Abstract:
A filtration system for a pull-down or pull-out faucet includes a multi-channel hose configured to fluidly couple to a spray head, a water filter configured to provide filtered water, and a diverter-equipped T-connector. The T-connector has a first branch configured to receive unfiltered water from a valve cartridge of the faucet, a second branch configured to receive filtered water from the water filter, and a third branch configured to deliver filtered and unfiltered water from the first and second branches to different channels of the multi-channel hose. The spray head also includes an activation switch configured to allow selective output of filtered and unfiltered water from the spray head.

Description:
CROSS-REFERENCE TO RELATED PROVISIONAL APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/238,910, filed on Oct. 8, 2015, the disclosure of which is hereby incorporated by reference herein in its entirety. 
     
    
     COPYRIGHT NOTICE 
       [0002]    Portions of the disclosure of this patent document contain materials that are subject to copyright protection. The copyright owner has no objection to the facsimile reproduction of the patent document or patent disclosure as it appears in the U.S. Patent and Trademark Office patent files or records solely for use in connection with consideration of the prosecution of this patent application, but otherwise reserves all copyright rights whatsoever. 
       FIELD OF THE INVENTION 
       [0003]    The present invention generally relates to embodiments of a new plumbing fixture having both faucet and filtration assemblies. 
       BACKGROUND OF THE INVENTION 
       [0004]    Faucets are ubiquitous plumbing products having the basic purpose of delivering hot, cold, or mixed water from a water supply (such as tap or well water) to a user. Some faucets, especially kitchen faucets, feature pull-down or pull-out spray mechanisms, which provide users with more flexibility in directing water output. Because tap and well water often include impurities, such as chlorine and other contaminants that could affect the taste, appearance, and safety quality of the water, people often choose to install water filtration devices to purify their water. However, conventional filter devices are either mounted at the faucet spout, which limits access to the sink, or under the sink deck and coupled to a side faucet separate from the main faucet, which occupies valuable deck real estate. These filter devices are also incompatible with pull-out faucet types. 
       SUMMARY OF THE INVENTION 
       [0005]    Generally speaking, it is an object of the present invention to provide improved plumbing fixtures, particularly pull-out faucets, having integrated filtration assemblies that overcome the above-mentioned disadvantages associated with conventional faucet filtration devices. 
         [0006]    According to an embodiment of the present invention, an integrated faucet filtration system includes a faucet assembly and a water filtration assembly. The faucet assembly includes a faucet body, a spout, a valve assembly, and a pull-out or pull-down spray head fluidly coupled to a multi-channel (e.g., 2-in -1) fluid hose running through the spout and body. The multi-channel hose can be made of flexible material that allows it to easily exit and enter the spout during pull-out and retraction of the spray head. 
         [0007]    The valve assembly includes a cartridge, a manifold, a hot water supply hose, a cold water supply hose, a mixed tap water hose, and a Tee piece (i.e., T-connector) having a first branch fluidly connectable to a cold water source, a second branch fluidly coupled to an input end of the cold water supply hose, and a third branch fluidly coupled to an input of a filter assembly of the filtration assembly. 
         [0008]    The multi-channel hose has two concentric layers. The interior layer provides a waterway for filtered water, and a tunnel between the interior layer and the exterior layer forms a waterway for unfiltered water. The spray head has complementary tunnels for receiving the filtered and unfiltered water from the multi-channel hose. These tunnels run from a reception portion of the spray head (which couples to the multi-channel hose), through the spray head, to complementary outlets of the spray head for separate dispensing of the two water types. According to one embodiment, the multi-channel hose includes a bonnet that couples to the to spray head&#39;s reception portion. The bonnet can include one or more sealing components that seal the connection between the multi-channel hose and the spray head. 
         [0009]    The water filtration assembly includes the filter assembly (which includes a head and a body), a pressure regulator installed upstream of the filter assembly (e.g., for regulating the line pressure to optimize filter performance), connecting hoses, and a diverter-equipped Tee piece (diverter-equipped T-connector) located downstream of the filter assembly. The diverter-equipped T-connector includes a first branch fluidly coupled, via an outlet hose, to an output of the filter, a second branch fluidly coupled to an output end of the mixed tap water hose leading from the valve assembly, and a third branch fluidly coupled (via complementary tunnels) to the filtered and unfiltered waterways at an input end of the multi-channel fluid hose. The multi-channel hose includes another bonnet that couples to the third branch of the diverter-equipped T-connector (e.g., in a manner similar to that of the connection between the multi-channel hose and the spray head). 
         [0010]    The diverter-equipped T-connector includes complementary waterways for passing filtered water (output by the filter assembly) and unfiltered water (from the mixed tap water hose). The diverting mechanism consists of a spring preloaded piston that interacts with the valve assembly cartridge, and can occupy open and closed states. When the cartridge is closed, pressure of the filtered water is unable to overcome the spring force, the piston blocks both filtered and unfiltered water from entering the respective waterways in the diverter-equipped T-connector, and no water is output therefrom. When the cartridge is open, pressure in the mixed tap water hose (as well as from the filtered water) overcomes the spring force and pushes the piston, opening the two waterways in the diverter-equipped T-connector for to passage of both filtered and unfiltered water into the multi-channel hose. 
         [0011]    According to one embodiment, the spray head is equipped with the filtered water outlet and two separate outlets for unfiltered water—an aerated outlet and a shower outlet. The spray head includes a switch (e.g., a toggle switch positioned on either a front, back, or side portion of the spray head) that selectively diverts discharge of unfiltered water between the aerated outlet and the shower outlet. The spray head additionally, or alternatively, includes a switch (e.g., a button, lever, knob, or the like) that controls output of filtered water from the spray head. The two switches can interact (e.g., via one or more interface components) such that the two types of water cannot be simultaneously output. In one embodiment, both filtered and unfiltered water (from the diverter-equipped T-connector) may be continually present in the spray head, and the switch only controls output of the two types of water from the spray head. 
         [0012]    Still other objects and advantages of the present invention will in part be obvious and will in part be apparent from the disclosure. 
         [0013]    The present invention accordingly comprises the features of construction, combinations of elements, and arrangement of parts, all as exemplified in the constructions herein set forth, and the scope of the invention will be indicated in the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The present invention is discussed in greater detail below with reference to exemplary embodiments illustrated in the accompanying drawings, in which: 
           [0015]      FIG. 1  is a front view of an exemplary faucet having an integrated filtration system, in accordance with an embodiment of the present invention; 
           [0016]      FIG. 2  is a schematic diagram illustrating the flow of filtered and unfiltered water in an integrated faucet filtration system, in accordance with an embodiment of the present invention; 
           [0017]      FIG. 3  is a cross-sectional view of the multi-channel hose, in accordance with an embodiment of the present invention; 
           [0018]      FIGS. 4 and 5  are perspective views of a faucet illustrating a spray head in docked and undocked positions, in accordance with an embodiment of the present invention; 
           [0019]      FIG. 6 a    is a side cross-sectional view of a spray head, in accordance with an embodiment of the present invention; 
           [0020]      FIGS. 6 b  and 6 c    are front cross-sectional views of the spray head embodiment of  FIG. 6 a   , illustrating unfiltered water travel paths in aerated and shower spray modes of the spray head; 
           [0021]      FIG. 6 d    is a front cross-sectional view of the spray head embodiment of  FIGS. 6 a -6 c   , illustrating the filtered water travel path in the filtered water output mode of the spray head; 
           [0022]      FIG. 6 e    is a partial cross-sectional view of the spray head embodiment of  FIGS. 6 a -6 d   , illustrating a portion of the filtered water travel path in the filtered water output mode; 
           [0023]      FIG. 6 f    is a partial cross-sectional view of the spray head embodiment of  FIGS. 6 a -6 e   , illustrating a cutoff of the unfiltered water travel path when the spray head is in the filtered water output mode; 
           [0024]      FIG. 6 g    is a partial cross-sectional view of the spray head embodiment of  FIGS. 6 a -6 f   , illustrating a cutoff of the filtered water travel path when the spray head is in either the aerated or shower spray modes; 
           [0025]      FIG. 6 h    is a table illustrating the various states of a filtered water activation switch and an unfiltered water output selection switch and corresponding water output modes of the spray head embodiment shown in  FIGS. 6 a   - 6   g;    
           [0026]      FIGS. 7 and 8  are front and partial front views of a spray head, in accordance with an embodiment of the present invention; 
           [0027]      FIG. 9 a    is a cross-sectional view of a multi-channel hose coupled to a diverter-equipped T-connector in a closed state, in accordance with an embodiment of the present invention; 
           [0028]      FIG. 9 b    is an exploded view of the multi-channel hose and diverter-equipped T-connector embodiment shown in  FIG. 9   a;    
           [0029]      FIGS. 9 c  and 9 d    are cross-sectional views of the diverter-equipped T-connector embodiment shown in  FIGS. 9 a  and 9 b   , illustrating the T-connector in closed and open states; and 
           [0030]      FIG. 10  is a perspective view of a faucet having an integrated filtration system, in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0031]      FIG. 1  is a front view of an exemplary faucet  100  having an integrated filtration system.  FIG. 2  is a schematic diagram illustrating the flow of filtered and unfiltered water in the integrated faucet filtration system. Faucet  100  includes a supporting base  102  that rests on a sink deck, a faucet body  104  disposed on the supporting base  102 , a handle  106  for controlling water output, a spout  108  mechanically coupled to body  104 , and a spray head  110  fluidly coupled to one end of a multi-channel hose  200  that is at least partially disposed in the spout. Spray head  110  includes a filtered water activation switch  111  and an unfiltered water output selection switch  113 . Multi-channel hose  200  runs through spout  108 , body  104 , supporting base  102 , and the sink deck, and is fluidly coupled, at its other end, to a branch  301  of a diverter-equipped T-connector  300 . A hot water supply hose  151  is fluidly coupled between a hot water source and a valve assembly cartridge  101  disposed in body  104 . A branch  171  of a T-connector  170  is coupled to a cold water source, a branch  172  is coupled to a cold water supply hose  152  that leads to valve assembly cartridge  101 , and a branch  173  is coupled to a hose  180  leading to a pressure regulator  182 . Pressure regulator  182  is, in turn, fluidly coupled to a filter assembly  184  via a hose  186 . Filter assembly  184  can employ any material suitable for purifying water (e.g., activated carbon microfilters). Pressure regulator  182  is configured to regulate the cold water pressure leading into filter assembly  184  to optimize filter performance. 
         [0032]    A mixed water hose  190  is fluidly coupled between valve assembly cartridge  101  and a branch  302  of diverter-equipped T-connector  300 . A branch  303  of diverter-equipped T-connector  300  is coupled to filter assembly  184  via a hose  188 . As illustrated in  FIGS. 1 and 2 , unfiltered hot water from the hot water source is delivered to valve assembly cartridge  101  via hot water supply hose  151 . Unfiltered cold water from the cold water source is delivered to T-connector  170  and subsequently delivered to pressure regulator  182  via hose  180  and to valve assembly cartridge  101  via cold water supply hose  152 . Filtered water output by filter assembly  184  is delivered to diverter-equipped T-connector  300  via hose  188 . Unfiltered hot and cold water is mixed in valve assembly cartridge  101  (e.g., according to the position of handle  106 ) and delivered to diverter-equipped T-connector  300  via the mixed water hose  190 . The filtered and unfiltered water is then finally delivered from diverter-equipped T-connector  300  to spray head  110  via multi-channel hose  200 . 
         [0033]      FIG. 3  is a cross-sectional view of multi-channel hose  200 . Multi-channel hose  200  can be composed of flexible, lightweight material, and includes two concentric layers—an interior layer  202  and an exterior layer  204 . Interior layer  202  provides a tunnel  210  that serves as a waterway for filtered water, and a tunnel  220  between interior layer  202  and exterior layer  204  forms a waterway for unfiltered water. 
         [0034]      FIGS. 4 and 5  are perspective views of faucet  100 , illustrating spray head  110  in docked and undocked positions.  FIG. 6 a    is a side cross-sectional view of spray head  110 .  FIGS. 6 b  and 6 c    are front cross-sectional views of spray head  110 , illustrating unfiltered water travel paths in aerated and shower spray modes of spray head  110 .  FIG. 6 d    is a front cross-sectional view of spray head  110 , illustrating the filtered water travel path in the filtered water output mode of spray head  110 .  FIG. 6 e    is a partial cross-sectional view of spray head  110 , illustrating a portion of the filtered water travel path in the filtered water output mode.  FIG. 6 f    is a partial cross-sectional view of spray head  110 , illustrating a cutoff of the unfiltered water travel path when spray head  110  is in the filtered water output mode.  FIG. 6 g    is a partial cross-sectional view of spray head  110 , illustrating a cutoff of the filtered water travel path when spray head  110  is in either the aerated or shower spray modes.  FIG. 6 h    is a table illustrating the various states of filtered water activation switch  111  and unfiltered water output selection switch  113  and the corresponding water output modes of spray head  110 .  FIGS. 7 and 8  are front and partial front views of spray head  110 . 
         [0035]    Spray head  110  includes water pathways  114  and  116  for receiving filtered and unfiltered water from respective tunnels  210  and  220  of multi-channel hose  200 . Water pathways  114  and  116  run internally in spray head  110 , from a threaded coupler  112  of spray head  110  to complementary outlet components—an aerator  119  and a shower spray outlet  121 —of spray head  110  that dispense the two types of water. Multi-channel hose  200  includes a bonnet  221  (e.g., attached to an end of multi-channel hose  200 ) having complementary threads for coupling to threaded coupler  112 . One or more sealing components are also included for sealing the connection between bonnet  221  and threaded coupler  112  to prevent water leakage. 
         [0036]    Aerator  119  is centrally disposed at an output end of spray head  110  and includes multiple aerator outlets  119   u  for outputting unfiltered water. Outlets  119   u  are arranged to circumscribe a separate and distinct filtered water outlet  119   f  of aerator  119 . Shower spray outlet  121  is also disposed at the output end of spray head  110  and includes multiple spray nozzles  121   u  for outputting unfiltered water. Nozzles  121   u  are arranged to generally circumscribe aerator  119 . 
         [0037]    Filtered water activation switch  111  and unfiltered water output selection switch  113  can be manipulated to regulate the passage of filtered and unfiltered water through water pathways  114  and  116 . As illustrated in  FIGS. 6 a  and 6 e -6 g   , activation switch  111  is coupled to a piston sub-assembly including a piston  111   p , sealing O-rings  111   r , and a spring  111   s  positioned over a guide pin  111   g . Actuation of activation switch  111  (e.g., by depressing activation switch  111  into spray head  110 ) switches spray head  110  to the filtered water output mode. In at least one embodiment, activation switch  111  is a spring-loaded push button that can be released from a depressed state upon subsequent depression of the button. 
         [0038]    Selection switch  113  is similarly coupled to a piston sub-assembly including a piston  113   p , sealing O-rings  113   r , and a spring  113   s  positioned over a guide pin  113   g . Actuation of an upper portion  113   a  of selection switch  113  (e.g., by depressing upper portion  113   a  into spray head  110 ) switches spray head  110  to the unfiltered water shower spray mode. Actuation of a lower portion  113   b  of selection switch  113  (e.g., by depressing lower portion  113   b  into spray head  110 ) switches spray head  110  to the unfiltered water aerated mode. 
         [0039]    Switching between the filtered water output mode and any of the unfiltered water output modes is achieved via a lever  112  coupled between pistons  111   p  and  113   p . Lever  112  is pivotable about a point  112   p  and includes an upper end that interacts with piston  111   p  and/or activation switch  111  and a lower end that interacts with piston  113   p  and/or selection switch  113 . When activation switch  111  is in a depressed state (and spray head  110  is in the filtered water output mode), subsequent depression of selection switch  113  (e.g., at upper portion  113   a  or lower portion  113   b ) causes lever  112  to rotate in a clockwise direction and drive activation switch  111  from the depressed state to an undepressed (e.g., neutral or reset) state. This switches spray head  110  from the filtered water output mode to either the unfiltered water aerated mode or the unfiltered water shower spray mode, depending on which portion of selection switch  113  is depressed. Conversely, when selection switch  113  is in a depressed state (e.g., when upper portion  113   a  is in a depressed state, with spray head  110  in the unfiltered water shower spray mode, or when lower portion  113   b  is in a depressed state, with spray head  110  in the unfiltered water aerated mode), subsequent depression of activation switch  111  causes lever  112  to rotate in a counter-clockwise direction and drive selection switch  113  from its depressed state to an undepressed (e.g., neutral or reset) state. This switches spray head  110  from the unfiltered water (aerated or shower spray) mode to the filtered water output mode. 
         [0040]    It is to be understood that selection switch  113  (and its associated components) can alternatively be configured to set spray head  110  to the unfiltered water aerated mode when upper portion  113   a  is depressed and to the unfiltered water shower spray mode when lower portion  113   b  is depressed. 
         [0041]      FIGS. 6 b  and 6 c    respectively illustrate the unfiltered water travel paths (represented by arrows  126 ) in shower spray and aerated spray modes of spray head  110 .  FIG. 6 d    illustrates the filtered water travel path (represented by arrows  146 ) in the filtered water output mode. 
         [0042]    When selection switch  113  is depressed at upper portion  113   a , unfiltered water is diverted to a channel  116   s  of pathway  116  for output via nozzles  121   u  of shower spray outlet  121  ( FIG. 6 b   ). When selection switch  113  is depressed at lower portion  113   b , unfiltered water in unfiltered water pathway  116  is diverted to a channel  116   a  of pathway  116  for output via outlets  119   u  of aerator  119  ( FIG. 6 c   ). Diversion between the shower spray and aerated modes is achieved via one or more components of (or coupled to) selection switch  113 , such as one or more movable arms of selection switch  113 . The component(s) prevents unfiltered water in unfiltered water pathway  116  from entering channel  116   a  when upper portion  113   a  is depressed, and prevents unfiltered water in unfiltered water pathway  116  from entering channel  116   s  when lower portion  113   b  is depressed. In either case, any filtered water that might be present in filtered water pathway  114  is prevented (e.g., by piston  111   p ) from entering a channel  114   a  of pathway  114  for output via filtered water outlet  119   f  of aerator  119  ( FIG. 6 g   ). 
         [0043]    When activation switch  111  is set to a first state (e.g., a depressed state), filtered water in filtered water pathway  114  is delivered to channel  114   a  for output via filtered water outlet  119   f  ( FIGS. 6 d  and 6 e   ). In this case, any unfiltered water that might be present in unfiltered water pathway  116  is prevented (e.g., by piston  113   p ) from entering any of channel  116   a , outlets  119   a , channel  116   s , and shower spray nozzles  121   u  ( FIG. 6 f   ). When activation switch  111  is switched from a depressed state to an undepressed (e.g., reset, neutral, or released) state, such as, for example, by depression of selection switch  113 ), unfiltered water is permitted to enter either channel  116   a  (for output via outlets  119   u ) or channel  116   s  (for output via nozzles  121   u ), depending on which portion of selection switch  113  is depressed, and filtered water in filtered water pathway  114  is prevented from entering channel  114   a  for output via filtered water outlet  119   f  ( FIG. 6 g   ). 
         [0044]      FIG. 9 a    is a cross-sectional view of multi-channel hose  200  coupled to diverter-equipped T-connector  300  in a closed state.  FIG. 9 b    is an exploded view of multi-channel hose  200  and diverter-equipped T-connector  300 .  FIGS. 9 c  and 9 d    are cross-sectional views of diverter-equipped T-connector  300  in closed and open states. Each of branches  301 - 303  includes a threaded coupling head (threaded coupling heads  301   a ,  302   a , and  303   a ) for threaded and fluid coupling to a corresponding one of hoses  188 ,  190 , and multi-channel hose  200 . Branch  303  includes a filtered waterway  303   w  for passing filtered water received from hose  188 . Branch  302  includes an unfiltered waterway  302   w  for passing unfiltered water from mixed water hose  190 . Branch  301  includes a filtered water path  301   f  that complementarily couples to filtered water tunnel  210  of multi-channel hose  200 , and an unfiltered water path  301   u  that complementarily couples to unfiltered water tunnel  220  of multi-channel hose  200 . 
         [0045]    As shown in  FIGS. 9 a  and 9 b   , multi-channel hose  200  includes a bonnet  222  that threadably and fluidly couples to threaded coupling head  301   a  of branch  301 . Hose  200  also includes a washer (that may, e.g., be composed of rubber or the like) for sealing waterway connections between hose  200  and branch  301 , as well as an O-ring  231 , an adapter  232 , a ferrule  233 , a washer  234 , and a barb  235  that form and/or seal the water connections between hose  200  and branch  301  when assembled. 
         [0046]    The diverting mechanism of diverter-equipped T-connector  300  includes a piston  320  having a head  320   h  and a rod  320   r . Piston  320  is preloaded by a spring  330  and sealed at head  320   h  and rod  320   r  by O-rings  319  and  329 . In the closed state of diverter-equipped T-connector  300  (e.g., when cartridge  101  is closed), no unfiltered water is delivered to branch  302 , and pressure of the filtered water in waterway  303   w  (represented by arrows  303   x ) is unable to overcome the spring force ( FIG. 9 c   ). In this scenario, piston  320  remains preloaded as shown in  FIGS. 9 a  and 9 c    (i.e., with head  320   h  being disposed proximate an open end of branch  302  and rod  320   r  of piston  320  being positioned so as to block the filtered water in waterway  303   w  from entering filtered water path  301   f ), and no water (filtered or unfiltered) is output to multi-channel hose  200 . In the open state of diverter-equipped T-connector  300  (e.g., when cartridge  101  is open), unfiltered water is delivered from mixed water hose  190  to branch  302 , pressure of the unfiltered water (represented by arrows  302   x ) drives head  320   h  of piston  320  rightward and enters passageway  320   p  in head  320   h  into waterway  302   w  on the opposite side of head  320   h , and the filtered water in waterway  303   w  (represented by arrows  303   x ) enters an opening in piston  320  ( FIG. 9 d   ). The filtered and unfiltered water respectively flow into filtered and unfiltered water paths  301   f  and  301   u  for output to multi-channel hose  200 . When cartridge  101  is subsequently closed, no unfiltered water is delivered to branch  302 , and spring  330  returns piston  320  to its closed position. 
         [0047]    It is to be understood that, in the open state of diverter-equipped T-connector  300 , either the pressure of the unfiltered water alone, or the combination of the pressure of both the unfiltered and filtered water, overcomes the spring force. 
         [0048]    It is to be appreciated that the spray head can alternatively include either an aerator or a shower spray outlet, but not both.  FIG. 10  is a perspective view of a faucet  1000 , illustrating a spray head  1010  in docked and undocked positions. In contrast to spray head  110  of  FIGS. 4 and 5 , spray head  1010  has a filtered water activation switch  1011 , but does not include an unfiltered water output selection switch (nor its associated internal components). Spray head  1010  also includes only one output for unfiltered water (e.g., only an aerator with aerated outlets or only a shower spray outlet with nozzles). The unfiltered waterway tunnel in spray head  1010  is thus continuously fluidly coupled to that one output, without the need for a diverting mechanism within spray head  1010 . 
         [0049]    Accordingly, an integrated faucet filtration system advantageously equips a pull-out or pull-down spray head with filtered water output capability, which eliminates the need for a separate side faucet for dispensing filtered water, and provides an easy-to-maintain sink deck environment. 
         [0050]    It should be understood that the various filtered and unfiltered waterways and tunnels in each of the multi-channel hose, spray head, and diverter-equipped T-connector are separate from one another, and thus prevents cross-contamination of the two types of water throughout the system. 
         [0051]    It will thus be seen that the aspects, features and advantages made apparent from the foregoing are efficiently attained and, since certain changes may be made without departing from the spirit and scope of the invention, it is intended that all matter contained herein shall be interpreted as illustrative and not in a limiting sense. 
         [0052]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.