A method for manufacturing a sponge with inner soap capsule
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Solution Overview
Problem
Existing wash sponges with inner soap capsules experience uncontrolled flow of liquid soap due to user pressure, leading to soap leakage even when the sponge is already sudsy.
Innovation Solution
The sponge features a sealed capsule with pressure-sensitive holes that remain closed under vertical pressure (normal use) and open under horizontal pressure (intentional squeezing), allowing controlled soap flow, and is manufactured using a nylon sleeve divided into capsules with tunnels for soap distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the capsule is made pliable to allow soap flow through holes, then soap can be released into the sponge, but uncontrolled soap flow occurs under user pressure
Solution Approach 1:
The holes in the capsule are designed to dynamically change their state between open and closed based on the direction and magnitude of applied pressure. When pressure is applied perpendicular to the holes, they close to prevent leakage. When pressure is applied parallel to the holes through intentional squeezing, they open to allow controlled soap release.
Solution Approach 2:
The capsule material properties are optimized to respond differently to pressure applied in different directions. The holes are designed with specific geometric parameters that allow them to deform and close under perpendicular pressure while remaining open under parallel pressure, enabling directional control of soap flow.
2Productivity
If holes are made larger to facilitate soap flow, then soap releases more easily, but soap leaks uncontrollably during normal use
Solution Approach 1:
The holes are designed with dynamic closure capability that responds to pressure direction. During normal use with perpendicular pressure, the holes close completely regardless of their size, preventing leakage. During intentional squeezing with parallel pressure, the holes open fully to allow rapid soap flow, thus achieving both controlled release and prevention of unwanted leakage.
3Reliability
If the capsule is sealed to prevent leakage, then soap flow is controlled, but intentional soap release becomes difficult
Solution Approach 1:
The capsule maintains a sealed appearance and structure under normal conditions, providing reliable soap containment. However, when the user applies squeezing pressure in the specific direction parallel to the holes, the holes dynamically open to facilitate easy soap release, thus combining both containment reliability and operational ease.
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
Prevents significant soap flow during normal use, ensuring soap is only released when intentionally squeezed, enhancing user control and reducing waste.
Implementation Method 1
The sponge (1) has pressure-sensitive holes (4) which are closed when pressure is applied perpendicular to the wide sides (21) (22) of the capsule (2) and which are opened when pressure is applied parallel to the wide sides (21) (22) of the capsule (2)
Data Source
Figure 1~4
Figure 5~6
Figure 7~8
AI summary
A wash sponge with a pliable, inner capsule that contains soap and has several holes. When the capsule is squeezed it discharges soap into the sponge. The holes, which are in fact cuts made in the sides of the capsule, serve as a kind of valve system that controls the flow of soap from the capsule into the sponge. The cuts are made in such a way that the entire circumference of the hole is not cut, and a flap if formed that remains attached to the capsule. When horizontal pressure is applied to the sponge (and the capsule), the holes open and the soap can flow out into the sponge; however, when incidental, vertical pressure is applied to the sponge (and capsule), the holes do not open significantly and soap does not flow out through the holes.