Multi-Diaphragm Foam Pump for Air-Liquid Ratio Control
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Solution Overview
Problem
Existing liquid dispenser systems fail to effectively dispense liquid in the form of foam by efficiently mixing liquid with air, resulting in suboptimal foam quality and consistency.
Innovation Solution
The development of sequentially activated multi-diaphragm foam pumps that incorporate a molded multi-chamber diaphragm with a liquid pump chamber and multiple air pump chambers, along with a mixing chamber and outlet valve, to create a foam dispenser system that mixes liquid with air to produce a consistent foam product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional mechanical piston foam pumps are used to mix liquid with air, then foam dispensing is achieved, but energy consumption is high and foam quality consistency is poor
Solution Approach 1:
The pump chamber is segmented into multiple diaphragms (first diaphragm for liquid, second and third diaphragms for air) that operate sequentially. This segmentation allows independent control of liquid and air pumping actions, enabling precise mixing ratios and consistent foam quality while reducing the energy required compared to conventional single-piston systems.
Solution Approach 2:
The foam pump utilizes periodic reciprocating motion of the diaphragms driven by a vibration motor. The first diaphragm pumps liquid during one phase of the cycle, while the second and third diaphragms pump air during other phases, creating a periodic action that efficiently mixes liquid and air to produce consistent foam with lower energy consumption.
2Manufacturing precision
If simple liquid dispensing is used, then device complexity is low, but foam quality and air-to-liquid ratio control are insufficient
Solution Approach 1:
The pump chamber is divided into multiple diaphragms (first diaphragm for liquid, second and third diaphragms for air) with separate control mechanisms. This segmentation enables precise control over the air-to-liquid ratio by independently adjusting the pumping action of each diaphragm, achieving high manufacturing precision in foam composition while maintaining manageable device complexity through modular design.
Solution Approach 2:
The system controls foam quality by changing the parameters of the diaphragm pumping action, including the volume displaced, frequency of operation, and timing sequence of each diaphragm. These parameter changes allow precise adjustment of the air-to-liquid ratio to achieve desired foam characteristics without requiring overly complex structural modifications.
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 achieves a controlled air-to-liquid ratio, enhancing foam quality and consistency, with the ability to adjust the ratio for different applications, and reduces energy consumption compared to conventional mechanical piston foam pumps.
Implementation Method 1
a first diaphragm for pumping liquid into a mixing chamber, a second diaphragm for pumping air into the mixing chamber, and a third diaphragm for pumping air into the mixing chamber
Implementation Method 2
The liquid and the air mix together in the mixing chamber to create a foam mixture
Data Source
AI summary
An exemplary foam dispenser includes a housing, a drive motor and a foam pump operatively coupled to the drive motor. The foam pump is secured to the housing and the foam pump includes a housing and a molded multi-chamber diaphragm. The molded multi-chamber diaphragm includes a liquid pump chamber, two or more air pump chambers; and an outlet valve. A mixing chamber is included and located downstream of the outlet valve for mixing foamable liquid from the liquid pump diaphragm with air from each of the two or more air pump chambers. In addition, a foam cartridge and an outlet for dispensing foam are also included.