Insulator Base for Electronic Faucet with Polymer Overmold
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Solution Overview
Problem
Electronic faucets with capacitive sensing features, often made of metal, face issues with water exposure affecting the performance of light emitters and associated circuitry when mounted on conductive surfaces like stainless steel sinks, requiring effective insulation to prevent electrical interference and damage.
Innovation Solution
An insulator base with a polymer overmold housing that secures a light assembly and electrical wire within a channel, forming a lens for light transmission while providing a sealing member to protect against water exposure, ensuring the electronic components remain insulated from the conductive sink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a metal or conductive material is used for the faucet body to enable capacitive sensing, then the sensing functionality is improved, but the faucet becomes vulnerable to water exposure and electrical interference
Solution Approach 1:
The patent introduces an insulator base as an intermediary component between the conductive faucet body and the mounting deck. This insulator base serves as a mediator that provides electrical insulation while still allowing the faucet to be mounted on conductive surfaces, thereby protecting the capacitive sensing components from water exposure and electrical interference while maintaining sensing functionality
Solution Approach 2:
The patent extracts the electrical insulation function from the faucet body itself and places it in a separate insulator base component. This allows the faucet body to remain fully conductive for capacitive sensing while the insulation function is isolated in a separate element that protects the electronic components from water and electrical interference
2Ease of operation
If the light assembly is exposed to provide visual indication, then the user feedback is improved, but the light emitter and circuitry are vulnerable to water damage
Solution Approach 1:
The patent nests the light assembly within the insulator base housing, creating a protected internal chamber. The light emitter is positioned inside the housing with an aperture that allows light to escape for visual indication, while the housing walls protect the light emitter and circuitry from water exposure. This nesting arrangement enables both user feedback visibility and protection from harmful environmental factors
Solution Approach 2:
The patent uses the housing of the insulator base as a protective shell that encloses the light assembly. This shell structure provides physical and environmental protection while still allowing the light to pass through the aperture for visual indication, effectively separating the light emitter from water exposure while maintaining usability
3Reliability
If the insulator base provides electrical insulation, then the protection from electrical interference is improved, but the structural complexity increases
Solution Approach 1:
The patent merges multiple functions into the insulator base housing: it provides electrical insulation, structural support for the faucet assembly, protection for the light emitter, and mounting interface with the mounting deck. By combining these functions into a single integrated component, the patent reduces overall device complexity while maintaining reliable electrical insulation and protection from water exposure
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 solution effectively protects the light emitter and circuitry from water exposure, ensuring reliable operation of capacitive sensing electronic faucets by maintaining electrical insulation and preventing damage from moisture, thus enhancing the durability and functionality of the faucet.
Implementation Method 1
A polymer overmold is coupled to the housing and secures the light assembly within the receiving chamber and the electrical wire within the channel
Implementation Method 2
The overmold defines a lens within the aperture of the outer sidewall, the lens permitting the transmission of light from the light emitter therethrough
Implementation Method 3
an electrically non-conductive mounting assembly may be used to insulate the metal capacitive sensing components of the faucet from the metal sink
Implementation Method 4
The polymer overmold further defines a downwardly extending sealing member for sealing with a mounting deck
Data Source
AI summary
An insulator base for an electronic faucet includes a housing supporting a light assembly and a connecting wire electrically coupled to the light assembly. A polymer overmold is coupled to the housing and secures the light assembly and the connecting wire within the housing.