SERVICEABLE SPRINKLER WITH NUTATING DISTRIBUTION PLATE

A sprinkler assembly with a nutating distribution plate can improve even distribution of water. The distribution plate can tilt and/or translate upon water impinging the distribution plate to disperse water in different directions. The sprinkler assembly can have a deflector assembly including the distribution plate and a spindle supported by a starter cap.

FIELD

The present disclosure relates to apparatuses for irrigating turf, agriculture, and/or landscaping.

BACKGROUND

In many parts of the world, rainfall can be insufficient and/or too irregular to keep turf and landscaping green and/or to sufficiently water crops and other agricultural products. Therefore, irrigation systems are often installed to provide adequate irrigation to landscaping and/or agricultural products.

SUMMARY

An aspect is directed to a sprinkler assembly comprises an inlet configured to receive water, a bracket supported by the inlet, a nozzle in fluid communication with the inlet and positioned downstream of the inlet, the nozzle being configured to direct the water out of the nozzle along an axis, a bearing surface positioned downstream of the nozzle and supported by the bracket, a deflector assembly configured to move with respect to the axis in one or both of a rotational and a tilting direction. The deflector assembly comprises a distribution plate positioned downstream of the nozzle and configured to deflect water from the nozzle, and a starter cap. The starter cap is sized and shaped so as to allow both the bearing surface and the distribution plate to independently articulate with respect to the starter cap at least during a startup of the sprinkler assembly.

A variation of the aspect above is, wherein the starter cap comprises a bullet-like shape.

A variation of the aspect above is, wherein the starter cap comprises a cup-like shape.

A variation of the aspect above is, wherein the starter cap comprises a thimble-like shape.

A variation of the aspect above is, wherein the starter cap comprises an inner bearing surface, the inner bearing surface contacting the bearing surface at least during the startup.

A variation of the aspect above is, wherein the starter cap comprises an outer bearing surface, and wherein the deflector assembly comprises a lower bearing surface, the outer bearing surface contacting the lower bearing surface at least during the startup.

A variation of the aspect above is, wherein the deflector assembly further comprises a spindle extending from a side of the distribution plate facing away from the nozzle and a bearing insert supported by the spindle, the bearing insert comprising the lower bearing surface.

A variation of the aspect above further comprises a retainer configured to capture the starter cap in an interior of the bearing insert.

A variation of the aspect above is, wherein the interior of the bearing insert comprises a groove sized and shaped to capture the retainer.

A variation of the aspect above further comprises a weight supported by the spindle.

A variation of the aspect above is, wherein a receptacle in the spindle comprises the bearing insert.

A variation of the aspect above is, wherein the bearing surface is a surface of a shaft at least partially disposed in the receptacle.

An aspect is directed to a sprinkler assembly comprises an inlet, a bracket connected to the inlet, a nozzle in fluid communication with the inlet and positioned downstream of the inlet, the nozzle configured to direct water out of the nozzle along a nozzle axis, and a deflector assembly downstream of the nozzle and configured to move with respect to the nozzle axis in one or both of a rotational and a tilting direction about a pivot point. The deflector assembly comprises a distribution plate configured to deflect water from the nozzle, a spindle extending from a side of the distribution plate facing away from the nozzle and terminating at a distal end, the distal end comprising a receptacle, a bearing insert disposed in the receptacle, a starter cap disposed in the bearing insert, and a bearing surface supported by the bracket and contacting the starter cap at least during a startup of the sprinkler assembly.

A variation of the aspect above is, wherein the starter cap comprises an inner bearing surface, the inner bearing surface contacting the bearing surface at least during the startup.

A variation of the aspect above is, wherein the starter cap comprises an outer bearing surface, and wherein the bearing insert comprises a lower bearing surface, the outer bearing surface contacting the lower bearing surface at least during the startup.

A variation of the aspect above is, wherein the inner bearing surface has a first radius and the outer bearing surface has a second radius greater than the first radius.

An aspect is directed to a method of starting up a sprinkler assembly from rest for irrigation. The method comprises receiving water at a predetermined pressure at an inlet of the sprinkler assembly, directing water from the inlet through a nozzle positioned downstream of and in fluid communication with the inlet, the water exiting the nozzle along a nozzle axis and impinging a distribution plate of a deflector assembly of the sprinkler assembly, the distribution plate positioned downstream of the nozzle and comprising a starter cap, the deflector assembly being supported by a bearing surface, and independently articulating both the bearing surface and the distribution plate with respect to the starter cap when the sprinkler assembly is starting up.

A variation of the aspect above is, wherein the starter cap comprises an inner bearing surface, the inner bearing surface contacting the bearing surface at least when the sprinkler assembly is starting up.

A variation of the aspect above is, wherein the starter cap comprises an outer bearing surface, and wherein the deflector assembly comprises a lower bearing surface, the outer bearing surface contacting the lower bearing surface at least when the sprinkler assembly is starting up.

A variation of the aspect above is, wherein the starter cap comprises a cup-like shape.

DETAILED DESCRIPTION

FIG.1is a front plan view of an embodiment of a sprinkler10with a distribution plate12configured to nutate in a counterclockwise direction during operation of the sprinkler10. The sprinkler10provides an improved startup by reducing friction forces acting on the distribution plate12. For example, in certain embodiments, the distribution plate12of the sprinkler10exhibits improved rotation, tilting, and nutation during startup.

An alternate distribution plate112that is configured to nutate in a clockwise direction is illustrated inFIGS.6and7. Thus, depending on which distribution plate12,112is incorporated into the sprinkler10, a radial angle of one or more grooves42,142in the distribution plate12,112causes the distribution plate12,112to rotate in the clockwise direction or the counterclockwise direction. As explained below, the distribution plate12,112is coupled to the sprinkler10so as exhibit a desired nodding or swaying motion about an axis of rotation during operation of the sprinkler10.

The sprinkler10can include an inlet14. The inlet14defines an upstream end of the sprinkler10. The inlet14can be configured to connect to a water source (e.g., an arm of an irrigation system, a water line, a hose, or some other source of water). In certain embodiments, the inlet14supports a frame or bracket16. In some embodiments, the inlet14can be formed as a part of the bracket16. In some embodiments, the inlet14can be a separate piece that is removably or permanently attached to the bracket16.

In some embodiments, the inlet14is configured to be secured to a water supply line on an irrigation system. In some embodiments, the inlet14is at least partially surrounded by threads18. The threads18can be screwed into the water supply line on the irrigation system. In some instances, a pressure regulator can be positioned between the water supply line and the sprinkler10. The inlet14can also be screwed into an outlet of the pressure regulator. Other attachment methods, including, but not limited to, glued connections, bayonet mounts, snap rings, keys, or collars can be used to secure the sprinkler10to either a water supply line or a pressure regulator.

FIG.2is a bottom perspective view of the sprinkler10ofFIG.1. The sprinkler10can include a nozzle20. The nozzle20can be in fluid communication with the inlet14. The nozzle20can extend at least partially beyond a downstream end of the inlet14. The nozzle20can be configured to output water that enters the nozzle20from the inlet14. In some embodiments, the nozzle20can output water in a pressurized manner. For example, the nozzle20can direct pressurized water received from the inlet14.

In some embodiments, the nozzle20can output water in a predetermined direction. For example, the nozzle20can output water along a longitudinal axis46of the nozzle20(seeFIG.10). In some embodiments, the nozzle20can direct water towards a predetermined location within the sprinkler10. In some embodiments, the nozzle20can direct water in a direction towards a component of the sprinkler10. In certain embodiments, the position of the component may be fixed, user adjustable, or movable with respect to the nozzle20. For example, the nozzle20can direct water in a direction towards the distribution plate12.

As mentioned above, in certain embodiments, the inlet14supports the bracket16. For example, in some embodiments, the bracket16is directly coupled to the inlet14. In some embodiment, the bracket16is indirectly coupled to the inlet14via another component of the sprinkler10. For example, in some embodiments, the bracket16is coupled to a spacer component or one or more nozzle carriers32(a),32(b).

In the illustrated embodiments, the bracket16is manufactured as an integral component with the inlet14. In alternate embodiments, the bracket16is manufactured as a separate component from the inlet14and subsequently coupled to the inlet14during assembly.

The bracket16is configured to generally support the distribution plate12relative to the inlet14and/or the nozzle20while allowing the distribution plate12to nutate during operation of the sprinkler10. In the illustrated embodiment, the bracket16is sized and shaped to allow the distribution plate12to nutate during operation of the sprinkler10while preventing the distribution plate12from separating from the sprinkler10. In this way, the bracket16prevents the distribution plate12from breaking free from the inlet14due to the force created by the pressurized water exiting the nozzle20impinging on the distribution plate12.

The bracket16can directly or indirectly couple to the distribution plate12. In the illustrated embodiment, the bracket16couples the inlet14to the distribution plate12via a housing40. In other embodiments, the bracket16directly couples to the distribution plate12while allowing the distribution plate12to nutate during operation of the sprinkler10. For example, the bracket16can couple to the distribution plate12via a joint such as a ball joint or ball-and-socket joint.

The bracket16can include one or more arms17(for example, one, two, three, four, or more). In embodiments which include a plurality of arms17, the arms17can be spaced apart from one another. As most clearly illustrated inFIG.4, the illustrated bracket16has three arms17. In some embodiments, one or more of the arms17can have an outwardly bulging middle section. The outwardly bulging middle section can be sized and shaped to accommodate movement of the distribution plate12. The one or more arms17can be joined at one or both of their upstream and downstream ends with a collar. In some embodiments, the upstream end of the bracket16is closer to the inlet14than the downstream end.

FIG.3is a top perspective view of the sprinkler10ofFIG.1showing one or more grooves42on an upstream side of the distribution plate12. The distribution plate12can be positioned downstream of the nozzle20. In some embodiments, the nozzle20is configured to direct water onto the distribution plate12.

Water impingement on the distribution plate12can cause the distribution plate12to “wobble.” For example, the distribution plate12can be configured to rotate and/or tilt with respect to the longitudinal axis46of the nozzle20or some other axis thereof, and/or undergo nutation in reaction to water impingement from the nozzle20onto the distribution plate12. In the illustrated embodiment, the water impingement from the nozzle20contacts the one or more grooves42on the upstream side of the distribution plate12imparting lateral forces on the distribution plate12. Wobbling of the distribution plate12can allow water to be dispersed in different directions. Dispersing water in different directions can facilitate a more even distribution of water about an area of irrigation than a sprinkler without the distribution plate12which nutates.

In the illustrated embodiment, the distribution plate12forms a component of a deflector assembly38which will be further described below. In some embodiments, the deflector assembly38is supported by the housing40so as to allow the deflector assembly38, which carries the distribution plate12, to “wobble” in concert with the distribution plate12. The deflector assembly38can be surrounded by the one or more arms17of the bracket16and/or the housing40. As mentioned above, the housing40, which will be described in greater detail below, can be releasably coupled to the bracket16.

FIG.4is a top view of the sprinkler10ofFIG.1showing two spare nozzles20(a),20(b) releasably coupled to two nozzle carriers32(a),32(b). In some embodiments, the sprinkler10can include only one carrier32(a) to hold one spare nozzle20(a). In some embodiments, the sprinkler10can have more than two carriers32(a),32(b) for holding more than two spare nozzles20(a),20(b).

In the illustrated embodiment, the one or more nozzle carriers32(a),32(b) are coupled to the inlet14of the sprinkler10. In other embodiments, the one or more nozzle carriers32(a),32(b) are coupled to other components of the sprinkler10such as, for example, the housing40or the bracket16.

In some embodiments, the one or more carriers32(a),32(b) are manufactured as an integral component with the inlet14. In other embodiments, each of the one or more carriers32(a),32(b) are separately manufactured and subsequently coupled to the inlet14. In this way, the one or more carriers32(a),32(b) can be removed and replaced relative to the inlet14.

FIG.5is a top view of the distribution plate12of the sprinkler10ofFIG.1showing the one or more grooves42radially angled to cause the distribution plate12to rotate in a counterclockwise direction when the water from the nozzle20impinges on the distribution plate12. In some embodiments, the one or more grooves42are disposed on an upstream side of the distribution plate12. The upstream side of the distribution plate12faces the nozzle20. The one or more grooves42can channel the water exiting the nozzle20to be ejected in a controlled direction. In some embodiments, the one or more grooves42can be radially angled to cause the deflector assembly38to rotate when the water from the nozzle20impinges the distribution plate12. In some embodiments, the one or more grooves42can be curved. In some embodiments, such as shown inFIG.5, the one or more grooves42can be identical or substantially identical in shape. The one or more grooves42can also be uniformly or substantially uniformly distributed on the upstream side of the distribution plate12.

FIG.6is a top view of a distribution plate112that is similar to the distribution plate12illustrated inFIG.5except the radial angle of the one or more grooves142inFIG.6causes the distribution plate112to nutate in the clockwise direction when the water from the nozzle20impinges on the distribution plate112.FIG.7is a front view of the distribution plate112ofFIG.6.

As explained above, the radial angle of the one or more grooves42,142in the distribution plate12,112causes the distribution plate12,112to rotate in the clockwise direction or the counterclockwise direction when the water from the nozzle20impinges on the distribution plate12,112. For example, the radial angle of the one or more grooves142illustrated inFIGS.6and7causes the distribution plate112to rotate in the clockwise direction when the water from the nozzle20impinges on the distribution plate112.

Although the sprinkler10has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the sprinkler10can comprise any combination of deflector assembly38(e.g., distribution plate12,112and spindle58) and still fall within the scope of this disclosure.

Example Operations of Certain Embodiments of a Sprinkler

FIGS.8and9illustrate example operations of the sprinkler10. As illustrated inFIG.8, when water pressure is applied to the sprinkler10during startup, water from the nozzle20can impinge on the distribution plate12and cause the distribution plate12to move angularly to a first side or first tilt position (the right-hand side as shown inFIG.8). In some embodiments, the distribution plate12can be pre-tilted to the first side or first tilt position before startup. The deflector assembly38can move until a wear sleeve52contacts the housing40. Additionally, the deflector assembly38can begin to rotate as a result of the water exiting the curved grooves42. As the deflector assembly38rotates, water can be dispersed in different directions.FIG.8illustrates the direction of water flow WF away from the distribution plate12when the distribution plate12is at the first side or first tilt position.

As shown inFIG.9, the deflector assembly38can move to a second side or second tilt position (the left-hand side as shown inFIG.9) relative to the first side illustrated inFIG.8as the water impinges on a different area of the distribution plate12. The direction of water flow WF can change after the deflector assembly38has moved to the second side or second tilt position. Continuous rotation of the distribution plate12about the central axis44combined with the central axis44moving back and forth relative to the longitudinal axis46of the nozzle20can create a nutating movement of the distribution plate12. The nutating movement of the distribution plate12can produce a substantially uniform water flow pattern on the plants being irrigated. The relative positioning of the bearing surface48, the bearing insert68, and the distribution plate12in relation to the wear sleeve52can reduce and/or minimize forces between the wear sleeve52and the housing40to reduce wear and/or extend the useable life of the wear sleeve52as explained in assignee's U.S. patent Application Publication No. 2021/0220849 A1, titled SERVICEABLE SPRINKLER WITH NUTATING DISTRIBUTION PLATE AND WEAR SLEEVE of Healy, the entirety of which is hereby incorporated herein by reference.

FIG.10is a cross-sectional view of the sprinkler10ofFIG.1, as viewed along the cut-plane10-10ofFIG.4, showing the distribution plate12located downstream of the nozzle20and temporarily positioned so that the central axis44of the distribution plate12is on axis with the longitudinal axis46of the nozzle20.FIG.11is a perspective exploded view of the sprinkler10fromFIG.10and further shows features of a subassembly74.

In some embodiments, the entire deflector assembly38, including the distribution plate12, is located downstream of the nozzle20. In the illustrated embodiment, the entire deflector assembly38, including the distribution plate12, is located downstream of a plane defined by the exit from the nozzle20. In this way, no portion of the deflector assembly38can contact the sprinkler10at a location that is upstream of the exit plane and interfere with operation of the sprinkler10.

In some embodiments, the sprinkler10includes a seal retainer22. In some embodiments, the seal retainer22is disposed in the inlet14. In some embodiments, the seal retainer22can be connected to the bracket16. In some embodiments, the seal retainer22can be removably connected to the bracket16. In some embodiments, the nozzle20can be coupled to the bracket16and positioned downstream from the seal retainer22. The seal retainer22has an internal flow path. In some embodiments, at least a portion of the internal flow path can be straight, substantially straight, and/or tapered inward between an upstream end of the seal retainer22and a downstream end of the seal retainer22.

In some embodiments, the seal retainer22can have one or more vanes24formed in the internal flow path. In certain embodiments, the one or more vanes24are sized and shaped to straighten water passing through the seal retainer22and flowing towards the nozzle20. The vanes24can reduce turbulence in the water as the water moves from the inlet14to the nozzle20.

In some embodiments, the sprinkler10includes a seal26. In some embodiments, the seal26is in the form of an O-ring. In some embodiments, the seal26can be positioned downstream of the seal retainer22to prevent pressurized water from leaking between the seal retainer22and the nozzle20. The upstream end of the seal retainer22can be positioned flush or downstream of the inlet14and/or the bracket16.

The nozzle20can be removed and reinstalled to position the nozzle20on the bracket16without any tools. As illustrated most clearly inFIG.3, a user can pinch tabs28and30on the nozzle20and then move the nozzle20slightly downwards to disengage the nozzle20from the bracket16and then laterally to remove the nozzle20from the sprinkler10. The nozzle20similarly can be replaced by reversing the procedure. In some embodiments, the nozzle20can be similar to, or the same as the nozzle disclosed in assignee's U.S. Pat. No. 8,556,196, titled QUICK CHANGE NOZZLE of Lawyer et. al., issued on Oct. 15, 2013, the entirety of which is hereby incorporated herein by reference. The nozzle20can also include an internal taper to accelerate and/or pressurize water flow out from the nozzle20.

The bracket16can support a bearing surface48relative to the inlet14. In the illustrated embodiment, the bearing surface48is disposed on the opposite side of the distribution plate12from the inlet14. In some embodiments, the bearing surface48can be positioned downstream of the distribution plate12. In some embodiments, the bearing surface48can act as a pivot point for the radial and side-to-side motion of the deflector assembly38.

In some embodiments, the bearing surface48is positioned so as to be elevated a distance away from a bottom of the sprinkler10. In some embodiments, the distance the bearing surface48is elevated from the bottom of the sprinkler10is selected so that the bearing surface48is located within the housing40. In some embodiments, the distance the bearing surface48is elevated from the bottom of the sprinkler10is selected so that a horizontal plane passes through both a portion of the bearing surface48and a portion of an upper portion56of the housing40. In some embodiments, the distance the bearing surface48is elevated from the bottom of the sprinkler10is selected so that a horizontal plane passes through both a portion of the bearing surface48and a portion of a wear sleeve52. The bearing surface48and the top of the shaft50can be formed to have a very low resistance to movement to facilitate very easy starting characteristics. During normal operation after startup, the bearing surface48may not be subject to high pressures or significant motion. The positioning of the bearing surface48relative to the wear sleeve52can cause the majority of the wear to be at the wear sleeve52during normal operation after startup and very little to no wear at the bearing surface48. In some embodiments, the top of the shaft50can be positioned below the center of the wear sleeve52during normal operation so that all, or most of the action of the deflector assembly38happens above the top of the shaft50to prevent or reduce load and wear on the bearing surface48after startup.

In some embodiments, by elevating the bearing surface48, the bearing surface48can be positioned closer to the distribution plate12. In some embodiments, by elevating the bearing surface48, the bearing surface48can be positioned near the upper portion56of the housing40. In some embodiments, by elevating the bearing surface48, a portion of the deflector assembly38can be disposed below the bearing surface48and in the housing40. In some embodiments, the portion of the deflector assembly38disposed below the bearing surface48is more than a quarter of the entire deflector assembly38. In some embodiments, the portion of the deflector assembly38disposed below the bearing surface48is selected to facilitate nutation of the deflector assembly38. In some embodiments, the portion of the deflector assembly38disposed below the bearing surface48is selected so that a resulting center of mass of the deflector assembly38is coplanar, slight below, or slight above the bearing surface48.

The bearing surface48can have a spherical or substantially spherical shape, or otherwise a curved shape. In some embodiments, the bearing surface48can be a separate component, such as a ball bearing, installed into the sprinkler10or a curved surface of the sprinkler10. In this way, the bearing surface48can support the deflector assembly38and provide a bearing surface upon which the deflector assembly38can move radially and from side to side. In the illustrated embodiment, the bearing surface48is a surface on a distal end of a shaft50. In the illustrated embodiment, the shaft50extends in an upward direction within the housing40.

In some embodiments, the shaft50is supported by the housing40. In the illustrated embodiment, the shaft50is supported by a boss84or other mounting feature of a weight72disposed within the housing40. In some embodiments, the boss84is configured to receive a portion of the shaft50in a press-fit manner. In some embodiments, a surface of the shaft50includes a groove or other locking feature configured to engage with a complementary locking feature of the boss84so as to secure the shaft50to the boss84. In some embodiments, the shaft50is inserted into the boss84and then rotated to a locked position. In some embodiments, at least a portion of the shaft50is knurled to enhance locking of the shaft50to the boss84.

In some embodiments, the weight72is molded around at least a portion of the shaft50. In some embodiments, the shaft50is inserted into the mold that forms the weight72. When the weight72is formed in the mold, at least a portion of the weights72surrounds at least a portion of the shaft50. In some embodiments, the weight72and the shaft50are formed as a single unit. In some embodiments, the shaft50is permanently connected to the weight72preventing the shaft50from being separated from the weight72without making at least either the weight72or the shaft50unusable. In some embodiments, at least a portion of the shaft50can be knurled, or otherwise deformed to increase the strength of a joint between the shaft50and the weight72. In some embodiments, an outer surface of the shaft50can include at least one groove150. In some embodiments, material of the weight72can flow into the at least one groove150to strengthen the joint between the shaft50and the weight72and prevent the shaft50from separating from the weight72.

In some embodiments, an outer surface of the boss84has a truncated conical shape or other preferred shape. In some embodiments, the outer surface of the boss84has a shape complementary to the shape of the receptacle60that does not interfere with the radial and side-to-side motion of the deflector assembly38.

The bracket16can further support the wear member or wear sleeve52. In some embodiments, the wear sleeve52can be positioned at or downstream of the distribution plate12. In some embodiments, at least a portion of the wear sleeve52is positioned between the deflector assembly38and the housing40. In some embodiments, the wear sleeve52is positioned between an outer surface of the deflector assembly38and an inner surface of the housing40.

In some embodiments, the wear sleeve52can surround a portion of the deflector assembly38. In some embodiments, the wear sleeve52forms a full circle around a portion of the deflector assembly38. In some embodiments, the wear sleeve52forms only a portion of a circle. In some embodiments, the wear sleeve52has a continuous circumference. In some embodiments, the circumference of the wear sleeve52is discontinuous. In some embodiments, the wear sleeve52has a gap between ends of the wear sleeve52. In some embodiments, the wear sleeve52is manufactured in two parts which are assembled together on the sprinkler10. In some embodiments, the wear sleeve52is manufactured in three parts which are assembled together on the sprinkler10.

In some embodiment, a cross-section of the wear sleeve52has a linear shape. In some embodiment, the cross-section of the wear sleeve52has a curved shape such as an L-shape. In the illustrated embodiment, the cross-section of the wear sleeve52is C-shaped. In some embodiment, the cross-section of the wear sleeve52is symmetrical. In some embodiment, the cross-section of the wear sleeve52is asymmetrical.

In some embodiments, the wear sleeve52is positioned to focus intermittent or transitory contact between the deflector assembly38and the sprinkler10during operation of the sprinkler10on a surface of the wear sleeve52. In some embodiments where the wear sleeve52has a curved shape such as an L or C-shape, the contact between the deflector assembly38and the sprinkler10can occur on multiple surfaces of the wear sleeve52. The shape and/or position of the wear sleeve52with respect to one or more of the bearings surface48, the distribution plate12, and the deflector assembly38can advantageously reduce wear and extend the usable life of the sprinkler10.

In the illustrated embodiment, a range of the radial and side-to-side motion of the deflector assembly38upon the bearing surface48is limited by the wear sleeve52. In this way, any resulting forces due to the deflector assembly38nutating during operation of the sprinkler10passes through the wear sleeve52and the bearing surface48. By limiting the range of motion of the deflector assembly38, the wear sleeve52keeps the distribution plate12in a working alignment with the longitudinal axis of the nozzle20. The working alignment can allow water out of the nozzle20to be directed to the distribution plate12.

As mentioned above, in some embodiments, the wear sleeve52is positioned between at least a portion of the outer surface of the deflector assembly38and at least a portion of the inner surface of the housing40. For example, the wear sleeve52can be positioned on the outer surface of the deflector assembly38and/or on the inner surface of the housing40. In the illustrated embodiment and as will be further explained below with respect toFIG.11, the wear sleeve52is disposed on or carried by the deflector assembly38. In some embodiments, the wear sleeve52is disposed on or carried by the housing40. As shown inFIG.10and in some embodiments, the wear sleeve52is the only transitory or intermittent contact portion of the deflector assembly38with the remainder of the sprinkler10after startup.

With continued reference toFIG.10, the deflector assembly38can be supported by the bearing surface48. All or substantially all of the weight of the deflector assembly38can be positioned on the bearing surface48when water is not applied and at startup. The weight on the bearing surface48can cause the wear sleeve52and the central axis44of the distribution plate12to be off-axis from the center axis46, which can be the longitudinal axis46of the nozzle20, when water is not being applied to the sprinkler10. The pre-tilting of the distribution plate12can cause the water from the nozzle20to apply more force to one side of the distribution plate12than to an opposite side of the distribution plate12during startup. The unequal weight distribution on the distribution plate12can cause the wear sleeve52to move towards an opposite side of the housing40and start the nutating (for example, rotating and wobbling) action of the distribution plate12when the pressurized water is supplied to the sprinkler10. In some embodiments, the pre-tilting of the distribution plate12can reduce the likelihood of prolonged alignment between the central axis44of the distribution plate12and the longitudinal axis46of the nozzle20when water first impinges the distribution plate12during startup.

FIG.11is a perspective exploded view of the sprinkler10ofFIG.1. The sprinkler10comprises exemplary features for reducing friction forces, resulting in improved rotation, tilting, and nutation of the distribution plate12during startup. In certain embodiments, the subassembly74comprises the shaft50, the starter cap251, and the bearing insert68. The shaft50can include the bearing surface48. The starter cap251can be disposed between the bearing insert68and the shaft50.

In some embodiments, the sprinkler10comprises, for example, one or more weights188. In certain embodiments, a location of the weight188can shift the center of mass closer to the distribution plate12along the central axis44. In certain embodiments, the mass of the weight188is distributed radially away from the central axis44.

In some embodiments, the deflector assembly38can include a spindle58extending from the distribution plate12on the opposite side of the distribution plate12than the one or more grooves42. In some embodiments, the spindle58directly couples the distribution plate12to the bearing surface48. In some embodiments, the spindle58indirectly couples the distribution plate12to the bearing surface48via one or more other components (e.g., starter cap251).

The spindle58supports the one or more weights188. In the illustrated embodiment, the spindle58supports one weight188. In other embodiments, the spindle58supports more than one weight188. Each of the one or more weights188can have the same weight or a different weight. In some embodiments, the one or more weights188can be constructed of a metal with an appropriate mass. For example, in certain embodiments, the one or more weights188are constructed of brass.

In some embodiments, the one or more weights188have an annular shape. In some embodiments, the one or more weights188are sized to engage with a portion of the spindle58. For example, in certain embodiments, the one or more weights188are pressed onto, or otherwise held securely to the spindle58. In some embodiments, the number and weight of the one or more weights188are selected to adjust or change the rotational speed of the spindle58. In some embodiments, adding the one or more weights188to the spindle58reduces the rotational speed of the spindle58, and subsequently the distribution plate12or112. In this way, water coverage by the sprinkler10can be customized.

As is illustrated in the embodiment ofFIG.11, the spindle58carries the wear sleeve52and the one or more weights188about its outer circumference. For example, the wear sleeve52and the one or more weights188can be installed around a surface70formed on the outer circumference of the spindle58between an end of the insert64and a ridge86of the spindle58. In certain embodiments, the wear sleeve52abuts against the insert64and the weight188so as to maintain a position of the wear sleeve52along the outer circumference of the spindle58during use of the sprinkler10. In certain embodiments, the one or more weights188abut against the wear sleeve52and the ridge86so as to maintain a position of the one or more weights188along the outer circumference of the spindle58during use of the sprinkler10.

In the illustrated embodiment, the spindle58includes an outer thread62for engagement with an inner thread66. In some embodiments, the inner thread66is disposed on the distribution plate12. In the illustrated embodiment, the inner thread66is disposed on an insert64that is press-fit or otherwise coupled to the distribution plate12. In some embodiments, the insert64can also be removably attached to the distribution plate12by using bayonet mounts, snap rings, keys, collars, or other attachment methods (e.g., attachment structures or methods that do not require use of tools or specialized tools for disconnection).

In some embodiments, the bearing surface48can be positioned between the spindle58and the housing40and/or the bracket16when assembled. In some embodiments, the bearing surface48can be a surface of the housing40. In some embodiments, the bearing surface48can be removably attached to the housing40.

As illustrated inFIG.11, the bearing surface48can be an upper or distal surface of the shaft50. The bearing surface48can have a spherical or substantially spherical shape, or otherwise a curved surface. The shaft50can be supported by the housing40. In the illustrated embodiment, a proximal end of the shaft50is coupled to a receptacle in the weight72. In some embodiments, the shaft50is coupled to the lower or upper portions54,56of the housing40. In some embodiments, the shaft50is coupled to the bracket16such as to, for example, the lower collar of the bracket16. The bearing surface48can support the deflector assembly38when water is not applied to the sprinkler10, and/or provide a smooth surface for the deflector assembly38to move relative to the housing40.

In some embodiments, the deflector assembly38includes a receptacle60configured to receive at least a portion of the shaft50. In some embodiments, the receptacle60can be a cone shape or other preferred concave surface. In some embodiments, the receptacle60is sized and shaped larger than the shaft50so that only the bearing surface48portion of the shaft50contacts the deflector assembly38over a range of the radial and side-to-side motion of the deflector assembly38. In some embodiments, the portion of the deflector assembly38in the receptacle60that contacts the bearing surface48has a shape complementary to the shape of the bearing surface48that does not interfere with the radial and side-to-side motion of the deflector assembly38.

Under some conditions, such as when water to the sprinkler10has been turned off and the sprinkler10is not pressurized, a lower bearing surface168of the bearing insert68(FIG.12) rests on the bearing surface48on the end of the shaft50as shown inFIG.10. A friction force between the bearing surfaces48and168which is dependent upon the surface area in contact and the weight of components such as the spindle58and weight188, may resist rotation and/or tilting of the distribution plate12and thus inhibit startup of the sprinkler10. Subsequently, the sprinkler10is pressurized, the water impinges upon the distribution plate12and applies a force along the longitudinal axis46of the nozzle20. A first portion of the force may push the bearing insert68into greater contact with the end of the shaft50and/or increase normal forces at the point of contact, thus increasing the friction force between the bearing surfaces48and168. A second portion of the force produces rotational forces or torques about the central axis44of the distribution plate12due to the flow of water through the grooves42. In most instances, the torques are sufficient to cause the distribution plate12to rotate, tilt, and nutate about the point of contact between the bearing surfaces48and168.

However, in some instances, the second portion of the force may not be sufficient to overcome the friction force between the bearing surfaces48and168, resulting in the distribution plate12remaining stationary. For example, if the water has been turned off for a period of time and subsequently is turned on at a low flow rate or low pressure, such as through a low flow nozzle, water flowing through the grooves42may not produce enough torque to overcome the friction force. The distribution plate12may remain stuck in a rest position.

In some embodiments, the bearing surface48portion of the shaft50directly contacts the spindle58. In some embodiments, the bearing surface48portion of the shaft50supports the spindle58via one or more other components. In the illustrated embodiment, the bearing insert68and the starter cap are251are disposed in the receptacle60and between the bearing surface48portion of the shaft50and the spindle58. In certain embodiments, the starter cap251is disposed between the receptacle60and the bearing surface48portion.

The bearing insert68can allow the deflector assembly38to rotatably pivot at the bearing surface48as well as slide or translate relative to the curved surface of the bearing surface48. In the illustrated embodiment when assembled, the bearing surface48portion of the shaft50loosely couples to the surface of the bearing insert68such that the deflector assembly38can wobble (e.g., tilt, oscillate, bounce, shake, or otherwise move) and rotate when pressurized water from the nozzle20impinges on the distribution plate12.

In some embodiments, the wear sleeve52is carried by a portion of the spindle58of the deflector assembly38. As is illustrated inFIG.11and in some embodiments, the spindle58carries the wear sleeve52about its outer circumference. For example, the wear sleeve52can be installed around a surface70formed on the outer circumference of the spindle58between an end of the insert64and a ridge86of the spindle58. In this way, the wear sleeve52abuts against the insert64and the ridge86so as to maintain a position of the wear sleeve52along the outer circumference of the spindle58during use of the sprinkler10. The wear sleeve52can contact an inner surface of the housing40during use of the sprinkler10, including normal operation of the sprinkler10.

In some embodiments, contacts between one or more surfaces of the wear sleeve52and the inner surface of the housing40can restrict the angular movement of the deflector assembly38and maintain a correct position of the deflector assembly38relative to the nozzle20during normal operation. The correct position can allow water out of the nozzle20to impinge on the distribution plate12.

In some embodiments, the wear sleeve52can provide a resistive interface between the deflector assembly38and the housing40to slow or otherwise regulate the speed of rotation of the distribution plate12during operation of the sprinkler10.

In some embodiments, the wear sleeve52can be a pliable, elastic, resilient, and/or flexible material that can cushion the impact of the deflector assembly38relative to the housing40during operation.

Still referring toFIG.11, in some embodiments, the housing40includes a lower portion54and the upper portion56mentioned above. In some embodiments, the weight72is disposed at least partially within the housing40. In the illustrated embodiment, the weight72can be installed at least partially inside of the lower potion54. The upper portion56can be place over the weight72to retain the weight72between the lower portion54and the upper portion56. In some embodiments, the weight72is a dense material. In some embodiments, the weight72comprises a metal such as zinc. In some embodiments, the weight72is die cast. In some embodiments, the weight72comprises a plurality of small weights such as shot. In some embodiments, the weight72comprises a liquid. In some embodiments, the weight62is positioned at or near the downstream end of the sprinkler10to reduce vibration of the sprinkler10during normal operation.

In some embodiments, the housing40is removable from the sprinkler10. In some embodiments, the lower portion54can be removably attached to the bracket16. In some embodiments, the upper portion56is only removable when the lower portion54is not installed to the bracket16.

In some embodiments, the deflector assembly38and the housing40together form the subassembly74which together couples to the bracket16via the lower portion54of the housing40. In this way, the subassembly74including the deflector assembly38and the housing40is removed from the sprinkler10by the user simply decoupling the lower portion54from the bracket16.

In some embodiments, the lower portion54can include one or more attaching tabs76. The bracket16can have openings78configured to receive the attaching tabs76. The openings78can be located on the collar connecting downstream ends of the plurality of arms17of the bracket16.

In some embodiments there can be three attaching tabs76and three openings78. In some embodiments there can be fewer than three attaching tabs76and openings78. In some embodiments there can be more than three attaching tabs76and openings78. The attaching tabs76and/or the openings78can be substantially uniformly spaced or otherwise around the lower portion54and/or the bracket16. Each of the attaching tabs76can engage one of the openings78to removably couple the lower portion54to the bracket16. The lower portion54can be at least partially disposed within a cavity of the bracket16(such as within a cavity of the collar) when coupled to the bracket16.

In some embodiments, a wear bumper80can surround (for example, completely surround) each of the attaching tabs76. In some embodiments, the attaching tabs76can each have a groove82to retain the wear bumper80. In some embodiments, the wear bumper80can fill at least a portion of any open space between the attaching tab76and the opening78. In some embodiments, the lower portion54can be coupled to the bracket16with each of the openings78surrounding at least a portion of each of the attaching tabs76and each of the wear bumpers80.

In some embodiments, the openings78can also form a bayonet locking mechanism so that the lower portion54can be rotated to a locked position when each of the attaching tabs76locks into each of the bayonet locks formed at the opening78. A user can also look through the openings78and visually verify that the attaching tabs76are in the locked position. In some embodiments, a bayonet locking mechanism can be formed or otherwise positioned in the bracket16without the openings78.

FIG.12is an enlarged portion ofFIG.10enclosed by circular dashed line D. As shown here, the starter cap251is disposed between the bearing surface48of the shaft50and the lower bearing surface168of the bearing insert68. The starter cap251may comprise a bullet-like shape, a cup-like shape, a thimble-like shape, or other shape with an inner bearing surface253and an outer bearing surface255. The inner bearing surface253defines an interior portion or cavity within the starter cap251. For example, the inner bearing surface253may define a cone-shaped cavity within the starter cap251having a circular opening at a lower end and partial spherical point at an upper end.

The outer bearing surface255defines an exterior portion of the starter cap251. For example, the outer bearing surface255may define a partial spherical surface at the upper end that transitions to a side skirt at the lower end which meets the inner bearing surface253.

The inner bearing surface253engages the bearing surface48of the shaft50and the outer bearing surface255engages the lower bearing surface168of the bearing insert68, thus creating two areas of engagement and two articulation points on which the deflector assembly38may rotate, tilt, and nutate. In one aspect, a retainer257may capture the starter cap251within an interior portion of the bearing insert68defined by the lower bearing surface168. The retainer257may include a snap-fit ring or clip. The retainer257may be configured to flex while being inserted into a circumferential groove259within the interior portion of the bearing insert68.

FIG.13is an exploded cross-sectional view of an upper end of the shaft50, the starter cap251, and the bearing insert68illustrating contact surfaces168,48,253,255. In one aspect, the bearing surface48comprises an outer surface on the upper end of the shaft50. The bearing surface48may include a generally conical shape having at an upper tip a radiused surface with a first radius R1. In certain embodiments, the tip of the bearing surface48may include a portion of a sphere. In certain embodiments, the tip of the bearing surface48may include a point. In certain embodiments, the bearing surface48includes a first surface area A1.

In other aspects, the inner bearing surface253comprises an inner surface of the interior portion of the starter cap251. In certain embodiments, the inner bearing surface253can include a generally conical-shaped cavity configured to receive and engage the bearing surface48of the shaft50. In certain embodiments, the inner bearing surface253can include an upper end having a radiused surface with a second radius R2. In certain embodiments, the upper end of the inner bearing surface253can include a portion of a sphere. In certain embodiments, the upper end of the inner bearing surface253can include a point. In certain embodiments, the inner bearing surface253includes a second surface area A2which contacts the first surface area A1of the shaft50. In certain embodiments, the second radius R2may be the same as the first radius R1. In certain embodiments, the second radius R2may be greater than the first radius R1. In certain embodiments, the second surface area A2may be the same as the first surface area A1. In certain embodiments, the second surface area A2may be greater than the first surface area A1.

In another aspect, the outer bearing surface255comprises an outer surface of the starter cap251. In certain embodiments, the outer bearing surface253may include a generally conical shape having at an upper tip a radiused surface with a third radius R3. In certain embodiments, the upper tip of the outer bearing surface255may include a portion of a sphere. In certain embodiments, the upper tip of the outer bearing surface255can include a third surface area A3. In certain embodiments, the third radius R3can be greater than the second radius R2. In certain embodiments, the third surface area A3can be greater than the second surface area A2.

In other aspects, the lower bearing surface168comprises an inner surface of the interior portion of the bearing insert68. In certain embodiments, the lower bearing surface168may include a generally conical-shaped cavity configured to receive and engage the outer bearing surface255of the starter cap251. In certain embodiments, the lower bearing surface168may include an upper end having a radiused surface with a fourth radius R4. In certain embodiments, the upper end of the lower bearing surface168may include a portion of a sphere. In certain embodiments, the lower bearing surface168includes a fourth surface area A4which contacts the third surface area A3of the starter cap251. In certain embodiments, the fourth radius R4may be the same as the third radius R3. In certain embodiments, the fourth radius R4may be greater than the third radius R3. In certain embodiments, the fourth surface area A4may be the same as the third surface area A3. In certain embodiments, the fourth surface area A4may be greater than the third surface area A3.

In some embodiments, the bearing insert68is press-fit into the receptacle60. In some embodiments, the bearing insert68can also be removably attached in the receptacle60by using bayonet mounts, snap rings, keys, collars, or other attachment methods (e.g., attachment structures or methods that do not require use of tools or specialized tools for disconnection). In some embodiments, the lower bearing surface168of the bearing insert68engages the outer bearing surface255due to a shape complementary to the shape of the outer bearing surface bearing255such that when the sprinkler10is in the rest position the two surfaces are substantially engaged.

In some embodiments, the bearing surface48on the distal end of the shaft50includes a cone shape or other preferred convex surface. In some embodiments, the bearing surface48includes conical shape with an apex or point at the distal end. The apex may include a second radius R2less than the first radius R1. In some embodiments, the inner bearing surface255is sized to fit over the bearing surface48of the shaft50. For example, the inner bearing surface255may include a radius that is less than the first radius R1and substantially the same as the second radius R2.

When there is no water flow, the deflector assembly38rests on the starter cap251and the starter cap251rests on the bearing surface48of the shaft50. As water impinges on the distribution plate12, the deflector assembly38is pushed into a rotary motion due to the grooves42in the distribution plate12. The starter cap251moves freely on the shaft50because the friction force is reduced by the decreased contact between surface area A2and surface area A1. As the deflector assembly38rotation accelerates, the increased rotational force overcomes any remaining friction force between surface area A4and surface area A3.

As the deflector assembly38rotation accelerates even more, the bearing insert68lifts off from the starter cap251due to the increased angle of tilt such that surface area A3is no longer in contact with surface area A4, thus eliminating forceful contact during operation. This double-articulation at the interfaces of the bearing insert68and starter cap251and the starter cap251and the bearing surface48of the shaft50reduces frictional contact between the deflector assembly38and the shaft50, especially during initial startup or after prolong periods of non-use and no water flow, thus allowing the sprinkler10to begin rotating, tilting, and nutating at low pressure and low flow. Further benefit is gained by eliminating forceful contact of the bearing insert68, the starter cap251, and the shaft50during operation, thus reducing wear and prolonging the life of the sprinkler10.

In some embodiments, every component of the sprinkler10can be serviced, cleaned, and/or replaced by a user with minimal tools and effort (such as without any tools, or with off-the-shelf tools like a standard-sized screwdriver and/or a standard sized wrench). The user can disassemble the sprinkler components in any order.

The user can also reassemble a cleaned or new starter cap251and/or bearing insert68into the receptacle60in the spindle58. The user can reinsert the weight72(together or separately from the lower portion54) so that the cleaned or new shaft50enters the receptacle60in the spindle58and positions the bearing surface48portion of the shaft50in contact with the starter cap251. The user can also re-engage the attaching tabs76(which can include mounting the wear bumper80onto the attaching tabs76) and the openings78to attach the lower portion54to the bracket16. The user can reassemble the components in any order.

Terminology

Although the sprinkler has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the sprinkler and subassemblies extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the embodiments and certain modifications and equivalents thereof. For example, some embodiments are configured to operate oriented such that the distribution plate is positioned above the nozzle and the nozzle directs water upward. Accordingly, it is intended that the scope of the sprinkler herein disclosed should not be limited by the particular disclosed embodiments described above but should be determined only by a fair reading of the claims that follow.