Polyurethane Portable Factory

PROTOTYPES ARE CURRENTLY IN DEVELOPMENT

ICF System

This is the company we have been working with: AZ Flow 7370 OPPORTUNITY ROAD, SUITE U SAN DIEGO CA 92111 TEL: 858-279-3569 FAX: 858-279-3570 EMAIL: ezflow@usa.com

SPECIFICATIONS

E-Z FLOW GHC-220 HEAVY DUTY SYSTEM

System Requirements:

Electric Power: 220 volts, single phase, at 30 amps (L6-30 receptacle recommended) Compressed Air: 90-120 PSI, 3-4 CFM, with filtration and dryer

Components:

  • Electronic Controller, 14” H x 12” W x 7” D, controls hose temperatures, with digital display of actual and set temperatures on both hoses, temperature adjustable from 80-170 degrees F
  • Heated Hoses, one each for “A” (isocyanate) and “B” (polyol resin), ½” I.D., braided stainless steel over Teflon, 20 ft long, with coil heater the full length of each hose, #8 JIC swivel fittings to attach to Gun
  • Dispensing Gun, with rebuildable Cartridge Assy (see below), impingement mix, air actuated, consisting of three subassemblies:
  • Handle Assy, Valve Block Assy, and Air Motor Assy. Weight of gun is 2 lbs 14 oz. Designed for fluid pressure of 200-300 PSI. Primary material: black anodized 6061 aluminum
  • Cartridge Assembly for Dispensing Gun, fully rebuildable, standard orifice size .040”, several other orifice sizes available from .020” to .060”. Standard ratio is 1:1, custom ratios available up to 3:1. Design life is 12,000 to 15,000 shots. Housing material is 303 Stainless, mixing chamber is of special grade Teflon, and valving rod is hardened stainless steel, ground and polished
  • Drum Pumps, 2” diameter, air actuated, inserted into drums, stainless, 2:1 ratio (100 PSI air input, 200 PSI fluid output), made by IPM, available in short (for 15 gallon sets) and standard (for 55 gallon drums) lengths.

Accessories:

  • Hose Hanger, for suspending hoses off the ground. Tool balancer (not included) may be added if desired; E-Z Flow recommends using W W Grainger # 6Z158
  • Gun Holder/Solvent Tray, stainless, includes wire brush for cleaning tip of Cartridge after each shot, designed to hold Gun when not in use
  • Capacities – Output: 6-10 pounds per minute of mixed chemicals, depending on input air pressure and viscosity of chemicals used. Under most conditions, this output can be sustained with good foam consistency for large void fills or for regular assembly line use Types of chemical: Most two part polyurethane formulations intended for pouring applications, including open cell, closed cell, froth foam, flotation foam, packaging foam, and insulation foam, with viscosities to approx. 1400 cps and finished densities up to approx. 3 lb/cu ft. With special setup, densities up to 20 lb/cu ft have been successfully dispensed. Please advise E-Z Flow if special chemicals are required

CHEMICALS DATA AND SPECS

ELASTOPOR® P 18820 R Resin / ELASTOPOR® P 1001 U Isocyanate DESCRIPTION AND USES:

The Elastopor® P 18820 R System is a two-component 0.4 pcf density packaging formulation polyurethane system designed for foam-in place applications. This low viscosity foam formulation can be processed through E-Z Flow polyurethane dispensing equipment. It is designed for custom-made packaging as well as for pre-molded packaging inserts. The cushioning foam provides excellent shock damping and product protection during shipping. The chemical formulation uses no CFC’s (chlorofluorocarbons).

Mixing Ratio (parts by volume) 50% A and 50% B

PROCESSING PARAMETERS @ 125o F:
Cream Time Seconds — 8 to 10
Rise Time Seconds — 20 to 25
Tack Free Time Seconds — 33 to 38

Note: A set of chemicals (55 gallons drums) makes 450 ICF blocks the house a 20’ x 26’ will use 310 ICF blocks

 

OPTION 1 26 feet x 20 feet

Option #1 -26×20 Duplexs
room size quantity windows doors
bed room 13’3″x 8′ 2 2 2
Living room 13’3″x 12’6″ 2 2 2
ICF blocks needed for this house 310

OPTION 2 20×20

Option #2 -20×20
room size quantity windows doors
bed rooms 10’3″x10’3″ 2 2 2
Living room 20’6″x10’3″ 1 2 2
ICF blocks needed for this house 210

 

 

 

DOING YOR OWN MOLD 4’ x 6”x 1’ Bottom baseplate of mold

The base of the mold is made out of different materials but most of it will be made out of solid aluminum

The bottom plate is 50 inches long by 9” inches wide and 1 inch thick

The torrent is 4”x 4” and 12” high made out of solid aluminum; at the bottom of the torrent we have a lip that is ½” wide making the grove of the ICF block. Between each torrent there is a space of 2” we want to make sure that the torrent’s centers are 6” apart like in picture.

At the top of the first and last torrent we want to put a toggle clamp to make pressure one the foam is raising

You want to weld the second part of the latch at the side of the base like shown in picture they can be place every 6” to 7” apart.

You may want to put handles to make it easy to transport this can be made out of metal

Case The case is made entirely out of solid aluminum dimensions are 50” long 8” wide and 12” high it is 1” thick, have in mind that you will need the ½” grove and lip to make sure that the ICF blocks can connect to each other

Lid

The lid is also made out of aluminum too; dimensions are 50”long 8” wide and 1” thick. This is very important this is the top of the mold wish will make to lip of the ICF block Don’t forget to put the holes for the toggle clamp on top of the first and last torrent like shown on picture are a very important part of the mold this will hold all the pressure that the chemical will be producing on the side of the mold

This is made out of metal it is ½” thick and goes around the aluminum mold.

Dimensions it 51” long 9” wide and 13 ½” tall

The latches have to be even with the ones you put on the bottom of the base this will make it stay together and will make it easy for you to open once the ICF block is dry The top of the frames has a toggle clamp that will help to keep everything together

How to assemble the Polyurethane Portable Factory