Foam Discharger Segmented Head Design
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Solution Overview
Problem
Conventional foam dispensers face challenges in achieving a large outlet size without increasing the dispenser head thickness, leading to restricted liquid passage and higher manufacturing costs.
Innovation Solution
A foam dispenser design featuring a dispenser head composed of two members with a unique structure, allowing for minimized thickness and enlarged outlet size, facilitated by a two-piece construction with engagement mechanisms and an annular drain recess to prevent water permeation and enhance stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the dispenser head is formed as a single part with large thickness, then the manufacturing is simple, but the outlet size is restricted and the dispensing amount is reduced
Solution Approach 1:
The dispenser head is divided into two separate members: a first member (50a) containing the nozzle (53) and a second member (50b) containing the fitting recesses (63, 64). These members are integrated by fitting, allowing each component to be optimized independently. The first member can have a minimized thickness while the second member provides the structural interface, thereby increasing the outlet size without compromising manufacturing simplicity.
2Productivity
If the dispenser head thickness is minimized, then the outlet size can be enlarged, but the manufacturing complexity increases
Solution Approach 1:
By segmenting the dispenser head into two members that are fitted together, the design achieves minimized thickness while maintaining structural integrity. The first member (50a) with the nozzle can be thin-walled, while the second member (50b) provides the mounting interface through fitting recesses (63, 64), reducing overall complexity compared to a thick single-piece design.
Solution Approach 2:
The first member (50a) is nested within or fitted to the second member (50b) through the fitting recesses (63, 64). This nesting arrangement allows the thinner first member to be supported by the second member, achieving both minimized thickness and structural stability without significant complexity increase.
3Productivity
If the outlet size is enlarged, then the dispensing amount increases, but the dispenser head thickness must be increased
Solution Approach 1:
The segmentation of the dispenser head into two members allows the outlet (nozzle 53) to be enlarged in the first member (50a) without increasing the overall thickness. The second member (50b) with fitting recesses (63, 64) provides the structural support and interface, enabling a large outlet while maintaining minimum thickness.
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 design achieves a larger dispensing capacity with reduced material usage, simplified assembly, and increased stiffness, while maintaining the conventional structure, thereby reducing manufacturing costs and preventing water ingress.
Implementation Method 1
the upward and the downward displacement of the actuator C causes a liquid within the liquid cylinder 21 and air within the air cylinder 20 to be mixed and foamed to be dispensed as a foam
Implementation Method 2
a hook 55 is provided to protrude from each of a lower surface of the nozzle 53 and a lower surface of the top plate 51 in correspondence with the fitting holes 65 so as to be hooked into the fitting holes 65
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Provided is a foam dispenser in which upward and downward displacement of an actuator causes a content liquid within a liquid cylinder (21) and air within an air cylinder (20) to be mixed and foamed, such that the foam so generated is dispensed from an outlet of a dispenser head (50). The dispenser head (50) has a structure with a minimized thickness to thereby increase the dispensing amount. The dispenser head (50) includes two members, i.e., a first member (50a) and a second member (50b), that have special configuration for allowing the two members (50a, 50b) to be easily removed from a die and formed in a small thickness.