Magnetic docking faucet

A faucet is provided. The faucet has a spout and a sprayhead releasably coupled to the spout. A hose having a magnetically responsive collar thereon provides fluid through the spout to the sprayhead. A magnet is located in the faucet such that when the sprayhead is coupled to the spout, the collar magnetically couples to the magnet, thereby applying sufficient magnetic force to the hose to retain the sprayhead against the spout.

BACKGROUND

The present application relates generally to the field of faucets. More specifically, the present application relates to systems and methods for releasably coupling a pullout sprayhead to a faucet body.

Some faucets, kitchen faucets in particular, employ a sprayhead attached to a flexible hose. When not needed, the sprayhead is typically docked into an end of a spout. Conventional methods for retaining the sprayhead in the spout include counterweights, mechanical snaps, compression fittings, and compression springs. U.S. Pat. No. 7,753,079 discloses using a magnet attached to each of the sprayhead and the end of the spout to retain the sprayhead therein. Counterweights may be noisy or come to rest on pipes or other items under the sink. Mechanical snaps and compression fit systems may wear over time. Compression springs may be noisy and tend to have a high retraction force when the sprayhead is fully extended and a low retraction force when the sprayhead is docked. Magnets in the sprayhead and at the end of the spout are often limited in size or drive the shape of the spout outlet, limiting aesthetic design options. Accordingly, there is a need for an improved docking system for releasably coupling a pullout sprayhead to a faucet body.

SUMMARY

One embodiment relates to a faucet having a spout and a sprayhead releasably coupled to the spout. A hose having a magnetically responsive collar thereon provides fluid through the spout to the sprayhead. A magnet is located in the faucet such that when the sprayhead is coupled to the spout, the collar magnetically couples to the magnet, thereby applying sufficient magnetic force to the hose to retain the sprayhead against the spout.

Another embodiment relates to a faucet having a sprayhead releasably supported by a spout, a hose passing through the spout, a magnetically responsive collar coupled to the hose, and a magnet. The hose has a first end for receiving fluid from a fluid source and a second end fluidly coupled to the sprayhead. The magnet is located in the faucet such that when the sprayhead is supported by the spout, the collar magnetically couples to the magnet, thereby applying sufficient magnetic force to the hose to retain the sprayhead against the spout.

Another embodiment relates to an apparatus for a releasably retaining a hose relative to a body. The apparatus includes a magnet defining an opening passing axially therethrough, a retainer having a sidewall extending axially through the opening of the magnet, the sidewall defining a bore, and a hose passing through the bore of the retainer. The hose includes a magnetically responsive collar coupled to the hose, an extracted position, in which the collar and the magnet magnetically decouple, and a retracted position, in which the collar and the magnet magnetically couple and the collar is located at least partially in the opening of the retainer.

DETAILED DESCRIPTION

Referring generally to the FIGURES, a faucet having a magnetic docking system and components thereof are shown according to an exemplary embodiment. The faucet includes a body, a spout, and a sprayhead releasably coupled to the spout. A hose carries fluid through the spout to the sprayhead, where the fluid is ejected (e.g., released, sprayed, output) to the environment, for example, into a basin, sink, tub, or shower stall.

The faucet shown inFIGS. 1 and 2is shown in a first or docked position, in which the sprayhead is coupled to the spout. The faucet shown inFIG. 7is shown in a second or undocked position. In the undocked position, the sprayhead is decoupled and spaced apart from the spout. In such a position, the hose is at least partially extracted from the spout. According to the embodiments shown, a magnetized docking assembly is located in the spout, and a magnetically responsive collar is coupled to the hose.

As the sprayhead is returned to the docked position, the docking assembly magnetically couples to and attracts the collar on the hose. According to the embodiment shown, the distance from the collar to the sprayhead is slightly less than the distance from the magnet to the end of the spout. Accordingly, the magnetic force of the docking assembly holds the sprayhead against the spout, thereby preventing the sprayhead from drooping from the spout end, which may be aesthetically unappealing. Further, the pull of the docking assembly transmitted through the sprayhead to the user provides the user a tactile feedback that the sprayhead is docked.

While the docking system herein is described with respect to a faucet, is contemplated that the docking system may be applied to any configuration that requires a hose, cable, rod, or line (e.g., rope, etc.) that needs to be temporarily held in position with or without tension, for example, water hoses for gardening or greenhouses, air hoses for industrial applications, hand held shower hose applications, halyards for banners or flagpoles, (electrical) extension cord coils, control devices, push/pull control rods, etc.

Before discussing further details of the faucet and/or the components thereof, it should be noted that references to “front,” “back,” “rear,” “top,” “bottom,” “inner,” “outer,” “right,” and “left” in this description are merely used to identify the various elements as they are oriented in the FIGURES. These terms are not meant to limit the element which they describe, as the various elements may be oriented differently in various applications.

Referring toFIGS. 1 and 2, a faucet and components thereof are shown, according to an exemplary embodiment. A faucet10includes a base12, a spout14, and a sprayhead16releasably coupled to the spout14. The faucet10is shown to include an arm18is configured to house and support a manual valve (not shown). The valve may be configured to control the volume, temperature, or some combination thereof, of the fluid (e.g., water, beverage, etc.) flow through the faucet. A handle20is coupled to the valve to control the operation thereof. According to other embodiments, the faucet10may not include an arm18, and the valve and handle20may be located remotely from the faucet10. According to various other embodiments, the faucet10may include an electronically controlled valve (e.g., solenoid valve) in addition to or instead of the manual valve.

The base12includes a sidewall22, extending between a first or bottom end24to a second or top end26, and an axially extending cavity28. The bottom end24is configured to provide stable support to the faucet10when coupled to a surface (e.g., countertop, wall, bar, table, support structure, etc.). A stem30may be threadedly coupled to the bottom end24to extend through the surface and to couple to a clamping mechanism32configured to couple the stem30to an opposite side (e.g., underside, inside, etc.) of the surface.

The sidewall22is shown to at least partially define the cavity28, which is configured to receive and permit the passage therethrough of water lines34. For example, the cavity28is shown to receive a cold water line34aand a hot water line34b. According to the exemplary embodiment shown, the faucet10further includes an intermediary line34c(e.g., jumper line, patch line, etc.), which extends between the manual valve and an electronically controlled valve (not shown).

Further referring toFIG. 3, the faucet10further includes an outlet line, shown as hose36, according to an exemplary embodiment. The hose36is configured to carry water through the spout14to the sprayhead16and is sufficiently flexible to permit the hose to travel through the shape of the spout14while the sprayhead16is moved between the docked and undocked position. The hose36is preferably substantially inelastic in an axial direction to facilitate operation of the magnetic docking system. According to the exemplary embodiment shown, the hose36extends from a first or inlet end38, which couples to the electronically controlled valve, to a second or outlet end40, which couples to the sprayhead16. According to another embodiment, the faucet10may not include an electronically controlled valve, in which case, the inlet end38of the hose36couples to the intermediary line34c. The hose36further includes an end portion, shown as ball42, coupled to the outlet end40. The ball42is shown to include a member, shown as stem43, extending into the hose36. The ball42may be secured to the hose36via a clamp, shown as ferrule45, that may be crimped or swaged onto the hose36and stem43.

Further referring toFIG. 4, the sprayhead16includes a sidewall44extending between a first or inlet end46and a second or outlet end48. The sprayhead16transfers fluid from the hose36to an outlet port. For example, the sprayhead16may include an aerator50and one or more non-aerated nozzles52. A diverter mechanism54controlled by a switch56may transition the flow between modes, e.g., divert flow to the aerator50, to the nozzles52, or pause the flow of fluid through the sprayhead16.

The spout14includes a sidewall60extending from a first or bottom end62to a second or top end64. The bottom end62couples to the top end26of the base12. According to other embodiments, the spout14may be fixed to the base12, but according to the embodiment shown, the spout14is rotatably coupled to the base12to provide direction and range of the outlet flow of fluid to the environment, i.e., provides a greater usable work area. The top end64is configured to releasably couple to the sprayhead16.

According to the embodiment shown, the spout14includes a sprayhead support66coupled to the top end64of the spout14. The sprayhead support66includes an at least partially annular flange68extending axially from the top end64and into the sprayhead16when the sprayhead16is in the docked position. The sprayhead support66helps to retain the sprayhead16in the docked position. For example, as shown, the annular flange68provides support to an inner portion of the sidewall44to resist shear forces and to align the inlet end46of the sprayhead16with the top end64of the spout14. The sprayhead support66further provides visual and tactile cues to a user attempting to dock the sprayhead16. The sprayhead support66may be threaded, press fit, or snapped into the spout14. According to the embodiment shown, the sprayhead support66is retained in the spout14by a resilient member70(e.g., o-ring, snap ring, etc.) that is trapped between an outwardly extending ledge72on the sprayhead support66and an inwardly extending ledge74on the sidewall60. According to other embodiments, the sprayhead support may be radially outward of (e.g., circumscribe) the sprayhead16and receive the sprayhead16therein, the sprayhead support may be coupled to the sprayhead16and extend into or around the top end64of the spout14, or the faucet10may not include a sprayhead support66.

As shown, the sprayhead16further includes a socket76proximate the inlet end46and configured to receive and retain ball42of the hose36. According to the exemplary embodiment shown, the socket76is threadedly coupled to the sprayhead16after the hose36is passed through the socket76. According to other embodiments, the socket76may be coupled to the sprayhead16, and the ball42is then pressed or snapped into the socket76.

Referring toFIGS. 1 and 2, the faucet10is shown in a first or docked position, and further referring toFIG. 7, the faucet10is shown in a second or undocked position, according to an exemplary embodiment. In the docked position, the sprayhead16is coupled to the top end64of the spout14. In the undocked position, the sprayhead16is decoupled and spaced apart from the spout14. In such a position, the hose36is at least partially extracted from the spout14.

Referring toFIG. 5, an enlarged portion of the exemplary embodiment ofFIG. 2is shown. A collar78is coupled to hose36, according to an exemplary embodiment. According to one embodiment, the collar78is spliced into the hose36. According to another embodiment, the collar78is “C” shaped collar that may be crimped onto the hose36. According to another embodiment, the collar78is tubular and is crimped onto the hose36in position, for example, after being placed over the end of the hose36during assembly. According to yet another embodiment, the collar78may be coupled to one or more portions of the hose36. For example, the collar78may join two portions of the hose36, for example, by threading, crimping, a quick disconnect system, etc., to end portions of each of the hoses. According to one embodiment, the collar78may be or include the ferrule45. For example, the collar78may be used to secure the stem43to the hose36. According to another embodiment, the collar78may be coupled to the ferrule45. The collar78may be made of any suitable magnetically responsive material (e.g., iron, steel, etc.). According to the exemplary embodiment shown, the collar78is formed of magnet grade stainless steel, i.e., stainless steel having high iron content.

The faucet10includes a docking assembly80, which includes a magnet82and may include a field expander, shown as washer84, and a retainer86. When the sprayhead16is in the docked position, the collar78on the hose36is positioned proximate the docking assembly80, and the magnet82magnetically couples to and attracts the collar78. When the sprayhead16is moved to the undocked position, the hose36is partially extracted from the spout14, and the collar78is moved away from the magnet82, as shown inFIG. 7. During normal use, the collar78is moved sufficiently remote from the magnet82that the collar78and the magnet82magnetically decouple (i.e., magnetic field is sufficiently weak that the magnetic force applied to the collar78is negligible).

As the sprayhead16is returned to the docked position, the magnetic field from the magnet82couples to and attracts the collar78. According to the embodiment shown, the distance from the collar78to the sprayhead16is slightly less than the distance from the magnet82to the end of the spout14. Accordingly, magnetic force of the docking assembly80holds the sprayhead16against the end of the spout14, thereby preventing the sprayhead from drooping, which may be aesthetically unappealing.

A weight88(shown inFIGS. 1 and 3) may be coupled to the hose36to help balance the sprayhead16and to retract the hose36into the spout14. The weight88may be less massive than a conventional weight because the weight88need not retain the entire weight of the sprayhead16in the docked position. For example, the weight88may only compensate for the weight of the hose36as it is being fed into the spout14while the sprayhead16is being returned to the docked position since the docking assembly80provides the force necessary to retain the sprayhead16in the docked position. According to another embodiment, conventional weight may be used to retract the sprayhead16back to the spout, i.e., the faucet10would have a “self-retracting” sprayhead16.

The magnet82is shown to have an annular shape having a bore90(e.g., aperture, opening, cavity, etc.) to permit the hose36to pass therethrough. The magnet82may be a permanent magnet, for example, formed of iron, nickel, cobalt, a rare earth element, etc. According to the exemplary embodiment, the magnet82is formed of neodymium. According to the exemplary embodiment, the docking assembly80is located in a portion of the faucet10having more available space than the top end64of the spout14. Accordingly, the docking assembly80may include a larger, less magnetically dense, lower cost magnet82. The docking assembly80may include magnets of various number, composition, shape, and size to provide customized performance for a given application. As will be described in detail below, the magnetic field from the magnet82is configured to selectively couple to the collar78to retain the sprayhead16in the docked position.

According to other embodiments, the magnet82may be an electromagnet. Using an electromagnet allows calibration or adjustment of the force required to decouple the sprayhead16from the spout14. For example, the user may be able to reduce the strength of the magnetic field to facilitate undocking of the sprayhead16. Another user may increase the strength of the magnetic field to inhibit unwanted undocking of the sprayhead16, for example, by a child. According to another embodiment, a controller may receive a signal from a touch sensor (e.g., capacitive sensor) that a user has touched the sprayhead16. The controller may then reduce or remove power from the electromagnet, thereby enabling easy removal of the sprayhead16from the spout14. The controller may then increase or restore power to the electromagnet when the controller receives a signal from the touch sensor that the user is no longer touching the sprayhead16, for example, when the sprayhead16has been returned to the docked position.

The docking assembly80may further include a washer84, configured to expand or elongate the magnetic field created by the magnet82. The field expander may be formed of any suitable material, for example, iron, steel, etc. As shown, the washer84has an annular shape having a bore92(e.g., aperture, opening, cavity, etc.) to permit the hose36pass therethrough. Referring toFIG. 8A, a schematic diagram of the magnet82and its flux lines94shows that the magnetic field extends a first distance from the magnet. Referring toFIG. 8B, a schematic diagram of the flux lines94′ of the magnet82as affected by the washer84shows that the washer84conducts the magnetic field to elongate or expand the field in an axial direction. Referring toFIG. 10, various numbers, sizes, shapes, and compositions of the washers84may be used to provide customized performance for various applications. As shown, the docking assembly180includes a retainer186, a magnet182, a first field expander184located on a first side of the magnet182, and a second field expander184′ located on a second side of the magnet182. The customized size, shape, and strength of the field may be used to attract a collar (not shown) coupled to the line or hose136.

Further referring toFIG. 6, the docking assembly80may further include a retainer86configured to support the magnet82and the washer84. The retainer86is shown to include an axially extending sidewall96having a first or top end and a second or bottom end axially opposite the first end. The sidewall96passes through bore90of the magnet82and the bore92of the washer84, and in turn the sidewall96defines a bore98(e.g., aperture, opening, cavity, passageway, etc.) configured to permit collar78to pass therethrough. The magnet82may be magnetized before or after the magnet82is coupled to the retainer86. A flange100extends outwardly from the top end and may define a cutout102configured to allow a wire or cable104to pass thereby. The cable104may carry electrical signals and/or power to or from a sensor106, which may be used to cause actuation of the electrically controlled valve. At least one boss108, shown as first boss108a, and second boss108b, may extend outwardly from the bottom end of the retainer86. The bosses108extend radially outwardly beyond the inner diameter of the magnet82. During assembly, the resilient nature of the boss108and/or sidewall96may permit the boss108and/or sidewall96to compress inwardly allowing the washer84and the magnet82to be forced (e.g., pushed, pulled, pressed, etc.) onto the retainer86. The boss108and/or the sidewall96then returned to their natural or uncompressed state, thereby mechanically retaining the washer84and the magnet82onto the retainer86. The retainer86further includes one or more upwardly extending fins110. The fins110include a top surface112that slopes downwardly an inwardly towards the bore98in order to guide the collar78into the bore98as the sprayhead16is returned to a docked position. The fins110may also help guide the hose end38through the retainer86during assembly.

According to one embodiment, the docking assembly80may be supported by coupling to the sidewall60of the spout14. According to another embodiment, the docking assembly80may be interconnectedly supported by the base12. According to the embodiment shown, the magnet82rests upon an annular support structure114. The support structure114has an outwardly extending flange116, which is supported by a column118, which in turn may be supported by or may be part of the base12. According to another embodiment, the docking assembly80may be supported by the base12. According to the embodiment shown, the support structure114is part of a swivel assembly enabling the spout14to swivel (i.e., rotate relative to) relative to the base12. Accordingly, the magnet82of the docking assembly80is proximate the swivel coupling between the base12and the spout14. In other embodiments, the magnet82and the docking assembly80may be located proximate the top end64of the spout14, between the top end64and the apex of the spout14, at the apex of the spout14, or between the apex of the spout14and the bottom end62of the spout14. While the docking assembly80is shown to be located in the spout14, is contemplated that the docking assembly80may be located elsewhere, for example, in the base12or a portion of the faucet beneath support surface.

Referring toFIG. 9A, a graph of load versus deflection and corresponding schematic diagrams9B-9D of the collar78relative to the docking assembly80are shown, according to exemplary embodiments.FIGS. 9B,9C, and9D generally correspond to abscissa120, abscissa122, and abscissa124inFIG. 9A, respectively. Specifically referring toFIG. 9B, the collar78is attracted to the center of the magnet82(e.g., the center of the magnetic field, the center of the magnetic flux, etc.). At this location, the magnetic forces attracting the collar78in both axial directions are balanced, and no resultant magnetic load is applied to the collar78. Referring toFIG. 9D, the collar78is sufficiently far away from the magnet82that the magnetic load on the collar78is negligible. Referring toFIG. 9C, the collar78is shown in a position at which the magnetic load on the collar78is at a maximum. This location is between the positions ofFIGS. 9B and 9D.

Referring toFIG. 9A, when the magnetic load exceeds a threshold value T, the magnetic forces on the collar78exceed the weight of the sprayhead16and an unsupported portion of the hose36. Thus, when the magnetic forces exceed the threshold value, the sprayhead16is retracted and/or retained to the spout14. This region in which the magnetic forces exceed the threshold value T may be referred to as the “sweet spot”. According to an exemplary embodiment, the collar78is located on the hose36such that when the sprayhead16is in the docked position, the collar78is in the sweet spot. Thus, a predictable minimum load is provided at all tolerance extremes, and the sprayhead16is retained in the docked position.

Further referring toFIG. 8A, the dashed line inFIG. 9Acorresponds to a docking assembly having a magnet82only. In such case the sweet spot A is relatively narrow, that is, the sweet spot has a relatively short axial length. Further referring toFIG. 8B, the solid line inFIG. 9Acorresponds to a docking assembly having a magnet82and a washer84. In such case, the magnitude of the magnetic forces remains substantially the same; however, the forces occur over a greater axial distance. Thus, the sweet spot B is expanded, thereby allowing greater tolerances and providing a more robust magnetic docking system. The dotted line inFIG. 9Acorresponds to a docking assembly having a field expander (e.g., a washer) and a larger magnet. In such case, the magnitude of the force increases and the forces occur over an even greater distance, thus creating an even larger sweet spot C. The long smooth curve of the larger magnet and field expander provides the user docking and undocking the sprayhead16a more gentle retraction and a more gentle extension. Accordingly, the size, shape, number, and composition (e.g., materials, magnetic density, etc.) of the magnets and field expanders may be selected to provide a desired force magnitude and sweet spot size for the space available in the faucet in view of cost constraints. Thus, while exemplary values and curves are shown and described inFIG. 9A, other curves may result for other configurations of magnets and field expanders.

Referring generally toFIGS. 11-12B, it is contemplated that the collar coupled to the hose may be magnetized (e.g., be a permanent magnet or an electromagnet). Referring specifically to the exemplary embodiment ofFIG. 11, a docking assembly280includes a retainer286supporting a magnetically responsive ring284. A magnetized collar278is coupled to the hose236. In operation, the magnetic interaction between the collar278and the ring284draw the collar278towards a position in which the ring284circumscribes a midpoint (e.g., midsection, equator, magnetic equator, etc.) of the collar278.

Referring to the exemplary embodiment ofFIGS. 12A and 12B, a docking assembly380includes a magnet382, a field expander384, and a retainer386. A hose336and a magnetized collar378pass through the docking assembly380.FIG. 12Ashows a first position in which the magnetic poles of the collar378are opposite the poles of the magnet382(e.g., N-S or S-N). Accordingly, the collar378is attracted to the magnet382, and a sprayhead coupled to the hose336is retained in a docked position.FIG. 12Bshows a second position in which the magnetic poles of the collar378are similarly aligned with the poles of the magnet382(e.g., N-N or S-S). Accordingly, the collar378is repelled by the magnet382, and the sprayhead coupled to the hose336is pushed out of the docked position. According to one embodiment, the hose336may be sufficiently rigid such that when the sprayhead is rotated (e.g., by a user desiring to undock the sprayhead), the collar378rotates relative to the docking assembly380from the first position to the second position, thereby easing removal of the sprayhead from the docked position. When the sprayhead is returned to the docked position, the magnetic fields of the collar378and the magnet382oppositely align the poles of the collar and the magnet into the first position. According to another embodiment, the magnet382is an electromagnet. A controller may be configured to reverse the polarity of the magnet382in response to a signal. For example, the signal may be from a touch sensor indicating that a user has touched the sprayhead16.

The construction and arrangement of the elements of the faucet as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements. The elements and assemblies may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Additionally, in the subject description, the word “exemplary” is used to mean serving as an example, instance or illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs. Rather, use of the word “exemplary” is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.