Liquid Dispenser Discharge Structure Deformation
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Solution Overview
Problem
Existing liquid dispenser manufacturing processes, particularly plastic injection molding, limit the flexibility in shaping the output opening, making it difficult to achieve complex or elongated designs.
Innovation Solution
A two-stage production process involving plastic injection molding to create a basic body, followed by mechanical force loading using a stamp or protective cap to deform the setting structure, allowing for the formation of complex output characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic injection molding is used to manufacture the housing component, then manufacturing efficiency and cost are improved, but the flexibility in shaping the discharge structure is limited due to mold complexity requirements
Solution Approach 1:
The manufacturing process is segmented into two independent stages: first, the base body is manufactured using conventional injection molding; second, the discharge structure is formed by applying mechanical force to deform the base body. This segmentation allows each stage to be optimized independently, maintaining manufacturing efficiency while achieving shaping flexibility.
Solution Approach 2:
The base body is prepared in advance with a simplified geometry that is easy to mold, and then the final discharge structure shape is created by subsequent deformation. This preliminary action separates the molding complexity from the final shape complexity, allowing efficient manufacturing of the base while achieving complex final geometries.
2Adaptability or versatility
If complex molds with slides are used to achieve complex discharge structures, then shaping flexibility is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The complexity of forming the discharge structure is extracted from the molding process and transferred to a separate deformation process. Instead of incorporating complex slides and mechanisms into the mold, the base body is molded with a simple geometry and then deformed afterward to create the complex discharge structure.
Solution Approach 2:
The mechanical complexity of mold slides and moving components is replaced by a simpler deformation mechanism that applies force to the base body after molding. This substitution eliminates the need for complex mold mechanisms while achieving the same shaping capability.
3Manufacturing precision
If the discharge structure is designed for droplet formation with elongated shapes, then dispensing performance is improved, but manufacturing difficulty increases due to undercut formation
Solution Approach 1:
The base body is molded with a simplified geometry that avoids undercuts, making demolding easy. The preliminary base body then serves as a substrate for subsequent deformation that creates the elongated discharge structure with precise droplet formation characteristics, which would be difficult to mold directly.
Solution Approach 2:
The manufacturing process transitions from a static molding operation to a dynamic deformation process. The base body is deformed after molding to create the final discharge structure shape, allowing complex geometries to be formed without the constraints of mold demolding.
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
This process enables the production of liquid dispensers with advanced output structures, such as drop formation areas, without the need for complex molds, offering high flexibility and accurate dosage control.
Implementation Method 1
a second step involves applying mechanical force to the as yet unfinished discharge structure, which leads to a deformation of the base body and thus to the formation of the discharge structure with its final shape
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5C
AI summary
A method for manufacturing a liquid dispenser (10) is described. In its finished state, the liquid dispenser (10) has a liquid reservoir (12) and a discharge opening (30) through which the liquid can be dispensed into the environment in a discharge direction (2). The liquid dispenser (10) has a housing component (14) which is penetrated by the discharge opening (30) and which has a discharge structure (40) forming the discharge opening and/or adjoining the discharge opening (30) for influencing a discharge characteristic.This housing component (14), which is penetrated by the discharge opening (30), is manufactured by first producing a base body (14') by plastic injection molding in a mold and then applying a mechanical force in the area of a preliminary discharge structure (40') of the base body (14') to deform the preliminary discharge structure and thus to create a final discharge structure (40).