Metal Faucet Casing Structure for Lower-Cost Durable Assembly
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Solution Overview
Problem
Faucet devices with resin casing members have high manufacturing costs, low durability, and maintenance issues due to material limitations, and metal casing options face challenges like lead elution and processing difficulties, necessitating a cost-effective and durable solution.
Innovation Solution
A faucet device with a metallic casing member formed from a plate or pipe, allowing for adjustable size and shape, integrated with a single lever cartridge and mechanical engagement means for enhanced strength and design flexibility, reducing manufacturing costs and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin casing member is used, then the manufacturing cost increases due to mold preparation, but the material processing is easier
Solution Approach 1:
The patent replaces expensive, complex metal casting molds with simpler resin injection molds that can be prepared more easily and at lower cost, accepting the trade-off of using resin material that may have shorter service life but sufficient durability for the application
Solution Approach 2:
The patent changes the material parameter from metal to resin, which fundamentally alters the manufacturing approach from casting to injection molding, enabling easier mold preparation and reduced manufacturing complexity while maintaining adequate strength through proper resin selection and design
2Adaptability or versatility
If a resin casing member is used, then the manufacturing cost increases, but the design freedom improves
Solution Approach 1:
The patent changes the material parameter from metal to resin, enabling complex geometries and design variations that would be difficult or expensive to achieve through metal casting, thereby improving design freedom while managing manufacturing costs through the simplicity of injection molding
Solution Approach 2:
The resin casing member is designed to serve multiple functions: structural housing, aesthetic appearance, and integration of mounting features, allowing a single component to fulfill diverse requirements and reduce the need for additional parts
3Device complexity
If a resin casing member is used, then the durability decreases due to material limitations, but the manufacturing cost increases
Solution Approach 1:
The patent employs composite construction by combining the resin casing member with metal components (such as metal fittings, connectors, or reinforcement elements) to achieve the durability and strength characteristics of metal while retaining the manufacturing advantages of resin, creating a hybrid structure that balances both requirements
4Reliability
If metal casing is used to improve durability, then the strength increases, but the manufacturing cost increases due to material price fluctuation
Solution Approach 1:
The patent uses composite construction combining resin and metal components, where the metal is strategically applied only in areas requiring high strength and durability, while the resin handles non-critical structural and aesthetic functions, thereby reducing overall metal consumption and cost while maintaining necessary durability
Solution Approach 2:
The patent applies different materials to different regions of the casing based on local requirements: metal is used in areas subject to high stress, wear, or corrosion, while resin is used in areas requiring complex geometry, aesthetic finish, or cost reduction, optimizing both performance and cost
5Reliability
If copper alloy is used for the casing member, then the durability improves, but the lead elution control becomes necessary
Solution Approach 1:
The patent replaces copper alloy with resin material, eliminating the lead elution problem entirely by using a material that does not contain lead or does not elute it under normal operating conditions, accepting the trade-off of managing resin durability through proper material selection and design
Solution Approach 2:
The patent turns the limitation of resin material (perceived lower durability) into an advantage by selecting high-performance resin materials with excellent corrosion resistance and longevity, while simultaneously eliminating the harmful lead elution issue associated with copper alloys, making the overall solution more beneficial
6Reliability
If stainless steel is used for the casing member, then the corrosion resistance improves, but the processing accuracy becomes difficult to achieve
Solution Approach 1:
The patent replaces stainless steel with resin material, eliminating the processing accuracy difficulties associated with metal machining while maintaining adequate strength and corrosion resistance through proper resin selection and design, accepting the trade-off of using a different material class with different processing characteristics
Data Source
AI summary
A faucet device includes: a base member; an outer shell member; a metallic casing member that is inserted in a columnar section of the outer shell member and whose one end is fixed to the base member; a hot-water supply pipe and a cold-water supply pipe that supply hot water and cold water, respectively; a single lever cartridge provided at the other end of the casing member; connecting members provided inside the casing member, connecting the hot-water supply pipe and the cold-water supply pipe to the single lever cartridge; a fixing member fixing the single lever cartridge to the connecting members; and mechanical engagement pins. The casing member is formed of a metallic plate or pipe with a size that allows the casing member to be insertable into the columnar section of the outer shell member, and capable of retaining the connecting member in accordance with the mechanical engagement means.