Faucet Main Body Overmolding for Leak-Free Inner Core Sealing
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Solution Overview
Problem
Conventional secondary injection-molded faucets are prone to leakage due to misalignment of positioning posts and insufficient temperature, leading to gaps between the main body inner core and the over-molded layer, causing water seepage and dripping.
Innovation Solution
A faucet main body structure with a through pipeline and water-passing joint, integrated into the injection-molded part, featuring a circular arc-shaped transition surface and valve spool accommodating chambers, which are fixed using valve spool cores and water outlet cores in the injection molding mold, eliminating the need for positioning posts and ensuring a tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If positioning posts and positioning protruding bits are used to position the main body inner core, then the main body inner core can be preliminarily positioned and stably placed in the molding cavity, but misalignment may occur during manual placement leading to gaps between the inner core and over-molded layer
Solution Approach 1:
The invention removes the positioning posts and positioning protruding bits from the main body inner core structure. Instead, it uses the circular arc-shaped transition surface to enable the over-molded layer to tightly wrap around the inner core, eliminating the need for separate positioning structures and their associated alignment issues.
Solution Approach 2:
The invention introduces a circular arc-shaped transition surface on the outer contour of the through pipeline. This curved surface allows the over-molded layer to conform and tightly wrap around the inner core, creating a gap-free interface that prevents water leakage while eliminating the need for rigid positioning posts.
2Stability of the object's composition
If multiple positioning structures are added to the main body inner core, then positioning stability is improved, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The invention merges the positioning function into the overall contour shape of the inner core by using the circular arc-shaped transition surface. This eliminates the need for separate positioning posts and protruding bits, simplifying the inner core structure while maintaining positioning stability through the tight wrap of the over-molded layer.
Solution Approach 2:
The circular arc-shaped transition surface provides a streamlined contour that naturally guides the over-molded layer to wrap tightly around the inner core. This curved geometry achieves positioning stability without requiring additional positioning structures, thereby reducing overall structural complexity.
3Manufacturing precision
If positioning posts and protruding bits are used for positioning, then the inner core can be fixed in position, but gaps are prone to form at these positioning areas causing water leakage
Solution Approach 1:
The invention removes the positioning posts and positioning protruding bits that create gap-prone areas. By eliminating these discrete positioning structures, the design prevents the formation of gaps at positioning interfaces, thereby eliminating the primary pathway for water leakage.
Solution Approach 2:
The circular arc-shaped transition surface creates a continuous, gap-free interface between the inner core and over-molded layer. This curved surface allows the over-molded material to wrap tightly around the inner core, eliminating the gap-prone flat or stepped interfaces that exist around positioning posts and protruding bits.
Data Source
AI summary
A faucet main body structure, an injection molding mold and a molding method are provided. A main body inner core is fixed in the injection molding mold by a new fixing method, ensuring that no additional positioning structure is required to be provided on the outer surface of the main body inner core, so that in the case that the main body inner core is subjected to over-molding, a main body injection-molded layer of the main body injection-molded part is enabled to closely attached to the main body inner core without causing gaps therebetween, which ensures that the faucet main body structure is not susceptible to water seepage, and prolongs the service life of the product.