Sequential Foam Pump Mixing for High Air-to-Liquid Ratios
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional foam dispensers typically have an air to liquid ratio of about 7 to 1, which may not provide a rich enough foam for users accustomed to conventional soap dispensers, and there is a need for systems that can create foams with higher air to liquid ratios for enhanced efficacy and visual appearance.
Innovation Solution
The development of sequentially activated multi-diaphragm foam pumps and dispenser systems that include a housing, container, motor, air pump, and mixing chambers to create a rich foam by pumping liquid and air sequentially, with adjustable ratios up to 50 to 1 through the use of multiple diaphragms and a second air pump for enhanced mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional foam dispensers with standard air to liquid ratio (7 to 1) are used, then the device complexity is low, but the foam quality and user satisfaction deteriorate
Solution Approach 1:
The foam pump is divided into multiple diaphragm chambers (at least two chambers) that operate sequentially. Each chamber independently pumps liquid or air, allowing precise control over the air to liquid ratio. This segmentation enables the system to achieve high air to liquid ratios (15 to 1 or greater) while maintaining manageable device complexity through modular chamber design.
Solution Approach 2:
The system uses dynamically adjustable air to liquid ratios through sequential activation of multiple diaphragm chambers. The ratio can be varied by controlling which chambers are active and their activation sequence, allowing the foam quality to be optimized for different applications while adapting the device behavior in real-time.
2Manufacturing precision
If multiple diaphragm chambers are used to achieve high air to liquid ratios, then the foam quality improves, but the device complexity increases
Solution Approach 1:
Multiple diaphragm chambers are merged into a single integrated foam pump assembly that shares common structural elements, valve mechanisms, and fluid pathways. This combining approach allows the system to achieve high air to liquid ratios through multiple chambers while avoiding proportional increases in overall device complexity.
Solution Approach 2:
The multiple diaphragm chambers serve multiple functions: they collectively pump liquid, collectively pump air, and can be selectively activated to control the air to liquid ratio. This multi-functionality reduces the need for separate dedicated components for each function, thereby managing device complexity while achieving superior foam quality.
3Quantity of substance
If sequential activation of multiple diaphragms is used, then the air to liquid ratio increases, but the energy consumption increases
Solution Approach 1:
The diaphragm chambers are activated in sequential periodic cycles rather than continuously. Each chamber is activated only when needed in the sequence, allowing the system to achieve high air to liquid ratios through timed periodic action rather than continuous operation of all chambers, thereby reducing overall energy consumption.
Solution Approach 2:
The sequential activation of multiple chambers creates a continuous pumping action where one chamber is always in the productive phase of its cycle. This continuity ensures that the high air to liquid ratio is maintained consistently without requiring all chambers to operate simultaneously, optimizing energy efficiency while maintaining the desired foam composition.
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
These systems generate a rich foam with adjustable air to liquid ratios, providing a more efficacious and visually appealing dose of foam, with pressures up to 17 psi, effectively addressing user expectations and soap concentration efficacy.
Implementation Method 1
The foam pump has a liquid pump portion that pumps liquid, and an air pump portion that pumps air
Implementation Method 2
the liquid and the air mix in the first mixing chamber to create a first foam mixture
Implementation Method 3
the first mixture and air from the air pump mix in the second mixing chamber to create a second foam mixture
Implementation Method 4
The second foam mixture travels through the foam cartridge and exits the outlet as rich foam
Implementation Method 5
injecting air into the liquid to create a foamy mixture of liquid and air bubbles
Data Source
AI summary
An exemplary foam dispenser system includes a housing, a container, a motor, an air pump, a foam pump, a first mixing chamber, a second mixing chamber, a foam cartridge, and an outlet for dispensing foam. The container holds a foamable liquid. The foam pump has a liquid pump portion that pumps liquid, and an air pump portion that pumps air. The first mixing chamber is located downstream of the liquid pump portion and the air pump portion, and the liquid and the air mix in the first mixing chamber to create a first foam mixture. The second mixing chamber is located downstream of the first mixing chamber and the air pump, and the first mixture and air from the air pump mix in the second mixing chamber to create a second foam mixture. The second foam mixture travels through the foam cartridge and exits the outlet as rich foam.