U.S. patent application number 15/277128 was filed with the patent office on 2018-03-29 for foam dispensing gun with third stream.
This patent application is currently assigned to ICP ADHESIVES AND SEALANTS, INC.. The applicant listed for this patent is ICP ADHESIVES AND SEALANTS, INC.. Invention is credited to Kerry W. Armes, Douglas A. Caffoe, Mojgan Cline, Stefan K. Gantenbein, Anthony J. Taylor.
Application Number | 20180085766 15/277128 |
Document ID | / |
Family ID | 61687451 |
Filed Date | 2018-03-29 |
United States Patent
Application |
20180085766 |
Kind Code |
A1 |
Gantenbein; Stefan K. ; et
al. |
March 29, 2018 |
Foam Dispensing Gun with Third Stream
Abstract
A two-component spray gun is illustrated that utilizes a third
stream for dispensing at least some, and in some instances all, of
the requisite foam precursor reactants and/or blowing agents in
combination with the "A" and "B" reactant streams.
Inventors: |
Gantenbein; Stefan K.;
(Medina, OH) ; Cline; Mojgan; (Copley, OH)
; Taylor; Anthony J.; (Medina, OH) ; Caffoe;
Douglas A.; (Aurora, OH) ; Armes; Kerry W.;
(Norton, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ICP ADHESIVES AND SEALANTS, INC. |
Norton |
OH |
US |
|
|
Assignee: |
ICP ADHESIVES AND SEALANTS,
INC.
Norton
OH
|
Family ID: |
61687451 |
Appl. No.: |
15/277128 |
Filed: |
September 27, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B05B 7/0018 20130101;
B05B 7/0408 20130101; B05B 12/00 20130101; G01K 11/16 20130101;
G01K 13/02 20130101; B05B 12/10 20130101; B05B 12/0026 20180801;
B05B 15/65 20180201; B05B 7/0025 20130101; B05B 15/63 20180201 |
International
Class: |
B05B 7/04 20060101
B05B007/04; B05B 7/00 20060101 B05B007/00; B05B 7/02 20060101
B05B007/02; B05B 12/00 20060101 B05B012/00; G01K 11/12 20060101
G01K011/12 |
Claims
1. A foam spray gun which comprises: a housing having a front and a
rear; a removable nozzle at the front of the housing; a pair of
input hoses for at least one polyol and at least one diisocyanate,
said pair of input hoses in fluid communication with the removable
nozzle at one end, said hoses also in fluid communication with a
storage container for each of said at least one polyol and at least
one diisocyanate at an opposed end, at least one of the at least
one polyol and at least one diisocyanate entering the opposed end
via a liquid pump; a third input hose in communication with said
removable nozzle for dispensing a liquid or a gas blowing agent or
combinations thereof; a pivotable trigger for controlling
dispensing of said at least one polyol and said at least one
diisocyanate in said pair of input hoses, said trigger adjacent a
handle; a control mechanism for controlling dispensing of said
liquid or gas from said third input hose wherein the control
mechanism is either a separate trigger or the pivotable trigger for
controlling dispensing of the at least one polyol and the at least
one diisocyanate.
2. The foam spray gun of claim 1, wherein said removable nozzle is
temperature sensitive changing from a first color to a second color
upon a temperature change within said nozzle.
3. The foam spray gun of claim 1, wherein said removable nozzle
further comprises: a temperature sensitive tape positioned on said
nozzle, said pressure sensitive tape being temperature sensitive
changing from a first color to a second color upon a temperature
change within said nozzle.
4. The foam spray gun of claim 1, wherein at least one of said pair
of hoses has a temperature sensitive tape positioned thereupon,
said pressure sensitive tape being temperature sensitive changing
from a first color to a second color upon a temperature change
within said hose.
5. The foam spray gun of claim 1, wherein said control mechanism
for controlling dispensing from said third hose is positioned on
said pivotable trigger.
6. The foam spray gun of claim 1, wherein said control mechanism
for controlling a dispensing from said third hose is positioned on
a side of a housing of said spray gun.
7. The foam spray gun of claim 1, wherein said control mechanism
for controlling a dispensing from said third hose is positioned
adjacent a handle of said spray gun.
8. The foam spray gun of claim 1, which further comprises: a
high/low pivotable control within said gun, said control within a
flow path within said gun and post ingress of said at least one
polyol and said at least one diisocyanate.
9. The foam spray gun of claim 1, which further comprises: a safety
lock biased in a locked position, said lock positioned on a front
face of said pivotable trigger for controlling dispensing of said
at least one polyol and said at least one diisocyanate.
10. The foam spray gun of claim 1, wherein said pair of input hoses
are upwardly canted to enter said gun from on top of a housing of
said gun.
11. A foam spray gun which comprises: a housing having a front and
a rear; a removable nozzle at the front of the housing; a pair of
input hoses for at least one pressurized "B-side" polyol and at
least one pressurized "A-side" diisocyanate, said pair of input
hoses in fluid communication with the removable nozzle at one end,
said hoses also in fluid communication with a storage container for
each of said at least one pressurized "B-side" polyol and at least
one pressurized "A-side" diisocyanate at an opposed end; a third
input hose in communication with said removable nozzle for
dispensing a pressurized liquid or a pressurized gas or
combinations thereof, the third input hose comprising at least one
gaseous agent and at least one additional reactant selected from
the group consisting of at least one different polyol from the at
least one "B-side polyol", at least one plasticizer, at least one
flame retardant, at least one surfactant, at least one catalyst, at
least one blowing agent, at least one pressurizing inert gas and
water; a pivotable trigger for controlling dispensing of said at
least one polyol and said at least one diisocyanate in said pair of
input hoses, said trigger adjacent a handle; and a control
mechanism for controlling dispensing of said liquid or gas from
said third input hose wherein the control mechanism is either a
separate trigger or the pivotable trigger for controlling
dispensing of the at least one polyol and the at least one
diisocyanate.
12. The foam spray gun of claim 11, wherein said removable nozzle
is temperature sensitive changing from a first color to a second
color upon a temperature change within said nozzle.
13. The foam spray gun of claim 11, wherein said removable nozzle
further comprises: a temperature sensitive tape positioned on said
nozzle, said pressure sensitive tape being temperature sensitive
changing from a first color to a second color upon a temperature
change within said nozzle.
14. The foam spray gun of claim 11, wherein at least one of said
pair of hoses has a temperature sensitive tape positioned
thereupon, said pressure sensitive tape being temperature sensitive
changing from a first color to a second color upon a temperature
change within said hose.
15. The foam spray gun of claim 11, wherein said control mechanism
for controlling dispensing from said third hose is positioned on
said pivotable trigger.
16. The foam spray gun of claim 11, wherein said control mechanism
for controlling a dispensing from said third hose is positioned on
a side of a housing of said spray gun.
17. The foam spray gun of claim 11, wherein said control mechanism
for controlling a dispensing from said third hose is positioned
adjacent a handle of said spray gun.
18. The foam spray gun of claim 11, which further comprises: a
high/low pivotable control within said gun, said control within a
flow path within said gun and post ingress of said at least one
polyol and said at least one diisocyanate.
19. The foam spray gun of claim 11, which further comprises: a
safety lock biased in a locked position, said lock positioned on a
front face of said pivotable trigger for controlling dispensing of
said at least one polyol and said at least one diisocyanate.
20. The foam spray gun of claim 11, wherein said pair of input
hoses are upwardly canted to enter said gun from on top of a
housing of said gun.
21. A foam spray gun which comprises: a housing having a front and
a rear; a removable nozzle at the front of the housing; a pair of
input hoses for at least one pressurized "B-side" reactant
comprising at least one polyol and at least one pressurized
"A-side" diisocyanate, said pair of input hoses in fluid
communication with the removable nozzle at one end, said hoses also
in fluid communication with a storage container for each of said at
least one pressurized "B-side" reactant and at least one
pressurized "A-side" diisocyanate at an opposed end; a third input
hose in communication with said removable nozzle for dispensing a
pressurized liquid or a pressurized gas or combinations thereof,
the third input hose comprising at least one additional reactant
selected from the group consisting of at least one gaseous blowing
agent, at least one polyol, at least one plasticizer, at least one
flame retardant, at least one surfactant, at least one catalyst, at
least one pressurizing inert gas and water, wherein at least one
additional reactant in the third input hose is the same as at least
one "B-side" reactant; a pivotable trigger for controlling
dispensing of said at least one polyol and said at least one
diisocyanate in said pair of input hoses, said trigger adjacent a
handle; and a control mechanism for controlling dispensing of said
liquid or gas from said third input hose wherein the control
mechanism is either a separate trigger or the pivotable trigger for
controlling dispensing of the at least one polyol and the at least
one diisocyanate.
22. The foam spray gun of claim 21, wherein said removable nozzle
is temperature sensitive changing from a first color to a second
color upon a temperature change within said nozzle.
23. The foam spray gun of claim 21, wherein said removable nozzle
further comprises: a temperature sensitive tape positioned on said
nozzle, said pressure sensitive tape being temperature sensitive
changing from a first color to a second color upon a temperature
change within said nozzle.
24. The foam spray gun of claim 21, wherein at least one of said
pair of hoses has a temperature sensitive tape positioned
thereupon, said pressure sensitive tape being temperature sensitive
changing from a first color to a second color upon a temperature
change within said hose.
25. The foam spray gun of claim 21, wherein said control mechanism
for controlling dispensing from said third hose is positioned on
said pivotable trigger.
26. The foam spray gun of claim 21, wherein said control mechanism
for controlling a dispensing from said third hose is positioned on
a side of a housing of said spray gun.
27. The foam spray gun of claim 21, wherein said control mechanism
for controlling a dispensing from said third hose is positioned
adjacent a handle of said spray gun.
28. The foam spray gun of claim 21, which further comprises: a
high/low pivotable control within said gun, said control within a
flow path within said gun and post ingress of said at least one
polyol and said at least one diisocyanate.
29. The foam spray gun of claim 21, which further comprises: a
safety lock biased in a locked position, said lock positioned on a
front face of said pivotable trigger for controlling dispensing of
said at least one polyol and said at least one diisocyanate.
30. The foam spray gun of claim 21, wherein said pair of input
hoses are upwardly canted to enter said gun from on top of a
housing of said gun.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] The invention described herein relates generally to a
two-component spray gun that utilizes a third stream for dispensing
at least some, and in some instances all, of the requisite foam
precursor reactants and/or blowing agents.
BACKGROUND OF THE INVENTION
[0002] This invention is particularly suited for in-situ
applications of liquid chemicals mixed and dispensed as a spray or
a foam and more specifically, to in-situ application of
polyurethane foam or froth. In-situ applications for polyurethane
foam have continued to increase in recent years extending the
application of polyurethane foam beyond its traditional uses in the
packaging, insulation and molding fields. For example, polyurethane
foam is being used with increasing frequency as a sealant in the
building trades for sealing spaces between windows and door frames
and the like and as an adhesive for gluing flooring, roof tiles,
and the like.
[0003] Polyurethane foam for in-situ applications is typically
supplied as a "one-component" froth foam or a "two-component" froth
foam in portable containers hand carried and dispensed by the
operator through either a valve or a gun. However, the chemical
reactions producing the polyurethane froth foam in a
"one-component" polyurethane foam is significantly different from
the chemical reactions producing a polyurethane froth foam in a
"two-component" polyurethane foam. Because the reactions are
different, the dispensing of the chemicals for a two-component
polyurethane foam involves different and additional concepts and
concerns than those present in the dispensing apparatus for a
"one-component" polyurethane froth foam.
[0004] A "one-component" foam generally means that both the resin
and the isocyanate used in the foam formulation are supplied in a
single pressurized container and dispensed from the container
through a valve or a gun attached to the container. When the
chemicals leave the valve, a reaction with moisture in the air
produces a polyurethane froth or foam. Thus, the design concerns
related to an apparatus for dispensing one-component polyurethane
foam essentially concerns the operating characteristics of how the
one-component polyurethane foam is throttled or metered from the
pressurized container. Post drip is a major concern in such
applications as well as the dispensing gun not clogging because of
reaction of the one component formulation with air (moisture)
within the gun. To address or at least partially address such
problems, a needle valve seat is typically applied as close to the
dispensing point by a metering rod arrangement which can be pulled
back for cleaning. While metering can occur at the needle valve
seat, the seat is primarily for shut-off to prevent post drip, and
depending on gun dimensioning, metering may principally occur at
the gun opening.
[0005] In contrast, a "two-component" froth foam means that one
principal foam component is supplied in one pressurized container,
typically the "A" container (i.e., polymeric isocyanate,
fluorocarbons, etc.) while the other principal foam component is
supplied in a second pressurized container, typically the "B"
container (i.e., polyols, catalysts, flame retardants,
fluorocarbons, etc.). In a two-component polyurethane foam, the "A"
and "B" components form the foam or froth when they are mixed in
the gun. Of course, chemical reactions with moisture in the air
will also occur with a two-component polyurethane foam after
dispensing, but the principal reaction forming the polyurethane
foam occurs when the "A" and "B" components are mixed or contact
one another in the dispensing gun and/or dispensing gun nozzle. The
dispensing apparatus for a two-component polyurethane foam
application has to thus address not only the metering design
concerns present in a one-component dispensing apparatus, but also
the mixing requirements of a two-component polyurethane foam.
[0006] Further, a "frothing" characteristic of the foam is enhanced
by the pressurized gas employed, e.g., fluorocarbon (or similar)
component, which is present in the "A" and "B" components. This
fluorocarbon component is a compressed gas which exits in its
liquid state under pressure and changes to its gaseous state when
the liquid is dispensed into a lower pressure ambient environment,
such as when the liquid components exit the gun and enter the
nozzle.
[0007] While polyurethane foam is well known, the formulation
varies considerably depending on application. In particular, while
the polyols and isocyanates are typically kept separate in the "B"
and "A" containers, other chemicals in the formulation may be
placed in either container with the result that the weight or
viscosity of the liquids in each container varies as well as the
ratios at which the "A" and "B" components are to be mixed. In
dispensing gun applications which relate to this invention, the "A"
and "B" formulations are such that the mixing ratios are generally
kept equal so that the "A" and "B" containers are the same size.
However, the weight, more importantly the viscosity, of the liquids
in the containers invariably vary from one another. To adjust for
viscosity variation between "A" and "B" chemical formulations, the
"A" and "B" containers are charged (typically with an inert gas) at
different pressures to achieve equal flow rates. The metering
valves in a two-component gun, therefore, have to meter different
liquids at different pressures at a precise ratio under varying
flow rates. For this reason (among others), some dispensing guns
have a design where each metering rod/valve is separately
adjustable against a separate spring to compensate not only for
ratio variations in different formulations but also viscosity
variations between the components. The typical two-component
dispensing gun in use today can be viewed as two separate
one-component dispensing guns in a common housing discharging their
components into a mixing chamber or nozzle. This practice,
typically leads to operator errors. To counteract this adverse
result, the ratio adjustment then has to be "hidden" within the
gun, or the design has to be such that the ratio setting is "fixed"
in the gun for specific formulations. The gun cost is increased in
either event and "fixing" the ratio setting to a specific
formulation prevents interchangeability of the dispensing gun.
[0008] Another element affecting the operation of a two-component
gun is the design of the nozzle. The nozzle is typically a throw
away item detachably mounted to the nose of the gun. Nozzle design
is important for cross-over and metering considerations in that the
nozzle directs the "A" and "B" components to a static mixer within
the tip. For example, one gun completely divides the nozzle into
two passages by a wall extending from the nozzle nose to the mixer.
The wall lessens but does not eliminate the risk of cross-over
since the higher pressurized component must travel into the mixer
and back to the lower pressure metering valve.
[0009] A still further characteristic distinguishing two-component
from one-component gun designs resides in the clogging tendencies
of two-component guns. Because the foam foaming reaction commences
when the "A" and "B" components contact one another, it is clear
that, once the gun is used, the static mixer will clog with
polyurethane foam or froth formed within the mixer. This is why the
nozzles, which contain the static mixer, are designed as throw away
items. In practice, the foam does not instantaneously form within
the nozzle upon cessation of metering to the point where the
nozzles have to be discarded. Some finite amount of time must
elapse. This is a function of the formulation itself, the design of
the static mixer and, all things being equal, the design of the
nozzle.
[0010] The dispensing gun of the present invention is suited for
use in two-component polyurethane foam "kits" typically sold to the
building or construction trade. Typically, the kit contains two
pressurized "A" and "B" cylinders (130-250 psi), a pair of hoses
for connection to the cylinders and a dispensing gun, all of which
are packaged in a container constructed to house and carry the
components to the site where the foam is to be applied. When the
chemicals in the "A" and "B" containers are depleted, the kit is
sometimes discarded or the containers can be recycled. The
dispensing gun may or may not be replaced. Since the dispensing gun
is included in the kit, kit cost considerations dictate that the
dispensing gun be relatively inexpensive. Typically, the dispensing
gun is made from plastic with minimal usage of machined parts.
[0011] Within each type of dispensing gun (e.g., one-component
dispensing gun, two-component dispensing gun), a metering rod is
utilized. The metering rod is a primary shutoff within the
dispensing gun that meters or controls dispensing of material. The
metering rod is often referred to as a needle or a pin and engages
a female type receiver to meter or shutoff flow of chemical (e.g.,
material, component "A," component "B," etc.). In one-component
dispensing guns, a single metering rod is included within a
dispensing passage. In two-component dispensing guns, a metering
rod is included within each dispensing passage associated with
component (e.g., material). In an embodiment, two-component
dispensing gun includes first dispensing passage and respective
metering rod and second dispensing passage and respective metering
rod. Upon use of a trigger, metering rod(s) allow material to be
dispensed.
[0012] Fabrication of metering rods for dispensing guns include
various challenges to produce an efficient dispensing gun at a
reasonable price point. Typically, metering rods are fabricated
incorporating brass, copper, and other materials (e.g., metallic,
non-metallic, etc.). Yet, such materials have increased in cost
and, in turn, increased cost of manufacturing dispensing guns.
Furthermore, the dispensing gun requires a secure mating between
receiver and metering rod in order to prevent inconsistent metering
(e.g., non-uniform dispensing of material, components, or chemical)
and incomplete shut off (in a closed position). Inaccuracy between
mating surfaces (e.g., receiver and metering rod) is typically
overcome by forcing two elements together during initial assembly
and allowing the more malleable of the two elements to take set.
This technique is referred to as presetting and typically requires
lengthy hold time which limits manufacturing of dispensing guns.
Overall, presetting increases the possibility of enabling two
mating surfaces to have secure connection (e.g., mating) to avoid
leakage and/or non-uniform dispensing but adds to the manufacturing
time.
[0013] Additionally, metallic metering rods are often fabricated
with turning or grinding techniques. In particular, during creation
of typical metallic metering rod(s), radial micro grooves are
present due to such turning or grinding technique. With repeated
use over duration of time, these micro grooves cause wear to the
more malleable mating surface. In general, micro grooves grind or
file away at the mating surface which can cause leakage of
chemical/material at the mating surface.
[0014] While two-component dispensing guns discussed above function
in a commercially acceptable manner, it is becoming increasingly
clear as the number of in-situ applications for polyurethane foam
increase, that the range or the ability of the dispensing gun to
function for all such applications has to be improved. As a general
example, metering rods that meter amount of dispensed material need
to be fabricated in a manner that prevent uneven dispensing of
materials as well as prevent incomplete shutoff.
[0015] Further limitations and disadvantages of conventional,
traditional, and proposed approaches will become apparent to one of
skill in the art, through comparison of such systems and methods
with certain embodiments the claimed invention as set forth in the
remainder of the present application with reference to the
drawings.
SUMMARY OF THE INVENTION
[0016] In one embodiment of the invention, a foam spray gun is
described in which a third input hose is provided for the spray gun
in communication with said removable nozzle for dispensing a liquid
or a gas. The gun will have a pivotable trigger for controlling
dispensing of the polyol and diisocyanate in the pair of input
hoses, and the gun may have a separate control mechanism for
controlling dispensing of at least a liquid or gas from the third
input hose.
[0017] In one aspect of the invention, the removable nozzle is
temperature sensitive, although the affixing of a temperature
sensitive tape to either the nozzle or at least one of the input
hoses is also employed.
[0018] In one embodiment of the invention, a foam spray gun is
described which includes: a housing having a front and a rear; a
removable nozzle at the front of the housing; a pair of input hoses
for at least one polyol and at least one diisocyanate, the pair of
input hoses in fluid communication with the removable nozzle at one
end, the hoses also in fluid communication with a storage container
for each of the at least one polyol and at least one diisocyanate
at an opposed end, at least one of the at least one polyol and at
least one diisocyanate entering the opposed end via a liquid pump;
a third input hose in communication with the removable nozzle for
dispensing a liquid or a gas blowing agent or combinations thereof;
a pivotable trigger for controlling dispensing of the at least one
polyol and the at least one diisocyanate in the pair of input
hoses, the trigger adjacent a handle; a control mechanism for
controlling dispensing of the liquid or gas from the third input
hose wherein the control mechanism is either a separate trigger or
the pivotable trigger for controlling dispensing of the at least
one polyol and the at least one diisocyanate.
[0019] The removable nozzle is preferably temperature sensitive
changing from a first color to a second color upon a temperature
change within the nozzle. Optionally, a temperature sensitive tape
is positioned on the nozzle, the pressure sensitive tape changing
from a first color to a second color upon a temperature change
within the nozzle. In another configuration, at least one of the
pair of hoses has a temperature sensitive tape positioned
thereupon, the pressure sensitive tape changing from a first color
to a second color upon a temperature change within the hose.
[0020] In one aspect of the invention, the control mechanism for
controlling dispensing from the third hose is positioned on the
pivotable trigger, although it is possible that the control
mechanism is positioned on a side of a housing of said spray gun or
is positioned adjacent a handle of said spray gun.
[0021] The foam spray gun typically will have a high/low pivotable
control within the gun, the control within a flow path within the
gun and post ingress of the at least one polyol and said at least
one diisocyanate.
[0022] The foam spray gun may have a safety lock biased in a locked
position, the lock positioned on a front face of the pivotable
trigger for controlling dispensing of the at least one polyol and
the at least one diisocyanate.
[0023] In another aspect of the invention, the foam spray gun will
include: a housing having a front and a rear; a removable nozzle at
the front of the housing; a pair of input hoses for at least one
pressurized "B-side" polyol and at least one pressurized "A-side"
diisocyanate, the pair of input hoses in fluid communication with
the removable nozzle at one end, the hoses also in fluid
communication with a storage container for each of the at least one
pressurized "B-side" polyol and at least one pressurized "A-side"
diisocyanate at an opposed end; a third input hose in communication
with said removable nozzle for dispensing a pressurized liquid or a
pressurized gas or combinations thereof, the third input hose
comprising at least one gaseous agent and at least one additional
reactant selected from the group consisting of at least one
different polyol from the at least one "B-side polyol", at least
one plasticizer, at least one flame retardant, at least one
surfactant, at least one catalyst, at least one blowing agent, at
least one pressurizing inert gas and water; a pivotable trigger for
controlling dispensing of said at least one polyol and said at
least one diisocyanate in the pair of input hoses, the trigger
adjacent a handle; and a control mechanism for controlling
dispensing of the liquid or gas from the third input hose wherein
the control mechanism is either a separate trigger or the pivotable
trigger for controlling dispensing of the at least one polyol and
the at least one diisocyanate.
[0024] In another embodiment of the invention, at least one
additional reactant in the third input hose will be the same as at
least one "B-side" reactant.
[0025] These and other advantages and novel features of the claimed
invention, as well as details of illustrated embodiments thereof,
will be more fully understood from the following description and
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 illustrates a perspective view of a Prior Art
dispensing gun;
[0027] FIG. 2 illustrates a perspective view of one aspect of the
invention in which a third stream input is illustrated, third
stream control trigger and a temperature sensitive nozzle;
[0028] FIG. 3 illustrates a perspective view of one aspect of the
invention in which a third stream input is illustrated with
corresponding third stream trigger control, high/low output control
and twist and "click" nozzle and temperature sensitive tape on the
nozzle;
[0029] FIG. 3A illustrates a rear elevational view of the nozzle
attachment of FIG. 3 showing the third hose positioned below the
pair of input hoses;
[0030] FIG. 3B illustrates a side elevational view of the housing
portion of the spray gun of FIG. 3 in which the housing has a high
throughput ability as well as a more restricted throughput;
[0031] FIG. 4 illustrates a perspective view of one aspect of the
invention in which a third stream input is illustrated with
temperature sensitive tape on at least one of the input hoses,
twist and "click" nozzle, third stream control via a push button on
both sides and an "automatic" safety lock;
[0032] FIG. 5 illustrates a perspective view of the spray gun with
a third stream forward of the dispensing trigger; and
[0033] FIG. 6 illustrates an exploded view of the yoke of the
safety trigger.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The best mode for carrying out the invention will now be
described for the purposes of illustrating the best mode known to
the applicant at the time of the filing of this application. The
examples are illustrative only and not meant to limit the
invention, as measured by the scope and spirit of the claims.
[0035] As used herein, "at least one," "one or more," and "and/or"
are open-ended expressions that are both conjunctive and
disjunctive in operation. For example, each of the expressions "at
least one of A, B, and C," "at least one of A, B, or C," "one or
more of A, B, and C," "one or more of A, B, or C," and "A, B,
and/or C" means A alone, B alone, C alone, A and B together, A and
C together, B and C together, or A, B, and C together.
[0036] Unless otherwise indicated, all numbers expressing
quantities, dimensions, conditions, and so forth used in the
specification and claims are to be understood as being modified in
all instances by the term "about".
[0037] The term "a" or "an" entity, as used herein, refers to one
or more of that entity. As such, the terms "a" (or "an"), "one or
more" and "at least one" can be used interchangeably herein.
[0038] The use of "including," "comprising," or "having" and
variations thereof herein is meant to encompass the items listed
thereafter and equivalents thereof as well as additional items.
Accordingly, the terms "including," "comprising," or "having" and
variations thereof can be used interchangeably herein.
[0039] Words written in all capital letters can refer to specific
acronyms; specific components, inputs, and/or fields; and/or
general components, inputs, and/or fields. Thus, in some cases the
word written in all capital letters is interchangeable with the
same word written in lower case letters.
[0040] It shall be understood that the term "means" as used herein
shall be given its broadest possible interpretation in accordance
with 35 U.S.C. Section 112(f). Accordingly, a claim incorporating
the term "means" shall cover all structures, materials, or acts set
forth herein, and all of the equivalents thereof. Further, the
structures, materials, or acts and the equivalents thereof shall
include all those described in the summary of the invention, brief
description of the drawings, detailed description, abstract, and
claims themselves.
[0041] FIG. 1 illustrates a Prior Art airless two-component
dispensing gun 10. Dispensing gun 10 may be viewed as comprising a
one-piece gun body 12 (which includes components to be described)
with a detachably secured disposable nozzle 13. In one preferred
embodiment, the gun is molded from polypropylene and the nozzle is
molded from an ABS (Acrylonitrile-Butadiene-Styrene) plastic. It is
to be appreciated that any suitable plastic material can be
utilized for the dispensing gun 10. While one of the objects of the
invention is to provide an inexpensive dispensing gun achieved in
part by the molding gun body 12 and nozzle 13 from plastic, the
invention in its broader sense is not limited to a dispensing gun
molded from any particular plastic and in a broader sense, includes
metallic dispensing guns and/or dispensing guns with some metallic
components either within portions or components of the housing of
the dispensing gun or within portions of the nozzle.
[0042] Gun body 12 may be further defined as having integral
portions including a longitudinally-extending valve portion 15 to
which nozzle 13 is releasably connected and terminating at a
longitudinally-extending trigger portion 16, in turn, terminating
at longitudinally-extending spring portion (not shown) from which
transversely extends handle portion 18. Within gun body housing 12
is a pair of hose openings 22, 23, canted as shown, to which the
"A" and "B" hoses (not shown) are attached, respectively, by
conventional quick connect couplings or other retaining mechanisms
(e.g., friction fitting O-rings). Dispensing gun 10 is also
provided with pivotable trigger 20 extending within trigger body
portion 16. It should be appreciated that when the operator grasps
dispensing gun 10 about handle 18 for finger actuation of trigger
20, that the position of hose openings 22, 23 is such that the kit
hoses will drape over the operator's forearm which is preferred
over other conventional hose attachment positions on the dispensing
gun. Canting hose openings 22, 23 is thus believed to provide some
ergonomic benefit while contributing to the improved performance of
dispensing gun 10 as described below. While a canted configuration
is illustrated, the invention is not limited to that arrangement,
and the "A" and "B" hoses may be positioned to enter the gun from
the base of handle 18 (not shown) or from the rear (not shown).
[0043] Referring now to FIG. 2, dispensing gun 10 is shown in a
manner similar to FIG. 1, in which canting hose openings 22,23 are
illustrated to communicate with removable nozzle 24 via openings
32, 30 respectively. Third hose opening 25 also communicates with
removable nozzle 24 via opening 34. The value of having a third
hose is that the user may supplement the options available through
the use of this third hose and by control using third stream
control trigger 28, may optionally dispense pressurized air (or
other gas) to clean a surface upon which foam is to be applied, or
to dispense a liquid cleaning medium through the nozzle (e.g.,
solvent) or to at least partially dispense a surfactant, a
catalyst, a flame retardant, or a liquid or gaseous blowing agent.
Wide safety lock 36 is accessed and controlled typically via thumb
control by the user. In one aspect of the invention, nozzle 24 is a
temperature sensitive nozzle in which the nozzle changes color
depending upon the temperature of the dispensed chemicals, thereby
permitting the user to visually see if the chemicals are being
dispensed at the proper temperature, which at least in part,
governs the applied A/B ratio. It is recognized that
color-sensitive dyes and pigments may be incorporated into the
plastic of nozzle 24.
[0044] As better illustrated in FIG. 3, dispensing gun 10 is shown
in which removable nozzle 38 is affixed by a "twist and click"
nozzle 44 and further in which third stream trigger control is
provided by pivotable trigger 46 adjacent handle 18. Temperature
sensitive tape 40 is affixed to nozzle 38 wherein the tape changes
color depending upon the temperature of the dispensed chemicals for
the reasons opined in the previous paragraph. The dispensing gun is
further provided with high/low output control lever 42 for further
control by an operator. As shown in FIG. 3A, the pair of canted
openings 22,23 are positioned above the third hose opening 25
whereas FIG. 3B illustrates the high and low volume throughput
control of output control lever 42. Further illustrated is safety
lock 48 positioned optimally on both sides of spray gun 10.
[0045] As shown in FIG. 4, dispending gun 10 is shown in which
removable nozzle 38 is affixed by the "twist and click" nozzle 44
of FIG. 3 and further wherein third hose 25 enters adjacent
removable nozzle 38. Temperature sensitive tape is affixed to at
least one hose 22, more preferably both hoses. Handle 18 is split
into two legs, preferably connected at the bottom. Automatic safety
lock 50 is positioned upon an exterior-facing side of trigger 50
which is biased in an "off" position by spring-biased trigger 52.
Third stream control is effected by push button 48 positioned on
both sides of the gun housing.
[0046] FIG. 5 illustrates another arrangement of a spray gun and
nozzle. As illustrated, spray gun 10 has a pair of canting hose
openings 22,23 in communication with removable nozzle 38. Third
hose opening 25 also communicates with removable nozzle 38. Safety
lock 48 is pivotally positioned within dispensing trigger 20 which
is positioned before rearward-sloping curvilinear handle 18. Safety
lock 48 is accessed and controlled typically via index finger
control by the user. In one aspect of the invention, "twist and
click" nozzle 38 is a temperature sensitive nozzle in which the
nozzle changes color depending upon the temperature of the
dispensed chemicals, thereby permitting the user to visually see if
the chemicals are being dispensed at the proper temperature, which
at least in part, governs the applied A/B ratio. Third stream
trigger 28 is pivotally positioned in front of pivotable dispensing
trigger 20 and governs the flow of the fluid (liquid or gas) within
the channel of third opening 25. The dispensing gun is further
provided with high/low or on/off output control lever 42 for
further control by an operator. When used for high/low flow
control, different diametered channels are bored into a transverse
shaft of control lever 42.
[0047] FIG. 6 illustrates yoke 66 of safety lock 48 positioned
within dispensing nozzle 20. As illustrated in the figure, safety
lock is biased in a forward direction with yoke 66 impinging upon a
rear lip. Depressing safety lock 48 pivotally elevates yoke 66 so
as to permit rearward movement of pivotable dispensing trigger.
[0048] Third Stream Content
[0049] The inclusion of a third stream is not only effective for
surface cleaning applications, but has applicability to modify the
proportions of reactants which are dispensed through the gun,
particularly vis-a-vis the contents of the "B" cylinder. For
example, current foam dispensing spray guns employ a combination of
blowing agent and reactant(s) and typically a pressurizing agent,
typically an inert gas in the A/B cylinders. In one aspect of this
invention, the amount of blowing agent is reduced (and in some
applications eliminated) by introducing the blowing agent, which in
some applications may be air, through the third stream input port.
The liquid contents of the A/B cylinders are added via the
combination of inert gas plus blowing agent vapor pressure. In one
aspect of this invention, when the blowing agent is added via the
third stream, some or all of the contents of the "B"-side cylinder
may be added via a liquid pump positioned on the cylinder.
[0050] The application of a third stream allows an end-user to
selectively add some, or a portion of, or all of the following
chemicals, the list being illustrative and not exhaustive.
[0051] Polyols
[0052] As illustrated in a non-exhaustive, non-exclusive, exemplary
list below, there are a myriad of polyols which are useful in
effecting the reaction with a diisocyanate to form a foam having
varying characteristics. The ability to add widely varying amounts
of polyols and/or different polyol combinations could easily be
effected via either supplementing existing amounts of "B-side"
polyol(s) via the third stream or by essentially eliminating
"B-side" polyol(s) and making their addition via the third stream.
In one aspect of the invention, the polyol(s) are added by using a
pumping mechanism from a "B-side" cylinder or other container, and
the third stream is employed to add the blowing agent and/or
pressurizing agent.
Polyester Polyol(s)
TABLE-US-00001 [0053] PS 2352 ##STR00001## Hydroxyl Number, mg
KOH/g 230-250 Water, % by wt., max. 0.15 Acid Number, mg KOH/g,
max. 0.6-1.0 Viscosity at 77.degree. F. (25.degree. C.), cP
2,000-4,500 Equivalent Weight (average) 234 Molecular Weight
(average) 468 Color, Gardner 4 Density at 77.degree. F. (25.degree.
C.), lb/U.S. gal 9.9 Specific Gravity at 77.degree. F. (25.degree.
C.) 1.19 TB-350 ##STR00002## Hydroxyl Number, mg KOH/g 335-365
Water, % by wt., max. 0.15 Acid Number, mg KOH/g, max. 0.5-2.0
Viscosity at 77.degree. F. (25.degree. C.), cP 2,500-3,500 Color,
Gardner 4-5 Specific Gravity at 77.degree. F. (25.degree. C.) 1.233
Functionality 2.2
Polyether Polyol(s)
TABLE-US-00002 [0054] Voranol 360 ##STR00003## sucrose polyether
polyol based on a sucrose-glycerol mixture with a functionality of
~4.5 having hydroxyl number ~360 Multranol aromatic amine-initiated
polyether polyol having a hydroxyl number of about 388 mg 8114
KOH/g and a functionality of 4 Poly-G .RTM. 30-280 ##STR00004##
glycerine-based oxypropylated polyether polyol having a
functionality greater than or equal to 3 and a molecular weight of
about 600, an OH number of about 274, an acid number (max) of 0.05,
an average pH of about 6.5 Poly-G .RTM. 30-168 ##STR00005##
1,2,3-propanetriol, methyloxirane polymer Poly-G .RTM. Polyether
triol having an average molcular weight of ~4,000 an OH number of
about 30-42 40, an acid number (max) of ~0.03, an average pH of
about 5.5 Jeffol .RTM. G 31-35 ##STR00006## ethylene oxide triol,
ethylene oxide capped and glycerine initiated where the polyol has
a hydroxyl number of ~35 and a M.W. of ~4800 and provides for chain
entanglement and packing without distorting a profile. Carpol TEAP-
265 ##STR00007##
3,3',3''-[nitrilotris(ethane-2,1-diyloxy)]tripropan-1-ol Poly-G
.RTM. 70-600 ##STR00008## Ethoxylatedtriethanolamine
[0055] Flame Retardants and/or Plasticizers
[0056] As illustrated in a non-exhaustive, non-exclusive, exemplary
list below, there are a myriad of flame retardants and/or
plasticizers which are useful in modifying the properties of the
reaction of a polyol with a diisocyanate to form a foam having
varying characteristics. The ability to add widely varying amounts
of flame retardants/plasticizers and/or different flame
retardant/plasticizer combinations could easily be effected via
either supplementing existing amounts of "B-side" flame
retardant(s)/plasticizer(s) via the third stream or by essentially
eliminating "B-side" flame retardant(s)/plasticizer(s) and making
their addition via the third stream.
##STR00009##
[0057] Surfactants
[0058] As illustrated in a non-exhaustive, non-exclusive, exemplary
list below, there are a myriad of surfactants which are useful in
modifying the properties of the reaction of a polyol with a
diisocyanate to form a foam having varying characteristics. The
ability to add widely varying amounts of surfactants and/or
different surfactant combinations could easily be effected via
either supplementing existing amounts of "B-side" surfactant(s) via
the third stream or by essentially eliminating "B-side"
surfactant(s) and making their addition via the third stream.
TABLE-US-00003 Trade name Composition (if known) Tegostab .RTM.
B-8433 Polyether polydimethylsiloxane copolymer Dabco .RTM. LK
.RTM.-443 Non-silicone organic surfactant Nonoxynol-9 ##STR00010##
the hydroxyl number is ~88 L12-8 ethoxylated alcohol (dodecyl
alcohol ethoxylate) ##STR00011##
[0059] Catalysts
[0060] As illustrated in a non-exhaustive, non-exclusive, exemplary
list below, there are a myriad of catalysts which are useful in
effecting the reaction of a polyol with a diisocyanate to form a
foam having varying characteristics. The ability to add widely
varying amounts of catalysts and/or different catalyst combinations
could easily be effected via either supplementing existing amounts
of "B-side" catalyst(s) via the third stream or by essentially
eliminating "B-side" catalyst(s) and making their addition via the
third stream.
TABLE-US-00004 Trade name and/or Chemical Name Chemical structure
Dabco .RTM. K-15 (Potassium octoate/DEG (diethylene glycol))
##STR00012## Polycat .RTM.-12 (Dicyclohexylmethyl amine)
##STR00013## DMDEE (Dimorpholinodiethyl ether) ##STR00014## Polycat
.RTM.-5 (N,N,N',N',N''-pentamethyldiethylenetriamine) ##STR00015##
Polycat .RTM.-8 (N,N-dimethylcyclohexylamine) ##STR00016##
N,N-dimethylhexylamine ##STR00017## NEM (N-Ethylmorpholine)
##STR00018## NMM (N-Methylmorpholine) ##STR00019## Polycat .RTM. 15
(Tetramethyldipropylene triamine) ##STR00020## DMP
(N,N'-Dimethylpiperazine) ##STR00021## Dabco .RTM. 33LV
(1,4-Diazabicyclo[2.2.2]octane) ##STR00022## Dabco .RTM. T
(N,N,N'-trimethylaminoethyl ethanolamine) ##STR00023## Dabco .RTM.
T-120
(CH.sub.3(CH.sub.2).sub.3).sub.2--Sn--S(CH.sub.2).sub.11CH.sub.3
(dibutyl tin dilauryl mercaptide) Jeffamine .RTM. D-2000
polyoxypropylenediamine ##STR00024##
[0061] Other
[0062] Water can be both beneficial and deleterious to catalyst
foams, depending on the blowing agent used or the end-use
application as illustrated below. For example, block fill foam is a
closed cell and requires a high crosslink density in order to be
dimensionally stable in the channel, and these characteristics
would be an anathema to the window lineal foam, which requires the
ability to pack and not distort a window lineal as noted in the
following Table. The ability to add widely varying amounts of water
could easily be effected via either supplementing existing amounts
of "B-side" water via the third stream or by essentially
eliminating "B-side" water and making its addition via the third
stream.
TABLE-US-00005 Block Fill Window "B-side" components foam
(preferred) Lineal foam (preferred) % water 1.0% 10-20% (15%) %
catalyst 2.2% 0.4-2% (0.5-0.7%) gel time <1 min. 2-6 min. (>3
min. <5 min.) "B-side" OHV 200-400 (300) 5-20 (8.5) (polyol
only) Polyol concentration 60-65% 5-10% Pressure Build irrelevant
important Robustness sturdy sensitive
[0063] Blowing Agent(s)
[0064] As illustrated in a non-exhaustive, non-exclusive, exemplary
list below, there are a myriad of blowing agents which are useful
in effecting the reaction of a polyol with a diisocyanate to form a
foam having varying characteristics. The ability to add widely
varying amounts of blowing agents and/or different blowing agent
combinations could easily be effected via either supplementing
existing amounts of "A-side" and/or "B-side" blowing agent(s) via
the third stream or by essentially eliminating blowing agent(s) and
making their addition via the third stream.
[0065] In one aspect of the invention, blowing agents having up to
four carbon atoms in their backbone and which are useful in this
invention fall within the general formula (I) illustrated
below:
[CV.sub.a].sub.m-A-[CX.sub.b].sub.n--B--[CY.sub.c].sub.o-D-[CZ.sub.d].su-
b.p
[0066] wherein [0067] C is a carbon atom; [0068] V, X, Y & Z
are independently selected from the group consisting of H, F and
Cl; [0069] a & d are independently selected from the integral
values ranging from 0 to 3 inclusive; [0070] b & c are
independently selected from the integral values ranging from 0 to 2
inclusive; [0071] o, p & n are equal to 1; [0072] m is selected
from the integral values ranging from 0 to 1 inclusive; [0073] A, B
& D are covalent bonds sufficient to satisfy the available
bonding sites of adjacent carbon atoms, if such carbon atoms are
present; and [0074] the blowing agent, including miscible blends
and azeotropes thereof, having a boiling point between
approximately 5-50.degree. C., and an ozone depletion potential of
essentially zero; and [0075] in a preferred embodiment, the blowing
agent is non-flammable, recognizing that co-blowing agents may be
flammable, although in a more preferred embodiment, the co-blowing
agent will be added in such an amount as to render the combination
non-flammable either as a blend or as an azeotrope.
[0076] In another aspect of the invention, and listed more
generically, the blowing agents having up to six carbon atoms in
their backbone and which are useful in this invention fall within
the general formula (II) illustrated below:
[CU.sub.e].sub.q-E-[CW.sub.f].sub.r--F--[CV.sub.a].sub.m-A-[CX.sub.b].su-
b.n--B--[CY.sub.c].sub.o-D-[CZ.sub.d].sub.p
[0077] wherein [0078] C is a carbon atom; [0079] U, W, V, X, Y and
Z are independently selected from the group consisting of H, F and
Cl; [0080] d & e are independently selected from the integral
values ranging from 0 to 3 inclusive; [0081] a,b,c & f are
independently selected from the integral values ranging from 0 to 2
inclusive; [0082] o, p & n are equal to 1; [0083] m, q & r
are independently selected from the integral values ranging from 0
to 1 inclusive; [0084] A, B, D, E and F are covalent bonds
sufficient to satisfy the available bonding sites of adjacent
carbon atoms, if such carbon atoms are present; [0085] the blowing
agent having a boiling point between approximately 5-50.degree. C.,
and an ozone depletion potential of not greater than 0.05; and
[0086] in a preferred embodiment, the blowing agent is
non-flammable, recognizing that co-blowing agents may be flammable,
although in a more preferred embodiment, the co-blowing agent will
be added in such an amount as to render the combination
non-flammable either as a blend or as an azeotrope.
[0087] As illustrated in a non-exhaustive, non-exclusive, exemplary
list below, there are a myriad of blowing agents which are useful
in effecting the reaction of a polyol with a diisocyanate to form a
foam having varying characteristics. The ability to add widely
varying amounts of blowing agents and/or different blowing agent
combinations could easily be effected via either supplementing
existing amounts of "A-side" and/or "B-side" blowing agent(s) via
the third stream or by essentially eliminating blowing agent(s) and
making their addition via the third stream.
##STR00025##
[0088] As used in this application, a non-limiting definition for
the term "blowing agent" which includes miscible mixtures and
azeotropes of blowing agents, means a propellant or solvent which
are useful and provide efficacy to various applications in the form
of insulation performance, pressure performance, or solubility,
without deleterious effect due to molar gas volume, flammability
migration, or GWP reduction, yet which have a vapor pressure within
defined limits as defined herein. Exemplary and non-limiting
blowing agents include HFC-245fa (Honeywell Intl.), namely
1,1,1,3,3 pentafluoropentane or HFO-1336mzz or sold under the trade
name Opteon 1100 (Chemours), namely 1,1,1,4,4,4
hexafluoro-2-butene.
[0089] And while the above identified blowing agents are preferred
from an ozone depletion potential (ODP) perspective as well as a
global warming potential (GWP) perspective, the third stream within
the spray gun offers the ability to use a myriad of blowing agents,
alone or in combination with others, the combination in one aspect
including all non-flammable blowing agents, while in another aspect
including a combination of non-flammable and flammable blowing
agents. A non-limiting list of other blowing agents includes, but
is not limited to air, C.sub.1 to C.sub.6 hydrocarbons, C.sub.1 to
C.sub.8 alcohols, ethers, diethers, aldehydes, ketones,
hydrofluoroethers, C.sub.1 to C.sub.4 chlorocarbons, methyl
formate, water, carbon dioxide, C.sub.3 to C.sub.4
hydrofluoroolefins, and C.sub.3 to C.sub.4
hydrochlorofluoroolefins. Examples of these non-exclusively include
one or more of difluoromethane, trans-1,2-dichloroethylene,
difluoroethane, 1,1,1,2,2-pentafluoroethane,
1,1,2,2-tetrafluoroethane, 1,1,1,2-tetrafluoroethane,
1,1,1-trifluoroethane, 1,1-difluoroethane, fluoroethane,
hexafluoropropane isomers, including HFC-236fa, pentafluoropropane
isomers of HFC-245fa, heptafluoropropane isomers, including
HFC-227ea, hexafluorobutane isomers, and pentafluorobutane isomers
including HFC-365mfc, tetrafluoropropane isomers, and
trifluoropropene isomers (HFO-1243). Specifically included are all
molecules and isomers of HFO-1234, including
1,1,1,2-tetrafluoropropene (HFO-1234yf),
trans-1-chloro-3,3,3-trifluoropropene (HFO-1233zd(E)) sold under
the trade name Solstice LBP by Honeywell and cis- and
trans-1,2,3,3-tetrafluoropropene (HFO-1234ye), HFC-1233zd, and
HFC-1225ye. The blowing agents may be used in combination with at
least one co-blowing agent which non-exclusively include:
hydrocarbons, methyl formate, halogen containing compounds,
especially fluorine containing compounds and chlorine containing
compounds such as halocarbons, fluorocarbons, chlorocarbons,
fluorochlorocarbons, halogenated hydrocarbons such as
hydrofluorocarbons, hydrochlorocarbons, hydrofluorochlorocarbons,
hydrofluoroolefins, hydrochlorofluoroolefins, CO.sub.2, CO.sub.2
generating materials such as water, and organic acids that produce
CO.sub.2 such as formic acid. Examples non-exclusively include
low-boiling, aliphatic hydrocarbons such as ethane, propane(s),
i.e. normal pentane, isopropane, isopentane and cyclopentane;
butanes(s), i.e. normal butane and isobutane; ethers and
halogenated ethers; trans 1,2-dichloroethylene, pentafluorobutane;
pentafluoropropane; hexafluoropropane; and heptafluoropropane;
1-chloro-1,2,2,2-tetrafluoroethane (HCFC-124); and
1,1-dichloro-1-fluoroethane (HCFC-141b) as well as
1,1,2,2-tetrafluoroethane (HFC-134); 1,1,1,2-tetrafluoroethane
(HFC-134a); 1-chloro 1,1-difluoroethane (HCFC-142b);
1,1,1,3,3-pentafluorobutane (HFC-365mfc);
1,1,1,2,3,3,3-heptafluoropropane (HCF-227ea);
trichlorofluoromethane (CFC-11), dichlorodifluoromethane (CFC-12);
1,1,1,3,3,3-hexafluoropropane (HFC-236fa);
1,1,1,2,3,3-hexafluoropropane (HFC-236ea); difluoromethane
(HFC-32); difluoroethane (HFC-152a); trifluoropropenes,
pentafluoropropenes, chlorotrifluoropropenes, tetrafluoropropenes
including 1,1,1,2-tetrafluoropropene (HFO-1234yf),
1,1,1,2,3-pentafluoropropene (HFO-1225ye), and
1-chloro-3,3,3-trifluoropropene (HCFC-1233zd). Combinations of any
of the aforementioned are useful including blends and azeotropes
thereof. The relative amount of any of the above noted additional
co-blowing agents, as well as any additional components included in
present compositions, can vary widely within the general broad
scope of the present invention according to the particular
application for the composition, and all such relative amounts are
considered to be within the scope hereof.
[0090] As used herein, a non-limiting definition for the term
"co-blowing agent" which includes mixtures or miscible blends
and/or azeotropes of blowing agents, means a one or more co-blowing
agents, co-propellants, or co-solvents which are useful and provide
efficacy to various applications in the form of insulation
performance, pressure performance, or solubility, without
deleterious effect due to molar gas volume, flammability
mitigation, or GWP reduction. These co-agents include but are not
limited to those described previously.
[0091] The application will now be described in a non-limiting,
exemplary, hypothetical series of examples as summarized in the
following table in which the contents of the "C" stream represents
the third stream content.
TABLE-US-00006 TABLE I Water Partitioning Reactant Example #1
Example #2 Example #3 Stream A B C A B C A B C pMDI 94.0% 94.0%
94.0% Voranol 360 20.0% 20.0% 35.0% TB-350 20.0% 38.0% 20.0% 20.0%
20.0% 20.0% TCPP 28.0% 28.0% 28.0% 28.0% 25.0% 28.0% PHT4-Diol
28.0% 5.0% 10.0% 10.0% Surfactant(s) 2.0% 2.0% 2.0% 2.0% 2.0% HFO
6.0% 28.0% 6.0% 40.0% 6.0% 40.0% Nitrogen/Air 200 psig 200 psig 200
psig Polycat .RTM. 12 2.0% 1.5% 1.0% Polycat .RTM. 5 2.0% 1.5% 2.5%
Dabco .RTM. T 1.5% Water 0.0% 2.0% 15.0% Total 100% 100% 100% 100%
100% 100% 100% 100% 100%
[0092] Example #1 illustrates the ability supplement the amount of
polyols in the final composition by allocating a portion of the
amount to both the "B" and "C" cylinders. The catalyst is added to
both streams and the pressurizing agent for the "B" stream is
nitrogen and/or air which obviously contains nitrogen, while the
HFO blowing agent is only illustrated as being contained in the "A"
and "C" cylinders. No added water is present in the reactants. When
higher amounts of HFO are employed (see Example #2), as well as
added water, the HFO blowing agent is preferably not added to the
cylinders containing the blowing agent due to shelf life and
performance characteristics. The addition of water has
traditionally limited the type (and amounts) of catalysts employed
in the reaction. Example #3 illustrates how this might impact the
formulation.
TABLE-US-00007 TABLE II Autocatalytic Polyols Reactant Example #4
Example #5 Example #6 Stream A B C A B C A B C pMDI 88.0% 88.0%
88.0% Carpol TEAP-265 20.0% Jeffamine D-2000 20.0% Poly-G .RTM.
70-600 20.0% TB-350 30.0% 23.0% 30.0% 23.0% 30.0% 23.0% TCPP 35.0%
35.0% 35.0% 35.0% 35.0% 35.0% PHT4-Diol 11.0% 10.4% 10.0%
Surfactant(s) 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% HFO
10.0% 40.0.% 10.0% 40.0% 10.0% 40.0% Nitrogen/Air 200 psig 200 psig
200 psig Dabco .RTM. 33 LV 0.5% 0.5% 0.5% Dabco .RTM. T 120 0.5%
0.0% 0.5% Dabco .RTM. K-15 1.0% 1.1% 0.0% Water 0.0% 1.0% 2.0%
Total 100% 100% 100% 100% 100% 100% 100% 100% 100%
[0093] Examples #4-#6 illustrate the flexibility of the
three-stream system when there is no HFO in the "B" cylinder
stream, thereby permitting the use of catalysts which would
normally not be usable with HFO blowing agents.
TABLE-US-00008 TABLE III Polyether Polyols Reactants Example #7
Example #8 Example #9 Stream A B C A B C A B C pMDI 84.0% 84.0%
84.0% Voranol 360 40.0% 20.0% Poly-G .RTM. 30-168 20.0% 20.0%
Poly-G .RTM. 30-42 10.0% 10.0% 20.0% TB-350 30.0% 18.0% 10.0% 40.0%
TCPP 10.0% 20.0% 27.0% 10.0% 32.0% 47.0% 10.0% 45.0% 12% PHT4-Diol
10.0% 5.0% 5.0% Surfactant(s) 3.0% 3.0% 3.0% 3.0% 3.0% 3.0% HFO
6.0% 36.0% 6.0% 36.0% 6.0% 36.0% Nitrogen/Air 200 psig 200 psig 200
psig Polycat .RTM. 12 6.0% 6.0% 6.0% Polycat .RTM. 5 2.0% 2.0% 2.0%
Dabco .RTM. K-15 2.0% 2.0% 2.0% Water 1.0% 1.0% 1.0% Total 100%
100% 100% 100% 100% 100% 100% 100% 100%
[0094] Examples #7-#9 illustrate the ability to employ various
catalysts in different reactant streams when using HFO blowing
agents.
TABLE-US-00009 TABLE IV Miscellaneous Reactant Example #10 Example
#11 Example #12 Stream A B C A B C A B C pMDI 94.0% 94.0% 94.0%
Multranol 8114 30.0% 10.0% Poly-G .RTM. 37-600 10.0% Poly-G .RTM.
76-120 9.5% 10.0% TB-350 20.0% 25.0% 26.5% 20.0% 38.0% TCPP 25.0%
40.0% 30.0% 35.0% 35.0% 25.0% PHT4-Diol 15.0% 15.0% 5.0% 30.0% 5.0%
Surfactant 2.0% 2.0% 4.0% 4.0% HFO 6.0% 40.0% 6.0% 40.0% 6.0% 40.0%
Nitrogen/Air 200 psig 200 psig 200 psig Dabco .RTM. T 0.5% 1.0%
Polycat .RTM. 5 0.5% 0.5% 1.0% Dabco .RTM. K-15 1.5% 1.0% 1.0%
Water 1.0% 2.0% 1.0% Total 100% 100% 100% 100% 100% 100% 100% 100%
100%
[0095] Examples #10-12 further illustrate the flexibility of the
three-component system when it comes to composition of the
reactants in each respective feed stream (cylinder).
[0096] Advantages of Third Stream Capability when Using HFOs as a
Blowing Agent
[0097] HFOs, HydroFluoroOlefins, which contain a double bond are
inherently unstable as evidenced in their low, below 10, global
warming potentials. In comparison, the most commonly and currently
used alkane HFC, HydroFluoroCarbon, 134a, has a GWP of
approximately 1350. Due to HFO's relatively short atmospheric life
time, it can be readily seen that their use in low pressure
polyurethane spray and pour in place systems which are required to
maintain desirable physical properties for a year's shelf life are
problematic. These disposable and refillable systems must maintain
year-long shelf life stability while under pressure and exposed to
high working temperatures.
[0098] Because of this instability, the formulator of such HFO
blown systems, in comparison to established HFC blown systems, has
been severely constrained as to which chemicals can be used in
order to create a stable system. Of key importance is the
deleterious effect of the following: established tertiary amine
catalysts cannot be used; less aggressive (sterically hindered)
catalysts must be substituted (this prevents the system from
achieving a desirable quick cure time); polyol selection is
constrained; polyether polyols cannot be used; autocatalytic (amine
containing) polyols cannot be used; flame retardant loading is
constrained; TCPP levels above 37% B-side blend by weight are
deleterious, (presents potential problems for achieving acceptable
flame ratings); water loading levels are constrained (water loading
levels above 2% are deleterious); prevents the formulation of low
density/open cell foams which have better yield.
[0099] Third stream capability will separate the incompatible raw
material streams while allowing the use of the aforementioned and
established raw materials commonly utilized to produce low
pressure, two component polyurethane foam systems. This will allow
for the return to standard practice.
[0100] Additionally, it is noted that when air and/or air/nitrogen
mixtures are employed in the third stream, the surface
characteristics of the blown foam are slightly different than when
no third stream is used. Specifically, the ratio of "high" to "low"
spots as measured by a calipers indicates that the value of the
ratio is closer to 1, and hence, the "smoother" the surface. The
decrease in the ratio is at least 5% closer to 1 than when no third
stream is present, preferably at least 10% closer to 1 in
comparison to no third stream . . . and in a more preferred
embodiment, the decrease is at least 25% closer to 1 in comparison
to no third stream being utilized.
[0101] Color-Changing Nozzles
[0102] The color-changing aspects of the invention above, use
thermochromism which is typically implemented via one of two common
approaches: liquid crystals and leuco dyes. Liquid crystals are
used in precision applications, as their responses can be
engineered to accurate temperatures, but their color range is
limited by their principle of operation. Leuco dyes allow wider
range of colors to be used, but their response temperatures are
more difficult to set with accuracy.
[0103] Some liquid crystals are capable of displaying different
colors at different temperatures. This change is dependent on
selective reflection of certain wavelengths by the crystalline
structure of the material, as it changes between the
low-temperature crystalline phase, through anisotropic chiral or
twisted nematic phase, to the high-temperature isotropic liquid
phase. Only the nematic mesophase has thermochromic properties.
This restricts the effective temperature range of the material.
[0104] The twisted nematic phase has the molecules oriented in
layers with regularly changing orientation, which gives them
periodic spacing. The light passing through the crystal undergoes
Bragg diffraction on these layers, and the wavelength with the
greatest constructive interference is reflected back, which is
perceived as a spectral color. A change in the crystal temperature
can result in a change of spacing between the layers and therefore
in the reflected wavelength. The color of the thermochromic liquid
crystal can therefore continuously range from non-reflective
(black) through the spectral colors to black again, depending on
the temperature. Typically, the high temperature state will reflect
blue-violet, while the low-temperature state will reflect
red-orange. Since blue is a shorter wavelength than red, this
indicates that the distance of layer spacing is reduced by heating
through the liquid-crystal state.
[0105] Some such materials are cholesteryl nonanoate or
cyanobiphenyls. Liquid crystals used in dyes and inks often come
microencapsulated, in the form of suspension. Liquid crystals are
used in applications where the color change has to be accurately
defined.
[0106] Thermochromic dyes are based on mixtures of leuco dyes with
suitable other chemicals, displaying a color change (usually
between the colorless leuco form and the colored form) in
dependence on temperature. The dyes are rarely applied on materials
directly; they are usually in the form of microcapsules with the
mixture sealed inside. An illustrative example would include
microcapsules with crystal violet lactone, weak acid, and a
dissociable salt dissolved in dodecanol; when the solvent is solid,
the dye exists in its lactone leuco form, while when the solvent
melts, the salt dissociates, the pH inside the microcapsule lowers,
the dye becomes protonated, its lactone ring opens, and its
absorption spectrum shifts drastically, therefore it becomes deeply
violet. In this case the apparent thermochromism is in fact
halochromism.
[0107] The dyes most commonly used are spirolactones, fluorans,
spiropyrans, and fulgides. The weak acids include bisphenol A,
parabens, 1,2,3-triazole derivates, and 4-hydroxycoumarin and act
as proton donors, changing the dye molecule between its leuco form
and its protonated colored form; stronger acids would make the
change irreversible.
[0108] Leuco dyes have less accurate temperature response than
liquid crystals. They are suitable for general indicators of
approximate temperature. They are usually used in combination with
some other pigment, producing a color change between the color of
the base pigment and the color of the pigment combined with the
color of the non-leuco form of the leuco dye. Organic leuco dyes
are available for temperature ranges between about 23.degree. F.
(-5.degree. C.) and about 140.degree. F. (60.degree. C.), in wide
range of colors. The color change usually happens in about a
5.4.degree. F. (3.degree. C.) interval.
[0109] The size of the microcapsules typically ranges between 3-5
.mu.m (over 10 times larger than regular pigment particles), which
requires some adjustments to printing and manufacturing
processes.
[0110] Thermochromic paints use liquid crystals or leuco dye
technology. After absorbing a certain amount of light or heat, the
crystalline or molecular structure of the pigment reversibly
changes in such a way that it absorbs and emits light at a
different wavelength than at lower temperatures.
[0111] The thermochromic dyes contained either within or affixed
upon either the disposable nozzle or hoses may be configured to
change the color of the composition in various ways. For example,
in one embodiment, once the composition reaches a selected
temperature, the composition may change from a base color to a
white color or a clear color. In another embodiment, a pigment or
dye that does not change color based on temperature may be present
for providing a base color. The thermochromic dyes, on the other
hand, can be included in order to change the composition from the
base color to at least one other color.
[0112] In one particular embodiment, the plurality of thermochromic
dyes are configured to cause the cleansing composition to change
color over a temperature range of at least about 3.degree. C., such
as at least about 5.degree. C., once the composition is heated to a
selected temperature. For example, multiple thermochromic dyes may
be present within the cleansing composition so that the dyes change
color as the composition gradually increases in temperature. For
instance, in one embodiment, a first thermochromic dye may be
present that changes color at a temperature of from about
23.degree. C. to about 28.degree. C. and a second thermochromic dye
may be present that changes color at a temperature of from about
27.degree. C. to about 32.degree. C. If desired, a third
thermochromic dye may also be present that changes color at a
temperature of from about 31.degree. C. to about 36.degree. C. In
this manner, the cleansing composition changes color at the
selected temperature and then continues to change color in a
stepwise manner as the temperature of the composition continues to
increase. It should be understood that the above temperature ranges
are for exemplary and illustrative purposes only.
[0113] Any thermochromic substance that undergoes a color change at
the desired temperature may generally be employed in the present
disclosure. For example, liquid crystals may be employed as a
thermochromic substance in some embodiments. The wavelength of
light ("color") reflected by liquid crystals depends in part on the
pitch of the helical structure of the liquid crystal molecules.
Because the length of this pitch varies with temperature, the color
of the liquid crystals is also a function of temperature. One
particular type of liquid crystal that may be used in the present
disclosure is a liquid crystal cholesterol derivative. Exemplary
liquid crystal cholesterol derivatives may include alkanoic and
aralkanoic acid esters of cholesterol, alkyl esters of cholesterol
carbonate, cholesterol chloride, cholesterol bromide, cholesterol
acetate, cholesterol oleate, cholesterol caprylate, cholesterol
oleyl-carbonate, and so forth. Other suitable liquid crystal
compositions are possible and contemplated within the scope of the
invention.
[0114] In addition to liquid crystals, another suitable
thermochromic substance that may be employed in the present
disclosure is a composition that includes a proton accepting
chromogen ("Lewis base") and a solvent. The melting point of the
solvent controls the temperature at which the chromogen will change
color. More specifically, at a temperature below the melting point
of the solvent, the chromogen generally possesses a first color
(e.g., red). When the solvent is heated to its melting temperature,
the chromogen may become protonated or deprotonated, thereby
resulting in a shift of the absorption maxima. The nature of the
color change depends on a variety of factors, including the type of
proton-accepting chromogen utilized and the presence of any
additional temperature-insensitive chromogens. Regardless, the
color change is typically reversible.
[0115] Although not required, the proton-accepting chromogen is
typically an organic dye, such as a leuco dye. In solution, the
protonated form of the leuco dye predominates at acidic pH levels
(e.g., pH of about 4 or less). When the solution is made more
alkaline through deprotonation, however, a color change occurs. Of
course, the position of this equilibrium may be shifted with
temperature when other components are present. Suitable and
non-limiting examples of leuco dyes for use in the present
disclosure may include, for instance, phthalides; phthalanes;
substituted phthalides or phthalanes, such as triphenylmethane
phthalides, triphenylmethanes, or diphenylmethanes;
acyl-leucomethylene blue compounds; fluoranes; indolylphthalides,
spiropyranes; cumarins; and so forth. Exemplary fluoranes include,
for instance, 3,3'-dimethoxyfluorane, 3,6-dimethoxyfluorane,
3,6-di-butoxyfluorane, 3-chloro-6-phenylamino-flourane,
3-diethylamino-6-dimethylfluorane,
3-diethylamino-6-methyl-7-chlorofluorane, and
3-diethyl-7,8-benzofluorane,
3,3'-bis-(p-dimethyl-aminophenyl)-7-phenylaminofluorane,
3-diethylamino-6-methyl-7-phenylamino-fluorane,
3-diethylamino-7-phenyl-aminofluorane, and
2-anilino-3-methyl-6-diethylamino-fluorane. Likewise, exemplary
phthalides include 3,3',3''-tris(p-dimethylamino-phenyl)phthalide,
3,3'-bis(p-dimethyl-aminophenyl)phthalide,
3,3-bis(p-diethylamino-phenyl)-6-dimethylamino-phthalide,
3-(4-diethylaminophenyl)-3-(1-ethyl-2-methylindol-3-yl)phthalide,
and
3-(4-diethylamino-2-methyl)phenyl-3-(1,2-dimethylindol-3-yl)phthalide.
[0116] Although any solvent for the thermochromic dye may generally
be employed in the present disclosure, it is typically desired that
the solvent have a low volatility. For example, the solvent may
have a boiling point of about 150.degree. C. or higher, and in some
embodiments, from about 170.degree. C. to 280.degree. C. Likewise,
the melting temperature of the solvent is also typically from about
25.degree. C. to about 40.degree. C., and in some embodiments, from
about 30.degree. C. to about 37.degree. C. Examples of suitable
solvents may include saturated or unsaturated alcohols containing
about 6 to 30 carbon atoms, such as octyl alcohol, dodecyl alcohol,
lauryl alcohol, cetyl alcohol, myristyl alcohol, stearyl alcohol,
behenyl alcohol, geraniol, etc.; esters of saturated or unsaturated
alcohols containing about 6 to 30 carbon atoms, such as butyl
stearate, methyl stearate, lauryl laurate, lauryl stearate, stearyl
laurate, methyl myristate, decyl myristate, lauryl myristate, butyl
stearate, lauryl palmitate, decyl palmitate, palmitic acid
glyceride, etc.; azomethines, such as benzylideneaniline,
benzylidenelaurylamide, o-methoxybenzylidene laurylamine,
benzylidene p-toluidine, p-cumylbenzylidene, etc.; amides, such as
acetamide, stearamide, etc.; and so forth.
[0117] The thermochromic composition may also include a
proton-donating agent (also referred to as a "color developer") to
facilitate the reversibility of the color change. Such
proton-donating agents may include, for instance, phenols, azoles,
organic acids, esters of organic acids, and salts of organic acids.
Exemplary phenols may include phenylphenol, bisphenol A, cresol,
resorcinol, chlorolucinol, b-naphthol, 1,5-dihydroxynaphthalene,
pyrocatechol, pyrogallol, trimer of p-chlorophenol-formaldehyde
condensate, etc. Exemplary azoles may include benzotriaoles, such
as 5-chlorobenzotriazole, 4-laurylaminosulfobenzotriazole,
5-butylbenzotriazole, dibenzotriazole, 2-oxybenzotriazole,
5-ethoxycarbonylbenzotriazole, etc.; imidazoles, such as
oxybenzimidazole, etc.; tetrazoles; and so forth. Exemplary organic
acids may include aromatic carboxylic acids, such as salicylic
acid, methylenebissalicylic acid, resorcylic acid, gallic acid,
benzoic acid, p-oxybenzoic acid, pyromellitic acid, b-naphthoic
acid, tannic acid, toluic acid, trimellitic acid, phthalic acid,
terephthalic acid, anthranilic acid, etc.; aliphatic carboxylic
acids, such as stearic acid, 1,2-hydroxystearic acid, tartaric
acid, citric acid, oxalic acid, lauric acid, etc.; and so forth.
Exemplary esters may include alkyl esters of aromatic carboxylic
acids in which the alkyl moiety has 1 to 6 carbon atoms, such as
butyl gallate, ethyl p-hydroxybenzoate, methyl salicylate, etc.
[0118] The amount of the proton-accepting chromogen employed may
generally vary, but is typically from about 2 wt. % to about 20 wt.
%, and in some embodiments, from about 5 to about 15 wt. % of the
thermochromic substance. Likewise, the proton-donating agent may
constitute from about 5 to about 40 wt. %, and in some embodiments,
from about 10 wt. % to about 30 wt. % of the thermochromic
substance. In addition, the solvent may constitute from about 50
wt. % to about 95 wt. %, and in some embodiments, from about 65 wt.
% to about 85 wt. % of the thermochromic composition.
[0119] Regardless of the particular thermochromic substance
employed, it may be microencapsulated to enhance the stability of
the substance during processing. For example, the thermochromic
substance may be mixed with a thermosetting resin according to any
conventional method, such as interfacial polymerization, in-situ
polymerization, etc. The thermosetting resin may include, for
example, polyester resins, polyurethane resins, melamine resins,
epoxy resins, diallyl phthalate resins, vinylester resins, and so
forth. The resulting mixture may then be granulated and optionally
coated with a hydrophilic macromolecular compound, such as alginic
acid and salts thereof, carrageenan, pectin, gelatin and the like,
semisynthetic macromolecular compounds such as methylcellulose,
cationized starch, carboxymethylcellulose, carboxymethylated
starch, vinyl polymers (e.g., polyvinyl alcohol),
polyvinylpyrrolidone, polyacrylic acid, polyacrylamide, maleic acid
copolymers, and so forth. The resulting thermochromic microcapsules
typically have a size of from about 1 to about 50 micrometers, and
in some embodiments, from about 3 to about 15 micrometers. Various
other microencapsulation techniques may also be used.
[0120] Thermochromic dyes are commercially available from various
sources. In one embodiment, for instance, thermochromic dyes
marketed by Chromadic Creations, Hamilton, Ontario and sold under
the trade name SpectraBurst Thermochromic Polypropylene.
[0121] The thermochromic dyes can be present in the composition in
an amount sufficient to have a visual effect on the color of the
composition. The amount or concentration of the dyes can also be
increased or decreased depending upon the desired intensity of any
color. In general, the thermochromic dyes may be present in the
composition in an amount from about 0.01% by weight to about 9% by
weight, such as from about 0.1% by weight to about 3% by weight.
For instance, in one particular embodiment, the thermochromic dyes
may be present in an amount from about 0.3% to about 1.5% by
weight.
[0122] As described above, thermochromic dyes typically change from
a specific color to clear at a certain temperature, e.g., dark blue
below 60.degree. F. (15.6.degree. C.) to transparent or translucent
above 60.degree. F. (15.6.degree. C.). If desired, other pigments
or dyes can be added to the composition in order to provide a
background color that remains constant independent of the
temperature of the composition. By adding other pigments or dyes in
combination with the thermochromic dyes to the composition, the
thermochromic dyes can provide a color change at certain
temperatures rather than just a loss of color should the
thermochromic dye become clear. For instance, a non-thermochromic
pigment, such as a yellow pigment, may be used in conjunction with
a plurality of thermochromic dyes, such as a red dye and a blue
dye. When all combined together, the cleansing composition may have
a dark color. As the composition is increased in temperature, the
red thermochromic dye may turn clear changing the color to a green
shade (a combination of yellow and blue). As the temperature
further increases, the blue thermochromic dye turns clear causing
the composition to turn yellow.
[0123] It should be understood, that all different sorts of
thermochromic dyes and non-thermochromic pigments and dyes may be
combined in order to produce a composition having a desired base
color and one that undergoes desired color changes. The color
changes, for instance, can be somewhat dramatic and fanciful. For
instance, in one embodiment, the composition may change from green
to yellow to red.
[0124] In an alternative embodiment, however, the composition can
contain different thermochromic dyes all having the same color. As
the temperature of the composition is increased, however, the shade
or intensity of the color can change. For instance, the composition
can change from a vibrant blue to a light blue to a clear
color.
[0125] In addition to the above, it should be understood that many
alterations and permutations are possible. Any of a variety of
colors and shades can be mixed in order to undergo color changes as
a function of temperature.
[0126] While the invention has been described with reference to
certain embodiments, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted without departing from the scope of the invention. In
addition, many modifications may be made to adapt a particular
situation or material to the teachings of the invention without
departing from its scope. Therefore, it is intended that the
invention not be limited to the particular embodiment disclosed,
but that the invention will include all embodiments falling within
the scope of the appended claims.
* * * * *