Substance applicator having a controllable substance flowrate
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Solution Overview
Problem
Existing disposable applicators are inadequate for dispensing large quantities of substances as they often result in non-uniform application, over-saturation, and loss of control over the dispensing process due to distortion or compression of the applicator head, making them unsuitable for single-use applications.
Innovation Solution
A flexible applicator system comprising a substance reservoir and a flexible support card with a score line that flexes to open, allowing for controlled dispensing through an applicator head with compressible pores, which can absorb and buffer the substance, maintaining uniformity and flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If disposable applicators are designed for dispensing small quantities of liquid, then they can maintain applicator head integrity, but they are inadequate for dispensing large quantities of substance
Solution Approach 1:
The applicator head is designed to dynamically change its state from compressed (during folding/activation) to expanded (during dispensing). The flexible support card allows the applicator head to transition between configurations, enabling it to accommodate large quantities of substance while maintaining structural integrity through controlled deformation and recovery.
Solution Approach 2:
The applicator head is constructed from flexible porous material that can bend and deform without breaking. This flexible structure allows the applicator to be folded for activation while maintaining its ability to hold and dispense large quantities of substance, resolving the contradiction between quantity capacity and structural integrity.
2Quantity of substance
If large volumes of liquid are dispensed through traditional applicators, then the quantity of substance increases, but the liquid gushes or over-saturates the applicator head causing waste and loss of control
Solution Approach 1:
The applicator head utilizes porous material with controlled pore structure that allows liquid to pass through at a regulated rate. The pores provide capillary action and surface tension effects that prevent gushing and over-saturation, enabling controlled dispensing of large volumes of liquid without losing operational control.
Solution Approach 2:
The flow rate parameter is controlled by changing the physical state of the applicator head from compressed to expanded configuration. This parameter change regulates the substance flow rate, allowing large quantities to be dispensed at a controlled pace rather than gushing uncontrollably.
3Quantity of substance
If foam or swab applicator heads are made larger to accommodate more substance, then the quantity capacity increases, but they become distorted and compressed during folding activation
Solution Approach 1:
The applicator head is designed to dynamically change its shape during activation. The flexible material allows controlled distortion during folding, and the structure recovers its intended configuration during dispensing, enabling larger capacity without permanent deformation or loss of function.
Solution Approach 2:
The applicator head uses flexible porous material that can withstand the compression and distortion of folding activation. This flexible construction allows the applicator to be manipulated into the folded state for activation while maintaining its ability to hold and dispense large quantities of substance without permanent shape distortion.
4Quantity of substance
If rigid applicators are used to dispense large quantities of fluid, then the quantity capacity increases, but they are complex to manufacture and difficult to control
Solution Approach 1:
The invention employs a disposable flexible applicator that eliminates the need for complex rigid structures and multiple molded components. The flexible single-use design simplifies manufacturing while providing the capacity to dispense large quantities of fluid, and the flexibility enables easy control during operation.
Solution Approach 2:
The flexible support card and applicator head construction replaces complex rigid assemblies with simple flexible components. This reduces manufacturing complexity while maintaining the ability to dispense large quantities of fluid, and the flexibility provides inherent control characteristics that rigid structures lack.
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 enables precise and uniform dispensing of larger quantities of substances by manipulating the flow rate through varying the force applied to the flexible card, reducing waste and maintaining applicator head flexibility for consistent application.
Implementation Method 1
The flexible support card comprises a closed score line defining an axis of rotation and is configured to flex about the axis of rotation between a closed configuration and an activated configuration
Implementation Method 2
the applicator head comprises a plurality of pores and is configured to flex with the flexible support card between the closed configuration in which at least a portion of the pores are compressed and an activated configuration in which at least a portion of the pores become less compressed
Implementation Method 3
the applicator head comprises a plurality of pores
Implementation Method 4
the applicator head comprises a sponge, a foam material (e.g., polyurethane foam), a nonwoven material, and/or a woven material compressed and/or biased in a direction perpendicular to the axis of rotation to define the closed configuration
Data Source
AI summary
Various embodiments are directed to an applicator for dispensing a substance according to a desired flow rate. The applicator comprises a flexible card, a substance reservoir attached thereto, and an applicator head secured to the flexible card opposite the substance reservoir. The applicator head comprises a plurality of pores that, when secured to the flexible card, are compressed. In various embodiments, the pores are compressed by physical compression and/or by annealing. Upon flexing the flexible card along a score line, the substance reservoir ruptures and the substance is directed into the applicator head. Upon introduction of the substance to the applicator head, the pores of the applicator head expand and the substance is directed to an applicator surface of the applicator head.