Note: Descriptions are shown in the official language in which they were submitted.
CA 02448878 2003-11-28
WO 02/101162 PCT/US02/17578
SPRAY HEAD
The present invention relates to spray heads, and particularly to spray heads
coupled to faucets. More particularly, the invention relates to spray heads
that
extend from the end of the faucet and generally continue with the same
diameter
as the faucet, eliminating the need for an enlarged outlet end.
Backuround of the Invention
Spray heads have been known in the art for years and include two types. The
first type of spray head is mounted to a sink deck at a distance from a
faucet.
Known as sidesprays, these spray heads were coupled to the faucet by a hose
and allowed a user to direct a spray of water to various parts of the sink
that
could not be reached by the faucet. A typical installation is illustrated in
U.S.
Design Patent No. 390,915 to Futo et al.
The second type of spray head is mounted to the distal end of the faucet. This
type of spray head is usually threaded into the distal end of the faucet and
includes a member that moves axially between a first position that provides an
aerated stream of water, and a second position that provides a spray of water.
This type of installation is disclosed in U.S. Patent No. 4,221,337 to Shames
et
al. The advantage of this type of spray head is that it eliminates the need
for an
extra hole in the sink deck or frees an existing hole for another use, such as
a
soap dispenser or air gap. One disadvantage of this type of spray head is that
it
is unable to direct a spray to many parts of the sink. Another disadvantage is
that
once the spray mode is selected, the user must manually reselect the aerated
stream mode.
In more recent times, spray heads have been integrated with the faucet to
combine the advantages of both. These integrated spray heads pull out of the
faucet and allow a user to direct a spray at any part of the sink while
freeing a
hole for other uses. Unfortunately, these integrated spray heads are generally
larger than the spout of the faucet due to the mechanism required to change
between the aerated stream and the spray. These enlarged spray heads have
proven disadvantageous when trying to design attractive faucets. Another
CA 02448878 2003-11-28
WO 02/101162 PCT/US02/17578
disadvantage with conventional integrated spray heads is that once the spray
function is selected, the user must continue to hold the actuator in position
to
retain the function. If the user releases the actuator, the spray head reverts
to
the aerated stream, which can be inconvenient.
Summary of the Invention
The present invention overcomes the above-cited disadvantages and others by
providing a compact pull-out spray head that can fit within the diameter of
the
spout and automatically retains the spray head in the spray mode without
requiring the user to continually hold the actuator.
A spray head according to the present invention comprises a flexible conduit
for
coupling the spray head to a faucet, a shell coupled to the conduit, and an
aerator coupled to the shell for providing an aerator mode of operation. A
spray
ring is disposed between the aerator and the shell for providing a spray mode
of
operation, wherein the spray ring cooperates with the shell to provide a
plurality
of fluid channels. The spray head further includes a diverter that has a
piston
and actuator. The actuator moves the piston between a first position, wherein
the
spray head operates in the aerator mode of operation, and a second position,
wherein the spray head operates in the sprayer mode of operation.
According to one aspect of the invention, the spray ring includes a plurality
of
grooves that cooperate with the shell to define the plurality of fluid
channels. The
spray ring is coupled to the aerator to form a unit, such that the spray ring
and
aerator are removable from the shell as a unit to facilitate cleaning of the
spray
ring and the aerator.
The body includes two fluid supply passages in fluid communication with the
conduit and disposed in spaced-apart relation forming an opening therebetween.
The diverter is disposed between the passages and the aerator and sprayer. In
the first position, the diverter diverts a stream of fluid from the passages
to the
2
CA 02448878 2003-11-28
WO 02/101162 PCT/US02/17578
aerator, and in the second position, the diverter diverts a stream of fluid
from the
passages to the sprayer.
According to another aspect of the invention, the spray head includes a shell
having a cutout and a resilient cover disposed in the cutout. The cover is
generally flush with the shell to form a tubular shape defining an interior
volume.
The body and diverter are disposed in the shell, and the aerator/sprayer
assembly has an outlet for a flow of fluid, with the outlet directing the flow
of fluid
along the longitudinal axis of the body.
Other features and advantages of the invention will become apparent from the
following portion of this specification and from the accompanying drawings,
which
illustrate a presently preferred embodiment incorporating the principles of
the
invention.
Brief Description of the Drawings
Figure 1 is a front view of a faucet incorporating a spray head according to
the
present invention.
Figure 2 is a side view of the faucet of Figure 7.
Figure 3 is a section view taken through a spray head according to the present
invention with the piston position to provide an aerated stream of water.
2S Figure 4 is a section view taken through a spray head according to the
present
invention with the piston position to provide a spray of water.
Figure 5 is a side view of a body and diverter for use with the spray head of
Figure 3.
Figure 6 is a top view of the body and diverter of Figure 5.
3
CA 02448878 2003-11-28
WO 02/101162 PCT/US02/17578
Figure 7 is a front view of the body of Figure 5.
Figure 8 is a section view taken through the body of Figure 7.
Figure 9 is a side view of the diverter housing of the present invention.
Figure 10 is an end view of the diverter housing of Figure 9.
Figure 11 is a section view taken through the diverter housing of Figure 9.
Figure 12 is a partially broken away side view of an aerator housing for use
with
the spray head of Figure 3.
Figure 13 is a plan view of a spray ring for use with the aerator housing of
Figure
12.
Figure 14 is section view taken through the aerator housing and spray ring.
Figure 15 is a plan view of a screen unit of an aerator insert for use with
the spray
head of Figure 3.
Figure 16 is a section view taken through the screen unit of Figure 15.
Figure 17 is a side view of a housing for receiving the screen unit of Figure
15.
Figure 18 is a side view of an aerator removal tool.
Figure 19 is a section view taken along line 19-19 in Figure 18.
Detailed Description of the Drawings
A spray head 10 is illustrated in Figures 1 and 2 in situ with a faucet
assembly 12.
The spray head 10, which is coupled to a control valve 14 by means of a
flexible
4
CA 02448878 2003-11-28
WO 02/101162 PCT/US02/17578
hose 13, preferably pulls out of the faucet spout 16 to allow a user to direct
a
spray of water to any area of a sink.
The spray head 10, as illustrated in Figure 3, includes an outer shell 18, a
body
20, a diverter assembly 22 coupled to the body 20, and an aerator/sprayer
assembly 24 coupled to the diverter assembly 22.
The outer shell 18 is a curved tubular member with a cutout 30 to provide user
access to an actuator for the diverter assembly 22. The cutout 30 receives a
flexible cover 32 that attaches to the shell 18 so as to continue the general
tubular shape of the shell 18, thereby providing a more aesthetically pleasing
appearance. The outer shell 18 includes a clip 16 configured to engage and
retain the body 20.
The body 20 is illustrated in Figures 5-8. The body 20 includes an inlet 36
and a
diverter support 38, with a pair of parallel water passages 40 extending
therebetween. The diverter support 38 includes a pair of parallel alignment
ridges
46, an annular disc 58, a central bushing 60 for receiving a diverter piston
62
(Figure 4), and an annular flange 64. The parallel water passages 40 include
inlet openings 42 (only one shown in Figure 8) in the inlet 36 and outlet
openings
44 in the diverter support 38 (Figure 7). Each passage 40 carries a flange 48
that
includes a pin-receiving bore 50.
The body 20 further includes an opening 52, best seen in Figure 6, defined by
the
diverter support 38, the parallel water passages 40 and the inlet 36. As
illustrated in Figure 3, the diverter actuator 54 is disposed in the opening
52 and
retained by a pivot pin 53 extending between the pin-receiving bores 50 formed
in
the flanges 48. The diverter actuator 54 engages the diverter piston 62 in the
opening 52. The fact that the actuator/piston engagement occurs in the opening
52 allows the actuator 54 to remain within the shell 18, with the flexible
cover 32
providing a slim design that has heretofore been unavailable.
5
CA 02448878 2003-11-28
WO 02/101162 PCT/US02/17578
The diverter assembly 22 includes the diverter support 38, a diverter housing
66
coupled to the diverter support 38, the diverter piston 62, and a diverter
seat 68.
The diverter housing 66, illustrated in Figures 9-11, includes an axis 69, a
base
70, and an externally threaded cylindrical sidewall 72 extending from the base
70.
The base 70 includes a pair of parallel alignment grooves 74 configured to
engage the alignment ridges 46, a central opening 76 disposed between the
grooves 74 and aligned with the axis 69, and a pair of openings 78 offset from
the
axis 69 and parallel thereto. The openings 78 align with the water passage
outlet
openings 44 in the diverter support 38. The base 70 further includes an
annular
groove 82 configured to engage the annular flange 64 on the diverter support
38,
a transverse through bore 84, and upper and lower outwardly extending flanges
86, 88. The upper and lower flanges 86, 88 are configured to receive an o-ring
90 (Figure 3). The through bore 84 extends between the openings 78 and, as
illustrated in Figure 10, the openings 78 extend beyond the axial location of
the
through bore 84. Thus, water entering the housing 66 through the openings 78
must flow in the "upstream" direction through the central opening 76 to get to
the
through bore 84.
The diverter piston 62 includes a shaft seal 96, typically an o-ring, and a
diverter
piston 98. The diverter piston 98 is disposed between the opening 76 and the
diverter seat 68 and is spring-biased against the central opening 76 as
illustrated
in Figure 3. In this position, the water flows into the diverter assembly 22
through
the openings 78 and out through the aerator 102 as indicated by the arrows 99.
In Figure 4, the diverter piston 98 is disposed against the diverter seat 68,
thereby blocking the flow of water to the aerator 102. Instead, the water
flows
into the central opening 76 to the through bore 84 and radially outwardly to a
flow
channel between the outer shell 18 and the aerator/sprayer assembly 24 as
indicated by arrows 101 providing a spray. In the spray position, water
pressure
retains the diverter piston 98 in position against the diverter seat 68,
enabling the
user to release pressure on the actuator 54. When the user turns off the
water,
the spring biasing automatically returns the diverter piston 98 to close the
central
opening 76 to reestablish an aerated stream of water.
6
CA 02448878 2003-11-28
WO 02/101162 PCT/US02/17578
Preferably, the diverter support 38 is molded integrally with the inlet 36 and
passages 40 of the body 20. The diverter housing 68 is preferably attached to
the diverter support 38 by ultrasonic welding. However, the housing 68 can be
attached to the support 38 by gluing, bonding, or the use of adhesives or the
like.
The aerator/sprayer assembly 24 includes an aerator housing 100, an aerator
insert 102 (Figures 15-17), a spray ring 104 and an aerator seal 106 (Figure
3).
The housing 100, illustrated in Figures 12 and 14, includes a longitudinally
extending central aperture 108, having an inlet 110 and an outlet 112, and an
external annular groove 914. The central aperture 108 includes an internally
threaded section 116 and a shoulder 118. The threaded section 116 is
configured to engage the external threads of the diverter housing 66, while
the
shoulder 118 is sized to receive the aerator insert 102. The spray ring 104,
illustrated in Figures 13-14, is a truncated cone with a central aperture 120
and a
plurality of axially extending grooves 122 evenly disposed around the
circumference of the ring 104. The ring 104 is designed to engage the shell
18,
with the grooves 122 and shell cooperating to provide water channels for the
spray function of the spray head 10. The housing 100 further includes a
plurality
of axially extending notches 126 evenly disposed about the outlet 112.
The aerator insert 102 includes a screen unit 130 and an air channel unit 132.
The screen unit includes an annular ring 136 and a conical inlet screen 138
attached to the ring 136. The ring 136 further includes an outwardly extending
flange 140. The air channel unit 132 includes a cylindrical wall 142 with a
plurality of air channels 144 disposed evenly around the wall 142. Each air
channel 144 terminates at an opening 146 through the wall 142. The screen unit
130 is operatively disposed in the air channel unit 132 with the flange 140
resting
on the top edge of the cylindrical wall 142 and extending radially outwardly
from
the wall 142.
An aerator removal tool 148, illustrated in Figures 18-19, includes a socket
150
and a handle 152. The socket 150 includes a sidewall 156 and a plurality of
teeth
158 extending inwardly from the socket sidewall 156. The teeth 158 are
7
CA 02448878 2003-11-28
WO 02/101162 PCT/US02/17578
configured and spaced about the sidewall 156 to engage the notches 126 formed
around the outlet 112 of the aerator housing 100. Advantageously, the aerator
removal tool 150 removes both the aerator and sprayer at the same time for
cleaning. Heretofore, a user had to remove the aerator and sprayer separately
which can be inconvenient.
The present invention has been described with respect to a preferred
embodiment. However, it will be obvious to one of ordinary skill in the art
that
modifications can be made to the described embodiment without departing from
the scope of the invention. For example, while the shelllcover combination has
been described as tubular and is illustrated as a curvilinear cylinder, the
tubular
shape could have an eliptical, oval, or polygonal cross section, or
combinations
thereof, without departing from the scope of the claims. One feature of the
invention is that the cover is flush with, and continues the shape of, the
shell
without adding bulges or protuberances, making the spray head a smooth
extension of the spout. Of course, the spray head could also be used as a
sidespray.
8
