Foam Dispenser with Inline Agitator to Reduce Mesh Clogging
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Solution Overview
Problem
Existing foam soap dispensers face issues with inconsistent foam quality due to mesh clogging and difficulty in maintenance, especially when using different types of liquid soap.
Innovation Solution
The use of static inline mixers, or agitators, within the dispensing conduit to mix and recombine fluid flows, combined with a mesh at the dispensing outlet, ensures consistent foam quality and easy maintenance by reducing the number of accessible clog-prone components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screens are placed in the mixing chamber to improve foam texture, then foam quality is improved, but the screens become clogged with debris and dried soap making maintenance difficult
Solution Approach 1:
The patent removes the screens from the mixing chamber entirely and replaces them with an agitator system that creates foam through mechanical agitation of the liquid soap and air mixture. This extraction eliminates the clogging problem while maintaining foam quality through a different mechanism - the agitator beats the air-liquid mixture to generate foam without requiring screens that can become blocked by debris and dried soap.
2Manufacturing precision
If multiple screens are used in the mixing chamber to obtain better foam texture, then foam quality improves, but the device complexity increases and components become harder to access for cleaning
Solution Approach 1:
The patent extracts multiple screens from the mixing chamber and replaces them with a single agitator component. This simplification reduces the number of parts while achieving the same foam quality goal through mechanical agitation rather than filtration. The agitator system eliminates the need for multiple screening layers, thereby reducing device complexity and improving maintainability.
Solution Approach 2:
The patent replaces the mechanical screening system with a mechanical agitation system. Instead of using screens to filter and shape the foam, the invention uses an agitator that beats the air-liquid mixture to generate foam through mechanical action. This substitution eliminates the clogging issue inherent in screen-based systems while maintaining effective foam production.
3Manufacturing precision
If screens are placed in the mixing chamber to generate foam, then foam quality improves, but the screens become completely clogged preventing foam dispensing
Solution Approach 1:
The patent removes screens from the mixing chamber to eliminate the clogging failure mode. By replacing the screen-based foam generation mechanism with an agitator-based system, the invention ensures continuous operation without the risk of complete blockage that would prevent foam dispensing.
Solution Approach 2:
The patent employs a mesh screen at the dispensing outlet that can be easily removed and cleaned when needed. This disposable-like approach to the outlet screen allows for quick maintenance without requiring disassembly of the mixing chamber, ensuring the system can quickly return to continuous operation after minor cleaning.
4Shape
If a skirt or removable panel is used to cover the soap dispenser under the counter, then aesthetics are improved, but maintenance personnel cannot easily access or clean the meshes
Solution Approach 1:
The patent extracts the foam generation function from the hidden mixing chamber area and places it at the dispensing outlet through the agitator system. This eliminates the need for screens in the concealed area under the counter, allowing the skirt or panel to remain in place for aesthetic purposes while maintenance personnel can easily access and clean the outlet screen without removing decorative coverings.
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 solution maintains consistent foam quality across varying liquid soap types and simplifies maintenance by minimizing clogged areas and allowing easy access to the mesh for cleaning.
Implementation Method 1
a first agitator downstream of the mixing chamber in the conduit... the first agitator is for converting said air-liquid mixture into a foam
Implementation Method 2
a first mesh proximate the dispensing outlet... a second mesh proximate the dispensing outlet and spaced apart from the first mesh
Data Source
Figure 1
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AI summary
A foam dispenser includes a dispensing a mixing chamber for receiving liquid from a liquid source and air from an air source, a conduit, and an agitator downstream of the mixing chamber in the conduit.