Toilet Sump Drain Casting for Precise Jet Orifice Placement
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Solution Overview
Problem
Plumbing fixtures with solid cast sumps face limitations in shape, location, and orientation of the jet orifice due to manual punching, leading to inconsistent hole sizes and reduced flushing efficiency.
Innovation Solution
A drain casting process is used to form the sump, allowing for various shapes and smoother surfaces, eliminating the need for manual punching and improving the consistency of the sump and jet orifice placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual punching is used to create holes in solid cast sumps, then the sump can be formed with basic shape, but the location and orientation of the jet orifice are limited and inconsistent
Solution Approach 1:
The jet orifice location and orientation are predetermined during the molding process rather than being created afterward through manual punching. The mold cavity is designed with the exact jet orifice position and orientation required, eliminating variability introduced by manual operations.
Solution Approach 2:
The manual punching operation is replaced with a molding process that forms the jet orifice directly during sump fabrication. This substitution eliminates the need for secondary machining operations and ensures consistent geometry and positioning.
2Ease of manufacture
If solid cast process is used to manufacture the sump, then the manufacturing process is simple, but the sump has rectangular shape with few smooth continuous curved surfaces
Solution Approach 1:
The mold cavity is designed with curved surfaces that form smooth continuous contours in the sump. This allows the sump to have complex curved geometries while still using a straightforward casting process, eliminating the need for post-casting machining to achieve smooth surfaces.
3Manufacturing precision
If manual punching is used to create connection holes, then the process can be performed with simple equipment, but material yield occurs and hole shape and location are inconsistent
Solution Approach 1:
The connection holes are formed during the initial molding process rather than being punched afterward. The mold cavity includes provisions for creating holes with precise shape and location, eliminating material removal and associated yield.
4Ease of manufacture
If sufficient room is provided in the sump for punching device insertion, then holes can be punched properly, but the sump shape is constrained to rectangular forms
Solution Approach 1:
The punching operation is completely replaced with a molding process that forms the sump and all necessary openings in a single operation. This eliminates the need for insertion space for punching devices and allows any shape to be formed within the mold cavity.
Data Source
AI summary
A sump for a toilet includes a first end of the sump, defined by a first boundary, and a second end of the sump, defined by a second boundary. The sump includes a channel running from the first end of the sump to the second end of the sump defined by a sump surface. The first end of the sump is configured to receive liquid and the second end of the sump is configured to supply liquid. The sump has a sump can-cut diameter corresponding to a diameter of the channel at the first end of the sump, a sump side radius extending from a center of the channel to an inner surface of the channel, and a sump depth corresponding to a largest vertical distance within the channel. The sump may be drain cast using a single continuous pathway.