Disc Valve Tolerance Compensation for Faucet Assembly
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Solution Overview
Problem
Disc valves for water faucets face manufacturing tolerance issues, requiring precise machining of the valve housing to compensate for tolerances, which is time-consuming and results in inconsistent faucet handle heights and visible gaps after assembly.
Innovation Solution
A disc valve with a tolerance compensation height within the housing, using adjustable elements such as a tolerance compensation element or varying thicknesses of the engaging disc, to maintain a consistent distance between the pivot point and the base surface, eliminating the need for large clearances and precise manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining the valve housing is performed to compensate for manufacturing tolerances, then the housing dimension consistency is improved, but the production time increases
Solution Approach 1:
The patent introduces a receiving element as an intermediary component between the valve actuating member and the disc stack. This receiving element with adjustable height compensates for manufacturing tolerances in the valve housing without requiring machining operations. The receiving element acts as a mediator that absorbs dimensional variations, allowing the use of cast or stamped housing components while maintaining precise positioning of the valve actuating member.
2Adaptability or versatility
If large clearances are provided between external parts to accommodate handle height variations, then the adaptability is improved, but the aesthetic appearance deteriorates due to visible gaps
Solution Approach 1:
The patent replaces the mechanical approach of providing large physical clearances with a tolerance compensation mechanism. By using a receiving element with adjustable height, the system maintains consistent faucet handle positioning despite manufacturing tolerances, eliminating the need for large clearances and thus avoiding visible gaps while preserving aesthetic appearance.
3Reliability
If precise manufacturing of valve elements is performed, then the sealing reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent enables the valve system to self-compensate for manufacturing tolerances through the adjustable receiving element. This self-service mechanism allows the use of standard manufacturing processes for the valve housing and components while maintaining reliable sealing performance, as the receiving element adjusts to accommodate dimensional variations in the assembled components.
Data Source
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AI summary
Disc valve (30; 130; 230) for controlling water dosage and/or water temperature of a water faucet (10), comprising a disc valve housing (40) having a base surface b, a disc stack (38) arranged in the disc valve housing (40), wherein the disc stack (38) comprises two valve discs (32, 34) displaceable to one another as valve means, a valve actuating member (62) engaged with the disc stack (38) by means of which one of the two valve discs (32, 34) can be displaced and a receiving element (64) having a height g and being configured to receive the valve actuating member (62) such that a pivot point (68) about which the valve actuating member (62) can pivot is provided. A predetermined distance d between the pivot point (68) and the base surface b is provided regardless of manufacturing tolerances by adjusting a tolerance compensation height h provided substantially within the disc valve housing (40).