SHEET FLOW SPOUT

Abstract: A spout (10) for providing a flow of water in the form of a sheet is disclosed. Water from a supply pipe (p) is diverted orthogonally in two directions as it enters a reservoir inside the spout. Water pooled in the reservoir (37) spills over a weir (46) to form a sheet-shaped flow stream as it flows down the weir. The weir has a raised section (50) which helps define a flow chamber (54) to promote and develop a stream which maintains a sheet shape even relatively great distances from the spout.

Description: The present invention relates to spouts for providing a stream of water in the shape of a sheet or curtain. The invention is especially useful as a bathtub spout. Spouts for providing a sheet flow of water, such as into a bathtub, are known. Streams so shaped are aesthetically pleasing and also do not make as much noise at typical cylindrical or turbulent flow streams. For example, U.S. Patent N°. 4,334,328 describes such a spout with a wide, thin flat, horizontal flow chamber. Maintaining the shape of the stream in a sheet becomes more difficult the further the stream flows from the spout on its way into a tub or whirlpool. The sheet shape tends to become turbulent and irregular the further the stream flows from the spout. This can detract from the appearance of the sheet and can cause a more noisy flow. Therefore, it can be seen that a need exists for a spout which provides a sheet-like flow stream which maintains its shape even relatively far from the spout. WO85/02132 relates to a nozzle for creating a wide mist spray pattern. FR-A-2333578 relates to a nozzle for creating a wide flow pattern. Neither of these publications disclose any means for solving the above-stated problem in a spout for a tub or whirlpool. It is therefore a principal object of the invention to provide a spout for connection to a water supply pipe to form a flow stream in the form of a sheet and wherein the flow stream maintains its sheet shape relatively far from the spout. The present invention therefor provides a spout for providing a flow of water in the shape of a sheet and having a flow surface past which the water flows and then exits the spout, said spout including inlet means upstream of the flow surface, the flow surface diverging in width in the direction of flow, wall means in combination with the flow surface defining a flow chamber, the flow chamber defining an elongate outlet through which the water exits the flow chamber, at least a portion of said wall means converging toward the flow surface in the direction of flow, characterized by an elongate crest downstream of the inlet means, the flow surface extending from the crest to the outlet, a center section of the flow surface being raised and arcuate in each of two orthogonal directions making the center of the flow chamber thinner in the area of the center section than at the sides of the chamber, one of said two directions being in the direction of flow and the other of said directions being transverse to the direction of flow, a first radius defining the center section in the flow direction to be concave up, a second radius defining the center section in the transverse direction to be convex, and the center section being adjacent to the outlet so that the outlet is thinner in the center than at the sides. One of the principal advantages of the invention is that spouts made in accordance with the invention can in large part be inexpensively manufactured. Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention together with the drawings, wherein: Fig. 1 is a sectional view taken along plane 1-1 of Fig. 2 of a spout of the invention; Fig. 2 is a view of the outlet of the spout taken along plane 2-2 of Fig. 1; Fig. 3 is a front elevation view of a base for the spout of Fig. 1; Fig. 4 is a rear elevation view of the base of Fig. 3; Fig. 5 is a front elevation view of a back for the spout of Fig. 1; Fig. 6 is a section taken along plane 6-6 of Fig. 3; Fig. 7 is a view of the front edge of the base taken along plane 7-7 of Fig. 6; Fig. 8 is an elevation view taken along plane 8-8 of Fig. 6; Fig. 9 is a section view taken orthogonally to the direction of flow along line 9-9 of Fig. 3 illustrating a cross-section of a flow surface of the spout; Fig. 10 is a section view similar to Fig. 9 but taken along line 10-10 of Fig. 3; and Fig. 11 is a section view similar to Fig. 9 but taken along line 11-11 of Fig. 3. Referring to Fig. 1, a sheet flow spout 10 of the invention is illustrated. The spout 10 includes a base 12, a back 13, a cover 15, a facade 16, a collar 18, an insert 19, an O-ring 20, a cover plate 21 and a screw 22. All of the parts except the collar 18, screw 22, facade 16 and O-ring 20 are preferably molded plastic. The facade 16, collar 18 and screw 22 are metal and the O-ring 20 is an elastomer. The rearmost surface 24 of the spout is flat to abut a vertical wall W (shown in phantom). A water supply pipe P (shown in phantom) protrudes from the wall and extends into the insert 19 to form a water-tight seal with the O-ring 20. The screw 22 can be tightened from beneath the spout to bear against the water supply pipe P to securely connect the spout to the water supply pipe. The spout 10 could also be adapted for connection to a vertical supply pipe. Referring to Fig. 5, the front of the back 13 has a number of reinforcing ribs 30. An annular groove 32 is defined between a ring projection 34 and a tubular projection 35 of the back 13. The forward end of the tubular projection 35 is closed by a wall 36 and a transverse bore 38 extends through opposite sides of the tubular projection 35 near the end thereof. The rear portion of the tubular projection 35 has a larger inside diameter than the forward portion to define a shoulder against which the O-ring 20 seats. After inserting the O-ring 20, the insert 19, which has an inside diameter approximately equal to the inside diameter of the forward portion of the tubular projection 35, is inserted. The collar 18 is annular and sized to fit into the annular groove 32. The inside diameter of the collar 18 is tapered to match the outer diameter of the rear portion of the tubular projection 35 to provide a tight fit between the collar 18 and tubular projection. The cover plate 21 has inner 39 and outer 40 stepped edges to match similarly stepped edges on the ring portion 34 and tubular projection 35. The cover plate 21 is sealed to the ring projection 34 and tubular projection 35 by ultrasonic welding, a suitable bonding agent or other appropriate means so as to make the joints between the cover plate and back 13 water-tight. The collar 18 has a threaded hole to engage the screw 22 which screw extends through a hole in the tubular projection 35 and a hole in the insert 19. Referring to Figs. 4 and 5, the rear edge 41 of the base 12 is sized and shaped to conform to the back 13. A rearmost edge 42 of the base 12 is stepped around its entire periphery except at the bottom to receive the back 13. A bottom portion 43 of the rear edge 41 is formed in the shape of a rearwardly opening "U" to receive a similarly shaped surface 44 of the back 13. This surface provides a "U"-shaped opening in the bottom rear of the spout 10 to allow access to the screw 22. The joint between the base 12 and back 13 is sealed by ultrasonic welding, a suitable bonding agent, or other appropriate means around its entire periphery to be water-tight. The rear of the base 12, including the rear edge 41, is defined by a portion 45. The lower approximately 3/5 of the front of portion 45 terminates in the rearward side of a duck bill-shaped weir 46. Referring to Fig. 6, the forward edge of the upper portion of the portion 45 defines an upper forward edge 49 of the base 12. The weir 46, back 13 and portion 45 form a reservoir 37 between them. The top of the weir 46 defines a crest 50 and the weir has a flow surface 47 on its front, upper side which diverges as it slopes downwardly. Substantially vertical side walls 48 extend upwardly from the edges of the weir 46 to define top edges 53 which slope downwardly continuously and fan out from the forward edge 49. A front edge 51 of the weir 46 is continuous from forward edges 52 of the side walls 48 to define the bottom edge and side edges, respectively, of an outlet or mouth 55. The cover 15 is smoothly arched concave up to conform with the edges 49 and 53 and to overlie the front of the base 12. It is not dished in the direction transverse to flow. The joint between the cover 15 and the base 12 around the edges 49 and 53 is sealed by ultrasonic welding, a bonding agent, or other appropriate means to be water-tight. Together with the side walls 48 and the weir 46, the cover 15 defines a flow chamber 54. Also, the front edge of the cover 15 defines the top edge of the outlet or mouth 55. The facade 16 is shaped to overlie the front and sides of the cover 15 and preferably has a polished metal finish for aesthetics. Water from the water supply pipe enters the tubular projection 35 and is diverted orthogonally in two directions normal to its flow direction by the wall 36 out through the bore 38 from opposite sides of the tubular projection into the reservoir 37. This diversion minimized turbulence in the reservoir which may otherwise interfere with the initial formation of the sheet-shaped stream. When the level in the reservoir reaches the crest 50, the water spills over the crest and flows down the flow surface 47 and out through the mouth 55. Referring to Figs. 3 and 6, the flow surface 47 is shaped to insure that a sheet-like stream issuing from the spout remains in the sheet shape even relatively far from the spout. To help insure this, the flow surface 47 is made up of four sections the divisions between which are illustrated by phantom lines in Figs. 3 and 8. A flat section 56 (Figs. 3 and 9) is provided adjacent to the crest 50 where the sheet-shaped stream begins. Thus, the crest 50 is substantially straight and horizontal to promote the formation of the sheet and the flat surface allows the sheet to reach some level of stability early in its development. Adjacent to the lower side of the flat section 56 are two side sections 57 and a center section 59 between the side sections 57. Referring to Fig. 6, the sections 57 are defined by a certain radius R p ₅₇ to be concave up in the direction of flow (the direction of flow being defined along a longitudinal center line 60 (Fig. 8) in the preferred embodiment). In the spout 10, the sections 57 are defined by surfaces shaped as shown by the phantom lines of an imaginary cylinder of radius R p ₅₇ having an axis A-1 which is transverse to the direction of flow. Thus, the sections 57 are not dished in the direction transverse to flow. The section 59 diverges in the direction of flow and is defined by a radius R p ₅₉ to be concave up in the direction of flow but is also defined by another radius R t to be convex up in the direction transverse to the direction of flow. That is, not only is the section 59 arcuate according to a certain radius R p ₅₉ as shown in Fig. 6, it is also arcuate according to a certain radius R t as shown in Fig. 7. The transverse curvature R t of the flow surface 59, as well as its divergence, is also depicted in Figs. 10 and 11. In the preferred embodiment, the flat surface 56 is approximately two inches long in the direction of flow, R p ₅₇ is about 8.4 inches (21.3 cm), R p ₅₉ is about 7.3 inches (18.5 cm) and R t is about 65 inches (1.7 m). The result of this construction is that the flow surface 59 is raised in the center section 59 relative to the side sections 57. This causes the flow chamber 54 to be thinner near the center than at the sides in the area of the center section 59. Also, because the center section 59 is adjacent to the mouth, the mouth is also thinner in the center than at the sides as best shown in Fig. 2. This enhances fanning of the stream after it exits from the spout. With the upper surface of the mouth flat and the lower surface convex in the center thereof, the mouth is in the shape of a single concave lens. It has been found that this arrangement results in a substantially laminar flow in the form of a sheet out through the mouth which maintains its sheet-like appearance relatively far from the spout. Since the flow surface 59 diverges in width in the direction of flow all the way up to the mouth through which the stream exits the spout 10, the stream fans out as it leaves the spout 10 to help counter the tendency of the stream to become tubulent and irregular. It should also be noted that in a flow chamber 54, the cover 15 converges toward the weir 46 in the direction of flow in the area of the flat section 56. This feature helps promote the formation of the sheet by gradually flattening it out to the desired thinness. Referring to Fig. 8, the lower edge of the mouth 55, which is defined by the front edge 51 of the weir 46, recedes at its ends from its foremost edge a distance d in the direction opposite to the flow. Also, the sidewalls terminate the same distance d back from the foremost lower edge of the mouth. It will be obvious to those of ordinary skill in the art that many modifications are possible to the preferred embodiment without deviating from the invention. For example, the spout 10 need not be in the orientation shown as it would also provide a sheet-shaped stream in a different orientation, such as upside down from the orientation illustrated. Also, the cover 15 could be raised in the center thereof to at least in part provide the thinning of the chamber 54.

Claims: 1. A spout for providing a flow of water in the shape of a sheet and having a flow surface (47) past which the water flows and then exits the spout, said spout including inlet means upstream of the flow surface, the flow surface diverging in width in the direction of flow, wall means (15) in combination with the flow surface (47) defining a flow chamber (54), the flow chamber (54) defining an elongate outlet (55) through which the water exits the flow chamber (54), at least a portion of said wall means (15) converging toward the flow surface (47) in the direction of flow, characterized by an elongate crest (50) downstream of the inlet means, the flow surface (47) extending from the crest (50) to the outlet (55), a center section (59) of the flow surface (47) being raised and arcuate in each of two orthogonal directions making the center of the flow chamber (54) thinner in the area of the center section than at the sides of the chamber (54), one of said two directions being in the direction of flow and the other of said directions being transverse to the direction of flow, a first radius defining the center section in the flow direction to be concave up, a second radius defining the center section in the transverse direction to be convex up, and the center section (59) being adjacent to the outlet (55) so that the outlet (55) is thinner in the center than at the sides. 2. The spout according to claim 1, characterized by a reservoir (37) between said inlet means and said crest (50) for pooling a flow of water. 3. The spout of claim 2, characterized in that the water is diverted in two opposite directions orthogonal to the flow of water through the inlet means upon entering the reservoir (37). 4. The spout of claim 1, wherein the outlet (55) of the chamber (54) has the cross-sectional shape of a single concave lens. 5. The spout of claim 1, wherein the center section diverges in the flow direction.

Inventors: GAFFNEY, THOMAS E., WAHLEN, PATRICK S.
Applicants: KOHLER CO.
Application year: 1988
Main classification: E03C1
IPC codes: E03C1, B05B1, A47K3