CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Application No. 62/833,922 filed April 15, 2019 for“SPRAY FOAM SPRAYING AND INSPECTION SYSTEM” by D. P. Ross, M. T. Weinberger, C. M. Lange and B. R. Godding, the disclosure of which is hereby incorporated in its entirety.

BACKGROUND

This disclosure relates generally to spray foam. More particularly, this disclosure relates to spray foam application.

Spray foam insulation is applied to substrates to provide thermal insulation. Both moisture and temperature of both the substrate and spray environment affect the quality of the spray foam. For example, adverse conditions can cause the spray foam to peel away from the substrate or not expand as desired.

The spray foam is applied to a desired depth to ensure that the spray foam provides the desired insulation. Typically, the user on the site inserts a length of an object, such as a nail, into the spray foam to determine the depth. The user will typically mark the desired depth on the shaft of the nail, such as 2 inches from the point of the nail, and will verify that the spray foam is the desired depth based on the location of that mark when the nail is inserted. The depth measuring objects do not provide any information as to the actual depth. In addition, the depth measuring object does not provide tracking regarding foam thicknesses at various locations throughout the job site.

SUMMARY

According to one aspect of the disclosure, a spray foam inspection tool includes a probe for measuring a thickness of spray foam by piercing the spray foam and proceeding through the spray foam until contacting a substrate disposed on an opposite side of the spray foam from the probe; a sensor configured to sense a distance that the probe extends into the spray foam and to generate thickness information based on the distance that the probe extends into the spray foam; and tool circuitry configured to generate a depth signal based on the thickness information generated by the sensor and to provide the depth signal to a remote computing device.

According to another aspect of the disclosure, a spray foam system includes a surface inspection tool, the surface inspection tool including at least one sensor configured to sense a parameter of a substrate; a spray foam applicator configured to apply a spray foam to the substrate; and a spray foam inspection tool comprising configured to measure a thickness of the spray foam applied to the substrate, to generate a depth signal based on the measured thickness of the spray foam, and to communicate the depth signal to a remote computing device.

According to yet another aspect of the disclosure, a method includes spraying foam onto a substrate; piercing the foam with a probe of a foam inspection tool until the probe contacts the substrate; generating thickness information regarding a distance that the probe extends into the foam with a sensor of the foam inspection tool; generating a depth signal, by tool circuitry of the foam inspection tool, based on the thickness information from the sensor; and communicating, by the foam inspection tool, the depth signal to a remote computing device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic block diagram of a spray foam system.

FIG. 2A is a block diagram of a spray foam inspection tool.

FIG. 2B is a block diagram of a spray foam inspection tool.

FIG. 3 is a schematic block diagram of a spray foam inspection tool.

DETAILED DESCRIPTION

FIG. 1 is a schematic block diagram of spray foam system 10. Spray foam system 10 includes applicator 12, surface inspection tool 14, foam inspection tool 16, and remote computing device 18. Applicator 12 includes material supplies 20a, 20b; pumps 22a, 22b; control unit 24; and dispenser 26. Surface inspection tool 14 includes parameter sensors 28. Foam inspection tool 16 includes probe 30 and sensor 32.

Spray foam system 10 is configured to generate and apply a coating of foam insulation onto substrate S. Control unit 24 of applicator 12 can control various other components of applicator 12, such as pumps 22a, 22b, to control generation of the spray foam and spraying of the spray foam.

Material supplies 20a, 20b store materials prior to spraying. Spray foam can be formed from multiple components that combine to create the spray foam. For example, material supply 20a can store a first component material, such as a resin, and material supply 20b can store a second component material, such as a catalyst. The first and second component materials combine at dispenser 26 and are applied as the plural component material. As such, dispenser 26 can alternatively be referred to as a mixer or mixing manifold. Dispenser 26 generates a spray of the plural component material, which is the spray foam, and sprays the plural component material onto the substrate. Pump 22a is configured to draw the first component material from material supply 20a and pump the first component material downstream to dispenser 26. Pump 22b is configured to draw the second component material from material supply 20b and pump the second component material downstream to dispenser 26. Pumps 22a, 22b can be controlled by control unit 24.

Surface inspection tool 14 is configured to sense various parameters of substrate S prior to applying the spray foam. Surface inspection tool 14 includes parameter sensors 28 that are configured to sense parameters of substrate S and/or environment that affect the quality of the spray foam during application. Surface inspection tool 14 can generate parameter signals indicative of the sensed parameters and can communicate the parameter signals to one or both of control unit 24 and remote computing device 18. Surface inspection tool 14 can include an internal memory within which surface inspection tool stores the parameter data generated by parameter sensors 28. Additionally and/or alternatively, surface inspection tool 14 can communicate the parameter data to one or both of control unit 24 and remote computing device 18. Surface inspection tool 14 can be configured to communicate the parameter data through either wired or wireless communications .

In one example, parameter sensor 28 can include one or more moisture sensors configured to sense a moisture content of substrate S and/or a humidity of the spray environment. Parameter sensor 28 can include one or more temperature sensors configured to sense a temperature of substrate S and/or a temperature of the spray environment. It is understood, however, that parameter sensors 28 can be of any desired configuration for sensing and generating data reading the spray environment prior to spraying. In addition, it is understood that surface inspection tool 14 can include as many or as few parameter sensors 28 as desired.

Foam inspection tool 16 is utilized to inspect the foam after application to substrate S. Foam inspection tool 16 includes probe 30 and sensor 32. Probe 30 projects from foam inspection tool 16 and is configured to pierce the spray foam. Sensor 32 is configured to sense the distance that probe 30 extends into the spray foam prior to contacting substrate S. Substrate S inhibits any further penetration of probe 30 into the spray foam. As such, the distance that probe 30 penetrates into the spray foam is the thickness of the spray foam applied to substrate S. Foam inspection tool 16 thereby senses a thickness of the spray foam at that location. Foam inspection tool 16 can include an internal memory within which foam inspection tool 16 stores the thickness data. Additionally and/or alternatively, foam inspection tool 16 can communicate the thickness data to one or both of control unit 24 and remote computing device 18. Foam inspection tool 16 can be configured to communicate the thickness data through either wired or wireless communications.

Control unit 24 is configured to control pumping by pumps 22a, 22b to ensure the quality of the spray foam at dispenser 26. Control unit 24 can control the speed of each pump 22a, 22b to ensure a proper ratio of the first component material and the second component material are provided at dispenser 26. Control unit 24 is further communicatively coupled to send data to and data from surface inspection tool 14 and foam inspection tool 16. Control unit 24 can control spray foam spraying based on the data received from surface inspection tool 14. Control unit 24 can also generate spray data regarding the application of the spray foam. The spray data can include the volume of component materials sprayed, the time of the spraying, the location of the spraying, the identity of the user, and the duration of the spraying, among other options.

Remote computing device 18, as illustrated in FIG. 1, is remote from and communicatively coupled with one or more of applicator 12, surface inspection tool 14, and foam inspection tool 16. Remote computing device 18 can be any device including processing circuitry and memory configured to operate in accordance with techniques described herein to receive one or more of parameter data, temperature data, and spray data and further generate job reports regarding a particular spray application. For example, remote computing device can be a smartphone or tablet that receives data from one or both of surface inspection tool 14 and foam inspection tool 16 and that can communicate that data to control unit 24 or another remote computing device. In other examples, remote computing device 18 can be a server computer that receives data from one or more of surface inspection tool 14 and foam inspection tool 16 and can store the data and or provide information to control unit 24 based on the data, such as spray instructions. In yet other examples, remote computing device 18 can be embodied in multiple computing devices that distribute functionality attributed herein to remote computing device 18 among the multiple devices.

Control unit 24 can be communicatively coupled to any of remote computing device 18, surface inspection tool 14, and foam inspection tool 16 through either wired or wireless connections. Control unit 24 can be communicatively coupled to either of surface inspection tool 14 and foam inspection tool 16 by an intermediate device, such as remote computing device 18. Prior to beginning spray foam application, the user can determine the environmental and substrate parameters. For example, surface inspection tool 14 can determine one or more of the moisture content of substrate S, the temperature of substrate S, the humidity of the spray environment, and the temperature of the spray environment. The parameter data generated by surface inspection tool 14 can be communicated to control unit 24 and/or to remote data store. In some examples, at least one of control unit 24 and remote computing device 18 can analyze the parameter data and can provide an indication to the user regarding the spray conditions.

For example, control unit 24 and/or remote computing device 18 can compare the parameter data from surface inspection tool 14 to a parameter range. In some examples, the parameter range can include more than one range, such as an ideal parameter range and an operable parameter range. The ideal parameter range can represent preferred conditions for applying the spray foam. The operable parameter range can represent acceptable conditions for applying the spray foam. As such, the ideal parameter range can be considered as included within the operable parameter range. In some examples, either of the ideal or operable parameter ranges include a maximum or minimum value as opposed to a true range.

Control unit 24 and/or remote computing device 18 can determine whether spraying should proceed based on the determination of which, if any, range the spray conditions fall within. In some examples, control unit 24 can prevent spraying when the parameter data indicates that the spray conditions fall outside of the operable range. For example, control unit 24 can prevent activation of pumps 22a, 22b unless the spray conditions are within the operable range. As such, the user will not apply the spray foam in such conditions. In some examples, control unit 24 can prompt the user to request user authorization prior to initiating any spraying. For example, the user can be informed, such as by a user interface of control unit 24 or remote computing device 18, that the spray conditions fall outside of the parameter range. The user can authorize spraying by entering such authorization to control unit 24 and/or remote computing device 18. The user authorization can cause control unit 24 to activate pumps 22a, 22b such that spray foam activation can proceed. The user authorization can be stored in one or both of control unit 24 and remote computing device 18 and can be associated with the spray job.

During spraying control unit 24 activates pumps 22a, 22b. Control unit 24 can control the speed of each pump 22a, 22b to ensure a proper ratio of the first component material and the second component material are provided at dispenser 26. The user manipulates dispenser 26 and applies the spray foam to substrate S. After the spray foam is applied, the user can utilize foam inspection tool 16 to verify the quality of the spray foam that was just applied.

Probe 30 of foam inspection tool 16 is inserted into the spray foam until probe 30 impacts substrate S. Sensor 32 senses the depth that probe 30 extends into the spray foam. Foam inspection tool 16 can generate and send thickness data to one or both of control unit 24 and remote computing device 18 based on the sensed depth of penetration of probe 30. In some examples, the user can take multiple readings at multiple locations throughout the spray site. The individual thickness measurements can all be associated with the current spray job by foam inspection tool 16, by control unit 24, and/or by remote computing device 18. The various thickness measurements can be stored for later use and to verify that the spray foam was actually applied to the desired thickness.

Any one or more of foam inspection tool 16, control unit 24, and remote computing device 18 can be configured to compare the sensed thickness with a target thickness. The user can be notified, such as by a user interface of foam inspection tool 16, when the sensed thickness falls below the target thickness. Various other information regarding the spray foam inspection can be generated and stored, such as the number of foam thickness checks, the minimum and maximum sensed thicknesses, the average thickness, and the locations of the thickness checks, among other options.

System 10 provides significant advantages. System 10 can prevent spray foam application where the spray conditions are less than ideal. Control unit 24 can lock when the parameter data indicates that the spray parameters, such as moisture and temperature, fall outside of a desired parameter range. In some cases, the user can override control unit 24, which can be tracked to provide tracking for the full spray job. A record of the spray job can be compiled by control unit 24 or remote computing device 18 based on the parameter data, the spray data, and the thickness data. Foam inspection tool 16 provides verification that the spray foam has been applied to the desired depth for the spray job. Foam inspection tool 16 can provide the thickness data to provide further tracking and management of the spray job. Foam inspection tool 16 can generate and store relevant information for the job, such as the number of foam thickness checks, the minimum and maximum sensed thicknesses, the average thickness, and the locations of the thickness checks, among other options.

FIG. 2 A is a block diagram of foam inspection tool 16 in a first state. FIG. 2B is a block diagram of foam inspection tool 16 in a second state. FIGS. 2 A and 2B will be discussed together. Foam inspection tool 16 includes probe 30, sensor 32, and housing 34. Sensor 32 includes slider 36 and spring 38.

Probe 30 extends from housing 34 and is configured to pierce spray foam F. Probe 30 can be of any suitable configuration for piercing the spray foam F, such as a wire or small diameter rod. Sensor 32 is configured to sense a thickness of the spray foam F based on a distance that probe 30 extends into the spray foam F. Slider 36 is disposed on probe 30 and is configured to slide along the length of probe 30. Spring 38 is disposed between slider 36 and housing 34. Spring 38 is configured to bias slider 36 away from housing 34 towards a distal end of probe 30. Housing 34 can contain various electronic components of foam inspection tool 16, as discussed in more detail below.

During operation, foam inspection tool 16 is shifted transverse relative to the spray foam F causing probe 30 to penetrate the spray foam F. The user pushes probe 30 into the spray foam F until the distal end of probe 30 contacts substrate S. Substrate S prevents the user from continuing to push probe 30 further into the spray foam F. As such, the user knows that probe 30 is indicating the full thickness of the spray foam F when substrate S prevents further movement of probe 30 into the spray foam F.

Slider 36 is sized such that slider 36 does not penetrate the spray foam F. Instead, the surface of the spray foam F maintains slider 36 outside of the spray foam F. Slider 36 abuts the exterior surface of the spray foam F. As such, slider 36 provides a brace of foam inspection tool 16 that braces against the exterior of the spray foam F as probe 30 penetrates the spray foam F. As probe 30 extends into the spray foam F, slider 36 slides along the length of probe 30 thereby compressing spring 38 between slider 36 and housing 34. In some examples, the user can zero out sensor 32 with slider 36 abutting the spray foam F prior to pushing probe 30 into the spray foam F, to ensure an accurate reading. For example, the user can reset the thickness reading to zero via a user interface of foam inspection tool 16.

In some examples, sensor 32 is configured to sense the linear displacement of slider 36 relative to probe 30. As such, sensor 32 can be a linear transducer. It is understood, however, that sensor 32 can be of any desired configuration for sensing the displacement of probe 30 into the spray foam F.

FIG. 3 is a schematic block diagram of foam inspection tool 16. Foam inspection tool 16 includes probe 30, sensor 32, housing 34, memory 40, tool circuitry 42, user interface 44, position sensor 46, and communications circuitry 48. Housing 34 contains various electronic components of foam inspection tool 16. Probe 30 extends from housing 34 and is configured to penetrate the spray foam, as discussed above. Sensor 32 is operatively connected to probe 30 to sense a distance that probe 30 extends into the spray foam. Sensor 32 is configured to generate thickness data regarding the distance that probe 30 extends into the spray foam. Sensor 32 can be of any desired configuration for sensing the distance that probe 30 extends into the spray foam. For example, sensor 32 can be a linear transducer. In one example, sensor 32 can sense linear displacement of probe 30 relative to sensor 32. In another example, sensor 32 and probe 30 can be linked for simultaneous movement, and sensor 32 can be configured to sense linear displacement relative to another object. For example, foam inspection tool 16 can be mounted on a support member that braces against the spray foam as probe 30 extends into the spray foam. Sensor 32 can be configured to sense linear movement relative to the support member. Foam inspection tool 16 thus includes a brace, which can be integrated into or separate from sensor 32, that braces against the exterior of the spray foam. The brace bracing against the exterior of the spray foam allows the user to zero foam inspection tool 16 prior to inserting probe 30 into the spray foam. With probe 30 moving relative to the brace, sensor 32 can sense the relative movement and provide the thickness data based on the relative movement.

Control circuitry 42 can include one or more processors, configured to implement functionality and/or process instructions. For example, control circuitry 42 can be capable of processing instructions stored in memory 40. Examples of control circuitry 42 can include any one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry.

Communications circuitry 48 is disposed in housing 34. Communications circuitry 48 is configured to facilitate wired or wireless communications by foam inspection tool 16. For example, communications circuitry 48 can facilitate radio frequency communications and/or can facilitate communications over a network, such as a local area network, wide area network, and/or the Internet.

Position sensor 46 is configured to sense one or more of the orientation and relative position of foam inspection tool 16. For example, position sensor 46 can be configured to sense the directional orientation of probe 30 extending from housing 34. Position sensor 46 can include a magnetometer, or other suitable device, to provide the relative directional orientation of sensor 32. For example, the magnetometer can indicate that probe 30 is facing north when a thickness measurement is taken. That directional orientation can be associated with the thickness data such that the user will be able to determine that that thickness measurement was taken at the north wall. Position sensor 46 can further include accelerometers, gyroscopes, or any other desired sensors suitable for determining movement and positioning of foam inspection tool 16. For example, position sensor 46 can sense movement of foam inspection tool 16 between a first measurement location and a second measurement location, such as where the user takes a first measurement of spray foam thickness on the north wall and a second measurement of spray foam thickness on the west wall. Position sensor 46, or a combination of multiple sensors that form position sensor 46, facilitate foam inspection tool 16 tracking the locations at which the various measurements are taken.

Memory 40 can be configured to store information within foam inspection tool 16 during operation. Memory 40, in some examples, are described as computer-readable storage media. In some examples, a computer-readable storage medium can include a non- transitory medium. The term“non-transitory” can indicate that the storage medium is not embodied in a carrier wave or a propagated signal. In certain examples, a non-transitory storage medium can store data that can, over time, change (e.g., in RAM or cache). In some examples, memory 40 is a temporary memory, meaning that a primary purpose of memory 40 is not long-term storage. Memory 40, in some examples, is described as volatile memory, meaning that memory 40 does not maintain stored contents when power to foam inspection tool 16 is turned off. Examples of volatile memories can include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile memories. In some examples, memory 40 is used to store program instructions for execution by tool circuitry 42. Memory 40, in one example, is used by software or applications running on tool circuitry 42 to temporarily store information during program execution.

Memory 40, in some examples, also include one or more computer-readable storage media. Memory 40 can be configured to store larger amounts of information than volatile memory. Memory 40 can further be configured for long-term storage of information. In some examples, memory 40 includes non-volatile storage elements. For example, foam inspection tool 16 can include non-volatile storage elements such as flash memories or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories. In some examples, memory 40 can be external and can be received in a memory card slot in foam inspection tool 16. For example, memory 40 can be an external hard drive, flash drive, memory card, secure digital (SD) card, micro SD card, or other such device.

Memory 40 can be encoded with instructions that, when executed by tool circuitry 42, causes foam inspection tool 16 to associate the thickness data generated by sensor 32 with the position data generated by position sensor 46. The associated data can be stored in memory 40 and/or communicated to an external device via communications circuitry 48. In some examples, foam inspection tool 16 can compare the sensed thickness to a target thickness and can further alert the user where the sensed thickness differs from the target thickness. Memory 40 can be further encoded with instructions that, when executed by tool circuitry 42, causes foam inspection tool 16 to determine the number of foam thickness checks, the minimum and maximum sensed thicknesses, the average thickness, and the locations of the thickness checks, among other options. The various information generated can be stored in memory 40.

User interface 44 can be any graphical and/or mechanical interface that enables user interaction with foam inspection tool 16. For example, user interface 44 can implement a graphical user interface displayed at a display device of user interface 44 for presenting information to and/or receiving input from a user. User interface 44 can include graphical navigation and control elements, such as graphical buttons or other graphical control elements presented at the display device. User interface 44, in some examples, includes physical navigation and control elements, such as physically-actuated buttons or other physical navigation and control elements. In general, user interface 44 can include any input and/or output devices and control elements that can enable user interaction with foam inspection tool 16.

During operation, foam inspection tool 16 measures the thickness of the spray foam that has been applied to the substrate. Foam inspection tool 16 can store the thickness data in memory 40 and/or can communicate the thickness data via communications circuitry 48.

Foam inspection tool 16 is braced against the exterior of the spray foam. A first measurement is taken. The user can zero out foam inspection tool 16 via user interface 44. Foam inspection tool 16 is shifted transverse to the spray foam to plunge probe 30 through the spray foam until the distal end of probe 30 contacts the substrate. Sensor 32 senses the distance that probe 30 moves into the spray foam, thereby sensing a thickness of the spray foam. The first thickness data generated by sensor 32 can be stored in memory 40. The first thickness data can also be communicated to an external device, such as control unit 24 (FIG. 1) and/or remote computing device 18 (FIG. 1), by communications circuitry 48. In addition, foam inspection tool 16 can associate the first thickness data with first positional data generated by position sensor 46 to generate a first associated data. For example, the first associated data can indicate that the spray foam has a thickness of 2 inches (5.08 cm) and was taken on a north wall.

Foam inspection tool 16 can then be moved to a second location within the job site. Foam inspection tool 16 is braced against the exterior of the spray foam at the second location. Foam inspection tool 16 is shifted transverse to the spray foam to plunge probe 30 through the spray foam until the distal end of probe 30 contacts the substrate. Sensor 32 senses the distance that probe 30 moves into the spray foam, thereby sensing a thickness of the spray foam. The second thickness data generated by sensor 32 can be stored in memory 40. The second thickness data can also be communicated to an external device, such as control unit 24 (FIG. 1) and/or remote computing device 18 (FIG. 1), by communications circuitry 48. In addition, foam inspection tool 16 can associate the second thickness data with second positional data generated by position sensor 46 to generate a second associated data. For example, the second associated data can indicate that the spray foam has a thickness of 2 inches and was taken on a west wall.

The user can continue to take additional thickness measurements at various locations throughout the job site. The various measurements can be combined to provide an overall indication of the quality and quantity of the spray foam applied at the site. The user can offload the data from foam inspection tool 16 via communications circuitry 48. Foam inspection tool 16 can be further configured to generate and store additional information regarding the spray foam inspection, such as the number of foam thickness checks, the minimum and maximum sensed thicknesses, the average thickness, and the locations of the thickness checks, among other options.

Foam inspection tool 16 provides significant advantages. Sensor 32 senses the distance that probe 30 extends into the spray foam. Thickness data taken at multiple locations throughout the job site and can be stored in memory 40. Memory 40 can store thickness data regarding any desired number of measurements. As such, the user does not need to manually measure and record the thicknesses. Foam inspection tool 16 can also communicate the thickness data to an external device, through either wired or wireless communications. In some examples, foam inspection tool 16 can compare the sensed thickness to a target thickness and can provide that comparison to the user, thereby providing greater user confidence and quality tracking. While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.