Multi-Diaphragm Foam Pump with Sequential Air-Liquid Actuation
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Solution Overview
Problem
Existing liquid dispenser systems struggle to efficiently dispense liquids in the form of foam by mixing them with air, often requiring complex mechanisms or inefficient methods.
Innovation Solution
The development of sequentially activated multi-diaphragm foam pumps that include a housing, drive motor, and a molded multi-chamber diaphragm with separate liquid and air pump chambers, which are sequentially actuated to mix and dispense foamable liquids with air, using a rotatable drive mechanism or wobble plate to achieve a desired foam consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex mechanisms are used to mix liquid with air for foam dispensing, then foam creation capability is improved, but device complexity increases
Solution Approach 1:
The pump is divided into multiple independent diaphragm chambers (liquid pump chamber, first air pump chamber, second air pump chamber) that operate sequentially. Each chamber has its own diaphragm and valve system, allowing independent control of liquid and air pumping actions. This segmentation enables complex foam creation functionality while maintaining manageable device complexity through modular design.
Solution Approach 2:
The pump utilizes periodic reciprocating motion of the diaphragms to alternately pump liquid and air into the mixing chamber. The sequential activation of different diaphragm chambers creates periodic action cycles that efficiently mix liquid with air to generate foam, achieving versatile foam creation without requiring continuously complex mechanisms.
2Manufacturing precision
If sequential activation of multiple diaphragms is implemented, then foam consistency is improved, but device complexity increases
Solution Approach 1:
Multiple diaphragm chambers are merged into a single integrated pump housing with a common drive mechanism. The liquid pump diaphragm, first air pump diaphragm, and second air pump diaphragm are all actuated by the same motor and transmission system, reducing overall actuation complexity while maintaining sequential activation for consistent foam production.
Solution Approach 2:
The pump controls foam consistency by changing operational parameters such as the sequential timing of diaphragm activation, the volume displacement of each chamber, and the pressure differentials created during pumping cycles. These parameter adjustments enable precise control of air-to-liquid ratios without requiring complex additional control mechanisms.
3Measurement precision
If separate liquid and air pump chambers are used, then air-to-liquid ratio control is improved, but device complexity increases
Solution Approach 1:
The pump chamber is segmented into distinct liquid pumping and air pumping sections with separate diaphragms and valves. This segmentation allows independent control of liquid and air intake, enabling precise measurement and control of the air-to-liquid ratio through the relative sizing and activation sequences of the separate chambers.
Solution Approach 2:
The multiple diaphragm chambers serve universal functions of pumping both liquid and air through a common outlet to the mixing chamber. This multi-functionality allows the same basic pump structure to handle different fluids (soap, sanitizer, lotion) while maintaining precise air-to-liquid ratio control through adjustable chamber activation parameters.
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 allows for efficient creation and dispensing of foam with controlled air-to-liquid ratios, enhancing the foam quality and consistency, and can be used in various dispenser systems for soap, sanitizer, or lotion applications.
Implementation Method 1
a liquid pump diaphragm for pumping liquid into a mixing chamber, a first air pump diaphragm for pumping air into the mixing chamber, and a second air pump diaphragm for pumping air into the mixing chamber
Implementation Method 2
The liquid and air mix in the mixing chamber to create a foam mixture
Data Source
AI summary
A foam dispenser includes a housing, a drive motor, and a foam pump. The foam pump includes a pump housing, and a molded multi-chamber diaphragm. The molded multi-chamber diaphragm includes a liquid pump diaphragm having a liquid pump stem and two or more air pump chambers each having an air pump stem. The length of the liquid pump stem is longer than the air pump stem. The foam pump further includes one or more outlet valves, a mixing chamber, an outlet for dispensing foam wherein the outlet is in fluid communication with the foam cartridge; and an actuator for sequentially actuating the liquid pump chamber and the two or more air pump chambers, wherein there is lost motion between the actuator and the liquid pump diaphragm.