| CPC B29C 41/003 (2013.01) [B29C 41/10 (2013.01); B29C 41/365 (2013.01); B29K 2075/00 (2013.01); B29K 2105/0026 (2013.01); B29K 2105/04 (2013.01)] | 19 Claims |
|
1. A method of applying a polyurethane spray foam onto a surface or into a mold, comprising:
providing a system comprising each of:
a) a polyurethane spray foam (“SPF”) raw material supply comprising each of:
i) an isocyanate-containing part A material stored in a first unpressurized container; and
ii) a polyol-containing part B material stored in a second unpressurized container;
wherein either or both of the part A or part B materials incorporate an amount of particles, and an agitator system is engaged with each of the part A and part B unpressurized containers, the agitator system being configured to provide mixing of the part A and part B materials prior to delivery of each into respective part A and part B materials conduits;
b) a fluid handling system comprising:
i) a controller configured for execution of instructions;
ii) the part A material conduit having each of a part A material stream entrance and a part A conduit exit;
iii) the part B material conduit having each of a part B material stream entrance and a part B conduit exit;
iv) at least one pump configured to convey the SPF raw material supply from the first and second unpressurized containers in separate part A and part B material streams into and through each of the part A and part B material conduits, wherein operation of the at least one pump is managed by the controller;
v) at least one heater configured to heat each of the part A and part B material streams, wherein operation of the at least one heater is managed by the controller;
vi) a power source; and
vii) electrical communications capability;
c) an air source configured to convey first and second air streams each having a flow rate defined by instructions associated with the fluid handling system;
d) a heated hose having a proximal end, a distal end, and a length, wherein the heated hose comprises:
i) an exterior covering;
ii) a heated hose part A material conduit defining a portion of a part A material stream path from a location adjacent to the fluid handling system part A conduit exit to and through the length of the heated hose, wherein the heated hose part A material conduit at the proximal end of the heated hose is configured for engagement with the fluid handling system at the part A conduit exit;
iii) a heated hose part B material conduit defining a portion of a part B material stream path from a location adjacent to the fluid handling system part B conduit exit to and through the length of the heated hose, wherein the heated hose part B material conduit at the proximal end of the heated hose is configured for engagement with the fluid handling system at the part B conduit exit;
iv) heated hose first and second air stream conduits, wherein a proximal end of each of the heated hose first and second air stream conduits is configured for engagement with first and second air conduits of the air source at the proximal end of the heated hose;
v) heated hose wiring configured to provide electrical communication between the fluid handling system and the heated hose, wherein a proximal end of the heated hose wiring is configured for engagement with fluid handling system wiring at the proximal end of the heated hose; and
vi) one or more heating elements configured to substantially maintain a target temperature of each of the part A and part B material streams when each of the part A and part B material streams are flowing in their respective heated hose part A and part B material conduits along the length of the heated hose;
e) a whip hose having a length, a proximal end and a distal end, wherein the whip hose comprises:
i) a whip hose part A material conduit defining a portion of the part A material stream path from a location adjacent to the distal end of the heated hose, wherein the whip hose part A material conduit at the proximal end of the whip hose is configured for engagement with the heated hose at the distal end of the heated hose;
ii) a whip hose part B material conduit defining a portion of the part B material stream path from a location adjacent to the distal end of the heated hose, wherein the whip hose part B material conduit at the proximal end of the whip hose is configured for engagement with the heated hose at the distal end of the heated hose;
iii) whip hose first and second air stream conduits, wherein each of the whip hose first and second air stream conduits at the proximal end of the whip hose is configured for engagement with each of the heated hose first and second air source conduits at the distal end of the heated hose; and
iv) whip hose wiring configured to provide electrical communication between the heated hose and the whip hose, wherein a proximal end of the whip hose wiring is configured for engagement with the heated hose wiring at the proximal end of the whip hose; and
f) a metal spray gun configured with each of:
i) an assembly comprising a forward manifold, a materials entry part, and a rear part, wherein:
1) The materials entry part comprises each of a part A material entry port and a part B material entry port configured for engagement with each of the distal end of the whip hose part A and part B material conduits, wherein each of the part A and part B material entry ports are in communication with each of part A and part B material flow paths defined by respective through-between openings in each of the materials entry part and the forward manifold;
2) The assembly includes each of part A and part B air inputs in fluid communication with the respective part A and part B material flow paths, wherein each of the part A and part B air inputs are located forward of each of the respective part A and part B material entry ports;
3) The forward manifold comprises a front side protuberance configured to communicate each of the part A and part B materials out of the assembly as separate material streams when the part A and part B material streams are conveyed from the SPF raw material supply to the spray gun; and
4) the assembly and rear part are engaged with valving configured to start and stop the part A and part B material stream flow;
ii) a trigger; and
iii) a handle;
generating, by the system, each of the part A and part B material streams, either or both of which comprise particles;
conveying, by the system, each of the part A and part B material streams through the system and into a disposable mixing nozzle engaged with the front side protuberance; and
applying, via the disposable mixing nozzle, a mixture of the part A and part B material streams to a surface or into a mold at a pressure of 250 psi or less.
|