Patent Application
20070018365
The present invention provides a method for manufacturing fountainheads. It further provides fountainheads made by the process that include non-circular and non-oval-shaped (e.g., square, triangular and rectangular) holes.
Water features have become very popular in homeowner landscape design, both for their aesthetic and property improvement value. Though not limited to these specific areas, dynamic water features are currently being marketed in the spa, hot tub, pool, fountain and general landscaping fields.
The water features come in a variety of shapes, sizes, costs and complexities; they are typically built into the design of a system. The features use pumps and controls integrated into the system to operate. A fountainhead, in such designs, creates the visual look, pattern and sound. The features often cannot be changed or modified by the customer, because different water features require entire systems unique to each design. This creates a large number of parts and processes to control and service. One method of addressing these issues is to have a water feature that includes a user-interchangeable nozzle, jet or fountainhead.
One issue raised by the interchangeable fountainhead is how to effectively and efficiently manufacture it. A fountainhead typically works best with a length of straight flow or constant cross-section, which allows a cohesive stream to flow through and out of the head. The length of the fountain body is usually drilled or machined in the manufacturing process with the desired flow or spray pattern. Injection molding usually provides the least expensive part, however, the necessary mold complexity to pull hole pins at the various angles, would result in an expensive and delicate mold. A second alternative is to create a single generic part and employ a secondary operation to drill the desired hole pattern at the required angles. Both of these processes are expensive manufacturing options.
The present invention is directed to a process of manufacturing a fountainhead and to the fountainheads manufactured by the process.
The present invention provides a method for manufacturing fountainheads. It further provides fountainheads made by the process that include non-circular and non-oval-shaped (e.g., square, triangular and rectangular) holes.
In a method aspect, the present invention provides a method of manufacturing a fountainhead. The method involves a number of steps including the following: creating a design for the fountainhead; constructing at least two mold cavities based on the design; using the two cavities to form fountainhead pieces; and, combining the fountainhead pieces. The fountainhead pieces typically include at least two channels that form non-circular and non-oval-shaped holes when they are combined. The holes are oftentimes square, triangular or rectangular in shape. In certain cases, channels of the fountainhead pieces run at different angles (i.e., they are not parallel to each other, or with respect to an axis of the fountainhead).
In an article of manufacture aspect, the present invention provides a fountainhead that is made by the method described above.
In another article of manufacture aspect, the present invention provides a fountainhead piece. The piece typically includes at least two rectilinear channels (i.e., bounded by straight rather than curved sections). The piece is capable of forming a fountainhead including non-circular or non-oval shaped holes (e.g., square, triangular or rectangular holes) when combined with a second fountainhead piece. The rectilinear channels of the fountainhead piece oftentimes run at different angles (i.e., are not parallel to each other or with respect to an axis of the piece).
In a business method aspect, the present invention provides a method of reducing the cost of manufacturing a fountainhead. The method involves a number of steps, including the following: creating a fountainhead design where the fountainhead has at least two square, triangular or rectangular holes; and, manufacturing the designed fountainhead from at least two fountainhead pieces. When the preceding method is employed, it typically provides a cost savings of at least ten, twenty, thirty or even forty percent as compared with manufacturing a fountainhead from a single piece.
In another article of manufacture aspect, the present invention provides a spa. The spa includes a fountainhead containing at least two non-circular or non-oval-shaped holes (e.g., square, triangular or rectangular holes) that provide for the spray of water, typically in different directions. Oftentimes, the fountainhead is formed from at least two fountainhead pieces including rectilinear channels, and the channels may run at different angles with respect to each other, and an axis of the fountainhead.
The present invention provides a method for manufacturing fountainheads. It further provides fountainheads made by the process that include non-circular and non-oval-shaped (e.g., square, triangular and rectangular) holes.
A fountainhead may be molded in two or more pieces using a simple open and close mold by using a non-circular or non-oval-shaped hole design (e.g., square, triangular or rectangular) for the spray pattern. The square or rectangular hole, for example, allows the stream-forming straight section of the fountainhead to be formed in each half of the molded part, at various angles both on the x- and y-axis. The use of the non-circular/non-oval-shaped hole eliminates the need for a further drilling step and allows for an easier mating of mold halves. The resulting, formed opening has a constant cross section, which provides a cohesive, shaped stream. Once the stream leaves the hole, the surface tension of the water reforms the stream into a traditional round-shaped stream.
The method of the present invention is further illustrated in reference to
The method of the present invention provides a significant economic advantage over other methods of fountainhead construction. For instance, the molds used will be about one-third to one-half the cost of a traditional, slide actuated mold. A simple gluing or joining operation will furthermore replace the expensive drilling of holes within the fountainhead at various angles. Both of the preceding cost-saving aspects will result in fountainhead manufacturing costs that are at least twenty percent less than typical manufacturing methods. Preferably, the costs will be thirty, forty, fifty, sixty or seventy percent less than such methods.
The fountainhead, or portion thereof, of the present invention is further illustrated in reference to
The invention embodiments discussed above and shown in
