Abstract: A fluid delivery system is provided as a modular system. The fluid delivery system provides a fluid to a robotic spray applicator system that may be used to spray a mold with a motor release compound or in-mold coating. The fluid to be dispensed is contained in the drum and is provided through a fluid circuit including a peristaltic pump, a filter and a heater. The fluid is pumped through the fluid circuit to an applicator that dispenses the fluid onto a mold. The system may also be used in conjunction with adhesives or other compositions that must be filtered, heated and provided to a spray applicator at a metered flow rate. The fluid delivery system may be used in conjunction with a robotic system. The displacement of the peristaltic pump may be controlled by a variable frequency drive or may be controlled by a programmable logic controller of the robotic system.

Abstract: A system and method for spray application of polyurethane used to spray form an article is disclosed. A spray nozzle is rotated as the polyurethane composition is sprayed onto a mold surface to apply a swath of polyurethane to the mold surface. The spray nozzle may be of an internal mixing or external mixing type that is moved relative to a mold surface in a path to create a skin layer with multiple partially overlapping swaths being applied in multiple passes. A motor and gear drive are used to rotate the nozzle tip and associated structure.

Abstract: A spray applicator for dispensing a multiple component reactant mixture and for also dispensing purge materials. The applicator has a valve plate with a plurality of valve seats for cylindrical valve elements that are arcuately shifted by a control air circuit.

Abstract: An in-mold applicator and method for spraying a coating on difficult-to-reach surfaces of a mold is disclosed. The applicator includes a spray head and a base portion at an oblique angle to each other. The outer dimensions of the body portion and the spray head are sufficiently small so that taken in combination with the oblique angle, the applicator and method can enhance the spraying of the coating to difficult-to-reach surfaces within the mold.

Abstract: A method of forming a polyurethane article wherein first and second components of a polyurethane system are sprayed into an unconfined space above a mold. The first and second components are sprayed together to mix initially in the space above the mold and then are deposited in the mold on an in-mold coating that was previously applied to the mold. The two components of the polyurethane system and in-mold coating are subsequently removed from the mold as a flexible polyurethane skin. The skin may then be placed in a second mold along with a reinforcement. Structural polyurethane foam may then be injected to the second mold where it bonds to the reinforcement and the skin to form a finished polyurethane article having a flexible skin adhered to its surface. A post-mix spray nozzle assembly is provided with a central nozzle forming a first hollow conical spray pattern and a coaxially aligned annular nozzle forming a second hollow conical spray pattern.

Abstract: A fluid delivery system is provided as a modular system. The fluid delivery system provides a fluid to a robotic spray applicator system that may be used to spray a mold with a motor release compound or in-mold coating. The fluid to be dispensed is contained in the drum and is provided through a fluid circuit including a peristaltic pump, a filter and a heater. The fluid is pumped through the fluid circuit to an applicator that dispenses the fluid onto a mold. The system may also be used in conjunction with adhesives or other compositions that must be filtered, heated and provided to a spray applicator at a metered flow rate. The fluid delivery system may be used in conjunction with a robotic system. The displacement of the peristaltic pump may be controlled by a variable frequency drive or may be controlled by a programmable logic controller of the robotic system.

Abstract: A method of spray forming articles with a nozzle that sprays in a flat fan-shaped spray pattern. The process may be used to form articles from a polyurethane composition. Repeated passes of the nozzle that partially overlap apply a deposit in a series of parallel paths. A primary flat fan-shaped spray is flanked by a pair of secondary sprays that are outboard of the primary spray. The secondary sprays facilitate feathering the edges of adjacent deposits and provide a spray application having a consistent thickness.

Abstract: A method of forming a polyurethane article wherein first and second components of a polyurethane system are sprayed into an unconfined space above a mold. The first and second components are sprayed together to mix initially in the space above the mold and then are deposited in the mold on an in-mold coating that was previously applied to the mold. The two components of the polyurethane system and in-mold coating are subsequently removed from the mold as a flexible polyurethane skin. The skin may then be placed in a second mold along with a reinforcement. Structural polyurethane foam may then be injected to the second mold where it bonds to the reinforcement and the skin to form a finished polyurethane article having a flexible skin adhered to its surface. A post-mix spray nozzle assembly is provided with a central nozzle forming a first hollow conical spray pattern and a coaxially aligned annular nozzle forming a second hollow conical spray pattern.

Abstract: An in-mold applicator and method for spraying a coating on difficult-to-reach surfaces of a mold is disclosed. The applicator includes a spray head and a base portion at an oblique angle to each other. The outer dimensions of the body portion and the spray head are sufficiently small so that taken in combination with the oblique angle, the applicator and method can enhance the spraying of the coating to difficult-to-reach surfaces within the mold.