Toilet Canned Sump Drain Casting for Jet Orifice Consistency
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Solution Overview
Problem
Plumbing fixtures with solid cast sumps face limitations in shape, location, and orientation of the sump and jet orifice due to manual punching, leading to inconsistent hole sizes and reduced flushing efficiency.
Innovation Solution
A drain casting process is used to form the sump, allowing for various shapes and smoother surfaces, with the jet orifice located near the trapway, improving fluid flow and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual punching is used to create holes in solid cast sumps, then the sump can be formed with basic shape, but the location and orientation of the jet orifice are limited and inconsistent
Solution Approach 1:
The sump is pre-formed with the jet orifice location and trapway orientation integrated into the mold design before casting, eliminating the need for post-casting manual punching operations. This preliminary action ensures consistent hole locations and enables greater shape flexibility.
Solution Approach 2:
The manual punching mechanical process is replaced with a drain casting process that forms the sump, jet orifice, and trapway in a single integrated operation, achieving both precision and versatility simultaneously.
2Productivity
If manual punching is used to connect sump to drain channel and bowl, then holes can be created, but material yield increases and flushing efficiency decreases
Solution Approach 1:
The sump, drain channel, and bowl connections are merged into a single integrated casting operation, eliminating multiple separate punching operations. This reduces manufacturing steps and material waste while improving consistency.
Solution Approach 2:
The manufacturing process changes from post-casting mechanical punching to pre-casting drain formation, fundamentally altering how connections are created and eliminating material yield associated with punching operations.
3Ease of manufacture
If solid cast process with manual punching is used, then basic sump formation is achieved, but the sump has rectangular shape with few smooth continuous curved surfaces
Solution Approach 1:
The sump design transitions from rectangular angles to smooth continuous curved surfaces, improving fluid flow characteristics. The drain casting process enables these curved geometries that are difficult to achieve with manual punching.
Solution Approach 2:
The mechanical punching process is replaced with drain casting that naturally forms smooth curved surfaces through the casting mold, eliminating the angular, rectangular geometry inherent in post-casting hole punching.
Data Source
AI summary
A sump for a toilet includes a first end of the sump, defined by a first boundary, and a second end of the sump, defined by a second boundary. The sump includes a channel running from the first end of the sump to the second end of the sump defined by a sump surface. The first end of the sump is configured to receive liquid and the second end of the sump is configured to supply liquid. The sump has a sump can-cut diameter corresponding to a diameter of the channel at the first end of the sump, a sump side radius extending from a center of the channel to an inner surface of the channel, and a sump depth corresponding to a largest vertical distance within the channel. The sump may be drain cast using a single continuous pathway.