Trigger Sprayer With Integral Plastic U-Shaped Spring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing and recycling of trigger sprayers are costly due to the need for multiple component parts, with the metal coil spring being the only non-plastic component that requires disassembly for recycling, increasing the complexity and expense of the process.
Innovation Solution
The trigger sprayer is designed with a plastic U-shaped spring integral to the pump piston rod, eliminating the need for a separate metal coil spring and reducing the number of components, allowing all parts to be constructed from plastic and facilitating easier recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal coil spring is used in the trigger sprayer, then the pump piston can be biased to the discharge position, but the recycling process becomes complex and costly due to the need to disassemble and remove the metal spring
Solution Approach 1:
The spring element is merged with the pump piston rod to form a single integral plastic component. The U-shaped spring is molded as one piece with the piston rod, eliminating the need for separate metal spring assembly and simplifying recycling to a single plastic component processing step.
Solution Approach 2:
The material parameter is changed from metal to plastic for the spring element. This material substitution maintains the elastic biasing function while enabling the entire assembly to be processed as plastic waste, fundamentally changing the recyclability parameter of the component.
2Adaptability or versatility
If multiple separate component parts are used in the trigger sprayer, then each part can be optimized for its specific function, but the manufacturing cost increases due to the need for multiple parts and assembly steps
Solution Approach 1:
Multiple separate components (spring, piston rod, collar) are merged into a single integral plastic part through injection molding. This consolidation reduces the number of parts from three to one, eliminating assembly steps and reducing manufacturing cost while maintaining all necessary functions.
Solution Approach 2:
The integral plastic component performs multiple functions simultaneously: the U-shaped spring provides elastic biasing, the piston rod provides mechanical connection, and the collar provides structural support. This multi-functionality in a single part reduces the need for multiple specialized components.
3Ease of operation
If a metal coil spring is used in the trigger sprayer, then the pump piston can be returned to the charge position, but all other component parts must be disassembled to remove the metal spring for recycling
Solution Approach 1:
The material parameter of the spring element is changed from metal to plastic, which fundamentally alters the recycling parameter. The plastic spring element allows the entire pump assembly to be recycled as a single plastic component, eliminating the need for disassembly and metal separation processes.
Solution Approach 2:
The metal spring element is extracted from the system and replaced with a plastic alternative. This extraction of the problematic metal component eliminates the need for its removal during recycling, while the plastic replacement maintains the necessary mechanical function.
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
This design reduces manufacturing costs by minimizing components and simplifies recycling, making the process more economical by eliminating the need to disassemble and handle metal components.
Implementation Method 1
A pair of springs 132 that are formed integrally with the piston rod 122 and the ring 124... The intermediate portions 138 of the springs 132 between the proximal ends 134 and the distal ends 136 are bent in an inverted U-shaped configuration... The springs 132 bias the piston rod 122 and the pump piston 102 away from the pump chamber rear wall 38
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A manually operated trigger sprayer is constructed with a reduced number of parts and in a novel manner in which all of the component parts of the sprayer are constructed of a plastic material. The construction of the trigger sprayer replaces the conventional metal coil spring in the pump chamber with a pair of plastic springs having inverted U-shaped configurations that are integral with the piston rod and are positioned outside the pump chamber. Constructing all of the sprayer parts of a plastic material enables a cost efficient recycling of the parts, which does not require disassembling the parts to remove a metal spring.