Integrated Faucet Valve Assembly for Quarter-Turn Installation

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Solution Overview

Problem

Current faucets have non-ergonomic installation processes, require manual threading, and cannot be water tested until almost fully assembled, leading to costly repairs if leaks are detected during testing.

Innovation Solution

The design includes a hydroformed faucet body with an integrated shank, a quarter turn attachment nut, a wave spring for compressive load, and a modular valve structure that allows for independent waterway assembly and testing, simplifying manufacturing and installation by standardizing parts and reducing the need for torque wrenches.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual threading is used to secure the faucet in place, then the faucet can be installed, but the installation process becomes non-ergonomic and time-consuming

Engineering Contradiction:

Improveinstallation ergonomicsVSAvoidinstallation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent replaces the traditional manual threading operation with a locking assembly that uses a quarter-turn mechanical locking mechanism. The locking assembly includes a locking member that engages with a locking feature on the valve structure, eliminating the need for manual threading and allowing quick installation without specialized tools or ergonomic strain.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the faucet is fully assembled before water testing, then complete assembly is achieved, but costly repairs are required if leaks are detected during testing

Engineering Contradiction:

Improveassembly efficiencyVSAvoidrepair cost

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The patent divides the faucet into modular components: a valve structure with integrated cup and mount, a separate faucet body, and a locking assembly. This segmentation allows the valve structure to be independently assembled and water-tested before final integration into the complete faucet, enabling leak detection and repair at an earlier stage without requiring full assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent enables preliminary water testing of the valve structure before final faucet assembly. The integrated cup and mount design allows the valve structure to be pre-assembled and tested for leaks, so that any issues are identified and corrected before the faucet is fully assembled and installed, preventing costly post-installation repairs.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If standardized components are used across different faucet configurations, then manufacturing is simplified, but customization for specific configurations is reduced

Engineering Contradiction:

Improvemanufacturing standardizationVSAvoidfaucet configuration flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent designs the valve structure with universal features including an integrated cup that can receive different valve types and a mount that can be locked to various faucet body configurations. The locking assembly provides a standardized interface that adapts to different faucet configurations while maintaining consistent manufacturing processes for the core valve structure components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11274761B2Faucet with integrated valve

Publication Date: 2022.03.15 KOHLER CO(US)

AI summary

A faucet that includes an external body having a base and a spout extending from the base; a unitary valve structure having a cup disposed in the external body and a tubular mount extending downwardly beyond the external body; a valve supported in the cup of the valve structure; and a locking assembly that detachably locks to the mount of the valve structure.