Faucet Casing Structure With Metal Insert for Low-Cost Durability
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Solution Overview
Problem
The existing faucet devices face challenges with high manufacturing costs, low durability due to resin materials, and difficulties in processing stainless steel for hot and cold water exposure, leading to demands for a copper-alloy-free and casting-free configuration that reduces costs and increases design freedom.
Innovation Solution
A faucet device design where a metallic casing member is inserted into a tubular columnar section of the outer shell member, with mechanical engagement means to retain the connecting member, allowing for adjustable size and shape without the need for a mold for each shape, using a metallic plate or pipe for increased strength and reduced thickness, and a secondary adapter member supports the spout-channel forming member to reduce outer shell member strength requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin material is used for the casing member, then the manufacturing cost is reduced, but the strength and durability are insufficient
Solution Approach 1:
The invention uses a composite structure combining resin and metal materials. The casing member is made of resin material for cost-effectiveness, while a metal reinforcing member is embedded within to provide the necessary strength and durability. This composite approach allows the structure to benefit from both the low cost and ease of manufacturing of resin and the high strength of metal.
2Reliability
If stainless steel is used for the casing member, then the corrosion resistance is improved, but the processing accuracy becomes difficult to achieve
Solution Approach 1:
The invention combines stainless steel (or other corrosion-resistant metal) with resin material. The metal component provides the necessary corrosion resistance for water exposure, while the resin component allows for easier and more precise manufacturing processes. This composite structure enables achieving both high corrosion resistance and good manufacturing precision that would be difficult to obtain with stainless steel alone.
3Strength
If copper alloy is used for the casing member, then the strength is improved, but the lead elution control and cost stability become problematic
Solution Approach 1:
The invention uses a composite structure where the metal reinforcing member can be made from copper alloy or other materials, but the resin casing member surrounds and contains it. This structure allows the metal to provide strength while the resin barrier prevents direct contact between water and the metal, thereby controlling lead elution. Additionally, the resin component helps stabilize costs by reducing dependence on fluctuating copper prices.
4Manufacturing precision
If a mold is prepared for each faucet device shape, then the manufacturing precision is improved, but the manufacturing cost increases
Solution Approach 1:
The invention uses a standardization approach where a common mold is used to manufacture the casing member for different faucet device types. The design of the casing member is made universal so that the same mold can produce components for various faucet configurations, reducing the need for multiple specialized molds and thereby lowering manufacturing costs while maintaining acceptable precision.
Solution Approach 2:
The invention divides the faucet device into modular components, with the casing member as a standardized base component that can be used across different product types. By segmenting the design into a universal casing and variable functional components, the need for custom molds for each faucet shape is reduced, lowering manufacturing costs while maintaining precision through standardized production.
Data Source
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AI summary
A faucet device (1) comprising: a base member (16); an outer shell member (8); a metallic casing member (40) that is inserted in a columnar section (8a) of the outer shell member (8) and whose one end is fixed to the base member (16); a hot-water supply pipe (44) and a cold-water supply pipe (46); a single lever cartridge (54) provided at the other end of the casing member (40); connecting members (50, 52) that are provided inside the casing member (40) and that connect the hot-water supply pipe (44) and the cold-water supply pipe (46) to the single lever cartridge (54); a fixing member (56) that fixes the single lever cartridge (54) to the connecting members (50, 52); and mechanical engagement means (58) and (60). The casing member (40) is formed of a metallic plate or pipe, and is capable of retaining the connecting member (50) in accordance with the mechanical engagement means (58, 60).