Shower Head Plastic Injection Molded Cover Reduces Copper Cost
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Solution Overview
Problem
Conventional shower heads face challenges in maintaining precision of through openings and high manufacturing costs due to copper usage, affecting the smoothness and uniformity of water flow.
Innovation Solution
A shower head design incorporating a shell, positioning base, water spraying heads, a plastic piece formed by injection molding, and a metal cover with a recessed receiving space, where the plastic piece corrects manufacturing errors and reduces copper usage by filling the receiving space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If through openings are made by mechanical processing and electroplating, then the shower head can be manufactured, but the precision of the through openings is difficult to control and manufacturing costs remain high
Solution Approach 1:
The patent replaces the traditional metal cover with through openings made by mechanical processing with an injection-molded plastic piece containing through holes. This substitution uses a cheaper, easier to manufacture material and process, while maintaining the functional requirement of water flow control. The plastic piece achieves sufficient precision through injection molding without the costly and imprecise mechanical drilling and electroplating processes.
2Reliability
If the entire metal cover is made by copper, then the shower head has good appearance and durability, but the manufacturing costs remain high
Solution Approach 1:
The patent changes the material parameter of the cover from entirely copper to a combination of plastic and copper. The plastic piece forms the main body with through holes, while copper is used only for the decorative outer layer and reinforcing ribs. This parameter change maintains the aesthetic and durable properties of copper where needed while dramatically reducing overall material cost.
Solution Approach 2:
The patent creates a composite structure combining plastic and copper materials. The plastic piece provides the structural base and water flow channels, while the copper layer provides appearance and localized durability. This composite approach allows each material to be used where it provides the most value, reducing overall manufacturing cost while maintaining product quality.
3Ease of operation
If through openings are made by mechanical processing, then the shower head can be assembled, but the spraying heads and through openings cannot be maintained at identical central position affecting water flow smoothness
Solution Approach 1:
The patent performs the positioning action during the injection molding process itself. The plastic piece is molded with through holes that are precisely positioned relative to the spray heads from the start. This preliminary action ensures correct alignment before assembly, eliminating the need for costly post-assembly adjustments and ensuring smooth water flow from the beginning.
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 design ensures consistent precision and smoother water flow while reducing costs by using injection molding and minimizing copper usage, making the shower head more competitive in the market.
Implementation Method 1
The plastic piece (40) is formed by injection molding and a through hole (41) is formed at center thereof
Data Source
AI summary
A shower head includes a shell, a positioning base, a plurality of water spraying heads, a plastic piece, a metal cover and a handle set. The positioning base has a flat board and a hanging base having an elongated hole at center thereof, and a plurality of hanging slots are circularly disposed at the periphery of the flat board. The water spraying head engages with several hanging slots so as to evenly circularly dispose at the flat board. The plastic piece is formed by injection molding and a through hole is formed at center thereof. The metal cover is made by copper, surface of which has a plurality of cover through holes. The handle set has a control unit, and a connecting rod eccentrically protrudes out from one end of the control unit, and the other end is provided for a nut to lock and engage with a movable handle.