Methods and apparatus for depositing spray-on foam insulation
OwnerKeith Y. Chong, Jeffrey S. Nichollsinventors
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Abstract
Systems and methods for forming a spray-on insulation (SOFI) coating on a structure include providing a resin material and an isocyanate material, both maintained at a temperature of between approximately 95 and 105° F., and mixing the resin material and the isocyanate material to produce a mixed material (e.g., using a spray gun having a mixing module). Using a repeated overlapping pattern having a periodicity of between approximately 5 to 10 inches, the mixed material on the structure is sprayed using a spray profile that is substantially flat and is produced at a predetermined spray distance between approximately 25-40 inches. A non-ozone-depleting blowing agent may be used.
Claims20
A method of forming a spray-on insulation (SOFI) coating on a structure, the method comprising:
- providing a resin material maintained at first predetermined temperature between approximately 95 and 105° F.;
- providing a isocyanate material maintained at the first predetermined temperature;
- mixing the resin material and the isocyanate material to produce a mixed material;
- spraying, using a repeated overlapping pattern having a periodicity of between approximately 5 to 10 inches, the mixed material on the structure using a spray profile that is substantially flat and is produced at a predetermined spray distance between approximately 25-40 inches.
A spray-on insulation (SOFI) system for coating a structure comprising:
- a resin material maintained at first predetermined temperature between approximately 95 and 105° F.;
- a isocyanate material maintained at the first predetermined temperature;
- a spray gun including a mixing module configured to mix the resin material and the isocyanate material to produce a mixed material;
- a robotic system mechanically coupled to the spray gun, the robotic system configured to move the spray gun with respect to the structure using a repeated overlapping pattern having a periodicity of between approximately 5 to 10 inches and to spray the mixed material on the structure using a spray profile that is substantially flat and is produced at a predetermined spray distance of between approximately 25-40 inches.
The method of claim 19, wherein the aperture of the pattern control disc is substantially diamond-shaped.
A method for applying a spray-on-foam-insulation layer on a structure, the method comprising:
- providing a resin material maintained at first predetermined temperature between approximately 95 and 105° F. and a first predetermined pressure between approximately 1000 and 1200 psig;
- providing a isocyanate material maintained at the first predetermined temperature and first predetermined pressure, wherein the resin material and the isocyanate material incorporate a blowing agent that is non-ozone-depleting;
- providing a pattern control disc having an aperture whose width is less than or equal to approximately one fourth of its length;
- maintaining the structure at a structure temperature of between approximately 125° F. and 135° F.
- mixing the resin material and the isocyanate material to produce a mixed material;
- spraying, using a repeated overlapping pattern having a periodicity of between approximately 5 to 10 inches, the mixed material on the structure using a spray profile that is determined by the pattern control disc and is produced at a predetermined spray distance of between approximately 25-40 inches.
Dependencies are inferred from the claim text.