IMPROVEMENTS IN OR RELATING TO SPRAY FITTINGS

Abstract: A shower handset (1) has a plurality of spray nozzles (28) arranged in concentric arrays (28). The innermost and outermost arrays of nozzles (28a, 28b and 28c, 28d) are permanently open. The intermediate arrays of nozzles (28e, 28f) are of increased axial length providing integral valve seats at the inner ends. A valve plate (16) is axially movable in response to rotation of a manually operable control member (17) to co-operate with the valve seats to close one or both intermediate arrays of nozzles (28e, 28f) to control the water flow through the handset (1). In an alternative arrangement (Figures 6 and 7), each intermediate array of nozzles (28e, 28f) has a common valve seat.

Description: IMPROVEMENTS IN OR RELATING TO SPRAY FITTINGS This invention concerns improvements in or relating to spray fittings for ablutionary appliances. The invention has particular, but not exclusive application to adjustable spray fittings for showers, especially instantaneous electric showers. In a typical instantaneous electric shower, a stream of cold water from the mains supply is heated in a heat exchanger to a comfortable temperature for showering. The temperature of the water is controlled initially by the power input to the heat exchanger and is fined tuned by adjusting the water flow rate. The temperature of the mains cold water supply varies during the year and can be as much as 20°C lower in winter than summer. With such seasonal temperature variation, the power input to an electric shower may be insufficient to attain the same shower temperature during the winter at the same high flow rates experienced during the summer. As a result, if the user requires the same shower temperature in the winter, the inlet flow rate has to be reduced. For example, flow rates can vary between approximately 2 to 5 litres per minute during the winter months, to between 4 to 7 litres per minute during the spring and autumn months, and between 5 to 12 litres per minute during the summer months. With such variations in flow rate, a fixed spray plate may not produce a sufficiently well defined spray at the low flow rates experienced during the winter months and may be too restrictive at the high flow rates experienced during the summer months. Variations in flow rate caused by seasonal variations in temperature of the cold water supply are a particular problem with lower power rating electric showers. It is already known to adjust the spray to reduce the effects of different flow rates but existing adjustable spray fittings are generally of complex construction. As a result, the assembly of such fittings is time consuming and often intermediate tests are required to check performance during the assembly process adding further to the manufacturing costs. It is an object of the present invention to provide an adjustable spray fitting for an ablutionary appliance which is of simple construction and is operable over a range of flow rates. According to the present invention an adjustable spray fitting comprises a plurality of spray nozzles of elastic or resilient material, each nozzle having an inlet end and an outlet end, an axially movable valve member on the inlet side of the spray nozzles, and at least one group of spray nozzles having an integral valve seat at the inlet end for co-operating with the valve member for controlling flow of water through the fitting. By providing the spray nozzles with an integral valve seat, the number of parts is reduced and assembly of the spray fitting is simplified. In one preferred arrangement, each nozzle in the group has a separate valve seat. For example, each nozzle may be of increased axial length on the inlet side. In an alternative arrangement, all the nozzles in the group have a common valve seat. For example, each nozzle may open into a channel communicating between the nozzles on the inlet side. More than one group of nozzles may be provided with a valve seat at the inlet end of each nozzle for co-operating with the valve member at different axially adjusted positions of the valve member. Advantageously, the groups of nozzles are arranged in concentric annular arrays of which the radially innermost and outermost arrays are preferably constructed to be permanently open. In this way, the spray shape is maintained when one or more intermediate arrays of nozzles is closed to restrict the flow of water. Preferably, the nozzles are located in holes in a spray plate with the outer ends of the nozzles projecting from the outer surface of the spray plate. In a preferred arrangement, the nozzles are formed separately from the spray plate. For example, the nozzles may be overmoulded on a support plate fitted inside the spray plate. Advantageously, the spray fitting includes a manually operable control member for adjusting the axial position of the valve member. In a preferred arrangement, the valve member is axially movable in response to rotation of the control member. The invention will now be described in more detail by way of example only with reference to the accompanying drawings wherein:- Figure 1 is a perspective view of a shower handset embodying the invention; Figure 2 is an exploded perspective view of the component parts of the handset shown in Figure 1; Figure 3 is a transverse section through the head portion of the handset shown in Figures 1 & 2; Figure 4 is a plan view of the inside of the spray plate of the handset shown in Figures 1 to 3 depicting a first arrangement of spray nozzles; Figure 5 is a section on the 5-5 of Figure 4 with the sealing plate added for clarity; Figure 6 is a plan view of the inside of the spray plate of the handset shown in Figures 1 to 3 depicting a second arrangement of spray nozzles; Figure 7 is a section of the lie 7-7 of Figure 6 with the sealing plate added for clarity; Figure 8 is a perspective view, similar to Figure 1 , of a modified shower handset embodying the invention; Figure 9 is an exploded perspective view of the component parts of the handset shown in Figure 8; Figure 10 is a perspective view, to an enlarged scale, of the sealing plate of the handset shown in Figures 8 and 9; Figure 11 is a plan view of the inside of the spray plate of the handset shown in Figures 8 and 9 depicting the arrangement of the spray nozzles; Figure 12 is a transverse section through the head portion of the handset shown in Figures 8 and 9 showing the sealing plate in the summer setting; Figure 13 is a transverse section similar to Figure 12 showing the sealing plate in the spring/autumn setting; and Figure 14 is a transverse section similar to Figure 12 showing the sealing plate in the winter setting. Referring first to Figures 1 to 3 of the accompanying drawings, there is shown a shower handset 1 having a hollow body 2 and an adjustable spray head 3. The body 2 has a grip portion 4 for holding the handset 1, and a head portion 5 for mounting the spray head 3. The body 2 is a plastics moulding to which any suitable surface finish or decoration may be applied. The body 2 has an externally threaded spigot 6 at the end remote from the head portion 5 for connection to a flexible hose (not shown) to connect the handset 1 to a water source (not shown) such as an instantaneous water heater for providing water at a pre-determined temperature selected by the user. In the spray head 3, there is an inlet mounting member 7 having an annular face plate 8 seated within a complementary annular wall 9 of the head portion 5. The mounting member 7 is secured to the body 2 by snap engagement of complementary rib formations 10,11 on the wall 9 and peripheral edge of the face plate 8. The centre portion of the face plate 8 is formed with a rearwardly extending recess 12 of stepped part annular form from which an inlet tube 13 extends. The distal end of the tube 13 is provided with an external groove 14 and is sealed within the grip portion 4 of the body 2 by an 0-ring (not shown) located in the groove 14. The mounting member 7 reinforces the head portion 5 of the body 2 and is made of rigid plastics material enabling a wider choice of plastics materials to be used for the body 2. The spray head 3 further includes an actuator ring 15, a sealing plate 16, and a spray plate 17 secured to the mounting member 7 for adjustable selection of the spray described later herein. The actuator ring 15 is of dished annular form with an inner flange 18 rotatably seated in the recess 12. An outer flange 19 of the actuator ring 15 is formed with an external screw thread (not shown) engaged by an internal screw thread 20 on the spray plate 17 to connect the actuator ring 15 and the spray plate 17 together. The mounting member 7 has a central boss 21 on which the actuator ring 15 is rotatably held in place by a retaining ring 22 secured to the boss 21 by a set screw 23. The sealing plate 16 is of generally annular form received within the outer flange 19 of the actuator ring 15 and is formed at the centre with an axial sleeve 24 having a series of circumferentially spaced apertures 25 through which water can flow. Water can also flow between the edge of the sealing plate 16 and the actuator ring 15. The sleeve 24 is formed with an internal thread (not shown) engaged by an external thread (not shown) on the retaining ring 23 to connect the sealing plate 16 and retaining ring 23 together. The inner surface of the outer flange 19 is formed with circumferentially spaced axial grooves 26 engaged by complementary radial projections 27 circumferentially spaced around the outer edge of the sealing plate 16. In this way, the sealing plate 16 is rotatable with and axially movable relative to the actuator ring 15 on rotation of the spray plate 17. Referring now to Figures 4 and 5, the spray plate 17 is provided with spray nozzles 28 from which the flow of water is controlled by the sealing plate 16 in response to rotation of the spray plate 17 to select spray settings for different flow rates as described later. The nozzles 28 are of tapered conical form produced by overmoulding rubber or like flexible elastic material onto a rigid support plate 29. The support plate 29 is located and secured within the spray plate 17 so that the nozzles 28 extend through aligned openings in the spray plate 17. The outer ends of the nozzles 28 are raised above the outer surface of the spray plate 17 so that the nozzles 28 can be cleaned by applying hand or finger pressure to the ends of the nozzles 28. In this way, any limescale which forms at the outlet ends of the nozzles 28 can be broken and flushed away by rubbing the outer surface of the spray plate 17. The inner ends of the nozzles 28 communicate with an outlet chamber 30 between the spray plate 17 and the actuator ring 15. As best shown in Figure 4, the nozzles 28 are arranged in concentric arrays. The nozzles 28a, 28b_ of the two innermost arrays are designed to give an impact feeling and the nozzles 28e,28d of the two outermost arrays are designed to define the spray shape and give good body coverage. The nozzles 28a, 28b, 28c, 28d of the innermost and outermost arrays are shorter than the nozzles 28e,28f of the other two intermediate arrays and are open in all adjusted positions of the sealing plate 16 as described later. The nozzles 28e,28f of the two intermediate arrays are of increased length on the inlet side for co-operation with the sealing plate 16 to close and seal each array in selected adjusted positions of the sealing plate 16 as described later. The nozzles 28s of the inner of the intermediate arrays are of the same length and are slightly shorter than the nozzles 28f of the outer of the intermediate arrays which are also of the same length. Figure 5 shows the position of the sealing plate 16 in the outlet chamber 30 allowing water to flow through all the arrays of nozzles 28. This position corresponds to the summer setting. On rotation of the spray plate 17 to move the sealing plate 16 axially towards the spray plate 17, the sealing plate 16 will first engage the inner ends of the outer of the two intermediate arrays of nozzles 28s, 28f, closing nozzles 28f. This position restricts the flow and corresponds to the spring/autumn setting. On further rotation of the spray plate 17 to move the sealing plate 16 towards the spray plate 17, the sealing plate 16 will compress the inner ends of the nozzles 28f and engage the inner ends of the inner of the two intermediate arrays of nozzles 28s, 28f, closing both intermediate arrays of nozzles 28s, 28f. This position further restricts the flow and corresponds to the winter setting. In each setting, the two outermost and two innermost arrays of nozzles are open ensuring that the spray shape is maintained and an acceptable spray impact feeling is obtained for all flow rates experienced during the year. As will now be understood, the inner ends of the intermediate arrays of nozzles 28e.28f form valve seats and the sealing plate 16 forms a valve member co-operable with the valve seats to close first the outer array and then the inner array to restrict the flow of water through the spray head 3. In this way, the user can select different spray settings to accommodate changes in flow rates caused by seasonal variations in the temperature of the mains cold water supply to produce a satisfactory spray throughout the year. For example, the winter setting is the most restrictive and produces a positive spray impact feeling with flow rates of 2 to 5 litres per minute. The spring/autumn setting is less restrictive and produces a positive spray impact feeling and more drenching spray at flow rates from 4 to 7 litres per minute. The summer setting is the least restrictive and produces both a good spray impact feeling and a drenching spray at flow rates from 5 to 12 litres per minute. Referring now to Figures 6 and 7, an alternative arrangement is shown for selectively closing the intermediate arrays of nozzles 28s, 28f to vary the spray. In this arrangement, the inlet ends of the nozzles 28e,28f open into respective annular channels 41,42 formed by three concentric annular rings 43,44,45 of the same height. The sealing plate 16 is provided on the underside with two concentric annular ribs 46,47 of which the outer rib 46 is longer and wider than the inner rib 47. Figure 7 shows the position of the sealing plate 16 in the outlet chamber 30 allowing water to flow through all the arrays of nozzles 28. This position corresponds to the summer setting. On rotation of the spray plate 17 to move the sealing plate 16 axially towards the spray plate 17, the outer rib 46 will engage the rings 43,44 to seal the outer channel 41 communicating with the outer of the two intermediate arrays of nozzles 28s, 28f, closing or isolating nozzles 28f. This position restricts the flow and corresponds to the spring/autumn setting. On further rotation of the spray plate 17 to move the sealing plate 16 towards the spray plate 17, the inner rib 47 will engage the ring 45 to seal and inner channel 42 communicating with the inner of the two intermediate arrays of nozzles 28≤,28f, closing or isolating both intermediate arrays of nozzles 28s, 28f. This position further restricts the flow and corresponds to the winter setting. As will now be understood, the rings 43,44,45 form valve seats at the inlet ends of the intermediate arrays of nozzles 28e,28f and the sealing plate 16 forms a valve member co-operable with the valve seats to close first the outer array and then the inner array to restrict the flow of water through the spray head 3. In this way, the flow of water can be selectively controlled to accommodate changes in flow rates caused by seasonal variations in temperature of the water supply in similar manner to the arrangement described above with reference to Figures 4 & 5. In another variation (not shown) the sealing plate 16 could be arranged to compress concentric rings of varying height to form a seal and prevent water flowing through respective concentric arrays of nozzles. A modified form of handset is shown in Figures 8 to 14. For convenience and ease of understanding, like reference numerals in the series 100 are used where appropriate to indicate parts corresponding to the handset above-described. In this embodiment, handset 101 has a spray plate 117 provided with circumferentially spaced ribs 148 providing finger grips to facilitate manual rotation of the spray plate 117 for adjustable selection of the type of spray. The spray plate 117 has openings 149 for groups of spray nozzles 128 formed in blocks 150 of rubber or like flexible elastic material that project through the openings 149. Forming the nozzles 128 in groups facilitates manufacture and assembly. Thus, grouping the nozzles 128 in blocks 150 reduces the number of openings 149 required in the spray plate 117 and enables the use of larger openings 149 so that alignment and insertion of the blocks 150 is easier. In addition, the size and shape of the openings 149 and blocks 150 can be varied to produce patterns having an attractive, decorative appearance as shown. Furthermore, the spray nozzles 128 can still be cleaned by applying pressure to the blocks 150 by rubbing with a hand to deform the nozzles 128 to break any limescale or dislodge detritus which is then flushed away in use of the handset. The component parts of the handset 101 are shown in Figure 9 and are generally similar to the previous embodiment with the addition of a lip seal 151 and a dished spring washer 152 between the mounting member 107 and actuator ring 115. An O-ring 153 for the distal end of the tube 113 is also shown. The spring washer 152 is located on a shoulder 154 of the central boss 121 of the mounting member 107 and takes up axial play between the components to give a smooth feel as the assembly of spray plate 117 and actuator ring 115 is rotated to adjust the spray. The spring washer 152 could be provided in the previous embodiment. The lip seal 151 is located between opposed surfaces of the mounting member 107 and actuator ring 115 to prevent leakage of water between the components when the assembly of spray plate 117 and actuator ring 115 is rotated. The lip seal 151 could also be provided in the previous embodiment. The intermediate arrays of nozzles 128e, 128f have inlet ends that open into respective annular channels 141, 142 formed by three concentric annular rings 143, 144, 145 moulded integrally with the nozzles 128 and the sealing plate 116 is formed with two concentric annular ribs 146, 147 on the underside for controlling water flow to the channels 141, 142 in accordance with the axially adjusted position of the sealing plate 116 similar to the arrangement shown in Figures 6 and 7. In this embodiment, however, the rings 143, 144, 145 are of different height and the ribs 146, 147 are provided with circumferentially spaced projections 155, 156 which give the ribs 146, 147 a castellated appearance. As best shown in Figure 10, the projections 155 of the inner rib 146 are chamfered on one side for co-operating with an inturned lip 143a of the inner ring 143. The outer rib 147 is stepped and the projections 156 are chamfered on both sides for co-operating with inturned lips 144a, 145a of the centre and outer rings 144, 145. The projections 155, 156 act as guides to align the associated rib 146, 147 with the channels 141 , 142 for all adjusted positions of the sealing plate 116. In this way, reliable operation of the sealing plate 116 to control the water flow to the intermediate arrays of nozzles 128e, 128f is assured. The sealing plate 116 is formed with openings 157, 158 through which water can flow for all adjusted positions of the sealing plate 116. The openings 157 communicate with the inner arrays of nozzles 128a, 128b and the openings 158 communicate with the outer arrays of nozzles 128c, 128d. The openings 158 could also be provided in the previous embodiment. Figure 12, shows the summer setting for discharge of water through all of the spray nozzles 128. In this position, the projections 155, 156 are located in the channels 141 , 142 with sealing faces of the ribs 146, 147 clear of the rings 143, 144, 145. As a result, water flowing through openings 157, 158 in the sealing plate 116 to the inner and outer arrays of nozzles 128a, 128b, 128c, 128d can also flow between the projections 155, 156 into the channels 141 , 142 to the intermediate arrays of nozzles 128e, 128f . On rotation of the spray plate 117 to move the sealing plate 116 axially towards the rings 143, 144, 145, the projections 154, 155 align and guide the ribs 146, 147 with respect to the channels 141 , 142 until the sealing faces of the outer, stepped rib 147 contact the centre and outer rings 144, 145 to close the outer channel 142 isolating the nozzles 128f. In this position, the other rib 146 is still clear of the inner ring 143 so that water can flow to the channel 141 as shown in Figure 13. This position restricts the flow and corresponds to the spring/autumn setting. On further rotation of the spray plate 117 to move the sealing plate 116 axially towards the rings 143, 144, 145, the sealing face of the inner rib 146 contacts the inner ring 143 to close the inner channel 141 isolating the nozzles 128e as shown in Figure 14. This position further restricts the flow and corresponds to the winter setting. In this way, the rings 143, 144, 145 from valve seats at the inlet ends of the intermediate arrays of nozzles 128e, 128f and the sealing plate 116 forms a valve member co-operable therewith to control water flow through the intermediate arrays of nozzles 128e, 128f in response to the adjusted position of the sealing plate 116. As a result, the flow of water can be selectively controlled to accommodate changes in flow rates caused by seasonal variations in temperature of the water supply in similar manner to the arrangement of Figures 6 and 7. It will be understood that other variations to the arrangement of the valve seats and sealing plate are possible and all such variations are deemed within the scope of the invention. As will be apparent from the foregoing description of exemplary embodiments, the arrangement of the sealing plate axially movable in the outlet chamber to co-operate with and seal groups of nozzles is simple and reduces the number of parts for manufacture and assembly of the spray head. This has various advantages for the logistic and assembly processes including reduced labour time and cost of assembly, simplified repair/replacement of failed components, reduced production and storage facilities, improved quality due to fewer parts to fail, and reduced assembly equipment costs. Other advantages and benefits of the invention will be understood by those skilled in the art.

Claims: CLAIMS 1. An adjustable spray fitting comprises a plurality of spray nozzles of elastic or resilient material, each nozzle having an inlet end and an outlet end, an axially movable valve member on the inlet side of the spray nozzles, and at least one group of spray nozzles having an integral valve seat at the inlet end for co-operating with the valve member for controlling flow of water through the fitting. 2. An adjustable spray fitting according to Claim 1 wherein each nozzle in the group has a separate valve seat. 3. An adjustable spray fitting according to Claim 2 wherein each nozzle in the group is of increased axial length on the inlet side. 4. An adjustable spray fitting according to Claim 1 wherein all the nozzles in the group have a common valve seat. 5. An adjustable spray fitting according to Claim 4 wherein each nozzle in the group opens into a channel communicating between the nozzles on the inlet side. 6. An adjustable spray fitting according to Claim 5 wherein the valve member is operable to close the channel to isolate all the nozzles in the group. 7. An adjustable spray fitting according to Claim 6 wherein the valve member has an annular rib for co-operating with and closing the channel. 8. An adjustable spray fitting according to Claim 7 wherein the rib has projections for aligning and guiding the rib relative to the channel. 9. An adjustable spray fitting according to any one of the preceding Claims comprising a plurality of groups of nozzles, each group of nozzles having an integral valve seat for co-operating with the valve member at different axially adjusted positions of the valve member. 10. An adjustable spray fitting according to Claim 9 further comprising at least one group of nozzles constructed to be permanently open in all axially adjusted positions of the valve member. 11. An adjustable spray fitting according to Claim 10 wherein the groups of nozzles are arranged in concentric annular arrays of which the radially innermost and outermost arrays are permanently open. 12. An adjustable spray fitting according to any one of the preceding Claims wherein the nozzles are located in holes in a spray plate. 13. An adjustable spray fitting according to Claim 10 wherein the outer ends of the nozzles project from the outer surface of the spray plate. 14. An adjustable spray fitting according to Claim 12 or Claim 13 wherein the nozzles are formed separately from the spray plate. 15. An adjustable spray fitting according to Claim 12 wherein the nozzles are overmoulded on a support plate fitted inside the spray plate. 16. An adjustable spray fitting according to any one of the preceding Claims further comprising a manually operable control member for adjusting the axial position of the valve member. 17. An adjustable spray fitting according to Claim 16 wherein the valve member is axially movable in response to rotation of the control member. 18. An adjustable spray fitting comprising a plurality of groups of spray nozzles, at least one group being made of elastic or resilient material with an integral valve seat for co-operating with an axially movable valve member in response to actuation of a manually operable control member for controlling water flow through the fitting. 19. An adjustable spray fitting according to Claim 18 wherein each nozzle of said at least one group has a separate valve seat. 20. An adjustable spray fitting according to Claim 18 wherein each nozzle of said at least one group has a common valve seat. 21. An adjustable spray fitting according to any one of Claims 18 to 20 wherein at least one group of nozzles is permanently open in all adjusted positions of the valve member. 22. An adjustable spray fitting according to any one of the preceding Claims comprising a shower handset. 23. A shower handset comprising a plurality of spray nozzles arranged in concentric arrays of which nozzles forming an innermost array and an outermost array are permanently open and nozzles of an intermediate array open into a channel defined between concentric rings separating the intermediate array from the innermost and outermost arrays, the nozzles and rings being formed of elastic or resilient material, and a valve plate axially movable in response to rotation of a manually operable control member to open and close the channel for controlling water flow through the intermediate array of nozzles. 24. A shower handset according to Claim 23 wherein two intermediate arrays of nozzles are provided with each array opening into respective concentric channels defined between concentric rings, and the valve member is operable to close the channels in sequence. 25. A shower handset according to Claim 23 or Claim 24 wherein the valve member has a rib aligned with the or each channel and arranged to close the channel in response to axial movement of the valve member. 26. A shower handset according to Claim 25 wherein the nozzles project through openings in a spray plate. 27. A shower handset according to Claim 26 wherein at least some of the openings contain more than one nozzle. 28. An adjustable spray fitting substantially as hereinbefore described with reference to Figures 1 to 5 of the accompanying drawings. 29. An adjustable spray fitting substantially as hereinbefore described with reference to Figures 1 to 5 of the accompanying drawings as modified by Figures 6 and 7 of the accompanying drawings. 30. An adjustable spray fitting substantially as hereinbefore described with reference to Figures 8 to 14 of the accompanying drawings.

Inventors: DEEN-WILLIAMS MICHELLE ANNE, DEEN-WILLIAMS, MICHELLE, ANNE
Applicants: CARADON MIRA LTD, DEEN WILLIAMS MICHELLE ANNE, CARADON MIRA LIMITED, DEEN-WILLIAMS, MICHELLE, ANNE
Application year: 1999
Main classification: B05B1
IPC codes: B05B1, B05B15