METHODS FOR FORMING FAUCETS AND FIXTURES

• US 20120186768A1
• Filed: 06/25/2010
• Published: 07/26/2012
• Est. Priority Date: 06/26/2009
• Status: Abandoned Application

• Current Assignee: Donald Sun, Mark William Vilimek
• Original Assignee: Donald Sun, Mark William Vilimek
• Inventors: Sun, Donald, Vilimek, Mark William
• Application Number:
  US13/379,634
• Publication Number:
  US 20120186768A1
• Time in Patent Office: Days
• US Class Current: 164/23
• CPC Class Codes: B22C 7/02 Lost patterns
• CPC Class Codes: B22C 9/04 Use of lost patterns
• CPC Class Codes: B22C 9/10 Cores; Manufacture or installation of cores breaker cores B22C9/084
• CPC Class Codes: B22C 9/22 Moulds for peculiarly-shaped castings
• CPC Class Codes: B22D 25/02 by its peculiarity of shape; of works of art cylinders, pistons B22D15/02
• CPC Class Codes: B22D 29/002 by leaching, washing or dissolving

Abstract

This invention provides methods for forming stainless steel, single-piece, multi-chambered water faucets and fixtures with a single one-body construction. A variety of stainless steel products can be formed with a main body having an internal hollow region and a plurality of dividing chambers. The main body may be constructed using high temperature resistant ceramic cores in combination with a lost wax investment casting process. The stainless steel products formed from a single piece construction can eliminate the need for additional time-consuming manufacturing steps, such as parts welding, screw assembly, or precision press fitting. In addition, water faucets and fixtures can be provided that are substantially lead-free, non-verdigris, and non-toxic in compliance with environmental regulations and lead/toxic limits.

Claims

1. A method of manufacturing a single-piece faucet body comprising:

forming a pattern material around one or more hollow cores,

forming a shell around the pattern material, wherein the shell and hollow core are joined at one or more locations,

removing the pattern material from the shell and hollow core, wherein the remaining shell and hollow core form an investment, and

casting the faucet body within the investment, wherein the faucet body comprises one or more internal chambers thereby forming at least a cold water inlet, a hot water inlet, and a warm water outlet.

2. The method of claim 1, wherein the pattern is formed around a plurality of hollow cores.

3. The method of claim 1, wherein the pattern material is wax or foam.

4. The method of claim 1, wherein the faucet body comprises stainless steel having a lead content of less than about 0.25%.

5. The method of claim 1, wherein the faucet body comprises one or more under-cut chambers.

6. The method of claim 1, wherein the hollow core is formed using ceramic injection molding.

7. The method of claim 1, wherein the shell is a ceramic material.