Trigger Sprayer Assembly Modular Design for Automated Manufacturing
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Solution Overview
Problem
Existing trigger sprayer assemblies are complex and time-consuming to assemble, with many small components and lack easy interchangeability of parts such as shrouds, trigger handles, and nozzles, making them difficult to assemble efficiently and automate.
Innovation Solution
A method for assembling a trigger sprayer assembly with components designed for efficient assembly, featuring a piston chamber and fluid passage, where a piston component is inserted and coupled with a trigger lever, and a shroud is coupled to the engine using rail protrusions and recesses, allowing for automated assembly along designated axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional trigger sprayer assemblies are designed with many small components to ensure durability and functionality, then the reliability and performance are improved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple small components into integrated assemblies. Specifically, the trigger mechanism is integrated with the pump assembly, and the nozzle is integrated with the spray mechanism. This merging reduces the number of separate parts while maintaining the functional reliability of each component, thereby simplifying the overall assembly process without compromising durability.
Solution Approach 2:
The patent segments the trigger sprayer into major functional modules: the engine assembly, the trigger assembly, and the nozzle assembly. Each module is designed as a separate unit that can be manufactured and tested independently, then assembled together using a simplified connection system. This segmentation maintains reliability through modular testing while reducing assembly complexity through standardized interfaces.
2Reliability
If traditional trigger sprayer assemblies use multiple small components, then the functional requirements are met, but the assembly time increases
Solution Approach 1:
The patent applies preliminary action by pre-assembling sub-components into integrated modules before final assembly. The trigger mechanism is pre-integrated with the pump assembly, and the nozzle is pre-attached to the spray mechanism. This preliminary integration reduces the number of assembly steps required during final assembly, significantly reducing assembly time while ensuring functional requirements are met through pre-tested modules.
Solution Approach 2:
The patent merges multiple components into integrated assemblies that can be assembled as single units. The engine assembly includes integrated seals and gaskets, the trigger assembly includes integrated springs and levers, and the nozzle assembly includes integrated spray holes and caps. This merging reduces the number of individual assembly operations required, thereby reducing assembly time while maintaining functional integrity.
3Duration of action of stationary object
If traditional trigger sprayer assemblies are designed for durability, then the product lifespan is improved, but the interchangeability of parts such as shrouds, trigger handles, and nozzles is reduced
Solution Approach 1:
The patent segments the trigger sprayer into distinct functional modules with standardized interfaces. The shroud, trigger handle, and nozzle are designed as separate interchangeable modules that connect to the core assembly through standardized mounting features. This segmentation allows different configurations and replacements while maintaining overall product durability through modular design.
Solution Approach 2:
The patent applies universality by designing standardized interfaces and mounting features that allow different shrouds, trigger handles, and nozzles to be interchangeably mounted on the same core assembly. This universal interface design enables users to swap components for different functions or aesthetic preferences while maintaining the durability and reliability of the core pump mechanism.
4Reliability
If traditional trigger sprayer assemblies use complex component designs, then the performance is improved, but automated and robotic assembly becomes difficult
Solution Approach 1:
The patent segments the complex trigger sprayer into distinct modular assemblies with standardized interfaces. Each module (engine assembly, trigger assembly, nozzle assembly) can be manufactured and quality-tested separately, then assembled through simple standardized connections that are easily automated. This segmentation maintains high performance through specialized module design while enabling automated assembly through standardized interfaces.
Solution Approach 2:
The patent merges multiple small components into integrated modular assemblies that have standardized external interfaces. By combining internal complexity within modules while standardizing external connection points, the design maintains high performance through integrated functionality while enabling automated assembly through simple standardized interfaces that robotic systems can easily manipulate and connect.
Data Source
AI summary
A method of assembling a trigger sprayer assembly includes providing an engine having a piston chamber and a fluid passage that is fluidly coupled to the piston chamber, the fluid passage extending from an input portion to an output portion. The method further includes inserting a piston component into the piston chamber, and coupling a trigger lever to the engine and the piston component. Pivoting the trigger lever relative to the engine pushes and pulls the piston component within the piston chamber to drive fluid from the input portion to the output portion of the fluid passage. The method further includes coupling a shroud to the engine, where the coupling comprises positioning a rail protrusion of the engine within a corresponding recess formed in the shroud, and inserting a shelf extending from an interior surface of the shroud into a pair of receiving clips extending from the engine.