Foam injection system with variable port inserts for slurry mixing and dispensing apparatus
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B01F-005/04
B01F-003/08
B28B-019/00
B28C-005/38
B28C-005/06
B28C-007/04
B01F-015/04
출원번호
US-0527417
(2014-10-29)
등록번호
US-10189180
(2019-01-29)
발명자
/ 주소
Wittbold, James
Carrazco, Luis
출원인 / 주소
United States Gypsum Company
대리인 / 주소
Leydig, Voit & Mayer, Ltd.
인용정보
피인용 횟수 :
0인용 특허 :
72
초록▼
A foam injection system for use in the manufacture of cementitious products includes a foam injection body and first and second port inserts. The foam injection body defines a slurry passageway and a port passageway having a port opening in fluid communication with the slurry passageway. The first a
A foam injection system for use in the manufacture of cementitious products includes a foam injection body and first and second port inserts. The foam injection body defines a slurry passageway and a port passageway having a port opening in fluid communication with the slurry passageway. The first and second port inserts respectively define first and second foam passageways having first and second orifice sizes. The first and second orifice sizes are different. The first and second port inserts are adapted to removably mount to the foam injection body such that the respective foam passageway is in fluid communication with the slurry passageway via the port opening of the port passageway. One port insert can be replaced with another to readily vary the pressure of the foam passing through the particular port insert and injected into a cementitious slurry traveling through the slurry passageway.
대표청구항▼
1. A foam injection system for a cementitious slurry mixing and dispensing assembly, the foam injection system comprising: a foam injection body, the foam injection body defining a slurry passageway and a first port passageway, the first port passageway having a port opening in fluid communication w
1. A foam injection system for a cementitious slurry mixing and dispensing assembly, the foam injection system comprising: a foam injection body, the foam injection body defining a slurry passageway and a first port passageway, the first port passageway having a port opening in fluid communication with the slurry passageway, the foam injection body including a body engaging surface;a first port insert, the first port insert defining a first foam passageway having a first orifice with a first orifice size, the first port insert adapted to removably mount to the foam injection body such that the first foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway, the first port insert including a port insert engaging surface adapted to engage the body engaging surface of the foam injection body when the first port insert is mounted thereto such that the first foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway; anda second port insert, the second port insert defining a second foam passageway having a second orifice with a second orifice size, the second port insert adapted to removably mount to the foam injection body instead of the first port insert such that the second foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway, and the second orifice size being different than the first orifice size, the second non insert including the port insert engaging surface such that the port insert engaging surface of the second port insert is adapted to engage the body engaging surface of the foam injection body when the second port insert, instead of the first port insert, is mounted to the foam injection body such that the second foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway. 2. The foam injection system of claim 1, wherein the foam injection body defines at least two port passageways, each port passageway having a port opening in fluid communication with the slurry passageway, and wherein the foam injection body is configured to permit either the first port insert or the second port insert to be removably mounted to the foam injection body to place the respective first and second foam passageway into fluid communication with each port passageway. 3. The foam injection system of claim 2, wherein the foam injection body comprises a foam ring having an outer circumferential surface and an inner circumferential surface in spaced radial relationship to the outer circumferential surface, the port passageways extending radially between the outer circumferential surface and the inner circumferential surface, and the inner circumferential surface defining the slurry passageway. 4. The foam injection system of claim 1, wherein the first port insert includes a port insert body having a foam supply end and a mounting end, the foam supply end adapted for retentive engagement with a foam supply conduit and defining a foam inlet opening, and the mounting end defining a foam outlet opening, the first foam passageway extending between and in fluid communication with the foam inlet opening and the foam outlet opening. 5. The foam injection system of claim 4, wherein the foam inlet opening is larger than the first orifice and the first foam passageway includes a tapered entry portion and a main portion, the tapered entry portion including the foam inlet opening and an entry outlet opening in fluid communication with the main portion, the entry outlet opening being smaller than the foam inlet opening and corresponding to the first orifice size such that the entry portion narrows from the foam inlet opening to the entry outlet opening, the main portion including the foam outlet opening and having a cross-sectional size corresponding to the first orifice size. 6. The foam injection system of claim 5, wherein the first port insert defines a pressure sensor passageway in fluid communication with the main portion of the first foam passageway. 7. The foam injection system of claim 4, wherein the mounting end includes the port insert engaging surface, the insert engaging surface comprising a threaded surface, the body engaging surface of the foam injection body comprising a mating threaded surface, the threaded surface of the first port insert adapted to retentively engage the mating threaded surface of the foam injection body associated with the first port passageway. 8. The foam injection system of claim 7, wherein the threaded surface of the mounting end defines an axis of rotation about which the first port insert rotates to threadingly engage and disengage the mating threaded surface of the foam injection body, and the port insert body includes a pair of planar surfaces in spaced relationship to each other, the planar surfaces being substantially parallel to each other and to the axis of rotation. 9. The foam injection system of claim 1, wherein the first port insert includes a port insert body having a foam supply end and a mounting end, the port insert body extending along a longitudinal axis between the foam supply end and the mounting end, the first port insert includes a mounting flange extending radially outwardly from the port insert body, the mounting flange defining a mounting hole configured to receive a fastener therethrough, and wherein the foam injection body defines a mating mounting hole therein configured such that the mounting hole of the mounting flange is alignable with the mating mounting hole of the foam injection body when the mounting end of the first port insert is aligned with the first port passageway and the mounting flange is adjacent the foam injection body. 10. The foam injection system of claim 9, wherein the mounting end of the first port insert has a distal end face, and the foam injection body has an inner surface defining the slurry passageway, the first port insert adapted to removably mount to the foam injection body such that the mounting end of the first port insert is disposed within the first port passageway and the distal end face of the first port insert is substantially aligned with the inner surface of the foam injection body. 11. The foam injection system of claim 9, wherein the first port insert includes a rib projecting from the port insert body and extending along the longitudinal axis, the rib including the port insert engaging surface, and wherein the body engaging surface of the foam injection body defines a keyway configured to retentively receive the rib therein such that the first port insert is substantially constrained from rotating about the longitudinal axis relative to the foam injection body by the interengagement of the rib and the keyway. 12. The foam injection system of claim 11, wherein the mounting end of the first port insert has a distal end face with a concave portion having a radius of curvature, and the foam injection body has an inner curved surface defining the slurry passageway, the inner curved surface having a concave portion adjacent the first port passageway with a radius of curvature substantially the same as the concave portion of the distal end face of the first port insert, the first port insert adapted to removably mount to the foam injection body such that the mounting end of the first port insert is disposed within the first port passageway and the concave portion of the distal end face of the first port insert is substantially concentrically disposed with respect to the concave portion of the foam injection body. 13. The foam injection system of claim 1, wherein the mounting end of the first port insert has a distal end face, and the foam injection body has an inner surface defining the slurry passageway, the first port insert adapted to removably mount to the foam injection body such that the mounting end of the first port insert is disposed within the first port passageway and the distal end face of the first port insert is adjacent the inner surface of the foam injection body. 14. The foam injection system of claim 1, wherein the first port insert includes a port insert body having a foam supply end and a mounting end, the port insert body extending along a longitudinal axis between the foam supply end and the mounting end, and the first port insert includes a rib projecting from the port insert body and extending along the longitudinal axis, the mounting end of the first port insert has a distal end face, the foam injection body has an inner surface defining the slurry passageway, and wherein at least one of the foam injection body and the first port insert includes an alignment mechanism adapted to provide the first port insert with a polarity such that the first port insert is removably mounted to the foam injection body with at least one particular orientation with respect to the foam injection body wherein the mounting end of the first port insert is disposed within the first port passageway and the distal end face of the first port insert is substantially aligned with the inner surface of the foam injection body. 15. The foam injection system of claim 1, wherein the first port insert defines a pressure sensor passageway in fluid communication with the first foam passageway. 16. A cementitious slurry mixing and dispensing assembly comprising: a mixer adapted to agitate water and a cementitious material to form an aqueous cementitious slurry;a slurry discharge conduit in fluid communication with the mixer;a foam injection system arranged with at least one of the mixer and the slurry discharge conduit, the foam injection system including: a foam injection body, the foam injection body comprising a part of at least one of the mixer and the slurry discharge conduit, the foam injection body defining a slurry passageway and a first port passageway, the slurry passageway configured to convey cementitious slurry therethrough, the first port passageway having a port opening in fluid communication with the slurry passageway, the foam injection body including a body engaging surface,a first port insert, the first port insert defining a first foam passageway having a first orifice with a first orifice size, the first port insert adapted to removably mount to the foam injection body such that the first foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway, the first port insert including a port insert engaging surface adapted to engage the body engaging surface of the foam injection body when the first port insert is mounted thereto such that the first foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway, anda second port insert, the second port insert defining a second foam passageway having a second orifice with a second orifice size, the second port insert adapted to removably mount to the foam injection body instead of the first port insert such that the second foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway, and the second orifice size being different than the first orifice size, the second port insert including the port insert engaging surface such that the port insert engaging surface of the second port insert is adapted to engage the body engaging surface of the foam injection body when the second port insert, instead of the first port insert, is mounted to the foam injection body such that the second foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway. 17. The cementitious slurry mixing and dispensing assembly of claim 16, wherein the foam injection body comprises a part of the discharge conduit. 18. The cementitious slurry mixing and dispensing assembly of claim 17, wherein the foam injection body comprises a foam ring, the foam ring having an outer circumferential surface and an inner circumferential surface in spaced radial relationship to the outer circumferential surface, the first port passageway extending radially between the outer circumferential surface and the inner circumferential surface, and the inner circumferential surface defining the slurry passageway. 19. The cementitious slurry mixing and dispensing assembly of claim 16, wherein the foam injection body defines at least two port passageways, each port passageway having a port opening in fluid communication with the slurry passageway, and wherein the foam injection body is configured to permit either the first port insert or the second port insert to be removably mounted to the foam injection body to place the respective first and second foam passageway into fluid communication with each port passageway. 20. The cementitious slurry mixing and dispensing assembly of claim 16, further comprising: a flow-modifying element associated with the discharge conduit and adapted to modify a flow of cementitious slurry from the mixer through the discharge conduit, the flow-modifying element being disposed downstream of the foam injection body relative to a flow direction of the flow of cementitious slurry from the mixer through the discharge conduit. 21. A method of preparing a cementitious product comprising: selecting a first port insert from a group including at least the first port insert and a second port insert, the first port insert defining a first foam passageway, and the second port insert defining a second foam passageway, the second foam passageway being different from the first foam passageway to produce a flow therethrough different from that through the first foam passageway, the second port insert being at least one of a different type and a different passageway size than the first port insert;removably mounting the first port insert to a foam injection body, the foam injection body defining a slurry passageway and a first port passageway, the first port passageway having a port opening in fluid communication with the slurry passageway, the first port insert removably mounted to the foam injection body such that the first foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway, the second port insert removably mountable to the foam injection body in place of the first port insert such that the second foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway;conveying a flow of aqueous foam to the first foam passageway of the first port insert removably mounted to the foam injection body; andinjecting the flow of aqueous foam in the first foam passageway of the first port insert under a first flow condition into a flow of aqueous cementitious slurry passing through the slurry passageway to form a flow of foamed cementitious slurry. 22. The method of claim 21, further comprising: discharging a main flow of aqueous cementitious slurry from a mixer;passing the main flow of aqueous cementitious slurry through the slurry passage of the foam injection body;wherein the main flow of aqueous cementitious slurry from the mixer comprises the flow of aqueous cementitious slurry passing through the slurry passageway into which the flow of aqueous foam in the first foam passageway of the first port insert is injected to form the flow of foamed cementitious slurry. 23. The method of claim 21, further comprising: measuring the pressure of the flow of aqueous foam in the first foam passageway of the first port insert. 24. The method of claim 21, further comprising: disengaging the first foam port insert from the foam injection body;removably mounting the second port insert to the foam injection body such that the second foam passageway is in fluid communication with the slurry passageway via the port opening of the first port passageway;conveying a flow of aqueous foam to the second foam passageway of the second port insert removably mounted to the foam injection body;injecting the flow of aqueous foam in the second foam passageway of the second port insert under a second flow condition into a flow of aqueous cementitious slurry passing through the slurry passageway to form a flow of foamed cementitious slurry, the second flow condition being different from first flow condition. 25. The method of claim 24, wherein the flow of aqueous foam exits the first foam passageway of the first port insert for injection into the flow of aqueous cementitious slurry passing through the slurry passageway at a first pressure, the flow of aqueous foam exits the second foam passageway of the second port insert for injection into the flow of aqueous cementitious slurry passing through the slurry passageway at a second pressure, and the first pressure is different than the second pressure. 26. The method of claim 21, wherein the foam injection body defines at least two port passageways, each port passageway having a port opening in fluid communication with the slurry passageway, and further comprising: removably mounting a corresponding number of first port inserts to the foam injection body such that the first foam passageway of each of the first port inserts is in fluid communication with the slurry passageway via the port opening of a respective one of the port passageways;conveying a flow of aqueous foam to each of the first port inserts removably mounted to the foam injection body;injecting the flow of aqueous foam in each of the first port inserts into a flow of aqueous cementitious slurry passing through the slurry passageway to form a flow of foamed cementitious slurry. 27. The method of claim 26, further comprising: disengaging the first foam port inserts from the foam injection body;removably mounting a number of second port inserts corresponding to the number of port passageways to the foam injection body, each of the second port inserts defining a second foam passageway having a second orifice with a second orifice size, the second port inserts removably mounted to the foam injection body such that the second foam passageway of each of the second port inserts is in fluid communication with the slurry passageway via the port opening of a respective one of the port passageways, and the second orifice size being different than the first orifice size;conveying a flow of aqueous foam to the second foam passageway of each of the second port inserts removably mounted to the foam injection body;injecting the flow of aqueous foam in the second foam passageway of each of the second port inserts into a flow of aqueous cementitious slurry passing through the slurry passageway to form a flow of foamed cementitious slurry. 28. The method of claim 21, wherein the foam injection body defines at least two port passageways, each port passageway having a port opening in fluid communication with the slurry passageway, the foam injection body being configured to permit either first port inert or the second port inert to be removably mounted to the foam injection body to place the respective first and second foam passageway into fluid communication with each port passageway, and further comprising: removably mounting to the foam injection body a set of port inserts including a number of port inserts corresponding to the number of port passageways, the set of port inserts including at least one first port insert and at least one second port insert;conveying a flow of aqueous foam to each first port insert and each second port insert removably mounted to the foam injection body;injecting the flow of aqueous foam in each first port insert and in each second port insert into a flow of aqueous cementitious slurry passing through the slurry passageway to form a flow of foamed cementitious slurry.
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