Mixing device and related method for two component polyurethane foam formulation

BACKGROUND OF THE INVENTION

<u>Field of the Invention</u>

0001The present invention concerns a mixing device suitable for mixing and applying two component polyurethane foam formulations, and a process for dispensing a non-frothed two-component polyurethane foam formulation using the mixing device.

<u>Introduction</u>

0002Two component polyurethane (2CPU) foam formulations are typically applied by feeding an isocyanate component (A- Component) with a polyol component (B-Component) to create a mixture and then spraying the mixture from a dispenser. There are two types of 2CPU foam formulations: frothed and non-frothed. Frothed foam formulations use a gaseous blowing agent (GBA) such as HFC-134 in the A-Component and a both a GBA and liquid blowing agent (LBA) in the B-Component. Frothed foam can be dispensed at low pressures (less than two megaPascals (MPa)) through a static mixer. In contrast, non-frothed 2CPU foam formulations are free of blowing agents in the A-Component and only have LBA in the B-Component. Non-frothed 2CPUs are dispensed at high pressures, typically 5.5-10 MPa and at an elevated temperature. When dispensing non-frothed 2CPU foam formulations the A and B components are mixed and atomized during application by high pressure impinging contact of the two Components. The high pressure accompanied by heating of non-frothed 2CPU foam formulations necessitates expensive mixing and dispensing devices that can tolerate the pressure and temperature requirements.

0003<patcit id="pcit0001" dnum="EP0001581A1"><text>EP 0 001 581 A1</text></patcit> discloses a method and apparatus for mixing a plurality of viscous, rapidly reacting, fluid materials. <patcit id="pcit0002" dnum="US6326413B1"><text>US 6, 326, 413 B1</text></patcit> discloses a process and apparatus for producing polyurethane foam. <patcit id="pcit0003" dnum="FR1479496A1"><text>FR 1.479.496 A1</text></patcit> discloses a device for mixing synthetic resins by air turbulence.

0004It is desirable to reduce the necessary pressure for non-frothed 2CPU foam formulations during mixing and application to less than two MPa, thereby eliminating the need for applicators that are robust at pressures in excess of 5 MPa as is typically required.

BRIEF SUMMARY OF THE INVENTION

0005The present invention solves the problem of effectively mixing and applying a non-frothed 2CPU foam formulation using a pressure of less than 5 MPa. The mixing device of the present invention enables mixing and applying non-frothed 2CPU foam formulations, that is, 2CPU foam formulations that are free of GBAs in the A-Component of the formulation at pressures of less than 5 MPa.

0006To solve this problem, the present invention provides a mixer design that carefully controls influx of air into the A and B Components as the A and B Components are combined and then directs the mixture of air and A and B Components through static mixers prior to applying the 2CPU form formulation to a desired substrate. The mixing device is of a design particularly well suited for injection molding thereby providing for a relatively low-cost device that can be made entirely of plastic.

0007In a first aspect, the present invention relates to a mixing device according to claim 1 comprising: (a) a housing that defines a mixing chamber, an A-Component feed channel entrance opening, a B-Component feed channel entrance opening, and air feed channel entrance opening, and an exit opening where the feed channel entrance openings and exit opening provide fluid communication into and/or out of the mixing chamber; and (b) a static mixing element housed within the mixing chamber between the three entrance feed channels and the exit opening; where the mixing device is characterized by the air feed channel entrance opening having a cross sectional area that is 0.7 square millimeters or greater and 7.7 square millimeter or less, and the mixing chamber being generally cylindrical in shape and having opposing ends with the exit opening at one end and the three feed channel entrance openings at the opposing end, and further characterized by a conical feature extending into but not sealing off the air feed channel entrance opening such that the cross sectional area left open around the conical feature corresponds to the air feed channel entrance opening cross sectional area, wherein the conical feature is held in place with respect to the air channel entrance opening by fins.

0008Preferably the mixing device is further characterized by the static mixing element comprising a series of semi-elliptical plates positioned in series along a central support with the central support extending in a general direction between the entrance openings and the exit opening.

0009Preferably the mixing device is further characterized by the static mixing element comprising a series of semi-elliptical plates positioned along a central support and the conical feature being attached to the central support of the static mixers.

0010Preferably the mixing device is further characterized by the entrance opening cross section area of the A-component feed channel being 0.5 times or larger and 16 times or smaller than the air feed channel entrance opening cross sectional area.

0011Preferably the mixing device is further characterized by the entrance opening cross section area of the B-Component feed channel being 0.7 times or larger and 25 times or smaller than the air feed channel entrance opening cross sectional area.

0012Preferably the mixing device is further characterized by the air feed channel entrance opening being generally centered on an end of the mixing chamber.

0013Preferably the mixing device is further characterized by the static mixing element comprising a series of plates in series along a central support, the central support having a conical end that extended into but not sealing off the entrance opening of the air feed channel such that the cross sectional area left open around the conical feature corresponds to the air feed channel entrance opening cross sectional area, the conical feature having three or more fins that contact a wall defining the air channel entrance opening and serve to hold the conical feature generally centrally position in the air channel entrance opening.

0014Preferably the mixing device is further characterized by having only three feed channel entrance openings.

0015In a second aspect, the present invention relates to a process according to claim 8 for dispensing a non-frothed two-component polyurethane foam formulation using the mixing device of the first aspect, the process comprising feeding an A-Component comprising an isocyanate and that is free of liquid blowing agent through the A-Component feed channel while feeding a B-Component comprising a polyol through the B-Component channel and while feeding air through the air feed channel, mixing the A- and B-Components with air in the mixing chamber and dispensing them through the exit opening.

0016The mixing device of the present invention is useful for preparing and applying non-froth 2CPU foam formulations according to the process of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

0017<figref idref="f0001 f0002">Figures 1-4</figref> illustrate an exemplary mixing device of the present invention. <figref idref="f0001">Figures 1 and 2</figref> illustrate side cross sectional views. <figref idref="f0002">Figure 3</figref> illustrates a cut-away view above the entrance feed channel openings. <figref idref="f0002">Figure 4</figref> illustrates a view of the cross sectional area of the air feed channel entrance opening.

DETAILED DESCRIPTION OF THE INVENTION

0018"And/or" means "and, or as an alternative". All ranges include endpoints unless otherwise indicated. "Multiple" means two or more.

0019The mixing device of the present invention comprises a housing. The housing defines a mixing chamber, three feed channel entrance openings and an exit opening. The three feed channel entrance openings are an A-Component feed Channel entrance opening, a B-Component feed channel opening and an air feed channel entrance opening. The three feed channel entrance openings and the exit opening each provides fluid communication into and/or out from the mixing chamber of the housing. The mixing device allows for fluid (that is, gas and/or liquid) flow through the feed channel entrance openings into the mixing chamber and out from the mixing chamber through the exit opening.

0020The mixing chamber is generally cylindrical in shape and has opposing ends with the exit opening at one end and the three feed channel entrance openings at the opposing end such that most of the mixing chamber volume resides between the feed channel entrance openings and the exit opening. For example, in one desirable design, the housing and mixing chamber are generally cylindrical in shape with a cross sectional shape that can be circular or any other shape including oval, rectangular, pentagonal or star shaped. The entrance openings are located at one end of the cylinder and the exit opening at the opposing end of the cylinder. In such an embodiment it is further desirable for the air channel entrance opening to be generally centrally located on one end of the cylindrical housing and mixing chamber. It is also desirable for the exit opening to be generally centrally located on an end of the housing and mixing chamber opposite from the air channel entrance opening regardless of whether the air channel entrance opening is centrally located on its end or not.

0021Each entrance opening has a cross sectional area. Determine cross sectional areas in a plane perpendicular to the direction of fluid flow. Cross sectional areas for the A-Component and B-Component entrance openings correspond to the smallest cross sectional area of each feed channel. Determine the cross sectional area for the air feed channel entrance opening where the outer sides (walls) that define the opening penetrate furthest into the mixing chamber (that is, furthest into the housing). The cross sectional area of the air feed channel entrance opening corresponds to the open area of the feed channel entrance opening taking into account any protrusions that extend into the air feed channel from inside the mixing chamber. For example, in a preferred embodiment as described below, a conical feature extends into the air feed channel so as to reduce the open area of the feed channel and to disperse the air flow around the conical feature. The cross sectional area of the air channel opening is the open area around the conical feature (and any supports for the conical feature as described below) within the air channel opening as determined in a cross sectional view taken through the conical feature in a plane where the outer sides of the opening penetrate furthest into the mixing chamber and perpendicular to fluid flow through the air channel prior to (which is equivalent to in an absence of) the conical feature.

0022The air channel entrance opening has a cross sectional area of 0.5 square millimeters (mm²) or more, preferably 0.7 mm² or more, still more preferably 1.0 mm² or more and can be 1.5 mm² or more, 2.0 mm² or more and even 3 mm² or more. At the same time, the air channel entrance opening has a cross sectional area of 8.0 mm² or less, preferably 7.7 mm² or less, still more preferably 7.5 mm² or less, yet more preferably 7.0 mm² or less and can be 6.5 mm² or less, 6.0 mm² or less, 5.0 mm² or less, 4.0 mm² or less, even 3.0 mm² or less. Ideally, the air channel entrance opening has a cross section area of 0.7 mm² or more and 7.7 mm² or less. When the air channel entrance opening has a cross sectional area of less than 0.5 mm² the air flow can be too restricted to adequately disperse the polyurethane foam formulation. When the air channel entrance opening has a cross sectional area of greater than 8.0 mm² there is a tendency for A-Component and/or B-Component to undesirably back flow into the air feed channel.

0023The A-Component entrance opening has a cross sectional area that is desirably 0.5 or more, preferably 1.0 times or more, still more preferably 1.5 times or more, yet more preferably 2.0 times or more, yet even more preferably 3.0 times or more and can be 4 times or more, 5 times or more, 6 times or more 7 times or more, 8 times or more, 9 times or more and even 10 times or more the size of the air channel entrance opening cross sectional area. At the same time, the A-Component entrance opening desirably has a cross sectional area that is desirably 16 times or less, preferably 15.5 times or less, more preferably 13 times or less and can be 12 times or less, 11 times or less, 10 times or less and even 9 times or less the size of the air channel entrance opening cross sectional area. A first cross sectional area is "x" times the size of a second cross sectional area if the first cross sectional area has a cross sectional area that is equal to the product of x and the second cross sectional area. When the A-Component entrance opening has a cross sectional area that is less than 0.5 times the size of the air channel entrance opening cross sectional area then air flow can inhibit adequate flow of the A-Component. When the A-Component entrance opening has a cross sectional area that is greater than 16 times the size of the air channel entrance opening cross sectional area then there may be insufficient air to properly disperse the polyurethane foam formulation.

0024The B-Component entrance opening has a cross sectional area that is desirably 0.7 times or more, preferably 1.0 times or more, still more preferably 2.0 times or more, more preferably 2.1 times or more, yet more preferably 3.0 times or more and can be 4 times or more, 5 times or more, 10 times or more 15 times or more, and even 20 times or more the size of the air channel entrance opening cross sectional area. At the same time, the B-Component entrance opening desirably has a cross sectional area that is 25 times or less, preferably 23 times or less, more preferably 22 times or less and can be 20 times or less, 15 times or less and even 10 times or less the size of the air channel entrance opening cross sectional area. When the B-Component entrance opening has a cross sectional area that is less than 2.0 time the size of the air channel entrance opening cross sectional area then air flow can inhibit adequate flow of the B-Component. When the B-Component entrance opening has a cross sectional area that is greater than 25 times the size of the air channel entrance opening cross sectional area then there may be insufficient air to properly disperse the polyurethane foam formulation.

0025It is further desirable for the B-Component entrance opening to have a larger cross sectional area than the A-Component entrance opening cross sectional area. The B-Component is generally more viscous than the A-Component so having a larger B-Component entrance opening facilitates achieving a properly balanced flow rate and mixing ratio of the A- and B-Components.

0026The mixing device further comprises a static mixing element housed within the mixing chamber between the three entrance feed channel openings and the exit opening. That means that at least a portion of, preferably all of, the static mixing element resides between the exit opening and the three entrance openings (though not necessarily between any two entrance openings). The static mixing element is designed so to mix together fluids flowing into the mixing chamber from the entrance openings to form a mixture of fluids prior to that mixture flowing out from the mixing chamber through the exit opening.

0027In one desirable design, the static mixing element comprises multiple semi-elliptical plates positioned in series along a central support that extends in a direction extending between the entrance openings and the exit opening where the semi-elliptical plates are tilted out of planar with respect to a cross sectional plane through the central support.

0028In one desirable mixing device, the static mixing element comprises a central support with a conical feature at an end with the conical feature penetrating into but not sealing off the air channel entrance opening. Even more desirably, the air channel is flared into a cone shape itself into which the conical feature penetrates. Alternatively, another desirable design includes a conical feature that is distinct from a central support of a static mixing element penetrating into but not sealing off the air channel entrance opening.

0029It is valuable for achieving consistent and controlled mixing that the air channel entrance opening cross sectional area and shape remain as constant as possible during use of the mixing device. Therefore, it is desirable for a conical feature that penetrates in to the air channel entrance opening to be held in place so as to avoid movement relative to the air entrance channel. In one desirable embodiment, a conical feature (as part of a central support of the mixing element or otherwise) is held into place with respect to the air channel entrance opening by fins, preferably three or more fins evenly spaced around the conical feature, that contact a wall defining the air channel entrance opening. Such fins prevent the conical feature from moving radially within the air channel entrance opening in the cross sectional plane of the air channel entrance opening. The fins can be attached to the wall defining the air channel entrance opening or merely touch the wall without attaching to the wall.

0030An example of a preferred embodiment of the mixing device of the present invention is illustrated in <figref idref="f0001 f0002">Figures 1-4</figref>.

0031<figref idref="f0001">Figure 1</figref> shows a cross sectional view of mixing device <b>10</b> where the viewing cross section extends in a plane that extends from the entrance openings to the exit opening and is perpendicular to the cross sections containing the cross sectional areas of the entrance openings. Housing <b>20</b> defines mixing chamber <b>30,</b> A-Component feed channel entrance opening <b>40,</b> B-Component feed channel entrance opening <b>50,</b> air feed channel entrance opening <b>60</b> and exit opening <b>70.</b> Mixing device <b>10</b> comprises static mixing element <b>80,</b> which comprises central support <b>82,</b> semi-elliptical plates <b>84</b> and conical feature <b>86.</b> Housing <b>20</b> and mixing chamber <b>30</b> are generally cylindrical in shape with entrance openings <b>40, 50</b> and <b>60</b> on one end and exit opening <b>70</b> on an opposing end.

0032<figref idref="f0001">Figure 2</figref> again illustrates mixing device <b>10</b> in like perspective as <figref idref="f0001">Figure 1. Figure 2</figref> identifies walls <b>62</b> that define air feed channel entrance opening <b>60</b> (shown in <figref idref="f0001">Figure 1). Figure 2</figref> also identifies viewing plane <b>A</b> and viewing plane <b>B</b> in which entrance opening cross sectional areas are determined. Determine the A-Component and B-Component feed channel entrance opening cross sectional areas in viewing plane A<b>,</b> which corresponds to the narrowest portion of the feed channels. Determine air feed channel entrance opening cross sectional area in viewing plane <b>B,</b> which is where the outer sides (walls <b>62</b>) of the air feed channel entrance opening penetrate furthest into mixing chamber <b>30.</b>

0033<figref idref="f0002">Figure 3</figref> provides yet another view of mixing device <b>10</b> as an angled view towards mixing element <b>80</b> from viewing plane <b>A</b> (that is, viewed in the opposite direction as the viewing arrows indicate for viewing plane <b>A</b> in <figref idref="f0001">Figure 2</figref>). The view of <figref idref="f0002">Figure 3</figref> reveals three fins <b>83</b> on conical feature <b>86</b> of mixing element <b>80.</b> Fins <b>83</b> rest against walls <b>62</b> of the air feed channel entrance opening and hold conical feature <b>86</b> from moving within the air feed channel entrance opening.

0034In the exemplary mixing device of <figref idref="f0001 f0002">Figures 1-3</figref> the A-Component and B-Component feed channel entrance opening cross sectional areas are circular in shape. The cross sectional area of A-Component feed channel entrance opening <b>40</b> is 11.3 mm² and the cross sectional area of B-Component feed channel entrance opening <b>50</b> is 16.4 mm². Air feed channel entrance opening <b>60</b> is similar to the cross section of a toroid with three sections blocked due to fins <b>83.</b><figref idref="f0002">Figure 4</figref> illustrates the cross sectional view that reveals air feed channel entrance opening <b>60.</b> The air feed entrance opening cross sectional area is 3.85 mm².

0035<figref idref="f0002">Figure 4</figref> illustrates the cross sectional view of the air feed channel entrance opening cross sectional area as viewed down viewing plane <b>B</b> of <figref idref="f0001">Figure 2</figref>. The air feed channel entrance opening cross sectional area is that of the air feed channel entrance opening <b>60</b> that remains open around conical feature <b>86,</b> fins <b>83</b> and within wall <b>62.</b>

0036The present invention includes a process for dispensing a non-frothed 2CPU foam formulation using the mixing device of the present invention. The process of the present invention comprises feeding an A-Component comprising an isocyanate and that is free of liquid blowing agent through the A-Component feed channel into the mixing chamber of the mixing device of the present invention while feeding into the mixing chamber a B-Component comprising a polyol through the B-component feed channel and air through the air feed channel, mixing the A- and B-Components with air in the mixing chamber to form a non-frothed 2CPU foam formulation and then dispensing the non-frothed 2CPU foam formulation through the exit opening.

0037Typically, the process includes providing an A-Component at a pressure in a range of 790 to 870 kiloPascals and providing a B-Component at a pressure in a range of 860 to 940 kiloPascals. Typically, provide air at a pressure of 1.5 megaPascals or less, preferably 1.4 megaPascals or less, more preferably 1.0 megaPascals or less and the air pressure can be 700 kiloPascals or less while at the same time it is typical to provide air at a pressure of 340 kiloPascals or higher, preferably 400 kiloPascals or higher, more preferably 500 kiloPascals or higher and even more preferably 550 kiloPascals or higher.

0038One novel characteristic of the mixing device of the present invention and the process of the present invention is that air is introduced to the A-Component and B-Components before the A- and B-Components finish interacting with the static mixing element, preferably before the A- and B-Components first contact the static mixing element.

0039With respect to locations within the mixing chamber, terms such as "before" and "after" are with respect to fluid flowing into the mixing chamber through the feed channel entrance openings and out from the mixing chamber from the exit opening. The three feed channel entrance openings are generally on opposite side of the mixing chamber from the exit opening. Hence, reference to "before" with respect to objects in the mixing chamber means relatively further from the exit opening while reference to "after" means generally more proximate to the exit opening.

0040The mixing device of the present invention has an added benefit of being able to be readily injection molded. By operating at lower pressures than typical non-frothed 2CPU foam formulation applicators the present mixing device can be manufactured entirely of plastic. The fact the mixing device can be entirely of plastic in combination with the design as set forth herein enables the mixing device to be readily injection molded. As a result, the mixing device of the present invention is cost effective (that is, relatively low cost) to manufacture relative to other non-froth 2CPU foam formulation applicators.