Claims:WE CLAIM:
1. A faucet (100) comprising:
a first assembly (110) having a first insert (112) and a second insert (114), the first insert (112) having a peg (112A) configured thereon, the second insert (114) having a first slot (114A) configured thereon, the peg (112A) positioning within the first slot (114) through a first fit thereby defining a first flow channel (116);
a second assembly (120) having a third insert (122) and a fourth inset (124), the third insert (122) connecting to the fourth insert (124) through a second fit; and
a fifth insert (130) positioned at a predefined position from the second assembly (120), wherein
the first assembly (110), the second assembly (120) and the fifth insert (130) being overmolded by a molding material (140).

2. The faucet (100) as claimed in claim 1, wherein the first fit and the second fit are press fit or an interference fit or a transitional fit or snap fit or any other mechanical fit.

3. The faucet (100) as claimed in claim 1, wherein the molding material (140) forms closed loop with the inserts (112), (114), (122), (124), (130).

4. The faucet (100) as claimed in claim 1, wherein the first insert (112), the second insert (114), the third insert (122), the fourth insert (124) and the fifth insert (130) are made of materials selected from group of modified polyphenylene ether resins, acrylonitrile butadiene styrene, polybutylene terephthalate, Chlorinated polyvinyl chloride.

5. The faucet (100) as claimed in claim 1, wherein the molding materials (140) are selected from the group of acrylonitrile butadiene styrene or polybutylene terephthalate.

6. The faucet (100) as claimed in claim 1, wherein the coating materials include metals ,metal alloys, PU paint, Epoxy Resin, Polyster.

7. A method for manufacturing a faucet as claimed in claims 1- 4 comprising the steps of:
molding a first insert (112), a second insert (114), a third inset (122), a fourth insert (124) and a fifth insert (130);
forming a first assembly (110) by fitting the first insert (112) with the second insert (114);
forming a second assembly (120) by fitting the third insert (122) with the fourth insert (124);
positioning the first assembly (110), the second assembly (120) and the fifth insert (130) at predefined positions in a mold;
injecting or pouring a molding material (140) in the mold thereby forming overmolded faucet (100); and
coating the overmolded faucet by a coating material thereby forming overmolded plated faucet (100).
Dated this 20th day of May, 2019
For The Supreme Industries Ltd.
By their Agent

GIRISH VIJAYANAND SHETH IN/PA- 1022
KRISHNA & SAURASTRI ASSOCIATES LLP
, Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULE, 2003
COMPLETE SPECIFICATION
[See Section 10, Rule 13]

OVER-MOLDED PLATED FAUCET;

THE SUPREME INDUSTRIES LTD., AN INDIAN COMPANY, HAVING ADDRESS: 4TH FLOOR, “ANTARIKSHA SIGNATURES”, BEHIND NYATI BULILDING, RADHA CHOWK, NEAR RADHA HOTEL 105/1/1/4, BANER, PUNE- 411045, MAHARASHTRA, INDIA

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

TECHNICAL FIELD OF THE INVENTION
The present invention relates to the field of faucets and more particularly to faucets made by over-molding process.
BACKGROUND OF THE INVENTION
Faucet is a device that controls the flow of liquid, out of a pipe. Conventionally, faucets may be made of metal, metal alloys or plastic. Faucets are generally manufactured by casting process where complex flow channel and different kind of shapes can be achieved. Such faucets require surface finishing of the cast body that consume time, money and labour that incurs cost. Further, faucets made by conventional process are heavy in weight.
Plastic plated faucets available in current state of art have limitations in complicated water flow path as well as in shape due to production process. In plastic insert moulded plated faucets, structural plastic inserts are attached with glues or by welding to get leak free water flow. After prolonged use of such faucets at pressure, bonding between surfaces of inserts and over-molded body gets relaxed and create leakage.
Accordingly, there is need of the insert moulded faucets which avoid metal insert and consumes less structural material without degrading its structural strength and eliminate costly and time consuming operation for joining its inserts.

SUMMARY OF THE INVENTION
The present invention provides an overmolded plated faucet that includes a first assembly having a first insert and a second insert. The first insert has a peg configured thereon and the second insert has a slot configured thereon. The peg is positioning within the slot through a first fit thereby defining a first flow channel. A second assembly includes a third insert and a fourth inset. The third insert connecting to the fourth insert through a second fit. A fifth insert is positioned at a predefined position from the second assembly. The first assembly, the second assembly and the fifth insert are overmolded by a molding material. The first fit and the second fit are press fit or an interference fit or a transitional fit or snap fit or any other mechanical fittings. The molding material forms closed loop with the inserts.
In another aspect, the present invention provides a method for manufacturing a faucet. Initially, a first insert, a second insert, a third inset, a fourth insert and a fifth insert are manufactured. In next step, a first assembly is formed by fitting the first insert with the second insert. In the next step, a second assembly is formed by fitting the third insert with the fourth insert. In the next step, the first assembly, the second assembly and the fifth insert are positioned at predefined positions in a mold. In the next step, a molding material is poured or injected in the mold thereby forming an overmold. The product can be used as it is or can be used after doing further aesthetic improving processes like painting, plating or powder coating.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
FIG. 1 shows a faucet in accordance with an embodiment of the present invention;
FIG 2 is a cross sectional view of an over-moulded faucet of FIG. 1;
FIG 3 is an exploded view of the faucet of FIG. 1;
FIG. 4A shows a first assembly of the faucet of FIG. 1; and
FIG. 4B shows a second assembly of the faucet of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION
Although specific terms are used in the following description for sake of clarity, these terms are intended to refer only to particular structure of the invention selected for illustration in the drawings, and are not intended to define or limit the scope of the invention.
References in the specification to “one embodiment” or “an embodiment” mean that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Referring to FIGS. 1 and 2, a faucet (100) in accordance with an embodiment of the present invention is shown. The faucet (100) includes a first assembly (110), a second assembly (120) and a fifth insert (130). The first assembly (110), the second assembly (120) and the fifth insert (130) are positioned in a mould at predefined positions and overmolded with a molding material (140). In an embodiment, the molding material (140) includes over-molding plastic selected from the group of acrylonitrile butadiene styrene or polybutylene terephthalate.
Referring to FIGS. 3 and 4A, the first assembly (110) includes a first insert (112) and a second insert (114). In this one embodiment, the first insert (112) is attached to the second insert (114) by a first fit thereby forming the first assembly (110). In this one embodiment, the first insert (112) has a peg (112A) configured thereon. The second insert (114) has a first slot (114A) configured thereon. The peg (112A) is positioned within the slot (114) through a first fit thereby defining a first flow channel (116). However, it is understood here other type of interference fit or snap fit may be used in alternative embodiment of the present invention. The inserts (112), (114) may be assembled with o-ring in there between to make leak free assembly (110).
In accordance with the present invention, the first assembly (110) defines a fluid flow channel (116) and helps to achieve desired aesthetic formation of faucet(100). The first insert (112) and the second insert (114) have predefined shapes as per the requirement of shape and configuration of the faucet (100). In an embodiment, the first insert (112) and the second insert (114) have cylindrical shapes and circular cross-section. The first insert (112) and the second insert (114) form the first channel (116) after fitting together. However, it is understood here that shape and configuration of the first insert (112) and the second insert (114) may vary in alternative embodiment of the present invention.
Referring to FIGS. 3 and 4B, in accordance with an embodiment, the second assembly (120) includes a third insert (122) and a fourth insert (124). In this one embodiment, the third insert (122) is attached to the fourth insert (124) by a second fit thereby forming the second assembly (120).In this one embodiment, the third insert (122) and the fourth insert (124) are fitted together by interference fit or snap fit. The inserts (122), (124) may be assembled with o-ring in there between to make leak free assembly (120). However, it is understood here that fit may include transitional fit or friction fit or clearance fit.
In accordance with the present invention, the third insert (122) and the fourth insert (124) have predefined shapes as per the requirement of shape and configuration of the faucet. In this one embodiment, the third insert (122) has circular disc shape and the fourth insert (124) have elongated cylindrical shape. The outer diameter of the third insert (122) fits with the inner diameter of the fourth insert (124) such that a second slot (124A) configured on a profile of the fourth insert (124) remains open to form a second flow channel (125). However, it is understood here that shape of the third insert (122) and the fourth insert (124) may vary in alternative embodiment of the present invention.
In accordance with an embodiment, all the inserts (112), (114), (122), (124) and (130) are made of the structural plastic selected from modified polyphenylene ether resins, polybutylene terephthalate (PBT) or Chlorinated polyvinyl chloride (CPVC). The inserts (112), (114), (122), (124) and (130) are manufactured by process of injection molding. It is understood here that material and process of manufacturing of inserts may vary in alternative embodiments of the present invention. The fifth insert (130) has a shape of circular hollow ring having threaded outer surface. The fifth insert (130) provides better strength to faucet (100). The shape of the fifth insert (130) may vary in alternative embodiments of the present invention.
Referring to FIGS. 1-4B, in operation, in a first step, the inserts (112), (114), (122), (124) and (130) are manufactured using a desired material by injection moulding process. In the step the first assembly (110) is formed by the first fit between the first insert (112) and the second insert (114) and the second assembly (120) is formed by the second fit between the third insert (122) and the fourth insert (124). In the next step, the first assembly (110), the second assembly (120) and the fifth insert (130) are placed at predefined positions in the mould. The second assembly (120) is positioned with respect to the first assembly (110) such the first flow channel (116) is aligned with the second flow channel (125) thereby forming a continuous flow channel between the first assembly (110) and the second assembly (120).
In the next step, the molding material (140) is injected in the mould thereby enclosing forming structure of the faucet (100). The second assembly (120) together with overmolded layer of the molding material (140) defines an inlet section of the faucet (100). This portion of the overmold plastic (140) forms a closed loop with the inserts (122), (124). The flow channel between the first assembly (110) and the second assembly (120) gets formed by overmolded material (140) injected on a predefined configuration of the first channel (114B) and the second channel (124A). If there is any kind of leakage between insert surface and overmold layer at high pressure, still fluid remains at inlet portion only.
The first assembly (110) together with the fifth insert (130) and overmolded layer (140) defines an outlet section of the faucet (100). The overmold (140) is formed throughout the first assembly (110), second assembly (120) and the fifth insert (130) and into the gaps among the inserts (112), (114), (122), (124) and (130) to provide greater bonding and enhancing structural strength. The molding material (140) layer is formed through the periphery of faucet (100) and form close loops with inserts(112), (114), (122), (124) and (130) for inlet and outlet portions of faucet(100). Inlet and outlet of the faucet (100) are blocked to restrict hazardous chemical entering into the flow path or in between insert and overmold layer while doing plating. Blocked holes are reopened after plating.
In accordance with the present invention, at the inlet section, the first coating material and fourth insert (124) form a combined waterway. In this portion first coating material forms a closed loop with the fourth insert (124). If there is any kind of leakage between insert surface and the molding material at high pressure, still fluid remains at inlet portion only. In the last step, the faucet (100) structured with the molding material (140) is plated with a coating material. The coating material includes metal or metal alloys or PU paint, Epoxy Resin, Polyster and the like to achieve premium appearance of the faucet (100).
In accordance with the present invention, over-molding is advantageous as these are corrosion free, economical, structurally strong and aesthetically rich because of their metallic appearance. The inlet and outlet molded inserts are blocked to avoid entering of hazardous chemical into the flow path while doing plating. Further, blocked holes are reopened by machining or drilling after applying the second coating material. Faucets are injection molded which eliminates operation like deburring, fettling, polishing of products. In the faucets (100) disclosed in the present invention, use of metal inserts is completely eliminated.
The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the present invention.