Mixing device for two component polyurethane foam formulation

1. A mixing device comprising:

(a) a housing that defines a mixing chamber, an A-Component feed channel entrance opening, a B-Component feed channel entrance opening, and air feed channel entrance opening, and an exit opening where the feed channel entrance openings and exit opening provide fluid communication into and/or out of the mixing chamber; and

(b) a static mixing element housed within the mixing chamber between the three entrance feed channels and the exit opening;

where the mixing device is further characterized by the air feed channel entrance opening having a cross sectional area that is in a range of 0.7 square millimeters to 7.7 square millimeters or less and further characterized by the mixing chamber being generally cylindrical in shape and having opposing ends with the exit opening at one end and the three feed channel entrance openings at the opposing end; and wherein the static mixing element comprises a central support with a conical feature at an end with the conical feature penetrating into but not sealing off the air channel entrance opening.

2. The mixing device of claim 1 , further characterized by the static mixing element comprising a series of semi-elliptical plates positioned in series along a central support with the central support extending in a general direction between the entrance openings and the exit opening.

3. The mixing device of claim 1 , wherein the conical feature is held into place with respect to the air channel entrance opening by fins that contact a wall defining the air channel entrance opening.

4. The mixing device of claim 1 , further characterized by the static mixing element comprises a series of semi-elliptical plates positioned along a central support and the conical feature being attached to the central support of the static mixers.

5. The mixing device of claim 1 , further characterized by the entrance opening cross section area of the A-component feed channel being 0.5 times or larger and 16 times or smaller than the air feed channel entrance opening cross sectional area.

6. The mixing device of claim 1 , further characterized by the entrance opening cross section area of the B-Component feed channel being 0.7 times or larger and 25 times or smaller than the air feed channel entrance opening cross sectional area.

7. The mixing device of claim 1 , further characterized by the air feed channel entrance opening being generally centered on an end of the mixing chamber.

8. The mixing device of claim 7 , further characterized by the static mixing element comprising a series of plates in series along a central support, the central support having a conical end that extended into but not sealing off the entrance opening of the air feed channel such that the cross sectional area left open around the conical feature corresponds to the air feed channel entrance opening cross sectional area, the conical feature having three or more fins that contact a wall defining the air channel entrance opening and serve to hold the conical feature generally centrally position in the air channel entrance opening.

9. A process for dispensing a non-frothed two-component polyurethane foam formulation using the mixing device of claim 1 , the process comprising feeding an A-Component comprising an isocyanate and that is free of liquid blowing agent through the A-Component feed channel while feeding a B-Component comprising a polyol through the B-Component channel and while feeding air through the air feed channel, mixing the A- and B-Components with air in the mixing chamber before the A- and B-Components finish interacting with the static mixing element and dispensing them through the exit opening.