Note: Descriptions are shown in the official language in which they were submitted.
CA 02304885 2000-04-07
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SH()WERHEAD ENGINE ASSEMBLY
Field of Art
This invention relates to showerhead engine assemblies and water aerators, and
more
particularly, to showerhead engine assemblies having different combinations of
continuous and
pulsating sprays.
Background of the Invention
Numerous showerheads assemblies are known in the prior art that operate in
multi-functional
modes. These assemblies provide fixed spray patterns in combination with
massaging action
generated by either pulsating or whirling the water through the showerhead.
Individual systems
include:
(1) A selector disk removably and rotatably mounted inside the selector
housing. The disk
selector has an inlet end facing the inlet end of the selector housing, and an
outlet end
opposite the inlet end of the disk selector. The showerhead includes a
selector face mounted
inside the selector housing and a diffuser plate mounted inside the selector
housing.
(2) A showerhead assernbly enabling the selection of various forms of output
streams,
including a set of streams having a large diameter, rich in bubbles when the
water pressure is
high, a set of streams having a smaller diameter full of bubbles when the
water pressure is
low, or a spray instead of the bubbly stream.
CA 02304885 2000-04-07
(3) A showering system fed from a source of hot water that produces steam. A
selectively
controlled diverter is disposed within the conduit and diverts the water
arriving from the source
away from the showerhea,d and through the outlet in the form of a mist. The
showerhead
includes a nozzle-driven turbine. Apertures in a flow director plate, governed
by a control
plate, feed nozzles predetE~rmined to vary the force of water delivered. The
water force varies
with the number of the nozzles that are open.
These systems have complex: internal bomponents which must be sealed relative
to each other,
are relatively expensive to produce, and due to the complexity of the
components often do not
operate in a manner which fully prevents leakage during use. In addition, the
showerhead outlet
ports often become obstructed by impurities causing almost random spray
patterns.
What is needed is a showering system that overcomes the disadvantages of the
prior art, that is
economical to manufacture and durable in use, that operates effectively within
a wide range of
water pressures, that enables the person to select from a regular continuous
spray, an aerated
spray, a pulsating spray, and several combinations thereof, and that is energy
efficient and yields
spray characteristics that are better than conventional showefiead engine
assemblies.
What is needed is a showerhead engine assembly having component parts that are
interchangeable with other assemblies, the number of component parts being
minimal, the
interchangeability reducing the number of spare parts necessary for repair
purposes, the
assembly enabling various combination of spray patterns including jet spray,
aeration, deflected
spray, pulsating jet spray, and pulsating deflected spray, while providing
self-cleaning
convenience.
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CA 02304885 2004-08-06
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Summary of the Invention
These needs are addressed by the preferred
embodiments of the showerhead engine assemblies of the
present invention. The term showerhead as used herein
designates any device which attaches to a shower fluid
supply through an inlet tube and creates a spray by changing
the fluid pattern, including (1) standard showerheads,
(2) pulsating showerheads, and (3) energy-savings, aerating
showerheads.
This invention relates to a showerhead engine
assembly comprising a spinner, a stator, a pressure plate, a
faceplate, the showerhead engine assembly enabling secure
retention of a showerhead, the showerhead engine assembly
comprising: means for generating a nonpulsating and non-
deflected spray pattern when the spinner is stationary and
the orientation of the faceplate relative to the pressure
plate is in a first position; means for generating a
nonpulsating and deflected spray pattern when the spinner is
stationary and the orientation of the faceplate relative to
the pressure plate is in a second position; means for
generating a pulsating and nondeflected spray pattern when
the spinner is rotating and the orientation of the faceplate
relative to the pressure plate is in a third position; and
means for generating a pulsating and deflected spray pattern
when the spinner is rotating and the orientation of the
faceplate relative to the pressure plate is in a fourth
position.
According to one aspect of the present invention,
there is provided a showerhead engine assembly comprising a
spinner, a stator, a pressure plate, a faceplate, the
showerhead engine assembly enabling secure retention of a
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showerhead, the showerhead engine assembly comprising: means
for generating a nonpulsating and nondeflected spray pattern
when the spinner is stationary and the orientation of the
faceplate relative to the pressure plate is in a first
position; means for generating a nonpulsating and deflected
spray pattern when the spinner is stationary and the
orientation of the faceplate relative to the pressure plate
is in a second position; means for generating a pulsating
and nondeflected spray pattern when the spinner is rotating
and the orientation of the faceplate relative to the
pressure plate is in a third position; means for generating
a pulsating and deflected spray pattern when the spinner is
rotating and the orientation of the faceplate relative to
the pressure plate is in a fourth position; and a ring
member having a plurality of pins extending therefrom in an
axial direction, each pin extending through a water outlet
providing a self-cleaning action when the faceplate is
rotated relative to the pressure plate.
According to another aspect of the present
invention, there is provided a showerhead engine assembly
which includes a spinner, a pressure plate, a faceplate, the
spinner being disposed relative to a shaft, the spinner
rotating about the axis of the shaft, the showerhead engine
assembly comprising: means for generating a nondeflected,
nonpulsating spray pattern and a deflected, nonpulsating
spray pattern when the spinner is stationary and the
orientation of the faceplate relative to the pressure plate
are securely aligned together; means for generating a
pulsating deflected spray pattern and a pulsating
nondeflected spray pattern when the spinner is rotating and
the orientation of the faceplate relative to the pressure
plate are securely aligned together, the spinner including a
passageway centrally disposed therethrough, a lip being
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positioned within the passageway, the lip being rotatably
retained about the shaft and providing a minimal bearing
surface for rotational purposes; and a ring member having a
plurality of pins extending therefrom in an axial direction,
each pin extending through a water outlet providing a self
cleaning action when the faceplate is rotated relative to
the pressure plate.
According to still another aspect of the present
invention, there is provided a showerhead assembly
comprising: a housing shell; a stator directing water
against a spinner, said spinner selectively rotatable about
an axis; an engager movable along said axis for selectively
engaging said spinner; a pressure plate fixed to said
housing comprising a plurality of fluid outlets; a face
plate fixed to said engager and axially moveable with said
engager, said face plate rotatable about said axis for
selection of a desired spray pattern; and said pressure
plate comprises several ramped portions cooperating with a
surface of said engager and said face plate for moving said
engager and said face plate axially.
In a first preferred embodiment of the showerhead
engine assembly of the present invention, the engine
assembly comprises five plastic parts plus an O-ring seal;
the parts being a stator, a spinner, an engager, a pressure
plate, and a faceplate, openings being disposed in the
pressure plate and faceplate to enable fluid flow
therethrough. Deflecting surfaces on the faceplate enable a
variety of different flow patterns. Rotation of the spinner
is dependent upon the particular spray pattern selected.
The stator includes a pair of stop flanges that engage and
disengage with the spinner. When the spinner is disengaged
and free to rotate, fluid flow through passages in the
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CA 02304885 2004-08-06
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spinner cause spinner rotation, creating a vortex. When the
spinner is free to rotate, the combination of the spinner,
stator, and pressure plate create pulsating action.
The spray patterns are formed external to the
pressure chamber. The spray selection occurs on more than
one plane, between the pressure plate and the faceplate, and
the spray selection occurs with water at atmospheric
pressure. The spray patterns are created by the deflecting
surfaces disposed on the faceplate. Four basic spray
patterns: (1) nonpulsating uninterrupted flow where the
spinner is stationary; (2) nonpulsating deflected flow where
the spinner is also stationary; (3) pulsating uninterrupted
flow where the spinner is rotating; and (4) pulsating
deflected flow where the spinner is rotating.
In a second preferred embodiment of the showerhead
engine assembly of the present invention, the engine
assembly comprises only a pressure plate and a faceplate,
without pulsation. A mechanism for alignment purposes is
preferably incorporated into the pressure plate and
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faceplate, since unless properly aligned, the water flow becomes random. Also,
a detente
mechanism can be used. The faceplate is identical to the faceplate in the
first preferred
embodiment. Two spray patterns are available: (1) nonpulsating uninterrupted
flow; and (2)
nonpulsating deflected flow.
The pressure chamber within the showefiead engine assembly disposed between
the stator and
the pressun: plate must be sealed from the spray selection chamber. In
contrast to conventional
showerhead engine assemblies where high-pressure seals are needed to provide
necessary
sealing, the showerhead engine assembly of the present invention only needs to
seal the
pressure chamber from the spray selection chamber.
Additional embodiments include showerhead engine assemblies similar to the
first and second
preferred embodiments that include a self-cleaning action. Six self-cleaning
pins disposed are
normal to the plane of the spring wire. The circular spring nests in a
circular slot in the pressure
plate. Each of the six orifice holes in the pressure plate comprise a cluster
of apertures disposed
about a central opening. The pins rest into each of the central openings. As
the relative position
of the faceplate is rotated about the pressure plate-spring combination as
spray selections are
made, the edges of the faceplate force the pins to move back and forth axially
within the central
openings generating the self-cleaning action. The pins translate within the
holes by the action of
rotation of the shower faceplate itself, resulting in the self-cleaning
action.
The advantages of the showerhead engine assembly of the present invention are
numerous.
These advantages include spray patterns formed external to the pressure
chamber; and a
dramatic reduction in the number of component parts, which keeps part count
down, improves
assembly time, reduces costs, and simplifies repair. The showerhead engine
assembly of the
present invention also provides crossing spray patterns; and families of
showerhead engine
assemblies that provide various spray patterns with interchangeable component
parts. Other
shaped and sized orifices in the faceplate enable a selection of a variety of
spray patterns with
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CA 02304885 2000-04-07
varying spray characteristics. Rotation and realignment of the faceplate
relative to the pressure
plate changes the orifice configurations and the number of spray selection
options.
For a more complete understanding of the showerhead engine assembly of the
present invention,
reference is made to the follo~nring detailed description and accompanying
drawings in which the
presently prefer-ed embodiments of the invention are shown by way of example.
As the invention
may be embodied in many forms without departing from spirit of essential
characteristics thereof,
it is expressly understood that: the drawings are for purposes of illustration
and description only,
and are not intended as a definition of the limits of the invention.
Detailed Description of the Drawings
FIGURE 1 discloses an exploded perspective view of the preferred embodiment of
the
showerhead engine assembly of the present invention comprising a stator, a
spinner, an
engager, an 0-ring, a pressure plate, and a faceplate retained within a handle
of a hand-held
showerhead;
FIGURE 2A discloses an exploded perspective view of the downstream surfaces of
the engager,
the spinner, and the stator of the showerhead engine assembly of FIGURES. 1
and 2B discloses
an exploded perspective view of the upstream undersurfaces of the engager,
spinner, and stator
of FIGURE ZA;
FIGURE 3A discloses a perspective view of the upstream surface of the engager
of the
showefiead assembly of FIGURE 1, and FIGURE 3B discloses a perspective view of
the
downstream surface of the enc~ager of FIGURE 3A;
FIGURE 4A discloses a perspective view of the upstream surface of the pressure
plate of the
showerhead assembly of FIGURE 1 and FIGURE 4B discloses a perspective view of
the
downstream surface of the pressure plate of FIGURE 4A;
CA 02304885 2000-04-07
FIGURE 5A discloses a perspective view of the upstream surface of the
faceplate of the
showerhead assembly of FIGURE 1, and FIGURE 5B discloses a perspective view of
the
downstream surface of the faaeplate of FIGURE 5A;
FIGURE 6 discloses an enlarged side sectional view of the assembly of the
engager, pressure
plate, and faceplate of FIGURE=1;
FIGURE 7A discloses a side view of the hand-held showefiead assembly of FIGURE
1, and
FIGURE 7B discloses a front view of the hand-held showerhead assembly of
FIGURE 1;
FIGURE 8A discloses a front view of the faceplate of the showefiead engine
assembly of
FIGURE 7B, the position of the faceplate being between deflected and
nondeflected flow relative
to the pressure plate; FIGURE 8B discloses a top view of the hand-held
showerhead engine
assembly of FIGURE 8A; and FIGURE 8C discloses a bottom view of the hand-held
showerhead
engine assembly of FIGURE 8A;
FIGURE 9 discloses an exploded perspective view of a second preferred
embodiment of the
showefiead engine assembly of the present invention comprising a shell, a
stator, a spinner, an
engager, an 0-ring, a pressures plate, and a faceplate;
FIGURE 10A discloses a side view of the showerhead engine assembly of the
present invention
as used in the fixed showerhead assembly of FIGURE 9; and FIGURE 10B discloses
a side
sectional front view of the shovverhead engine assembly of FIGURE 10A;
FIGURE 11A discloses a perspective view of the downstream surface of another
preferred
embodiment of the faceplate of the shawefiead engine assembly of the present
invention, the
faceplate having two spray selection modes of operation - aeration spray and
nondeflected spray;
FIGURE 11 B discloses a pe~~spective view of the upstream undersurface of the
faceplate of
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CA 02304885 2000-04-07
FIGURE 11A; and FIGURE 1'1C discloses an enlarged detail view of the one of
the deflectors of
the faceplate of the showerhe<3d assembly of FIGURE 11 B;
FIGURE 12A discloses a perspective view of the upstream surface of another
preferred
embodiment of the pressure plate of the showerhead engine assembly of the
present invention,
this preferred embodiment for use with an interchangeable faceplate, the
faceplate being shown
FIGURES 5A and 5B for a two-piece showerhead engine assembly; and FIGURE 12B
discloses
a perspective view of the downstream undersurface of the pressure plate of
FIGURE 12A;
FIGURE 13 discloses an exploded perspective view of yet another preferred
embodiment of the
showerhead engine assembly of the present invention, with the showerhead
engine assembly of
FIGURE 1 including a self-clE~aning ring that cleans apertures within the
pressure plate as the
faceplate is rotated relative to '~:he pressure plate;
FIGURE 14 discloses an exploded perspective view of still yet another
preferred embodiment of
the showerhead engine assembly of the present invention, with a two-piece
fixed showerhead
engine assembly of FIGURE 9, and with the self-cleaning ring shown in FIGURE
13;
FIGURE 15 discloses an enlarged, partial perspective view of the cooperative
engagement
between the self-cleaning ring and the pressure plate of FIGURES 13 and 14;
and
FIGURE 16A, 16B, 16C, and '16D show enlarged views of the cooperative
engagement between
the faceplate and the self-cleaning ring of FIGURES 13 and 14.
Detailed Description of the Preferred Embodiments
Attention is initially drawn to the drawings, as FIGURE 1 discloses an
assembly view of the
preferred embodiment of the hand-held embodiment of the showefiead engine
assembly 10A of
the present invention. FIGURES 7A, 7B, 8A, 8B, and 8C show additional views of
the hand-held
7
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CA 02304885 2002-12-20
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showerhead shell and casing 15A. The showerhead engine assembly 10A of the
present invention
comprises a stator 20, a spinner 30, an engager 40, an 0-ring 50, a pressure
plate 60, and a
facepiate 80.
High-pressure water enters the back end of the showerhead shell of the present
invention at
between about 20 to 80 psi with a maximum flow of 2.5 gaUonslminute @ 80 psi.
The water is
thrust through the stator 20 and into the spinner 30, passing into and through
the pressure plate
60 and is discharged through the faceplate 80. The spinner 30, O~ing 50, and
engager 40 are
inserted into the pressure plate 60. The stator 20 is snapped into the
pressure plate 60 and the
faceplate 80 is snapped into the engager. An essentially conventional hand-
held shell 15A is
used.
Reference is now drawn to FIGURES 2A and 2B which disclose the downstream and
upstream
surfaces, respectively, of the stator 20, spinner 30, and engager 40. Water
enters the
showerhead engine assembly 10A of the present invention tangentially through
four evenly-spaced
passages 22 disposed at the periphery of the stator 20. Such tangential flow
generates a vortex
in the pressure chamber within the showerhead engine assembly, causing the
spinner 30 to
rotate.
The stator 20 is a flat, circular disc. The stator 20 has a centrally disposed
stator hub 21 with a
centrally disposed orifice 24 for receiving the shaft of the engager 40
therethrough. The stator 20
has eight spokes, the spokes 23 being evenly and symmetrically spaced about
the stator hub 21.
The spokes 23 extend from the stator hub 21 to the perimeter of the stator 20.
Four stator
passages 22 are disposed on alternating spokes on the distal half portion of
each spoke 23. The
stator peripheral passages 22 are defined by and are formed between a flag-
shaped raised
portion of the essentially flat surface of the stator 20, the stator 20 being
sloped in a rearward
direction toward the shell 15A. Abutting two of the opposing stator peripheral
passages 22 are a
pair of flanges 26 extending normal to the plane of the stator 20. The flanges
26 extend from the
stator upstream surface 20A and engage the inner surface of the shell 15A.
This secures the
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CA 02304885 2002-12-20
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stator 20 relative to the shell 15 thereby preventing any rotary motion of the
stator 20 when the
pressurized water enters the showerhead assembly and into the showerhe~ engine
assembly
of the present invention. The stator 20 remains engaged and retained by the
shell during all
spray selection patterns. The stator 20 also includes a pair of stopping ribs
28 extending from the
stator downstream surface 20B. The stopping ribs 28 serve to engage the
spinner 30, and block
spinner rotation when the spinner 30 is positioned axially in the upstream
direction toward the
stator 20. The stator ribs 28 are so positioned that when the spinner 30 is
restricted from
rotation, the pads 37 do not obstruct flow through the stator peripheral
passages 22.
The spinner 30 has a arcular shape with a centrally disposed spinner hub 32,
an opening 33
being disposed in the center of the spinner hub 32. The spinner hub 32 has a
generally tubular
extension 35, protruding outward from the spinner 34 extending toward the
stator 20. The tubular
extension 35 nests within the stator hub 25. The spinner 30 preferably has
twelve blades 34
extending from the spinner hub 32 to the spinner perimeter, the positioning of
the blades 34 being
symmetrical and evenly spaced. The blades 34 extend in the axial direction and
are so
posifloned that water entering through the stator passages 22 will propel the
blades 34 when the
spinner 30 is released from the stator 20 causing a spinning action. The
blades 34 are
essentially radial except that they are slightly offset from the spinner
center, simulaflng the shape
of a spiral. The spiral shape enhances rotation. Two arcuately-shape pads 37
opposing each
other extend circumferenbally about the perimeter of the spinner 30, each pad
37 joining three of
the blades 34 together. The blades 34 are not secured together.
When the spinner 30 is rotating, the pressurized water strikes the pads 37,
interrupting water
flow. When the pressurized water does not strike the pads 37, flow is
continuous. The
sequencing of interrupted and uninterrupted flow creates the pulsating effect.
The two pads 37
intemrpt water flow through the showerhead engine assembly 10A of the present
invention,
causing the jet streams to have differing velocities, and thereby causing a
"massage° action.
The pads 37 are so configured that when the spinner 30 is engaged with the
stator 20, the
spinner being stationary, the pads 37 are not in the path of the water flow,
so that all flow is
9
CA 02304885 2000-04-07
essentially continuous, Either expanding or reducing the number of blades 34
covered by each
pad 37 generates other pulsation patterns.
As shown in FIGURES 3A and 3B, the engager 40 includes a stem-like member 42.
The
engager upstream surface 40A has a center section that forms a central
chamber. Centrally
disposed and extending in the upstream direction is the stem 42. The stem 42
has a thicker
inboard portion 42A for nesting engagement with the spinner hub 32, and a
thinner outboard
portion 42B for nesting engagement with the stator hub 21. A shoulder 44 is
disposed between
the stem inboard portion 42A <~nd the stem outboard portion 42B. The shoulder
44 prevents axial
movement of the spinner 30. The spinner 30 moves axially with the engager 40
on the stem
inboard portion 42A. The stator 20 is secured relative to the shell 15A.
The spinner 30 seats on the thicker inboard portion of the engager stem 42,
and the stator 20
seats on the thinner outboard portion 42A of the engager stem 42. In order to
minimize the
bearing surface of the spinner 30 on the engager 40, a central passageway 31
extends through
the spinner 30 and tapers inwardly, preferably on the upstream edge, which
results in less of a
frictional surface between the engager stem 42 and the spinner 30.
The outer perimeter of the engager 40 is defined by an annulus 48 that
surrounds the engager
center section 45. The annulus 48 is secured to the engager center section 45
by three radial
spokes 46, the engager radial spokes 46 being evenly spaced about the engager
40. The
inboard half of each spoke 46 is roughly three times as thick as the outboard
half of each
engager spoke 46 for purposes of strength. The engager spokes 46 divide the
engager
perimeter into three outer sections 47, each perimeter section 47 having an
arcuate segment of
about 120 degrees. Each perimeter section 47 has a centrally disposed nub 50,
the nub 50 being
less than a forty-five degree sector of each perimeter section 47. The nubs 50
provide the
engager 40 with elasticity and improve the secure engagement of the engager 40
with the
pressure plate 60.
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CA 02304885 2000-04-07
Centrally disposed within the engager downstream surface 40B is a recess 52
and a middle
chamber 56. Three evenly spaced ribs 54 extend radially outward between an
inner tubular wall
53 defining the central recess. 52 and an outer tubular wall 55 surrounding
the middle chamber
56. The ribs 54 divide the middle chamber 56 into three sections, each section
having an arcuate
segment of about 120 degrees. Each section is aligned with the three perimeter
sections 47 of
the engager 40.
While the engager 40 is seated within the pressure plate 60, the engager 40
moves axially within
the pressure plate 60 with the faceplate 80, the faceplate 80 moving axially
with the manual
selection of spray patterns. INhen the engager 40 is repositioned axially
toward the shell 15A,
the spinner 30 is forced into engagement with the pair of opposing stopping
ribs 28 disposed on
two opposing blades 34 of this stator 20. This engagement locks the spinner 30
relative to the
stator 20. When the engager 40 moves axially downstream with the faceplate 80,
the spinner 30
also moves axially toward the faceplate 80 on the engager stem 42, releasing
the spinner 30 from
the stator 20. This causes the high pressure water to pass between the blades
34 in the spinner
30 causing the spinning action.
The axial force is controlled by the size of the 0-ring 50 sealing the engager
stem 45A inside the
bore in the pressure plate 60. The size of this 0-ring 50 and shaft are
determined by the size
needed to transmit torque befiNeen the faceplate 80 and the engager stem 45A.
FIGURE 4A shows the pressure plate upstream surface 60, and FIGURE 4B shows
the pressure
plate downstream undersurface 60B. The pressure plate upstream surface 60A
cooperatively
engages the engager downstream surface 40B, and the pressure plate downstream
surface 60B
cooperatively engages the faceplate upstream surface 80A.
The pressure plate 60 includes a central opening 64 for receiving the engager
outer tubular wall
55. The wall 65 defining the central opening 64 on the pressure plate upstream
surface 60A is
vamped inwardly and outwardky. The inner section of the pressure plate
upstream surface 60A is
CA 02304885 2002-12-20
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surrounded by a concentric cylindrical wail 66. The concentric wall 66
surrounds the engager
annulus 48 during engagement.
The opening wall 65 is camped having three each sloped upward segments 61A,
flattened top
segments 61 B, sbped downward segments 61 C, and flattened base segments 61 D.
The length
and slope of the sloped upward segments 61 A is the same as the length and
slope of the sloped
downward segments 61 C. The length of the flattened top segments 61 B is the
same as the
length of the flattened base segments 61 D. The ramps 61 in the opening wall
65 separate the
opening wall into six equal sections. Since the engager 40 moves axially and
rotationally with the
faceplate 80, the ramps 61 cooperatively engage the engager perimeter sections
47. When the
engager 40 is in a forward position, the engager spokes 46 are aligned with
the flattened base
segments 61 D, and the ramps 61 nest within the open engager perimeter
sections 47. When the
engager 40 moves rearward toward the shell 15A, the ramps 61 are aligned with
the engager
spokes 46 that separate the engager perimeter sections 47.
The midsection of the pressure plate 60 is divided into twelve pie-shaped
sections. Alternating
sections include a cluster 72 of jet orifices 73 that extend through the
pressure plate 60, Each
cluster 72 of jet orifices 73 has a box-type configuration. The clusters 72 of
jet orifices 73 are
posifloned on alternating sections. The openings are arranged in two groups of
two, an upper
group being aligned with and disposed above the lower group. The other
alternative sections
have no jet or'rfrces. The outer section of the pressure plate upstream
surface 60A includes a
circumferentially disposed recess 68 sandwiched between two annular flanges 67
and 69 for
cooperative engagement with the hand-held showefiead shell 15A.
The hub 62B of the pressure plate downstream surface 60B includes another
series of three
ramps 71 for cooperative engagement with three ramps 81 on the faceplate
upstream surface
80A. Each of the ramps 71 on the pressure plate downstream surface 60B are out
of phase and
aligned with the ramps 61 on the pressure plate upstream surface 60A. The top
portion 71 B of
each downstream ramp 61 is aligned with a ramp spacing 61 D disposed on the
pressure plate
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CA 02304885 2002-12-20
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upstream surface 60A. The ramps 71 on the pressure plate downstream surface
60B have the
same shape and configuration as the ramps 81 on the f~eplate upstream surface
SOA as
hereinafter set forth. The hub 628 of the pressure plate 60 and the hub 82 on
the faceplate
upstream surface 80A are each divided into six equal sections - alternating
sections including a
ramp (either 71 or 81). The length of the top and botkom ramp sections of the
engager 40,
pressure plate 60, and faceplate 80 are each sized so that the faceplate 80
and the er~ager 40
move freely together into the proper axial position as shown in FIGURES 3B,
4A, 4B, and 5A.
The relative position of the ramps 71 and 81 moves the faceplate 80 axially
relative to the
pressure plate 60 during the manual selection of spray paitems. Again, each
ramp 71 and 81
includes an upward camped surface 71A and 81A and a downward camped surface
71C and
71C. The length of each up-camped surface 71A and 81A is the same and opposite
to the slope
of the opposing camped surface 71C and 81C. The pressure plate downstream
surface 608 also
includes a cylindrical flange for receiving the faceplate 80.
The central opening 64 of the pnasure plate 60 is surrounded by an annular
sleeve 68. A
plurality of platforms 43 are arcuately positioned about the annular sleeve
68. The pressure plate
upstream surface 60A includes a recess 63 disposed between an outer perimeter
67 and an
outer rim 69 as shown in FIGURE 4A. The recess 63 enables the pressure plate
60 to be
securely retained onto the shell 15 of the showerhead. The pressure plate 60
includes a circular
lip 70 extending from the pressure plate downstream surface 60B. The lip 70 is
concentric with
the central passageway 63, and encases the faceplate 80.
The faceplate 80 has a generally cylindrical shape, with a upstream surface
80A as shown in
FIGURE 5A, and a generally flat downstream surface 80B as shown in FIGURE 5B.
The
faceplate upstream surface 80A includes a center shaft 84 that extends
upstream toward the
showerhead shell 15A. The center shaft 84 of the faceplate 80 nests within the
center portion of
the engager 40. Surrounding the shaft is a cylindrical wall having three
notches 85. Each notch
85 is evenly spaced and extends from the flat faceplate upstream surface SOA
to the distal end of
the cylindrical wall. The notches 85 mesh with the engager ribs 54 downstream
surface 40B.
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CA 02304885 2000-04-07
The center section of the faceplate upstream surface 80A includes three ramps
81, as already
described, for cooperative engagement with the ramps 71 on the pressure plate
downstream
surface 60B.
The outer section of the faceplate downstream surface 80A includes twelve
passages 92 of the
same size and shape, each passage 92 being symmetrically spaced about the
center shaft along
a common circumference. Six of the passages 92A are hollow and unobstructed
for nondetlected
flow. Alternating passages 92B are divided into four equal quadrants by a pair
of crossing
portions 93. The outer perimeter of the faceplate upstream surface SOA is a
cylindrical flange 88
for retention within the pressure plate 60. The faceplate downstream surface
80B includes
convex bubble-shaped deflector surfaces 98 covering the passages 92B.
Deflected flow occurs
when the bubble-shaped deflector surfaces 98 are aligned with the clusters 72
of jet orifices in
the pressure plate 60. Nondetlected flow occurs when the nondeflecting outlet
passages 92A are
aligned with the clusters 72 of jet orifices in the pressure plate 60. A spray-
pattern selector 99
extends radially outward and then rearward from the perimeter of the faceplate
80. The spray-
pattem selector 99 enables a secure grasp for repositioning of the faceplate
80 relative to the
shell 15 for spray pattern selection. Since the only jet impingement striking
the faceplate 80 is
through the bubble-shaped deflector surfaces 98, the faceplate 80 only
requires attachment to
the engager stem 42 with a low force snap fit.
The spacing 81 D between each ramp is sufficient to enable ramps on opposing
surfaces to nest
therebetween during selected spray patterns. The ramps enable (a) the
faceplate 80 and the
engager 40 to move axially relative to the pressure plate 60, and also (b) the
spinner 30 to move
axially relative to the stator 20, alternately, engaging and releasing the
spinner 30. As the
incoming spray alternately is projected through the bubble-shaped deflector
surfaces 98 and the
nondeflecting passages 92A of the faceplate 80, and the spinner 30 is
alternately engaged and
released, four distinct spray patterns are enabled.
14
CA 02304885 2000-04-07
The pressure chamber is the area between the pressure plate upstream surface
60A and the
shell 15A. The spray selection chamber is positioned between the pressure
plate downstream
surface 60B and the faceplate upstream surface 80A. Water enters the stator 20
at between 12
and 18 psi and leaves the spinner 30 at between 7 and 14 psi and water leaves
the pressure
plate 60 at atmospheric pressure. The engager 40 acts as an adapter to
cooperatively engage
the pressure chamber with the spray selection chamber. The 0-ring 50 is
disposed onto the
engager downstream surface 4108, providing a seal between the pressure chamber
and the spray
selection chamber.
The pressure plate 60 is secured to the shell and does not move in either the
axial or rotation
positions relative to the shell. Similarly, the stator 20 is engaged with the
pressure plate 60 and
does not move either axially or rotationally relative to the shell. The
faceplate 80 is rotated
relative to the shell during manual selection of spray patterns. As the
faceplate 80 is rotated
relative to the pressure plate 60 during spray pattern selection, the
faceplate 80 moves inward
and outward axially - one complete rotation includes six inward positions and
six outward
positions. The faceplate 80 moves axially with alternate position selections,
the pattern being A,
A, B, B, A, A, B, B, A, A, B, arid B for each complete rotation. The hole
clusters in the pressure
plate 60 are either aligned with the bubble shaped deflector surfaces or the
passages disposed
between the bubble shaped deflector surfaces, to provide a variety of spray
patterns.
The preferred embodiment of the showerhead engine assembly of the present
invention as
depicted in FIGURES 1 through 8 includes two pulsated positions and two
nonpulsated positions.
Since the faceplate 80 is dividE:d radially into twelve equal sections, the
spray selection pattern is
repetitive three times during a complete rotation of the faceplate 80.
As the spray-pattern selector 99 is rotated to select a spray pattern, the
axial position of the
spinner 30 moves forward and backward relative to the stator 20 as described
above.
IS
CA 02304885 2000-04-07
When the engager perimeter sections 47 are in alignment with the pressure
plate ramps 61, the
ramps 61 nest with the perimeter sections 47, moving the engager 40 forward
relative to the
pressure plate 60, and moving the spinner 30 forward relative to the stator
20. Forward
movement of the spinner 30 relative to the stator 20 releases the spinner 20
from engagement
with the stator stopping ribs 2E.. With the jets orifices 73 in the pressure
plate 60 aligned with the
nondeflecting passages 92A in the faceplate 80, the water jets continue in a
straight, narrow
(nondeflected) spray pattern. 19y continuing to rotate the faceplate 80
relative to the shell 15, the
bubble-shaped deflector surfaces 98 are brought into alignment with the jet
orifices 73. This time,
the water jets are deflected into a larger spray pattern. During rotation of
the spinner 30, the
pressurized water entering through the stator peripheral passages 22 is
stopped by opposing
pads 37 from exiting jet orifices 73 of the plate 60. Rotation of the spinner
30 enables a
deflected, pulsating mode and a nondeflecting, pulsating mode.
To operate in the nonpulsatinq modes, the faceplate 80 is again rotated. The
ramps 61 on the
pressure plate upstream surface 60A move into alignment with the engager
spokes 46. This
results in the engager 40 moving backward, bringing the spinner 30 into
contact with the stator
stopping ribs 28. Such engagement blocks the spinner 30 allowing the water
jets to exit the
showerhead engine assembly 10 of the present invention in a continuous,
uninterrupted spray
pattern. With the jets orifices T3 in the pressure plate 60 aligned with the
nondeflecting passages
92A in the faceplate 80, the water jets continue undeflected in a straight,
narrow spray pattern.
By continuing to rotate the fa~ceplate 80 relative to the shell 15, the bubble-
shaped deflector
surfaces 98 are brought into alignment with the jets orifices 73. This time,
the water jets are of a
relatively constant velocity and deflect into a larger spray pattern. Once
again, the correct
alignment is secured by virtue of the detenting action of the engager 40
(which is snap-fit to the
faceplate 80) into the pressure plate 60.
The number of seals in the showerhead engine assembly of the present invention
is independent
of the number of spray patterns. Fewer seals result in fewer sealing surfaces.
The pressure
16
CA 02304885 2002-12-20
68432-355
ranges in the showerhead ermine assembly of the present invention are unique
in that the fluid
pressure of the water leaving the pressure plate 60 is essentially
atmospheric.
Refemng now to FIGURE 9, an assembly view of a second preferred embodiment of
the
showerhead engine assembly 10B of the present invention is shown. The
showerhead engine
assembly 1 OB is a fixed unit being mounted onto a shell 15B. The showerhead
engine assembly
comprises a stator 20, a spinner 30, an engager 40, an 0-ring 50, a pressure
plate 60, and a
faceplate 80 identical to the stator 20, spinner 30, engager 40, 0-ring 50,
pressure plate 60, and
facepfate 80 of the first preferred embodiment of the showefiead engine
assembly of FIGURE 1.
The shell 15B is essentially the same as any conventional shell for a fixed
showefiead assembly.
FIGURE 10A discloses a side view of the showerhead shell and casing of FIGURE
9; and
FIGURE 10B discloses a sectional front view of the showerhead engine assembly
of FIGURE
10A.
The shell 15B is part of the permanent attachment mech~ism that is welded to
the pressure
plate 60, and the shell 15B is affixed directly to the water connection
mechanism of the fixed unit
shown in FIGURE 9. A bushing is threadedly attached to the shell 15B. The
shell further
includes crossing rods that divide the shower spray into equal qu~lrants (not
shown). Care is
taken to prevent any welding at locations other than the main weld. In some
instances dissimilar
materials are used, such as ABS (acrylonitrile-butadiene-styrene) or Acetal,
to limit the weld surface.
Alternatively, the spinner 30, engager 40 and stator 20 are assembled onto the
pressure plate 60 and
the showerhead engine assembly of the present invention is then welded to the
shell. Then, the
faceplate 80 is pressed onto the engager 40 and the engager 40 is firmly
seated against the stator 20.
FIGURES 11A and 11B disclose the downstream and upstream surfaces,
respectively, of an
alternate embodiment of a faceplate 180 for use with the showerhead engine
assembly of the
present invention. This faceplate 180 shown provides aerated spray, and
nondeflected spray.
When used with a spinner and stator, pulsating selection modes can also be
provided. This
faceplate 180 is compatible with the pressure plate 60, engager 40, 'spinner
30, and stator 20,
m
CA 02304885 2000-04-07
and shell of FIGURE 1. The .aerating flow is at near atmospheric pressure. The
aerating flow
passages 1928 alternate with nondeflected passages 192A and include an inlet
head 196
centrally disposed and positioned on the faceplate upstream surface 80A. As
shown in FIGURE
11 C, each inlet head 196 is surrounded by eight spokes 197 radially extending
therefrom. The
inlet heads 196 and spokes 197 are integral with the flow passages 1928 - the
spokes 197 do
not rotate. The inlet head 196 is dome-shaped. Water jets passing through the
pressure plate 60
strike the inlet heads 196, disrupting the water jets while entraining air
into the flow passages
1928. The surface tension forces are sufficient to divert the path of the
water jets so that they fail
to leave the inlet head 196 cleanly and becomes attached to the top face inlet
head 196. Once
attached to the surface, the water jets tend to remain attached due to surface
tension forces
(Coanda effect). This occurs when a water jet strikes the convex surface of
the inlet head 196,
generating internal pressure forces that effectively entrain the water jets
towards the surface. The
inlet heads 196 can be used with the bubble-shaped deflector surfaces 98 to
provide deflected
and aerated spray. The inlet heads 196 can also be used with the spinner 30
and stator 20 to
provide massaging spray modEa.
These water streams are redirected by impinging the jets upon various
deflector surfaces
disposed within the faceplate 80. These deflector surfaces are positioned
within alternating
openings in the faceplate 80 - an exploded detail view of an aerating
deflector surface is shown
in FIGURE 11C. The water jet, pass through an opening and are not deflected or
strike a series
of deflector surfaces and are redirected, resulting in a more diverse and less
directed spray
pattern. Spray pattern selection occurs by rotating the faceplate 80 relative
to the pressure plate
60. The faceplate 80 is "keyedl" and press fitted to the engager 40. The
rotation of this assembly
results in the open hole or the deflector surfaces aligned with the jet
orifices 73.
FIGURES 12A and 12B disclose another preferred embodiment of a pressure plate
260 for the
showerhead engine assembly of the present invention. In this embodiment, the
hub portion of
the pressure plate 260 has been modified, eliminating ramp features 61 and 71,
and including a
central boss to receive faceplate boss 84. This pressure plate 260 is
compatible with the
18
CA 02304885 2000-04-07
faceplate 80 of FIGURE 5 to firm a two-piece assembly. Since connection to the
engager is not
required, no pressure seal is required, and 0-ring 50 can be eliminated. The
assembly provides
only two modes of operatioin: (1) nondeflected, and nonpulsated spray; and (2)
deflected
nonpulsated spray. Again spray selection is made by rotating the faceplate 80
relative to the
pressure plate 260. This enables the faceplates and the pressure plates to be
interchangeable
with similar components in the other assemblies, reducing the number of
replacement parts
needed for stocking inventory. A decent feature can be included between
faceplate 80 and
pressure plate 260.
Refemng now to FIGURES 13, 14, 15, 16A, 168, 16C, and 16D, a novel self-
cleaning
showerhead engine assemble is shown. FIGURE 13 discloses an assembly view of a
preferred
embodiment with the showerhead engine assembly of FIGURE 1 including a self-
cleaning ring
110 that cleans apertures within the pressure plate 60 as the faceplate 80 is
rotated relative
thereto. Similarly, FIGURE 14 discloses an assembly view of the same self-
cleaning ring 110
shown in FIGURE 13 with the :;howerhead engine assembly of FIGURE 9.
Six self-cleaning pins 103 are disposed normal to the plane of the spring wire
ring 105. The jet
orifices 173 now comprise a primary central opening 173A with four smaller
openings 1738
intersecting the central opening 173A (see FIGURE 16D). Each pin 103 of the
spring wire ring
105 is positioned in a central opening 1T3A. The pin 103 is made to translate
within the holes 65
by the action of rotation of the shower faceplate 80, resulting in a cleansing
action.
As the relative position of the faceplate 80 is rotated about the shell-spring
combination as spray
selections are made, the edges of the faceplate 80 force the pins 103 to move
forward and
backward in an axial direction within the jet orifices 173. Both the jet
orifice 173 and the pin 103
are tapered and the upward movement of the pin 103 into the jet orifice 173
results in the inside
edge of each of jet orifice 173 to be opened and flushed.
19
CA 02304885 2000-04-07
FIGURE 15 discloses an exploded view of the cooperative engagement between the
self
cleaning spring-wire ring and the pressure plate 60 of FIGURES 13 and 14; and
FIGURE 16A,
16B, 16C, and 16D show exF~loded views of the cooperative engagement between
the faceplate
80 and the self-cleaning ring of FIGURES 13 and 14.
While the self-cleaning embodiments are shown with the preferred embodiment of
FIGURE 1 and
FIGURE 9, one skilled in the <~rt will readily recognize that these principles
regarding self-cleaning
can be readily applied to all of the other embodiments depicted herein. In
addition to being
applicable to both hand-held and fixed showerheads, the principles of the
present invention are
also applicable to other type of shower, nozzle, and sprinkler configurations
including lawn
sprinklers, dental appliances;, and sprinkler systems in manufacturing and
process control
operations.
It is evident that many alternatives, modifications, and variations of the
showerhead engine
assembly of the present invention will be apparent to those skilled in the art
in light of the
disclosure herein. It is intended that the metes and bounds of the present
invention be
determined by the appended claims rather than by the language of the above
specification, and
that all such alternatives, modifications, and variations which form a
conjointly cooperative
equivalent are intended to be included within the spirit and scope of these
claims.
