Plural component application system

A method for forming a solid reinforced structure of urethane material comprising:

• providing a temperature-controlled supply of a first urethane component of components of a urethane material to be reacted together;
• providing a temperature-controlled supply of a second urethane component of the components of urethane material to be reacted together;
• generating a controlled flow of the first urethane component with a first pump means, said controlled flow of the first urethane component being directed through a first conduit connected with said first pump, said sprayer and said temperature-controlled supply of said first urethane component for obtaining a consistent spraying temperature for said first urethane component;
• continuously recirculating said first urethane component through said first conduit between said sprayer and said temperature-controlled supply of said first urethane component for obtaining a consistent spraying temperature for said first urethane component;
• generating a controlled flow of the second urethane component with a second pump means, said controlled flow of the second urethane component being directed through a second conduit connected with said second pump, said sprayer and said temperature-controlled supply of said second urethane component;
• continuously recirculating said second urethane component through said second conduit between said sprayer and said temperature-controlled supply of said second component for obtaining a consistent spraying temperature for said second urethane component;
• providing a temperature-controlled supply of a first urethane component of components of a urethane material to be reacted together;
• providing a temperature-controlled supply of a second urethane component of the components of urethane material to be reacted together;
• generating a controlled flow of the first urethane component with a first pump means, said controlled flow of the first urethane component being directed through a first conduit connected with said first pump, said sprayer and said temperature-controlled supply of said first urethane component;
• continuously recirculating said first urethane component through said first conduit between said sprayer and said temperature-controlled supply of said first urethane component for obtaining a consistent spraying temperature for said first urethane component;
• generating a controlled flow of the second urethane component with a second pump means, said controlled flow of the second urethane component being directed through a second conduit connected with said second pump, said sprayer and said temperature-controlled supply of said second urethane component;
• continuously recirculating said second urethane component through said second conduit between said sprayer and said temperature-controlled supply of said second component for obtaining a consistent spraying temperature for said second urethane component;
• calibrating the rates of flow of said first and second urethane components and driving said first and second pump means by a common driving means to maintain their relative calibration;
• mixing the urethane components to be reacted at the spraying zone and breaking the mixed urethane components into particles directed at a substrate to form the solid structure;
• directing lengths of reinforcing fiber into the particles of urethane components being directed at the substrate;
• controlling the pressures of the flowing urethane components at the spraying zone to break the mixed urethane components into particles having mass-to-surface ratios sufficiently large such that the mixed urethane components wet the lengths of reinforcing fiber;
• and
• reacting the urethane components on the substrate and in contact with the wetted fibers to form said solid reinforced structure.

A system for manufacturing solid structures from mixed reactive urethane components, comprising:

• (a) a first source of a resin component for a reactive urethane chemical system;
• (b) a second source of an isocyanate component for said reactive urethane chemical system;
• (c) a sprayer for mixing the resin component and the isocyanate component and for forming particles of mixed urethane components to be directed from the sprayer by an operator;
• (d) a supply system for providing a flow of said urethane components to a sprayer, said supply system comprising:
• (i) a first positive displacement pump connected to said first source of said resin component;
• (ii) a second positive displacement pump connected to said second source of said isocyanate component;
• (iii) Common drive means for said first and second positive displacement pumps;
• (iv) a resin delivery system including first conduit means connecting said first source, said first positive displacement pulp, and said sprayer, and including second conduit means for recirculating said resin from said sprayer to said first source, and further including a first delivery control and calibration system at said first source providing means to calibrate the rate of flow of resin from said sprayer, said first delivery control and calibration means including first pressure indicating means adapted to indicate the pressure of said resin at said sprayer, first flow restrictive means to simulate, in said first delivery control and calibration means, the flow paths of said sprayer, fifth conduit means permitting recirculation of said resin at said first source, and first valve means permitting the selection of the calibration means, the recirculation means, or the closing off of the first source;
• and
• (v) an isocyanate delivery system including third conduit means connecting said second source, said second positive displacement pump, and said sprayer, and including fourth conduit means for recirculating said isocyanate from said sprayer to said second source, and further including a second delivery control and calibration system providing means to calibrate the rate of flow of isocyanate form said sprayer, said second delivery control and calibration means including a second pressure indicating means adapted to indicate pressure of said isocyanate at said sprayer, second flow restrictive means to simulate, in said second delivery control and calibration means, the flow paths of said sprayer, sixth conduit means permitting recirculation of said isocyanate at said second source, and second valve means permitting the selection of the calibration means, the circulation means, or the closing off of the second source.

A system for manufacturing structures from mixed reactive components comprising:

• (a) a first source of a first component for a reactive chemical system;
• (b) a second source of a second component for said reactive chemical system;
• (c) a mixing and dispensing device for mixing said first and second components and for dispensing said mixture;
• (d) a first positive displacement delivery system for maintaining a flow of said first component from said first source to said mixing and dispensing device and from said mixing and dispensing device back to said first source;
• (e) a second positive displacement delivery system for maintaining a flow of said second component from said second source to said mixing and dispensing device and from said mixing and dispensing device back to said second source;
• (f) a common drive means for driving said first and second positive displacement delivery systems;
• (g) means for permitting the independent adjustment of the variation of the displacement of said first and second positive displacement delivery systems;
• (h) means associated with said mixing and dispensing device for selectively directing the flow of said first and second components from said first and second delivery systems into said mixing and dispensing device to be mixed therein and the mixture dispensed therefrom;
• and
• (i) means for calibrating the rate of flow of said first and second components through said first and second delivery systems, respectively, comprising a first calibrated test container, a second calibrated test container, and means for directing the flow of said first and second components from said first and second delivery systems into said first and second calibrated test containers for a controlled time duration.

A system for manufacturing structures from mixed reactive components comprising:

• (a) a first source of a first component for a reactive chemical system;
• (b) a second source of a second component for said reactive chemical system;
• (c) a mixing and dispensing device for mixing said first and second components and for dispensing said mixture;
• (d) a first positive displacement delivery system for maintaining a flow of said first component from said first source to said mixing and dispensing device and from said mixing and dispensing device back to said first source;
• (e) a second positive displacement delivery system for maintaining a flow of said second component from said second source to said mixing and dispensing device and from said mixing and dispensing device back to said second source;
• (f) a common drive means for driving said first and second positive displacement delivery systems;
• (g) means for permitting the independent adjustment of the variation of the displacement of said first and second positive displacement delivery systems;
• (h) means associated with said mixing and dispensing device for selectively directing the flow of said first and second components from said first and second delivery systems into said mixing and dispensing device to be mixed therein and dispensed therefrom;
• (i) a first delivery control and calibration means for said fist component;
• and
• said first and second delivery control and calibration means being carried by the first and second sources of components, respectively, and each delivery control and calibration means being adapted to permit calibration of the flow from the mixing and dispensing device from adjacent said first and second source of components.