Abstract:
A faucet spout assembly providing multiple spouts with different heights and curvature which are interchangeable within the same faucet. Laminar flow from the spout is achieved with a flow control device upstream of the spout outlet A check valve is optionally used in the inlet to the spout to promote greater flexibility in placement of the flow control device within the assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This application claims the benefit of prior filed provisional application No. 60/331,848 filed Nov. 20, 2001 entitled Interchangeable Gooseneck Faucet. 
     
    
     
       TECHNICAL FIELD OF THE INVENTION  
         [0002]    This invention relates generally to a faucet spout assembly and more particularly to a faucet assembly with interchangeable spouts which provide laminar, non-splashing water flow without any stream regulating attachment at the outlet of the spout  
         BACKGROUND OF THE INVENTION  
         [0003]    Faucet spout assemblies are widely used in households, industry, scientific laboratories, hospitals, etc. It is desired in some settings that faucet spouts of different configurations be available for use with a single faucet fixture. This raises a problem of how to economically achieve interchangeability of spouts  
           [0004]    Others have approached this problem as follows. According to Baker U.S. Pat. No. 6,256,810 an easy connect and disconnect faucet spout assembly is disclosed which can be mounted and removed in a quick and easy manner with a minimum of tools or operations, and without disassembling the faucet spout assembly or the water supply lines. At the same time, a spout assembly, according to the Baker patent, is comprised of a number of parts, some of which have a complicated shape. Moreover, each spout must be equipped with a special spout-mounting plate so interchangeability of spouts is expensive and requires a large parts inventory.  
           [0005]    Another approach to providing adjustable spouts of varying heights in a faucet is disclosed in U.S. Pat. No. 6,273,138. This patent describes a height adjustable spout with a spigot-clamping member that is used to sealingly locate the spout at the desired height on the faucet This apparatus, however, has the distinct disadvantage of having a clamp handle extending into the useable space over the basin. This would not be commercially acceptable because of poor aesthetics and the collection of mold and bacteria on the clamp.  
           [0006]    Another problem with commonly used spout assemblies is the location of outlet devices used to soften the flow of water out of the spout They are typically located at the outlet of the spout. Examples of such devices are disclosed in U.S. Patent Nos. 4,884,596; 5,108,606; 5,165,121; 5,242,119. Such devices—aerators, flow regulators and stream straighteners which are sometimes collectively referred to as laminar flow devices—serve as a trap, and consequently collector, for various germs and dirt because of their location at the spout outlet This problem is particularly acute in hospitals and health care facilities which must be particularly wary of areas where viruses like staphylococcus can take hold At the same time, it is difficult to abandon such spout end attachments in most applications because most faucet users demand a soft, non-splashing flow of water from a faucet spout.  
         SUMMARY OF THE INVENTION  
         [0007]    An object of the present invention is, therefore, a faucet spout assembly with easily interchangeable spouts.  
           [0008]    Another object of the invention is to provide new methods of forming a laminar stream at the outlet of a spout while at the same time preventing accumulation of germs and dust around the apparatus providing the laminar flow  
           [0009]    Still another object of the invention is to provide faucet spout assembly constructed of a minimal amount of parts, wherein each of them is simple and easy to assemble.  
           [0010]    Yet another object of this invention is to provide a flow restriction device in the faucet in a location that facilitates use of interchangeable spouts  
           [0011]    Still another object of the invention is to provide a sealing engagement of spout to faucet that provides an effective water-tight seal between these parts while accommodating slight dimensional variation among the spouts when positioned on the faucet.  
           [0012]    These and other objects may be achieved in this invention by placing a flow restrictor or flow control device in the faucet body adjacent to or near the upstream end of the interchangeable spout. Alternatively, the flow control device can be located further upstream in the water flow, for example, in the inlet of the valve controlling flow through the spout  
           [0013]    One end of the water supply pipe of the faucet of this invention includes a spout receptacle at the point where it mates with the interchangeable spout A flange lies atop the receptacle. A mating flange on each interchangeable spout is designed to be removably connected to the flange on the receptacle, for example, by suitable bolts or other fasteners.  
           [0014]    The spout receptacle and/or spout preferably contain at least two sealing means associated therewith to insure a water tight seal and accommodate dimensional differences among the interchangeable spouts. In one embodiment of the invention, a flat washer is arranged in the bottom of the spout receptacle. This washer is dimensioned so that its outside circumference snugly fits within the spout receptacle and its inside opening is slightly smaller than the outside diameter of the spout so that it snugly fits around the circumference of the spout The flat washer is dimensioned to be slightly thicker than the nominal distance between the bottom of the spout and the bottom of the spout receptacle when the spout is placed in the receptacle By fabricating this washer from resilient compressible material such as Santoprene or an ethylene—propylene, diene monomer (EPDM), dimensional differences in the manufacture of the interchangeable spouts can be accommodated. Thus, if the distance between the bottom of the flange on the spout and the top of the washer is slightly greater than designed, compression of the washer will accommodate that difference while guaranteeing an effective water tight seal.  
           [0015]    The sealing of the spout within the spout receptacle is completed with an O-ring arranged in a grove around the upper/inner periphery of the spout receptacle. Alternatively, the o-ring may be arranged so that a grove need not be formed in the spout receptacle. In this configuration, the O-ring is compressed between the flanges on the spout and spout receptacle.  
           [0016]    Other approaches to sealing the spout within the spout receptacle are also contemplated. More particularly, as more fully discussed below, it has been found advantageous to include a check valve in the upstream end of the interchangeable spout which fits into the spout receptacle A cylindrical check valve holder is sized to fit within that end of the spout The check valve holder is preferably cylindrical with a peripheral rim that is pressed into engagement with the flat washer at the bottom of the spout receptacle. This provides some additional sealing since the bottom surface of the check valve holder is greater, and flatter, than the bottom of the spout. This increased surface area in contact with the flat washer reduces the opportunity for leakage at this point (spout-flat washer interface) of the faucet spout assembly.  
           [0017]    A flow control device is used in the faucet assembly to provide a smooth, laminar flow of water from the spout. Devices providing laminar flow are typically located at the outlet of the faucet spout. Such a location has the disadvantage of being a collector of germs and dirt This presents a health issue and hospitals and some health care facilities have prohibited use of such devices in faucet spouts for that reason. Surprisingly, applicant(s) have found that placement of a flow restrictor or flow control device upstream of the spout outlet provides laminar flow at the outlet when the spout has a goose-neck shape  
           [0018]    Replacing a spout in the faucet of this invention is a simple operation of releasing bolts, or any affixing element, from the mating flanges on the faucet and spout. To place a new spout into the faucet, it is enough to insert the inlet end thereof into the spout receptacle and reattach the bolts or other affixing element joining the flanges of the spout and spout receptacle. These are tightened until the spout is sealed in the spout receptacle.  
           [0019]    Further details of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific drawings, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:  
         [0021]    [0021]FIG. 1 is a perspective view of multiple spouts interchangeably useable in the faucet assembly according to the invention;  
         [0022]    [0022]FIG. 2 is a sectional elevational view of the cup-like spout receptacle with the flow restrictor, sealing washer and sealing O-ring illustrated in the drawings and taken along a mid-line of all of them.  
         [0023]    [0023]FIG. 3 is a front elevational view, partly in section, of the faucet spout assembly according to the present invention,  
         [0024]    [0024]FIG. 4 is a partial side elevational view of faucet spout assembly according to the present invention;  
         [0025]    [0025]FIG. 5 is an exploded view of the faucet assembly, including spout, spout receptacle and solenoid valve with interconnecting piping.  
         [0026]    [0026]FIG. 6 is a side elevational view of the faucet assembly FIG. 7 is a top plan view of FIG. 6.  
         [0027]    [0027]FIG. 8 is a cross-sectional, side elevational view of a faucet spout with a check valve and check valve holder arranged in the inlet of the spout  
         [0028]    [0028]FIG. 8A is a fragmental side elevational view of a different shape of a gooseneck spout with an aerated outlet.  
         [0029]    [0029]FIG. 9 is a top plan view of a check valve holder and check valve.  
         [0030]    [0030]FIG. 10 is a side elevational view of the check valve holder  
         [0031]    [0031]FIG. 11 is a cross-sectional view in elevation of the check valve holder with check valve shown in partial cross-section  
         [0032]    [0032]FIG. 12 is a side elevational view of a solenoid valve control for the faucet spout assembly showing a laminar flow control device in the inlet of the solenoid valve control.  
         [0033]    [0033]FIG. 13 is a side elevational view, partially broken away, showing a laminar flow control device.  
         [0034]    [0034]FIG. 14 is a top plan view of the flow control device 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0035]    With reference to the accompanying drawings, the readily interchangeable faucet spout assembly according to the present invention will be described.  
         [0036]    Referring first to FIG. 5, the environment in which the invention is particularly useful is illustrated. The overall faucet spout assembly  10  of this invention is illustrated in this Figure. The faucet spout assembly  10  is connected to a water supply, not shown, through a solenoid valve  11  and interconnecting piping  15  although this illustrated piping is not essential to the operation of the faucet spout assembly. This piping  15  may be connected to a spout  24  by the means of a spout receptacle  12  with a flange  13  containing suitable openings therein for receipt of fasteners  21 . The spout receptacle  12  or inlet to solenoid  11  may also contain a flow control device  14 . The spout receptacle  12  may also contain sealing means such as a sealing washer  16  and/or sealing O-ring  18  therein (See FIG. 1). A flange  20  having axial opening  22  therein is adapted to fit over inlet end  24  of the spout  26  by brazing, solder or the like. The distance of the inlet end  24  of spout  26  extending beyond the bottom of flange  20  is dimensioned so that the inlet end  24  of the spout  26  will engage the upper surface of washer  16  in sealing engagement therewith. The flange  13  on the spout receptacle  12  and the spout flange  20  are held together by any means known in the art, for example, by bolts  21 . Spouts A, B, and C, shown on the FIG. 1, are interchangeable in the spout assembly, though differ from each other by both height H (H 1 , H 2 , H 3 ) and radius R (R 1 , R 2 , R 3 ) of curvature  
         [0037]    As is shown in FIG. 2, the spout receptacle  12  comprises two communicating portions: upper end  28  and lower end  30 , wherein the upper end  28  has a greater diameter D 1  than the diameter D 2  of the lower end  30 , so that the two portions form together a circular seat  32 . As illustrated in these Figures, the seat  32  receives a flow control device  14 , which is fixed in place by a snap ring  33 . A sealing washer  16  is placed around the flow restrictor  14  at the bottom of the upper end  28  of spout receptacle  12 . There is a circular recess  36  at the mouth of the upper end  28 . O-ring  18  is placed in this recess  36 .  
         [0038]    Flange  20  on the inlet end  24  of spout  26  has openings aligned with like openings in spout receptacle  13  so that, upon tightening the bolts  21 , or any other fasteners, the flanges are held together (FIG. 3). When so fastened, O-ring  18  is pressed between these flanges in recess  36  and the spout  26  is securely held in the faucet assembly. A double seal at this point is achieved when the bottom of spout  24  is sealingly engaged on washer  16 . Any dimensional variance in placing flange  20  on spout  26  is accommodated by the compressibility of washer  16 . Other spouts  26  can be easily substituted by simply undoing fasteners  21 , lifting out one spout  26 , replacing it with another and tightening fasteners  21   
         [0039]    Flow control device  14  is held in place on seat  32  of spout receptacle  12  by snap ring  33  which is press fit into the interior of spout receptacle  12 . Water flowing through flow control device  14  assumes a soft, laminar flow as it exits the spout  26 . It is believed that the soft, laminar flow is a result of maintaining a steady flow of water into the spout via the flow control device  14  in combination with the gooseneck shape of the spout  26 .  
         [0040]    In another embodiment of this invention illustrated in FIGS.  5 - 13 , laminar flow from spout  26  is achieved even though the laminar flow control device  14  is far removed from the outlet of spout  26 . In this embodiment, the interchangeability of spouts  26  is achieved using means described above. However, instead of placing a laminar flow control device  14  in spout receptacle  12 , it is placed well upstream in the inlet to solenoid valve  11 . Alternatively, flow control device  14  can be placed elsewhere in the piping  15  interconnecting the solenoid and spout receptacle  12 . It has been found that the noise associated with operation of the faucet assembly  10  is lower when the flow control device  14  is placed in the solenoid  11  inlet versus in the spout receptacle  12 .  
         [0041]    A placement of the laminar flow control device  14  in the inlet of solenoid valve  14  is illustrated in FIGS.  5 - 6  and  12 - 14 . In this embodiment, the flow control device  14  contains an inner passage  34  through which water passes on the way to spout  26 . The interior walls of this passage are flexible and respond to varying water pressure in a manner that assures constant flow levels through the spout  26 . An O-ring  36  on the exterior of flow control device  14  seals it within the inlet of solenoid  11 .  
         [0042]    This placement of the flow control device  14  in the faucet spout assembly  10  is facilitated by location of a check valve  38  in the inlet to spout  26 . Unexpectedly, it has been found that the placement of the check valve  38  near the inlet to spout  26  traps a certain amount of water in the vertical portion  24  of spout  26  after each usage of the faucet spout assembly  10 . This column of water promotes laminar flow out of the spout  26 . While the exact mechanism of this laminar flow and its relationship to check valve  38  is not yet fully understood, the effect has been proven. Check valve  38  operates in a normal manner to prevent backflow of water through spout  26  to solenoid  11  and ultimately the water supply. The check valve thus prevents contamination of the water supply, as well as enhancing laminar flow. The check valve  38  has a spring biased closure  42  which seals opening  44  in check valve  38  when flow of water to spout  26  is halted by solenoid  11  (See FIG. 11).  
         [0043]    Check valve  38  is positioned in the inlet portion  24  of spout  26  within a check valve holder  40  as illustrated in FIG. 8. Check valve holder  40  is preferably cylindrical with an exterior dimension closely matching the interior dimension of spout  26 . One end of the check valve holder  40  contains a rim  46  which increases the sealing area of the holder when placed into spout receptacle  12 .  
         [0044]    An arrangement of check valve holder  40  in spout receptacle  12  and its mating relationship with the lower end  24  of spout  26  is shown in FIG. 8 As illustrated, seat  32  receives washer  16  in a manner previously described The bottom surface  47  of the check valve holder is sealingly positioned on the upper surface of washer  16 . It is pressed against washer  16  by the bottom edge of spout  26 , pressing on the top of rim  46  as the flanges  20  and  13  on the spout  26  and spout receptacle  12 , respectively, are secured to each other by fasteners  21  Additional sealing at this juncture is achieved by o-ring  18  interposed around the periphery of spout  26  and between the flanges  13  and  20 .  
         [0045]    Although the preferred means of achieving a non-splashing flow from spout  26  is use of a flow control device  14  as described above, other means such as an aerator  48  can be used to achieve this goal (See FIG. 8A). When an aerator is used on one of the interchangeable spouts, use of a check valve in the assembly is optional.