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Our new metering machine is designed to meet the needs of customers who produce PU components that are too small for conventional solvent free high pressure machines.
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Proven Mixing Principle
Wide Output Range
Variable Chamber Geometry
No Jet Limitations
No Stripping
Injection
Variable Dispensing
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Variable Throttle Mixing
Highly Compatible
Proven Metering Technology
Longer Operating Life
Benefits
Protected Technology
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The new system employs well-known impingement mixing principles via a grooved mixing piston and larger diameter-cleaning chamber; we combine them with a novel and new method of low to high output dosing control. |
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The metering unit is capable of dispensing a maximum of 150 grams per second in ‘continuous pouring’ mode, whilst also being able to achieve a minimum output of 4 grams per second in ‘multi shot’ mode at a ratio of up to 4:1.
In addition the dispensing rate can be adjusted to any output in between on a shot to shot basis being fully controlled by the metering unit’s software program. |
| Variable Chamber Geometry |
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| The key difference in the CTM approach is to vary the chamber volume of the mixing head in a controlled way rather than varying the mixing rate as is the case with other systems. The CTM approach avoids any need for very small injectors and thus eliminates all of the associated problems with blocking and pressure stability. |
| No Jet Limitations |
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There is no requirement for altering injector pressure settings or high-pressure pump outputs between operating modes. Unlike other designs of low output mixing heads, mixing ratios of up to 4:1 do not limit the range of low output that is achievable from the new mixing head. Dual hardness /dual density mixing via two mixing chambers is also possible. |
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| The mixing head’s unique design geometry enables the use of a much shorter outlet nozzle. Laminar flow is achieved across the whole output range with only a 20mm long outlet nozzle. The new mixing head reduces any stripping or de-mixing effect that can be a problem for standard mixing heads with their requirement for a longer outlet nozzle. |
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| The mixing head has several additional features; it is possible to apply considerable injection or dosing pressures at controlled rates without an adverse affect on the quality of component mixing. The mixing head can apply considerable pressure to the reacting mixture thus opening up many possibilities for controlled injection techniques. |
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| A further benefit of the mixing head is an ability to vary output rate during the dispensing phase, this has particular value for example: When producing automotive panel air filters. Over filling in the corners is easily corrected, in addition higher straight-line pouring speeds are possible. Radial filters requiring larger amounts of PU can be produced at the same time. |
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Difficult to mix PU systems are often processed using mixing heads with a fixed throttle. The concept is simple in that the clean out piston is held short in a fixed mechanical position so as to partially restrict the exit point of the mixing chamber. There are two key disadvantages with a fixed system. A) The variable output range of the mixing head is seriously limited and B) High side forces are created that lead to accelerated ware on the clean out due to reacted material being trapped.
Neither disadvantage is a problem for the Varithane mixing head. A position sensor located with the mixing head allows the control system to correctly position the clean out piston in the optimum position at all times. |
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| The Varithane metering unit, whilst able to operate the new three piston mixing head can also support additional traditional 2-piston L type high-pressure mixing heads working at the same time. |
Proven Metering Technology
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| The high-pressure metering unit required for the mixing head remains largely unchanged being based upon a 50Kg max per minute high-pressure machine, an accurate component flow measurement system c/w an enhanced hydraulic and control software are all of the changes required. |
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Mixing head reliability is enhanced by designing in an internal pump within two central chambers. Lubricant is forced through these internal chambers every working cycle.
A water-cooling chamber is fitted to the main body of the mixing head so as to maintain a steady operating temperature at all times. |
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- Solvent free micro dosing high pressure mixing technology.
- Proven mixing principles
- 1g/s to 150g/s output capability on a shot to shot basis.
- Reduced stripping effects when processing high viscosity polyol.
- Laminar flow characteristics from very a short outlet nozzle.
- High pressure mould injection.
- Variable dispense rates in pouring from 5 to 150 g/sec at up to 4:1.
- Programmable throttling of mixing chamber at mixing start.
- Compatible with standard mixing heads.
- Variable dispense rates in pouring from 5 to 150 g/sec.
- Proven metering principles.
- Longer operating life.
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| An active UK and American patent covers the mixing head’s principle of operation. This first patent is being extended to include a number of further regions globally. A second patent is also being pursued that covers a further mode of operation. |
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If you would like to know more about how our new machine can aid your production process, then simply e mail Shane Wootton directly at the address below.
shane@ctmukltd.com |
