Fluid dispensing apparatus and method of manufacture

The present invention provides a fluid dispensing apparatus and a method of manufacturing a fluid dispensing apparatus.

FIELD

The present invention relates generally to a fluid dispensing apparatus and a method of manufacturing a fluid dispensing apparatus.

BACKGROUND

Fluid dispensing apparatuses, such as faucets and soap dispensers, are well known. Such fluid dispensing apparatuses are used in residential and commercial applications, such as in kitchens, bathrooms, and various other locations.

Fluid dispensing apparatuses are manufactured using many different techniques. One of these techniques is casting. The manufacture of fluid dispensing apparatuses using casting poses many difficulties.

SUMMARY

The present invention provides a fluid dispensing apparatus. In an exemplary embodiment, the fluid dispensing apparatus comprises a core and a shell. The core is formed from a metal alloy. The core metal alloy has a melting point. The core has an inner surface and an outer surface. The core has an inlet and an outlet. The core has a passageway extending from the inlet to the outlet. The shell is formed from a metal alloy. The shell metal alloy has a melting point. The shell is cast around the outer surface of the core. The melting point of the core metal alloy is approximately the same as the melting point of the shell metal alloy.

In another exemplary embodiment, the fluid dispensing apparatus comprises a core and a shell. The core is formed from a metal alloy. The core metal alloy has a ductility. The core includes a unitary bent tube. The core has an inner surface and an outer surface. The core has an inlet and an outlet. The core has a passageway extending from the inlet to the outlet. The shell is formed from a metal alloy. The shell is cast around the outer surface of the core. The ductility of the core metal alloy enables the tube to be bent.

The present invention provides a method of manufacturing a fluid dispensing apparatus. In an exemplary embodiment, the method comprises the steps of forming a core and casting a shell. The core is formed from a metal alloy. The core metal alloy has a melting point. The core has an inner surface and an outer surface. The core has an inlet and an outlet. The core has a passageway extending from the inlet to the outlet. The shell is cast around the outer surface of the core. The shell is formed from a metal alloy. The shell metal alloy has a melting point. The melting point of the core metal alloy is approximately the same as the melting point of the shell metal alloy.

In another exemplary embodiment, the method comprises the steps of forming a core and casting a shell. The core is formed from a metal alloy. The core metal alloy has a ductility. The core is formed by bending a unitary tube. The core has an inner surface and an outer surface. The core has an inlet and an outlet. The core has a passageway extending from the inlet to the outlet. The shell is cast around the outer surface of the core. The shell is formed from a metal alloy. The ductility of the core metal alloy enables the tube to be bent.

DETAILED DESCRIPTION

The present invention provides a fluid dispensing apparatus and a method of manufacturing a fluid dispensing apparatus. In an exemplary embodiment, the fluid dispensing apparatus is a faucet. However, one of ordinary skill in the art will appreciate that the fluid dispensing apparatus could be a showerhead, a handheld shower, a body spray, a side spray, or any other plumbing fixture fitting. In another exemplary embodiment, the fluid dispensing apparatus is a soap dispenser.

Throughout the detailed description and the drawings, each similar component of the fluid dispensing apparatus will be referred to using the same reference number with the suffix “-X” indicating a generic embodiment of the component of the fluid dispensing apparatus and the suffix “-#” indicating a specific embodiment of the component of the fluid dispensing apparatus.

Exemplary embodiments of a fluid dispensing apparatus10-X are illustrated inFIGS. 1a-1e, 2a-2e, 3a-3e, 4a-4d, and 5a-5b. In the exemplary embodiments, the fluid dispensing apparatus10-X includes a core12-X and a shell14-X.

The core12-X is formed from a metal alloy. The core12-X has an inner surface16-X and an outer surface18-X. The core12-X has an inlet20-X and an outlet22-X. The core12-X has a passageway24-X extending from the inlet20-X to the outlet22-X.

The shell14-X is formed from a metal alloy. The shell14-X is cast around the outer surface18-X of the core12-X. In exemplary embodiments, the shell14-X is cast using pressure die casting or low pressure permanent mold casting. The shell14-X has an inner surface26-X and an outer surface28-X.

In an exemplary embodiment, the fluid dispensing apparatus10-X includes a liner30-X. The liner30-X is operable to prevent fluid flowing through the passageway24-X of the core12-X from contacting the inner surface16-X of the core12-X. In an exemplary embodiment, the liner30-X is formed from a flexible material. In an exemplary embodiment, the liner is formed from a non-metal. In an exemplary embodiment, the liner30-X is operable to be inserted in the passageway24-X of the core12-X. In an exemplary embodiment, the liner30-X is operable to be applied to the inner surface16-X of the core12-X.

The core metal alloy has a melting point, and the shell metal alloy has a melting point. In an exemplary embodiment, the melting point of the core metal alloy is approximately the same as the melting point of the shell metal alloy.

Although the core metal alloy and the shell metal alloy have been described as having a melting point, one of ordinary skill in the art will appreciate that the melting point is not a discrete temperature, but includes a range of temperatures between a solidus and a liquidus. The solidus is the temperature below which a substance is completely solid. The liquidus is the temperature above which a substance is completely liquid. The melting range of temperatures between the solidus and the liquidus are the temperatures at which a substance is a mixture of solid and liquid. A melting point of one metal alloy is approximately the same as the melting point of another metal alloy if the melting range of the one metal alloy overlaps the melting range of the other metal alloy.

In an exemplary embodiment, the solidus of the core12-X is within fifty degrees Fahrenheit (50° F.) of the solidus of the shell14-X.

In an exemplary embodiment, the solidus of the core12-X is within one hundred degrees Fahrenheit (100° F.) of the liquidus of the shell14-X.

In an exemplary embodiment, the core12-X includes one or more core components32-X. Each core component32-X is cast. In exemplary embodiments, each core component32-X is cast using pressure die casting or low pressure permanent mold casting.

In an exemplary embodiment, the core12-X includes a unitary core component32-X. In an exemplary embodiment, the core12-X includes a plurality of core components32-X. The plurality of core components32-X are operable to be joined together to form the core12-X. The plurality of core components32-X are joined together using any known technique such that the shell14-X does not penetrate the passageway24-X of the core12-X when the shell14-X is cast around the core12-X.

In an exemplary embodiment, the core12-X is formed from a first core half34-X and a second core half36-X. In an exemplary embodiment, the first core half34-X and the second core half36-X are mirror images of each other. In an exemplary embodiment, the first core half34-X and the second core half36-X are not mirror images of each other.

In an exemplary embodiment, such as shown inFIG. 6, the first core half34-X includes a groove38-X (such as groove38-6in first core half34-6), and the second core half36-X includes a tongue40-X (such as tongue40-6in second core half36-6). The groove38-X of the first core half34-X is operable to receive the tongue40-X of the second core half36-X to join together the first core half34-X and the second core half36-X.

In an exemplary embodiment, the core components32-X are formed from a zinc alloy or an aluminum alloy, and the shell14-X is formed from a zinc alloy or an aluminum alloy. Exemplary zinc alloys include Zamak 2, Zamak 3, Zamak 5, Zamak 7, ZA-8, ZA-12, ZA-27, and ACuZinc. Exemplary aluminum alloys include 242, 319, 360, 362, 380, A380, B380, 384, 390, 413, and 712.

In an exemplary embodiment, the core12-X includes a bent tube42-X. In an exemplary embodiment, the core12-X is formed by bending a unitary straight tube. The core metal alloy has a ductility. In an exemplary embodiment, the ductility of the core metal alloy enables the tube42-X to be bent. In an exemplary embodiment, the tube42-X is hydroformed after it is bent.

In an exemplary embodiment, the core12-X has a thickness L, and the shell14-X has a thickness L. In an exemplary embodiment, around a substantial portion of the outer surface18-X of the core12-X, the thickness tsof the shell14-X is less than the thickness tcof the core12-X. In an exemplary embodiment, around a substantial portion of the outer surface18-X of the core12-X, the thickness tsof the shell14-X is approximately the same as the thickness tcof the core12-X. In an exemplary embodiment, a substantial portion means at least twenty percent (20%). In an exemplary embodiment, a substantial portion means at least thirty percent (30%). In an exemplary embodiment, a substantial portion means at least fifty percent (50%).

In an exemplary embodiment, the core12-X has a microstructure, and the shell14-X has a microstructure. In an exemplary embodiment, the microstructure of the shell14-X is finer grained than the microstructure of the core12-X.

In an exemplary embodiment, the shell14-X has the outer surface28-X. In an exemplary embodiment, the outer surface28-X of the shell14-X is substantially free from voids. Voids include porosity and planar defects, such as cracks and cold shuts. Substantially free from voids means that the outer surface28-X is capable of being plated and passing industry standard plating quality tests. In an exemplary embodiment, such as shown inFIG. 7, the core14-7includes voids44-7, while the outer surface28-7of the shell12-7is free from voids.

In an exemplary embodiment, the tool (e.g., die or mold) in which the shell14-X is formed is maintained at a temperature above room temperature, but the cast core12-X is not preheated to the tool temperature before being placed in the tool. As a result, the temperature of the tool and the temperature of the metal alloy from which the shell14-X is to be formed are increased above the temperatures that are suitable if the tool is empty (i.e., if there is no cast core12-X in the tool). In an exemplary embodiment in which the core12-X and the shell14-X are formed from a zinc alloy, the temperature of the tool is increased by approximately forty degrees Fahrenheit (40° F.), and the temperature of the zinc alloy from which the shell14-X is to be formed is increased by approximately ten degrees Fahrenheit (10° F.).

In a first exemplary embodiment shown inFIGS. 1a-1e, the faucet10-1includes a core12-1and a shell14-1.

The core12-1is formed from a metal alloy, such as a zinc alloy. The core12-1has an inner surface16-1and an outer surface18-1. The core12-1has an inlet20-1and an outlet22-1. The core12-1has a passageway24-1extending from the inlet20-1to the outlet22-1.

The shell14-1is formed from a metal alloy, such as a zinc alloy. The shell14-1is cast around the outer surface18-1of the core12-1. The shell14-1has an inner surface26-1and an outer surface28-1.

The core12-1includes two core components32-1—a first core half34-1and a second core half36-1. Each core component32-1is cast. The first core half34-1and the second core half36-1are mirror images of each other. The first core half34-1and the second core half36-1are operable to be joined together to form the core12-1. The first core half34-1and the second core half36-1are joined together using any known technique such that the shell14-1does not penetrate the passageway24-1of the core12-1when the shell14-1is cast around the core12-1.

In a second exemplary embodiment shown inFIGS. 2a-2e, the soap dispenser10-2includes a core12-2and a shell14-2.

The core12-2is formed from a metal alloy, such as a zinc alloy. The core12-2has an inner surface16-2and an outer surface18-2. The core12-2has an inlet20-2and an outlet22-2. The core12-2has a passageway24-2extending from the inlet20-2to the outlet22-2.

The shell14-2is formed from a metal alloy, such as a zinc alloy. The shell14-2is cast around the outer surface18-2of the core12-2. The shell14-2has an inner surface26-2and an outer surface28-2.

The core12-2includes two core components32-2—a first core half34-2and a second core half36-2. Each core component32-2is cast. The first core half34-1and the second core half36-1are mirror images of each other. The first core half34-2and the second core half36-2are operable to be joined together to form the core12-2. The first core half34-2and the second core half36-2are joined together using any known technique such that the shell14-2does not penetrate the passageway24-2of the core12-2when the shell14-2is cast around the core12-2.

In a third exemplary embodiment shown inFIGS. 3a-3e, the faucet10-3includes a core12-3and a shell14-3.

The core12-3is formed from a metal alloy, such as a zinc alloy. The core12-3has an inner surface16-3and an outer surface18-3. The core12-3has an inlet20-3and an outlet22-3. The core12-3has a passageway24-3extending from the inlet20-3to the outlet22-3.

The shell14-3is formed from a metal alloy, such as a zinc alloy. The shell14-3is cast around the outer surface18-3of the core12-3. The shell14-3has an inner surface26-3and an outer surface28-3.

The core12-3includes two core components32-3. Each core component32-3is cast. The first core half34-1and the second core half36-1are not mirror images of each other. The two core components32-3are operable to be joined together to form the core12-3. The two core components32-3are joined together using any known technique such that the shell14-3does not penetrate the passageway24-3of the core12-3when the shell14-3is cast around the core12-3.

In a fourth exemplary embodiment shown inFIGS. 4a-4d, the faucet10-4includes a core12-4and a shell14-4.

The core12-4is formed from a metal alloy, such as a copper alloy. The core12-4has an inner surface16-4and an outer surface18-4. The core12-4has an inlet20-4and an outlet22-4. The core12-4has a passageway24-4extending from the inlet20-4to the outlet22-4.

The shell14-4is formed from a metal alloy, such as a zinc alloy. The shell14-4is cast around the outer surface18-4of the core12-4. The shell14-4has an inner surface26-4and an outer surface28-4.

The core12-4includes a unitary bent tube42-4. The core12-4is formed by bending a unitary straight tube. The core metal alloy has a ductility. In an exemplary embodiment, the ductility of the core metal alloy enables the tube42-4to be bent.

In a fifth exemplary embodiment shown inFIGS. 5a-5b, the soap dispenser10-5includes a core12-5, a shell14-5, and a liner30-5.

The core12-5is formed from a metal alloy. The core12-5has an inner surface16-5and an outer surface18-5. The core12-5has an inlet20-5and an outlet22-5. The core12-5has a passageway24-5extending from the inlet20-5to the outlet22-5.

The shell14-5is formed from a metal alloy. The shell14-5is cast around the outer surface18-5of the core12-5. The shell14-5has an inner surface26-5and an outer surface28-5.

The liner30-5is operable to prevent fluid flowing through the passageway24-5from contacting the inner surface16-5of the core12-5. The liner30-X is formed from a flexible material. In an exemplary embodiment, the liner is formed from a non-metal. The liner30-5is operable to be inserted in the passageway24-5of the core12-5.

In the illustrated embodiments, the core12-X includes structure that extends outside of the shell14-X before finishing of the fluid dispensing apparatus10-X. This structure is used to place and retain the core12-X in the tool and is removed during finishing of the fluid dispensing apparatus10-X.

One of ordinary skill in the art will now appreciate that the present invention provides a fluid dispensing apparatus and a method of manufacturing a fluid dispensing apparatus. Although the present invention has been shown and described with reference to particular embodiments, equivalent alterations and modifications will occur to those skilled in the art upon reading and understanding this specification. The present invention includes all such equivalent alterations and modifications and is limited only by the scope of the following claims in light of their full scope of equivalents.