Insert-Molded Electrical Components in Plumbing Fixtures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional plumbing fixtures, particularly toilets, face challenges in integrating electrical components during the manufacturing process without damage, leading to exposed components that require additional waterproofing, increasing costs and complexity. Additionally, designing new toilet aesthetics results in significant engineering time and effort due to the need for re-engineering the entire flush engine, slowing market introduction.
Innovation Solution
The integration of electrical components, such as sensors and light sources, is achieved by insert-molding them within a polymeric material structure around a standardized pre-formed flush engine, allowing for varied aesthetic designs without altering the engine's performance characteristics, and using a polymeric shell to conceal and protect these components, reducing engineering time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components are installed in the plumbing fixture during the molding process, then the components can be concealed within the fixture for protection from water, but the high temperatures and molding process cause damage to the components
Solution Approach 1:
The patent divides the manufacturing process into two independent stages: first, electrical components are installed in the flush engine at lower temperatures; second, the polymeric material is molded around these pre-installed components at high temperatures. This segmentation allows each stage to operate under optimal conditions, protecting components from thermal damage while achieving waterproof encapsulation.
Solution Approach 2:
The electrical components are installed in the flush engine before the polymeric molding process begins. This preliminary installation ensures components are in place and protected by the subsequent polymeric encapsulation, avoiding exposure to high temperatures during the molding process that would damage them.
2Adaptability or versatility
If the entire flush engine is re-engineered for each new toilet aesthetic design, then the design can be customized, but the engineering time and effort increase significantly
Solution Approach 1:
The patent separates the flush engine (functional component) from the aesthetic features (external design elements). The standardized flush engine can be produced once and reused across multiple designs, while only the aesthetic portions need to be modified for each new design. This segmentation dramatically reduces engineering time while maintaining design versatility.
Solution Approach 2:
The standardized flush engine serves as a universal base that can be combined with various aesthetic designs. This multi-functional approach allows a single engineered flush engine to support multiple product variants, reducing overall development time and engineering effort across the product line.
3Strength
If electrical components are installed later in the manufacturing process rather than during molding, then the components are protected from damage, but the components remain exposed to water requiring additional waterproofing
Solution Approach 1:
The patent combines the flush engine and electrical components into a single integrated assembly that is then encapsulated by the polymeric material. This merging creates a unified waterproof structure where the polymeric material serves both as structural support and as the waterproof barrier, eliminating the need for separate waterproofing components.
Solution Approach 2:
The polymeric material acts as a flexible protective shell that encapsulates the electrical components and flush engine assembly. This thin film-like polymeric layer provides waterproof protection while allowing the components to be installed at lower temperatures before encapsulation, combining component protection with water sealing.
Data Source
AI summary
A plumbing fixture includes an electrical component insert-molded within a portion of the plumbing fixture, the portion formed from an epoxy. The electrical component is offset from and disposed below an outer surface of the plumbing fixture. A method of forming a toilet assembly includes casting a flush engine from vitreous material, installing a functional insert on the flush engine, placing the flush engine in a mold, and inserting a material in the mold to create a cavity with the functional insert.