Sprayer

A sprayer has a hollow housing with an inlet port and an outlet opening. A cap assembly closes the outlet opening and includes a plurality of sets of discharge orifices with each set exhibiting an individually different characteristic of orifice flow of fluid from the housing interior. The orifice sets are selectively opened to the passage of flow out of the housing and that flow is valved. Different sets of the orifices provide for a fine-spray cone, larger streams and a swirling jet. A porting seal cooperates with a selector plate to enable fluid communication to different sets of orifices and an overall valving assembly also is included. Still further is a stand for the sprayer which supports it, when desired, above a holder or in a manner which enables convenient storage.

The present invention pertains to a sprayer. More particularly, it relates 
to a multiple-function spray device as well as to associated apparatus. 
Many conventional kitchen sinks include a device known as a vegetable 
spray. It seats in an opening to one side of the main faucet assembly and 
is connected to a diverter valve in the main incoming supply line so as to 
be supplied with water at least whenever the main faucet assembly is 
supplied with water. The vegetable spray normally includes a head mounted 
upon a flexible hose which may be withdrawn from a seat so as to enable 
the spray to be used within the sink for a variety of purposes. Usually, 
the spray head includes its own valve for controlling the emission of the 
spray. The discharge is typically in a cone of individual jets so as to 
perform like a showerhead. Of course, it has proved to be most useful in 
cleaning food products under preparation as well as in performing other 
chores such as cleaning cookingware. 
Somewhat recently, it has been suggested to modify the formerly 
conventional vegetable spray by including a water filter employed in one 
of its modes of operation. In that case, a normal cone diffusion of spray 
is provided in a manner of flow which is exclusive of the filter, while a 
different mode of water discharge is provided for water that flows through 
the filter. One example of that is disclosed in application Ser. No. 
784,420, now U.S. Pat. No. 4,107,046 filed Apr. 4, 1977. As particularly 
embodied, the spray cone is of fixed configuration. 
On the other hand, considerable interest has in recent years been shown 
with respect to the implementation of a variety of spray modes in 
showerheads designed for bathing. Much attention has been directed to the 
provision of pulsating, swirling or other modes of spray delivery, in 
addition to continuous spray, for the purpose of achieving enhanced 
results. Exemplary of such approaches are those described in U.S. Pat. 
Nos. 3,762,648, 3,801,019 and 3,958,756. In terms of structure, such 
devices may become rather involved in order to achieve best performance. 
In view of the foregoing, it is a general object of the present invention 
to provide a multiple-mode sprayer which is effective in achieving that 
end while yet being comparatively simple in structure. 
Another object of the present invention is to provide a new and improved 
sprayer which provides a range of control as between vigorous and gentle 
action of the outletted spray. 
One specific object of the present invention is to provide a new and 
improved vegetable spray. 
Still another object of the present invention is to provide a new and 
improved sprayer that affords versatile characteristics of operation and 
yet which is so arranged as to be economical of production, assembly and 
adaptation to usage. 
Basically, the invention pertains to a sprayer which includes a hollow 
housing that has an inlet port and an outlet opening. A cap closes the 
outlet opening and includes a plurality of sets of discharge orifices with 
each set exhibiting an individually different characteristic of orifice 
flow of fluid from the interior of the housing. Also included are means 
for selectively opening respective orifice sets for the passage of flow 
out the housing and valving the flow of fluid through the housing. One 
improvement takes the form of a first set of orifices in the cap 
circumferentially spaced apart and individually sized to define a 
fine-spray cone. A second set of orifices in the cap are circumferentially 
spaced apart individually and sized to define respective streams 
substantially larger than the spray elements from the orifices of the 
first set. Still another orifice in the cap, which is independent of the 
first and second sets, is furnished to define a different flow 
characteristic. The opening means selects as between the first set, the 
second set and that other orifice. 
Another feature relates to the inclusion of one orifice sized to define a 
stream and selectable for flow by the opening means. Included in the cap 
is an interior cup which surrounds that orifice. A plurality of nozzles 
also are defined in the cap and are directed into the cup at an angle so 
as to induce a swirling of the stream and produce a mist. 
Still another feature has to do with a porting seal which is disposed 
adjacent to the interior wall of the cap and includes a plurality of 
apertures individually distributed in an array such that different ones of 
the apertures communicate with respective different ones of the sets of 
orifices. A selector plate is disposed adjacent to the interior side of 
the seal and includes at least one hole selectively movable to communicate 
with respective apertures. 
As a still further feature, there is an element disposed within the housing 
that is rotatable for effecting the selective determination of the opening 
of respective orifice sets. A stem coupled at one end to the element moves 
the latter in rotation. Disposed on the stem is a valve member. A valve 
seat formed in the housing cooperates with the valve member, upon 
reciprocation of the stem, for opening and closing the passage of fluid 
flow from the inlet toward the outlet opening. Exposed outside the housing 
and coupled to the stem is means for enabling either rotation or 
reciprocation of the stem. 
Finally, there also is an associated sprayer stand for use to support the 
sprayer above a holder. The stand includes a releasable clamp securable 
upon the device and a support rod of a length to extend between the holder 
and the clamp. There is an opening through the holder in which the rod is 
slidable to accommodate storage of the device. An upstanding recess in the 
holder seats a lower end of the rod to dispose the upper end of the same 
above the holder, with the clamp being secured upon the upper end of the 
rod. 
The features of the present invention which are believed to be novel are 
set forth with particularity in the appended claims.

A sprayer 10 is illustrated as used in association with a kitchen or 
bathroom sink or lavatory 11 mounted in a countertop 12. The lavatory 
includes the usual faucet 13 for delivering hot or cold water as selected 
by the user. Sprayer 10 may be located in a storage position as shown in 
FIG. 1 or held in a raised position as shown in FIG. 2. Details of the 
positioning arrangement will be explained later. 
In accordance with a presently preferred embodiment, and as best seen in 
the overall in FIGS. 7 and 8, sprayer 10 includes a hollow housing 20 that 
has an inlet port 22 and an outlet opening 24. A cap 26 closes opening 24 
by being threaded upon that end of housing 20 as indicated at 27. While 
cap 26 may be formed all in one piece, it preferably is composed of an 
orifice plate 28 oriented by a lug 28a and secured in proper position 
across opening 24 by a retaining ring 29 threaded onto housing 20 by 
threads 27. The inner end of ring 29 seats against a trim ring 29a. 
Secured to and downwardly depending from housing 20, like a pistol grip, 
is barrel 30 the internal bore 32 of which communicates at its upper end 
with port 22. The lower end of bore 32 is enlarged and internally threaded 
as at 34 to receive a conventional fitting or coupling 36 which couples a 
flexible hose 38 to the lower end of bore 32. As at least generally 
standardized in the plumbing industry, fitting 36 is well known in 
connection with vegetable sprays installed on kitchen sinks. While forming 
no part of the present invention, as such, such a fitting is described in 
detail in co-pending application Ser. No. 784,420, now U.S. Pat. No. 
4,107,046 filed Apr. 4, 1977 and that application is incorporated herein 
by reference. Hose 38 connects to the conventional diverter valve 39 that 
cuts off flow to the sink faucet when the usual sprayer is operated. 
Plate 28 includes a plurality of sets of discharge orifices with each set 
exhibiting an individually different characteristic of orifice flow of 
fluid from the interior of housing 20. A first set of orifices 40 are 
circumferentially spaced apart individually and sized and oriented to 
define an outer fine-spray discharge cone. As illustrated, there are 
eighteen of orifices 40. A second set of orifices 42 are circumferentially 
spaced apart individually in a ring which lies concentrically within the 
ring defined by orifices 40. Orifices 42 are individually each larger in 
diameter than orifices 40 so as to be sized to define respective jet 
streams substantially larger than the spray elements discharged from 
orifices 40. In this case, there are three of orifices 42 spaced apart 
equally. Yet another orifice 44, which is independent of orifices 40 and 
42, is disposed centrally in plate 28 and is of a size smaller than any of 
orifices 42. With reference to FIG. 5, it will be observed that sprayer 10 
thus is capable of emitting a fine-spray cone 45a from orifices 40, a 
pattern of jets 45b from orifices 42 or a flow 45c from orifice 44 which, 
as will be discussed further, has a special character. 
Disposed within housing 20 are means for selectively opening respective 
orifice sets to the passage of flow out of the housing and for valving 
that flow of fluid through the housing. That is, there is selectability as 
between orifices 40, 42 and 44. In more detail, a porting seal 46 is 
disposed adjacent to the interior wall of plate 28 and includes a 
plurality of apertures 48 distributed in an array such that different ones 
of apertures 48 communicate with respective different ones of orifices 40, 
42 and 44. Disposed adjacent to the interior side of seal 46 is a selector 
plate 50. Plate 50 has to include at least one and in this case includes 
three holes 52 circumferentially spaced equally in a circle which 
corresponds in diameter to that of the circle defined by apertures 48. 
Plate 50 is movable so as to permit selective alignment of holes 52 with 
different ones of apertures 48 and thereby enables communication between 
holes 52 and respective different ones of apertures 48. 
Porting seal 46 is of a resilient material such as thermoset rubber. 
Selector plate 50 is of a more rigid material such as a plastic. Moreover, 
selector plate 50 includes a plurality of nubs 54 which project outwardly 
toward seal 46 and are so disposed as to be seatable in different ones of 
apertures 48 upon selective movement of plate 50. A similar nub is formed 
at the location of each of holes 52, but the latter holes are formed 
through a central area of those particular nubs so as to leave only an 
outer perimeter 53 of those nubs remaining, although that perimeter still 
is seatable in different ones of apertures 48. 
It will be observed that individual different ones of each set of orifices 
40, 42 and 44 are disposed at respective different distances from the 
center of plate 28. Apertures 48 are disposed in a circular array which in 
this case is of a diameter corresponding to that of the circular array 
defined by orifices 42. Recessed into the interior wall of plate 28 are a 
first plurality of three channels 56 which serve to communicate between a 
corresponding three different ones of apertures 48 and orifices 40. 
Orifices 40 are formed at the bottom of a circular recess 58 so as to 
permit the distribution of water to all of orifices 40 by way of the three 
channels 56. Disposed in the middle of each of channels 56, just inside 
recess 58, is an upright post 60 which serves to maintain planar 
continuity of the peripheral margin of seal 46 and prevent seal extrusion 
into channels 56 when under pressure. Another set of channels 62 lead to 
central orifice 44 from three different respective locations alignable 
with another corresponding three different ones of apertures 48. At their 
outer ends, each of channels 62 terminates in a projecting hollow lug 64 
of a diameter to seat within the corresponding one of apertures 48, 
preventing rotation of porting seal 46 as selector plate 50 is rotated. 
Plate 28 includes an interior cup 66 that surrounds orifice 44. Each of 
channels 62 enters the side wall of cup 66 at a tangential angle so as to 
constitute a nozzle directed into the cup. Thus, fluid flowing through 
channels 62 effects a swirling of the water which flows outwardly from 
orifice or opening 44. The size of orifice 44 is sufficiently small that 
the swirling action creates the discharge of a mist. 
Seal 46 includes an outwardly projecting integral lip 70 which 
circumscribes its outer margin and engages with the inner wall of housing 
20 at the front of opening 24. Both the outer margin of lip 70 and that 
portion of opening 24 are tapered inwardly toward the central axis so as 
to facilitate assembly and aid in the attainment of a peripheral seal. 
Seal 46 thereby serves to provide resilient detenting seats for nubs 54 on 
plate 50, as a barrier between the different fluid passageways formed into 
plate 28 and to prevent the escape of fluid around the passageways. The 
entrance of each of apertures 48 is beveled as shown at 72 following which 
the inner walls of those apertures are tapered slightly inwardly toward 
the outlet side of the apertures. The bevel facilitates the seating of 
nubs 54, and the taper enables the achievement of well-defined streams 
outletting from orifices 42. 
It will be seen that the combination of the fluid passageways in plate 28, 
porting seal 46 and selector plate 50 serves as a composite element by 
means of which rotatable movement effects a selective determination of the 
opening of respective sets of orifices. In one possible but not preferred 
alternative, one or more of apertures 48, alignable with whatever number 
of openings 52 are provided in plate 50, may be plugged so as to establish 
one rotative position of plate 50 in which all fluid flow is blocked. 
Thus, plate 50 may serve both as an on-off valve as well as a selector of 
discharge characteristics. 
Desirably, and as herein specifically embodied, that valving function is 
separately though relatedly obtained. To that end, a stem 76 is coupled at 
one end to plate 50 in a manner to permit moving plate 50 in rotation. A 
knob 78 exposed outside housing 20 and located on the end thereof opposite 
cap 26 is affixed on the other end of stem 76 for enabling rotation of the 
stem and corresponding rotation of selector plate 50. A stub 80 outwardly 
projecting from a portion of knob 78 has a groove 81 which is receivable 
over any one of a circumferentially-spaced series of ribs 82 on the inner 
wall of housing 20, so as to detent the rotational position of knob 78 in 
any one of three different positions corresponding to the selection of the 
three different sets of orifices 40, 42 and 44. A hollow boss 84 projects 
integrally inward from plate 50 and includes a pair of space-opposed 
interior ears 86. The front end of stem 76 is necked down and shaped to 
define a pair of space-opposing lugs 88 matably received with respect to 
ears 86 so as to establish a rotational coupling between stem 76 and plate 
50. An additional pair of ribs 83, spaced on either side of detent ribs 
82, project inwardly from the inner wall of housing 20 and engage stub 80 
affixed to knob 78 so as to limit the degree of rotation of the knob. 
A cylinder 90 integrally formed within housing 20 serves as a valve seat. 
An intermediate portion 92 of stem 76 is of reduced diameter and 
terminates at each end with an outward flare followed by respective 
grooves 94 and 96 in which are seated corresponding resilient O-rings 98 
and 100. O-ring 100 serves to prevent the escape of fluid entering through 
port 22 toward knob 78. On the other hand, O-ring 98 constitutes a valve 
member engageable with valve seat 90 upon reciprocation of stem 76 for 
opening and closing the passage of fluid flow from port 22 toward outlet 
opening 24. A coil spring 102 encircles boss 84 and is compressed between 
the interior wall of selector plate 50 and a C-washer 103 seated on stem 
76 and normally urged against a transverse wall 104 integrally formed 
within housing 20. Washer 103 has a slotted lug projecting from one side 
to facilitate its assembly or disassembly. Spring 102 serves to urge plate 
50 tightly against porting seal 46, while at the same time spring 102 
urges stem 76 rearwardly so that O-ring or valve member 98 closes the 
valve assembly and blocks fluid flow. Thus, selector plate 50 and the 
valve composed of O-ring 98 and valve seat 90 are urged in 
mutually-opposing directions. 
The forward or outlet end portion of cylindrical bore 90 is fluted so as to 
define a series of lands 105 circumferentially spaced around stem 76. 
Lands 105 serve to guide the stem and prevent extrusion of O-ring 98 while 
the water is outletted between the lands upon depression of knob 78. 
Slots formed axially into the lower portion of the inner rim of knob 78 
form a pair of circumferentially-spaced fingers 106. Those slots are 
engageable over a hub 107 formed in the facing interior margin of housing 
20. The cooperation of fingers 106 and hub 107 prevents rotation of knob 
78 when depressed. This avoids excessive wear on seal 46 when under fluid 
pressure. Also, fingers 106 are so positioned relative to hub 107 as to 
prevent depression of knob 78 except when it is detented in one of the 
rotational positions corresponding to a desired flow pattern. Thus, the 
user cannot actuate flow when knob 78 is rotationally positioned between 
proper locations. 
As shown in FIG. 7, an annular brush 108 has a split-ring collar 109 that 
is frictionally engaged over ring 29. Of course, brush 108 serves in use 
to enable scrubbing of an object being sprayed. 
Desirably, careful attention is given to the respective flow rates in the 
different modes or patterns. The fine spray of pattern 45a and the jets of 
pattern 45b have orifices sized to deliver a nominal flow rate above one 
gallon per minute at twenty pounds per square inch water pressure. That is 
a rate sufficient to cause the conventional flow diverter 39 in a kitchen 
sink unit to actuate. On the other hand, orifice 44, which delivers a mist 
spray, is sized to deliver a flow rate below the actuation threshold of 
the diverter. Typically, that threshold is at about one-half gallon per 
minute. Moreover, the mist spray flow rate should be sufficiently low as 
to avoid chattering of the diverter valve. Even with conventional diverter 
valve 39 operated to a position designed for normal faucet flow, there is 
sufficient leakage to hose 38 for use of the sprayer in the mist mode of 
delivery from orifice 44. Thus, the rate of flow from orifice 44 is 
sufficiently small to avoid excessive humidification of the entire 
surrounding area of the kitchen or like enclosure. 
When used with a kitchen sink or the like, a sprayer such as that described 
often is useful for rinsing dishes or other large objects that are too big 
to fit under the conventional faucet installation. The separate sprayer 
can be raised to a higher elevation in that situation. FIGS. 2-4 depict an 
arrangement for holding sprayer 20 in a raised position. To that end, a 
special bushing 110 is inserted into the conventional opening 112 formed 
in the surface flange 114 of the sink and locked into place by a nut 116 
threaded onto the lower sleeve 118 of bushing 110. Extending vertically 
through bushing 110 is a central opening 120 that freely accommodates 
passage of hose 38 and includes an upwardly-facing hollow boss 122 in 
which the lower portion 124 of coupling 36 may be seated when the sprayer 
is in its storage position as shown in FIGS. 1 and 3. 
Formed into the upper surface of bushing 110 and slanting slightly in an 
outward direction is a well 125. Receivable within well 125 is the lower 
end of an elongated rod 126 that preferably is bifurcated as indicated at 
128 so as to provide a pair of tongs 130 and 132 sufficiently spread to 
insure snug seating. If desired, several of wells 125 may be spaced around 
bushing 110 so as to permit insertion of rod 126 at any of corresponding 
different locations. 
The upper end of rod 126 is connected by a pin 134 to a clamping ring 136 
seatable around portion 124 of coupling 36. Ring 136 is radially split at 
138 (FIGS. 23-26) so as to enable its expansion or contraction as either 
to free or clamp portion 124. Projecting laterally outward from ring 136 
on respective opposite sides of radial split 138 are ears 140 and 142 each 
of which includes mutually transverse interior channels 144 and 146. 
Channels 144 define a space slightly larger than the diameter of rod 126 
so that, when the end of that rod is received within channels 144, ring 
136, which is of resilient metal or plastic, is enabled to exert a 
clamping force upon portion 124. On the other hand, channels 146 define a 
space slightly narrower than rod 126 so that, when rod 126 is oriented in 
a position generally parallel to the longitudinal axis of portion 124, 
ears 140 and 142 are forceably spread apart in a manner to widen the 
diameter of ring 136 and thereby free portion 124 of the clamping by ring 
136. 
Also extending downwardly through bushing 110 is a hole 148 in which rod 
126 may be received during storage of the sprayer by disposing portion 124 
in boss 122. In that storage condition, rod 126 is oriented relative to 
ring 136 so as to dispose the upper end of rod 126 within channel 146 and 
thereby free portion 124 to enable withdrawal of the sprayer upwardly and 
away from ring 136. In the alternative, the sprayer may be elevated and 
ring 136 together with rod 126 drawn upwardly in which case ring 136 may 
be placed around portion 124 and be so oriented, as shown in FIG. 4, that 
the upper end of rod 126 is moved into channel 144 and ring 136 is thereby 
permitted to clamp upon portion 124 and hold the sprayer in an operative, 
elevated position. 
Of course, the upstandable support assembly just described need not be 
confined for use with the particular sprayer illustrated and described. 
The assembly is particularly advantageous in permitting any kind of 
sprayer to be so mounted as to serve as an auxiliary faucet which may be 
located at a higher elevation than is conventional. 
The sprayer itself which is the subject of this application is decidedly 
advantageous in permitting the selective determination of several 
different spray characteristics. Except for the sealing elements, which 
desirably are of rubber or the equivalent, all parts of the sprayer may 
readily be molded from plastic material. Requiring no more space than that 
typically occupied by conventional sprayers which exhibit only a single 
mode of operation, the newly-disclosed sprayer becomes quite attractive. 
While particular embodiments of the invention have been shown and 
described, it will be obvious to those skilled in the art that changes and 
modifications may be made without departing from the invention in its 
broader aspects, and, therefore, the aim in the appended claims is to 
cover all such changes and modifications as fall within the true spirit 
and scope of the invention.