Foam Dispenser Pump Mixing Zone Design
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Solution Overview
Problem
Existing hand-operable foam dispensers face challenges in producing uniform foam due to inefficient air and liquid mixing, often resulting in wet or non-uniform foams, which are not commercially acceptable.
Innovation Solution
A foam dispenser design featuring a novel inlet structure with a restricted liquid jet and separate air intake conduit, incorporating check valves and porous regulator elements to promote turbulent mixing and uniform bubble formation, allowing for efficient foam generation and dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional piston/cylinder plunger pump with separate air and liquid pump cylinders is used, then well-defined proportions of air and liquid are mixed, but the dispenser becomes large and expensive
Solution Approach 1:
The patent combines the air and liquid pump cylinders into a single pump chamber, eliminating the need for separate cylinders, valves, and pistons. The plunger directly draws both air and liquid into the chamber where they mix turbulently, simplifying the overall structure while maintaining mixing control.
Solution Approach 2:
The patent segments the mixing process into distinct functional zones within the single pump chamber: an air inlet region, a liquid inlet region, and a turbulent mixing zone. This segmentation allows independent control of air and liquid intake while achieving thorough mixing in a compact space.
2Device complexity
If air and liquid are drawn into a single pump chamber under turbulent mixing conditions, then the structure is simplified, but uniform foam generation becomes difficult to achieve
Solution Approach 1:
The patent creates different flow conditions in different regions of the pump chamber. The air inlet is positioned to create high-velocity turbulent flow in the mixing zone, while the liquid inlet provides a controlled stream that breaks up into droplets. This local variation in flow characteristics ensures uniform foam generation despite the simple single-chamber structure.
Solution Approach 2:
The patent introduces a vertical dimension to the mixing process by positioning the air inlet above the liquid inlet and utilizing the plunger's reciprocating motion to create vertical turbulent flow patterns. This three-dimensional mixing approach enhances foam uniformity compared to simple horizontal mixing.
3Quantity of substance
If the liquid intake conduit has a large opening, then liquid flow is sufficient, but air entrainment and turbulent mixing are reduced
Solution Approach 1:
The patent optimizes the liquid inlet opening parameters (size, shape, position) to achieve the right balance between liquid flow rate and mixing efficiency. The inlet is sized to provide sufficient liquid flow while creating appropriate velocity for turbulent mixing and air entrainment in the pump chamber.
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 solution effectively produces high-quality, uniform foam with adjustable air and liquid ratios, maintaining consistency even under varying conditions, such as when the liquid becomes aerated, and allows for a simpler and more cost-effective design compared to traditional two-piston foamer systems.
Implementation Method 1
mixing the air and liquid under turbulent conditions
Implementation Method 2
passed through one or more meshes to regulate the foam
Implementation Method 3
with respective inlet valves and pistons carried by a single plunger
Data Source
AI summary
A foam dispenser has a foam-generating pump (1) mounted on a container (100) to hold liquid. The pump (1) has a liquid intake conduit with a ball valve (27) and an air intake conduit (45) provided partly by a jacket component (4) fitting around the pump body (2) with clearance. The pump has structure defining a mixing zone (50) for mixing air and liquid, a foam chamber (28) for holding foam received from the mixing zone, and a discharge conduit leading from the foam chamber to a discharge outlet (36). The mixed air and liquid pass through a permeable foam regulator mesh (54). One or more air inlets (47) lead into the mixing zone (50) from the air intake conduit (45). A liquid inlet in the form of a restricted jet orifice (89) leads into the mixing zone (50) from the liquid intake conduit, upstream of the inlet ball valve (27). A regulator mesh (53) is also provided between the liquid inlet and mixing zone.