Faucet Liner Casting for Smooth Internal Water Channels
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Solution Overview
Problem
Traditional metal faucet manufacturing methods using low-pressure die casting result in irregular appearances, poor consistency, rough surfaces, and residual sand core residues, limiting the use of zinc and aluminum alloys and increasing production costs due to the need for plastic pipes and complex valve cores.
Innovation Solution
A manufacturing method involving a stainless-steel liner with a cavity, filled with a liner filler such as resin sand or silica gel, allowing high-pressure die casting to form a smooth internal channel, eliminating the need for core extraction and simplifying the valve core structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional low-pressure die casting with sand cores is used, then manufacturing process is simple, but production efficiency is low and product quality is poor
Solution Approach 1:
The patent changes the pressure parameter from low-pressure die casting to high-pressure die casting (10-50 MPa), which fundamentally improves production efficiency and product quality while maintaining process simplicity through the use of a liner-filled cavity system that accommodates the high pressure
2Ease of manufacture
If traditional low-pressure die casting with sand cores is used, then manufacturing process is simple, but manufacturing precision is poor
Solution Approach 1:
The patent applies high-pressure die casting (10-50 MPa) instead of low-pressure casting, which significantly improves manufacturing precision, surface quality, and product consistency while maintaining process simplicity through the liner-filled cavity approach
Solution Approach 2:
The patent introduces a liner filled with filler material as an intermediary element that shapes the cavity and enables high-pressure die casting, allowing for precise control of the mold cavity geometry and elimination of sand core residues
3Reliability
If zinc alloy or aluminum alloy faucets are manufactured with plastic pipes inside, then water passage is enabled, but appearance is constrained and structure becomes complex
Solution Approach 1:
The patent extracts and removes the plastic pipe component entirely, replacing it with a liner-filled cavity system that enables direct water contact with the metal faucet body, thereby simplifying the overall structure and improving appearance while maintaining functionality
Solution Approach 2:
The patent uses a liner filled with filler material as an intermediary that creates a smooth internal cavity for water passage, eliminating the need for separate plastic pipes and complex valve core structures
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
The method enhances production efficiency, reduces material consumption, and enables direct water contact, resulting in a faucet with regular appearance, high consistency, and reduced production costs.
Implementation Method 1
the liner filler is compression-molded under a pressure after entering the liner
Implementation Method 2
conducting high-pressure die casting, cooling for solidification
Data Source
AI summary
Provided is a manufacturing method of a faucet, including: (1) fabricating a liner with a cavity; (2) injecting a liner filler into the cavity of the liner, and allowing forming of the liner filler in the cavity; and (3) placing the liner injected with the liner filler in a mold, conducting high-pressure die casting, cooling for solidification, and removing the liner filler from the cavity to produce the faucet. The liner filler is one or more of a resin, a silica gel, a foam material, a resin sand, a steel ball, a cement, a wood shaving, a flour, a wax, an ice, and a dry ice. A raw material for fabricating the liner is at least one of a stainless steel, a titanium metal, copper, and aluminum. The method is simple and features low difficulty in industrial production. The faucets have a smooth liner, regular appearance, and excellent consistency.