Multi-Chamber Diaphragm Pump Design for Compact Foam Dispensers
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Solution Overview
Problem
Existing touch-free foam and soap dispensers are bulky and require large batteries due to high power consumption, making them unsuitable for spaces with limited space and energy constraints.
Innovation Solution
A compact multi-chamber diaphragm pump system that separates liquid and air pumping, mixing them at a remote foam generator, using a dual flapper valve and valve plate to create a compact and energy-efficient dispenser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional pump and drive systems are used in touch-free dispensers, then reliable foam dispensing is achieved, but the device requires a large footprint and cannot be installed in space-constrained areas
Solution Approach 1:
The pump system is segmented into separate liquid pump chambers and air pump chambers within a single diaphragm assembly. This segmentation allows independent optimization of each pumping function while reducing overall system size, enabling compact installation without compromising dispensing reliability
Solution Approach 2:
Multiple pump chambers are nested within a single pump housing structure. The liquid pump chambers and air pump chambers are integrated into one compact assembly, with shared components such as the diaphragm drive mechanism, significantly reducing the footprint while maintaining reliable operation
2Use of energy by moving object
If traditional pump systems are used in dispensers, then adequate pumping capacity is achieved, but large batteries are required due to high power consumption
Solution Approach 1:
The pump system uses periodic diaphragm actuation to create alternating suction and discharge phases for both liquid and air pumping. This periodic action allows the pump to achieve adequate pumping capacity through rhythmic cycles rather than continuous high-power operation, significantly reducing overall power consumption and battery size requirements
Solution Approach 2:
The system utilizes pneumatic principles where compressed air pumped by the air pump chambers is mixed with liquid soap to create foam. This pneumatic foaming mechanism reduces the mechanical pumping capacity needed for liquid delivery while maintaining effective dispensing, thereby reducing power consumption
3Area of stationary object
If compact pump design is implemented, then space constraints are satisfied, but system complexity increases due to multi-chamber diaphragm and valve plate integration
Solution Approach 1:
The valve plate is designed as a multi-functional component that serves multiple purposes: it acts as a structural support, provides sealing surfaces for both liquid and air chambers, incorporates flapper valves for flow control, and integrates passageways for both liquid and air streams. This universality reduces the number of separate components needed, simplifying the overall system despite the compact multi-chamber design
Solution Approach 2:
Multiple functional elements are merged into integrated components. The liquid pump diaphragm and air pump diaphragms share a common drive mechanism and housing. The valve plate combines sealing, guiding, and flow control functions. This merging reduces the number of discrete parts and assembly steps, managing system complexity while achieving compact dimensions
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 system allows for a compact dispenser design that complies with space constraints and reduces energy consumption, enabling efficient foam dispensing with an air-to-liquid ratio of 5:1 to 15:1, suitable for various mounting options.
Implementation Method 1
multi-chamber diaphragm pumps that separately pump liquid and air
Implementation Method 2
pump and drive systems
Implementation Method 3
dual flapper valve system with a valve plate with air and liquid passages
Implementation Method 4
pumping both liquid and air to a remote foam generator where the liquid and air are mixed together
Data Source
AI summary
Exemplary compact multi-chamber diaphragm pumps and dispensers for dispensing foam soap or sanitizer are disclosed herein. An exemplary pump for pumping soap or sanitizer and air separately to be mixed remote from the pump and dispensed as a foam includes a liquid pump diaphragm and a dual flapper valve, wherein a first of the dual flapper valves is a liquid inlet valve and a second of the dual flapper valves is a liquid outlet valve. The pump further includes two or more air pump diaphragms and a valve plate. The valve plate has a liquid inlet passage, a liquid outlet passage, a liquid outlet valve seat, two or more air inlet passages, two or more air inlet valve anchors and two or more air inlet valves secured to the valve plate. A pump manifold is also included, the pump manifold includes a liquid inlet valve seat.