Foam Dispenser Piston Dome Volume Control
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Solution Overview
Problem
Current foam dispensers have opportunities for cost reduction through simplification of manufacturing processes and improvement in foam quality, while maintaining reduced liquid usage per application.
Innovation Solution
A foam dispenser design featuring a resiliently deformable piston dome, an air chamber, a liquid chamber, and a mixing zone with an elongate venturi tube structure, which adjusts volume ratios between air and liquid chambers during activation and return strokes, incorporating a porous member in the exit nozzle for efficient mixing and reduced liquid usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional foam dispenser design is used, then foam can be generated, but the device complexity and manufacturing cost are higher
Solution Approach 1:
The patent combines the air chamber and liquid chamber into a single integrated pump body with a common piston dome, eliminating the need for separate diaphragms and reducing the number of parts. The mixing chamber is integrated directly into the pump body structure, simplifying the overall device architecture while maintaining foam generation functionality.
Solution Approach 2:
The piston dome serves multiple functions: it acts as a seal between air and liquid chambers, a piston for generating pressure, and a structural component defining both chambers. The mixing chamber integrates mixing, pressurization, and foam generation functions in a single component, reducing device complexity.
2Quantity of substance
If more liquid is dispensed per shot, then foam quantity increases, but packaging size must increase
Solution Approach 1:
The patent changes the air-to-liquid volume ratio parameter by reducing air chamber volume relative to liquid chamber volume. This allows more liquid to be dispensed per shot while maintaining the same packaging size, as the reduced air volume means less packaging space is required for the same foam output.
Solution Approach 2:
The mixing chamber has a specific local geometry with an elongate mixing channel and chamfer that creates localized turbulence and mixing efficiency. This local quality optimization allows effective foam generation with reduced air volume, enabling higher liquid dispensing rates without increasing packaging size.
3Quantity of substance
If air to liquid volume ratio is reduced, then more liquid can be dispensed per shot, but foam quality may deteriorate
Solution Approach 1:
The patent optimizes the air-to-liquid volume ratio parameter by reducing air chamber volume while increasing liquid chamber volume. This parameter change allows more liquid to be dispensed per shot while maintaining acceptable foam quality through the optimized mixing chamber design that compensates for the reduced air volume.
Solution Approach 2:
The mixing chamber features an elongate mixing channel with specific geometry and a chamfer that creates localized turbulence and efficient mixing. This local quality optimization ensures that even with reduced air volume, the liquid and air mix effectively to produce acceptable foam quality.
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 commercially acceptable foam quality with reduced air to liquid volume ratios, allowing for more liquid to be dispensed per shot while maintaining packaging size, and potentially lowering production costs.
Implementation Method 1
the piston dome is a resiliently deformable piston dome and has an at rest position and a depressed position
Implementation Method 2
The porous member is in the exit nozzle downstream of the mixing zone
Implementation Method 3
a mixing zone with an elongate venturi tube structure, which adjusts volume ratios between air and liquid chambers during activation and return strokes
Data Source
Figure 1
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AI summary
A foam assembly connectable to a liquid container includes a main pump body, a resiliently deformable piston dome, an air chamber, a liquid chamber, a mixing zone and a porous member. The main pump body has an exit nozzle with the porous member therein. The air chamber and the liquid chamber are each defined by the piston dome and the main pump body. The liquid chamber has a liquid inlet valve and a liquid outlet valve. The mixing zone is in flow communication with the air chamber and the liquid chamber. The volume of the air chamber and the liquid chamber are each dependent on the position of piston dome and during an activation stroke the piston moves from the at rest position to the depressed position and responsively the volume of the air chamber and the volume of the liquid chamber are reduced.