A METHOD OF MANUFACTURING SANITARY ARMATURE MEMBERS

Abstract: In a method of manufacturing different types of water and sanitary fitting elements, such as taps and mixers, there is used a plurality of functional parts (1-19) that have parts which come into contact with water in use, and one or more casing parts (20-22) which are at least partially visible. The water-contacted functional parts are formed in a module system that comprises a limited number of elements, e.g. 10-15 in number, and are made of a material that will not deliver harmful substances to the water. The casing parts are made of another material and are given an inner shape or form which is adapted to the outer shape or form of the functional parts so said casing parts will surround said functional parts, either completely or partially, in an exchangeable manner. The functional parts may be made of a plastic material, e.g. a thermoplastic material, while the casing parts may be made of any chosen material. The invention also relates to a module system built-up of functional parts and casing of the aforesaid kind.

Description: A METHOD OF MANUFACTURING SANITARY ARMATURE MEMBERS FIELD OF INVENTION The present invention relates to the manufacture of fittings or fixtures, and more particularly to a method of manufacturing different types of water and sanitary fittings or components, such as taps and mixers, each of which includes a number of functional parts of which one or more have portions that are in contact with water in use, and one or more casing parts which are at least partially visible. The invention also relates to different types of functional parts affiliated with such sanitary fittings, and to casing parts associated therewith. DESCRIPTION OF THE BACKGROUND ART The functional parts of different types of water taps and mixers that are in contact with water have hitherto been given a design which is adapted primarily to the type of fitting with which said functional part shall be used. Consequently, the area in which such functional parts can be used is limited. This means, among other things, that in the case of new constructions of the casing part of a sanitary fitting it is also necessary to redesign the functional parts included in said fitting and to impart to said functional parts a form or configuration that will fit the casing part concerned. Normally, it is not possible to use one and the same functional part in different types of fittings fixtures. Functional parts that have been produced from metal will normally often deliver a hazardous quantity of metal ions to the water flowing through said parts, resulting in serious health and environmental problems - particularly in respect of drinking water. This problem is not as serious in the case of plastic functional parts, e.g. thermal plastic parts. Examples of functional parts produced from thermoplastic material will be found in WO- Al 97/17501, DE-A1 2 613 965, SE-B 401 552 and DE-A1 2 614 063. None of these documents states that the functional parts illustrated and described therein can be used in different types of sanitary fittings or fixtures. OBJECTS OF THE INVENTION According to one aspect, an object of the invention is to provide a method relating to the manufacture of fittings of the aforedescribed kind that will enable the manufacture of functional parts that fit will different types of sanitary fittings in a simple and inexpensive manner, and with which parts the aforementioned health and environmental hazards are avoided. Another object is to provide such a method with which resultant functional parts can be combined in different ways to produce different types of mixer. Another object is to provide a method of manufacturing sanitary fittings which enables the casing parts, i.e. the outside of the fittings to be varied in respect of design, material and surface treatment in accordance with developments in technology and fashion changes without needing to change/switch the functional parts. A further object is to provide a method of manufacturing sanitary fittings which greatly reduces lead times and costs in respect of model changes. SUMMARY OF THE INVENTION These and other objects are fulfilled by an inventive method of the aforedescribed kind having features set forth in the characterising clause of Claim 1. Because the water-contacted functional parts form a module system that is constructed from a limited number of elements, said parts can be combined in different ways to produce different types of mixers. The fittings can be said to be built-up in accordance with a type of lego-system, which includes a limited number of elements, for example from 10- 15 elements. Thus, a series of mixers and taps of different kinds can be produced from a limited number of standardised module elements. At the same time, the casing parts, i.e. the outside of respective fittings, can be varied with respect to shape, material and surface treatment without needing to change the functional parts. One significant advantage afforded by the invention is that the load on the environment is greatly reduced. The module elements shall thus be produced from environmentally friendly material which is accepted by current laws and product rules and regulations. The fittings become lighter and the surface treatment of casing parts that was earlier necessary can be omitted completely when using certain materials. According to one method preferred in practice, the functional parts are made from a plastic material, for instance from a thermoplastic material. This greatly reduces the risk of the release of harmful quantities of metal or other toxic substances, since no metal will come into contact with the water and since only material that is accepted with regard to foodstuffs is used. In addition, it is preferred that the modularised functional parts are provided with given interfaces or boundary surfaces and that they can be typically core drawn in conjunction with injection moulding processes. The module elements, i.e. the functional parts, can thus be produced from thermoplastic material with the aid of traditional injection moulding machines and injection moulding methods. Alternatively, the module elements can be produced from some other material and with the aid of some other method of manufacture without departing from the concept of the invention. The casing part may be produced from any one of a number of different materials, such as from stainless steel, zinc, plastic, brass, etc. In one beneficial method of manufacture, the functional parts are provided with abutments or engaging parts which will enable a relevant number of functional parts to be readily mounted in a casing part. Further advantages are gained when the casing part or parts is/are designed to hold the functional parts in place in their mounted position in said casing part or parts. To this end, one or more casing parts and functional parts may be provided with co-acting devices, e.g. projections or wedges, that interact with grooves for fixing the functional parts in position in a casing part. The casing part will therewith ensure that the functional parts remain in their respective mounted positions. Alternatively, a nut, a bayonet fitting or some other connection means may be used to this end. In another aspect of the invention, the invention also relates to a functional part of a sanitary fitting of the kind in question, said functional part having the features set forth in the accompanying Claim 7. According to a further aspect, the invention also relates to a casing part of a sanitary fitting that has been given the features set forth in Claim 9. Different aspects of the invention will now be made apparent in the following description of exemplifying embodiments described with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figs, la- Ik are - in certain cases - partially cut-away side views of a number of functional elements which are built-up to form a module system and which can be used in a method of manufacture according to the invention. Fig. 2 is an exploded perspective view of a functional part in the form of a lever provided with a single-grip mixer insert, said figure also showing two alternative insert carrying parts. Fig. 3 is a partially cut-away side view of a washbasin mixer that has a few functional parts mounted in a casing part, in accordance with the invention. Fig. 4 is a partially cut-away view, corresponding to the side view in Fig. 1, of a sink mixer which includes certain functional parts that are similar to those of the Fig. 3 embodiment, together with other different functional parts. Fig. 5 is a partially cut-away side view of a thermostat mixer that includes a number of functional elements mounted in the casing part, and also hot water and cold water connecting elements. Fig. 6 is a side view of an alternative thermostat mixer which has hot water and cold water connecting elements projecting out from the casing part. Fig. 7 is an exploded view of all elements included in a washbasin mixer, said elements also including functional parts and a casing part designed in accordance with the invention. DESCRIPTION OF PREFERRED EMBODIMENTS Figs, la- Ik illustrate a number of different modularised functional parts for different types of single-lever mixers. For instance, Fig. la illustrates a single-lever-regulating element 1 for washbasin mixers or sink mixers, while Fig. lb illustrates a corresponding functional element 1' for a shower or bathtub mixer. Fig. lc illustrates two flanged hot water and cold water connecting pipes 3, intended for the two functional parts mentioned above, for instance. Fig. Id illustrates an outlet pipe or spout 4 having a connecting portion 4a provided with an internal screw thread 4b, intended, for instance, for a washbasin mixer according to Fig. la or Fig. lb. Figs, le and If illustrate respectively a pair of angled connecting pipes 5 and 5' for a thermostat mixer or a single-grip lever, both of said functional parts having a connecting portion provided with an external screw thread 5 a. Fig. lg illustrates a corresponding connecting pipe 5" that includes a connecting portion 5"a and an inner screw thread 5"b. Fig. lh illustrates a changeover device or switch 8 for a bathtub mixer, used in connection with a shower or a bath. Figs, li, lj and Ik illustrate a few examples of separate connecting pipes and branch pipes 9, 9' and 9", the connecting portions of which may be provided with a sealing O-ring (not shown). Fig. 2 illustrates an insert 12 equipped with a manoeuvring lever 12b, and two alternative accommodating parts 13 and 13', a blind plug 13a and flanged connecting pipes 3 for a single-grip mixer. The illustrated functional parts constitute module elements that may be included in mixer fittings of many different kinds and in varying forms. Fig. 3 is a partially cut-away view of a washbasin mixer that includes a lever-equipped insert 12, a short accommodating part 13 according to Fig. 2, and an outlet spout 4 in accordance with Fig. Id. The mixer also includes a jet concentrator at the forward end of the spout 4. The functional parts are held in place by an outer casing 20 which surrounds the functional parts included in a module system, either completely or partially. Fig. 4 is a partially cut-away view of a sink mixer equipped with a standard outlet pipe 15 and two supply pipes 3' whose design differs to that of the supply pipes shown in Fig. la and Fig. 2. The module unit formed by the lever-equipped insert 12 and the accommodating part 13 is the same as that shown in Fig. 3, although said unit takes a different position in relation to the casing 21, whose design is different to that of the casing in the last-mentioned figure. The mixer may also include a connection part (not shown) that is pressed in from one side. In the case of this embodiment, the casing has a holding function obtained by the parts 21a and the bottom part 21b, which is pushed in from beneath and which fixes the position of the functional parts together with said parts 21a. Fig. 5 is a partially cut-away view of a thermostatic mixer that includes functional parts that come into contact with water, such as angled connecting elements 5, 5' and a changeover device or switch 8 for switching between shower and tub, in accordance with the earlier figures. In addition, there is included, among other things, a pressure-balanced thermostat insert 26 and shut-off element 27 that includes a valve member and valve seat in accordance with normal standards in this field. C.f. elements 9' and 9" in Figs, lj and Ik respectively. The connecting elements 5, 5' are located within the surrounding casing 22, which also contributes towards fixing the relevant functional parts in position. Reference numerals 30 and 31 indicate typical knobs for adjusting temperature and water flow rate. Fig. 6 illustrates a modified embodiment of the thermostat mixer shown in Fig. 5, where the ends 5a, 5'a of the connecting parts 5, 5' lie outside the casing 22'. In the case of this embodiment, the mixer can be mounted tightly adjacent a wall, in a bathroom, for instance. Fig. 7 is an exploded view of a washbasin mixer with the components of a traditional insert arranged in an accommodating part 13 provided with an outlet spout 4 according to Fig. lc (not shown). The components or elements included in the insert are in the following order as seen from top to bottom: handle part 12, cap 15, nut 16 with washer 16a, temperature limiting part 17, flow limiting part 18, and ceramic shut-off and regulating part 19. The insert is thus located in the illustrated insert accommodating part 13, which constitutes a functional part in the inventive module system. Thus, as opposed to known mixers, the mixer casing 20 does not conduct water and can therefore be made of a material, such as metal, which can satisfy aesthetic requirements primarily, without danger of harmful metal ions being delivered to the drinking water. On the other hand, those functional parts of the module system that come into contact with water are produced from a material which is not harmful in the aforesaid respect, e.g. from a thermoplastic material. Certain functional parts may also be made of certain metals that do not emit harmful ions. Consequently, it will be understood that the illustrated embodiments merely comprise a number of examples of fitting components produced in accordance with the invention, where functional parts belong to a module system comprised of a limited number of elements, while the casing parts may have a design which varies in accordance with fashion swings and produced from material different to that used for the water-contacting functional parts. These persons skilled in this art will realise that a module system comprised of functional parts in accordance with the invention may be produced in different ways and with differently designed units than those described above and illustrated in the accompanying drawings.

Claims: CLAIMS 1. A method of manufacturing different types of water and sanitary fittings, for instance taps and mixers, each including a number of functional parts (e.g. 1-19), of which one or more have parts that come into contact with water in use, and one or more casing parts (20- 22), which are at least partially visible, characterised in that water-contacted functional parts are constructed as belonging to a module system that comprises a limited number of elements, e.g. 10-15 in number; in that said water-contacted functional parts are comprised of a material which will not deliver harmful quantities of metal or other toxic substances to the water; and in that the casing parts are produced from a different material and given an internal design which is so adapted with respect to the outer form of the modularised functional parts as to replaceably surround said components either completely or partially. 2. A method according to Claim 1, wherein the functional parts are made of a plastic material, e.g. a thermoplastic. 3. A method according to Claim 2, wherein the modularised functional parts are given an interface or boundary surface and can be produced by traditional core drawing in injection moulding processes. 4. A method according to any one of Claims 1-3, characterised in that the functional parts (1-19) are provided with abutments or engagement parts that are so adapted in respect of adjacent functional parts as to enable a relevant number of functional parts to be readily mounted in a casing part (20-22). 5. A method according Claim A, characterised in that one or more casing parts is/are designed to hold the functional parts in their mounted positions in said casing part or casing parts. 6. A method according to Claim 5, characterised in that one or more of the casing parts and functional parts are provided with co-acting elements, e.g. projections or ridges that interact with co-acting grooves for fixing functional parts in position in a casing part. 7. A functional part of a sanitary fitting, such as a tap or mixer, which is in contact with water in use and which is adapted for accommodation in a casing part (20-22) of said fitting, characterised in that a) said functional component is comprised of a module system that comprises a limited number of elements, e.g. 10-15 in number, wherein said module elements can form in different combinations functional parts for different types of fittings; b) in that the functional component is made of a material that will not deliver harmful quantities of metal or other toxic substances to the water; and c) in that said functional component is adapted for mounting in different types of casing parts in a readily exchangeable fashion. 8. A functional part according to Claim 1, characterised in that said functional part is made of a thermoplastic material. 9. A casing part for a sanitary fitting, characterised a) in that said casing part is adapted to accommodate one or more module-forming functional parts (1-19) of the kind defined in Claim 7 or Claim 8; b) in that said casing part is made of a material different to that of the functional parts; and c) in that said casing part includes elements, e.g. grooves or projections, for co-action with corresponding elements, e.g. projections or grooves, or one or more of said functional parts such as to fix said component or components in its/their operative position in said casing part.

Inventors: ERICSSON STEFAN, ERICSSON, STEFAN
Applicants: ERICSSON STEFAN, MATTSSON AB F M, ERICSSON, STEFAN, FM MATTSSON AB
Application year: 2001
Main classification: F16K11
IPC codes: E03C1, F16K11, F16K27