can be used to create an aerated plural component material at dispenser28. The air provided by air line23can also be used to accelerate and fluid at dispenser28to create a spray and can enhance mixing of the constituent materials to provide a higher quality plural component material. Air source19can be a source of pressurized air, such that a pump is not required for air to flow from air source19, through air line23and to dispenser28. Additionally and/or alternatively, one or more pumps and/or compressors can be disposed in air source19or along air line23to pressure air flowing to dispenser28. For example, air source19can be a pressurized tank or an air compressor, among other options.

As referred to herein, “air” or “nucleation air” can refer to any suitable inert gas or combination of inert gases for aerating a plural component mixture with a dispenser or nozzle assembly disclosed herein. For example, the air can include one or more of N2, O2, CO2, or a noble gas, among other options. As a specific example, the air or nucleation air can be entirely N2, O2, or CO2, or can include a combination of N2, O2, and CO2. In yet further examples, the air can be an atmospheric air.

Dispenser28is configured to receive the multiple constituent materials and the air, and further mix the constituent materials with the air to form the plural component material. The plural component material formed by dispenser28can be, for example, an aerated plural component material. Dispenser28can be of any desired configuration for applying the multiple component material. In some examples, dispenser28can be an automatic dispenser configured to dispense the plural component material, such as a dispenser28mounted on a serial robot arm or other type of position manipulator.

Controller16is operatively connected, electrically and/or communicatively, to other components of plural component dispense system10. In the example shown, controller16is operatively connected at least to pump drive14, air source19, and dispenser28, among other components. Controller16is configured to control operation of one or more of the various components, provide operating instructions to one or more of the various components, and/or receive information from one or more of the various components. Controller16is configured to store software, implement functionality, and/or process instructions. The controller16can include memory44and control circuitry46configured to implement functionality and/or process instructions. For example, the control circuitry46can be capable of processing instructions stored in the memory44. Examples of the control circuitry46can include one or more of a processor, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry. The controller16can be of any suitable configuration for gathering data, processing data, etc. The controller16can receive inputs, provide outputs, generate commands for controlling operation of components of plural component dispense system10, etc. The controller16can include hardware, firmware, and/or stored software. The controller16can be entirely or partially mounted on one or more circuit boards. The controller16can be configured to receive inputs and/or provide outputs via user interface48.

User interface48can be any graphical and/or mechanical interface that enables user interaction with controller16. For example, user interface48can implement a graphical user interface displayed at a display device of user interface48for presenting information to and/or receiving input from a user. User interface48can include graphical navigation and control elements, such as graphical buttons or other graphical control elements presented at the display device. User interface48, in some examples, includes physical navigation and control elements, such as physically actuated buttons or other physical navigation and control elements. In general, user interface48can include any input and/or output devices and control elements that can enable user interaction with controller16.

Memory44can be configured to store data and information before, during, and/or after operation. The memory44, in some examples, is described as computer-readable storage media. In some examples, a computer-readable storage medium can include a non-transitory medium. The term “non-transitory” can indicate that the storage medium is not embodied in a carrier wave or a propagated signal. In certain examples, a non-transitory storage medium can store data that can, over time, change (e.g., in RAM or cache). In some examples, the memory44is a temporary memory, meaning that a primary purpose of the memory44is not long-term storage. The memory44, in some examples, is described as volatile memory, meaning that the memory44does not maintain stored contents when power to controller16is turned off. Examples of volatile memories can include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile memories. In some examples, the memory44is used to store program instructions for execution by the control circuitry46. The memory44, in one example, is used by software or applications running on controller16to temporarily store information during program execution. The memory44, in some examples, also includes one or more computer-readable storage media. The memory44can be configured to store larger amounts of information than volatile memory. The memory44can further be configured for long-term storage of information. In some examples, the memory44includes non-volatile storage elements. Examples of such non-volatile storage elements can include magnetic hard discs, optical discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.

Controller16is operatively associated with material pumps12a,12bto control the material outputs of material pumps12a,12b. For example, controller16can provide a command to pump drive14to control the reciprocation speed of the fluid displacers40a,40bof material pumps12a,12b. Where plural component dispense system10includes one or more valves along output lines22a,22b, controller16can also be operatively connected to those valves to control their operation. Similarly, where plural component dispense system10includes one or more pumps at air source19or along air line23, controller16can be operatively connected to those pumps to control their operation.

Plural component dispense system10advantageously can dispense multiple different forms of plural component materials by feeding different constituent materials to plural component dispense system10and can create aerated plural component materials by mixing air from air source19with different constituent materials. Notably, as air from air source19can be both used to create a plural component plural component material and to accelerate fluids within dispenser28for spraying the aerated plural component material, material pumps12a,12bcan be configured to operate at lower pressures than pumps of systems that use the pressure of material flowing through output lines22a,22bto generate a spray. Similarly, mixing of air and the component materials can occur at relatively low pressures, meaning that plural component dispense system10does not require specialized components for mixing air with one or more high-pressure component materials. Further, as mixing of air and the plural component materials occurs at dispenser28rather than a point upstream of dispenser28, plural component dispense system10does not require specialized components to aerate the component materials upstream of dispenser28. Accordingly, plural component dispense system10is simpler and less expensive than other systems for creating aerated plural component materials.

While foam is used herein as an exemplar, it is understood that the resultant plural component can be an insulator, such as foam, or can be paint, sealant, coating, adhesive, etc. In some examples, plural component dispense system10is configured to combine a first component material, such as a resin (e.g., polyol resin), and a second component material, such as a catalyst (e.g., isocyanate), that combine to form a spray foam. While plural component dispense system10is shown and described as a system that combines two component materials to form the plural component material, it is understood that plural component dispense system10can be configured to combine more than two component materials to form the plural component material.

FIG.2is an exploded isometric view of dispensing assembly100, which is a spray dispenser suitable for use as dispenser28in plural component dispense system10.FIG.3is a perspective view of dispensing assembly100assembled together.FIGS.2and3will be discussed together herein. In the depicted example, dispensing assembly100includes mixing channel110and shroud120. Mixing channel110includes tip portion122, channel housing124, mixer126, inlet portion128, and tip orifice129. Shroud120includes outlet attachment portion132, shroud housing134, and inlet attachment portion138.

Mixing channel110is hollow and extends along axis A-A. The hollow structure of mixing channel110allows component materials (e.g., from material supplies18a,18bof plural component dispense system10;FIG.1) to flow through mixing channel110. Channel housing124is generally cylindrical and defines a flow passage that extends along axis A-A through the interior of mixing channel110. Tip portion122is formed in a terminal portion of channel housing124and includes tip orifice129, which is located at the downstream end of tip portion122and is configured to spray material from the flow passage defined by channel housing124. In some examples, tip orifice129may be referred to as a “nozzle orifice.” In the depicted example, tip portion122tapers in a downstream direction to narrow a width of the flow passage through mixing channel110. In other examples, tip portion122does not taper. Inlet portion128is formed in the terminal portion of channel housing124opposite tip portion122along axis A-A, and is configured to receive component materials from one or more material sources and/or from a fluid manifold fluidly connected to inlet portion128. For example, inlet portion128can be fluidly connected to output lines22a,22bto receive materials from material supplies18a,18bof plural component dispense system10(FIG.1).

Mixer126is disposed within the flow space defined by channel housing124and functions to mix component materials prior to spraying through tip orifice129in tip portion122. In the depicted example, mixer126is a static mixer, such that mixer126has a static position and does not require moving components to provide continuous mixing of component materials flowing through mixer126. Rather, mixer126defines one or more helical passageways through the flow space defined by channel housing124that agitate and thereby mix component materials as those component materials flow through mixer126. The helical passageways defined by mixer126extend along a helical axis that is coaxial with axis A-A and is parallel to the flow direction through channel housing124. In other examples, mixer126can be a static mixer having a different geometry that causes mixing of component materials. In yet further examples, mixer126can be a dynamic mixer having one or more moving parts that cause mixing of component materials.

In operation, component materials are received by inlet portion128, which defines an upstream end of mixing channel110. Component materials received at inlet portion128then pass through mixer126and are mixed to form a plural component material. Mixer126does not extend through the entire length of mixing channel110. Rather, the axially downstream end of mixer126, located closest to tip orifice129, is located upstream of tip portion122and tip orifice129. The plural component material then flows downstream to tip portion122, which defines the downstream end of mixing channel110, and is sprayed through tip orifice129. A human operator can grasp and position mixing channel110to apply the material sprayed by mixing channel110. Additionally and/or alternatively, a serial robot arm or other type of position manipulator can be used to position mixing channel110to apply the sprayed plural component material. In some examples, one or more valve elements can be interposed within and/or upstream of mixing channel110to selectively allow flow of component materials through mixing channel110, and thereby allow for selective application of the plural component material by mixing channel110. The one or more valve elements can be actuated by, for example, a trigger operatively connected to the one or more valve elements.

Shroud120is disposed around mixing channel110and receives at least a portion of mixing channel110. Should120can structurally support mixing channel110. Shroud120can facilitate the connection of dispensing assembly100to various components. Shroud housing134is generally cylindrical and is also hollow, such that mixing channel110can be disposed within shroud housing134, as is depicted inFIG.3. In some examples, the inner diameter of the cylindrical portion of shroud housing134is substantially the same as the outer diameter of the cylindrical portion of channel housing124, such that the outer surface of channel housing124of mixing channel116contacts the inner surface of shroud housing134of shroud120.

Inlet attachment portion138is formed at the upstream end of shroud housing134and outlet attachment portion132is formed at the downstream end of shroud housing134. Inlet attachment portion138can allow dispensing assembly100to connect to a fluid manifold or other components for providing component material to inlet portion128of mixing channel110. For example, inlet attachment portion138can allow dispensing assembly100to be adapted to fluidly connect with output lines22a,22bof plural component dispense system10(FIG.1). Dispensing assembly100can form a portion of the dispenser28and can connect to a body of the dispenser28. Outlet attachment portion132can allow dispensing assembly100to be adapted to various nozzles that fluidly connect to tip orifice129in tip portion122of mixing channel110. The nozzles fluidly connected to tip orifice129can be used to provide a different spray pattern than the pattern provided by tip orifice129and tip portion129.

Inlet attachment portion138and outlet attachment portion132can each have one or more types of connectors for connecting and/or attaching to other components. For example, inlet attachment portion138and/or outlet attachment portion132can be attached to other components by a screw attachment, a bayonet attachment, interference fit attachment, or a sleeve connector, among other options. In the example shown, inlet attachment portion138includes interior threading configured to mate with exterior threads on another component. In the example shown, outlet attachment portion132includes exterior threading configured to mate with interior threads on another component. Attaching components to inlet attachment portion138and outlet attachment portion132rather than directly to inlet portion128and tip portion122can improve the strength of seals between mixing channel110and those components, thereby reducing the incidence of leaks and maintaining adequate fluid pressure for spray application. In some examples, inlet portion attachment138and/or outlet attachment portion132can include additional seal elements to further improve sealing between dispensing assembly100and any upstream and/or downstream components.

Further, mixing channel110can clog during use, such as due to the component materials reacting and curing when mixed. When mixing channel110clogs, dispensing assembly100can be removed from shroud120and the clogged mixing channel110can be replaced with a new, unclogged mixing channel110of the same or a different configuration as the mixing channel110just removed. Dispensing assembly100can then be reassembled and plural component material application can be resumed without requiring significant downtime of the spray system. Forming mixing channel110as a replaceable component also allows mixing channel110to be formed of a polymer material or another relatively inexpensive material. Shroud120can be formed of a more resilient material (e.g., metal such as steel) than mixing channel110that is tolerant of the pressures of the plural component materials flowing through, received by, and sprayed by dispensing assembly100. Shroud120can thereby structurally support mixing channel110, thereby allowing mixing channel110to be formed of a less expensive material that may be susceptible to pressure-induced deformation.

FIGS.4-16show various embodiments of spray dispenser assemblies that include mixing channel110and introduce air to the plural component material downstream of mixer126. Specifically, the dispenser assemblies shown inFIGS.4-16introduce air from an external air source and include one or more air lines and/or air passages that flow the air from a point external to mixing channel110to a flow of plural component material flowing through mixing channel110. The embodiments shown inFIGS.4-16flow air through and/or around channel housing124of mixing channel110. The air introduced by the air passages shown inFIGS.4-16is nucleation air that aerates the plural component material and enhances mixing of the component materials into the aerated plural component material. The aerated plural component material can then be applied by spraying through tip orifice129of mixing channel110. As will be explained in more detail subsequently, the nucleation air introduced by the air passages described inFIGS.4-16is introduced at outlets disposed downstream of mixer126, such that the point at which air is introduced does not radially overlap with mixer126. Components can be considered to radially overlap when the components are disposed at a common location along axis A-A such that a radial line extending orthogonally from axis A-A passes through each of those radially overlapping components. Introducing air downstream of mixer126in mixing channel110produces aerated plural component materials having more desirable foam characteristics than existing systems that introduce air upstream of mixer126and/or upstream of the spray dispenser at another point in a dispensing system. By locating the air outlet downstream of mixer126such that air is introduced to the plural component material downstream of mixer126, the embodiments shown inFIGS.4-16introduce air into a plural component material that is fully or substantially mixed rather than into a partially mixed plural component material or into unmixed component materials, and thereby produce aerated plural component material having improved foam characteristics as compared to existing systems. The improved foam characteristics provided by the embodiments disclosed herein include foams with reduced cell size, improved cell density, and improved cell uniformity, among other characteristics.

The systems shown inFIGS.4-16provide a number of additional advantages. Introducing air into the flow space defined by housing124of mixing channel110allows for the production of an aerated plural component material by aerating the plural component material rather than be aerating a component material of the plural component material. Notably, specialized and/or complex components are often required to aerate a component material upstream of a mixer in a plural component dispensing system and also to mix an aerated component material into a non-aerated component material to produce an aerated plural component material. Accordingly, the embodiments shown inFIGS.4-16advantageously allow for simpler plural component dispensing systems to be used to create and dispense aerated plural component materials than existing systems. Further, the embodiments shown inFIGS.4-16allows for aeration of plural component materials into aerated plural component materials using lower pressure air than existing systems. Specifically, the introduction of aeration air into a mixed plural component material downstream of mixer126in mixing channel110requires lower pressure air to create aerated plural component mixtures having desirable foam qualities than existing systems. In some examples, the embodiments shown inFIGS.4-16can use air having a pressure of about 30-100 pounds per square inch (“psi”) (about 0.2 megapascal (MPa) to about 0.69 MPa) to produce high-quality foam. In further examples, air having a pressure of about 80-100 psi (about 0.55 MPa to about 0.69 MPa) can be used to produce high-quality foam. Advantageously, it is less expensive and requires less complex equipment to produce air in the ranges used by the dispenser assemblies ofFIGS.4-16than the air used by existing spray foam systems.

The nucleation air can be flowed into the plural component material in an upstream direction (i.e., away from tip orifice129and toward inlet portion128along axis A-A), though it is understood that not all examples are so limited. Flowing nucleation air in an upstream direction can advantageously create aerated plural component materials having improved foam characteristics as compared to materials aerated by air directed in a downstream direction or in a direction transverse to axis A-A. In further examples, dispensing assembly100can produce high quality foam when nucleation air is emitted into the flow space defined by housing124within a threshold range of angles relative to axis A-A.

The nucleation air used by the dispenser assemblies ofFIGS.4-16can be any inert gas or combination of inert gases. For example, the air can include one or more of N2, O2, CO2, or a noble gas, among other options. As a specific example, the air or nucleation air can be entirely N2, O2, or CO2, or can include a combination of N2, O2, and CO2. In yet further examples, the air can be an atmospheric air.

FIGS.4-6show dispensing assembly200, which includes mixing channel110and aerator210. Dispensing assembly200is substantially similar to dispensing assembly100in that nucleating air is introduced to the plural component material upstream of tip orifice129and downstream of mixer126. Aerator210includes air line240, air outlet250and air inlet260. Aerator210is configured to introduce nucleation air into plural component material downstream of mixer126to form aerated plural component materialFIGS.4-6will be discussed together.FIG.4is an isometric view of dispensing assembly200and shows mixing channel110, shroud120, tip portion122, tip orifice129, inlet attachment portion138, aerator210, air line240, and axis A-A.FIG.5is an isometric end view of dispensing assembly and shows and depicts mixing channel110, tip portion122, outlet attachment portion132of shroud120, aerator210, and air line240.FIG.6is a cross-sectional view of dispensing assembly200taken along axis A-A and shows mixing channel110, tip portion122, shroud120, channel housing124, mixer126, inlet portion128, tip orifice129, shroud housing134, inlet attachment portion138, aerator210, air line240, air outlet250, and air inlet260.

As shown inFIGS.4-6, air line240of aerator210receives nucleation air from air inlet260and flows the air into the inner flow space defined within mixing channel110to aerate the plural component material. More specifically, air line240defines an internal air passage that can flow air from air inlet260to air outlet250. Air line240is non-linear and has a “U” shape that allow air line240to extend around tip portion122and into the inner flow space of mixing channel110through tip orifice129. Air line240extends in an upstream direction through tip portion122and terminates at air outlet250, which is configured to emit air in an upstream direction through mixing channel110. The shape of air line240allows air line240to turn the flow of air accepted at air inlet260. In the depicted example, air line240accepts air flowing into air inlet260in a first direction and turns the flow of air to flow in a second direction opposite the first before the air is emitted by air outlet250. While air line240is depicted inFIGS.4-6as extending only partway through tip portion122, in other examples air line240can extend to any suitable point within mixing channel110downstream of mixer126. Air inlet260can be connected to and receive air from any suitable source of air for aerating the plural component material. For example, air inlet260can be configured to receive nucleation air from air source19. Air outlet250is depicted as aligned with axis A-A, but in other examples air outlet250can be radially offset from axis A-A. Air outlet250can be oriented to emit air in a direction coaxial with axis A-A or in a direction parallel but not coaxial with axis A-A.

While air line240and air outlet250are described herein as emitting air in a generally upstream direction, in some examples air line240and air outlet250can be positioned to inject air in a direction transverse to the direction of flow through mixing channel110or in a downstream direction. For example, air line240and air outlet250can be positioned and configured to flow air in a direction that is transverse or perpendicular to axis A-A, or parallel and/or coaxial with axis A-A and in a downstream direction. In these examples, air line240can still adopt a “U” shape and air outlet250can be repositioned based on the desired direction of air flow into the flow of plural component material.

FIGS.7-9are perspective views of dispensing assembly300, which includes mixing channel110and aerator310. Dispensing assembly300is substantially similar to dispensing assembly100and dispensing assembly200in that nucleating air is introduced to the plural component material upstream of tip orifice129and downstream of mixer126. Aerator310includes air line340, air inlet360, and extends through tip portion122of mixing channel110at interface370.FIGS.7-9will be discussed together herein. Like aerator210, aerator310is also configured to introduce nucleation air into plural component material downstream of mixer126to form aerated plural component material.

FIG.7is an isometric view of dispensing assembly300and depicts shroud120, tip portion122of mixing channel110, tip orifice129, outlet attachment portion132, aerator310, air line340, air inlet360, interface370, and axis A-A.

FIG.8is an isometric end view of dispensing assembly300that depicts tip portion122, tip orifice129, outlet attachment portion132, aerator310, air line340, and interface370.

FIG.9is a cross-sectional view of dispensing assembly300taken along axis A-A and shows mixing channel110, tip portion122, shroud120, channel housing124, mixer126, inlet portion128, tip orifice129, shroud housing134, inlet attachment portion138, aerator310, air line340, air outlet350, air inlet360, and interface370.

Similar to the arrangement described previously with respect to air line240, air outlet250, and air inlet260, air line340receives nucleation air from air inlet360and flows the nucleation air to air outlet350, which emits the nucleation air within tip portion122of mixing channel110to aerate plural component material into aerated plural component material. More specifically, air line340defines an internal air passage that can flow air from air inlet360to air outlet350. Air line340is non-linear and has a “J” shape. In the examples shown, air line340extends through channel housing124at tip portion122and flows air in an upstream direction (i.e., away from tip orifice129) and into mixing channel110. Air line340extends through the wall of tip portion122and into the interior of tip portion122. Air line340extends through the wall of tip potion122at a location upstream of tip orifice129. In other examples, air line340can be formed as a linear channel and air outlet360can be positioned to inject air in an upstream direction through mixing channel110.

Where air line340extends through channel housing124, air line340forms interface370between air line340and channel housing124. Air line340forms a seal with channel housing124at interface370, such that fluid (e.g., plural component material, air, etc.) does not flow through interface370during operation of dispensing assembly300. Air line340is configured to emit air in an upstream direction into plural component material flowing downstream through the interior of mixing channel110. Air inlet360can be connected to and receive air from any suitable source of air for injecting the nucleating air into the plural component material. For example, air inlet360can be configured to receive nucleation air from air source19(FIG.1). Further, while air line340is depicted inFIGS.6and7as extending into mixing channel110through tip portion122, in other examples air line240can extend through any suitable point of mixing channel110downstream of mixer126.

The shape of air line340allows air line340to turn the flow of air accepted at air inlet360to flow in a different direction at air outlet350. In the depicted example, air line340accepts air flowing into air inlet360in a first direction and turns the flow of air to flow in a second direction opposite the first before the air is emitted by air outlet350. Air outlet350is depicted as aligned with axis A-A inFIGS.7-9, but in other examples air outlet350can be radially offset from axis A-A. Air outlet350can be oriented to emit air in a direction coaxial with axis A-A or in a direction parallel but not coaxial with axis A-A.

While air line340and air outlet350are described herein as emitting air in a generally upstream direction, in some examples air line340and air outlet350can be positioned to inject air in a direction transverse to the direction of flow through mixing channel110or in a downstream direction. For example, air line340and air outlet350can be positioned and configured to flow air in a direction that is transverse or perpendicular to axis A-A, or parallel and/or coaxial with axis A-A and in a downstream direction. In these examples, air line340can still adopt a “J” shape and air outlet350can be repositioned based on the desired direction of air flow into the flow of plural component material.

FIGS.10-12depict dispensing assembly400, which includes mixing channel110, shroud120, and aerator410. Dispensing assembly400is substantially similar to dispensing assembly100, dispensing assembly200, and dispensing assembly300in that nucleating air is introduced to the plural component material upstream of an outlet that emits the plural component material from the dispenser and downstream of mixer126. Aerator410includes spray head420, air passage440, air outlet450, flow inlet460, attachment portion464, outlet passage466, spray outlet468, air inlet470, and screw attachment480. Air inlet470includes elbow490.

FIG.10is a cross-sectional view of dispensing assembly400taken along axis A-A and depicts mixing channel110, shroud120, tip portion122, mixer126, tip orifice129, outlet attachment portion132, aerator410, air passage440, air outlet450, flow inlet460, attachment portion464, sealing flange465, outlet passage466, spray outlet468, axis A-A, upstream direction UD, and downstream direction DD.

FIG.11is another cross-sectional view of dispensing assembly400taken along axis A-A that illustrates further components of aerator410.FIG.11depicts tip portion122, tip orifice129, aerator410, air passage440, air outlet450, flow inlet460, attachment portion464, outlet passage466, spray outlet468, air inlet470, screw attachment480, elbow490, axis A-A, upstream direction UD, and downstream direction DD.

FIG.12is a cross-sectional view of dispensing assembly400taken in a plane along axis B-B perpendicular to axis A-A that illustrates the partially-concentric arrangement of flow inlet460and air outlet450.FIG.12depicts aerator410, air passage440, air outlet450, flow inlet460, and screw attachment480.FIGS.10-12will be discussed together herein.

Aerator410is an attachment that can be affixed at the downstream end of mixing channel110by connecting to, for example, outlet attachment portion132of shroud120. Like aerators210and310, aerator410is configured introduce nucleation air into plural component material downstream of mixer126to form aerated plural component material. Aerator410can be used to inject air into a flow of plural component material to aerate the plural component material. In the example shown, aerator410is configured to inject the air in upstream direction UD against the flow of the plural component material through aerator410. Upstream direction UD and downstream directions DD are shown as arrows indicating the direction of upstream and downstream flow, respectively, inFIGS.11-12. Fluid flows through dispensing assembly400in upstream direction UD when it flows away from spray outlet468and toward mixer126. Fluid flows through dispensing assembly400in downstream direction DD when it flows away from mixer126and toward spray outlet468. Downstream direction DD and upstream direction UD define flow directions that are generally parallel with axis A-A, though all examples may not be so limited.

In the depicted embodiment, nucleation air is flowed through air passage440to air outlet450and from air outlet450in an upstream direction towards tip orifice129. In some examples, air passage440and air outlet450deliver air into the inner space of tip portion122of mixing channel110. In some examples, the sections of spray head420defining the flow path of air toward tip orifice129(e.g., air passage440, air outlet450, and/or air inlet460) can be referred to as an “air line.” The nucleation air aerates the plural component material mixed by mixer126that flows generally in downstream direction DD and through flow inlet460into outlet passage466. The aerated plural component material flows downstream through outlet passage466to spray outlet468, which is configured to emit a spray of the aerated plural component material. In the depicted example, outlet passage466is generally cylindrical and spray outlet468is a circular orifice, but in other examples, outlet passage466and spray outlet468can adopt different shapes for creating a suitable spray of plural component material.

Flow inlet460is depicted as having a smaller cross-sectional area (as taken in a plane orthogonal to axis A-A) than the cross-sectional are of tip orifice129(as taken in a plane orthogonal to axis A-A) or the cross-sectional area of outlet passage466(as taken in a plane orthogonal to axis A-A). This depicted configuration of flow inlet460, tip orifice129, and outlet passage466can increase fluid turbulence through flow inlet460, causing increased mixing of plural component materials that can increase the homogeneity of the aerated plural component material emitted by spray outlet468. In other examples, flow inlet460, tip orifice129, and outlet passage466can adopt different relative sizes and cross-sectional areas.

Spray head420is configured to produce and spray aerated plural component. Spray head420includes air passage440, air outlet450, flow inlet460, outlet passage466, spray outlet468, and screw attachment480. Aerator410is attached to inlet attachment portion138of shroud120by attachment portion464. Attachment portion464at least partially circumferentially surrounds tip portion122and includes sealing flange465, which forms a seal against tip portion122. In the depicted example, sealing flange465forms a seal with an axial end face of tip portion122, but in other examples other seal configurations are possible. Attachment portion464and spray head420are depicted inFIGS.10-11as separate components, but in other examples, attachment portion464and spray head420can be formed as a single, integral component.

Generally, attachment portion464is configured such that when aerator410is attached to mixing channel110/shroud120, tip portion122is sealed against sealing flange465to reduce or prevent a flow of fluid backward through the interface between the exterior of tip portion122and the interior of attachment portion464, thereby maintaining the pressure of plural component material as it is aerated in tip portion122and subsequently flowed downstream to flow inlet460. Air outlet450is positioned downstream of tip orifice129and is configured to inject air into the plural component material emitted from tip orifice129. Air outlet450is depicted as aligned with axis A-A inFIGS.10-12, but in other examples air outlet450can be radially offset from axis A-A. Air outlet450can be oriented to emit air in a direction coaxial with axis A-A or in a direction parallel but not coaxial with axis A-A.

Air is provided to air passage440through air inlet470, which is connected to air passage440by screw attachment480in the depicted embodiment. Air passage440is formed within aerator410in the depicted example. In operation, a flow of nucleation air is received at air inlet470from an air source (e.g., air source19of plural component dispense system10;FIG.1), flowed toward elbow490downstream direction DD, turned at elbow490, such as at a right angle though it is understood that other angles are possible, including no turn in examples in which air inlet470projects radially from aerator410relative to axis A-A. The air is flowed through the remainder of air inlet470to air passage440along axis B-B. Air passage440includes a bend that turns the air, such as at a right angle, to flow in upstream direction UD along axis A-A and to air outlet450. The nucleation air is then emitted through air outlet450and into the flow space through dispensing assembly400to aerate the plural component material mixed by mixer126. Accordingly, air is flowed in a first direction from air inlet470toward elbow490, turned by elbow490and turned again by air passage440and emitted by air outlet450in a second direction opposite the first direction. In other examples, air inlet470and air passage440can be formed as integrated parts. In yet further examples, air inlet470can lack elbow490, such that air inlet470flows nucleation air to air passage440without turning the nucleation air. Further, while screw attachment480, forming a threaded connection, is used to affix air inlet470to air passage440in the depicted example, another suitable type of attachment can be used in other examples (e.g., a bayonet attachment, an interference fit attachment, etc.).

As illustrated clearly inFIG.12, flow inlet460is formed as an arc that partially circumferentially surrounds air outlet450. Accordingly, in the depicted example, plural component material flows along a flow path that is coaxial with axis A-A upstream of flow inlet460. Aerated plural component material flows along a flow path that is parallel with axis A-A but is not coaxial with axis A-A (i.e., that is offset from axis A-A) through flow inlet460and along a flow path that is parallel and coaxial with axis A-A_ downstream of flow inlet460(i.e., through outlet passage466and spray outlet468). Flow inlet460is formed as an approximately 180° arc inFIG.12, but in other examples, flow inlet460can take other suitable shapes. Further, in the example depicted inFIGS.10-12, flow inlet460and are air passage440are centered on a single plane extending along axis B-B and perpendicular to axis A-A, such that the aperture formed by flow inlet460and air passage440are substantially co-planar. However, in other examples, flow inlet460and air passage440can be formed such that flow inlet460and air passage440are not co-planar. Flow inlet460radially overlaps with air outlet450along axis A-A. Components can be considered to radially overlap when the components are disposed at a common location along axis A-A such that a radial line extending from axis A-A passes through each of those radially overlapping components.

While air outlet450is described herein as emitting air in a generally upstream direction, in some examples air outlet450can be positioned to inject air in a direction transverse to the direction of flow through mixing channel110or in a downstream direction. For example, air outlet450can be positioned and configured to flow air in a direction that is transverse or perpendicular to axis A-A, or parallel and/or coaxial with axis A-A and in a downstream direction. For example, air outlet450can be configured to flow air in a direction that is perpendicular to axis A-A and parallel with axis B-B. As a specific example, air outlet450can be configured to flow air directly into the plural component mixture as the plural component mixture flows through flow inlet450. As yet a further example, air outlet450can be configured to flow air in a generally downstream direction to aerate plural component material flowing through outlet passage466.

FIGS.13-15depict dispensing assembly500and will be discussed together herein. Dispensing assembly500is substantially similar to dispensing assembly100, dispensing assembly200, dispensing assembly300, and dispensing assembly400in that nucleating air is introduced to the plural component material upstream of an outlet that emits the plural component material from dispensing assembly500and downstream of mixer126. Dispensing assembly500is substantially similar to dispensing assembly100, dispensing assembly200, and dispensing assembly300in that nucleating air is introduced to the plural component material upstream of tip orifice129and downstream of mixer126.

Dispensing assembly500includes mixing channel110, shroud120, and aerator510. Aerator510includes attachment housing512and piercing adapters520A-C (collectively herein “piercing adapters520” or “piercing adapter520”). In some examples, a piercing adapter described herein may be referred to as a “piercing channel.” Attachment housing512includes receiving apertures530A-C (collectively herein “receiving apertures530” or “receiving aperture530”) and piercing adapters520A-C respectively include housings522A-C (collectively herein “housings522” or “housing522”), passages540A-C (collectively herein “passages540” or “passage540”), attachment sections542A-C (collectively herein “attachment sections542” or “attachment section542”), piercing tips550A-C (collectively herein “piercing tips550” or “piercing tip550”), tips551A-C (collectively herein “tips551” or “tip551”), air outlets560A-C (collectively herein “air outlets560” or “air outlet560”), and passage inlets561A-C (collectively herein “passage inlets561” or “passage inlets561”). Each passage540includes an upstream section563and a downstream section564, inFIGS.13-15tip portion122of mixing channel110includes pierced apertures562A-C, and attachment housing512includes attachment portion568. Each piercing adapter520can be connected to an inlet connector570, which includes elbow572and screw attachment573.

FIG.13is an isometric cross-sectional view taken along axis A-A and depicts mixing channel110, shroud120, tip portion122, tip orifice129, outlet attachment portion132, aerator510, attachment housing512, piercing adapters520A-C, receiving apertures530A-C, passages540A-C, attachment sections542A-C, piercing tips550A-C, air outlets560A-C, pierced apertures562A-C, attachment portion568, axis A-A, axis C-C, upstream direction UD, and downstream direction DD.

FIG.14is an isometric view of dispensing assembly500and depicts shroud120, outlet attachment region132, inlet attachment portion138, aerator510, attachment housing512, piercing adapter520C, receiving apertures530A-C, inlet connector570, elbow572, screw attachment573, and axis C-C.

FIG.15is an enlarged isometric view showing a portion of dispensing assembly500and depicts shroud120, tip orifice129, piercing adapter520C, receiving aperture530A, inlet connector570, and elbow572.

FIG.16is a perspective view of a piercing adapter520, and depicts a housing522, an attachment section542, a piercing tip550, an air outlet560, alignment indicator598, and axis C-C.FIG.16will be discussed together withFIGS.13-15.

Aerator510is an attachment that can be affixed at the downstream end of mixing channel110by using, for example, outlet attachment portion132of shroud120. Like aerators210,310, and410, aerator510is configured introduce nucleation air into plural component material downstream of mixer126to form aerated plural component material. Aerator510circumferentially surrounds tip portion122. The position of aerator510, and specifically of attachment housing512, allows piercing adapters520A-C to form flow paths from outside of aerator510through receiving apertures530A-C and pierced apertures562A-C, respectively, to inject air upstream of tip orifice129and downstream of mixer126. Pierced apertures562A-C are apertures formed in tip portion122of mixing channel110and are sealed circumferentially against the exterior of piercing tips550A-C, respectively. Pierced apertures562A-C can be formed using piercing tips550A-C or by another method, as described in more detail subsequently.

Upstream direction UD and downstream directions DD are shown as arrows indicating the direction of upstream and downstream flow, respectively, inFIG.13. The upstream direction UD is against the material flow through dispensing assembly400. Fluid flows through dispensing assembly400in downstream direction DD when it flows away from mixer126and toward spray outlet468. Downstream direction DD and upstream direction UD define flow directions that are generally parallel with axis A-A, though all examples may not be so limited.

As shown inFIGS.14-15, in operation, attachment housing512can be configured to receive one piercing adapter520A-C to flow air into tip portion122and tip portion122can include one pierced aperture562A-C to accommodate the piercing tip550A-C of the singular piercing adapter520A-C. Piercing adapters520A-C shown inFIG.13are substantially the same and represent alternative locations of a piercing adapter520in attachment housing512. Notably, adding additional piercing adapters520to introduce further air can negatively impact the quality of aerated plural component material sprayed by dispensing assembly500. However, as shown inFIGS.14-15, attachment housing512of aerator510can include multiple receiving apertures530A-C. As will be explained in more detail, adding additional receiving apertures530A-C can increase the number of possible locations at which a pierced aperture562A-C can be created and where air can be injected into a plural component material within tip portion122. Alternatively, attachment housing512can include only one receiving aperture530A-C to simplify assembly of attachment housing512.

Piercing adapters520include housing522, which defines passages540, attachment sections542, piecing tips550, air outlets562, and passage inlets561. Passages540flow air from passage inlets561to air outlet560. More specifically, passage inlets561receive air from an external air source (e.g., air source19;FIG.1) and passages540flow that air to the inner volume of tip portion122and thereby to air outlets562. In the depicted example, passage inlets561are disposed on an axial end of piercing adapters520(i.e., according to axis C-C) opposite piercing tips550. In other examples, however, passage inlets561can be disposed in other locations of piercing adapters520. In the depicted example, each of passages540includes upstream section563that connects to an inlet connector570and downstream section564formed within piercing tips550, where upstream section563has a larger cross-sectional diameter than downstream section564. In other examples, the cross-sectional diameter of passages540can be substantially constant along the length of passages540. Piercing tip550is a tapered cylinder that tapers along axis C-C away from the end of piercing adapter520at which passage inlets561are formed. Specifically, the diameter and cross-sectional area of piercing tip550decrease along axis C-C toward tip551and away from passage inlet561(i.e., piercing tip550tapers along axis C-C toward tip551and away from passage inlet561). Piercing tip550tapers to tip551at an axially-terminal end of piercing adapter520(i.e., according to axis C-C) and is configured to be inserted through and form a seal against pierced aperture562to reduce or prevent flow of plural component material and/or aerated plural component material through pierced aperture562. In at least some examples, piercing tip550is also configured to form pierced apertures562. For example, where attachment section542includes screw threading that interfaces with screw threading of receiving aperture530, attachment section542can screw into receiving aperture530and the screw interface can be used to axially translate piercing tip550(i.e., along axis C-C) and cause tip551of piercing tip550to penetrate tip portion122of channel housing124, thereby forming a pierced aperture562against which tip551can form a seal.

Upstream section563of passage540is partially circumferentially surrounded by attachment section542. Air outlet560is formed inward from terminal end of piercing tip550and on a sidewall of piercing tip550. In the depicted example, the sidewall of air outlet560is partially annular, such that air outlet560is disposed on a circumferentially-outer surface of piercing tip550, such that air outlet560can be positioned to inject air in an upstream direction when installed in attachment housing512. Piercing adapters520can include an alignment indicator (e.g., alignment indicator598;FIG.16) that a user can use to determine the orientation of air outlet560. Where air outlet560is placed on a circumferentially-outer surface of piercing tip550, the alignment indicator can be placed on the same side of an external portion of the piercing adapter520(i.e., external of attachment housing512), such that air outlet560is in the correct orientation when the alignment indicator is pointed in a generally upstream direction (i.e., in upstream direction UD). Air outlet560can be aligned with axis A-A or can be radially offset from axis A-A. Air outlet560can be oriented to emit air in a direction coaxial with axis A-A or in a direction parallel but not coaxial with axis A-A.

As depicted inFIG.15, upstream section563of passage540C is centered on axis C-C and downstream section564is parallel with but offset from axis C-C. The offset position of downstream section564allows downstream section564to extend generally parallel to axis C-C in a substantially straight manner while still connecting to air outlet560C on an upstream side of piercing tip550. The offset structure of passages540shown inFIG.15can thereby advantageously simplify the process of manufacturing and/or fabricating downstream section564of passages540while still allowing passages540to connect to an outlet on an upstream side of piercing tips550.

In the examples shown inFIGS.14-15, air is provided to passage inlet561of air passage540of an installed piercing adapter520through inlet connector570, which can be removably attached to the piercing adapter520by a screw attachment or another suitable attachment means. In the examples depicted inFIGS.14-15, inlet connector570is connected to piercing adapter520at passage inlet561by screw attachment573. In operation, inlet connector570receives nucleation air from an air source (e.g., air source19;FIG.1) and flows that nucleation air toward elbow572, where the flow of nucleation air is turned, such as at a right angle though it is understood that other angles are possible, including no turn in examples in which inlet connector570projects radially from aerator510relative to axis A-A (i.e., in a direction parallel to axis C-C). The nucleation air is then flowed through the remainder of inlet connector570to passage inlet561, then to upstream portion563of passage540, then to downstream portion564of passage540, and then to air outlet560. Passage540turns the air, such as at a right angle, to air outlet560, which injects the nucleation air in an upstream direction (i.e., against the direction of flow) into plural component material flowing through tip portion122of mixing channel110. As described previously, the plural component material that is aerated by the nucleation air is formed by mixing two or more component materials with mixer126in mixing channel110. The nucleation air aerates the plural component material that can be emitted from mixing channel110through tip orifice129. Air is injected downstream of mixer126such that the nucleation air is injected into a mixed (i.e., fully or substantially mixed) plural component material rather than unmixed or partially mixed component materials, which, as described previously, produces aerated plural component materials having more highly desirable foam characteristics (e.g., cell size, cell uniformity, cell density, etc.). Accordingly, air is flowed in a first direction from air inlet570toward elbow572, turned by elbow572and turned again by passage540and emitted by air outlet560in a second direction opposite the first direction. In some examples, the sections of aerator510defining the flow path of air into plural component material flowing through tip portion122(e.g., piercing adapter, and/or inlet connector570) can be referred to as an “air line.”

While air outlet560is described herein as emitting air in a generally upstream direction, in some examples air outlet560can be positioned on piercing tip550to inject air in a direction transverse to the direction of flow through mixing channel110or in a downstream direction. For example, air outlet560can be positioned on an axial end of piercing tip550(i.e., along axis C-C) and configured to flow air in a direction that is transverse or perpendicular to axis A-A. As another example, air outlet560can be positioned on a circumferentially-outer surface of piercing tip550(i.e., with respect to axis C-C) and configured to flow air in a direction that is transverse or perpendicular to axis A-A, or parallel and/or coaxial with axis A-A and in a downstream direction.

In the example depicted inFIGS.13-15, tip portion122extends beyond the axially-downstream end of attachment housing512. In other examples, tip orifice129can be used to spray aerated plural component material where tip portion122and attachment housing512are positioned such that tip orifice129has the same axial position along axis A-A as the axially-downstream end of attachment housing512. In yet further examples, attachment housing512or another element of aerator510can include a downstream channel that receives aerated plural component material from tip orifice129and flows the aerated plural component material to an additional spray orifice configured to emit the aerated plural component mixture as a spray.

Attachment portion568of aerator510is configured to interface with outlet attachment portion132to allow attachment portion568to attach to shroud120. In the depicted example, attachment portion568comprises screw threads that interface with screw threads of outlet attachment portion132. In other examples, attachment portion568and outlet attachment portion132can interface by any suitable connector or interface type, such as a bayonet connector, an interference fit attachment, or a sleeve connector, among other options. In other examples, attachment portion568can be configured to attach directly to mixing channel110.

Attachment sections542A-C of piercing adapters520A-C are configured to interface with receiving apertures530A-C of aerator510. As shown with respect to attachment section542C of piercing adapter520C inFIG.16, attachment section542C includes screw threading that can interface with screw threading on receiving apertures530A-C. In some examples, the screw threading on attachment sections542A-C can be configured such that, when fully tightened against receiving apertures530A-C, air outlets560A-C are oriented to inject air in an upstream direction. In other examples, attachment sections542A-C and receiving aperture530A-C can interface by anu suitable connector or interface type, such as a bayonet connector, an interference fit attachment, or a sleeve connector, among other options.

Aerator510can be installed on mixing channel110and shroud120by affixing attachment housing512to outlet attachment portion132with attachment portion568. When attachment housing512is attached, a pierced aperture562can be created. In some examples, a receiving aperture530can be used as a guide to drill a pierced aperture562. Following drilling, a piercing adapter520can be inserted such that the air outlet560of the piercing adapter520extends into the inner space of tip portion122and that the piercing tip550forms a seal against the pierced aperture562. Accordingly, the surface or sidewall of piercing tip550includes air outlet560and forms a seal against pierced aperture562to reduce or prevent leakage of plural component material through pierced aperture562. In other examples, piercing tip550can be used to form the pierced aperture562in tip portion122. Specifically, piercing adapter520can be tightened into a receiving aperture530using screw threads (i.e., screw threads of attachment section542and receiving apertures530) or another suitable means to allow piercing tip550to penetrate channel housing124at tip portion122. piercing adapter520can then be positioned such that air outlet560is pointed to inject air in an upstream direction (i.e., toward mixer126) in tip portion122.

Although aerators410,510have been described herein as attachments for shroud120and/or mixing channel110, in some examples, aerators410,510can be formed integrally with one or more of shroud120and/or mixing channel110. In these examples, aerators410,510can be referred to as components of shroud120and/or mixing channel110, respectively. For example, in examples where shroud120is omitted from a dispensing assembly, aerators410,510can be formed integrally with mixing channel110. Similarly, in examples including shroud120, aerators410,510can be formed integrally with shroud120and mixing channel110can be inserted into the integral shroud120and aerator410,510assembly before the resulting dispensing assembly is used to dispense an aerated plural component material.

FIG.16is an isometric view of piercing adapter520that shows housing522, attachment section542, piercing tip550, tip551, air outlet560, passage inlet561, alignment indicator598, adapter head599, and axis C-C. As depicted inFIG.16, air outlet560is located at an axial end of piercing adapter520(i.e., along axis C-C) and formed by an axial end of housing522. The axial end of housing522opposite passage inlet561forms piercing tip550. Piercing tip550includes air outlet560and tip551. As described previously, air can flow through piercing adapter520from passage inlet561to air outlet560, thereby allowing piercing adapter520to deliver air from an external air source to plural component material mixed in mixing channel110. As shown more clearly inFIG.16, the axial end of housing522that defines passage inlet561also defines adapter head599, such that adapter head599circumferentially surrounds passage inlet561. Adapter head599extends beyond attachment housing512when piercing adapter520is installed in a receiving aperture530of attachment housing512. Adapter head599allows a user to grip piercing adapter520during installation of piercing adapter520in attachment housing512. For example, where attachment section542is screw threading, adapter head599can form a tool interface to allow a user to grip piercing adapter520(e.g., with a tool such as a wrench) as the user turns piercing adapter520to interface with screw threading of receiving aperture530.

Alignment indicator598is disposed on adapter head599and is configured to enable a user to align air outlet560with the upstream direction of dispensing assembly600such that air outlet560can emit air into tip portion122of mixing channel110in a generally upstream direction to aerate plural component material. Alignment indicator598is shown as an “X” character inFIG.16, but in other examples, any suitable character for indicating the position of air outlet560can be used. Alignment indicator598can be made using any other suitable technique, such as an engraving, painting, etching, among other options. In the depicted example, alignment indicator598is aligned with air outlet560, such that a user can use the visual position of alignment indicator598in order to position of air outlet560in a desired orientation for flowing air into plural component material flowing through mixing channel110. In the depicted example, a user can position alignment indicator to be facing in upstream direction UD of dispensing assembly600to position air outlet560such that air is emitted in upstream direction UD. In other examples, alignment indicator598can be positioned in a different known orientation relative to air outlet560, and a user can use the known circumferential offset of air outlet560and alignment indicator598to properly position air outlet560. For example, other examples, air outlet560and alignment indicator598can be circumferentially opposed (i.e., offset 180° about axis C-C), such that air outlet560is positioned to emit air in an upstream direction when alignment indicator598faces in downstream direction DD of dispensing assembly600.

As described previously, the embodiments shown inFIGS.4-16allow for relatively low-pressure air to be used to create high-quality aerated plural component materials. For example, pressures as low as 30-100 psi (about 0.2 megapascal (MPa) to about 0.69 MPa) can be used to create aerated plural component mixtures having desirable characteristics (e.g., cell size, cell uniformity, cell density, etc.). In all examples, the pressure of air flowing through air passages240,340,440and passage540and at outlets250,350,450,560, respectively, is sufficient to significantly reduce or prevent back flow of sprayed material through outlets250,350,450,560respectively, which can damage components of a spray dispensing assemblies200,300,400,500, respectively, or another component connected to a dispensing system including the spray dispensing assemblies200,300,400,500.

In some examples, air can be introduced at a point along mixer126to produce aerated plural component mixture have acceptable foam qualities.FIG.17is a perspective view of dispensing assembly600, which introduces air at a location upstream of the downstream end of mixer126to aerate the plural component material. Dispensing assembly600includes mixing channel110and aerating sleeve610. Aerating sleeve610includes air inlet channel624, air inlet628, valve632, an air passage extending through housing124of mixing channel126, and an air outlet disposed at the interior end of the air passage. The air outlet of aerating sleeve610is configured to inject air in an upstream direction through mixer126. Accordingly, aerating sleeve610allows for air to be flowed through channel housing124to aerate a flow of component materials flowing through mixer126. The upstream air injection of aerating sleeve610provides the benefits of upstream air injection described previously with respect to dispensing assemblies200,300,400,500. In other examples, aerating sleeve can inject air in a direction transverse or perpendicular to the direction of flow, or parallel to the direction of flow and in a downstream direction. Air inlet channel624delivers air from an air source (e.g., air source19;FIG.1) to air inlet628, where it is flowed to the air passage extending through housing124and into component materials flowing through mixer126of mixing channel110. The air is flowed in an upstream direction and aerates the component materials flowing through mixer126in a downstream direction. The aerated component materials become fully mixed as they pass through the remainder of mixer126and are subsequently emitted from tip orifice129of mixing channel110. Valve632can be used to selectively allow flow into the flow space defined by channel housing124of mixing channel110. Valve632can be any suitable type of valve and can be mechanically- and/or electrically-actuated. Valve632is actuatable to control a volume of air flowing to mixing channel110. Valve632can be actuated to a closed position to stop flow of air into mixing channel110. Dispensing assembly600is not depicted as including shroud120, but in other examples, dispensing assembly600can include shroud120and the air passage of dispensing assembly600can extend through both channel housing124and shroud housing134to flow air into component materials mixing in mixing channel110.

The nucleation air used by dispenser assembly600can be any inert gas or combination of inert gases. For example, the air can include one or more of N2, O2, CO2, or a noble gas, among other options. As a specific example, the air or nucleation air can be entirely N2, O2, or CO2, or can include a combination of N2, O2, and CO2. In yet further examples, the air can be an atmospheric air.

Dispensing assembly600also offers a number of advantages. Specifically, as dispensing assembly600injects air at mixer126, plural component dispense system10does not require the specialized components used by existing plural component dispensing systems to introduce air at a point upstream of dispensing assembly600where the component materials are at higher pressure. Accordingly, dispensing assembly600allows for aerated plural component materials to be produced using simpler and less expensive dispensing systems than what is required by existing dispensing systems.

Discussion of Possible Embodiments

The following are non-exclusive descriptions of possible embodiments of the present invention.

An embodiment of a nozzle assembly includes a mixing channel having upstream and downstream ends defining a flow direction through the mixing channel and an aerator configured to flow nucleation air to a location downstream of the mixer and into a flow of the plural component material, the mixing channel comprising a housing wall and a mixer. The housing wall comprises an inlet portion disposed at the upstream end and configured to receive a first material and a second material and a tip orifice disposed at the downstream end and configured to emit a plural component material from the mixing channel. The mixer is disposed within the mixing channel, the mixer configured to mix the first material and the second material into the plural component material.

The nozzle assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing nozzle assembly, wherein the aerator comprises a nucleation air passage extending from an exterior of the housing into the flow passage.

A further embodiment of any of the foregoing nozzle assemblies, wherein the nucleation air passage extends through the housing wall.

A further embodiment of any of the foregoing nozzle assemblies, wherein the housing wall comprises a tapered section extending from a point downstream of the mixer to the tip orifice and the nucleation air passage extends through the tapered section of the housing wall.

A further embodiment of any of the foregoing nozzle assemblies, wherein the nucleation air passage extends through the tip orifice.

A further embodiment of any of the foregoing nozzle assemblies, wherein the nucleation air passage is non-linear.

A further embodiment of any of the foregoing nozzle assemblies, wherein the mixing channel extends along an axis and the aerator comprises an attachment housing disposed at a downstream end of the mixing channel, the attachment housing defining an air outlet configured to flow nucleation air to a location downstream of the tip orifice to create aerated plural component material, a flow inlet radially overlapping, with respect to the axis, with the air outlet, the flow inlet configured to accept a flow of aerated plural component material, a spray outlet downstream of the flow inlet for emitting the aerated plural component material, and an outlet passage that fluidly connects the flow inlet to the spray outlet.

A further embodiment of any of the foregoing nozzle assemblies, further comprising a shroud at least partially surrounding an exterior of the mixing channel, wherein the attachment housing is attached to a downstream end of the shroud.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator is configured to flow nucleation air in an upstream direction relative to the flow of the plural component material.

A further embodiment of any of the foregoing nozzle assemblies, wherein the mixing channel is configured to flow the first material, the second material, and the plural component material in a first direction, the aerator is configured to flow nucleation air in a second direction, and the first direction is opposite the second direction.

A further embodiment of any of the foregoing nozzle assemblies, wherein the static mixer defines a helically-shaped section of the flow passage and the helically-shaped section is configured to mix the first material and the second material.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator comprises a housing, the housing comprising a tapered tip at a first end of the housing, an air outlet defined in the tapered tip, an air inlet formed in a second end of the housing, and an air passage defined by the housing fluidly connecting the air inlet to the air outlet, wherein the aerator is configured to the flow nucleation air from the air inlet to the air outlet and from the air outlet into the flow of the plural component material.

A further embodiment of any of the foregoing nozzle assemblies, and further comprising a shroud at least partially surrounding the mixing channel.

A further embodiment of any of the foregoing nozzle assemblies, wherein an inner surface of the shroud contacts an outer surface of the mixing channel.

An embodiment of a method of dispensing a plural component material includes receiving a first material and a second material at an inlet of a mixing channel, the mixing channel having upstream and downstream ends defining a first flow direction through the mixing channel, and the mixing channel comprising a housing wall defining a flow passage, flowing the first material and the second material through a mixer disposed within the flow passage to produce a plural component material, flowing nucleation air into the plural component material at a location downstream of the mixer in a second flow direction to form an aerated plural component material, and dispensing the aerated plural component material.

The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing method, wherein flowing the nucleation air into the plural component material comprises flowing the nucleation air through an air passage extending through the tip orifice.

A further embodiment of any of the foregoing methods, wherein dispensing the aerated plural component material comprises dispensing the aerated plural component material from the tip orifice.

A further embodiment of any of the foregoing methods, wherein dispensing the aerated plural component material comprises flowing the aerated plural component material through an outlet passage downstream of the tip orifice and dispensing the aerated plural component material from a spray outlet downstream of the outlet passage.

A further embodiment of any of the foregoing methods, wherein the second flow direction is opposite the first flow direction.

A further embodiment of any of the foregoing methods, wherein flowing the nucleation air through the plural component material comprises flowing the nucleation air from an air source exterior to the housing through an air passage extending through the housing wall and further flowing the nucleation air through a nucleation air orifice disposed within the flow passage.

A further embodiment of any of the foregoing methods, wherein flowing the nucleation air through the plural component material comprises flowing the nucleation air through a non-linear channel extending from an exterior air source through the tip orifice and further flowing the nucleation air through a nucleation air orifice formed at a tip of the non-linear channel disposed within the flow passage.

A further embodiment of any of the foregoing methods, wherein the nucleation air has a pressure of 40 pounds per square inch at the nucleation air orifice.

A further embodiment of any of the foregoing methods, wherein flowing the first material and the second material through the mixer to produce the plural component material comprises flowing the first material and the second material through a helical passage and the helical passage extends along a helical axis parallel to the first flow direction.

An embodiment of a method of forming a nozzle assembly includes inserting a polymer mixing tube into a shroud, forming a hole in the polymer mixing tube using the guide hole and inserting a nucleating air channel through the guide hole and the hole in the polymer mixing tube to extend into the flow passage. The polymer mixing tube comprises a polymer wall defining a flow passage having upstream and downstream ends and a mixer disposed downstream of the inlet portion and upstream of the tip orifice, the mixer configured to mix the first material and the second material into the plural component material. The polymer wall comprise an inlet portion disposed at the upstream end and configured to receive a first material and a second material and a tip orifice disposed at the downstream end and configured to emit a plural component mixture formed from the first material and the second material. The shroud comprises a shroud wall that at least partially circumferentially surrounds the polymer mixing tube when the polymer tube is inserted into the shroud and a guide hole that extends through the shroud wall.

An embodiment of a nozzle assembly includes a mixing channel having upstream and downstream ends defining a flow direction through the mixing channel and an aerator. The mixing channel comprises a housing wall defining a flow passage and a mixer disposed within the mixing channel, the mixer configured to mix the first material and the second material into the plural component material, the housing wall comprising an inlet portion disposed at the upstream end and configured to receive a first material and a second material a tip orifice disposed at the downstream end and configured to emit a plural component material from the mixing channel. The aerator is configured to flow nucleation air into the flow passage at a location downstream of the mixer and into a flow of the plural component material, the aerator comprising a nucleation air line extending through the housing wall, the air line defining an internal air passage.

The nozzle assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing nozzle assembly, wherein the housing wall comprises a tapered section extending from a point downstream of the mixer to the tip orifice and the nucleation air line extends through the tip section.

A further embodiment of any of the foregoing nozzle assemblies, wherein the mixing channel is configured to flow the plural component material in a first direction, the aerator is configured to flow nucleation air in a second direction, and the first direction is opposite the second direction.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator is configured to accept a flow of nucleation air flowing in a first air direction and is further configured to turn the flow of nucleation air to flow the nucleation air into the flow of the plural component material in a second air direction opposite the first.

An embodiment of a nozzle assembly includes a mixing channel having upstream and downstream ends defining a flow direction through the mixing channel and an aerator. The mixing channel comprises a housing wall defining a flow passage and a mixer disposed within the mixing channel, the mixer configured to mix the first material and the second material into the plural component material, the housing wall comprising an inlet portion disposed at the upstream end and configured to receive a first material and a second material a tip orifice disposed at the downstream end and configured to emit a plural component material from the mixing channel. The aerator is configured to flow nucleation air into the flow passage at a location downstream of the mixer and into a flow of the plural component material, the aerator comprising a nucleation air line extending through the housing wall, the air line defining an internal air passage.

The nozzle assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing nozzle assembly, wherein the mixing channel is configured to flow the plural component material in a first direction, the aerator is configured to flow nucleation air in a second direction, and the first direction is opposite the second direction.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator is configured to accept a flow of nucleation air flowing in a first air direction and is further configured to turn the flow of nucleation air to flow the nucleation air into the flow of the plural component material in a second air direction opposite the first.

An embodiment of a nozzle assembly includes a mixing channel having upstream and downstream ends defining a flow direction through the mixing channel and an aerator. The mixing channel comprises a housing wall defining a flow passage and a mixer disposed within the mixing channel, the mixer configured to mix the first material and the second material into the plural component material, the housing wall comprising an inlet portion disposed at the upstream end and configured to receive a first material and a second material a tip orifice disposed at the downstream end and configured to emit a plural component material from the mixing channel. The aerator is configured to flow nucleation air into the flow passage at a location downstream of the mixer and into a flow of the plural component material, the aerator comprising a nucleation air line extending through the housing wall, the air line defining an internal air passage. The aerator is aerator configured to flow nucleation air into a flow of the plural component material downstream of the mixer, the aerator comprising an attachment housing disposed at a downstream end of the mixing channel an air outlet configured to flow nucleation air out of the attachment housing and into the plural component material at a location downstream of the tip orifice to create an aerated plural component material, a flow inlet extending from upstream of the air outlet to downstream of the air outlet, the flow inlet configured to accept a flow of aerated plural component material, and a spray outlet downstream of the flow inlet for emitting the aerated plural component material from the attachment housing.

The nozzle assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing nozzle assembly, wherein the flow inlet at least partially circumferentially surrounds the air outlet.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator is configured to accept a flow of nucleation air flowing in a first air direction and is further configured to turn the flow of nucleation air to flow the nucleation air into the flow of the plural component material in a second air direction opposite the first.

A further embodiment of any of the foregoing nozzle assemblies, wherein the mixing channel is configured to flow the plural component material in a first direction along the axis, the aerator is configured to flow nucleation air in a second direction, and the first direction is opposite the second direction.

A further embodiment of any of the foregoing nozzle assemblies, and further comprising a shroud at least partially surrounding an exterior of the mixing channel, wherein the attachment housing is attached to a downstream end of the shroud.

A further embodiment of any of the foregoing nozzle assemblies, wherein the air outlet extends along an outlet axis and the flow direction extends along a flow axis that is at least partially coaxial with the outlet axis.

An embodiment of a nozzle assembly includes a mixing channel having upstream and downstream ends defining a flow direction through the mixing channel and an aerator. The mixing channel comprises a housing wall defining a flow passage and a mixer disposed within the mixing channel, the mixer configured to mix the first material and the second material into the plural component material, the housing wall comprising an inlet portion disposed at the upstream end and configured to receive a first material and a second material a tip orifice disposed at the downstream end and configured to emit a plural component material from the mixing channel. The aerator comprises a tapered tip at a first end of a passage housing, an air outlet defined in the tapered tip, an air inlet formed in the passage housing, and an air passage defined by the passage housing, the air passage fluidly connecting the air inlet to the air outlet, wherein the aerator is configured to the flow nucleation air from the air inlet to the air outlet and from the air outlet into the flow passage at a location downstream of the mixer and into a flow of the plural component material.

The nozzle assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing nozzle assembly, wherein the aerator further comprises an attachment housing disposed at a downstream end of the mixing channel, wherein the attachment housing extends along an axis, the attachment housing defines a plurality of receiving apertures at a plurality of axial positions, and each receiving aperture of the plurality of receiving apertures is configured to receive the passage housing.

A further embodiment of any of the foregoing nozzle assemblies, and further comprising a shroud at least partially surrounding an exterior of the mixing channel, wherein the attachment housing is attached to a downstream end of the shroud.

A further embodiment of any of the foregoing nozzle assemblies, wherein the mixing channel is configured to flow plural component material in a first direction, the air outlet of the aerator is configured to flow nucleation air in a second direction into the flow of plural component material, and the first direction is opposite the second direction.

A further embodiment of any of the foregoing nozzle assemblies, wherein the tapered tip extends through an aperture formed in the housing wall, such that the air outlet is disposed within the mixing channel and the air inlet is disposed outside of the mixing channel.

A further embodiment of any of the foregoing nozzle assemblies, wherein the tapered tip forms a seal against the aperture.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator extends along an aerator axis and the air outlet is defined, with respect to the aerator axis, in a circumferentially outer surface of the tapered tip.

A further embodiment of any of the foregoing nozzle assemblies, wherein the air inlet is formed in a second end of the passage housing.

A further embodiment of any of the foregoing nozzle assemblies, wherein the second end is opposite the first end.

A further embodiment of any of the foregoing nozzle assemblies, wherein the air passage includes a first section and a second section, the first section extends along a first axis, the second section extends along a second axis, the first and second axes are offset, such that the first and second axes are not coaxial.

A further embodiment of any of the foregoing nozzle assemblies, wherein the first and second axes are parallel.

An embodiment of an aerator includes a tapered tip at a first end of a passage housing, the passage housing extending along an axis, an air outlet defined in the tapered tip, an air inlet formed in a second end of the passage housing, and an air passage defined by the passage housing, the air passage fluidly connecting the air inlet to the air outlet.

The aerator of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing aerator, wherein the air outlet extends through a circumferentially outer surface of the tapered tip.

A further embodiment of any of foregoing aerators, wherein the air passage includes a first section and a second section, the first section extends along a first axis, the second section extends along a second axis, the first and second axes are offset, such that the first and second axes are not coaxial.

A further embodiment of any of foregoing aerators, wherein the first and second axes are parallel.

An embodiment of a nozzle assembly includes a mixing channel having upstream and downstream ends defining a flow direction through the mixing channel and an aerator. The mixing channel comprises a housing wall defining a flow passage and a mixer disposed within the mixing channel, the mixer configured to mix the first material and the second material into the plural component material, the housing wall comprising an inlet portion disposed at the upstream end and configured to receive a first material and a second material a tip orifice disposed at the downstream end and configured to emit a plural component material from the mixing channel. The aerator is configured to flow nucleation air to a location downstream of an upstream end of the mixer and into a flow of the plural component material.

The nozzle assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing nozzle assembly, wherein the aerator is configured to flow nucleation air to a location downstream of an upstream end of the mixer and upstream of a downstream end of the mixer.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator is configured to flow nucleation air to a location downstream of a downstream end of the mixer.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator comprises an air line that extends through the housing wall.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator comprises an air line that extends through the tip orifice.

A further embodiment of any of the foregoing nozzle assemblies, wherein the aerator is configured to flow nucleation air to a location downstream of the tip orifice.

An embodiment of a method of aerating a plural component material includes receiving a first material and a second material at an inlet of a mixing channel, the mixing channel having upstream and downstream ends defining a first flow direction through the mixing channel, and the mixing channel comprising a housing wall defining a flow passage, flowing the first material and the second material through a mixer disposed within the flow passage to produce a plural component material, and flowing nucleation air into the plural component material at a location downstream of an upstream end of the mixer and into the plural component material in a second flow direction to form an aerated plural component material.

The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing method, and further comprising dispensing the aerated plural component material onto a substrate.

A further embodiment of any of the foregoing methods, wherein flowing the nucleation air into the plural component material at the location downstream of an upstream end of the mixer comprises flowing the nucleation air to a location downstream of a downstream end of the mixer.

A further embodiment of any of the foregoing methods, wherein flowing the nucleation air into the plural component material at the location downstream of an upstream end of the mixer further comprises flowing the nucleation air to a location upstream of a downstream end of the mixer.

A further embodiment of any of the foregoing methods, wherein flowing the nucleation air into the plural component material at the location downstream of an upstream end of the mixer comprises flowing the nucleation air through an air passage extending through the housing wall.

A further embodiment of any of the foregoing methods, wherein dispensing the aerated plural component material comprises dispensing the aerated plural component material from a tip orifice formed in the downstream end of the mixing channel.

A further embodiment of any of the foregoing methods, wherein flowing the nucleation air into the plural component material at the location downstream of an upstream end of the mixer comprises flowing the nucleation air through an air passage extending through a tip orifice formed in the downstream end of the mixing channel.

A further embodiment of any of the foregoing methods, wherein dispensing the aerated plural component material comprises dispensing the aerated plural component material from the tip orifice.

A further embodiment of any of the foregoing methods, wherein flowing the nucleation air into the plural component material at the location downstream of the downstream end of the mixer comprises flowing the nucleation air at a location downstream of a tip orifice formed in a downstream end of the mixing channel.

While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.