Trigger Sprayer Simplified Design Reduces Part Count
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Solution Overview
Problem
Existing hand-held trigger sprayers are complex and costly due to their numerous parts, making assembly and manufacturing inefficient.
Innovation Solution
A simplified trigger sprayer design with only six easily assembled parts, including a dip tube, ball valve, molded flexible pump diaphragm, molded shroud with trigger, molded body, and molded combination nozzle and door assembly, which reduces assembly steps and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional trigger sprayer design is used, then functionality and reliability are maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate components into integrated molded parts. The shroud integrates the trigger mechanism, pump housing, and valve assembly into a single molded component. The nozzle assembly integrates the discharge nozzle, door, and locking mechanism into another molded part. This merging reduces the total part count while maintaining all necessary functions.
Solution Approach 2:
The molded shroud serves multiple functions simultaneously: it acts as the pump housing, contains the trigger mechanism, provides structural support, and integrates the valve assembly. This multi-functionality eliminates the need for separate components for each function, reducing overall device complexity.
2Reliability
If traditional trigger sprayer design is used, then operational reliability is maintained, but assembly difficulty and manufacturing time increase
Solution Approach 1:
The sprayer is divided into six main modular components: dip tube, ball valve, molded flexible pump diaphragm, molded shroud, molded body, and molded combination nozzle and door assembly. Each component can be manufactured separately and then assembled through simple coupling mechanisms, improving assembly efficiency while maintaining operational reliability.
Solution Approach 2:
The complex molded components are pre-formed with all necessary features (trunnions, coupling elements, internal passages) during the molding process. This preliminary action eliminates the need for post-manufacturing assembly of complex sub-assemblies, reducing assembly time and improving productivity.
3Ease of manufacture
If simplified design with fewer parts is used, then assembly ease and manufacturing cost improve, but structural integrity and reliability may be compromised
Solution Approach 1:
The patent uses composite construction by molding multiple materials together in integrated components. The molded shroud and body combine rigid structural materials with flexible sealing elements, creating composite structures that maintain structural integrity while reducing part count. The flexible pump diaphragm provides both sealing and structural support in a single component.
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 simplified design allows for straightforward assembly in five steps, reducing overall costs and complexity while maintaining functionality, enhancing manufacturing efficiency and user experience.
Implementation Method 1
a molded flexible pump diaphragm having a circumferential flange and a valve lip
Implementation Method 2
a ball valve
Implementation Method 3
a coil spring seated in the pump chamber
Data Source
AI summary
A trigger sprayer having six parts: (i) a dip tube, (ii) a valve, (iii) a flexible pump diaphragm having a circumferential valve lip, (iv) a shroud having a trigger, an element which engages the diaphragm, and front and rear mating elements, (v) a body having a closure for a container, an inlet coupled to the dip tube, a valve seat for the valve, an element which engages the valve lip, a discharge barrel having a proximal opening into which the valve lip seats, a vent chamber, a vent barrel coupled to the vent chamber, a rear mating structure coupling to the rear mating element of the shroud so that the shroud can pivot, and a forward mating element, and (vi) a combination nozzle and door assembly with a nozzle which couples to the fluid discharge barrel of the molded body, and has a trigger locking element.