Faucet Body Brushed Texture via Injection Mold and Coating

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Solution Overview

Problem

The existing methods for manufacturing faucet bodies for sanitary faucets result in long production times and high costs due to the need for mechanical brushing and re-galvanization to achieve a brushed texture.

Innovation Solution

A method involving injection molding to produce a faucet body with a brushed texture, followed by coating with a copper layer and a nickel-phosphorus alloy layer, which reduces the need for mechanical brushing and subsequent re-galvanization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mechanical brushing and grinding are used to produce brushed texture on plastic faucet bodies, then a visually appealing brushed texture is achieved, but production time increases and manufacturing costs increase due to subsequent re-galvanization requirements

Engineering Contradiction:

Improvebrushed texture qualityVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The brushed texture is pre-formed on the mold surface before injection molding, so the texture is automatically imprinted on the faucet body during molding. This preliminary preparation of the mold surface eliminates the need for subsequent mechanical brushing and re-galvanization operations, directly reducing production time while maintaining texture quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical brushing and grinding process is replaced by an injection molding process that uses a pre-textured mold surface to directly form the brushed texture on the faucet body. This substitution eliminates the need for mechanical post-processing and subsequent re-galvanization, improving productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If mechanical brushing and re-galvanization are performed to achieve brushed texture, then the desired surface appearance is obtained, but manufacturing costs increase

Engineering Contradiction:

Improvebrushed texture qualityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The mold surface is pre-prepared with a negative brushed texture before production, allowing the texture to be automatically transferred to the faucet body during injection molding. This eliminates the need for costly subsequent mechanical brushing and re-galvanization operations, directly reducing manufacturing costs while maintaining texture quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The expensive mechanical brushing and re-galvanization process is replaced by a single injection molding operation using a pre-textured mold. This substitution eliminates multiple costly post-processing steps while achieving the same brushed texture appearance, thereby reducing manufacturing costs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If the faucet body is brushed into the copper layer to produce brushed texture, then the desired surface finish is achieved, but the production process becomes more complex and time-consuming

Engineering Contradiction:

Improvesurface finishVSAvoidproduction process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The brushed texture is pre-formed on the mold surface before injection molding, so the texture is automatically imprinted on the faucet body during molding. This eliminates the need for subsequent mechanical brushing into the copper layer and re-galvanization operations, simplifying the production process while maintaining surface finish quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The texture formation and molding operations are merged into a single injection molding process. The brushed texture is integrated into the mold surface, allowing the texture to be automatically transferred to the faucet body during molding, thereby combining multiple operations into one and reducing process complexity

Inventive Principle:

Principle #5Merging (Combining)

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

This method allows for the manufacture of faucet bodies in shorter times and at lower costs while maintaining a visually appealing brushed texture.

Implementation Method 1

a mold surface of the injection mold or a mold surface of the hollow space of the injection mold is at least partially formed by a negative of the brushed texture, which is positively imprinted on the surface of the faucet body in step a)

Methodology Applied

Scientific EffectNegative imprinting:

Implementation Method 2

coating the faucet body with at least one first layer comprising copper; and coating the faucet body with at least one second layer comprising a nickel-phosphorus alloy

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS20250043550A1Method of manufacturing a faucet body for a sanitary faucet and a faucet body for a sanitary faucet

Publication Date: 2025.02.06 GROHE AG

AI summary

A method for manufacturing a faucet body (1) for a sanitary faucet, having at least the following steps: a) production of the faucet body (1) in an injection mold, wherein the injection mold at least partially forms a brushed texture (3) on a surface (2) of the faucet body (1); b) coating the faucet body (1) with at least one first layer (4) comprising copper; and c) coating the faucet body (2) with at least one second layer (5) comprising a nickel-phosphorus alloy. A faucet body of plastic for a sanitary faucet is also proposed.