Magnetic coupling for faucet handle

A fluid delivery device including a body having at least one waterway, a valve assembly in fluid communication with the at least one waterway, the valve assembly including a movable valve member configured to control the flow of water through the at least one waterway and a stem operably coupled to the moveable valve member for movement therewith, and a handle coupled to the stem for movement therewith. A magnetically attractive element is supported by one of the handle and the stem, and at least one magnet is supported by the other of the handle and the stem that is configured to magnetically attract the magnetically attractive element to couple the handle to the stem.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to plumbing fixtures and, more particularly, to a magnetic coupling for plumbing fixtures.

Faucets may include one or more handles for controlling the flow rate and temperature of an outlet water stream delivered from a spout. Traditional two-handle faucets may include one handle that controls the flow of hot water in the outlet stream and another handle that controls the flow of cold water in the outlet stream. Single-handle faucets, on the other hand, typically include a single handle that controls both the temperature of the outlet stream and the flow rate of the outlet stream. The single handle is movable in distinct directions to adjust the total amount and relative proportions of hot and cold water in the outlet stream.

According to an illustrative embodiment of the present disclosure, a fluid delivery device includes a body including at least one waterway, a valve assembly in fluid communication with the at least one waterway, the valve assembly including a movable valve member configured to control the flow of water through the at least one waterway and a stem operably coupled to the moveable valve member for movement therewith, the stem having a longitudinal axis, and a handle operably coupled to the stem for movement therewith. The fluid delivery device further includes a magnetically attractive element supported by one of the handle and the stem and at least one magnet supported by the other of the handle and the stem that is configured to magnetically attract the magnetically attractive element to couple the handle to the stem, the at least one magnet interfacing the magnetically attractive element along an interface plane that extends substantially perpendicular to the longitudinal axis of the stem.

According to another illustrative embodiment of the present disclosure, a fluid delivery device includes a body including at least one waterway, a valve assembly in fluid communication with the at least one waterway, the valve assembly including a movable valve member configured to control the flow of water through the at least one waterway and a stem operably coupled to the moveable valve member for movement therewith, the stem having a longitudinal axis. The fluid delivery device further includes a handle operably coupled to the stem for movement therewith under a magnetic coupling force, the magnetic coupling force between the handle and the stem oriented in a direction substantially parallel to the longitudinal axis of the stem.

According to yet another illustrative embodiment of the present disclosure, a method is provided for adjusting a fluid delivery device. The method includes the step of providing a fluid delivery device including a body having at least one waterway, a handle, and a valve assembly in fluid communication with the at least one waterway, the valve assembly including a moveable valve member and a stem operably coupled to the moveable valve member and to the handle for movement therewith. The method also includes the steps of adjusting the handle to move the stem, the stem actuating the moveable valve member to control the flow of water through the at least one waterway, and removing the handle from the stem by sliding the handle in a direction substantially perpendicular to a longitudinal axis of the stem with sufficient force to overcome a magnetic coupling force between the handle and the stem.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to precise forms disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention. Although the disclosure is described in connection with water, it should be understood that additional types of fluids may be used.

With reference toFIGS. 1-4, an illustrative embodiment faucet10is provided. Faucet10illustratively includes body11having base12and spout14, a single handle16, and a single valve assembly18. Faucet10is configured to fluidly couple to hot and cold water supplies (not shown).

In operation, a user manipulates handle16of faucet10to select a desired fluid temperature and fluid flow rate. Base12of faucet10receives hot and cold water streams from the hot and cold water supplies, valve assembly18of faucet10mixes the hot and cold water streams based on the position of handle16to produce an outlet water stream, and spout14of faucet10delivers the outlet water stream into a sink basin (not shown) or a tub (not shown), for example. As shown inFIG. 4, base12of faucet10defines mounting hole19that is configured to receive a mounting shank (not shown) to couple faucet10to a horizontal surface of the sink deck or the tub deck.

Base12of the illustrative faucet10includes hot water inlet chamber20(FIG. 4), cold water inlet chamber22(FIG. 4), and outlet chamber24(FIG. 2). Hot water inlet chamber20of base12is in fluid communication with the hot water supply (not shown), and cold water inlet chamber22of base12is in fluid communication with the cold water supply (not shown). In operation, the hot and cold water inlet chambers20,22, of base12receive and deliver hot and cold water streams to valve assembly18for mixing.

As shown inFIGS. 2-4, valve assembly18of the illustrative faucet10includes valve body30, base31, gasket32, nut33, and bonnet34. Valve assembly18also includes a moveable valve member, illustratively moveable disc35, and a stationary valve member, illustratively stationary disc36. It is also within the scope of the present disclosure that the moveable valve member may include a moveable ball or another suitable component that moves relative to the stationary valve member to control the flow of fluid through valve assembly18. Valve assembly18also includes stem37that is operably coupled to moveable disc35.

Valve assembly18is supported by base12. To secure valve assembly18to base12, nut33threadably engages base12and bonnet34surrounds and threadably engages nut33, as shown inFIG. 2. To help locate and prevent valve assembly18from rotating or shifting within base12, the illustrative valve assembly18includes pegs38that extend into base12.

Valve assembly18of the illustrative faucet10further includes hot water inlet port40, cold water inlet port42, and outlet port44, as shown inFIG. 4. When valve assembly18is secured to base12, hot water inlet port40of valve assembly18is in fluid communication with hot water inlet chamber20of base12, cold water inlet port42of valve assembly18is in fluid communication with cold water inlet chamber22of base12, and outlet port44of valve assembly18is in fluid communication with outlet chamber24of base12. As shown inFIG. 2, outlet chamber24of base12may split into first portion24athat extends upward to communicate with spout14(FIG. 2) and a second portion (not shown) that extends downward through base12to communicate with an auxiliary fluid dispensing device, such as a side sprayer (not shown).

Handle16of the illustrative faucet10is coupled to stem37of valve assembly18for movement therewith. As shown inFIG. 1, handle16may be configured to rotate stem37about a first axis in the direction of arrow R, as well as tilt or pivot stem37about a second axis perpendicular to the first axis in the direction of arrow T. In use, moving handle16of faucet10relative to base12actuates stem37of valve assembly18, which moves moveable disc35relative to stationary disc36to control the mixing of hot and cold water and the flow rate of water through valve assembly18. Therefore, by adjusting handle16of faucet10, a user is able to selectively vary the temperature and flow rate of water supplied from hot and cold water inlet ports40,42, to outlet port44of valve assembly18. Because outlet port44of valve assembly18is in fluid communication with outlet chamber24of base12, adjusting handle16of faucet10allows the user to selectively vary the temperature and flow rate of water supplied to outlet chamber24of base12. Faucet10may include a diverter valve (not shown) that controls whether the outlet water stream travels through first portion24aof outlet chamber24to be dispensed from outlet end14aof spout14(FIG. 1), and/or whether the outlet water stream travels through the second portion (not shown) of outlet chamber24to be dispensed from an auxiliary side sprayer (not shown), for example.

According to an exemplary embodiment of the present disclosure, handle16is removably coupled to stem37of valve assembly18. Handle16may be removed from valve assembly18to adjust, clean, replace, or repair the components, for example.

To removably couple handle16to stem37of valve assembly18, the illustrative faucet10includes bracket50. As shown inFIGS. 2-4, bracket50includes first surface52that faces valve assembly18, second surface54that faces handle16, and a square-shaped outer periphery56or any other shape with the ability to translate torque, such as a spline.

Bracket50includes central aperture58that is sized and shaped to receive stem37of valve assembly18. An exemplary central aperture58of bracket50is non-circular in shape to prevent bracket50from spinning freely relative to stem37. For example, central aperture58of bracket50may be substantially square or rectangular in shape to receive stem37of a corresponding shape.

Bracket50itself may be removably coupled to valve assembly18. For example, in the illustrative embodiment ofFIGS. 2-4, bracket50is removably coupled to stem37of valve assembly18using screw60. With head62of screw60resting against second surface54of bracket50, screw60extends through central aperture58of bracket50and into an internally threaded bore64of stem37to secure bracket50onto stem37. Because the illustrative bracket50is coupled to stem37of valve assembly18for movement therewith, bracket50should be spaced a sufficient distance from bonnet34to avoid interfering with movement of stem37.

As shown inFIGS. 3 and 4, bracket50includes a plurality of rails66that project from outer periphery56. As shown inFIG. 2, handle16defines corresponding grooves68that are configured to receive rails66. With handle16fully seated onto bracket50, handle16may be prevented from moving relative to stem37of valve assembly18, except along axis A. Thus, handle16may be removed from valve assembly18by pulling handle16upward along axis A. According to an exemplary embodiment of the present disclosure, when handle16is attached to bracket50, bracket50prevents handle16from moving relative to stem37under the force of gravity to reduce the likelihood that handle16will unintentionally detach from stem37.

To further secure handle16onto stem37of valve assembly18, the illustrative faucet10includes at least one magnet and at least one magnetically attractive element. In use, the at least one magnet attracts the at least one magnetically attractive element to couple handle16to stem37of valve assembly18for movement therewith. The magnetically attractive element may itself comprise a magnet, or the magnetically attractive element may be formed of a material that is merely attracted to another magnet. In certain illustrative embodiments, the magnetically attractive element may be formed of iron or steel, such as 410 stainless steel or galvanized steel.

As shown inFIGS. 2-4, the illustrative faucet10includes first magnet70and second magnet72. In other words, the at least one magnetically attractive element is itself a magnet. First magnet70of the illustrative faucet10is coupled to bracket50, which is in turn coupled to stem37of valve assembly18for movement therewith. More specifically, first magnet70is received within recess74of bracket50, as shown inFIG. 3. Second magnet72of the illustrative faucet10is coupled to handle16. More specifically, second magnet72is received within recess76of handle16, as shown inFIG. 4.

First and second magnets70,72, may be secured in place by a variety of suitable techniques. For example, bracket50and/or handle16may be manufactured from a magnetically attractable material, such as iron or steel, to hold first and second magnets70,72within their respective recesses74,76. As another example, a fastener or adhesive may be used to secure first and second magnets70,72, in place.

When second magnet72on handle16is positioned proximate to first magnet70on stem37of valve assembly18, as shown inFIG. 2, first and second magnets70,72, attract one another to magnetically couple handle16to stem37for movement therewith. In an illustrative embodiment, first and second magnets70,72, have an axially facing arrangement. For example, as shown inFIG. 2, first and second magnets70,72, interface along plane P that is oriented substantially perpendicular to longitudinal axis L of stem37. In this illustrative embodiment, magnetic coupling force F between first and second magnets70,72, is oriented in a direction parallel to longitudinal axis L of stem37, as shown inFIG. 2.

According to an exemplary embodiment of the present disclosure, first and second magnets70,72, generate a total coupling force of approximately 10 lbf, 20 lbf, 30 lbf, or more. The coupling force should be strong enough to hold handle16in place during normal operation of faucet10. However, the coupling force should be weak enough to allow a user to overcome the force and remove handle16from faucet10when desired, such as when handle16needs to be repaired or replaced. First magnet70may be positioned in direct contact with second magnet72, as shown inFIG. 2, to generate a sufficient coupling force.

First and second magnets70,72, may be of any conventional design. As is known, magnets have magnetic fields defined by their strength and orientation. Magnetic poles are regions in the magnet where the field of the magnet is most intense, each of which is likened to a geographic direction, north (N) or south (S). The direction of the magnetic field is the direction of a line that passes through the north (N) and south (S) poles of the magnet. Generally, the direction is perpendicular to the magnetic surface of the magnet. The orientation of the magnetic field is the direction pointed to by the north (N) pole of the magnet.

Magnets with a single magnetic field are considered dipolar because they have two poles: a north (N) pole and a south (S) pole. The magnetic field of dipolar magnets can interact with other magnetic fields to produce a repelling or an attracting force. Also, magnets may interact with magnetically attractive materials, such as iron or steel, that are naturally attracted to magnets.

There are several different types of magnets. A permanent magnet has a constant, or permanent, magnetic field. However, an electromagnet generates a magnetic field only when a flow of electric current passes through it. The strength of an electromagnetic field can be altered by changing the current that flows through the electromagnet. Once the current stops flowing through the material, the magnetic field disappears. The magnetic force of any magnet may be changed by altering the position of the magnet relative to another magnet or attractable material.

First and second magnets70,72, may include rare earth magnets. In one illustrative embodiment, first and second magnets70,72, are formed from a neodymium magnetic slurry. While first and second magnets70,72, of the present embodiment are permanent magnets, it is envisioned that other types of magnets, including electromagnets, could be used.

First and second magnets70,72, may be coated or plated to prevent humidity and wetness from corroding and decreasing the magnetic strength. For example, as shown inFIG. 2A, first magnet70includes coating71and second magnet72includes coating73. In an illustrative embodiment, each coating71,73, of first and second magnets70,72, includes an inner-most, first nickel layer, a copper layer on top of the first nickel layer, a second nickel layer on top of the copper layer, and an outer-most, epoxy layer on top of the second nickel layer. In another illustrative embodiment, each coating71,73, is formed of a suitable polymer that is overmolded onto first and second magnets70,72, respectively.

In the illustrated embodiment ofFIGS. 2-4, bracket50and first and second magnets70,72, cooperate to retain handle16in place on stem37of valve assembly18during normal operation of faucet10. As discussed above, and as shown inFIG. 4, rails66of bracket50are received within corresponding grooves68of handle16to prevent handle16from moving relative to stem37, except along axis A. Furthermore, the magnetic coupling force between first and second magnets70,72, resists movement of handle16relative to stem37, even along axis A.

When the user chooses to remove handle16from stem37, the user may pull handle16upward along axis A with enough force to overcome the magnetic coupling force between first and second magnets70,72. When the user chooses to replace handle16, the user may push handle16downward along axis A until handle16is fully seated onto bracket50and first and second magnets70,72, reconnect. Advantageously, these steps of removing and replacing handle16may be completed without the use of tools.

The illustrative faucet10ofFIG. 1achieves an attractive exterior appearance that lacks visible fasteners for securing handle16onto stem37of valve assembly18. Rather, bracket50and first and second magnets70,72, of the illustrative faucet10are interior components that are hidden from view (seeFIG. 2).

With reference toFIGS. 5-7, another illustrative embodiment faucet110is provided. Faucet110ofFIGS. 5-7includes certain features similar to faucet10ofFIGS. 1-4, with like numerals indicating like elements. Faucet110illustratively includes body111having base112and spout114. Faucet110also includes hot and cold handles116a,116b, and hot and cold valve assemblies118a,118b. Faucet110is configured to fluidly couple to hot and cold water supplies (not shown). To couple faucet110to a horizontal surface, such as a sink deck (not shown) or a tub deck (not shown), the illustrative faucet110includes a plurality of escutcheons104,104a,104b, and seals106,106a,106b, that rest atop the sink deck and a plurality of mounting nuts108,108a,108b, that rest beneath the sink deck, as shown inFIG. 6.

In operation, a user manipulates handles116a,116b, of faucet110to select a desired fluid temperature and fluid flow rate. Faucet110receives hot and cold water streams from the hot and cold water supplies, valve assemblies118a,118b, of faucet110provide hot and cold water streams to base112for mixing based on the position of each handle116a,116b, and spout114of faucet110delivers an outlet water stream into a sink basin (not shown) or a tub (not shown), for example.

As shown inFIGS. 6 and 7, each valve assembly118a,118b, of the illustrative faucet110includes valve body130a,130b, base131a,131b, gasket132a,132b, a first, externally threaded nut133a,133b, and a second, internally threaded nut134a,134b. To secure each valve assembly118a,118b, in place, first nuts133a,133b, surround and engage valve bodies130a,130b, and second nuts134a,134b, surround and threadably engage first nuts133a,133b, as shown inFIG. 6. Second nuts134a,134b, rest above escutcheons104a,104b, to hold valve assemblies118a,118b, in place relative to the sink deck (not shown). Each valve assembly118a,118b, may also include an optional spacer ring139a,139b, that rests between the corresponding handle116a,116b, and second nut134a,134b, to maintain a desired position between handles116a,116b, and valve assemblies118a,118b.

Each valve assembly118a,118b, of the illustrative faucet110also includes a moveable valve member, illustratively moveable disc135a,135b, and a stationary valve member, illustratively stationary disc136a,136b. It is also within the scope of the present disclosure that the moveable valve member may include a moveable ball or another suitable component that moves relative to the stationary valve member to control the flow of fluid through each valve assembly118a,118b. Each valve assembly118a,118b, also includes stem137a,137b, that is operably coupled to the corresponding moveable disc135a,135b.

Referring still toFIG. 6, hot valve assembly118aof the illustrative faucet110further includes hot water inlet port140aand hot water outlet port144a, and cold valve assembly118bof the illustrative faucet110further includes cold water inlet port142band cold water outlet port144b. Hot water inlet port140ais in fluid communication with the hot water supply (not shown) and cold water inlet port142bis in fluid communication with the cold water supply (not shown).

Handles116a,116b, of the illustrative faucet110are coupled to stems137a,137b, of valve assemblies118a,118b, for movement therewith. As shown inFIG. 6, handles116a,116b, may be configured to rotate stems137a,137b, about an axis in the direction of arrows R′. In use, moving each handle116a,116b, of faucet110actuates the corresponding stem137a,137b, which then moves the corresponding moveable disc135a,135b, relative to stationary disc136a,136b, to control the mixing of hot and cold water and the flow rate of water through each valve assembly118a,118b. Therefore, by adjusting handles116a,116b, of faucet110, a user is able to selectively vary the flow rate of water supplied from hot and cold water inlet ports140a,142b, to hot and cold water outlet ports144a,144b, of valve assemblies118a,118b. Because outlet ports144a,144b, of valve assemblies118a,118b, are in fluid communication with outlet waterway124of base112, and because waterway124of base112is in fluid communication with outlet end114aof spout114(FIG. 5), adjusting handles116a,116b, of faucet110allows the user to selectively vary the temperature and flow rate of water dispensed form outlet end114aof spout114.

According to an exemplary embodiment of the present disclosure, handles116a,116b, are removably coupled to stems137a,137b, of valve assemblies118a,118b. Handles116a,116b, may be removed from valve assemblies118a,118b, to adjust, clean, replace, or repair the components, for example. The following paragraphs may refer only to handle116aand valve assembly118a, but identical or substantially similar components may be used to removably couple handle116bto valve assembly118b.

Bracket150aincludes central aperture158athat is sized and shaped to receive stem137aof valve assembly118a. Like bracket50ofFIGS. 1-4, bracket150amay be prevented from spinning freely relative to stem137a. For example, central aperture158aof bracket150amay be non-circular in shape to receive stem137aof a corresponding shape, or central aperture158aof bracket150amay include a plurality of internal, radially spaced ridges180athat are sized to receive corresponding, radially spaced protrusions182athat extend from stem137a.

Bracket150aitself may be removably coupled to valve assembly118a. For example, in the illustrative embodiment ofFIGS. 6 and 7, bracket150ais removably coupled to stem137aof valve assembly118ausing screw160a. With head162aof screw160aresting against second surface154aof bracket150a, screw160aextends through central aperture158aof bracket150aand into an internally threaded bore164aof stem137ato secure bracket150aonto stem137a. Because the illustrative bracket150ais coupled to stem137aof valve assembly118afor movement therewith, bracket150ashould be spaced a sufficient distance from second nut134ato avoid interfering with movement of stem137a.

As shown inFIGS. 6 and 7, bracket150aincludes a plurality of radially spaced rails166athat project from outer periphery156a. Handle116adefines corresponding, internal grooves168athat are configured to receive rails166a. With handle116afully seated onto bracket150a, handle116amay be prevented from moving relative to stem137aof valve assembly118a, except along axis A′. Thus, handle116amay be removed from valve assembly118aby pulling handle116aupward along axis A′. According to an exemplary embodiment of the present disclosure, when handle116ais attached to bracket150a, bracket150aprevents handle116afrom moving relative to stem137aunder the force of gravity to reduce the likelihood that handle116awill unintentionally detach from stem137a.

To further secure handle116aonto stem137aof valve assembly118a, the illustrative faucet110includes at least one magnet and at least one magnetically attractive element. In use, the at least one magnet attracts the at least one magnetically attractive element to couple handle116ato stem137aof valve assembly118afor movement therewith.

Unlike faucet10which includes first and second magnets70,72, the illustrative faucet110ofFIGS. 6 and 7includes only a single magnet172aper handle116a. Magnet172ais coupled to handle116a, and more specifically to shoulder176aof handle116a, as shown inFIG. 6. Magnet172amay be secured against shoulder176aof handle116ausing a fastener or adhesive, for example. Magnet172amay be substantially similar to magnets70,72, described above with respect toFIGS. 1-4. For example, magnet172amay generate a magnetic coupling force of approximately 10 lbf, 20 lbf, 30 lbf, or more.

In the illustrative embodiment ofFIGS. 6 and 7, bracket150aitself serves as the magnetically attractive element. In other words, bracket150ais formed of a material that is attracted to magnet172a. For example, bracket150amay be formed of iron or steel, such as 410 stainless steel or galvanized steel. Although this embodiment is described as having only a single magnet172a, it is within the scope of the present disclosure that bracket150aitself may comprise a magnet.

When magnet172aon handle116ais positioned proximate to bracket150aon stem137aof valve assembly118a, as shown inFIG. 6, magnet172aattracts bracket150ato magnetically couple handle116ato stem137afor movement therewith. In an illustrative embodiment, magnet172aand bracket150ahave an axially facing arrangement. For example, as shown inFIG. 6, magnet172aand bracket150ainterface along plane P′ that is oriented substantially perpendicular to longitudinal axis L′ of stem137a. In this illustrative embodiment, magnetic coupling force F′ between magnet172aand bracket150ais oriented in a direction parallel to longitudinal axis L′ of stem137a, as shown inFIG. 6.

According to an exemplary embodiment of the present disclosure, the magnetic coupling between magnet172aand bracket150agenerates a total coupling force of approximately 10 lbf, 20 lbf, 30 lbf, or more. The coupling force should be strong enough to hold handle116ain place during normal operation of faucet110. However, the coupling force should be weak enough to allow a user to overcome the force and remove handle116afrom faucet110when desired, such as when handle116aneeds to be repaired or replaced. Magnet172amay be positioned in direct contact with bracket150a, as shown inFIG. 6, to generate a sufficient coupling force.

In the illustrated embodiment ofFIGS. 6 and 7, bracket150aand magnet172acooperate both mechanically and magnetically to retain handle116ain place on stem137aof valve assembly118aduring normal operation of faucet110. As discussed above, rails166aof bracket150aare received within corresponding grooves168aof handle116ato prevent handle116afrom moving relative to stem137a, except along axis A′. Furthermore, the magnetic coupling force between magnet172aand bracket150aresists movement of handle116arelative to stem137a, even along axis A′.

When the user chooses to remove handle116afrom stem137a, the user may pull handle116aupward along axis A′ with enough force to overcome the magnetic coupling force between magnet172aand bracket150a. When the user chooses to replace handle116a, the user may push handle116adownward along axis A′ until handle116ais fully seated onto bracket150aand magnet172areconnects with bracket150a. Advantageously, these steps of removing and replacing handle116amay be completed without the use of tools.

The illustrative faucet110ofFIG. 5achieves an attractive exterior appearance that lacks visible fasteners for securing handles116a,116b, onto stems137a,137b, of valve assemblies118a,118b. Rather, brackets150a,150b, and magnets172a,172b, of the illustrative faucet110are interior components that are hidden from view (seeFIG. 6).