Abstract:
A faucet body ( 10 ) is molded from a plastic material and coupled to an underbody that is likewise molded from a plastic material. The unitary faucet body includes a spout portion ( 12 ) and a base portion ( 14 ). The underbody comprises a manifold ( 40 ) including an inlet ( 48 ) and an outlet ( 50 ). An end body ( 24 ) is coupled to the manifold and to the base portion. The end body includes means for coupling the faucet body to the manifold. A valve ( 96 ) is coupled to the end body. Alternatively, the faucet spout and base can be molded as a unitary structure using a lost core method, thereby eliminating the need for a separate manifold.

Description:
[0001]    The present invention relates generally to faucets having an underbody and a faucet body that fits over the underbody and, in particular, to faucets that use a common underbody with multiple faucet body configurations. The faucet body and underbody can be molded together as a unitary structure using lost core methodologies. The invention is further related to faucets that have a reduced number of waterway parts and use the end bodies to hold a cartridge seal and orient the cartridge. In addition, the invention relates to faucet bodies that are molded from plastic and can be mounted on a sink deck without an intervening putty plate.  
         BACKGROUND AND SUMMARY OF THE INVENTION  
         [0002]    Conventional faucets are made using a brass casting that is machined to provide water inlets and a water outlet. A finishing cover, usually made of chrome plated metal, is used to cover the finished casting and provide a more pleasing appearance. A brass faucet is polished and plated. In some cases, the spout is formed from brass tubing that is plated, bent to the desired shape, and joined to a casting. Unfortunately, casting and machining brass is expensive in terms of time, labor, and material.  
           [0003]    Another disadvantage with conventional faucets is related to the brass composition. Some brass compositions contain lead that can leach out of the brass into the water passing through the faucet. It would be advantageous, therefore, to provide an alternative material that would be cheaper to produce while eliminating the possibility of lead leaching into the drinking water.  
           [0004]    The present invention overcomes these and other disadvantages by providing a faucet body molded from a plastic material and coupled to an underbody that is likewise molded from a plastic material. The use of a molding process is cheaper that casting and machining, and the use of plastic material eliminates the possibility of lead leaching into the drinking water. In preferred embodiments, the plastic faucet body is covered with a metallic coating to provide a more pleasing appearance.  
           [0005]    According to the present invention, a two-handled faucet assembly comprises a unitary faucet body, a manifold, at least one end body, and a valve. The unitary faucet body includes a spout portion and a base portion, wherein the spout portion includes a water passage and the base portion includes at least one hole for receiving the end body. The manifold includes in inlet and an outlet and the end body is coupled to the manifold and to the base portion. The end body further includes means for coupling the faucet body to the manifold. The valve is coupled to the end body.  
           [0006]    According to one aspect of the invention, the manifold includes a first portion coupled to the faucet body base portion and a second portion coupled to the spout portion. The faucet body portion defines a pair of end body-receiving holes and includes an alignment feature disposed adjacent each end body-receiving, hole to prevent improper alignment of the end body relative to the manifold.  
           [0007]    According to another aspect of the invention, the end body includes a first retainer nut and a second retainer nut, the first retainer nut retaining the end body in the end body-receiving hole. The first and second retainer nuts cooperate to couple the faucet assembly to a sink deck.  
           [0008]    One embodiment of the invention is formed using lost core technology. The faucet includes a spout having a first water passage and a base having a second water passage in fluid communication with the first water passage. The spout and base are molded as a unitary structure around a fusible core that is later removed from the unitary structure, the void left by the fusible core defining the first and second passages.  
           [0009]    Other features and advantages of the invention will become apparent from the following portion of this specification and from the accompanying drawings, which illustrate a presently preferred embodiment incorporating the principles of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    [0010]FIG. 1 is a top view of a faucet body for use with the present invention.  
         [0011]    [0011]FIG. 2 is a front view of the faucet body of FIG. 1.  
         [0012]    [0012]FIG. 3 is a bottom view of the faucet body of FIG. 1.  
         [0013]    [0013]FIG. 4 is a section view taken along line  4 - 4  of FIG. 2.  
         [0014]    [0014]FIG. 5 is a section view taken along line  5 - 5  of FIG. 1.  
         [0015]    [0015]FIG. 6 is an end view of an underbody for use with the invention.  
         [0016]    [0016]FIG. 7 is a front view, partially broken away, of the underbody of FIG. 6.  
         [0017]    [0017]FIG. 8 is a bottom view of the underbody of FIG. 6.  
         [0018]    [0018]FIG. 9 is a partial section view taken along line  9 - 9  of FIG. 7.  
         [0019]    [0019]FIG. 10 is a front view, partially broken away, of an assembled faucet incorporating the faucet body and underbody of the present invention.  
         [0020]    [0020]FIG. 11 is a side view of an end body.  
         [0021]    [0021]FIG. 12 is a section view taken along the longitudinal axis of the end body of FIG. 11.  
         [0022]    [0022]FIG. 13 is a top view of the end body of FIG. 11.  
         [0023]    [0023]FIG. 14 is an exploded perspective view of a valve for use in the present invention.  
         [0024]    [0024]FIG. 15 is a section view taken along the longitudinal axis of the valve of FIG. 14.  
         [0025]    [0025]FIG. 16 is a bottom view of the stem of the valve in FIG. 14.  
         [0026]    [0026]FIG. 17 illustrates an alternative embodiment of the invention manufactured using a lost core method. 
     
    
     DETAILED DESCRIPTION  
       [0027]    FIGS.  1 - 5  illustrate a faucet body  10  according to the present invention. The faucet body  10  is preferably injection molded as a single piece using gas assisted injection molding techniques and then coated or plated as desired to provide a pleasing finish acceptable to consumers. The faucet body  10  includes a spout portion  12  and a base portion  14 . As illustrated in FIG. 3, the base portion  14  further includes a perimetral seal-receiving channel  16 , a pair of fastener-receiving members  18 , and a pair of end body-receiving bores  20 . Each of the end body-receiving bores  20  includes a plurality of ribs  22  spaced around the perimeter of their respective bores  20  and projecting inwardly therefrom. Preferably, each bore includes five ribs  22  spaced at 60° intervals around the perimeter, with a gap in the spacing provided at the point closest to the spout portion  12 . The ribs  22  provide support and alignment for a hexagonal portion of an end body  24  (FIG. 10), and prevent the end body from rotating in the bore  20 .  
         [0028]    As illustrated in FIG. 4, the spout portion  12  includes a water passage  26  and a channel  28  for receiving a pop-up knob  30  (FIG. 10) for operating a drain sub-assembly (not shown). The spout portion  12  includes an outlet  32  with internal or external threads for coupling an aerator  34  (FIG. 10) to the spout portion  12 . The water passage  26  includes a stepped inlet  36  that extends through the base portion  14  and into the spout portion  12 . The water passage  26  continues from the stepped inlet  36  through the spout portion  12  to the outlet  32 .  
         [0029]    A water manifold  40  according to the present invention is illustrated in FIGS.  6 - 9 . The water manifold  40  includes a base  46 , a pair of water inlets  48  and a water outlet  50 , preferably molded as a unitary piece. The base portion  46  includes a first end  54  and a second end  56 , with the first end  54  including a pair of fastener-receiving holes  58  and a central bore  60 . Each inlet  48  includes a tubular member  62  extending from the outlet  50 . When the water manifold  40  is mounted in the faucet body  10 , the tubular members  62  extend to the end body-receiving bores  20  to engage an end body outlet  66 , as illustrated in FIG. 10. The manifold outlet  50  includes a tube with a stepped sidewall  70  that is configured to match and engage the stepped inlet  36  of the water passage  26 . An O-ring can be installed between the manifold outlet  50  and the stepped inlet  36  to ensure a watertight seal.  
         [0030]    The base portion  46  is configured to fit in the base portion  14  of the faucet body  10 , with the fastener-receiving holes  58  aligned with the fastener-receiving members  18 . The under body  40  is attached to the base portion  14  by fasteners, such as screws, that are passed through the fastener-receiving holes  58  to engage the fastener-receiving members  18 . When the under body  40  is attached to the base portion  14 , the central bore  60  aligns with the channel  28  to allow the pop-up knob  30  to pass through the faucet body  10  and water manifold  40  to engage the drain sub-assembly (not shown). In preferred embodiments, the first and second ends  54 ,  56  are contoured to match and abut the perimeter of the faucet body  10  to provide additional stability for the mounted water manifold  40 .  
         [0031]    The end body  24 , as illustrated in FIGS.  11 - 13 , includes an externally threaded tubular lower portion  76  and an upper portion  78  having an outlet  66  and upper and lower hexagonal flanges  80  extending around the perimeter of the upper portion  78 . The hexagonal flanges  80  are sized to engage the ribs  22  in the end body-receiving bore  20  so that the outlet  66  is directed to engage the underbody water inlet  48 . The separation between the upper and lower flanges  80  provides longitudinal stability to the end body  24 .  
         [0032]    The upper portion  78  also includes internal threads  84 , external threads  85 , a capping wall  82  that caps the lower portion  76 , and a bow tie-shaped water inlet  86 . The bow tie-shape is “closed” by a first arcuate member  86   a  that extends between the two upper arms of the bow tie and a second arcuate member  86   b  that extends between the two lower arms of the bow tie, thereby forming a pair of generally triangular openings. The bow tie shape of the water inlet  86  is defined by upwardly extending sidewalls  88  and includes an bow tie-shaped floor  90  with a pair of triangular holes  94  passing through the capping wall  82  to the tubular lower portion  76 . The sidewalls  88  and the floor  90  cooperate to receive and support a resilient bow tie-shaped seal  92  (FIG. 14).  
         [0033]    A valve  96  for use with the end body  24  is illustrated in FIGS.  14 - 16 . The valve  96  includes a stem  98 , a housing  100 , and a valve disk  102  and is held in position by a nut engaging the internal threads  84 . An O-ring  104  can be installed with the valve  96  to provide a watertight seal. The stem  98  includes a splined portion  108  and a base plate  110 . The base plate  110  extends radially outwardly from the perimeter of the stem  98  and includes a bow tie-shaped projection  114  depending downwardly from the plate  110 . The bow tie-shaped projection  114  is substantially similar in size and configuration to the bow tie-shaped inlet  86  and is disposed on the plate  110  to align with the inlet  86  when the valve  96  is in the closed position. A skirt  116  depends downwardly from the edge of the bow tie-shaped projection  114  in two segments  120 ,  122  where the edge of the projection  114  coincides with the edge of the plate  110 . Each segment  120 ,  122  includes a break  124 ,  126 , respectively, for receiving the valve disk  102 . Preferably, the breaks  124 ,  126  are not the same size and are not located on a common diameter of the plate  110  to prevent misalignment of the valve disk  102 .  
         [0034]    The valve disk  102  is a generally circular plate having a pair of triangular holes  128  and a pair of tabs  132 ,  134  extending radially from the disk  102 . The disk  102  is sized and configured to allow the disk  102  to fit snuggly against the skirt segments  120 ,  122 . The tabs  132 ,  134  fit in the breaks  124 ,  126 , respectively, in the skirt segments  120 ,  122  to provide for proper alignment of the disk  102  on the stem  98 . When the disk  102  is properly installed, the disk triangular holes  128  are disposed outside the bow tie-shape of the projection  114 . Thus, when the disk triangular holes  128  are aligned with the inlet triangular holes  94 , the valve  96  is in the open position. When the valve stem  98  is rotated 90°, the disk triangular holes  128  are no longer aligned with the inlet triangular holes  94 . Instead, the remaining unbroken portion of the disk  102  is aligned with the inlet triangular holes  94 , thereby blocking flow of water through the valve  96 , and the valve  96  is closed.  
         [0035]    The water manifold  40  is coupled to the end bodies  24  by inserting the end body outlets  66  into the water inlets  48  to form an underbody. The underbody is then assembled with the faucet body  10  by inserting the end bodies  24  in the end body-receiving bores  20  and threading a retaining nut  106  (FIG. 10) onto the external threads  85  of the end body  24  to abut the base portion  14  of the faucet body  10 . Alternatively, the end bodies  24  can be retained in the faucet body  10  by a hub and handle combination, wherein the hub is configured to threadedly engage the external threads  85  of the end body  24 . The base  46  of the water manifold  40  is then attached to the faucet body  10  by screws or other fasteners. The retaining nuts, the hexagonal flanges  80 , and the screws cooperate to hold the underbody firmly in place in the faucet body  10 . Adding the desired handles and hubs to operate and cover the valves completes the faucet assembly. The faucet assembly is mounted to a sink deck by inserting the end bodies  24  through holes in the sink deck and threading retaining nuts  140  (FIG. 10) onto the end bodies  24 .  
         [0036]    The resulting faucet assembly is relatively inexpensive to produce and assemble, thereby providing a cost advantage to the manufacturer. In addition, the faucet assembly includes fewer parts than a conventional faucet, thereby reducing the number of parts in inventory for additional cost savings. Moreover, the underbody can provide a common base for use with other faucet body designs, allowing for faster development of new faucet designs and providing a marketing advantage to the manufacturer.  
         [0037]    It will be understood by one of ordinary skill in the art that the fasteners may not be necessary and the underbody can be coupled to the faucet body by just the end bodies. The geometry of the underside of the faucet body can be designed to conform to the shape of the underbody to prevent movement of the underbody once the underbody is in position within the faucet body and prevent the end bodies from separating from the manifold. The retainer nuts would couple the underbody to the faucet.  
         [0038]    In an alternative embodiment of the invention, illustrated in FIG. 17, the entire faucet body  210 , including the spout portion  212  and the base portion  214 , is molded as a single unit using lost core methodologies. The lost core method includes the step of forming a core member (not shown), from a fusible material that defines the contours of the internal passages of the spout and base. The core member is then positioned in a mold of the faucet body and plastic is injected into the mold. After the plastic solidifies, the faucet body is removed from the mold and the core member is melted from the interior of the faucet body. The void caused by the removal of the core defines the internal passage of the spout and base. Of course, an important consideration in the choice of fusible material is its ability to retain its shape during the molding process, yet melt out of the interior of the plastic faucet body without damaging the faucet body. Several advantages flow from the use of lost core methodologies, such as the reduction in the number of parts, a reduction in the number of assembly steps, and a reduction in inventory costs.  
         [0039]    A faucet with underbody has been described with respect to a presently preferred embodiment. However, it will be understood that various modifications can be made within the scope of the invention as claimed below