Stepped Foam Dispenser Pump with Coaxial Liquid-Air Chambers
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Solution Overview
Problem
Existing liquid dispensers fail to efficiently dispense soaps and similar fluids in foam form, which requires less liquid, reduces runoff, and is more effective for cleaning.
Innovation Solution
A pump assembly with a dual-piston mechanism that displaces liquid and air in a coordinated manner, using a series of coaxial chambers and discs to create a foam by mixing liquid and air, either through a foam generator or atomization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If liquid is dispensed in liquid form, then the dispenser structure is simple, but more liquid is required and it runs off surfaces
Solution Approach 1:
The pump assembly is segmented into two separate pumps working in coordination: a first pump with a first piston for drawing and dispensing liquid, and a second pump with a second piston for drawing in air. This segmentation allows independent control of liquid and air displacement volumes, enabling precise foam generation with reduced liquid consumption while maintaining a manageable structural complexity through modular design.
Solution Approach 2:
The first pump is nested within the second pump structure, with both pistons sharing a common axis and operating within concentric chambers. The first inner chamber containing the first piston is positioned within the second outer chamber containing the second piston. This nested arrangement consolidates two pumping functions into a single integrated device, reducing overall structural complexity while achieving the dual function of liquid and air displacement for foam generation.
2Ease of operation
If liquid is dispensed in foam form, then less liquid is required and runoff is reduced, but the dispenser structure becomes complex
Solution Approach 1:
The first pump and second pump are merged into a single integrated pump assembly sharing common structural elements including the piston rod, seals, and housing. Both pumps operate simultaneously and coordinate their discharge to mix liquid and air, creating foam at the discharge point. This merging approach delivers the cleaning effectiveness of foam dispensing while minimizing structural complexity through shared components and synchronized operation.
3Quantity of substance
If a single pump is used, then the device is simple, but it cannot efficiently mix liquid and air to create foam
Solution Approach 1:
The first pump and second pump are designed to operate simultaneously and continuously throughout each pumping cycle, with both pistons moving in unison. The first pump continuously draws and dispenses liquid while the second pump continuously draws in air, ensuring uninterrupted mixing and foam generation. This continuous coordinated operation maintains an efficient liquid-to-air ratio for optimal foam creation without requiring complex intermittent control mechanisms.
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
The solution allows for efficient dispensing of soap in foam form, reducing the amount of liquid needed and minimizing runoff, while effectively cleaning surfaces.
Implementation Method 1
the piston forming element forms a vacuum in the chamber to draw liquid from the reservoir
Implementation Method 2
The piston forming element forms a vacuum in the chamber to draw liquid from the reservoir
Implementation Method 3
a piston forming element axially slidable inwardly and outwardly between an inward retracted position and an outward extended position
Data Source
AI summary
A pump assembly with a first pump to displace a first volume and a second pump to displace a second volume greater than the first volume. The first pump draws liquid from a reservoir and dispenses it to the second pump. The second pump draws in the discharge from the first pump and an additional volume of air such that the second pump discharges both liquid and air. The first pump preferably has a piston movable in a first inner chamber and the second pump has the same piston movable in a second outer chamber. The first and second chambers communicate together. In one version, a one-way valve provides flow outwardly only from the first chamber to the second chamber and the first pump discharges while the second pump draws in, and vice versa.