Cleaning Concentrate Dispenser With Pump Control for Precise Dilution
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Solution Overview
Problem
Existing cleaning concentrate dispensers are limited by the need for placement at water sources, inaccuracy in dilution, susceptibility to impurities, high maintenance costs, and inability to handle dilutions beyond 500:1 due to precision issues.
Innovation Solution
A cleaning concentrate dispenser assembly with an RFID reader, level sensor, controller, and dispensing pump that intelligently dispenses the correct amount of concentrate into containers, eliminating the need for water-driven systems and enabling precise dilution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If water-driven vacuum devices are used for mixing chemicals with water, then dilution can be achieved, but measurement precision deteriorates with inaccuracies of +/- 5% and susceptibility to water pressure variables
Solution Approach 1:
The patent replaces water-driven vacuum mechanical mixing systems with an electrically-powered peristaltic pump system. The peristaltic pump uses rotational motion to compress and release tubing, creating a vacuum that draws liquid through the system without relying on water pressure. This mechanical-to-electrical substitution eliminates susceptibility to water pressure variables and enables precise metering of chemical concentrates through controlled rotational cycles.
Solution Approach 2:
The patent incorporates flow meters and sensors that monitor the actual flow rates of both chemical concentrate and water. This feedback is fed to a controller that adjusts pump speeds and operational parameters to maintain accurate dilution ratios. The feedback mechanism compensates for variations and ensures measurement precision remains within tight tolerances regardless of external conditions.
2Productivity
If vacuum dilution devices are used, then chemical mixing can be performed, but the devices build up with water impurities and require difficult and costly maintenance
Solution Approach 1:
The patent extracts the mixing function from a centralized vacuum dilution device and distributes it to multiple standalone dispenser units. Each dispenser is a self-contained system that mixes chemicals locally at the point of use. This eliminates the common maintenance problem where centralized devices accumulate water impurities from multiple sources, as each unit processes and dispenses its own mixture independently, preventing impurity buildup in shared components.
Solution Approach 2:
The patent employs disposable or easily replaceable cartridges containing the chemical concentrate reservoir and mixing components. When these components become contaminated or wear out, the entire cartridge can be quickly replaced rather than performing complex maintenance on the mixing mechanism itself. This significantly reduces maintenance difficulty and cost while ensuring continuous productivity.
3Ease of operation
If vacuum dilution devices are used, then chemical dispensing can be achieved, but the devices are expensive to make and install
Solution Approach 1:
The patent divides the chemical dispensing system into modular segments: a centralized storage facility for bulk chemicals, multiple distributed dispenser units for local mixing and dispensing, and separate delivery mechanisms for both chemical and water. This segmentation allows each unit to be manufactured independently using simpler, less expensive components compared to a single complex centralized vacuum dilution system, reducing overall manufacturing and installation costs while maintaining dispensing functionality.
Solution Approach 2:
The patent designs the dispenser units with universal components that can handle different chemical types and concentrations. The peristaltic pump mechanism, flow meters, and control systems are standardized across all units, allowing for economies of scale in manufacturing. This multi-functionality reduces per-unit costs compared to specialized vacuum dilution devices designed for specific applications.
4Measurement precision
If conventional dispensers are used, then dilution can be achieved, but dilutions over 500:1 are not practical due to lack of sufficient precision
Solution Approach 1:
The patent uses dynamically adjustable peristaltic pumps with variable speed controls and programmable operational parameters. The system can adapt its pumping speed, cycle frequency, and metering volume based on the required dilution ratio. This dynamic adjustment capability enables the system to achieve precise measurements across an extended range of dilution ratios, from concentrated to highly diluted solutions, far beyond the fixed 500:1 limitation of conventional devices.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise dispensing of cleaning concentrates into containers, reducing plastic waste and transportation energy, while maintaining accurate inventory and facilitating efficient data management.
Implementation Method 1
a peristaltic pump having a rotational member that rotates about an axis of rotation, a drive shaft, and a plurality of drive members
Implementation Method 2
a flow meter in fluid communication with the concentrate container and having a sensing element that extends into the concentrate container and a body that extends outwardly from the concentrate container
Data Source
AI summary
A cleaning concentrate dispenser assembly, including: a housing sub-assembly; an energy source; an RFID reader; a level sensor; a controller (printed circuit board); a cleaning concentrate reservoir; a dispensing pump; and a cleaning concentrate output.