Living-Hinge Drain Coupling for Easier Faucet Installation
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Solution Overview
Problem
Conventional lavatory faucet drain assemblies require installers to connect components from below the sink deck in cramped and dimly lit areas, making it difficult to attach and adjust the lever arm to the lift rod.
Innovation Solution
A drain assembly with a lift rod and lever arm actuated by a coupling device featuring a living hinge, a collet with a concave tapering surface, and a retainer with a conical portion, allowing for secure attachment and easy actuation of the drain plug without the need for reaching high under the sink deck.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lever arm is attached to the lift rod from below the sink deck using conventional methods, then the drain assembly can be assembled, but the installation process becomes difficult and time-consuming due to cramped and dimly lit work areas
Solution Approach 1:
The coupling device is designed to be actuated from above the sink deck rather than from below. The lever arm extends upward through the sink deck and can be manually actuated by the installer standing at the accessible side, reversing the conventional approach where components must be manipulated from beneath the deck.
Solution Approach 2:
The coupling device serves as an intermediary mechanism that transmits force from the lever arm (actuated from above) to the drain plug (operating below). This mediator allows the installer to work from the accessible upper position while still controlling components that operate in the cramped lower space.
2Productivity
If the installer reaches up high under the sink deck with a wrench to attach the lever arm, then the components can be connected, but installer comfort and efficiency deteriorate
Solution Approach 1:
The actuation direction is inverted so that the installer works from the comfortable upper position rather than reaching upward into the confined space below the sink deck. The lever arm is positioned to be manipulated from above, reversing the awkward conventional approach.
3Ease of repair
If a conventional coupling mechanism is used to attach the lever arm to the lift rod, then the components can be connected, but the adjustment process becomes difficult in cramped spaces
Solution Approach 1:
The coupling device is segmented into distinct functional portions: a first coupling portion that attaches to the lift rod, a second coupling portion that attaches to the lever arm, and a living hinge that connects them. This segmentation allows each portion to be optimized for its specific function and facilitates easier assembly and adjustment from the accessible upper position.
Solution Approach 2:
The living hinge provides dynamic flexibility to the coupling device, allowing it to pivot and adjust during installation and operation. This dynamic characteristic enables the installer to manipulate the lever arm through a range of motions from above, making adjustment easier compared to rigid conventional couplings that require precise alignment in cramped spaces.
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
Facilitates easier installation and adjustment of the drain assembly by allowing actuation of the lever arm and drain plug from a more accessible position, improving installer comfort and efficiency.
Implementation Method 1
a living hinge coupling the first coupling portion to the second coupling portion. The living hinge facilitates actuation of the lever arm and the drain plug upon actuation of the lift rod.
Implementation Method 2
The collet includes a concave tapering surface and a first threaded surface. A retainer includes a conical portion receiving the lift rod and including a convex tapering surface, the retainer further includes a second threaded surface. The second threaded surface is engagable with the first threaded surface of the collet to cause the convex tapering surface to engage the concave tapering surface of the collet to urge the conical portion to engage the lift rod.
Data Source
AI summary
A drain assembly for a faucet includes a lift rod configured to be carried by the faucet and actuated relative to the faucet. A lever arm is configured to actuate a drain plug. A coupling device includes a first coupling portion coupled to the lift rod, a second coupling portion coupled to the lever arm, and a living hinge coupling the first coupling portion to the second coupling portion. The living hinge facilitates actuation of the lever arm and the drain plug upon actuation of the lift rod.