Trigger Sprayer Integrated Valve System Cost Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing trigger sprayers are costly to manufacture and lack efficiency in dispensing a range of liquid products with varying output requirements, particularly in household, lawn, and garden applications.
Innovation Solution
A low-cost, all-plastic trigger sprayer design featuring an open and closed opposing valve system with a one-piece piston, a plastic return spring, and a one-piece valve system for priming and check functions, along with a swirl component for fluid break-up, optimized for minimal components and easy assembly to reduce weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional trigger sprayer designs are used, then manufacturing cost is high, but manufacturing cost reduction is needed
Solution Approach 1:
The patent combines the priming valve and check valve into a single integrated valve system, reducing the number of separate components and assembly steps. This merging of functions into one component lowers manufacturing cost while maintaining the reliability of liquid dispensing through the integrated valve mechanism.
Solution Approach 2:
The trigger actuator serves multiple functions: it compresses the piston for liquid discharge, opens the priming valve for chamber filling, and actuates the check valve for one-way liquid flow. This multi-functionality reduces the number of separate components needed, lowering manufacturing cost while ensuring reliable operation of all dispensing functions.
2Reliability
If multiple separate valve components are used, then valve function is reliable, but assembly complexity increases
Solution Approach 1:
The priming valve and check valve are merged into a single integrated valve component, reducing the number of separate parts that need to be assembled. This integration maintains the reliability of both valve functions while significantly simplifying the assembly process and reducing assembly complexity.
3Manufacturing precision
If multiple separate components are used, then component function is precise, but manufacturing cost increases
Solution Approach 1:
The integrated valve system combines priming and check valve functions into one precision-machined component, maintaining the manufacturing precision needed for reliable valve operation while reducing the total number of parts to be manufactured, assembled, and quality-checked, thereby lowering overall manufacturing cost.
Solution Approach 2:
The trigger actuator is designed as a multi-functional component that performs piston compression, priming valve actuation, and check valve operation. This consolidation maintains the precision needed for each function while reducing the number of separate components that require manufacturing and quality control.
4Reliability
If traditional valve systems are used, then liquid flow control is reliable, but dispensing efficiency decreases
Solution Approach 1:
The trigger actuator simultaneously performs multiple functions: compressing the piston for liquid discharge, opening the priming valve for chamber refilling, and actuating the check valve for one-way flow control. This multi-functionality enables all these operations to occur in a single trigger pull, significantly improving dispensing efficiency while maintaining reliable liquid flow control through the integrated valve system.
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 design enables efficient dispensing of liquids in various forms (spray, stream, or foam) across different products, with reduced manufacturing costs and improved quality, facilitating high-speed automated assembly and accommodating different bottle neck sizes.
Implementation Method 1
a plastic return spring (3) molded or attached mechanically to the top of the internal surface (4) of the trigger sprayer cover component (20). When the plastic spring structure (3) is assembled into the housing (6), it provides a bias against the actuator (14) to force the return of the actuator to its at-rest position after each compression of the stroke.
Data Source
AI summary
A trigger sprayer has a housing, a piston bore within the housing, and a piston reciprocally mounted with the piston bore. The housing further includes a flow passage through which liquid passes from a passage inlet to a passage outlet. An actuator is operable to reciprocate the piston within the piston bore between a vacuum stroke creating reduced pressure in the piston bore and a compression stroke creating increased pressure in the piston bore. A valve unit within the flow passage controls the flow of liquid through the flow passage upon operation of the actuator. The valve unit further comprises a check valve and priming valve. The check valve is shaped in a frusto-conical manner and is assembled into the check valve seat which is not part of the housing but is a separate component. The sprayer has a free spinning threaded type closure for mounting the sprayer to a container, the closure formed separately from and secured to said housing.