Patent Application
20100125946
1. Field of the Invention
The invention is related to faucets including pull out sprayers for spraying a wide area at angles, particularly with respect to such pull-out spraying faucets that are used for kitchen sink use.
2. Description of Related Art
It is known in the art to use diverter valves and mechanisms to switch a faucet sprayer from regular, aerated water flow to a spray-head spray. Such diverters come in various configurations including a pull-down diverter mechanism, wherein the user pulls downward on the diverter mechanism at the end of a faucet to create a spray or “shower” effect.
Kitchen faucets typically have a direct aerated water flow. Water enters kitchen faucets through a copper inlet tube or flexible hose, which generally has a metallic connector linking into the body of the faucet for delivering water flow to the portion of the faucet body having the faucet outlet. In some cases, the water outlet hose from the hot and cold mixer is split below the body and base plate of the faucet to provide a divided and separate hose and direction of flow, generally including a diverter mechanism to allow a side stream of water to enter a hand-held sprayer mechanism separate and apart from the faucet body. Many such hand-held sprayers are located on one side of the faucet assembly with a separate opening in the sink base outside of the faucet base plate. When the handle of the hand-held sprayer is actuated, it operates a diverter mechanism that diverts flow from the portion of the hose directing water to the faucet body to the hand-held sprayer portion and away from the direct faucet stream.
More recently, an improvement was developed to avoid use of significant additional parts below the surface of the sink or use of a divided and separate hose section, by making the faucet body itself capable of performing the spray function as well by virtue of a multi-part combination spray-head and faucet assembly, wherein a sprayer handle portion of the faucet is detachable from the body of the faucet. This allows for a hand-held sprayer portion to detach from the faucet body and be separated therefrom by a flexible hose that runs through the faucet body and attaches at the faucet-facing end of the hand-held sprayer portion. The hose is typically connected via a reinforced metallic coupling nut/threaded connection to the rear (or faucet-body facing end) of the detachable hand held sprayer. Thus, when the hand-held sprayer portion is pulled outwardly from the faucet, the hose pulls up through and out of the faucet body with the sprayer, and water then flows through the faucet body within the extended hose and coupling nut connection into the hand-held sprayer and outwardly through a reinforced interior of the hand-held sprayer to a diverter mechanism, if any. Use of such diverters for switching from a shower spray to a direct aerated spray are generally operated by push button mechanisms located on the top portion of the hand-held sprayer, by a diverter switch or diverter handle.
Such faucets, while useful over prior art faucets having wholly separate spray functions, so as to become multifunctional and compact regarding the space required for use, still typically require many working parts, and have reasonably high manufacturing costs for forming a reinforced hand-held sprayer portion as well as for preparing various required metallic connectors and internal pieces. In addition, many of the push-button and switch mechanisms for existing hand-held sprayers fail over time and/or do not work smoothly. In many cases, they are positioned, such that while the user is holding the nozzle head, it is easy to put pressure inadvertently on the diverter actuator and shut off the shower sprayer while in use.
Accordingly, there is a need in the art for improved combination faucet assemblies that provide diverse features using less space, particularly for kitchen faucets, while providing a compact, detachable configuration and hand-held sprayer, and easy actuation of the shower spray to aeration diverter function, but which are also inexpensive to manufacture and are also durable and reliable.
The invention includes a faucet comprising, a faucet body having a first opening configured for connection with a faucet base, a second opening, and a faucet body portion having an opening therein, wherein the faucet body has an inner wall defining a passage extending therethrough; a mechanism to control liquid flow through the faucet body; and a spray handle having a first end section and a sprayer end section, wherein the first end section is configured to be detachably connected to the faucet body portion, an inner wall defining a passage extending therethrough in open communication with the passage extending through the faucet body, and a hose connection is positioned within the spray end section of the spray handle, the hose connection being configured for receiving a hose extending through the spray handle. In one embodiment, the faucet described herein is a kitchen faucet.
In a further embodiment, the faucet herein further includes a spray handle having a pull-down diverter in liquid communication with the hose connection in the spray end section of the spray handle, the diverter being capable of providing a first spray mode and a second spray mode.
The invention further includes a faucet comprising: a faucet body having a first open end configured for connection with a faucet base, a second open end, and a faucet body portion having an opening therein, wherein the faucet body has an inner wall defining a passage extending therethrough; a mechanism to control liquid flow; and a spray handle having a first end section and a sprayer end section, wherein the first end section is configured to be detachably connected to the faucet body portion, an inner wall defining a passage extending therethrough in open communication with the passage extending through the faucet body, a hose connection configured for receiving a hose for delivering liquid to the spray handle, and a pull-down diverter in liquid communication with the hose connection, wherein the pull-down diverter is in the spray end section of the spray handle, the diverter being capable of providing a first spray mode and a second spray mode.
A faucet is also within the invention that comprises: a faucet body having a first open end configured for connection with a faucet base, a second open end, and a side faucet body portion having a side opening therein, wherein the faucet body has an inner wall defining a passage extending therethrough; a mechanism to control liquid flow through the faucet body; and a spray handle having a first end section and a sprayer end section, wherein the first end section is configured to be detachably connected to the side faucet body portion, an inner wall defining a passage extending therethrough in open communication with the passage extending through the faucet body, a hose connection within the spray end section of the spray handle, wherein the hose connection is configured for receiving a hose extending through the spray handle; and a pull-down diverter in liquid communication with the hose connection, wherein the pull-down diverter is in the spray end section of the spray handle, the diverter being capable of providing a first spray mode and a second spray mode.
The invention further includes a faucet assembly comprising: a faucet having a faucet body comprising a first open end connected to a faucet base, a second open end having a faucet handle movably connected thereto, the faucet handle being capable of controlling the flow of liquid through the faucet, wherein the faucet body further has a faucet body portion with an opening therein and an inner wall defining a passage extending therethrough; a spray handle having a first end section and a sprayer end section, wherein the first end section is configured to be detachably connected to the faucet body portion, an inner wall defining a passage extending therethrough in open communication with the passage extending through the faucet body, a hose connection within the spray end section of the spray handle, wherein the hose connection is configured for receiving a hose extending through the spray handle; a faucet connector having a first portion configured to be engage the inner wall of the first end section of the spray handle and a second portion configured to be within first end section of the spray handle which is configured to be positioned within the faucet body through the opening in the faucet body portion, a pull-down diverter in liquid communication with the hose connection, wherein the pull-down diverter is in the spray end section of the spray handle, the diverter being capable of providing a first spray mode and a second spray mode; and a flexible hose capable of containing a liquid to be delivered through the faucet, wherein the hose extends from a connection end in communication with a liquid source, through the passage in the faucet body and the side opening therein, through the faucet connector, through the passage in the spray handle to the hose connection.
A method of delivering a liquid through a faucet is also within the invention as described herein and comprises: introducing the liquid from a liquid source into a first end of a hose, wherein the hose is situated within: a passage defined by an inner wall of a faucet body and extending through the faucet body, a passage defined by an inner wall of a spray handle and extending through the spray handle, wherein the spray handle has a first end section and a sprayer end section, wherein the first end section is configured to be detachably connected to a faucet body portion of the faucet body, and wherein the passage in the spray handle is in open liquid communication with the passage through the faucet body, and a hose connection within the spray end section of the spray handle, wherein the hose connection is configured for receiving a hose extending through passage in the spray handle; passing the liquid through the hose and out a second end of the hose, then through the hose connection; and passing the liquid through an outlet in the spray end section of the spray handle.
In one embodiment herein, the step of passing the liquid through the outlet in the spray end section of the spray handle further comprises passing the liquid through a pull-down diverter positioned in the spray end section of the spray handle, wherein the liquid exits the diverter as a first spray or a second spray.
The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments that are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
The invention herein is described with reference to an exemplary preferred embodiment, which is not intended to be limiting. As used herein, the words “right” and “left,” “inner” and “outer,” “up” and “down,” and words of similar import are used for convenience only in describing the invention with reference to directions in the drawings, and are also not intended to be limiting. Described herein are embodiments of a faucet, faucet assembly and method for delivering a liquid through a faucet. In one embodiment, a faucet assembly, generally referred to herein as assembly 10 is shown in perspective view in
The faucet 12 in the embodiment shown has a faucet body 14 which is of a branched configuration. Faucets according to the invention have at least two open ends for receiving a faucet base and/or handle and preferably also have a third opening in a portion of the faucet for receiving a spray handle. The arrangement of the openings can be as shown in the Figures herein or reversed so that the handle is on the bottom and other fixtures like a cap or base is on the top and/or side of the faucet. Further the handle may be located on the side, the base on the bottom and the sprayer on the top. The arrangement shown is a preferred embodiment, however, it should not be taken to be a limiting configuration. The faucet body may be a standard shaped faucet body of a generally tubular, generally cylindrical or branched generally cylindrical configuration as shown, but may have other shapes and cross-sectional configurations as well for decorative or aesthetic changes, such as a generally square, generally rectangular, generally elliptical, outwardly curved spherical or generally triangular cross-sectional shape. Further, the faucet body may be elongated so as to stretch in the longitudinal, upright direction or may be wider than taller so as to extend more broadly in the transverse, horizontal direction.
The faucet body may be formed of metallic material, such as a stainless steel or other metal, having a chrome or other polished finish or may be molded of a polymeric material having a lighter weight. Composite or laminated materials with chromium or other colored or decorative outer layers or coloring may be used as well. Any suitable faucet body material known or to be developed may be used provided that it is preferred that the faucet body have sufficient structural integrity to sustain repeat use, manual operation and secure the integrity of the inner parts of the faucet and resist pressure from the flow of water should an internal piece of hose connection fail.
As shown in the embodiment of
As shown in
The faucet body 14 may have any suitable handle located preferably at the top end thereof. Many such types of handles are shown and it should be understood that the location of the handle as shown on the upper end of the faucet body, instead of on a lower opening or side end, is illustrated herein for convenience only and to demonstrate a preferred embodiment. As with the faucet body, the handle may be of varied sizes, shapes and configurations, and made be made of a variety of materials, including chrome, polymers, composites, stainless steel, laminated materials and the like. Various aesthetic features or decorative features may also be added to such a handle without departing from the spirit and scope of this invention. Regardless of whether a handle is used, while preferred for controlling liquid flow, the faucet should have some liquid flow control mechanism. If a handle is not positioned within one of the faucet body openings, the opening may be in communication with another actuator or flow control mechanism, such as a push button, push/pull device, squeeze mechanism or the like. In addition, if a handle is used as a flow control actuating mechanism, it is within the scope of the invention also to include other flow controlling mechanisms, valves, on-off mechanisms and the like, provided there is some mechanism as are known in the art or to be developed, which allows for control of liquid flow through the faucet.
As shown in
The mixing mechanism may be any suitable liquid mixing mechanism known in the art or to be developed for similar uses. Preferably it includes several parts including a cartridge 38 having cartridge adjustment screws for adjustably securing the cartridge at least partially within the faucet body 14 and beneath the cap retainer 40 and cap 42. The mixing mechanism also includes a spacer 36 and a manifold assembly 34. The cartridge has openings in the bottom portion thereof to allow for inflow of two liquid streams, such as hot and cold water from hot and cold water sources as well as a flow opening for mixed liquids coming out of the mixing mechanism. The openings preferably include elastomeric or other sealing components. Liquids, such as hot and cold water from hot and cold water sources, can thus flow upward through hot and cold water conduits 128, 130, respectively, through openings in the manifold assembly 34 and into the spacer 36 through corresponding openings and then into the cartridge 38. The mixing mechanism may also include other components as are known or to be developed in the art, such as flow regulating devices (for example check valves to prevent backflow), and can also be fitted with a vacuum breaker if desired.
Mixed temperature water then flows through conduit 132, preferably downwardly, and the outlet conduit is then connected to a flexible hose for allowing water flow to be communicated to the sprayer handle such as through flexible hose 122 as shown in
Such handles and mixing mechanisms are well known in the art, and any suitable handle and mixing mechanism may be used that currently is developed or may be developed in the future, provided it does not otherwise interfere with the novel features described herein. It is also within the scope of the invention to locate the mixing mechanism outside of the faucet body, for example, beneath the base 20 so as to minimize the amount of hardware used within the faucet body.
The base 20 of the faucet assembly may also be a standard faucet base 20 so that any suitable faucet base may be used including those now in use or to be developed as the nature of the base or material of construction thereof is not critical to the invention herein. The base 20 as shown includes an escutcheon kit 24, which may be putty sealed to the base and a sink or other basin, for example, and a base plate 22 for positioning between the escutcheon 24 and a sink or basin surface. O-rings such as O-rings 30 or other sealing components are preferably used between the base and the faucet body. If the faucet body 14 has an inner protective piece for guiding the internal conduits, such as inner body 28 as shown in
The flexible hose 122 preferably passes through the entire assembly 10 extending from the sprayer end section 58 of the spray handle 54 through a faucet body portion, such as side faucet body portion 46 of the faucet body 14, down through the passage 52 within the faucet body within the inner body 28, through the base 20 and below the base for connection to an outflow conduit 132.
The faucet 12 herein includes a spray handle 54 which is detachable from the faucet body 14. The spray handle has a first end section 56 and a sprayer end section 58. The first end section 56 is configured to be detachably connected to the side faucet body portion 46 of the faucet body 14. The spray handle 54 has an inner wall 60 that defines a passageway 62 extending through the spray handle. The passage 62 is in open liquid communication with the passage 52 in the faucet body.
One of the benefits of the embodiment of the invention herein wherein the spray handle 54 includes a hose connection as described further herein in the sprayer end section 58 of spray handle 54 is that by virtue of such configuration of the spray handle, the shell material used for making the spray handle and other mechanical components within the sprayer end section 58 of the spray handle need not be especially reinforced to resist open water pressure within the passage of the spray handle 54. In prior art spray handles wherein the hose connection is on the end of the spray handle away from the sprayer end section, a water delivery hose typically does not pass through the spray handle. In such a case, water enters the interior of the spray handle, which must be either reinforced metal and/or formed of other more costly reinforcing materials for an outer shell in a tube-in-tube design. However, the present embodiment spray handle allows for passage of a reinforced water hose such as flexible hose 122 to pass through the passage 62 in the spray handle so that the spray handle shell may be formed of less costly and lighter weight materials.
In one embodiment herein the spray handle shell may be molded of a thermoplastic material, which may be filled or unfilled with reinforcing material. Such materials may include standard heat moldable materials which may include standard or specialty, additives, fillers, fibrous materials and the like as well as colorants (such as pigments or dyes) for varying aesthetic looks and/or may have a laminated, composite construction as well (for example, use of a molded shell having a chromium molded thermoplastic laminate outer coating). In one preferred embodiment, the shell of the spray handle 54 is formed of a thermoplastic such as acrylonitrile-butadiene-styrene (ABS), however, other similar thermoplastics which are sufficiently durable for hand held use and wear, such as polystyrene (PS), polyamides (PA), polycarbonates (PC), polyrurethanes (PU), polyimides (PI), polyetherimides (PEI), polysulfone (PS), polyethersulfone (PES), polyolefins such as polypropylene (PP), polyethylene (PE), and high-density polyethylene (HDPE), and polyoxyalkylenes such as polyoxymethylene (POM) and similar molding materials as well as blends and copolymers of such materials may be used. The shell may be made using any suitable technique, including heat molding, compression molding, vacuum molding, lamination and heat molding and the like.
The spray handle 54 may be detachably connected to the faucet body using any suitable attachment means which is easily releasable under manual push/pull force, but is sufficiently sturdy so as not to fall out or detach from the faucet body without use of applied manual force. Preferably, a faucet connector is used such as connector 112. The connector has a first portion 116 that is configured to be engaged with the inner wall 60 of the spray handle 54. The first portion 116 may be releaseably engaged to the inner wall 60 or permanently engaged either through friction fit or fused as an integral part (through heat molding techniques or adhesive). The first end section 56 of the spray handle is preferably configured so as to receive the first portion 116 of the faucet connector 112. As shown in more detail in
The faucet further preferably includes an adapter 120 for strain relief, preferably but not necessarily formed of similar polymeric material to that used for forming connector 112. The adaptor helps to maintain the flexible hose 122 in a stable position within the first end section 56 of the spray handle 54 and prevents harm to the diverter portion of the spray handle by providing strain relief. The adaptor is preferably situated so as to be within the first end section 56 of the spray handle within an interior space 114 of the faucet connector 112.
Within the spray handle 54, the faucet preferably includes a hose connection. In one preferred embodiment, as shown in
Preferably a flow regulator of some kind is also provided within the flow portions of the mechanisms within the sprayer end of the spray handle. In one preferred embodiment, at least one check valve, such as check valve 70 is located within the hose connector 65 before the clip 74 so as to ensure no backflow at the hose connection to prevent dirty water from flowing backwards and to provide positive pressure. While the current embodiment shown, only one such check valve is necessary, other such valves or other flow regulators may be used in various locations within the design without departing from the scope of the invention.
The connection clip 74 and hose connection may also be formed of the same molding materials noted above, and preferably, but not necessarily of the same materials as the connector 112 and adaptor 120. O-rings and other gasketing material used herein may be formed of elastomeric materials, thermoplastic materials, thermoplastic elastomer materials or any suitable leak preventing material for providing a tight seal, but which preferably would not extrude under temperatures encountered in the hose 122 and through the faucet 12. Suitable elastomers for o-rings include ethylene-propylene diene rubber (EPDM), ethylene propylene rubber (EPR), polytetrafluoroethylene (PTFE, commercially available as Teflon®), polyolefinic and other thermoplastic materials, polyurethane rubber, fluoroelastomers (FKM), perfluoroelastomers (FFKM), neoprene, butadiene, styrene-butadiene-styrene rubber (SBS), styrene-ethylene-butadiene-styrene rubber (SEBS) and the like. The check valves or other flow regulators may be any suitable check valve or flow regulator for use in faucets, including check valves commercially available, for example, under the name Neoperl®, of Waterbury, Conn.
The hose connection 64 is preferably in liquid communication with a diverter, such as pull down diverter 80. A preferred connection such as conduit 76 provides a waterway from the hose 122 and hose connection 64 to the diverter 80. The conduit 76 is preferably angled in a way compatible with the design of the outer shell of the spray handle. The conduit is preferably also formed of a molding material as described elsewhere herein, such as preferably, but not necessarily, POM. As shown, the sprayer end 58 of the spray handle 54 is curved downward to direct liquid flow through an outlet 82 of the spray handle in a downward direction in standard faucet seated position and for directional flow when used as a detached spray handle. Thus, the conduit 76 is also preferably curved or angled so as to direct liquid from the hose towards the outlet and diverter. As shown, an extension arm of the conduit can fit within the clip 74 and the end of the hose connector so as to sealingly engage the check valve for a tighter flow. Liquid exiting the other end of the conduit has a larger diameter opening for directing liquid into the diverter 80.
As shown, in one preferred embodiment, the faucet described herein provides a pull down diverter mechanism to the pull-out spray handle, wherein the faucet is also preferably a kitchen faucet. Such pull-down diverters are not believed to be known for adaptation to a kitchen pull-out spray faucet, regardless of whether the faucet has the novel feature mentioned above and shown in the drawings herein concerning placement of a hose connection in the sprayer end of a pull-out spray head. Both of these features, use of a pull-down diverter in a pull-out sprayer, particularly in a kitchen faucet having a pull-out spray handle, and use of a hose connection in a pull-out spray handle that is located in the sprayer end of the spray handle are significant improvements in the various embodiments of the invention. Thus, it is within the scope of the invention to use a pull-down diverter in a kitchen faucet regardless of the location of the hose connection (i.e., whether it is located at the sprayer end of a spray handle according to a preferred novel embodiment herein or located at the opposite end of the spray handle as in prior art combination sprayers). It is also within the scope of the invention to use another sprayer diversion mechanism (aside from the pull-down diverter shown in the preferred embodiment herein) with the novel feature of locating the hose connection in the sprayer end of the spray handle as shown in the drawings. It is preferred to use each of these features together, but one skilled in the art will appreciate that either novel feature may be used alone without departing from the spirit and scope of the invention.
In the preferred embodiment shown, the pull-down diverter 80 can have varying configurations (see
The aerator 104 sits within the central portion of the downward adjuster piece 94, preferably having a washer 98 situated around the top of the aerator within the downward adjuster piece 94, and also within the central axially extending hole in a ring-shaped elastomeric nozzle for spray delivery 100. The aerator may be any suitable aerator useful for providing an aerated direct liquid flow from a faucet. Such aerators are commercially available as Neoperl®. The nozzle 100 sits within a face plate 108 which may optionally also have a decorative ring 110 or other design piece for downward pulling of the diverter. The nozzle 100 is preferably formed of a material with structural integrity, good thermal properties and flexibility. While any of the thermoplastic or elastomer materials noted above are suitable, preferably a thermoplastic olefin elastomer is used, for example Santoprene®, commercially available from ExxonMobil or a similar material. The faceplate should be somewhat more resistant to pressure so as to hold the spray nozzle spraying functional features in place. While any suitable material for other parts and/or components of the spray handle noted herein may be used to form the faceplate 108, it is preferred that a reinforced and/or composite material is used to provide good structural integrity, such as a composite of glass-fiber reinforced polypropylene (having 20% by volume glass fiber). The decorative ring should be formed of a any of the materials noted herein, but is preferably formed of a moldable thermoplastic or elastomeric material similar to that of the faucet body so as to withstand manual wear and use as well as cleaning materials, preferably ABS or a similar polymeric material.
The spray holes 102 extending transversely through the nozzle 100 may be circularly aligned around the centrally located aerator as shown in the preferred embodiment in
As shown in
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
