Abstract:
A shower head having a plurality of nozzles capable of attachment to a flexible shower arm. The shower head has a unique nozzle construction that allows for the manipulation of an external flexible nozzle to remove mineral deposits and has an internal, rigid nozzle structure for efficiently forming an aesthetically pleasing water stream. The shower head may have two available flow configurations which are selectable by a valve.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This nonprovisional application claims priority to U.S. nonprovisional patent application Ser. No. 10/021,852, filed Dec. 12, 2001 and titled “Shower Head Assembly,” which in turn claims priority to U.S. provisional patent application serial No. 60/255,369, filed on Dec. 12, 2000. The entire contents of the nonprovisional application and the provisional application are incorporated in their entirety by reference herein. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to a shower head and the nozzle configuration thereof.  
         BACKGROUND OF THE INVENTION  
         [0003]    Generally, shower heads are used to direct water from the home water supply onto a user for personal hygiene purposes. Showers are an alternative to bathing in a bath tub.  
           [0004]    In the past, bathing was the overwhelmingly popular choice for personal cleansing. However, in recent years showers have become increasingly popular for several reasons. First, showers generally take less time than baths. Second, showers generally use significantly less water than baths. Third, shower stalls and bath tubs with shower heads are typically easier to maintain. Over time, showers tend to cause less soap scum build-up.  
           [0005]    With the increase in popularity of showers has come an increase in shower head designs and shower head manufacturers. Over time, several shortcomings with existing shower head designs have been identified. For example, lime and calcium deposits from high mineral content water supplies have been found to clog up the shower head apertures. As a result, shower head designers have sought to use more flexible materials in the construction of shower head nozzles. Flexible shower head nozzles allow the user to manually manipulate the shower head nozzle in an effort to clear the nozzle of lime and calcium deposits. However, existing shower head designs utilizing flexible material for their shower head nozzles are often found to have poor seals thereby resulting in a leaky shower head. Leaky shower heads are noisy, wasteful and generally unappealing. Shower head designs utilizing flexible material for the nozzle portion have also been found to have irregular shower spray streams.  
           [0006]    Another shortcoming of existing shower head designs is that the face of existing shower head designs generally have a small surface area. Correspondingly, the surface area of jet nozzles on existing shower head designs is also small. A smaller surface area of jet nozzles generally reduces the overall area of impact of the shower.  
           [0007]    Existing shower head designs include the use of an all rubber nozzle, which can lead to difficulty in controlling water streams. Since the nozzle material is highly compliant, the water streams are not uniform and produce irregular spray patterns where the water streams are not aimed in a uniform pattern, such as a cone. Further, the manufacturing processability of the injection molded rubbers typically used for this application often produces higher degrees of flash at the orifice location resulting in inconsistent and misdirected water streams. Flash is the residual, undesired portion of material that remains with the desired portion after the molding process. One example of such a design is shown in U.S. Pat. No. 5,730,361.  
           [0008]    Additionally, current designs are limited in the ability to change the position of shower heads during use. Many shower heads are attached directly to the shower pipe and therefore can only be adjusted in limited directions. Recently, rainfall-type or drenching-type flow patterns, in which the water is delivered at a lower velocity to the user, are gaining popularity. However, in order to achieve this effect, the shower head should be positioned nearly directly over the head of the user. Existing shower heads are often limited in this capacity.  
           [0009]    Accordingly, as recognized by the present inventors, there is a need for a shower head that allows the user to manually remove lime and calcium deposits that form in the shower head nozzle and also includes a leak-proof type seal. As recognized by the present inventors, there is also need for a shower head that includes flexible nozzles and a consistent, controllable shower spray stream. Additionally, as recognized by the present inventors there is a need for a shower head having an enlarged face with increased nozzle surface area that is capable of positioning directly over the head of a user and delivering a rainfall-type or drenching-type flow configuration.  
           [0010]    It is with these shortcomings in mind that embodiments of the present invention have been developed.  
         SUMMARY OF THE INVENTION  
         [0011]    According to one embodiment of the present invention, disclosed herein is a shower head that includes flexible nozzles that can be manually manipulated by a user and also provide a leak-proof seal. In one embodiment, the shower head includes at least one inner nozzle that provides improved control of the spray stream, and at least one flexible external nozzle associated with the inner nozzle.  
           [0012]    A flexible external nozzle is readily cleanable since the buildup can be broken up by lightly pressing on each nozzle during normal cleaning. Further, the stream of water through a rigid inner nozzle can be precisely controlled and directed, as opposed to a flexible material nozzle that is much more difficult to form and directionally control.  
           [0013]    Also disclosed herein is an enlarged shower head assembly with an outer housing having a diameter of between about 6 and 10 inches. The outer housing has a lower surface with a plurality of apertures. According to this embodiment, the shower head assembly also has a first and second set of nozzles providing for at least two flow configurations. By providing an enlarged shower head having multiple modes of water delivery, this embodiment provides an effective, lightweight enlarged shower head capable of use with flexible shower arms which can be positioned directly above the user.  
           [0014]    According to another embodiment, disclosed herein is a shower head which includes a lower shell having a face plate with at least one aperture. At least one external nozzle protrudes through the aperture and extends below the exterior surface of the face plate. At least one inner nozzle nests within the external nozzle. The bottom surface of an inner nozzle cover having a top surface and a bottom surface is connected with the inner nozzle. An upper shell is connected to the lower shell to form an internal cavity. At least a portion of the external nozzle, the inner nozzle, and the inner nozzle cover reside within the internal cavity. In addition, the shower head of this embodiment includes a means for connecting the shower head to a home water supply and a means for controlling the level of flow that exits the shower head.  
           [0015]    Another embodiment of the present invention includes a shower head assembly comprising a lower shell having at least one aperture, an external nozzle layer, an inner nozzle insert having at least one inner nozzle corresponding with and extending into the external nozzle, and an upper shell connected to the lower shell forming an internal cavity housing therein at least a portion of the external nozzle layer and inner nozzle insert.  
           [0016]    In another embodiment of the present invention, a shower head nozzle assembly comprises an inner nozzle having an upper and lower portion, and an external nozzle having an upper and lower portion. The inner nozzle is nested within the external nozzle and the lower portion of the external nozzle extends below the lower portion of the inner nozzle defining a void space within the external nozzle between the lower portion of the inner nozzle and the lower portion of the external portion  
           [0017]    In another embodiment, a shower head assembly comprises an outer housing defining an internal cavity and having at least one aperture. A first means for providing consistent, directional control of a water stream through the aperture is located within the internal cavity of the housing. A second means for sealing the first means and the outer housing and for removing mineral deposits is located between the outer housing and the first means.  
           [0018]    According to another embodiment of the present invention, a shower assembly is provided comprising an enlarged shower head having a diameter of between about 6 and 10 inches, and a flexible arm assembly operably attached to the enlarged shower head. The enlarged shower head also has a plurality of water nozzles. The water nozzles have a first inner nozzle having an upper and lower portion, and an external nozzle having an upper and lower portion disposed about the inner nozzle. The lower portion of the external nozzle extends below the lower portion of the inner nozzle defining a void space within the external nozzle between the lower portion of the inner nozzle and the lower position of the external nozzle. 
       
    
    
       [0019]    Other features, utilities and advantages of various embodiments of the invention will be apparent from the following more particular description of embodiments of the invention as illustrated in the accompanying drawings.  
       BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    [0020]FIG. 1 is a right side view of one embodiment of the present invention.  
         [0021]    [0021]FIG. 2 is a bottom isometric view of the embodiment depicted in FIG. 1 of the present invention.  
         [0022]    [0022]FIG. 3 is a front isometric view of one embodiment of the present invention.  
         [0023]    [0023]FIG. 4 is a section view of an adjustable arm assembly having an interconnecting bead structure designed for attachment of a shower head to a water pipe, which may be used with an embodiment of the present invention.  
         [0024]    [0024]FIG. 5 is an enlarged section view of the interconnecting bead structure of FIG. 4.  
         [0025]    FIGS.  6 A-B are an exploded view of the embodiment depicted in FIG. 1 of the shower head of one embodiment of the present invention.  
         [0026]    [0026]FIG. 7 is a bottom view of the rigid nozzle cover showing a wall extending downwardly defining two separate water channels in accordance with one embodiment of one embodiment of the present invention.  
         [0027]    [0027]FIG. 8 is a top view of the rigid nozzle layer showing a wall extending upwardly defining two water channels corresponding with the channels shown in FIG. 9 in accordance with one embodiment of the present invention.  
         [0028]    [0028]FIG. 9 is a top view of an external nozzle layer having a plurality of external nozzles connected by a web in accordance with one embodiment of the present invention.  
         [0029]    [0029]FIG. 10 is a side view of an inner nozzle insert in accordance with another embodiment of the present invention.  
         [0030]    [0030]FIG. 11 is a section view of the rigid nozzle insert shown in FIG. 10 taken through section  11 - 11 .  
         [0031]    [0031]FIG. 12 is an enlarged section view of a nozzle assembly in accordance with one embodiment of the present invention.  
         [0032]    [0032]FIG. 13 is an enlarged section view of a nozzle assembly in accordance with one embodiment of the present invention showing mineral deposit build-up.  
         [0033]    [0033]FIGS. 14 and 15 illustrate a user manipulating the external nozzle to clear the lime or calcium build-up from the nozzle assembly.  
         [0034]    [0034]FIG. 16 is a section view of an assembled shower head taken through the nozzles. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0035]    As shown generally in the drawings, one embodiment of the present invention provides for a shower head assembly  30  having an enlarged surface area (often called a “pan head”) and having at least one external, flexible nozzle. The shower head can be connected to a flexible arm assembly, in one embodiment.  
         [0036]    [0036]FIG. 1 is a right side view of the external design of one embodiment of the present invention. FIG. 2 is a bottom isometric view of the shower head depicted in FIG. 1. While embodiments of the invention will be described in detail including the flexible shower arm shown in FIG. 2, the flexible shower arm is not required. FIG. 3 is a front isometric view of a shower head according to one embodiment of the present invention, without a shower arm assembly.  
         [0037]    Referring to one embodiment of FIG. 1, the shower head assembly  30  includes a shower head  40  having an outer housing  42  with an upper dome shaped portion  44 , a stem arm  46 , a lower apertured portion  48  with a plurality of nozzles  50 , and a flexible arm  64 . The outer housing  42  of the shower head  40  is preferably molded from a lightweight plastic material or the like, such as ABS plastic, or any suitable thermoplastic known to those in the art. The outer housing  42  can be made from a plurality of molded pieces adapted to fit together.  
         [0038]    The upper portion  44  of the outer housing is a shallow dome shape and forms the top surface of the shower head  40 . The upper portion also has an elongated portion  52  which extends toward the arm assembly  64  and forms a part of the elongated stem  46  described below.  
         [0039]    The elongated stem  46  increases in diameter and extends from the adjustable arm assembly  64  toward the front end  54  of the shower head  40 . The stem  46  is formed with a lower stem portion  56  that is adapted to fit with the elongated portion  52  of the upper portion  44 . The elongated portion  52  of the upper shell portion  44  is curved in a semi-circular shape extending from the rear end up to the head portion  54  of the shower head  40 . The lower stem portion  56  stem is similarly curved until it reaches the head portion  54  of the shower head  40 . Both the upper portion  44  and the lower stem portion  56  have a notch  58 ,  60  to receive a means  62  to adjust the flow from the arm assembly to the plurality of nozzles  50 . As illustrated in FIG. 1, the ends of a spool valve  62 , extend from the upper portion  44  of the stem on both sides of the stem  46 . In use, either end of the spool valve can be pressed to vary the flow of water from the flexible arm assembly  64  to the nozzles.  
         [0040]    The lower portion  48  has an apertured plate, or cosmetic cover, that is adapted to fit with the upper portion  44 . The lower portion  48  mates with the upper portion through a connector ring  102  (not shown). Protruding through the apertures in the rigid cosmetic cover  48  are external nozzles  50 . During operation, water from the shower arm  64  travels through the stem  46  of the shower head  40  into the internal cavity of the shower head  40 , defined by the upper  44  and lower portions  48  of the housing, and out the external nozzles  50  projecting through the rigid cosmetic cover  48  of the shower head  40 .  
         [0041]    In one embodiment, the cosmetic cover  48  is used to entrap the external nozzles  50  and provide an aesthetic contrast with the external nozzles  50 , both by color and texture. The rigid cosmetic cover  48  may not be necessary in some applications, depending on the desired exterior configuration of the shower head  40 . In a smaller configuration, for example, an appearance may be desired in which the external nozzle  50  is exposed without a separate cosmetic cover  48 .  
         [0042]    As shown in FIG. 2, the shape of the shower head  40  is substantially round. Other shapes may be substituted as desired. The number of external nozzles  50 , and accordingly, the surface area of the shower stream, are substantially increased in the present invention. As shown in FIG. 2, there are approximately  105  nozzles  50  provided in the enlarged shower head  40 , in one example. This increase in the number of nozzles  50  provides a corresponding increase in the area of water delivery to the user above and beyond conventional shower heads, which are typically only ½″ to 3″ in diameter. In one embodiment, the shower head  40  may be between about 6″ and 10″ in diameter, such as between about 7″ and 9″ in diameter.  
         [0043]    The shower head assembly  30  may also include an elongated flexible shower arm  64 . As shown in FIG. 4, the shower arm  64  has first  66  and second  68  opposing ends, and a water conduit along its entire length. The first end  66  of the flexible shower arm  64  is attached to a shower pipe connector nut  72 . The shower pipe connector nut  72  is in turn attached to a standard shower pipe extending from the wall of a shower stall (not shown). The second end  68  of the flexible shower arm  64  is adapted to receive the shower head. A connection structure  74  is used between the second end  68  of the flexible shower arm and the shower head  40 .  
         [0044]    In use, water flows from the shower pipe through the shower pipe connector nut  72 , and into the flexible shower arm  64 . The water flows through the conduit  70  (a continuous internal cavity) formed along the entire length of the flexible shower arm  64  to reach the shower head  40 , and then through the nozzles  50  of the shower head  40 . The flexible shower arm  64  can be configured by the user to take any of a number of positions, which allows the user to position the shower head  40  and the direction of the shower spray as desired.  
         [0045]    As shown in FIG. 5, the flexible shower arm is made of a plurality of interlinked ball and socket beads  76  interconnected together, with each of the beads being pivotable with respect to each of the adjacent beads due to the ball and socket structure. Each bead defines an internal cavity  78  extending therethrough, and when interconnected the internal cavity is continuous and extends along the entire length of the flexible shower arm  64 . Referring back to FIG. 4, a flexible hose  80  is positioned through the continuous internal cavity, or water conduit  78 , for carrying fluid through the flexible arm  64  from the shower pipe nut  72  to the shower head  40 . A sleeve  82  encompasses the length of the flexible shower arm  64  and extends from the shower pipe connector nut  72  to the base of the shower head  40 . The sleeve  82  protects the beads  76  from moisture, dirt and other contaminants which may affect the performance of the flexible shower arm  64 .  
         [0046]    In more detail, referring to FIGS. 4 and 5, the flexible shower arm is made up of a plurality of ball and socket beads  76  which are interconnected for rotational and pivotal movement between adjacent beads. The beads are preferably made of a thermoplastic material, such as Teflon® impregnated acetal. Each bead has a smaller end  84  and a larger end  86 , with a tapered neck area  88  defined between the two ends. The cavity  78  formed through the bead defines an opening  90  at the smaller end of the bead and an opening  92  at the larger end of the bead  76 . The external surface  94  at the smaller end of the bead is substantially spherical in shape. The internal walls  96  of the cavity formed at the larger end  86  of the bead  76  have a substantially spherical shape for rotatably and pivotally receiving the smaller end  84  of the adjacent bead. The beads are interconnected with one another by inserting the smaller end  84  of a first bead into the cavity in the larger end  86  of the adjacent bead and so on, as shown in FIGS. 4 and 5. The engagement of the external walls  94  of the smaller end  84  of one bead with the internal walls  96  of the larger end  86  of an adjacent bead allows the plurality of beads to pivot and rotate with respect to adjacent beads to form a variety of shapes.  
         [0047]    The shape of the cavity  78  formed in the large end  86  of the bead  76  is appropriately sized to tightly receive the smaller end  84  of an adjacent bead such that the beads  76  can rotate and pivot with respect to one another under the force of the user, however, the fit is sufficiently tight to create adequate friction to maintain the relative positions of the beads  76  once the flexible shower arm  64  is shaped by the user. This flexible shower arm assembly  64  is described in more detail in U.S. Pat. No. 5,865,378, the contents of which are hereby incorporated by reference. It is contemplated, however, that any structure which allows for repeated flexible movement to a fixed final position, and can accommodate the desired fluid transfer characteristics could be utilized for this purpose.  
         [0048]    FIGS.  6 A-B are an exploded view of a shower head assembly  30  according to one embodiment of the present invention. As shown in FIGS.  6 A-B, the shower head assembly  30  is constructed using several layers of elements. Starting from the top of the shower head  40 , the first layer is the upper portion  44  of the outer housing  42  of the shower head  40 . The upper portion  44  has a shallow dome-shaped top and an elongated portion  52 . The elongated end  52  of the upper shell portion  44  is adapted to receive an o-ring. On the underside of the elongated portion  52  of the upper shell is a notch  58  that enables access to a means  62  for controlling the level of flow of water exiting the shower head  40 , such as a spool valve. The top of the upper shell portion  44  is a substantially circular or oval dome-like structure. The underside  98  of the dome-like structure is flat for connecting to the matching flat portion  100  of the lower shell portion  48 , however, this need not necessarily be the case so long as it matches the lower shell portion  48  described below.  
         [0049]    In one embodiment of the shower head assembly  30 , the head portion of the upper shell portion  44  and lower shell portion  48  are connected together using a detent-type structure or connection ring  102 . The connector ring  102  includes a groove  103  on the top and bottom which correspond to the outermost edges of the flat portions  98 ,  100  of the upper and lower shells. The connector ring  102  provides for a uniform connection between the upper  44  and lower housing  48  and helps hold the outer housing together. In other embodiments the head portion of the upper  44  and lower shell  48  portions can be connected using any other means including adhesives and welds.  
         [0050]    Moving from top to bottom in FIG. 6, the next layer is the inner nozzle cover  104 . The inner nozzle cover  104  is contained within the upper  44  and lower shell portions  48  and is generally not visible from the exterior of the shower head  40  when assembled. The inner nozzle cover is substantially the same shape as the head portion  44  of the shower head  40 —e.g., substantially round or oval. The inner nozzle cover  104  includes a cap portion  106  extending from the portion of the inner nozzle cover  104  adjacent to the notched portion  58  on the underside of the upper shell portion. The cap portion  106  covers a water supply conduit  108  formed in the inner nozzle layer  118  described below to define a water supply channel  110 .  
         [0051]    [0051]FIG. 7 shows a bottom view of an exemplary design for the inner nozzle cover  104 . The inner nozzle cover preferably has at least one wall  112  extending downwardly from the bottom surface of the inner nozzle cover  104 . This wall  112  forms at least two water channels  114 ,  116 . The inner nozzle cover  104  and the inner nozzle layer  118  are connected to form the channel and distribution system for the water, generally  110 , and specifically  114 ,  116 . The inner nozzle cover  104  and the inner nozzle layer  118  are preferably connected using a hotplate weld, but can be connected using any other means capable of withstanding the shower head operating pressures (e.g., adhesives or other weld means). The channels  114 ,  116  are formed in a pressure vessel defined by the inner nozzle cover  104  and inner nozzle layer  118  and act to decrease the overall water pressure flowing through the inner nozzles by reducing the area of the water flow.  
         [0052]    In one embodiment, the wall  112  disposed between the inner nozzle layer  118  and the inner nozzle cover  104  extends down from the inner nozzle cover  104  and meets with the upper portion  120  of the inner nozzle layer  118 . The inner nozzle layer  118  typically has a corresponding structure designed to mate with the downwardly extending wall  112  of the nozzle cover  104 . This structure may be a similar wall structure, or a seat to receive the downward extending wall from the inner nozzle cover.  
         [0053]    As shown in FIG. 7, the wall  112  defines a first  114  and second  116  water channel. The first channel  114  diverts the water flow to the center of the shower head  40 . The second water channel  116  distributes the water flow to the nozzles located toward the outside of the shower head in a roughly star-shaped pattern. The nozzle layout and type is dependant on the particular implementation.  
         [0054]    Referring back to FIG. 6A, underneath and connected to the inner nozzle cover  104  is the inner nozzle layer  118 . The inner nozzle layer  118  is also contained within the outer housing  42  when assembled. In an alternative embodiment, a portion of the nozzles  122  of the inner nozzle layer  118  extend below the lower apertured portion  48 . Preferably, the inner nozzle layer  118  is constructed of a material capable of withstanding the operating water pressures of the shower head  40 . The inner nozzle layer  118  is substantially the same shape as the inner nozzle cover  104 , e.g., substantially round or oval. The bottom portion  124  of the inner nozzle layer  118  is apertured and includes at least one conical or frusto-conical nozzle  122  extending downward from the aperture  126  and decreasing in diameter (see FIG. 12). In one embodiment, the bottom portion  124  of the inner nozzle layer  118  includes sets of apertures  126  and nozzles  122  that are grouped based on their type of flow. In one embodiment, a fine mist water flow flows through a first set of nozzles  128 , while turbulent flow flows through the second set  130 .  
         [0055]    A water supply conduit  108  is formed at the portion of the inner nozzle layer  110  adjacent to the notch  58  in the upper shell portion  44  (See FIG. 8). The water supply conduit  108  angles downwardly into the stem  46  of the outer housing  42  and connects to the water supply line at a location preferably within the stem  46 . The throat  132  of the water supply conduit  108  includes a tunnel-like valve receiving chamber  134  that extends through the conduit  108  and is perpendicular to both the conduit  108  and the stem  46 . The spool valve  136  is of generally cylindrical shape and has two annular openings  138 ,  140 . Three o-rings  142  separate the annular openings  138 ,  140  and provide a seal between the annular openings  138 ,  140  and the ends of the spool valve  136  within the chamber  134 . The spool valve  136  resides in the receiving chamber  134  and both ends of the spool valve  136  extend from the holes defined by the notches  58 ,  60  in both the upper  44  and lower  56  shell portions.  
         [0056]    Below the valve receiving chamber  134  is a threaded annular recess  144  in the sidewalls of the conduit  108 . The annular recess  144  receives and holds the end of the hose grommet  146  attached to the water supply hose  80  and attaches to the outer sleeve  82  (See FIG. 6B).  
         [0057]    [0057]FIG. 8 shows a top view of the inner nozzle layer  118  having a wall  148  extending upwardly from the top surface of the layer  118 . This wall  148  preferably corresponds to the wall  112  shown in FIG. 7. The wall  148  defines a first  114  and a second  116  water channel. As can be seen from FIG. 8, the conduit  108  is divided into channels by a vertical wall  148  matching that shown in FIG. 7. In one embodiment, two channels  114 ,  116  exist for directing the supply water to either the first set of nozzles  128  or the second set of nozzles  130 . However, in other embodiments, additional channels may be defined for various types of water flow. Water supply holes  150  are formed in the valve receiving chamber  134 , and allow the supply water to enter the water supply channels  114 ,  116 . There is a water supply hole  150  for each existing water supply channel  114 ,  116  in one example. The spool valve  136 , shown in FIG. 6, when inserted into the valve receiving chamber  134 , is used to control which water supply hole  150  the supply water enters. The spool valve  136  includes o-rings  142  and can effectively seal off one or more of the water supply holes  150  by pushing on either side of the spool valve  136 . For instance, if a user wants the water to only flow into the water supply holes  150  that supply water to the first set of nozzles  128 , the user may adjust the spool valve to a first position. In the first position, the second annular opening  140  in the spool value is aligned with the water supply hole  150  in the first water channel  114 . However, if the user wants the water to only flow into the water supply holes  150  that supply water to the second set of nozzles  130 , the user may adjust the spool valve  136  to a second position by pushing on the other side of the spool valve  136 . In the second position, the first annular opening  138  of the spool valve is aligned with the water supply hole  150  that supplies the second water channel  116 . The first set of nozzles  128  in the center of the shower head are preferably fine mist nozzles. The second set of nozzles  130  within the second water channel  116  are preferably different than the fine mist nozzles, such as turbulent flow nozzles.  
         [0058]    Referring to FIGS.  6 A-B, the inner nozzle layer  118  is connected to the water supply by a hose grommet  146  connected to the bottom end of the water conduit  108 . The hose grommet  146  extends through a snap-in part  152  and into a water supply hose  80 . The snap-in part  152 , snaps into the bottom end of the water conduit. The hose grommet  146  also has an o-ring  158 , which serves to seal the water supply hose  80  within the bottom end of the water conduit  108 . The water supply hose  80  extends down the stem  46  of the shell and is connected to a water supply pipe or shower arm  64 . A collar  154  and a stem connection piece  156  connect the sleeve  82  to the outer housing  42  and facilitate holding the outer housing together.  
         [0059]    Below the inner nozzle layer  118  is an external nozzle layer  160  (shown in FIG. 6B) having a plurality of external nozzles  162 . In one example, the plurality of external nozzles  162  are joined through a web  164 , so that all of the nozzles  162  can be assembled to the rigid nozzle layer  118  in one piece. FIG. 9 shows a top plan view of an embodiment of the external nozzle layer  160  in accordance with the present invention having a plurality of external nozzles  162  connected via a web  164  of the same material the external nozzles  162  are fabricated from. The external nozzle layer  160  is preferably formed from a soft, flexible material that can be manipulated by a user (e.g., rubber or plastic). The external rubber nozzle layer  160  is shaped substantially the same as the apertured portion of the rigid nozzle layer  118 . The top side  166  of the external rubber nozzle layer  160  is apertured  170  and the bottom side  168  of each aperture  170  includes rubber nozzles  162  extending therefrom. The pattern of apertures  170  and nozzles  162  in the external nozzle layer  160  is matched with the pattern of apertures and nozzles  122  in the inner nozzle layer  118 . The inner nozzles  122  extend into, and nest within, the external nozzle layer apertures  170  and reside partially within the external nozzle layer nozzles  162 . The nozzles  162  of the external nozzle layer  160  extend downwardly through corresponding apertures  172  formed in the lower shell portion  48  and reside external to the shower head outer housing  42 . In an alternative embodiment, a portion of the inner nozzle  122  also extends downwardly through corresponding apertures  172  in the lower shell portion  48 .  
         [0060]    In another embodiment, an inner nozzle insert  174  is provided. A section view of an inner nozzle insert  174  according to one embodiment of the present invention is shown in FIG. 10. The inner nozzle insert  174  is also enclosed by the outer housing  42  when assembled. The inner nozzle insert  174  has a top  176  and bottom  178  portion. The bottom portion  178  includes a plurality of inner nozzles  122 . The inner nozzles  122  may be one consistent type of nozzle or any combination of nozzles yielding various types of water flow as described above. The inner nozzle insert  174  can have multiple water channels for distribution of water to various groups of inner nozzles  122  or alternatively can have only one water distribution channel. The insert can be easily manufactured through known processes such as injection molding. In the embodiment having only one water distribution channel, there is no need for a valve to divert the flow of water from the arm assembly to the various nozzles. However, if desired, a valve can be included to temporarily slow the flow of water to the inner nozzles to a drip.  
         [0061]    [0061]FIG. 11 is a section view of the rigid nozzle insert taken along section lines  11 - 11  of FIG. 10. This section view shows the wall assembly  112  that defines at least two water channels  114 ,  116  as discussed above. As shown in FIG. 11, a wall  112  is disposed between the top layer  176  and bottom layer  178  of the inner nozzle insert  174 . The wall  112  defines a first water channel  114  and a second water channel  116 . The flow of water preferably is directed to either the first  114  or second  116  water channel by adjusting the spool valve  136 . This configuration is only one example showing the use of a wall  112  defining two separate water channels. A variety of configurations creating multiple water channels distributing the flow of water in numerous ways will be readily appreciated by one of ordinary skill in the art.  
         [0062]    An alternative design is to use a separate and independent external nozzle  162  for each inner nozzle  122 . A further alternative is to mold the external nozzle  162  onto the rigid nozzle  122  using a two step molding technique whereby a water channel  174  is first molded using a rigid material and the external nozzle  162  is formed onto the water channel using an injection mold. This alternative has a more expensive tooling cost, but results in a stronger bond between the two materials and lowers assembly costs. Another alternative is to first mold the rigid cosmetic cover  48  and second mold the external nozzle  162  onto the cosmetic cover  48  using an injection mold. The cosmetic cover  48  can then be fastened or adhered to the inner nozzle layer  118  using mechanical fasteners or adhesives. Both the inner nozzle layer  118  and the cosmetic cover  48  may be constructed of ABS plastic or a similar rigid plastic material.  
         [0063]    Referring back to FIGS.  6 A-B, the lower apertured portion  48  resides below the external nozzle layer  160 , or insert  174 , and includes apertures  172  that correspond to the nozzles  162  in the external nozzle layer  160 . The apertures  172  are sized to allow the external nozzles  162  to extend through the lower shell portion  48 . The apertured portion of the lower shell portion  48  is relatively flat around the perimeter  100 , corresponding with the flat perimeter portion  98  of the upper shell portion  44 . The perimeters are connected via a connector ring  102  as discussed above. The bottom side  180  of the lower shell forms a rigid cosmetic cover  48  for protecting the internal elements of the shower head. The lower shell portion  48  may include detents or recesses  182  to correspond with detents/recesses in the upper shell portion  44 . The lower shell portion  48  also includes an angled elongated stem portion  56  that corresponds with the stem portion  52  of the upper shell portion  44 . The angled elongated stem portion  56  also includes a notch  60  that corresponds with the notch  53  in the upper shell portion  52  to define a hole  184  in the stem portion  46  of the shell  42 . The bottom end  186  of the stem portion  56  is adapted to receive an o-ring similar to the upper portion  188 . An o-ring (not shown) is used to help hold the upper and lower shell portions together.  
         [0064]    [0064]FIG. 12 is an enlarged section view of a shower head nozzle assembly  190  according to one embodiment of the present invention. Each nozzle assembly  190  includes an inner nozzle  192  and an external nozzle  194 . The inner nozzle  192  is preferably nested within the external nozzle  194 . Each nozzle  192 ,  194  has an upper  196 ,  198  and a lower  200 ,  202  portion. The lower portion  200 ,  202  of the each nozzle ends in a nozzle tip, or orifice  204 ,  206 . The nozzles  192 ,  194  are nested such that a void space  200  is defined within the external nozzle  194  between the tips  204 ,  206  of the external nozzle  194  and the inner nozzle  192 .  
         [0065]    The inner nozzle  192  has a nozzle reservoir  210  as well as a nozzle cavity  212  defining an upper portion  196  which tapers down to the lower portion  200 . The lower portion  200  terminates at an inner nozzle orifice  204 . The inner nozzle orifice  204  preferably has a smaller cross-sectional surface area compared to the upper portion  196  of the nozzle cavity  212 .  
         [0066]    The external nozzle  194  has an upper portion  198  and a lower portion  202 . The lower portion  202  terminates in an external nozzle orifice  206 . The external nozzle  194  is sized to allow the inner nozzle  192  to nest within the inner portion  212  of the external nozzle  192 . The upper portion  198  of the external nozzle  192  also has a seal or flange  214  extending radially outward from the center of the external nozzle  192 .  
         [0067]    As illustrated in FIG. 12, water  216  from a water supply channel  114 ,  116  enters the enlarged nozzle reservoir portion  210  of the inner nozzle  192  and flows downwardly into the frusto-conical nozzle cavity  212  of the inner nozzle  210 , through the lower portion  200  of the inner nozzle  192 , and exits the nozzle structure through an external nozzle orifice  204 .  
         [0068]    Such a nozzle assembly may provide precise directional control of the water stream  216  which in turn provides clean, crisp water streams that are directed in a conical or other pattern. To facilitate the precise directional control of the water stream  216 , the inner nozzle  192  is preferably a rigid nozzle. The external nozzle  194  is preferably a flexible, rubber-type nozzle. The external nozzle orifice  206  is also preferably a larger diameter than the inner nozzle orifice diameter  204  so as not to interfere with the precise flow stream created by the inner nozzle  192 . However, it is also contemplated that the outer nozzle  194  is made from a material of such flexibility that it would not affect the flow pattern of the water stream  216  exiting the inner nozzle  192  regardless of diameter.  
         [0069]    While the inner nozzle  192  is preferably rigid, it is also contemplated that the inner nozzle  192  can be a flexible material, similar to the external nozzle  194 . Due to the fact that the inner nozzle  192  is nested within the outer nozzle  194 , the portion of the external nozzle  194  that is in contact with the inner nozzle  192  serves to add additional support to the inner nozzle  192  by increasing the effective thickness of the inner nozzle  192 .  
         [0070]    The material for the external nozzle  194  is selected so that the nozzle is flexible enough to yield during cleaning. Suitable materials include soft elastomeric materials such as santoprene, and monoprene having a Shore A hardness of 40-50. When shower heads  40  are used in areas where a high concentration of calcium exists in the water supply, it has been found the water dries on the outer most edge of the nozzle and forms a deposit  218 . Over time, this deposit  218  can build up into a hard formation that impedes the water stream and adversely affects the performance of the shower head  40 . The cleaning procedure for the flexible nozzle  194  is to rub the flexible nozzle  194  with a finger  220  or cleaning rag and effectively break apart any hard residue  218  that has dried on the nozzle (see FIGS. 14 and 15).  
         [0071]    The preferred material for the external nozzle  194  is typically a low durometer rubber that often results in a high amount of flash from molding. In one embodiment, the inside diameter of the external nozzle  194  can tolerate a relatively larger amount of flash than can be tolerated on the orifice  206  and still give excellent performance.  
         [0072]    The materials selected for the inner nozzle  192  are preferably materials with a high degree of moldability, where the flash obtained as a result of the molding process is kept to a minimum at the orifice. Suitable materials include ABS plastic, Norel®, or any other thermoplastic known to those is the art.  
         [0073]    The geometry of both the inner nozzle  192  and the external nozzle  194  along with the water pressure help determine the type of water flow experienced by the user (e.g. fine mist or turbulent). Myriad nozzle structures are possible so long as they are designed to handle the corresponding water pressures. A preferred nozzle assembly  190  is one that provides a drenching rain-like experience. This type of nozzle assembly  190  is constructed by creating a nozzle  192  with less taper and a larger nozzle orifice  204 . The nozzle orifice  204  can also be decreased to provide a higher velocity, piercing type stream of water.  
         [0074]    As seen in FIG. 13, lime and calcium deposits  218  from mineral-laden supply water build up inside the end of the external nozzle  194  within the void space  208 . Such a build-up can impede the supply water thereby disrupting the designed flow quality. It has been found by the present inventors that mineral deposits  218 , such as lime and calcium deposits, form at the lower most portion of a shower nozzle  190 . In this case, the structure of the corresponding inner  192  and external  194  nozzles facilitates formation of any mineral deposits  218  at the end of the external nozzle  194  and in the void space  208  between the lower portion  200  of the inner nozzle  192  and the lower portion  202  of the external nozzle  194 . Thus, embodiments of the present invention provide the dual benefit of a means for accurate and precise directional control of water streams while simultaneously providing the ability to quickly and easily remove any mineral deposits  218  from the shower head  40  which may effect the performance of the shower head assembly  30 . This means can be, among other things, a nozzle, a projecting vent or projecting spout, or a fluid focusing device.  
         [0075]    As shown in FIGS. 14 and 15, by manipulating the external rubber nozzle  194  with a finger  220 , the user can cause the lime and calcium deposits  218  to be dislodged from the interior of the external rubber nozzle  194  thereby restoring the flow  216  from the rubber nozzle  194  to its designed flow quality.  
         [0076]    In the event that a rigid cosmetic cover  48  is selected for use in the shower head as described above, the inner nozzle  192  presses downwardly into the external nozzle  194 , or external nozzle layer  160  and the rigid cosmetic cover  48  presses upwardly against the bottom side  168  of the external nozzle  194 . The external nozzle  194  thus acts as a means for sealing the apertures  172  of the outer housing and for removing mineral deposits  218  by preventing supply water  216  from exiting the shower head  40  through any means other than the rigid nozzle orifice  204  and the external nozzle orifice  206 . The external nozzle  194  thereby serves two purposes; keeping any water from leaking through the apertures  172 , and providing a flexible orifice  206  for build-up of mineral deposits  218  which can be easily manipulated for removal. Other means for sealing the apertures  172  of the outer housing can include, among other things, a flange, a web, an o-ring or a gasket.  
         [0077]    The upper  44  and lower shell  48  portions of the outer housing  42  when connected together hold the nozzle structure  190  together with sufficient pressure on the nozzle structure  190  to further effectuate the sealing action of the external rubber nozzle  194 . When properly held in place, the external nozzle  194  extends downwardly through an aperture  172  in the rigid cosmetic cover  48  of the lower shell portion. The user is able to manipulate the external rubber nozzles  194  with a finger  220  to clear any lime and calcium deposits  218  that may accrue within the void space  208  or exterior of the external nozzle  194 .  
         [0078]    In accordance with another embodiment of the present invention, the enlarged shower head  40  is provided with a first set of nozzles  128  and a second set of nozzles  130  each providing a different flow stream, or pattern. The configuration of the shower head is such that a plurality of water channels  114 ,  116  are formed within the housing  42  of the shower head  40  as described with respect to FIGS. 7, 8 and  11  above. The water channels  114 ,  116  are configured to deliver the flow of water to the first set of nozzles  128  or the second set of nozzles  130 . The shower head also may have a means  62  for directing the flow of water from the water supply pipe or shower arm  64  to either the first set of nozzles  128 , second set of nozzles  130 , or both. One example of this means for directing flow is the spool valve  136 . Additional sets of nozzles can be added to provide for additional flow streams.  
         [0079]    According to another embodiment of the present invention, an enlarged shower head  40  is particularly useful when used in conjunction with a flexible shower arm assembly  64  because of the shower head&#39;s shallow profile and lightweight materials. Conventional shower heads with larger diameters are often too heavy to be supported by adjustable arm assemblies. In one example, the total weight of the assembled shower head is lightweight, often less than 2 pounds, and even less than 1.5 pounds. The structure of the shower head  40  also decreases the amount of water contained within the shower head during operation, thereby decreasing the total weight of the shower head during use. This allows for the use of an enlarged shower head  40  in combination with a flexible arm assembly  64 . The water channels  114 ,  116  of the shower head are designed to have shallow openings between the top and bottom portions of the channels. The height of the water channels is preferably less than 0.25 inches. More preferably, the distance between the water channels is between 0.24 inches and 0.18 inches. The shape of the channels is generally rectangular and the height of the channels is preferably less than the width.  
         [0080]    [0080]FIG. 16 illustrates a cross sectional view of an assembled shower head  40  according to one embodiment of the present invention. The rigid nozzle cover  104  and the rigid nozzle layer  118  form the channel and distribution system for the water. These two parts  104 ,  118  are preferably composed of rigid plastic and hot plate welded together. The water flows through the inlet channel and into a plurality of distribution channels  222 . The channels  222  are sized so that there is little flow restriction with respect to the exit orifice to give equal flow through every nozzle assembly  190 . The water is channeled through a taper  224  prior to exiting the nozzle assembly  190 . The precise configuration of the taper  224  and nozzle may be changed for various applications, for example to direct the water in a certain pattern and to regulate the velocity and flow of the water stream.  
         [0081]    Although embodiments of the present invention have been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example, and changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.