Methods for forming faucets and fixtures

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.

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.