Faucet Handle Hub Coupler for Tolerance-Resilient Valve Assembly
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Solution Overview
Problem
Conventional faucet valve assemblies require tight tolerances for the lever and handle hub to operate smoothly, leading to manufacturing difficulties, aesthetic issues, and inconsistent function due to dimensional variations.
Innovation Solution
A valve assembly design featuring a coupler that couples the valve stem with the handle hub, including a coupler base and engagement member with circumferentially spaced slots, allowing for pivoting movement and simultaneous rotation, which facilitates smoother operation and reduces manufacturing complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tight tolerances are used for lever and handle hub mating components, then operational consistency is improved, but manufacturing difficulty and assembly difficulty increase
Solution Approach 1:
The patent introduces an insert as an intermediary component between the lever and handle hub. This insert includes a slot that receives the lever and allows relative movement, while the handle hub has a corresponding slot that receives the insert. This intermediary mechanism absorbs dimensional variations and allows the components to self-align during assembly, eliminating the need for tight tolerances on the mating surfaces of the lever and handle hub while maintaining operational consistency.
2Reliability
If tight tolerances are used for lever and handle hub mating components, then operational consistency is improved, but assembly difficulty increases
Solution Approach 1:
The insert acts as a mediator that simplifies assembly. The handle hub slot receives the insert, and the lever slot receives the lever, allowing each component to be assembled independently into the insert rather than requiring precise alignment between the lever and handle hub. This intermediary approach breaks down the complex multi-component alignment problem into simpler, sequential assembly steps.
3Reliability
If tight tolerances are used for lever and handle hub, then functional consistency is improved, but aesthetic design quality deteriorates
Solution Approach 1:
The insert provides a hidden intermediary structure that allows the lever and handle hub to have more generous, aesthetically pleasing dimensions without compromising functional consistency. The slots in the insert and handle hub can be designed with smoother transitions and better proportions since they don't need to maintain tight clearance fits, improving the overall aesthetic appearance while maintaining reliable operation.
Data Source
AI summary
A valve assembly for a faucet including a valve cartridge having a valve stem and supported within a valve body, a handle operably coupled to the valve stem, a handle hub supported for rotation relative to the valve body, and a coupler operably coupling the valve stem with the handle hub.