High-expansion foam generator

A high-expansion foam generator comprising:

• a nozzle manifold having at least one nozzle housing and at least one header to receive a foam solution;
• at least one nozzle assembly attached to the nozzle manifold, each nozzle assembly having,
• a nozzle having an inlet to receive the foam solution from the nozzle manifold and an outlet configured to discharge the foam solution, and
• a nozzle insert disposed within the nozzle and attached to the nozzle in a stationary position;
• and
• a foam generator assembly disposed adjacent the nozzle manifold, the foam generator assembly including,
• a body portion having an inlet to receive the foam solution from the at least one nozzle assembly,
• a first foam generating portion having a tapered configuration, a base of the first foam generating portion being connected to an outlet of the body portion such that a portion of the foam solution exiting the body portion impinges on an interior surface of the first foam generating portion, and
• a second foam generating portion having a tapered configuration, a base of the second foam generating portion being connected to an apex of the first foam generating portion, and wherein the second foam generating portion protrudes into an interior of the first foam generating portion,
• wherein a ratio of a largest inlet dimension of the foam generator assembly to a length of the foam generator assembly is 0.50 or less, and
• wherein the at least one nozzle housing is configured to receive a respective nozzle assembly and is disposed on the at least one header such that a ratio of a diameter of an inlet of the respective nozzle to a distance from an inner wall surface of the at least one header to the inlet of the respective nozzle is 0.8 or less,
• wherein each nozzle insert includes a flow divider positioned in the nozzle at the inlet of the nozzle and swirl vanes between the flow divider and the outlet of the nozzle, the swirl vanes creating a swirl pattern in a flow of the foam solution, the flow divider and the swirl vanes splitting a flow path of the foam solution through the respective nozzle into two flow streams;
• wherein the swirl vanes comprise a first swirl vane on one side of the flow divider, the first swirl vane having a first upstream solid surface and a first downstream solid surface, and a second swirl vane on another side of the flow divider, the second swirl vane having a second upstream solid surface and second downstream solid surface,
• wherein the first downstream solid surface crossovers the flow divider and connects with the second upstream solid surface,
• wherein the second downstream solid surface crossovers the flow divider and connects with the first upstream solid surface,
• wherein the flow divider transitions with a first non-sharp transition member to the first upstream solid surface,
• wherein the flow divider transitions with a second non-sharp transition member to the second upstream solid surface.