Continuous Trigger Sprayer Diaphragm for Recyclable Spray Flow
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Solution Overview
Problem
Existing trigger sprayers made from a single grade of polymeric material lack continuous spray functionality and are not recyclable, as they often rely on non-recyclable materials like metal or elastomers, and existing designs with recyclable materials fail to provide consistent fluid dispensing without continuous actuation.
Innovation Solution
A continuous-spray trigger dispenser with a resiliently-deformable diaphragm interposed between the pump chamber and nozzle outlet, supplemented by biasing members, allows for a volume of fluid to be dispensed as a continuous stream by controlling fluid ingress and egress through valves, using recyclable polymeric materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If trigger sprayers are made from a single grade of polymeric material to improve recyclability, then recyclability is improved, but continuous spray functionality is lost
Solution Approach 1:
The patent employs a flexible diaphragm made from the same polymeric material as the pump chamber, allowing the diaphragm to deform elastically to store and release fluid. This flexible membrane structure enables continuous spray functionality while maintaining single-material construction for recyclability, as the diaphragm is formed from the same polymer without requiring metal or elastomer components.
Solution Approach 2:
The invention introduces a dynamic diaphragm mechanism that can deform and recover repeatedly. The diaphragm flexes during pump operation to trap fluid, then returns to its original position to release the stored fluid continuously. This dynamic behavior enables continuous spray without requiring continuous actuation, achieving both recyclability and continuous functionality.
2Ease of manufacture
If bellows-form chambers are used to avoid metal and improve recyclability, then recyclability is improved, but dispensing effectiveness deteriorates
Solution Approach 1:
Instead of using bellows-form chambers, the patent employs a flexible diaphragm that can be molded from standard plastics like polypropylene. The diaphragm's flexibility allows it to be deformed during the dispensing stroke and restore itself, providing reliable dispensing effectiveness while maintaining recyclability through single-material construction.
Solution Approach 2:
The invention changes the physical state and mechanical properties of the pump chamber by using a flexible diaphragm made from thermoplastic material. The diaphragm can be heated during molding and then cools to provide elastic restoring force, enabling reliable fluid dispensing while being fully recyclable, thus improving both dispensing effectiveness and recyclability.
3Reliability
If pre-compression arrangement is added to ensure consistent fluid dispensing, then dispensing consistency is improved, but device complexity increases
Solution Approach 1:
The patent implements pre-compression by deforming the flexible diaphragm during the pump's initial operation to store fluid under pressure. This preliminary action ensures that when the diaphragm releases the stored fluid, consistent dispensing occurs without requiring additional complex pre-compression mechanisms or valves.
Solution Approach 2:
The invention merges the pre-compression function with the pump chamber's pumping action. The same diaphragm that performs the pumping stroke also serves as the pre-compression element by deforming to store fluid. This integration eliminates the need for separate pre-compression components, maintaining dispensing consistency while minimizing device complexity.
4Productivity
If continuous spray capability is implemented without continuous actuation, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent achieves continuous spray capability by using the flexible diaphragm to store fluid during pump actuation and then release it continuously. The diaphragm's elastic recovery creates a continuous flow without requiring continuous trigger actuation, improving productivity while adding minimal complexity through the use of a simple elastic membrane mechanism.
Solution Approach 2:
The invention employs the diaphragm's inherent elastic properties to automatically return to its original position after deformation, thereby releasing stored fluid continuously. This self-service mechanism eliminates the need for continuous external actuation or complex control systems, achieving continuous spray capability through the material's natural elastic recovery.
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 dispenser achieves a continuous fluid dispensing capability without continuous actuation, allowing for prolonged dispensing times and simplifying recycling by eliminating non-recyclable components.
Implementation Method 1
a resiliently-deformable diaphragm interposed between the pump chamber and nozzle outlet
Implementation Method 2
supplemented by biasing members, allows for a volume of fluid to be dispensed as a continuous stream
Data Source
AI summary
An all-plastic, continuous trigger sprayer is contemplated that avoids the use of metal parts, elastomers, or other disparate and non-recyclable materials. A reservoir diaphragm is provided within the sprayer head, interposed between the actuation mechanism and the outlet, so as to ensure a steady flow of dispensed fluid is delivered even after actuation has ceased.