Spray Gun Foam Insulation Applicator by Carlisle Construction Markets Companies

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DESIGN DETAILS
DESIGN NAME:
Spray Gun

PRIMARY FUNCTION:
Foam Insulation Applicator

INSPIRATION:
The human hand and how it grasps and holds a handle. All the forms of this spray applicator are roughly based on human anatomy. The users of this system work long house in very difficult conditions that may range in temperature over 35c in a day depending on the application environment. Their comfort greatly enhances the ability to provide a consistent and professional spray pattern from the applicator gun. The key was to create a handle that is supportive, comfortable and provides ease of use.

UNIQUE PROPERTIES / PROJECT DESCRIPTION:
The handle shape, size and wings of the applicator gun is smaller, lighter, better balanced and more compact than current spray guns on the market. The safety strap is unique to this market and also allows the user to relax their grip to prevent hand-cramps. The use of the wings, flared surfaces at the top of the handle help to relieve the stresses and pressure points to the hand in operation. When used with the safety strap these features act in parallel to unite the user and gun

OPERATION / FLOW / INTERACTION:
1.Select and insert the proper diameter nozzle for the materials and rate being sprayed. 2.Connect the A and B side fluid supply lines. 3.Attach the air hose to the applicator gun. 4.Pick up gun and insert your hand through the safety strap, adjust strap to desired tension. 5.Release the safety valve, knob at back, to the open or the spray position. 6.Point and pull trigger gently to spray foam insulation.

PROJECT DURATION AND LOCATION:
This project was started in June of 2017 Oakdale, NM and launched to public view in February 2020 at the SPFA-120 contractors show in Las Vegas NV

FITS BEST INTO CATEGORY:
Building Materials and Construction Components Design

PRODUCTION / REALIZATION TECHNOLOGY:
The gun is a high pressure two part spray foam applicator that is capable of pressures in excess of 340bar. The gun handle and head are made from high-strength aluminum alloy that is forged to a near net shape, then machined to very high tolerances and plated with a durable hard coat anodizing. Graphics and identity are lasered through the plating into the aluminum for a permeant graphic application. Other gun parts are cast, stamped, and machined stainless steel.

SPECIFICATIONS / TECHNICAL PROPERTIES:
W-74mm x D-166mm x H-196mm for the overall gun size. There is a strap pivot that works with an air exhaust in the handle. A sliding piston in the body provides pressure control while the unique and patented valving in the mix chamber do the brunt of the work.

TAGS:
Spray Foam applicator gun, two part insulation, Carlisle, FS1, high pressure impingement mixing,

RESEARCH ABSTRACT:
Type of Research: Empirical. Research Objectives: Develop a comfortable long term use handle and market dominating aesthetics for an applicator gun. Methodology: Ideation sketching, clay models, Mass models and testing with weighted wood models for scale and balance. 3D laser scanning of empirical models into CAD software. Use models made from Rapid Prototypes for user touch and feel testing. Machined functional sample prototypes for field testing and production development. Data Collection and Research Tools Used, Participants or Experiments: - Process: Sketching, then selection of form. - Referencing ergonomic data for hand sizes and grasping power attributes of fingers. - User audits and surveys looking for problems with current systems. - Clay model construction for hand fit and comfort, Audits of various hand types and size ranges. - This process while long and complex rendered a final form that meets a large slice of the human anatomical hand size which provides a comfortable fit in the 98th percentile of users surveyed. Results: A finished applicator gun that is industry leading in application, size and comfort. Insights and Impacts, Effect of the Research in Real-Life: This design is the culmination of a large variety of hand modeling, 3D prototypes, CAD modeling and development, user testing and general tweaking for comfort. We found that smaller had sizes were more difficult to accommodate due to finger size and reach. The strap has been an interesting adaptation, with some users not initially liking it, until they actually used it, whereupon the adoption rate has been almost 100%. Phenomena such as Business, Society and Design Itself: This design is comfortable to the users, is lighter and easier to use than the closest competitive gun available in the market. It is simpler, more easily cleaned, repaired and has dramatically better ergonomics with the fit and load dispersion which creates a more consistent and better pattern application of spray foam insulation, also it is more attractive and has been called “very sexy” by the press at launch.

CHALLENGE:
Actually, finding a supplier that could laser engrave the rotated overwrap graphics through the hard coat into the aluminum was a real challenge. The design of the shape and form was a pleasure through the whole project. The back cap and safety knob had challenges in clocking the threads, and graphic placements. Also balancing the need to disassemble the rear cap which many users do with a pipe wrench. The small indentations provide enough grip to sufficiently tighten the cap by hand but not allow over tightening. Merging the formative aesthetics of the body, sweep and cone, and playing the tri lobe features off one another into a harmonious pleasing form really integrates the design. From an engineering stand point, the challenges were endless as the high pressures contained within the body and existing competitive patents were hoops to jump through. We were able to achieve the results we wanted. Also, mid project we had a new management team that needed to be brought on board and up to speed on the process and objectives. Lastly, costs and pricing is always a challenge but can lead to improvements and better development of the form and function of a project. With this project pricing became an issue but helped to pare some features and attributes down to the essential design which I feel is very successful.

ADDED DATE:
2020-02-28 16:28:49

TEAM MEMBERS (8) :
Peter Byrne, Eric Donaldson, Jake Jacobson, Bruce Nelson, Tomas Reeder, Forrest Wilde, Fred Sutter and

IMAGE CREDITS:
Image #1: Creator Forrest Wilde, FSI Spray Foam Applicator Gun, 2020.
Image #2: Creator Forrest Wilde, FSI Spray Foam Applicator Gun, 2020.
Image #3: Photographer Brandon Sullivan, FSI Spray Foam Applicator Gun, 2019.
Image #4: Photographer Brandon Sullivan, FSI Spray Foam Applicator Gun, 2019.

PATENTS/COPYRIGHTS:
Patents pending 2019 Copyrights belong to Carlisle Companies, Carlisle Construction Materials, 2020

Visit the following page to learn more: http://www.carlisle.com
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CLIENT/STUDIO/BRAND DETAILS
NAME:
Carlisle ST1

PROFILE:
Carlisle Companies Incorporated is a diversified, global portfolio of niche brands and businesses that manufactures highly engineered products and solutions for its customers. Driven by our strategic plan, Vision 2025, Carlisle is committed to generating superior shareholder and stakeholder returns by combining an entrepreneurial management style under a center-led approach, and balanced capital deployment, all with a culture of responsible stewardship and continuous improvement as embodied in the Carlisle Operating System. Carlisle’s markets include: commercial roofing, specialty polyurethane, architectural metal, aerospace, medical technologies, defense, transportation, industrial, protective coating, auto refinishing, agriculture, and construction. Carlisle’s worldwide team of employees generated $4.8 billion in revenues in 2019.

NOMINATION DETAILS

Spray Gun Foam Insulation Applicator by Carlisle Construction Markets Companies is a Nominee in Hardware, Power and Hand Tools Design Category.

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AWARD DETAILS

Spray Gun Foam Insulation Applicator by Carlisle Construction Markets Companies is Winner in Hardware, Power and Hand Tools Design Category, 2019 - 2020.



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