Multi-Diaphragm Foam Pump for Stable Air-Liquid Mixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing liquid dispenser systems fail to effectively dispense liquids as a foamy mixture by efficiently mixing liquid soap, sanitizer, or lotion with air, often resulting in inconsistent foam quality and air-to-liquid ratios.
Innovation Solution
The development of sequentially activated multi-diaphragm foam pumps and refill units that include a diaphragm assembly with a liquid pump diaphragm and multiple air pump diaphragms, a mixing chamber, and an actuation mechanism to control the sequential activation of diaphragms, ensuring a consistent air-to-liquid ratio and enhanced foam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single diaphragm pump is used to mix liquid and air, then the device complexity is low, but the foam quality consistency and air-to-liquid ratio control are poor
Solution Approach 1:
The pump system is segmented into multiple diaphragms (at least two diaphragms) that operate independently to separate liquid pumping and air pumping functions. This segmentation allows each diaphragm to be optimized for its specific function, improving foam quality consistency while maintaining manageable device complexity through functional division.
Solution Approach 2:
The diaphragms are configured to operate sequentially in a dynamic cycle, with at least one diaphragm pumping liquid and at least one other diaphragm pumping air. This dynamic operation enables precise control of air-to-liquid ratios and consistent foam quality, resolving the contradiction between precision and complexity.
2Quantity of substance
If air is injected into liquid to create foam, then the foam output volume increases, but the air-to-liquid ratio consistency deteriorates
Solution Approach 1:
The injection system is segmented into separate liquid injection and air injection pathways controlled by different diaphragms. This allows independent control of liquid flow and air flow, maintaining consistent air-to-liquid ratios while achieving high foam output volume through coordinated operation of multiple diaphragms.
Solution Approach 2:
The multi-diaphragm system operates in a continuous sequential cycle where liquid pumping and air pumping occur in succession without interruption. This continuous action ensures consistent air-to-liquid mixing ratios while maintaining high foam output volume throughout operation.
3Manufacturing precision
If multiple diaphragms are used to improve foam quality, then the manufacturing precision increases, but the device complexity increases
Solution Approach 1:
The complex function of precise air-to-liquid ratio control is segmented across multiple diaphragms, each handling a specific portion of the task. This segmentation improves manufacturing precision while keeping individual diaphragm components simple and manageable, reducing overall assembly complexity.
Solution Approach 2:
Multiple diaphragms serve universal functions within the system - each diaphragm can be configured for liquid or air pumping as needed. This multi-functionality allows the same basic diaphragm design to be replicated and configured in different arrangements, improving precision without proportionally increasing complexity.
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 achieves a consistent and high-quality foamy mixture with adjustable air-to-liquid ratios, improving user experience and operational efficiency in dispensing foam products.
Implementation Method 1
The diaphragm assembly includes a liquid pump diaphragm in fluid communication with the container, a plurality of air pump diaphragms
Implementation Method 2
A mixing chamber for mixing foamable liquid from the liquid pump diaphragm with air from the plurality of air pump diaphragms
Implementation Method 3
The foam pump includes a liquid outlet valve having a cracking pressure of at least about 5 pounds per square inch; and two or more air outlet valves having cracking pressure of less than about 5 pounds per square inch
Data Source
AI summary
An exemplary foam dispenser includes a housing, a container for holding foamable liquid and a foam pump in fluid communication with the container. The foam pump has a plurality of diaphragm pumping chambers wherein at least one diaphragm pumping chamber pumps liquid, and at least two diaphragm pumping chambers pump air. The foam pump includes a liquid outlet valve having a cracking pressure of at least about 5 pounds per square inch; and two or more air outlet valves having cracking pressure of less than about 5 pounds per square inch. A mixing chamber is located downstream of the plurality of diaphragm pumping chambers for mixing liquid and air to form a foamy mixture. A foam cartridge located downstream of the mixing chamber and an outlet is provided for dispensing foam.