MOBILE FOAM DISPENSER

Abstract

A foam dispenser assembly may include a base portion, a flexible-walled vessels for A and B components that may include walls that define a volume and an opening, an insert within the volume to separate the walls and maintain the opening unobstructed when the volume is under a negative pressure, and a dry disconnect coupling connected to the opening. A head portion that may be connected to the base portion and associated with the flexible-walled vessels may include a tank and a nozzle assembly that mixes the A and B components and dispenses a foam product generated thereby. The tank is preferably disposed adjacent to the nozzle assembly and in communication with one of the flexible-walled vessels and the nozzle assembly. The tank may include a warming assembly.

Description

RELATED APPLICATIONS

This application is a non-provisional patent application that claims the benefit of and the priority from U.S. Provisional Patent Application No. 61/386,878, filed Sep. 27, 2010, titled FOAM DISPENSER and is a continuation-in-part patent application that claims the benefit of and the priority from U.S. patent application Ser. No. 13/160,327, filed Jun. 14, 2011, titled FOAM DISPENSER, which is a non-provisional patent application that claims the benefit of and priority from U.S. Provisional Patent Application No. 61/354,540, filed Jun. 14, 2010, titled FOAM DISPENSER, all of which are expressly incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to foam dispensers, and more particularly, to a mobile self-contained foam dispensing assembly.

BACKGROUND

It is commonly understood and known that mixing A and B components (i.e., isocyanate is commonly referred to as the “A component” and or just the “iso” and the blend of polyols and other additives is commonly referred to as the “B component” or as the “poly”) will generate a polyurethane foam product that may be used advantageously in packaging and other industries. For example, the foam products may function as packing material to protect items during transportation.

In many cases, a foam dispensing device, such as a gun, may be used to generate the foam at packaging sites. For example, the shipped item may be placed inside a box that is larger than the item and the empty volume between the interior surfaces of the box and the exterior surfaces of the item may be filled with the expanding foam which is preferably confined by a barrier, such as a plastic bag, or vice verse with the item. This foam packaging technology may be used as an alternate to other known packaging technologies such as small packing chips, a sheet of bubble wrap, or other lose packing material. Conventional foam dispensing devices may use a foam guns to produce the packaging foam. Such devices may also generally include pumps, one to control the flow of each of the two chemical components to precise and required amounts to achieve the proper mix. The storage containers for the A and B components may also be heated using heating coils to achieve a better mix or to change the time for hardening of the foam. However, one disadvantage with heating the A and B components is that conventional methods adjust the temperature of the components at the bulk container for the components. Also, heating of the container is inefficient, which is why conventional foam dispensing devices use heated hoses which are very expensive. Additionally, in those foam dispensing devices that heat the container and use a flexible bag, there is considerable inefficiencies because the heat source warms a metal plate that is in contact with the aluminum foil bag. As a result, there is considerable resistance and convective losses. Moreover, when heating the contents of the entire container, any adjustments to the temperature will be slow due to the considerable mass versus the heat source energy that can be provided. As a result, disadvantageous solutions have been developed, such as for example, a specific container must be used, an additional device must be inserted into the container or the warming apparatus must be adapted to be used in connection with the container. Another disadvantage, is the inability to extract or use nearly or virtually all of the A or B component in the container, especially in the instance where a flexible container is used that often collapses before a substantial majority of the applicable component has been extracted.

The hardening foam for packing has a plurality of commercial application, one of which is packaging and shipping of fragile items. In one embodiment, two flexible plastic bags are used to confine the solidifying foam as it expands and hardens. In an empty box, a first bag is filled with a pre-determined volume of expanding foam. The bag is rested in the bottom of the box and the fragile item is placed in the foam as it hardens. To complete protection, a second bag may be used cover the upper portion of the fragile item not covered by the expanding foam of the first bag.

In other foam producing devices, instead of using a pump driven by a motor, the device may use pressurized air or gas in the storage containers for the A and B components. However, using the pressurized container technology to produce the foam product results in difficulties of control for the proportion of each of the chemicals at the mixing point.

Therefore, it is desirous to have a new and non-obvious foam dispenser assembly including a warming apparatus remote from the A and B component containers yet very close to the dispensing nozzle that warms smaller volumes accurately and flexible-walled A and B component vessels that can be nearly or virtually completely emptied, among other things.

BRIEF DESCRIPTION OF THE DRAWINGS

The following disclosure as a whole may be best understood by reference to the provided detailed description when read in conjunction with the accompanying drawings, drawing description, abstract, background, field of the disclosure, and associated headings. Identical reference numerals when found on different figures identify the same elements or a functionally equivalent element. The elements listed in the abstract are not referenced but nevertheless refer by association to the elements of the detailed description and associated disclosure. Certain embodiments are shown in the drawings. However, it is understood that the present disclosure is not limited to the arrangements and instrumentality shown in the attached drawings.

FIG. 1 is a rear isometric view of the mobile foam dispensing assembly in accordance with one embodiment of the present disclosure.

FIG. 2 is a side view of the mobile foam dispensing assembly as shown in FIG. 1.

FIG. 3 is a front view of the mobile foam dispensing as shown in FIG. 1.

FIG. 4A1 is a front isometric view of one embodiment of a base attachment assembly useful in connection with the mobile foam dispensing assembly as shown in FIG. 1.

FIG. 4A2 is an exploded view of the base attachment assembly embodiment of FIG. 4A1.

FIG. 4B1 is a front isometric view of another embodiment of a base attachment assembly useful in connection with the mobile foam dispensing assembly as shown in FIG. 1.

FIG. 4B2 is an exploded view of the base attachment assembly embodiment of FIG. 4B1.

FIG. 4C1 is a front isometric view of yet another embodiment of a base attachment assembly useful in connection with the mobile foam dispensing assembly as shown in FIG. 1.

FIG. 4C2 is an exploded view of the base attachment assembly embodiment of FIG. 4C1.

FIG. 5 is a partial cross-sectional view of one embodiment of one of the flexible component containers useful in connection with the mobile foam dispensing assembly as shown in FIG. 1.

FIG. 6 is a partially exploded and cross-sectional view of one embodiment of one of the tanks useful in connection with the mobile foam dispensing assembly as shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

For the purposes of promoting and understanding the principles disclosed herein, reference is now made to the preferred embodiments illustrated in the drawings, and specific language is used to describe the same. It is nevertheless understood that no limitation of the scope of the invention is hereby intended. Such alterations and further modifications in the illustrated devices and such further applications of the principles disclosed and illustrated herein are contemplated as would normally occur to one skilled in the art to which this disclosure relates.

In one aspect of the present disclosure, a foam dispenser assembly may include a base portion including a support, a flexible-walled vessels for A and B components on the support, and the A and B components each disposed in one of the respective flexible-walled vessels. One of the flexible-walled vessels may include walls that define a volume and an opening, an insert within the volume that may separate the walls and maintain the opening unobstructed when the volume is under a negative pressure, and a dry disconnect coupling connected to the walls about the opening. A head portion may be connected to the base portion and associated with each of the flexible-walled vessels that includes a tank and a nozzle assembly to mix the A and B components and dispense a foam product. The tank may be disposed adjacent to the nozzle assembly and connected to one of the flexible-walled vessels and the nozzle assembly. The tank may include a warming assembly.

In another aspect of the present disclosure, the insert may have a thickness of approximately 0.005 inches to approximately 0.100 inches, or may include a plurality of enlarged portions connected by links, an enlarged portion disposed adjacent the opening, or a main link having an enlarged portion disposed at each end of the main link, a first arm link connected to the main link having an enlarged portion at its end, and a second arm link connected to each main link enlarged portion having an enlarged portion disposed at its end, or may define a pathway through the volume when the walls are in contact over nearly all of a surface area of the walls as a result of the negative pressure so that nearly 100% of the contents of the flexible-walled vessel are withdrawn through the opening.

In another aspect of the present disclosure, the warming assembly may include a heat sink in direct contact with the contents of one of the flexible-walled containers and a heat source or may include a baffle next to the heat sink to define a warming volume between the baffle and the heat sink with a remainder of the interior volume above the baffle that facilitates movement of the contents from the interior volume to the warming volume and retention of heat generated by the heat source within the warming volume for quicker temperature adjustment of the contents disposed in the warming volume.

FIG. 1 is a rear isometric view of the mobile foam dispensing assembly 100 in accordance with one embodiment of the present disclosure. FIGS. 2 and 3, are, respectively, side and front views of the mobile foam dispensing assembly 100 as shown in FIG. 1. In one embodiment, the foam dispensing assembly 100 may include two main elements: a head portion 100 and a base portion 104 (that may include, among other things, a vertically adjustable stand 106), both of which are similar to the corresponding parts as described in U.S. Provisional Application Nos. 61/354,540 and 61/386,878 and U.S. patent application Ser. No. 13/160,327, each of which is incorporated herein fully by reference, and for the sake of brevity will not be further repeated herein except to the extent necessary for further explanation of the subject disclosure or that there are differences applicable to the subject disclosure.

Various embodiments of the base potion 104 are shown in FIGS. 1 through 4. The base portion 104 provides support to hold the other portions of the foam dispensing assembly 100 and mobility of the foam dispensing assembly 100. In one embodiment, the base portion 104 may include casters or wheels 122 as shown or any other suitable apparatus or device that provide the intended functionality, such as moving the foam dispensing assembly 100 by an operator. In one embodiment, the base portion 104 may include a base unit 124 that may be configured from suitable components, such as metal or plastic tubing or channel, with an “H” shape, but any structure capable of supporting the other portions of the foam dispensing assembly 100 and providing mobility therefor is within the teachings of this disclosure.

The base portion 104 may also include a support 108, as shown in FIGS. 1-4, that may be configured as a shelf 126 (see FIGS. 1-4A2) or a workstation 150 (see FIGS. 4B1-4C2), both of which are preferably connected to the base unit 124. Preferably, a flexible-walled vessel 130 for each of the A and B components is disposed on the support 108. In one embodiment, the contents disposed in the respective flexible-walled vessels 130 includes the A component and the B component. The shelf 126 may have any suitable configuration or construction in order to support containers 128 to store the A and B component vessels 130 (see FIGS. 4A2, 4B2 and 4C2 and 5 with respect to the vessels 130). The workstation 150 provides the same functionality as the shelf 126, however in a different manner, namely, doors or drawers that are openable to store the A and B component vessels 130 (see FIGS. 4A2, 4B2 and 4C2 and 5 with respect to the vessels 130). In one embodiment, the workstation 150 may include a housing 152, a work surface 154, and multiple access doors or drawers 156 (the doors may open to provide access to a shelf or the drawers may slide in and out of housing 152). The work surface 154 may have any suitable surface but preferably has non-slip surface that is also friendly to a work environment that may include spills of fluids or other substances.

The housing 152 may be configured from walls defining an inner chamber. A variety of objects could be located within the inner chamber. Packaging supplies such as bags, packaging tools, or replacement components of the foam dispensing assembly (such as a nozzle) could be stored within the inner chamber. A warming element or recharge packages of chemical products for the foam dispenser could be located there as well. Alternatively, storage vessels for A and B component chemicals could be located in the inner chamber of housing 152. These storage vessels 130 could be associated, fluidly connected and in fluidic communication with the head portion 102 (and the tanks 118 as described herein) via hoses (such as 218 in FIG. 6) located either along the rectangular channel 134 or via hoses located inside rectangular channel 134. In order to facilitate the flow of the A and B components from the vessels 130 to the head portion 102, a pump or a motor could be located on or in the foam dispenser assembly 100 as described in the incorporated applications or herein.

In another embodiment, the workstation 150 may also include a work table 160, a plurality of storage bins 162 and extended compartments 164. The worktable 160 extends to the left and right lateral sides of the support 108 and the base portion 104 generally overlying and replacing the work station 150 with an increased size and raising it closer to the head portion 102. The storage bins 162 may be located beneath the work table 160 and are movable to allow access by the user of the foam dispensing unit. In FIGS. 4C1 and 4C2, the storage bins 162 are shown with open fronts to allow further access by the user. Extended compartments 164 are open containers that are movably connected to the workstation 150 via rails so as to allow the extended compartments to slide forward and backward relative to the base portion to allow access to the inside of the compartments. One of ordinary skill in the art will recognize that the storage bins and extended compartments provide additional functionality as described with respect to similar structure in the subject disclosure.

The stand 106 may include a motor for moving the two part stand up and down so as to adjust the height of the head portion 102 with respect to the base portion 104. Handles may be provided to assist movement or manually move the head portion 102 relative to the base portion 104. User inputs 105 may be located on the stand 106 within easy access for the user in order to control of the operations of the foam dispensing assembly 100, such as movement of the stand as discussed earlier or for control of the flow or temperature of chemicals. The stand 106 may also include gauges, other instruments, feedback, etc. that could provide the user with information regarding the operation of the foam dispenser assembly 100. A control unit 136 may house the electronic components of the mobile foam dispensing assembly 100 and electrically connect the other components of the foam dispensing assembly 100 requiring electrical control and power such as the head portion 102, the motor, and the control panel. The electrical controls located in the control unit 136 may also include a CPU, transformer, or other similar devices. Alternatively, the control unit 136 may also house other components of the pumping system such as a motor or a pump to fluidly connect (in fluidic communication) to facilitate movement of the A and B components from the vessels 130 to the tanks 118 and ultimately, the nozzle assembly. A motor or pump located in control unit 136 (or anywhere else on the foam dispenser assembly 100, even on or adjacent to the head portion 102) could then be fluidly connected to the A and B components and the head portion 102 (e.g., tanks 118, nozzle assembly, etc.). It is within the teachings of the present disclosure that any suitable conventional structure, apparatus, device or assembly including any electrical or mechanical connections or couplings necessary to support or facilitate the structure and functionality of the present disclosure may be incorporated or provided to achieve the described conventional functionality.

In one embodiment, at least one flexible-walled vessel 130 may include walls 140 (that may be formed of multiple layers, such as low density polyethylene, nylon, aluminum, polyethylene, and the like, etc.) connected about a perimeter 142 (in any suitable manner such as sealing, folds, lamination, or the like, etc. and may include a handle defined therein for handling by an operator) to define a volume 144 (within the perimeter) and an opening 146 (defined through the perimeter from the volume), an insert 148 disposed within the volume 144 to separate the walls 140 from one another in an area 149 adjacent to the insert 148 and to maintain the opening 146 unobstructed when the volume 144 is under a negative pressure (such as, when a pump is activated to draw the A or B component out of the respective vessel in order to move such component to the tank 118), and a dry disconnect coupling 170 (such as, for example only, a female shut-off fitment from Kent Systems, part number 4BX-220-006, a fry-break connection, that is liquid tight to prohibit leaks or the like, etc.) connected to the walls 140 about the opening 146 to seal the walls 140 to the coupling 170 for a leak-proof connection. Preferably, the insert 148 includes a plurality of enlarged portions 172 connected by links 174. In one embodiment, the insert 148 may include an enlarged portion 172 disposed adjacent the opening 146. In another embodiment, the insert 148 may include a main link 176 having an enlarged portion 172 disposed at each distal end 178 of the main link 176, a first arm link 180 connected to and extending from the main link 176 having an enlarged portion 172 disposed at a distal end 182 of the first arm link 180, and a second arm link 184 connected to and extending from each main link enlarged portion 172 having an enlarged portion 172 disposed at a distal end 186 of each second arm link 184. In one embodiment, the insert 148 may have a thickness of approximately 0.005 inches to approximately 0.100 inches. Preferably, the insert 148 thickness may be approximately 0.010 inches to approximately 0.030 inches. More preferably, the insert 148 thickness may be approximately 0.015 inches to approximately 0.025 inches. In one embodiment, an insert 148 thickness of approximately 0.020 inches is advantageous. The links and enlarged portions may have any suitable configuration in order to provide the intended functionality.

In operation, the insert 148 defines a pathway 188 through the volume 144 when the walls 140 are disposed in contact over nearly all of a plan view surface area of the walls 140 as a result of the negative pressure applied by the pump that removes the contents of the vessel (i.e., the pump is pulling or drawing the contents to another location after the pump output, but the vessel is sealed, so removal of the contents causes the walls 140 to collapse until they are in contact with one another) so that nearly 100% of the contents of the flexible-walled vessel 130 are withdrawn through the dry disconnect coupling 170. This overcomes the problem observed with similar constructions where the walls 140 collapse near the opening 146 (for the reasons set forth herein) and the remainder of the contents of the vessel 130 cannot be withdrawn by the pump without the operator jostling or manipulating the vessel 130 to re-open the collapsed walls 140 near the opening 146.

The head portion 102 may include a nozzle assembly (not shown, but fully described in incorporated applications) disposed within a nozzle housing 190 that may have a front panel 112 and a back panel 114 pivotally connected at the top at hinge 116, a control panel 120 that may have an LCD screen or other suitable user interface that can deliver information regarding operation of the foam dispensing assembly 100, stand 106, vessels 130 or nozzle assembly as well as provide user input for controlling various aspects of the foam dispensing assembly 100, and tanks 118, as shown on FIGS. 1, 2 and 6. In one embodiment, the tanks 118 may be disposed near or immediately adjacent the nozzle assembly and may be connected to the nozzle assembly by hoses or other suitable conduit for the contents that are moved from the vessels 130 by a pump disposed in the control unit 136 through similar hoses or other suitable conduits. A shield 192 may be connected to a rearmost portion of the tanks 118 for protection against impact and damage. In one embodiment, the channel 134 may be formed of links 194, similar to a chain, that form an enclosed or partially open chase or raceway in order to route the electrical power and control wires and hoses from the control unit 136 to the head portion 102 for the control panel 120, nozzle assembly and tanks 118, as applicable.

As shown in FIG. 6, the tanks 118 may include a housing 200 that defines an interior volume 196, warming assembly 198, inlet port 202, outlet port 204, cover 214 and fasteners 216 (to connected all the elements as shown into an integral unit). As described above, the inlet port 202 may be associated with the vessels 130 by connection to the pump disposed in the control unit 136 by a hose 218 or any other suitable structure that may provide the intended functionality. The outlet port 204, as described above, may be connected to the nozzle assembly by a hose 218 or any other suitable structure that may provide the intended functionality. Preferably, the hose 218 between the outlet port 204 and the nozzle assembly is as short as possible so that precise temperature control of the contents may be maintained. The warming assembly 198 may include a baffle 206, seal 208, heat sink 210 and heat source 212. In one embodiment, the heat sink 210 may have an upper side 220 in direct contact or contiguous with the contents of one of the flexible-walled vessels 130 when the contents are disposed in the interior volume 196 and a lower side 222 contiguous with a heat source 212. The heat sink 210 may be formed from any suitable heat conducting material. Preferably, such material will have a very high heat transfer coefficient. In one embodiment, the heat sink 210 may be formed from aluminum or a like material and may include a plurality of fins that extend into the interior volume 196 so as to increase the surface area of the heat sink 210 and the heat transfer capability or potential. In one embodiment, the baffle 206 may be disposed in spaced relation to the heat sink 210 to define a warming volume 224 between the baffle 206 and the heat sink 210 such that a remainder of the interior volume 196 is disposed above the baffle 206. Preferably, the baffle 206 facilitates movement of the contents from the interior volume 196 to the warming volume 224 and retention of heat generated by the heat source 212 within the warming volume 224 for quick temperature adjustment of the contents disposed in the warming volume 224. The baffle 206 may be configured with a plurality of apertures or openings in any specific or non-specific pattern or any other suitable configuration to provide the intended functionality and may be formed from metal, plastic, composite, hybrid, 2 component or any other suitable material to provide the intended functionality. In one embodiment, the heat source 212 may be configured as a cartridge heater, pair of cartridge heaters, or other suitable electrical, liquid or similar conventional apparatus, device or assembly capable of providing heat energy to the heat sink 210. Level switches 226 may be provided that may be associated with the control panel 120 or control unit 136 to facilitate control of the pumps for the contents of the vessels 130.

In operation, the vessels 130 are disposed into the containers 128, hoses 218 that are connected to the intake side of the pump in the control unit 136 may then be connected to the disconnect coupling 170 with a complimentary configured fitting for leak-proof operation disposed at a distal end of the hoses 208 (hoses connected to the outlet side of the pump are connected to the inlet port 202 on the tank 118 and hoses connected to the outlet port 204 on the tank are connected to the nozzle assembly). A preselected amount of the contents is moved from the vessels 130 to the tank 118 as determined by the level switches 226 by the pump in the control unit 136. The warming assembly 198 raises the temperature of the contents in the warming volume 224 to the desired set point and maintains such contents temperature around such predetermined by conventional control algorithms. Now, the foam dispensing assembly 100 is ready for operation as based on the indication output from the control panel 120 to the operator that all systems are ready. The operator may select the desired output from the nozzle assembly from the control panel 120, which signals the control unit 136 to perform the necessary steps in order to carry out the desired action. The assembly 100 may remain idle until another foam dispensing request is made from the control panel 120.

It is understood that the preceding detailed description of some examples and embodiments of the present invention may allow numerous changes to the disclosed embodiments in accordance with the disclosure made herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden.

Claims

1. A foam dispenser assembly comprising:

a base portion including a support, a flexible-walled vessel for each of an A component and a B component disposed on the support, and contents disposed in the respective flexible-walled vessels including the A component and the B component, at least one flexible-walled vessel including walls connected about a perimeter to define a volume and an opening, an insert disposed within the volume to separate the walls and maintain the opening unobstructed when the volume is under a negative pressure, and a dry disconnect coupling connected to the walls about the opening;

a head portion connected to the base portion and associated with each of the flexible-walled vessels, the head portion including a tank and a nozzle assembly that mixes the A component and the B component and dispenses a foam product generated thereby; and

the tank disposed immediately adjacent to the nozzle assembly and in fluidic communication with one of the flexible-walled vessels and the nozzle assembly, the tank including a warming assembly that defines a base of an interior volume of the tank.

2. The foam dispenser of claim 1, wherein the insert has thickness of approximately 0.010 inches to approximately 0.030 inches.

3. The foam dispenser of claim 1, wherein the insert includes a plurality of enlarged portions connected by links.

4. The foam dispenser of claim 1, wherein the insert includes an enlarged portion disposed adjacent the opening.

5. The foam dispenser of claim 1, wherein the insert includes a main link having an enlarged portion disposed at each distal end of the main link, a first arm link connected to and extending from the main link having an enlarged portion disposed at a distal end of the first arm link, and a second arm link connected to and extending from each main link enlarged portion having an enlarged portion disposed at a distal end of each second arm link.

6. The foam dispenser of claim 1, wherein the insert defines a pathway through the volume when the walls are disposed in contact over nearly all of a plan view surface area of the walls as a result of the negative pressure so that nearly 100% of the contents of the flexible-walled vessel are withdrawn through the dry disconnect coupling.

7. The foam dispenser of claim 1, wherein the warming assembly includes a heat sink having a upper side in direct contact with the contents of one of the flexible-walled containers when disposed in the interior volume and a lower side contiguous with a heat source.

8. The foam dispenser of claim 7, wherein the warming assembly includes a baffle disposed in spaced relation to the heat sink to define a warming volume between the baffle and the heat sink such that a remainder of the interior volume is disposed above the baffle, the baffle facilitates movement of the contents from the interior volume to the warming volume and retention of heat generated by the heat source within the warming volume for quicker temperature adjustment of the contents disposed in the warming volume.

9. A foam component container comprising:

a flexible-walled vessel including walls connected about a perimeter to define a volume and an opening, an insert disposed within the volume to separate the walls and maintain the opening unobstructed when the volume is under a negative pressure, a dry disconnect coupling connected to the walls about the opening and one of an A component and a B component.

10. The foam component container of claim 9, wherein the insert has thickness of approximately 0.010 inches to approximately 0.030 inches.

11. The foam component container of claim 9, wherein the insert includes a plurality of enlarged portions connected by links.

12. The foam component container of claim 9, wherein the insert includes an enlarged portion disposed adjacent the opening.

13. The foam component container of claim 9, wherein the insert includes a main link having an enlarged portion disposed at each distal end of the main link, a first arm link connected to and extending from the main link having an enlarged portion disposed at a distal end of the first arm link, and a second arm link connected to and extending from each main link enlarged portion having an enlarged portion disposed at a distal end of each second arm link.

14. The foam component container of claim 9, wherein the insert defines a pathway through the volume when the walls are disposed in contact over nearly all of a plan view surface area of the walls as a result of the negative pressure so that nearly 100% of the contents of the flexible-walled vessel are withdrawn through the dry disconnect coupling.