Spout including a stream straightener

A faucet spout assembly including a spout shell and a stream straightener insert. The spout shell includes an inlet end, an outlet end, and a waterway that extends between the inlet end and the outlet end. Water flows around the stream straightener insert and is delivered from the outlet end of the spout shell in a laminar, sheet-like column, giving the appearance of a large volume of water being dispensed from the faucet spout assembly.

BACKGROUND AND SUMMARY

The present disclosure relates generally to faucet spout assemblies and, more particularly, to a faucet spout assembly incorporating a stream straightener insert.

A faucet spout assembly traditionally includes a spout shell that defines a waterway. In use, water is introduced into an inlet end of the spout shell and is directed through the waterway. The water is then delivered from an outlet end of the spout shell into a receiver, such as sink, a bath tub, or a shower basin.

To increase the turbulence of the water delivered from the outlet end of the spout shell, the faucet spout assembly may include an aerator. The aerator mixes air into the water stream, thereby increasing the velocity of the water stream, reducing splashing, and/or conserving water, for example.

The present disclosure provides a faucet spout assembly including a stream straightener insert. Water flows around the insert and is delivered from the outlet end of the spout shell in a laminar, sheet-like column having a hollow center portion, giving the appearance of a large volume of water being dispensed from the faucet spout assembly.

According to an illustrative embodiment of the present disclosure, a faucet spout assembly includes a spout shell having an inlet end coupled to a fixed mounting surface, an outlet end, and a waterway that extends between the inlet end and the outlet end. An insert is coupled to the spout shell to define a hollow stream of water dispensed from the outlet end of the spout shell.

According to a further illustrative embodiment of the present disclosure, a faucet spout assembly includes a spout shell having an inlet end, an outlet end, and a waterway that extends between the inlet end and the outlet end. A diverter valve assembly is received within the spout shell and includes a plug that is configured to open and close the waterway. An insert is received within the spout shell and includes a body that forces water around the insert and prevents water from being dispensed through the insert to define a hollow stream of water dispensed from the outlet end of the spout shell.

According to another illustrative embodiment of the present disclosure, a faucet spout assembly includes a spout shell having an inlet end coupled to a fixed mounting surface, an outlet end, and a waterway that extends between the inlet end and the outlet end. The waterway is at least partially defined by an interior surface of the spout shell. An insert is received within the waterway of the spout shell and includes an exterior surface. The interior surface of the spout shell and the exterior surface of the insert cooperate to define a hollow stream of water dispensed from the outlet end of the spout shell.

DETAILED DESCRIPTION

Referring initially toFIGS. 1-3, the present disclosure relates to a faucet spout assembly, illustratively a wall-mounted faucet spout assembly10for a bath tub. While the present disclosure relates to a faucet spout assembly10for use with a bath tub, it should be appreciated that the faucet spout assembly10may find use with other faucets, including those mounted to a horizontal mounting deck or vertical wall for dispensing water into a sink or basin.

Faucet spout assembly10illustratively includes spout shell12having interior surface13that extends between inlet end14and outlet end16. Spout shell12may be formed of a rigid metal material, such as brass, steel, zinc, or chrome, a rigid polymer material, or a rigid ceramic material, for example.

Referring next toFIGS. 4 and 5, faucet spout assembly10also includes hollow conduit18and inlet port20. Conduit18and inlet port20are received within spout shell12. Together, spout shell12, conduit18, and inlet port20, cooperate to define waterway22. Inlet port20includes internal threads24for coupling with a conventional water supply line25that extends from a fixed mounting surface, such as wall W (FIG. 5). In use, water from the supply line25is directed into inlet end14of spout shell12and flows through waterway22. As shown inFIGS. 2 and 3, conduit18and inlet port20may be provided with a suitable number of sealing rings26to reduce water leakage between the components.

Referring again toFIGS. 1-3, faucet spout assembly10also includes diverter valve assembly30. According to an exemplary embodiment of the present disclosure, illustrated inFIGS. 2 and 3, diverter valve assembly30includes handle32, cap34, sealing ring35, stem36, and plug38. Cap34and sealing ring35of diverter valve assembly30are coupled to spout shell12to prevent water in waterway22from leaking out of spout shell12. Handle32, stem36, and plug38of diverter valve assembly30are coupled together and are movably received within spout shell12. Specifically, top end40of stem36is coupled to handle32, and bottom end42of stem36is coupled to plug38. Handle32, stem36, and/or plug38may be integrally formed or coupled together using a suitable attachment method. For example, handle32may be threaded onto top end40of stem36. As another example, plug38may include clip44that is configured to snap into annular groove46of stem36. According to an exemplary embodiment of the present disclosure, diverter valve assembly30may be removed from spout shell12and replaced, if necessary.

Diverter valve assembly30allows a user to open and close faucet spout assembly10. Diverter valve assembly30is illustrated in the open position inFIGS. 4-6, thereby allowing the flow of water from inlet port20to outlet end16. With handle32of diverter valve assembly30lowered relative to spout shell12, waterway22is not obstructed by plug38. Thus, water entering waterway22flows through outlet end16of spout shell12and may be delivered into a bath tub (not shown), for example. Diverter valve assembly30is illustrated in the closed position inFIGS. 7-9, thereby preventing water from flowing from inlet port20to outlet end16. With handle32of diverter valve assembly30raised relative to spout shell12, stem36and plug38coupled thereto are also raised to obstruct waterway22. Thus, water entering waterway22is prevented from flowing to outlet end16of spout shell12. Instead, the water may be diverted to a different fluid delivery device, such as a shower head (not shown).

Referring next toFIG. 10, faucet spout assembly10further includes insert50. Insert50may be received within spout shell12, and specifically within outlet end16of spout shell12. In one embodiment, insert50may be coupled directly to spout shell12. In another embodiment, insert50may be coupled to conduit18. In yet another embodiment, illustrated inFIGS. 2,3, and5, insert50may be coupled to cap34of diverter valve assembly30. For example, insert50may include external threads52, and cap34may include internal threads54configured to mate with external threads52of insert50to hold insert50within outlet end16of spout shell12. According to an exemplary embodiment of the present disclosure, insert50may be removed from spout shell12and replaced, if necessary. Insert50may be formed of a rigid metal material, a rigid polymer material, or a rigid ceramic material, for example.

Referring back toFIGS. 2 and 3, an illustrative insert50is sized and shaped to fit within outlet end16of spout shell12. According to an exemplary embodiment of the present disclosure, insert50may be sized and shaped to reduce and/or to avoid obstructing the free flow of water through waterway22, thereby reducing the potential for water to be inadvertently diverted to a shower head (not shown), also known as shower rise. For example, insert50may be a bell-shaped body that narrows from base end60to top end62to fit within outlet end16of spout shell12by mimicking (i.e. following the contour of) the narrowing shape of spout shell12. It is also within the scope of the present disclosure that insert50may be located at and/or extend beyond outlet end16of spout shell12, while still being positioned in fluid communication with waterway22.

Also, an exemplary insert50is sized and shaped to accommodate diverter valve assembly30. For example, insert may include passage64that is configured to receive stem36and plug38of diverter valve assembly30. In the illustrative embodiment ofFIG. 6, stem36and clip44extending from plug38are able to move freely within passage64as diverter valve assembly30is opened and closed.

Referring toFIGS. 5 and 6, insert50includes wall66defining a hollow chamber68and an exterior surface70. In operation, when diverter valve assembly30is in the open position, water flows through waterway22and around insert50. Because exterior surface70of insert50is solid and lacks apertures, the water is not able to flow through insert50. Rather, the water is forced to flow around insert50. After flowing around insert50, the water is illustratively delivered in a substantially laminar, sheet-like column referred to herein as hollow stream S. Hollow stream S provides an aesthetically pleasing flow pattern, giving the appearance of a large volume of water being dispensed from faucet spout assembly10. Hollow stream S may extend smoothly and continuously until contacting a solid surface beneath faucet spout assembly10, such as a surface of a bath tub (not shown).

According to an exemplary embodiment of the present disclosure, water flows through gap72located between wall68of insert50and spout shell12, and specifically through gap72located between exterior surface70of insert50and interior surface13of spout shell12. As shown inFIG. 5, interior surface13of spout shell12may include flange74. Along flange74, interior surface13of spout shell12and exterior surface70of insert50may extend substantially parallel to one another to promote substantially laminar water flow through gap72. The distance between insert50and spout shell12(or the thickness of gap72) may determine the wall thickness of hollow stream S.

According to another illustrative embodiment of the present disclosure, insert50includes at least one alignment tab76that projects outwardly from exterior surface70of wall66. Alignment tab76maintains a desired minimum distance between insert50and spout shell12. In an embodiment, multiple alignment tabs76are distributed around insert50to control the spacing between insert50and spout shell12around the perimeter of insert50. Also, alignment tabs76may prevent insert50from rotating relative to spout shell12. For example, as shown inFIG. 10, spout shell12may include alignment grooves78that are aligned and sized to receive alignment tabs76that project from insert50. In addition, alignment tabs76may promote the substantially laminar flow of water around insert50. In one embodiment, alignment tabs76are spaced above base end60of insert50. The continuous columnar flow of water around insert50may be interrupted by alignment tabs76; however, after passing over alignment tabs76, the continuous columnar flow of water may be restored near base end60of insert50. It is also within the scope of the present disclosure that the alignment tabs may extend from shell12and may be received within grooves in insert50, for example.

The cross-sectional shape of insert50determines the cross-sectional shape of hollow stream S. According to an exemplary embodiment of the present disclosure, inserts50may be provided in various cross-sectional shapes to alter the cross-sectional shape of hollow stream S. For example, the cross-sectional shape of insert50may be circular, elliptical, triangular, square, rectangular, or another polygonal shape, to provide water streams having corresponding cross-sectional shapes.