Non-Aerosol Foam Pump for Stable Alcohol Sanitizer Bubbles
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Solution Overview
Problem
Conventional non-aerosol foam pumps struggle to produce high-quality foam sanitizers, particularly with alcohol-based formulations, due to the defoaming properties of alcohol, resulting in inconsistent and less effective foam quality compared to aerosol-based systems.
Innovation Solution
A non-aerosol foam pump design featuring a sequentially activated multi-diaphragm mechanism that continuously mixes small amounts of liquid with air at higher pressures, using a unique foaming cartridge with sponges of varying porosities and firmness to enhance foaming, producing foam bubbles with consistent sizes and higher density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional non-aerosol foam pumps are used to dispense alcohol-based sanitizer, then the liquid can be dispensed, but the foam quality is poor and inconsistent due to alcohol's defoaming properties
Solution Approach 1:
The patent employs a sequentially activated multi-diaphragm pump mechanism where diaphragms are activated in sequence to create periodic pumping action. This periodic action allows continuous mixing of small amounts of liquid with air at higher pressures, generating consistent foam quality despite alcohol's defoaming properties. The sequential activation creates repeated cycles of liquid intake, air mixing, and foam discharge that maintain foam stability.
Solution Approach 2:
The invention changes key parameters including operating at higher pressures during the mixing process and controlling the ratio of liquid to air mixing. By adjusting these parameters and using a unique foaming cartridge with sponges of varying porosities, the system overcomes alcohol's defoaming effect and produces high-quality foam with over 50% of bubbles between 50-250 µm in size.
2Reliability
If alcohol is used in the sanitizer formulation, then effective sanitizing is achieved, but foam formation is inhibited due to alcohol's defoaming properties
Solution Approach 1:
The patent converts the harmful defoaming effect of alcohol into a beneficial process feature. By using a sequentially activated multi-diaphragm pump that mixes small amounts of liquid with air at higher pressures, the system creates foam stability through continuous mixing action. The sequential diaphragm activation ensures that alcohol-based liquid is continuously replenished and mixed with air, converting alcohol's instability into a controlled foaming process that maintains both sanitizing effectiveness and foam stability.
3Reliability
If aerosol-based foam systems are used, then high quality foam is produced, but hydrocarbon propellants are required which have environmental and safety concerns
Solution Approach 1:
The patent replaces the chemical propellant-based aerosol system with a mechanically-driven sequentially activated multi-diaphragm pump system. This mechanical substitution eliminates the need for hydrocarbon propellants while achieving comparable or superior foam quality. The pump uses mechanical compression and sequential diaphragm activation to generate the necessary pressure and mixing action, producing high-quality foam through mechanical means rather than chemical propellants.
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 high-quality foam with over 50% of bubbles between 50 µm and 250 µm in size, improved stability, and a higher perceived quality, comparable to aerosol-based foams without the need for hydrocarbon propellants, providing better skin feel and environmental sustainability.
Implementation Method 1
a non-aerosol foam pump design featuring a sequentially activated multi-diaphragm mechanism that continuously mixes small amounts of liquid with air at higher pressures
Implementation Method 2
a unique foaming cartridge with sponges of varying porosities and firmness to enhance foaming, producing foam bubbles with consistent sizes and higher density
Implementation Method 3
a unique foaming cartridge with sponges of varying porosities and firmness to enhance foaming
Data Source
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AI summary
Exemplary embodiments of high non-aerosol foam sanitizers are disclosed herein. An exemplary embodiment of high non-aerosol foam sanitizer includes a liquid mixture that includes an alcohol, water and a surfactant mixed with and entrapping air to form a plurality of foam bubbles. Wherein more than about 50 percent of the foam bubbles have a size of between about 50 μm and about 250 μm.