WO2017019688A1 - Passive flow synchronizer - Google Patents

Passive flow synchronizer Download PDF

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Publication number
WO2017019688A1
WO2017019688A1 PCT/US2016/044046 US2016044046W WO2017019688A1 WO 2017019688 A1 WO2017019688 A1 WO 2017019688A1 US 2016044046 W US2016044046 W US 2016044046W WO 2017019688 A1 WO2017019688 A1 WO 2017019688A1
Authority
WO
WIPO (PCT)
Prior art keywords
gear
gear set
component
disposed
outlet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2016/044046
Other languages
French (fr)
Inventor
Martin P. MCCORMICK
Joseph E. Tix
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Graco Minnesota Inc
Original Assignee
Graco Minnesota Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Graco Minnesota Inc filed Critical Graco Minnesota Inc
Publication of WO2017019688A1 publication Critical patent/WO2017019688A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D11/00—Control of flow ratio
    • G05D11/005—Control of flow ratio using synchronised pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B1/00—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C11/00—Combinations of two or more machines or pumps, each being of rotary-piston or oscillating-piston type; Pumping installations
    • F04C11/001—Combinations of two or more machines or pumps, each being of rotary-piston or oscillating-piston type; Pumping installations of similar working principle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2/00—Rotary-piston machines or pumps
    • F04C2/08—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing
    • F04C2/12—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type
    • F04C2/14—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type with toothed rotary pistons
    • F04C2/18—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type with toothed rotary pistons with similar tooth forms
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2220/00—Application
    • F04C2220/24—Application for metering throughflow

Definitions

  • This disclosure relates generally to multiple component applicators, and more particularly to a passive component synchronizer for a multiple component applicator.
  • Multiple component applicators apply a resultant material, such as a foam insulation, that is formed from multiple component materials.
  • the component materials react with each other in a short time period, so the component materials are stored separately until application.
  • the component materials are mixed in a mixing manifold, which is generally attached to the applicator gun, immediately prior to application of the resultant material.
  • the component materials must be mixed at a constant predetermined ratio.
  • the user takes samples of each component material and compares the weights of multiple samples to determine a ratio.
  • a ratio between the first component material and the second component material is determined by taking a sample flow of the first component material and measuring the sample flow against a sample flow of the second component material. If the ratio is incorrect, then the pressure in the material tanks is adjusted and additional samples are taken until the desired ratio is achieved. Measuring the ratio samples by hand wastes component materials, creates chemical waste, and is time consuming.
  • a passive fluid flow synchronizer includes a first component meter housing, a second component meter housing, a barrier plate disposed between the first component meter housing and the second component meter housing, a first gear set, and a second gear set.
  • the first component meter housing has a first inlet, a first outlet, and a first flow path extending between the first inlet and the first outlet.
  • the second component meter housing has a second inlet, a second outlet, and a second flow path extending between the second inlet and the second outlet.
  • the barrier plate is configured to separate the first flow path and the second flow path.
  • the first gear set is disposed within the first flow path between the first inlet and the first outlet.
  • the second gear set is disposed within the second flow path between the second inlet and the second outlet.
  • the first gear set is coupled to the second gear set such that the first gear set and the second gear set rotate synchronously to provide a set volumetric ratio of a first component material to a second component material through the first outlet and the second outlet.
  • a multiple component dispenser includes a first material tank, a second material tank, a passive fluid flow synchronizer connected to the first material tank with a first supply hose and connected to the second material tank with a second supply hose, a first nozzle hose, a second nozzle hose, and a material applicator.
  • the passive flow synchronizer includes a first component meter housing having a first inlet, a first outlet, and a first flow path extending between the first inlet and the first outlet, a second component meter housing having a second inlet, a second outlet, and a second flow path extending between the second inlet and the second outlet, a barrier plate disposed between the first component meter housing and the second component meter housing and isolating the first flow path from the second flow path, a first gear set disposed within the first flow path between the first inlet and the first outlet, and a second gear set disposed within the second flow path between the second inlet and the second outlet.
  • the first supply hose is attached to the first inlet and the second supply hose is attached to the second inlet.
  • the first nozzle hose is connected to the first outlet and configured to receive the first material from the first flow path.
  • the second nozzle hose is connected to the first outlet and configured to receive the second material from the second flow path.
  • the first gear set is configured to meter the flow of a first material through the first flow path.
  • the second gear set is configured to meter the flow of a second material through the second flow path.
  • the first gear set is coupled to the second gear set such that the first gear set and the second gear set rotate synchronously.
  • the material applicator is configured to receive the first material from the first nozzle hose and the second material from the second nozzle hose.
  • a method of synchronizing multiple flows includes coupling a first gear set disposed on a first side of a barrier plate to a second gear set disposed on a second side of the barrier plate such that the first gear set and the second gear set rotate synchronously, flowing a first material through a first flow path and the first gear set, flowing a second material through a second flow path and the second gear set, and providing a set volumetric ratio of the first material to the second material by the synchronous rotation of the first gear set and the second gear set.
  • FIG. 1 is a schematic view of a multiple component dispensing system.
  • FIG. 2A is an exploded view of a passive flow synchronizer.
  • FIG. 2B is a top cross-sectional view of a passive flow synchronizer.
  • FIG. 2C is an isometric cross-sectional view of a passive flow synchronizer.
  • FIG. 2D is a side elevation cross-sectional view of a passive flow synchronizer.
  • FIG. 3 is a cross-sectional view of a passive flow synchronizer.
  • FIG. 1 is a schematic view of multiple component dispensing system 10.
  • Multiple component dispensing system 10 includes material tank 12a, material tank 12b, supply hose 14a, supply hose 14b, passive flow synchronizer 16, nozzle hose 18a, nozzle hose 18b, and material applicator 20.
  • Supply hose 14a extends between material tank 12a and passive flow synchronizer 16.
  • Supply hose 14a provides a first component material from material tank 12a to passive flow synchronizer 16.
  • supply hose 14b extends between material tank 12b and passive flow synchronizer 16.
  • Supply hose 14b provides a second component material from material tank 12b to passive flow synchronizer 16.
  • Passive flow synchronizer 16 receives both the first component material and the second material and provides the first material and the second material downstream.
  • Nozzle hose 18a is connected to passive flow synchronizer 16 and receives the first component material from passive flow synchronizer 16.
  • Nozzle hose 18a provides the first component material to material applicator 20.
  • Nozzle hose 18b is also connected to passive flow synchronizer 16, and nozzle hose 18b receives the second component material from passive flow synchronizer 16 and provides the second component material to material applicator 20.
  • Material tank 12a stores the first component material under pressure and material tank 12b stores the second component material under pressure.
  • the first component material and the second component material may be components in a two- component, quick-cure polyurethane foam, whereby the first component material reacts with the second component material to create the polyurethane foam.
  • the first component material is stored separate from the second component material until the time of application, as the first component material and the second component material react quickly to form the resultant foam. As such, the first component material is maintained separate from the second component material until application of the resultant material. To ensure that the resultant material has the desired properties, the first component material and the second component material are combined at a set ratio.
  • Triggering material applicator 20 causes the pressure within nozzle hoses 18a and 18b to drop.
  • the pressure within material tank 12a then drives the first component material downstream through supply hose 14a, passive flow synchronizer 16, and nozzle hose 18a.
  • the pressure within material tank 12b drives the second component material downstream through supply hose 14b, passive flow synchronizer 16, and nozzle hose 18b.
  • Passive flow synchronizer 16 meters the flow of the first component material and the second component material such that the first component material and the second component material are provided downstream from passive flow synchronizer 16 at a set ratio.
  • the first component material flows downstream from passive flow synchronizer 16 through nozzle hose 18a and to material applicator 20.
  • the second component material flows downstream from passive flow synchronizer 16 through nozzle hose 18b and to material applicator 20.
  • the first component material and the second component material are combined at material applicator 20 and applied to a desired surface.
  • Passive flow synchronizer 16 ensures that the ratio of the first component material to the second component material provided to material applicator 20 remains constant. By ensuring a constant ratio of the first component material to the second component material at material applicator 20, passive flow synchronizer 16 reduces chemical waste, ensures that the resultant material has the desired properties, and reduces the time requirement needed to prepare multiple component dispensing system 10. Passive flow synchronizer 16 ensures a constant ratio between the first component material and the second component material, thereby eliminating the need to sample the first component material and the second component material. Eliminating sampling reduces chemical waste and reduces the time necessary to set up multiple component dispensing system, thereby saving time and money.
  • FIG. 2A is an exploded view of passive flow synchronizer 16.
  • FIG. 2B is a top cross-sectional view of passive flow synchronizer 16.
  • FIG. 2C is an isometric cross-sectional view of passive flow synchronizer 16.
  • FIG. 2D is a side-elevation cross- sectional view of passive flow synchronizer 16.
  • FIGS. 2A-2D are substantially similar and will be discussed together.
  • Passive flow synchronizer 16 includes component meter housing 22a, component meter housing 22b, barrier plate 24, gear set 26a, gear set 26b, static seal 28a, static seal 28b, aligning pins 30, and fasteners 32.
  • Component meter housing 22a includes inlet 34a and outlet 36a.
  • Component meter housing 22b includes inlet 34b and outlet 36b.
  • Gear set 26a includes first gear 38a, second gear 40a, bearings 42a, and aligning mechanism 44a.
  • gear set 26b includes first gear 38b, second gear 40b, bearings 42b, and aligning mechanism 44b.
  • Aligning mechanism 44a includes magnets 46a.
  • Aligning mechanism 44b includes magnets 46b.
  • First gear 38a includes first gear teeth 48a
  • first gear 38b includes first gear teeth 48b.
  • Second gear 40a includes second gear teeth 50a
  • second gear 40b includes second gear teeth 50b.
  • Barrier plate 24 is disposed between component meter housing 22a and component meter housing 22b. Fasteners 32 extend through component meter housing 22a, barrier plate 24, and component meter housing 22b to secure component meter housing 22a, barrier plate 24, and component meter housing 22b together. Aligning pins 30 are configured to extend through barrier plate 24 and into component meter housing 22a and component meter housing 22b. Aligning pins 30 ensure that component meter housing 22a, barrier plate 24, and component meter housing 22b are properly aligned.
  • Static seal 28a is disposed between barrier plate 24 and component meter housing 22a and is configured to prevent a fluid flowing through component meter housing 22a from leaking between component meter housing 22a and barrier plate 24.
  • static seal 28b is disposed between barrier plate 24 and component meter housing 22b and is configured to prevent a fluid flowing through component meter housing 22b from leaking between component meter housing 22b and barrier plate 24.
  • Gear set 26a is disposed within component meter housing 22a and adjacent barrier plate 24.
  • First gear 38a is intermeshed with second gear 40a such that first gear 38a and second gear 40a rotate synchronously, in opposite directions of rotation.
  • the meshing of first gear 38a and second gear 40a prevents the first component material from flowing between first gear 38a and second gear 40a, such that the first component material must instead flow around first gear 38a and second gear 40a, as shown by flow lines Fl in FIG. 2D.
  • Thrust bearings 42a are disposed between barrier plate 24 and first gear 38a and second gear 40a.
  • gear set 26b is disposed within component meter housing 22b and adjacent barrier plate 24.
  • First gear 38b is intermeshed with second gear 40b such that first gear 38b and second gear 40b rotate synchronously, in opposite directions of rotation.
  • the meshing of first gear 38b and second gear 40b prevents the second component material from flowing between first gear 38b and second gear 40b, and as such, the second component material must instead flow around first gear 38b and second gear 40b, similar to the first component material flowing around first gear 38a and second gear 40a.
  • Thrust bearings 42b are disposed between barrier plate and first gear 38b and second gear 40b.
  • Bearings 42a and bearings 42b may be of any suitable configuration for supporting gear set 26a and gear set 26b on barrier plate 24.
  • bearings 42a and bearings 42b may be ball-type thrust bearings, needle-type thrust bearings, a carbine pin pressed through barrier plate 24, carbide shell bearings, or any other suitable bearing.
  • Aligning mechanism 44a is disposed on first gear 38a and second gear
  • Aligning mechanism 44b is disposed on first gear 38b and second gear 40b. Aligning mechanism 44a includes magnets 46a that extend through first gear 38a and second gear 40a. Magnets 46a are disposed on first gear 38a in an alternating north-south manner, best seen in FIG. 2B. Magnets 46a are also disposed on second gear 40a in an alternating north-south manner, best seen in FIG. 2B. Similarly, aligning mechanism 44b is disposed on first gear 38b and second gear 40b. Aligning mechanism 44b includes magnets 46b that extend through first gear 38b and second gear 40b. Similar to magnets 46a, magnets 46b are disposed on first gear 38b in an alternating north-south manner. Magnets 46b are also disposed on second gear 40b in an alternating north-south manner.
  • Aligning mechanism 44a is configured to couple to aligning mechanism
  • gear set 26a is coupled to gear set 26b.
  • gear set 26a is coupled to gear set 26b by aligning mechanisms 44a and 44b for synchronous rotation of gear set 26a and gear set 26b.
  • Magnets 46a and magnets 46b are attracted to each other such that first gear 38a and first gear 38b rotate synchronously. As such, the rotation of either first gear 38a or first gear 38b will simultaneously drive the rotation of the other of first gear 38a and first gear 38b.
  • magnets 46a may be arranged on first gear 38a and second gear 40a in any suitable manner for linking gear set 26a and gear set 26b; for example, magnets 46a may include multiple, round neodymium magnets, radial magnets, or any other suitable configuration.
  • barrier plate 24 is preferably made of a non-ferrous material, such as plastic or aluminum, suitable for providing a barrier between a first component material flowing through component meter housing 22a and a second component material flowing through component meter housing 22b.
  • passive flow synchronizer 16 is configured to meter the first component material and the second component material such that a fixed ratio of the first component material to the second component material is provided downstream.
  • the first component material is provided to component meter housing 22a through supply hose 14a (shown in FIG. 1) and inlet 34a.
  • the second component material is provided to component meter housing 22b through supply hose 14b (shown in FIG. 1) and inlet 34b.
  • the first component material and the second component material are stored under pressure in material tank 12a (shown in FIG. 1) and material tank 12b (shown in FIG. 1), respectively.
  • an applicator is triggered.
  • Triggering the applicator causes the pressure in nozzle hose 18a and nozzle hose 18b to drop, creating a pressure differential between inlet 34a and outlet 36a, and between inlet 34b and outlet 36b.
  • the storage pressure within material tank 12a causes the first component material to flow downstream through passive flow synchronizer 16 and to the applicator
  • the storage pressure within material tank 12b causes the second component material to flow downstream through passive flow synchronizer 16 and to applicator 20.
  • Aligning mechanism 44a and aligning mechanism 44b couple gear set 26a to gear set 26b such that gear set 26a and gear set 26b rotate synchronously and thus meter the first component material and the second component material at the same rate.
  • passive flow synchronizer 16 ensures that a ratio of the first component material to the second component material provided downstream through outlets 36a and 36b is constant.
  • FIG. 2B a flow of a component material is shown through component meter housing 22a and gear set 26a.
  • gear set 26a and gear set 26b meter fluid is substantially the same manner, and as such, while the discussion of FIG. 3A is directed towards gear set 26a, it is understood that the discussion of gear set 26a is equally applicable to gear set 26b.
  • Component meter housing 22a includes inlet 34a and outlet 36a.
  • Gear set 26a is disposed within component meter housing 22a between inlet 34a and outlet 36a.
  • Gear set 26a includes first gear 38a, second gear 40a, and magnets 46a.
  • First gear 38a includes first gear teeth 48a
  • second gear 40a includes second gear teeth 50a.
  • First gear teeth 48a are intermeshed with second gear teeth 50a such that first gear 38a and second gear 40a rotate synchronously.
  • the component material enters component meter housing 22a through inlet 34a, is metered by gear set 26a, and exits component meter housing 22a through outlet 36a.
  • An upstream pressure drives the component material through component meter housing 22a.
  • a material applicator 20 shown in FIG. 1
  • the downstream pressure drops, and the upstream pressure drives the component material through component meter housing 22a.
  • Magnets 46a extend though first gear 38a and second gear 40a.
  • first gear 38a includes the same number of magnets 46a as first gear teeth 48a
  • second gear 40a includes the same number of magnets 46a as second gear teeth 50a.
  • first gear teeth 48a and second gear teeth 50a Due to the meshing of first gear teeth 48a and second gear teeth 50a, the component material cannot flow between first gear 38a and second gear 40a. Instead, the component material causes first gear 38a to rotate in direction Rl and second gear 40a to simultaneously rotate in direction R2. As first gear 38a and second gear 40a rotate, the component material is captured in a first volume defined between adjacent first gear teeth 48a and in a second volume defined between adjacent second gear teeth 50a. The component material fills the first volume and the second volume proximate inlet 34a. The component material is retained in the first volume and the second volume as first gear 38a and second gear 40a rotate. The component material exits the first volume and the second volume proximate outlet 36a and continues downstream through outlet 36a.
  • the first volume and the second volume are known, and as such, a set, known volume of component material is provided to outlet 36a for each rotation of first gear 38a and second gear 40a.
  • Gear set 26a provides a set, known volume of the component material, however, regardless of the rate of rotation.
  • gear set 26a is disposed within component meter housing 22a between inlet 34a and outlet 36a.
  • Gear set 26b is disposed within component meter housing 22b between inlet 34b and outlet 36b.
  • Barrier plate 24 is disposed between and separates gear set 26a and gear set 26b, and barrier plate 24 prevents the first component material, flowing through component meter housing 22a, from interacting with the second component material, flowing through component meter housing 22b, as the first component material and the second component material pass through passive flow synchronizer 16.
  • Aligning mechanism 44a extends through gear set 26a, and aligning mechanism 44b extends through gear set 26b. More particularly, magnets 46a extend through first gear 38a and second gear 40a, and magnets 46b extend through first gear 38b and second gear 40b.
  • Aligning mechanism 44a is coupled to aligning mechanism 44b, such that gear set 26a is coupled to gear set 26b for synchronous rotation.
  • Magnets 46a are positioned on first gear 38a and second gear 40a in an alternating, north-south manner. As such, each magnet 46a extending through first gear 38a and second gear 40a preferably has an opposite polarity from any adjacent magnet 46a.
  • magnets 46b are positioned on first gear 38b and second gear 40b in an alternating, north-south manner, such that each magnet 46b has an opposite polarity from any adjacent magnet 46b. Arranging magnets 46a and magnets 46b in an alternating north-south manner increases the overall locking power of magnets 46a and increases the ease of assembly.
  • Gear set 26a is disposed on an opposite side of barrier plate 24 from gear set 26b. However, gear set 26a is magnetically coupled to gear set 26b by magnets 46a and magnets 46b. Due to the magnetic coupling of gear set 26a and gear set 26b, barrier plate 24 is preferably made from a non-ferrous material, such as thermoplastic, aluminum, or any other suitable material. Magnets 46a extend about first gear 38a and second gear 40a in an alternating, north-south manner. Arranging magnets 46a in an alternating north-south manner increases the overall locking power of magnets 46a and increases the ease of assembly.
  • Magnets 46a are attracted to magnets 46b such that first gear 38a is magnetically coupled to first gear 38b and second gear 40a is magnetically coupled to second gear 40b, such that gear set 26a and gear set 26b rotate synchronously. As such, the rotation of either second gear 40a or second gear 40b will simultaneously drive the rotation of the other of second gear 40a and second gear 40b. While magnets 46a are described as extending through both first gear 38a and second gear 40a, it is understood that magnets 46a may extend through only one of first gear 38a or second gear 40a. In such a case, magnets 46b may also extend through one of first gear 38b or second gear 40b.
  • magnets 46a may extend through only first gear 38a such that first gear 38a and first gear 38b are magnetically coupled. Even where second gear 40a and second gear 40b do not include magnets, second gear 40a and second gear 40b maintain synchronous rotation due to second gear 40a meshing with first gear 38a and second gear 40b meshing with first gear 38b.
  • the magnetic coupling of gear set 26a and gear set 26b ensures synchronous rotation of both gear set 26a and gear set 26b, thereby ensuring that a set ratio of the first component material to the second component material is provided downstream by passive flow synchronizer 16.
  • gear set 26a and gear set 26b eliminates over-pressure and vacuum concerns, because gear set 26a may decouple from gear set 26b where the difference between the first pressure differential and the second pressure differential is too high.
  • the magnetic coupling prevents any damage to either gear set 26a or gear set 26b, as gear set 26a and gear set 26b are not mechanically coupled.
  • a set volume of the first component material is provided to outlet 36a for each rotation of first gear 38a and second gear 40a.
  • a set volume of the second component material is provided to outlet 36b for each rotation of first gear 38b and second gear 40b.
  • the first pressure differential drives the first component material through gear set 26a
  • the second pressure differential drives the second component material through gear set 26b.
  • Coupling gear set 26a and gear set 26b for synchronous rotation ensures a known, steady ratio of the first component material to the second component material is provided by passive flow synchronizer 16.
  • Gear set 26a provides a set volume of the first component material to outlet 36a for each rotation of first gear 38a and second gear 40a
  • gear set 26b provides a set volume of the second component material to outlet 36b for each rotation of first gear 38b and second gear 40b.
  • coupling gear set 26a and gear set 26b for synchronous rotation ensures that a set ratio is provided downstream. Where gear set 26a is not coupled to gear set 26b, gear sets 26a and 26b may rotate at different rates where the first pressure differential differs from the second pressure differential.
  • Rotating gear set 26a at a different rate than gear set 26b causes an unknown ratio of the first component material to the second component material at material applicator 20, thus leading to undesirable properties in the resultant material.
  • gear set 26a is magnetically coupled to gear set 26b such that the rotation of one of gear set 26a or gear set 26b causes synchronous rotation of the other of gear set 26a and gear set 26b.
  • Passive flow synchronizer 16 may meter the first component material and the second component material such that any desired ratio of the first component material to the second component material is provided downstream.
  • a 1 : 1 ratio may be provided by having first gear 38a and second gear 40a be identical to first gear 38a and second gear 40a, thereby ensuring that the same volume of the component material is provided for each rotation.
  • a 2:1 ratio may be provided by utilizing a gear set 26a where first gear 38a and second gear 40a have a gear height twice that of first gear 38b and second gear 40b. The greater height of first gear 38a and second gear 40a provides more volume between the first gear teeth and the second gear teeth, and thus a greater volume of the first component material is provided downstream for each rotation of first gear 38a and second gear 40a. Any desired ratio of the first component material to the second component material may be achieved by varying the gear configuration.
  • Component meter housing 22a includes inlet 34a and outlet 36a.
  • Component meter housing 22b includes inlet 34b and outlet 36b.
  • Component meter housing 22a is attached to component meter housing 22b, with barrier plate 24 disposed between and separating component meter housing 22a and component meter housing 22b.
  • Gear set 26a is disposed within component meter housing 22a between inlet 34a and outlet 36a.
  • Gear set 26b is disposed within component meter housing 22b between inlet 34b and outlet 36b on an opposite side of barrier plate 24 from gear set 26a.
  • Static seal 28a is disposed between component meter housing 22a and barrier plate 24.
  • Static seal 28b is disposed between component meter housing 22b and barrier plate 24.
  • a first downstream pressure, at outlet 36a, and a second downstream pressure, at outlet 36b drop.
  • the drop in the first downstream pressure and the second downstream pressure creates a first pressure differential between inlet 34a and outlet 36a and a second pressure differential between inlet 34b and outlet 36b.
  • the first pressure differential drives the first component material into component meter housing 22a through inlet 34a, through gear set 26a, and downstream through outlet 36a, as shown by flow lines Fl.
  • the second pressure differential simultaneously drives the second component material into component meter housing 22b through inlet 34b, through gear set 26b, and downstream through outlet 36b, as shown by flow lines F2.
  • gear set 26a is coupled to gear set 26b such that gear set 26a and gear set 26b rotate synchronously, regardless of a difference between the first pressure differential and the second pressure differential.
  • passive flow synchronizer 16 synchronizes the flow of the first component material and the second component material without requiring extensive adjustments to the first upstream pressure and the second upstream pressure.
  • aligning mechanism 44a and aligning mechanism 44b maintain the coupling of gear set 26a and gear set 26b.
  • gear set 26a and gear set 26b meter the flow of the first component material and the second component material to provide a set ratio of the first component material to the second component material to a downstream applicator.
  • Coupling gear set 26a and gear set 26b for synchronous rotation provides significant advantages.
  • Coupling gear set 26a and gear set 26b ensures a set ratio of the first component material to the second component material is provided to material applicator 20. Because the ratio is set, regardless of the difference between the first pressure differential and the second pressure differential, passive flow synchronizer 16 eliminates the needs to take samples of the first component material and the second component material with special nozzles into separate containers to verify the mix ratio. As such, passive flow synchronizer 16 reduces waste and makes application of the resultant material more efficient, as the time required to verify the mix ratio is eliminated.
  • aligning mechanisms 44a and 44b are magnets, the use of external or internal dynamic seals is eliminated, thereby reducing the complexity of the system.
  • magnetic coupling eliminates over-pressure and vacuum concerns, as the magnets will decouple where the difference between the first pressure and the second pressure is undesirably high.
  • FIG. 3 is a cross-sectional view of passive flow synchronizer 16'.
  • Passive flow synchronizer 16' differs from passive flow synchronizer 16 in that passive flow synchronizer 16' includes mechanical coupling while passive flow synchronizer 16 includes magnetic coupling.
  • Passive flow synchronizer 16' includes component meter housing 22a', component meter housing 22b', barrier plate 24', gear set 26a', gear set 26b', static seal 28a', static seal 28b', fasteners 32', and aligning mechanism 44'.
  • Gear set 26a' includes first gear 38a', second gear 40a', and bearing 42a'.
  • Gear set 26b' includes first gear 38b', second gear 40b', and bearing 42b'.
  • Barrier plate 24' is disposed between component meter housing 22a' and component meter housing 22b'. Fasteners 32' extend through component meter housing 22a', component meter housing 22b', and barrier plate 24' to connect component meter housing 22a', component meter housing 22b', and barrier plate 24' together.
  • Gear set 26a' is disposed between component meter housing 22a' and barrier plate 24' and is configured to meter a flow of a first component material through component meter housing 22a'.
  • Gear set 26b' is disposed between component meter housing 22b' and barrier plate 24' and is configured to meter a flow of a second component material through component meter housing 22b'.
  • Bearing 42a' extends into barrier plate 24' and second gear 40a'.
  • bearing 42b' extends into barrier plate 24' and second gear 40b'.
  • Aligning mechanism 44' extends through barrier plate 24' between first gear 38a' and second gear 40a' and connects first gear 38a' and first gear 38b'.
  • the first component material is driven through component meter housing 22a' by a first upstream pressure.
  • the second component material is driven through component meter housing 22b' by a second upstream pressure.
  • the first component material flows through gear set 26a' and is metered by first gear 38a' and second gear 40a' such that a set first volume of the first component material is provided downstream for each rotation of first gear 38a' and second gear 40a'.
  • the second component material is metered by gear set 26b', such that a set second volume of the second component material is provided downstream for each rotation of first gear 38b' and second gear 40b'.
  • Aligning mechanism 44' connects first gear 38a' and first gear 38b' such that the rotation of one of first gear 38a' and first gear 38b' simultaneously drives the other of first gear 38a' and first gear 38b'. In this way, aligning mechanism 44' ensures that gear set 26a and gear set 26b will maintain the same rotational rate, thereby ensuring that a constant ratio of the first component material to the second component material is provided downstream by passive flow synchronizer 16'.

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Abstract

A passive flow synchronizer maintains a set ratio between a first flow and a second flow. A first component material flows through a first flow path, and a second component material flows through a second flow path that runs parallel to and is separate from the first flow path. A first gear set is disposed in the first flow path and meters the flow of the first fluid through the first flow path. A second gear set is disposed in the second flow path and meters the flow of the second fluid through the second flow path. The first gear set is linked to the second gear set such that both the first gear set and the second gear set rotate synchronously.

Description

PASSIVE FLOW SYNCHRONIZER
CROSS-REFERENCE TO RELATED APPLICATION This application claims priority to U.S. Provisional Application No. 62/197,350 filed on July 27, 2015, and entitled "PASSIVE VOLUMETRIC FLUID FLOW SYNCHRONIZER," the disclosure of which is incorporated by reference in its entirety.
BACKGROUND
This disclosure relates generally to multiple component applicators, and more particularly to a passive component synchronizer for a multiple component applicator.
Multiple component applicators apply a resultant material, such as a foam insulation, that is formed from multiple component materials. The component materials react with each other in a short time period, so the component materials are stored separately until application. The component materials are mixed in a mixing manifold, which is generally attached to the applicator gun, immediately prior to application of the resultant material. To ensure that the quality of the resultant material, the component materials must be mixed at a constant predetermined ratio. To ensure that the correct ratio is being provided to the mixing manifold, the user takes samples of each component material and compares the weights of multiple samples to determine a ratio. Typically, a ratio between the first component material and the second component material is determined by taking a sample flow of the first component material and measuring the sample flow against a sample flow of the second component material. If the ratio is incorrect, then the pressure in the material tanks is adjusted and additional samples are taken until the desired ratio is achieved. Measuring the ratio samples by hand wastes component materials, creates chemical waste, and is time consuming.
SUMMARY
According to an aspect of the disclosure, a passive fluid flow synchronizer includes a first component meter housing, a second component meter housing, a barrier plate disposed between the first component meter housing and the second component meter housing, a first gear set, and a second gear set. The first component meter housing has a first inlet, a first outlet, and a first flow path extending between the first inlet and the first outlet. The second component meter housing has a second inlet, a second outlet, and a second flow path extending between the second inlet and the second outlet. The barrier plate is configured to separate the first flow path and the second flow path. The first gear set is disposed within the first flow path between the first inlet and the first outlet. The second gear set is disposed within the second flow path between the second inlet and the second outlet. The first gear set is coupled to the second gear set such that the first gear set and the second gear set rotate synchronously to provide a set volumetric ratio of a first component material to a second component material through the first outlet and the second outlet.
According to another aspect of the disclosure, a multiple component dispenser includes a first material tank, a second material tank, a passive fluid flow synchronizer connected to the first material tank with a first supply hose and connected to the second material tank with a second supply hose, a first nozzle hose, a second nozzle hose, and a material applicator. The passive flow synchronizer includes a first component meter housing having a first inlet, a first outlet, and a first flow path extending between the first inlet and the first outlet, a second component meter housing having a second inlet, a second outlet, and a second flow path extending between the second inlet and the second outlet, a barrier plate disposed between the first component meter housing and the second component meter housing and isolating the first flow path from the second flow path, a first gear set disposed within the first flow path between the first inlet and the first outlet, and a second gear set disposed within the second flow path between the second inlet and the second outlet. The first supply hose is attached to the first inlet and the second supply hose is attached to the second inlet. The first nozzle hose is connected to the first outlet and configured to receive the first material from the first flow path. The second nozzle hose is connected to the first outlet and configured to receive the second material from the second flow path. The first gear set is configured to meter the flow of a first material through the first flow path. The second gear set is configured to meter the flow of a second material through the second flow path. The first gear set is coupled to the second gear set such that the first gear set and the second gear set rotate synchronously. The material applicator is configured to receive the first material from the first nozzle hose and the second material from the second nozzle hose.
According to yet another aspect of the disclosure, a method of synchronizing multiple flows includes coupling a first gear set disposed on a first side of a barrier plate to a second gear set disposed on a second side of the barrier plate such that the first gear set and the second gear set rotate synchronously, flowing a first material through a first flow path and the first gear set, flowing a second material through a second flow path and the second gear set, and providing a set volumetric ratio of the first material to the second material by the synchronous rotation of the first gear set and the second gear set.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of a multiple component dispensing system. FIG. 2A is an exploded view of a passive flow synchronizer.
FIG. 2B is a top cross-sectional view of a passive flow synchronizer.
FIG. 2C is an isometric cross-sectional view of a passive flow synchronizer.
FIG. 2D is a side elevation cross-sectional view of a passive flow synchronizer.
FIG. 3 is a cross-sectional view of a passive flow synchronizer.
DETAILED DESCRIPTION FIG. 1 is a schematic view of multiple component dispensing system 10. Multiple component dispensing system 10 includes material tank 12a, material tank 12b, supply hose 14a, supply hose 14b, passive flow synchronizer 16, nozzle hose 18a, nozzle hose 18b, and material applicator 20.
Supply hose 14a extends between material tank 12a and passive flow synchronizer 16. Supply hose 14a provides a first component material from material tank 12a to passive flow synchronizer 16. Similarly, supply hose 14b extends between material tank 12b and passive flow synchronizer 16. Supply hose 14b provides a second component material from material tank 12b to passive flow synchronizer 16. Passive flow synchronizer 16 receives both the first component material and the second material and provides the first material and the second material downstream. Nozzle hose 18a is connected to passive flow synchronizer 16 and receives the first component material from passive flow synchronizer 16. Nozzle hose 18a provides the first component material to material applicator 20. Nozzle hose 18b is also connected to passive flow synchronizer 16, and nozzle hose 18b receives the second component material from passive flow synchronizer 16 and provides the second component material to material applicator 20.
Material tank 12a stores the first component material under pressure and material tank 12b stores the second component material under pressure. The first component material and the second component material may be components in a two- component, quick-cure polyurethane foam, whereby the first component material reacts with the second component material to create the polyurethane foam. The first component material is stored separate from the second component material until the time of application, as the first component material and the second component material react quickly to form the resultant foam. As such, the first component material is maintained separate from the second component material until application of the resultant material. To ensure that the resultant material has the desired properties, the first component material and the second component material are combined at a set ratio.
Triggering material applicator 20 causes the pressure within nozzle hoses 18a and 18b to drop. The pressure within material tank 12a then drives the first component material downstream through supply hose 14a, passive flow synchronizer 16, and nozzle hose 18a. Similarly, the pressure within material tank 12b drives the second component material downstream through supply hose 14b, passive flow synchronizer 16, and nozzle hose 18b. Passive flow synchronizer 16 meters the flow of the first component material and the second component material such that the first component material and the second component material are provided downstream from passive flow synchronizer 16 at a set ratio. The first component material flows downstream from passive flow synchronizer 16 through nozzle hose 18a and to material applicator 20. The second component material flows downstream from passive flow synchronizer 16 through nozzle hose 18b and to material applicator 20. The first component material and the second component material are combined at material applicator 20 and applied to a desired surface.
Passive flow synchronizer 16 ensures that the ratio of the first component material to the second component material provided to material applicator 20 remains constant. By ensuring a constant ratio of the first component material to the second component material at material applicator 20, passive flow synchronizer 16 reduces chemical waste, ensures that the resultant material has the desired properties, and reduces the time requirement needed to prepare multiple component dispensing system 10. Passive flow synchronizer 16 ensures a constant ratio between the first component material and the second component material, thereby eliminating the need to sample the first component material and the second component material. Eliminating sampling reduces chemical waste and reduces the time necessary to set up multiple component dispensing system, thereby saving time and money.
FIG. 2A is an exploded view of passive flow synchronizer 16. FIG. 2B is a top cross-sectional view of passive flow synchronizer 16. FIG. 2C is an isometric cross-sectional view of passive flow synchronizer 16. FIG. 2D is a side-elevation cross- sectional view of passive flow synchronizer 16. FIGS. 2A-2D are substantially similar and will be discussed together. Passive flow synchronizer 16 includes component meter housing 22a, component meter housing 22b, barrier plate 24, gear set 26a, gear set 26b, static seal 28a, static seal 28b, aligning pins 30, and fasteners 32. Component meter housing 22a includes inlet 34a and outlet 36a. Component meter housing 22b includes inlet 34b and outlet 36b. Gear set 26a includes first gear 38a, second gear 40a, bearings 42a, and aligning mechanism 44a. Similarly, gear set 26b includes first gear 38b, second gear 40b, bearings 42b, and aligning mechanism 44b. Aligning mechanism 44a includes magnets 46a. Aligning mechanism 44b includes magnets 46b. First gear 38a includes first gear teeth 48a, and first gear 38b includes first gear teeth 48b. Second gear 40a includes second gear teeth 50a, and second gear 40b includes second gear teeth 50b.
Barrier plate 24 is disposed between component meter housing 22a and component meter housing 22b. Fasteners 32 extend through component meter housing 22a, barrier plate 24, and component meter housing 22b to secure component meter housing 22a, barrier plate 24, and component meter housing 22b together. Aligning pins 30 are configured to extend through barrier plate 24 and into component meter housing 22a and component meter housing 22b. Aligning pins 30 ensure that component meter housing 22a, barrier plate 24, and component meter housing 22b are properly aligned. Static seal 28a is disposed between barrier plate 24 and component meter housing 22a and is configured to prevent a fluid flowing through component meter housing 22a from leaking between component meter housing 22a and barrier plate 24. Similarly, static seal 28b is disposed between barrier plate 24 and component meter housing 22b and is configured to prevent a fluid flowing through component meter housing 22b from leaking between component meter housing 22b and barrier plate 24.
Gear set 26a is disposed within component meter housing 22a and adjacent barrier plate 24. First gear 38a is intermeshed with second gear 40a such that first gear 38a and second gear 40a rotate synchronously, in opposite directions of rotation. The meshing of first gear 38a and second gear 40a prevents the first component material from flowing between first gear 38a and second gear 40a, such that the first component material must instead flow around first gear 38a and second gear 40a, as shown by flow lines Fl in FIG. 2D. Thrust bearings 42a are disposed between barrier plate 24 and first gear 38a and second gear 40a. Similar to gear set 26a, gear set 26b is disposed within component meter housing 22b and adjacent barrier plate 24. First gear 38b is intermeshed with second gear 40b such that first gear 38b and second gear 40b rotate synchronously, in opposite directions of rotation. The meshing of first gear 38b and second gear 40b prevents the second component material from flowing between first gear 38b and second gear 40b, and as such, the second component material must instead flow around first gear 38b and second gear 40b, similar to the first component material flowing around first gear 38a and second gear 40a. Thrust bearings 42b are disposed between barrier plate and first gear 38b and second gear 40b. Bearings 42a and bearings 42b may be of any suitable configuration for supporting gear set 26a and gear set 26b on barrier plate 24. For example, bearings 42a and bearings 42b may be ball-type thrust bearings, needle-type thrust bearings, a carbine pin pressed through barrier plate 24, carbide shell bearings, or any other suitable bearing.
Aligning mechanism 44a is disposed on first gear 38a and second gear
40a. Aligning mechanism 44b is disposed on first gear 38b and second gear 40b. Aligning mechanism 44a includes magnets 46a that extend through first gear 38a and second gear 40a. Magnets 46a are disposed on first gear 38a in an alternating north-south manner, best seen in FIG. 2B. Magnets 46a are also disposed on second gear 40a in an alternating north-south manner, best seen in FIG. 2B. Similarly, aligning mechanism 44b is disposed on first gear 38b and second gear 40b. Aligning mechanism 44b includes magnets 46b that extend through first gear 38b and second gear 40b. Similar to magnets 46a, magnets 46b are disposed on first gear 38b in an alternating north-south manner. Magnets 46b are also disposed on second gear 40b in an alternating north-south manner.
Aligning mechanism 44a is configured to couple to aligning mechanism
44b such that gear set 26a is coupled to gear set 26b. With first gear 38a coupled to first gear 38b and with second gear 40a coupled to second gear 40b, gear set 26a and gear set 26b are coupled for synchronous rotation. Gear set 26a is coupled to gear set 26b by aligning mechanisms 44a and 44b for synchronous rotation of gear set 26a and gear set 26b. Magnets 46a and magnets 46b are attracted to each other such that first gear 38a and first gear 38b rotate synchronously. As such, the rotation of either first gear 38a or first gear 38b will simultaneously drive the rotation of the other of first gear 38a and first gear 38b. Utilizing an equal number of magnets 46a as first gear teeth 48a allows gear set 26a to line up with gear set 26b without requiring the gears to be clocked to a specific gear tooth. It is understood, however, that magnets 46a may be arranged on first gear 38a and second gear 40a in any suitable manner for linking gear set 26a and gear set 26b; for example, magnets 46a may include multiple, round neodymium magnets, radial magnets, or any other suitable configuration. Where aligning mechanism 44a and aligning mechanism 44b include magnets 46a and 46b, barrier plate 24 is preferably made of a non-ferrous material, such as plastic or aluminum, suitable for providing a barrier between a first component material flowing through component meter housing 22a and a second component material flowing through component meter housing 22b.
During operation, passive flow synchronizer 16 is configured to meter the first component material and the second component material such that a fixed ratio of the first component material to the second component material is provided downstream. The first component material is provided to component meter housing 22a through supply hose 14a (shown in FIG. 1) and inlet 34a. Simultaneously, the second component material is provided to component meter housing 22b through supply hose 14b (shown in FIG. 1) and inlet 34b. The first component material and the second component material are stored under pressure in material tank 12a (shown in FIG. 1) and material tank 12b (shown in FIG. 1), respectively. To mix and apply the first component material and the second component material, an applicator is triggered. Triggering the applicator causes the pressure in nozzle hose 18a and nozzle hose 18b to drop, creating a pressure differential between inlet 34a and outlet 36a, and between inlet 34b and outlet 36b. The storage pressure within material tank 12a causes the first component material to flow downstream through passive flow synchronizer 16 and to the applicator, and the storage pressure within material tank 12b causes the second component material to flow downstream through passive flow synchronizer 16 and to applicator 20. Aligning mechanism 44a and aligning mechanism 44b couple gear set 26a to gear set 26b such that gear set 26a and gear set 26b rotate synchronously and thus meter the first component material and the second component material at the same rate. As such, even where a difference exists between the first pressure differential and the second pressure differential, passive flow synchronizer 16 ensures that a ratio of the first component material to the second component material provided downstream through outlets 36a and 36b is constant.
In FIG. 2B, a flow of a component material is shown through component meter housing 22a and gear set 26a. As discussed above, gear set 26a and gear set 26b meter fluid is substantially the same manner, and as such, while the discussion of FIG. 3A is directed towards gear set 26a, it is understood that the discussion of gear set 26a is equally applicable to gear set 26b. Component meter housing 22a includes inlet 34a and outlet 36a. Gear set 26a is disposed within component meter housing 22a between inlet 34a and outlet 36a. Gear set 26a includes first gear 38a, second gear 40a, and magnets 46a. First gear 38a includes first gear teeth 48a, and second gear 40a includes second gear teeth 50a.
First gear teeth 48a are intermeshed with second gear teeth 50a such that first gear 38a and second gear 40a rotate synchronously. The component material enters component meter housing 22a through inlet 34a, is metered by gear set 26a, and exits component meter housing 22a through outlet 36a. An upstream pressure drives the component material through component meter housing 22a. When a material applicator 20 (shown in FIG. 1) is triggered, the downstream pressure drops, and the upstream pressure drives the component material through component meter housing 22a. Magnets 46a extend though first gear 38a and second gear 40a. Preferably, first gear 38a includes the same number of magnets 46a as first gear teeth 48a, and second gear 40a includes the same number of magnets 46a as second gear teeth 50a.
Due to the meshing of first gear teeth 48a and second gear teeth 50a, the component material cannot flow between first gear 38a and second gear 40a. Instead, the component material causes first gear 38a to rotate in direction Rl and second gear 40a to simultaneously rotate in direction R2. As first gear 38a and second gear 40a rotate, the component material is captured in a first volume defined between adjacent first gear teeth 48a and in a second volume defined between adjacent second gear teeth 50a. The component material fills the first volume and the second volume proximate inlet 34a. The component material is retained in the first volume and the second volume as first gear 38a and second gear 40a rotate. The component material exits the first volume and the second volume proximate outlet 36a and continues downstream through outlet 36a. The first volume and the second volume are known, and as such, a set, known volume of component material is provided to outlet 36a for each rotation of first gear 38a and second gear 40a. The greater the pressure differential, the greater the rate of rotation for both first gear 38a and second gear 40a. Gear set 26a provides a set, known volume of the component material, however, regardless of the rate of rotation.
In FIG. 2C, a connection of gear set 26a and gear set 26b is shown. Gear set 26a is disposed within component meter housing 22a between inlet 34a and outlet 36a. Gear set 26b is disposed within component meter housing 22b between inlet 34b and outlet 36b. Barrier plate 24 is disposed between and separates gear set 26a and gear set 26b, and barrier plate 24 prevents the first component material, flowing through component meter housing 22a, from interacting with the second component material, flowing through component meter housing 22b, as the first component material and the second component material pass through passive flow synchronizer 16. Aligning mechanism 44a extends through gear set 26a, and aligning mechanism 44b extends through gear set 26b. More particularly, magnets 46a extend through first gear 38a and second gear 40a, and magnets 46b extend through first gear 38b and second gear 40b.
Aligning mechanism 44a is coupled to aligning mechanism 44b, such that gear set 26a is coupled to gear set 26b for synchronous rotation. Magnets 46a are positioned on first gear 38a and second gear 40a in an alternating, north-south manner. As such, each magnet 46a extending through first gear 38a and second gear 40a preferably has an opposite polarity from any adjacent magnet 46a. Similarly, magnets 46b are positioned on first gear 38b and second gear 40b in an alternating, north-south manner, such that each magnet 46b has an opposite polarity from any adjacent magnet 46b. Arranging magnets 46a and magnets 46b in an alternating north-south manner increases the overall locking power of magnets 46a and increases the ease of assembly.
Gear set 26a is disposed on an opposite side of barrier plate 24 from gear set 26b. However, gear set 26a is magnetically coupled to gear set 26b by magnets 46a and magnets 46b. Due to the magnetic coupling of gear set 26a and gear set 26b, barrier plate 24 is preferably made from a non-ferrous material, such as thermoplastic, aluminum, or any other suitable material. Magnets 46a extend about first gear 38a and second gear 40a in an alternating, north-south manner. Arranging magnets 46a in an alternating north-south manner increases the overall locking power of magnets 46a and increases the ease of assembly.
Magnets 46a are attracted to magnets 46b such that first gear 38a is magnetically coupled to first gear 38b and second gear 40a is magnetically coupled to second gear 40b, such that gear set 26a and gear set 26b rotate synchronously. As such, the rotation of either second gear 40a or second gear 40b will simultaneously drive the rotation of the other of second gear 40a and second gear 40b. While magnets 46a are described as extending through both first gear 38a and second gear 40a, it is understood that magnets 46a may extend through only one of first gear 38a or second gear 40a. In such a case, magnets 46b may also extend through one of first gear 38b or second gear 40b. For example, where magnets 46a extend through only first gear 38a, magnets 46b may extend through only first gear 38b such that first gear 38a and first gear 38b are magnetically coupled. Even where second gear 40a and second gear 40b do not include magnets, second gear 40a and second gear 40b maintain synchronous rotation due to second gear 40a meshing with first gear 38a and second gear 40b meshing with first gear 38b. The magnetic coupling of gear set 26a and gear set 26b ensures synchronous rotation of both gear set 26a and gear set 26b, thereby ensuring that a set ratio of the first component material to the second component material is provided downstream by passive flow synchronizer 16. In addition, magnetically coupling gear set 26a and gear set 26b eliminates over-pressure and vacuum concerns, because gear set 26a may decouple from gear set 26b where the difference between the first pressure differential and the second pressure differential is too high. The magnetic coupling prevents any damage to either gear set 26a or gear set 26b, as gear set 26a and gear set 26b are not mechanically coupled.
As discussed above, a set volume of the first component material is provided to outlet 36a for each rotation of first gear 38a and second gear 40a. A set volume of the second component material is provided to outlet 36b for each rotation of first gear 38b and second gear 40b. The first pressure differential drives the first component material through gear set 26a, and the second pressure differential drives the second component material through gear set 26b.
Coupling gear set 26a and gear set 26b for synchronous rotation ensures a known, steady ratio of the first component material to the second component material is provided by passive flow synchronizer 16. Gear set 26a provides a set volume of the first component material to outlet 36a for each rotation of first gear 38a and second gear 40a, and gear set 26b provides a set volume of the second component material to outlet 36b for each rotation of first gear 38b and second gear 40b. As such, coupling gear set 26a and gear set 26b for synchronous rotation ensures that a set ratio is provided downstream. Where gear set 26a is not coupled to gear set 26b, gear sets 26a and 26b may rotate at different rates where the first pressure differential differs from the second pressure differential. Rotating gear set 26a at a different rate than gear set 26b causes an unknown ratio of the first component material to the second component material at material applicator 20, thus leading to undesirable properties in the resultant material. However, gear set 26a is magnetically coupled to gear set 26b such that the rotation of one of gear set 26a or gear set 26b causes synchronous rotation of the other of gear set 26a and gear set 26b. By ensuring that gear set 26a and gear set 26b rotate synchronously, a set ratio of the first component material to the second component material is provided.
Passive flow synchronizer 16 may meter the first component material and the second component material such that any desired ratio of the first component material to the second component material is provided downstream. For example, a 1 : 1 ratio may be provided by having first gear 38a and second gear 40a be identical to first gear 38a and second gear 40a, thereby ensuring that the same volume of the component material is provided for each rotation. A 2:1 ratio may be provided by utilizing a gear set 26a where first gear 38a and second gear 40a have a gear height twice that of first gear 38b and second gear 40b. The greater height of first gear 38a and second gear 40a provides more volume between the first gear teeth and the second gear teeth, and thus a greater volume of the first component material is provided downstream for each rotation of first gear 38a and second gear 40a. Any desired ratio of the first component material to the second component material may be achieved by varying the gear configuration.
In FIG. 2D, a flow of a first component material and of a second component material through passive flow synchronizer 16. Component meter housing 22a includes inlet 34a and outlet 36a. Component meter housing 22b includes inlet 34b and outlet 36b. Component meter housing 22a is attached to component meter housing 22b, with barrier plate 24 disposed between and separating component meter housing 22a and component meter housing 22b. Gear set 26a is disposed within component meter housing 22a between inlet 34a and outlet 36a. Gear set 26b is disposed within component meter housing 22b between inlet 34b and outlet 36b on an opposite side of barrier plate 24 from gear set 26a. Static seal 28a is disposed between component meter housing 22a and barrier plate 24. Static seal 28b is disposed between component meter housing 22b and barrier plate 24.
When a downstream material applicator is triggered, a first downstream pressure, at outlet 36a, and a second downstream pressure, at outlet 36b, drop. The drop in the first downstream pressure and the second downstream pressure creates a first pressure differential between inlet 34a and outlet 36a and a second pressure differential between inlet 34b and outlet 36b. The first pressure differential drives the first component material into component meter housing 22a through inlet 34a, through gear set 26a, and downstream through outlet 36a, as shown by flow lines Fl. The second pressure differential simultaneously drives the second component material into component meter housing 22b through inlet 34b, through gear set 26b, and downstream through outlet 36b, as shown by flow lines F2.
As discussed above, gear set 26a is coupled to gear set 26b such that gear set 26a and gear set 26b rotate synchronously, regardless of a difference between the first pressure differential and the second pressure differential. As such, passive flow synchronizer 16, synchronizes the flow of the first component material and the second component material without requiring extensive adjustments to the first upstream pressure and the second upstream pressure. Instead, regardless of the difference between the first pressure differential and the second pressure differential, aligning mechanism 44a and aligning mechanism 44b maintain the coupling of gear set 26a and gear set 26b. As such, gear set 26a and gear set 26b meter the flow of the first component material and the second component material to provide a set ratio of the first component material to the second component material to a downstream applicator.
Coupling gear set 26a and gear set 26b for synchronous rotation provides significant advantages. Coupling gear set 26a and gear set 26b ensures a set ratio of the first component material to the second component material is provided to material applicator 20. Because the ratio is set, regardless of the difference between the first pressure differential and the second pressure differential, passive flow synchronizer 16 eliminates the needs to take samples of the first component material and the second component material with special nozzles into separate containers to verify the mix ratio. As such, passive flow synchronizer 16 reduces waste and makes application of the resultant material more efficient, as the time required to verify the mix ratio is eliminated. In addition, where aligning mechanisms 44a and 44b are magnets, the use of external or internal dynamic seals is eliminated, thereby reducing the complexity of the system. Furthermore, magnetic coupling eliminates over-pressure and vacuum concerns, as the magnets will decouple where the difference between the first pressure and the second pressure is undesirably high.
FIG. 3 is a cross-sectional view of passive flow synchronizer 16'. Passive flow synchronizer 16' differs from passive flow synchronizer 16 in that passive flow synchronizer 16' includes mechanical coupling while passive flow synchronizer 16 includes magnetic coupling. Passive flow synchronizer 16' includes component meter housing 22a', component meter housing 22b', barrier plate 24', gear set 26a', gear set 26b', static seal 28a', static seal 28b', fasteners 32', and aligning mechanism 44'. Gear set 26a' includes first gear 38a', second gear 40a', and bearing 42a'. Gear set 26b' includes first gear 38b', second gear 40b', and bearing 42b'.
Barrier plate 24' is disposed between component meter housing 22a' and component meter housing 22b'. Fasteners 32' extend through component meter housing 22a', component meter housing 22b', and barrier plate 24' to connect component meter housing 22a', component meter housing 22b', and barrier plate 24' together. Gear set 26a' is disposed between component meter housing 22a' and barrier plate 24' and is configured to meter a flow of a first component material through component meter housing 22a'. Gear set 26b' is disposed between component meter housing 22b' and barrier plate 24' and is configured to meter a flow of a second component material through component meter housing 22b'. Bearing 42a' extends into barrier plate 24' and second gear 40a'. Similarly, bearing 42b' extends into barrier plate 24' and second gear 40b'. Aligning mechanism 44' extends through barrier plate 24' between first gear 38a' and second gear 40a' and connects first gear 38a' and first gear 38b'.
During operation, the first component material is driven through component meter housing 22a' by a first upstream pressure. Similarly, the second component material is driven through component meter housing 22b' by a second upstream pressure. The first component material flows through gear set 26a' and is metered by first gear 38a' and second gear 40a' such that a set first volume of the first component material is provided downstream for each rotation of first gear 38a' and second gear 40a'. Similarly, the second component material is metered by gear set 26b', such that a set second volume of the second component material is provided downstream for each rotation of first gear 38b' and second gear 40b'.
Aligning mechanism 44' connects first gear 38a' and first gear 38b' such that the rotation of one of first gear 38a' and first gear 38b' simultaneously drives the other of first gear 38a' and first gear 38b'. In this way, aligning mechanism 44' ensures that gear set 26a and gear set 26b will maintain the same rotational rate, thereby ensuring that a constant ratio of the first component material to the second component material is provided downstream by passive flow synchronizer 16'.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims

CLAIMS:
1. A passive fluid flow synchronizer includes:
a first component meter housing having a first inlet, a first outlet, and a first flow path extending between the first inlet and the first outlet; a second component meter housing having a second inlet, a second outlet, and a second flow path extending between the second inlet and the second outlet;
a barrier plate disposed between the first component meter housing and the second component meter housing and configured to separate the first flow path and the second flow path;
a first gear set disposed within the first flow path between the first inlet and the first outlet;
a second gear set disposed within the second flow path between the second inlet and the second outlet;
wherein the first gear set is coupled to the second gear set such that the first gear set and the second gear set rotate synchronously to provide a set volumetric ratio of a first component material to a second component material through the first outlet and the second outlet.
2. The passive fluid flow synchronizer of claim 1, and wherein:
the first gear set includes a first gear meshed with a second gear, wherein the first gear and the second gear are disposed adjacent a first side of the barrier plate; and
the second gear set includes a third gear meshed with a fourth gear, wherein the third gear and the fourth gear are disposed adjacent a second side of the barrier plate.
3. The passive fluid flow synchronizer of claim 2, and further comprising:
an aligning mechanism coupling the first gear to the third gear and coupling the second gear to the fourth gear.
4. The passive fluid flow synchronizer of claim 3, wherein the aligning mechanism comprises a plurality of magnets.
5. The passive fluid flow synchronizer of claim 4, wherein the plurality of magnets comprises: a first magnetic ring attached to the first gear and disposed about an axis of rotation of the first gear;
a second magnetic ring attached to the second gear and disposed about an axis of rotation of the second gear;
a third magnetic ring attached to the third gear and disposed about an axis of rotation of the third gear;
a fourth magnetic ring attached to the fourth gear and disposed about an axis of rotation of the fourth gear;
wherein the first magnetic ring is attracted to the third magnetic ring such that the first gear and the third gear rotate synchronously; and wherein the second magnetic ring is attracted to the fourth magnetic ring such that the second gear and the fourth gear rotate synchronously.
6. The passive fluid flow synchronizer of claim 5, wherein the first magnetic ring, the second magnetic ring, the third magnetic ring, and the fourth magnetic ring each comprise an even number of magnets.
7. The passive fluid flow synchronizer of claim 6, wherein the first magnetic ring and the third magnetic ring comprise the same number of magnets, and wherein the second magnetic ring and the fourth magnetic ring comprise the same number of magnets.
8. The passive fluid flow synchronizer of claim 2, wherein the first gear and the second gear are identical, and wherein the third gear and the fourth gear are identical.
9. The passive fluid flow synchronizer of claim 8, wherein the first gear and the second gear each have a first height, wherein the third gear and the fourth gear each have a second height, and wherein the first height is different from the second height.
10. The passive fluid flow synchronizer of claim 3, wherein the aligning mechanism comprises a first pin extending through the barrier plate and coupling the first gear to the third gear, and a second pin extending through the barrier plate and coupling the second gear to the fourth gear.
11. A multiple component dispenser comprising:
a first material tank;
a second material tank;
a passive fluid flow synchronizer connected to the first material tank with a first supply hose and connected to the second material tank with a second supply hose, wherein the passive fluid flow synchronizer comprises: a first component meter housing having a first inlet, a first outlet, and a first flow path extending between the first inlet and the first outlet, wherein the first supply hose is attached to the first inlet;
a second component meter housing having a second inlet, a second outlet, and a second flow path extending between the second inlet and the second outlet, wherein the second supply hose is attached to the second inlet; a barrier plate disposed between the first component meter housing and the second component meter housing and isolating the first flow path from the second flow path;
a first gear set disposed within the first flow path between the first inlet and the first outlet and configured to meter the flow of a first material through the first flow path;
a second gear set disposed within the second flow path between the second inlet and the second outlet and configured to meter the flow of a second material through the second flow path; and
wherein the first gear set is coupled to the second gear set such that the first gear set and the second gear set rotate synchronously;
a first nozzle hose connected to the first outlet and configured to receive the first material from the first flow path;
a second nozzle hose connected to the first outlet and configured to receive the second material from the second flow path; and
a material applicator disposed downstream of the passive fluid flow synchronizer and connected to the first nozzle hose and the second nozzle hose, wherein the material applicator is configured to receive the first material from the first nozzle hose and the second material from the second nozzle hose.
The multiple component dispenser of claim 11 , and wherein:
the first gear set includes a first gear meshed with a second gear, wherein the first gear and the second gear are disposed adjacent a first side of the barrier plate; and the second gear set includes a third gear meshed with a fourth gear, wherein the third gear and the fourth gear are disposed adjacent a second side of the barrier plate.
13. The multiple component dispenser of claim 12, and further comprising:
an aligning mechanism coupling the first gear to the third gear and coupling the second gear to the fourth gear.
14. The multiple component dispenser of claim 13, wherein the aligning mechanism comprises a plurality of magnets.
15. The multiple component dispenser of claim 14, wherein the barrier plate comprises a non-ferrous material.
16. The multiple component dispenser of claim 12, and further comprising:
a first bearing disposed between the first gear and the barrier plate;
a second bearing disposed between the second gear and the barrier plate; a third bearing disposed between the third gear and the barrier plate; and a fourth bearing disposed between the fourth gear and the barrier plate.
17. The multiple component dispenser of claim 13, wherein the aligning mechanism comprises a first pin extending through the barrier plate and coupling the first gear to the third gear, and a second pin extending through the barrier plate and coupling the second gear to the fourth gear.
18. A method of synchronizing multiple flows, the method comprising:
flowing a first material through a first flow path and a first gear set disposed on a first side of a barrier plate; and flowing a second material through a second flow path and the second gear set disposed on a second side of the barrier plate and coupled to the first gear set such that the first gear set and the second gear set rotate synchronously to provide a set volumetric ratio of the first material to the second material by the synchronous rotation of the first gear set and the second gear set.
19. The method of claim 18, and further comprising:
providing a first synchronizing mechanism on the first gear set;
providing a second synchronizing mechanism on the second gear set; linking the first gear set to the second gear set with the first synchronizing mechanism and the second synchronizing mechanism such that rotation of the first gear set drives the rotation of the second gear set, and rotation of the second gear set drives the rotation of the first gear set.
20. The method of claim 19, wherein the first synchronizing mechanism comprises a first magnet and the second synchronizing mechanism comprises a second magnet.
PCT/US2016/044046 2015-07-27 2016-07-26 Passive flow synchronizer Ceased WO2017019688A1 (en)

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