DE102022104380A1 - Method for producing a fitting housing for a sanitary fitting and sanitary fitting with a fitting housing - Google Patents

Abstract

Method for producing a fitting housing (1) for a sanitary fitting (2), at least having the following steps: a) providing at least one functional component (3.1, ... 3.5) for the sanitary fitting (2); andb) producing the fitting housing (1) by at least partially encapsulating the at least one functional component (3.1, ... 3.5) by means of thermoplastic foam injection molding. A sanitary fitting (2) with a fitting housing (1) is also proposed.

Description

The present invention relates to a method for producing a fitting housing for a sanitary fitting and a sanitary fitting with a fitting housing. With such sanitary fittings, in particular, a liquid can be dispensed as required at a washbasin, shower and/or bathtub.

Sanitary fittings can be used in particular for mixing cold water and hot water to form a mixed water with a desired mixed water temperature and for dosing the mixed mixed water. In known sanitary fittings, the mixed water is routed from a mixing cartridge via fluid channels in a fitting housing of the sanitary fitting to an outlet opening of an outlet of the fitting housing. Since the water is in contact with the housing of the fitting, the housing of the fitting must be made of a material that is suitable for drinking water and not susceptible to corrosion, such as brass. In order to be able to use less expensive materials, such as zinc alloys, for fitting housings, sanitary fittings are already known in which the fluid channels in the fitting housing are designed as functional components in the manner of plastic inserts. The plastic inserts prevent the mixed water from coming into contact with the fitting housing. In addition, it is known to produce fitting housings from plastic. However, these often do not have sufficient strength.

The object of the invention is therefore to at least partially solve the problems described with reference to the prior art and in particular to specify a method for producing a fitting housing for a sanitary fitting, by means of which fitting housings can be produced with a high level of strength. In addition, a sanitary fitting is also to be specified, the fitting housing of which is characterized by high strength.

These objects are solved with a sanitary fitting according to the features of the independent patent claims. Further advantageous refinements of the invention are specified in the dependent patent claims. It should be pointed out that the features listed individually in the dependent patent claims can be combined with one another in any technologically meaningful manner and define further refinements of the invention. In addition, the features specified in the patent claims are specified and explained in more detail in the description, with further preferred configurations of the invention being presented.

1. a) Bereitstellen zumindest einer Funktionskomponente für die Sanitärarmatur; und
2. b) Erzeugen des Armaturengehäuses durch zumindest teilweises Umgießen der zumindest einen Funktionskomponente mittels Thermoplast-Schaumspritzgießen.

A method for producing a fitting housing for a sanitary fitting, which has at least the following steps, contributes to this:

1. a) providing at least one functional component for the sanitary fitting; and
2. b) producing the fitting housing by at least partially encapsulating the at least one functional component by means of thermoplastic foam injection molding.

The sanitary fitting is used in particular for mixing cold water and hot water to form mixed water with a desired mixed water temperature and/or for dosing the mixed mixed water. Such sanitary fittings are regularly used for sinks, washbasins, showers and/or bathtubs. A fitting housing for the sanitary fitting can have an outlet having an outlet opening. The fitting housing can be fastened to a support, for example a worktop, the sink, the washbasin, the shower or the bathtub. The (protruding or branching) outlet can be rigidly or movably connected to the fitting housing and/or at least partially tubular. The faucet housing may have a decorative exterior surface. The outlet can have an outlet opening through which a liquid, in particular (mixed) water, can be dispensed.

In a step a), at least one functional component for the sanitary fitting is provided. A plurality of functional components can also be provided which are at least partially connected to one another and/or at least partially attached to one another. The at least one functional component is provided in particular in a cavity of an injection mold. In particular, the cavity forms a negative of an outer contour of the fitting housing. The at least one functional component can in particular be a component for guiding the liquid in the fitting housing, for controlling a property of the liquid and/or for mixing the liquid. The functional component can consist at least partially of plastic or metal. Furthermore, the functional component can be designed at least partially in the manner of a plastic injection molded part.

In a step b), the fitting housing is produced by at least partially or completely encapsulating the at least one functional component by means of thermoplastic foam injection molding (TSG). Thermoplastic foam injection molding is a special form of plastic injection molding in which a thermoplastic Plastic foams in the cavity of the injection mold. For this purpose, a blowing agent is added to a plastic granulate, which is activated when the plastic melts in the injection mold and/or in an injection molding machine. When the plastic melts, the blowing agent is in particular thermally decomposed and dissolved into gaseous components, causing the melt to foam.

By encapsulating the at least one functional component, the at least one functional component can be at least partially embedded in the fitting housing or in the material of the fitting housing. This can mean, for example, that an inner surface of the fitting housing (directly) surrounds the at least one functional component and/or (completely) follows an outer surface of the at least one functional component. Alternatively or cumulatively, this can mean in particular that the at least one functional component cannot be moved and/or (without destroying the at least one functional component and/or the fitting housing) cannot be detached from the fitting housing.

A (substantially) smooth inner surface and/or outer surface or outer shell of the fitting housing can be produced by the encapsulation. A foam structure can be produced between the inner surface and the outer surface or the outer shell. In particular, the foam structure has a large number of pores. For example, the foam structure may have 10 to 1000 pores/cm ³ [pores per cubic centimeter] and/or a density that is, for example, 20% to 80% lower than the plastic used in thermoplastic foam injection molding.

Compared to conventional plastic injection molding or overmolding with metal, such as zinc, thermoplastic foam injection molding can prevent damage to and/or destruction of the at least one functional component due to the lower pressures and/or temperatures of the melt in the injection mold.

The faucet housing can be produced entirely from plastic and/or in one piece or in one piece, as a result of which dividing lines on an outer surface of the faucet housing can be avoided.

Compared to classic plastic injection molding, thermoplastic foam injection molding allows the valve housing to be manufactured with greater wall thicknesses and/or greater differences in wall thickness, which increases its strength.

The at least one functional component can be at least one liquid supply line, at least one liquid guide, a mixing valve, a valve, a mixing cartridge, a cartridge adapter, at least one seal, at least one fixing element, at least one jet former, a shaft, at least one electronic component and/or or at least act an electric line.

In particular, the cold water and/or hot water can be supplied to the mixing valve or the mixing cartridge by means of the at least one liquid supply line. For this purpose, the at least one liquid supply line can be designed, for example, in the manner of a (flexible) hose or a (rigid) tube.

The cartridge holder or the cartridge adapter is used in particular for receiving and/or fastening the mixing valve or the mixing cartridge. The cartridge holder or the cartridge adapter is at least partially tubular, so that the mixing valve or the mixing cartridge can be arranged at least partly in the cartridge holder or the cartridge adapter.

In particular, cold water with a cold water temperature and hot water with a hot water temperature can be mixed to form mixed water with a desired mixed water temperature by means of the mixing valve or the mixing cartridge. The cold water temperature is in particular a maximum of 25° C. (Celsius), preferably 1° C. to 25° C., particularly preferably 5° C. to 20° C. and/or the hot water temperature is in particular a maximum of 90° C., preferably 25° C. to 90° C. more preferably 55°C to 65°C. The mixing valve or the mixing cartridge can be actuated in particular by means of an actuating lever of the sanitary fitting. For example, the mixed water temperature and/or a discharge quantity of the mixed water can be adjusted by means of the actuating lever. The mixing valve or the mixing cartridge can be designed, for example, in the manner of a single-lever mixer.

The mixed water can be fed in particular to the outlet opening of the fitting housing or at least to a jet generator through the at least one liquid guide, which can be designed, for example, in the manner of a (flexible) hose or a (rigid) pipe. The mixed water can be dispensed in particular in a predetermined or specifiable jet type by means of the jet former. The dispensing of the liquid can be controllable in particular with the mixing valve, the mixing cartridge or the valve.

In particular, a connection between two functional components can be sealed by the at least one seal, so that no liquid can escape into the fitting housing. In particular, two functional components can be connected to one another by the at least one fixing element. The at least one fixing element can be secured against loosening in particular by overmoulding the at least one functional component. The shaft can be at least partially tubular. Furthermore, the shank can be used in particular to fasten the sanitary fitting to the carrier. For this purpose, the shank can extend at least partially out of the fitting housing, so that the portion of the shank protruding from the fitting housing can be plugged into a fastening opening of the carrier. A fastening element, for example in the manner of a fastening nut, can be fastened to a longitudinal end of the shank, by means of which the sanitary fitting can be fastened to the carrier. The at least one electronic component can be designed, for example, in the manner of a controller, a microcontroller, at least one sensor or at least one display.

In step b), the fitting housing can be produced at least partially from acrylonitrile-butadiene-styrene copolymers (ABS).

In step b), an outer contour of the fitting housing can be generated. This can mean, for example, that in step b) a final contour of the fitting housing is produced and/or the fitting housing is not overmoulded with a further layer and/or a further plastic in or after step b).

In step b), the fitting housing can be produced with a wall thickness of 1 mm [millimeter] to 50 mm. The wall thickness can in particular be measured (orthogonally to the outer surface of the fitting housing) from the outer surface of the fitting housing to the inner surface of the fitting housing.

In step b), the fitting housing can be produced in such a way that no cavity is created between the at least one functional component and the fitting housing.

In step a), a plurality of functional components can be provided, wherein in step b) at least one liquid connection between the functional components is sealed by means of thermostatic load foam injection molding. The at least one liquid connection allows the liquid, the cold water, the hot water and/or the mixed water to be routed, for example, from a first functional component to a second functional component. The at least one liquid connection can be designed, for example, in the manner of a connection point and/or plug-in connection. The at least one liquid connection can be surrounded directly and/or completely by the fitting housing, so that no liquid can escape from the at least one liquid connection into the fitting housing.

In a step c), the fitting housing can be electroplated. During electroplating, a metal, in particular, can be electrochemically deposited on the outer surface of the fitting housing. For example, a chromium layer can be deposited on the outer surface. The chromium layer can have a layer thickness of 0.1 μm [microns] to 5.0 μm, for example.

• - zumindest eine Funktionskomponente; und
• - ein Armaturengehäuse, das zumindest teilweise um die zumindest eine Funktionskomponente gegossen ist und zumindest teilweise eine Schaumstruktur aufweist.

According to a further aspect, a sanitary fitting is also proposed which has at least the following:

• - at least one functional component; and
• - A fitting housing which is at least partially cast around the at least one functional component and at least partially has a foam structure.

The sanitary fitting is produced in particular using the method according to the invention. For further details on the sanitary fitting, reference is made in full to the description of the method.

• 1: Funktionskomponenten für eine Sanitärarmatur in einem Längsschnitt;
• 2: die Sanitärarmatur in einem Längsschnitt; und
• 3: eine Schaumstruktur eines Armaturengehäuses der Sanitärarmatur in einem Längsschnitt.

The invention and the technical environment are explained in more detail below with reference to the figures. It should be pointed out that the figures show a particularly preferred embodiment variant of the invention, but this is not limited to this. The same components in the figures are provided with the same reference numbers. They show schematically:

• 1 : Functional components for a sanitary fitting in a longitudinal section;
• 2 : the sanitary fitting in a longitudinal section; and
• 3 : a foam structure of a fitting housing of the sanitary fitting in a longitudinal section.

The 1 shows functional components 3.1, ..., 3.5 for one in the 2 Sanitary fitting 2 shown. A first functional component 3.1 is a mixing cartridge to which cold water and hot water can be supplied separately via second functional components 3.2 in the form of liquid supply lines. The liquid supply lines run through a third functional component 3.3 net in the form of a shaft, the mixing cartridge and other components for in the 2 Sanitary fitting 2 shown is based or on which the mixing cartridge and the other components for the sanitary fitting 2 are arranged. The shaft is tubular. The cold water and warm water can be mixed proportionately to mixed water with a desired mixed water temperature by means of the mixing cartridge. The mixing cartridge is fluidly connected via a fourth functional component 3.4 in the form of a tubular liquid duct to a fifth functional component 3.5 in the form of a jet generator, so that the mixed water after the production of the 2 Sanitary fitting 2 shown can be released via the jet former. The functional components 3.1, ..., 3.5 are used to produce one in the 2 shown fitting housing 1 of the sanitary fitting 2 in a step a) provided in a cavity of an injection mold, not shown here, which is a negative of a in the 2 shown outer contour 4 of the fitting housing 1 forms.

The 2 shows the functional components 3.1, ..., 3.5 after they have been encapsulated in a step b) to produce the fitting housing 1 of the sanitary fitting 2 by means of thermoplastic foam injection molding. Subsequently, in a step c), the outer contour 4 or an outer surface 6 of the fitting housing 1 was galvanized or chrome-plated. In step d), an actuating lever 7 was connected to the first functional component 3.1 or the mixing cartridge, via which a user of the sanitary fitting 2 can control a mixed water temperature of the mixed water and a dispensing quantity of the mixed water via the fifth functional component 3.5 or the jet former.

The 3 shows the in the 2 with a rectangle 8 marked area of the fitting housing 1. It can be seen in FIG 3 that the fitting housing 1 has a foam structure 5 in a core 9 as a result of thermoplastic foam injection molding, which has a compact first cover layer 11 in the area of the outer surface 6 of the fitting housing 1 and a compact second cover layer 12 in the area of an inner surface 10 of the fitting housing 1. The inner surface 10 is immediately adjacent to the 1 and 2 functional components shown 3.1, ..., 3.5. The foam structure 5 has a large number of pores 13, so that the foam structure 5 has a lower density in comparison to the compact cover layers 11, 12.

With the present invention, the fitting housing of the sanitary fitting can be manufactured with high strength.

Reference List

1

dashboard

2

sanitary fitting

3.1, ..., 3.5

functional component

4

outer contour

5

foam structure

6

outer surface

7

operating lever

8th

rectangle

9

core

10

Inner surface

11

first top layer

12

second top layer

13

pore

Claims (9)

Method for producing a fitting housing (1) for a sanitary fitting (2), at least having the following steps: a) providing at least one functional component (3.1, ... 3.5) for the sanitary fitting (2); and b) producing the fitting housing (1) by at least partially encapsulating the at least one functional component (3.1, ... 3.5) by means of thermoplastic foam injection molding. procedure after patent claim 1 , wherein the at least one functional component (3.1, ... 3.5) is at least one liquid supply line, at least one liquid guide, a mixing valve, a valve, a mixing cartridge, a cartridge adapter, at least one seal, at least one fixing element, at least one jet former, a shaft, at least one electronic component and/or at least one electrical line. Method according to one of the preceding claims, wherein in step b) the fitting housing (1) is produced at least partially from acrylonitrile-butadiene-styrene copolymers (ABS). Method according to one of the preceding claims, wherein an outer contour (4) of the fitting housing (1) is produced in step b). Method according to one of the preceding claims, wherein in step b) the fitting housing (1) is produced with a wall thickness of 1 mm to 50 mm. Method according to one of the preceding claims, wherein in step b) the fitting housing (1) is produced in such a way that no cavity is formed between the at least one functional component (3.1, ... 3.5) and the fitting housing (1). Method according to one of the preceding claims, wherein in step a) a plurality of functional components (3.1, ... 3.5) is provided and wherein in step b) at least one liquid connection between the functional components (3.1, ... 3.5) by means of the thermoplastic Foam injection molding is sealed. Method according to one of the preceding claims, wherein in step c) the fitting housing (1) is electroplated. Sanitary fitting (2), at least having: - At least one functional component (3.1, ... 3.5); and - A fitting housing (1) which is at least partially cast around the at least one functional component (3.1, ... 3.5) and at least partially has a foam structure (5).

Images