Method for rapid insulation of expanses

• US 7,717,357 B2
• Filed: 01/09/2006
• Issued: 05/18/2010
• Est. Priority Date: 01/09/2006
• Status: Active Grant

• Current Assignee: ICP Construction, Inc. (Innovative Chemical Products Group LLC)
• Original Assignee: Fomo Products, Inc. (ICP Group SA)
• Inventors: Fishback, Thomas L., Taylor, Anthony J., Hurray, Paul, Dansizen, Richard L., Gantenbein, Stefan
• Primary Examiner(s): Ganey; Steven J
• Application Number:
  US11/306,722
• Publication Number:
  US 20060192033A1
• Time in Patent Office: 1,590 Days
• Field of Search: 239/8, 239/10, 239/13, 239/128, 239/135, 239/303, 239/304, 239/413, 239/414, 239/432, 239/433, 239/525, 239/597, 239/601, 222/137, 222/145.5, 222/145.6, 222/146.1
• US Class Current: 239/13
• CPC Class Codes: B01F 25/43161 composed of consecutive sections of flat pieces of material
• CPC Class Codes: B01F 25/4319 Tubular elements
• CPC Class Codes: B01F 25/431972 Mounted on an axial support member, e.g. a rod or bar
• CPC Class Codes: B05B 7/0408 with arrangements for mixing two or more liquids
• CPC Class Codes: B05B 9/04 with pressurised or compressible container aerosol containers B65D83/14; with pump
• CPC Class Codes: B29B 7/325 Static mixers in general B01F25/42
• CPC Class Codes: B29B 7/7419 with static or injector mixer elements
• CPC Class Codes: B29B 7/7447 including means for feeding the components
• CPC Class Codes: E04F 21/12 acting by gas pressure, e.g. steam pressure

Abstract

A process for cost-effectively and rapidly insulating a desired surface with spray foam insulation is described which includes the application of a polyurethane foam dispensed through heated conduits into a dispensing gun having a nozzle with essentially planar divergent lips having a triangular prism opening, the lips of the nozzle diverging at an angle of between about 5 and 35° inclusive, more preferably between 8 to 15° inclusive, most preferably 10 to 12° inclusive, thereby achieving application rates which are in excess of 70 Ft²/min, and optimally in excess of 100 Ft²/min.

Claims

1. A process for insulating a desired surface with spray foam insulation which comprises:

(a) pressurizing at least two storage volumes containing chemical components of polyurethane spray insulation to a pressure less than or equal to about 200 psi;

(b) attaching one end of a pair of heatable conduits to said storage volumes;

(c) attaching opposed ends of said conduits to a mixing and dispensing nozzle, said nozzle comprising;

(i) a body;

(ii) a removable nozzle attached to said body,

(iii) said nozzle having a static mixing means within said nozzle;

(iv) said nozzle further having a pair of lips diverging at an angle of between about 8° and

15°

inclusive; and

(v) said nozzle further having a pair of opposed essentially triangular-shaped notches at each end of said lips; and

(d) dispensing said insulation on said desired surface at an application rate greater than or equal to approximately 70 Ft²/min.

2. The process of claim 1 wherein said storage volumes are portable.

3. The process of claim 2 wherein said step of pressurizing said storage volumes is by use of an inert gas.

4. The process of claim 3 wherein said inert gas is nitrogen.

5. The process of claim 4 wherein said nozzle further comprises a trigger to control dispensing rate.

6. The process of claim 1 wherein said conduits have an insulating cover along at least a portion of a length of said conduits.

7. The process of claim 6 wherein said insulating cover is a fiberglass sheath.

8. The process of claim 1 wherein

said application rate is greater than or equal to approximately 80 Ft²/min.

9. The process of claim 8 wherein

said nozzle lips diverge at an angle between 10 and 12°

inclusive; and

said application rate is greater than or equal to approximately 90 Ft²/min.

10. A process for insulating a desired surface with spray foam insulation which comprises:

(a) pressurizing at least two storage volumes containing chemical components of polyurethane spray insulation to a pressure less than or equal to about 200 psi;

(b) attaching one end of a pair of heatable conduits to said storage volumes;

(c) attaching opposed ends of said conduits to a mixing and dispensing nozzle, said nozzle comprising;

(i) a body;

(ii) a removable nozzle attached to said body,

(iii) said nozzle having a static mixing means within said nozzle;

(iv) said nozzle further having a pair of lips diverging at an angle of between about 8 and 15°

inclusive; and

(v) said nozzle further having a pair of opposed notches at each end of said lips; and

(d) dispensing said insulation on said desired surface at an application rate greater than or equal to approximately 80 Ft²/min.

11. The process of claim 10 wherein said storage volumes are portable.

12. The process of claim 11 wherein said step of pressurizing said storage volumes is by use of an inert gas.

13. The process of claim 12 wherein said inert gas is nitrogen.

14. The process of claim 13 wherein said nozzle further comprises a trigger to control dispensing rate.

15. The process of claim 10 wherein said conduits have a protective cover along at least a portion of a length of said conduits.

16. The process of claim 15 wherein said protective cover is a woven fiberglass sheath.

17. The process of claim 10 wherein

said nozzle lips diverge at an angle between 10 and 12°

inclusive; and

said application rate is greater than or equal to approximately 90 Ft²/min.

18. The process of claim 17 wherein said application rate is greater than or equal to approximately 100 Ft²/min.

19. A process for insulating a desired surface with spray foam insulation which comprises:

(a) pressurizing at least two portable storage volumes containing chemical components of a two-component polyurethane spray insulation to a pressure less than or equal to about 200 psi with nitrogen;

(b) attaching one end of a pair of sheathed, heated conduits to said storage volumes, said conduits heated to approximately 70°

F. to 90°

F. inclusive;

(c) attaching opposed ends of said conduits to a mixing and dispensing nozzle, said nozzle comprising;

(i) a body;

(ii) a removable nozzle attached to said body,

(iii) said nozzle having a static mixing means within said nozzle;

(iv) said nozzle further having a pair of essentially planar lips diverging at an angle of between about 10 and 12°

inclusive;

(v) said nozzle further having a pair of opposed notches at each end of said lips; and

(vi) said nozzle further comprising a trigger to control dispensing; and

(d) dispensing said insulation on said desired surface at an application rate greater than or equal to approximately 90 Ft²/min.

20. The process of claim 19 wherein said application rate is greater than or equal to approximately 100 Ft²/min.