Abstract:
A mixer tap assembly is shown which has a mixing chamber for mixing fluids from two inputs, and a mix controller to control the ratio of fluid flow into the mixing chamber from the inputs. The mix controller includes a mix actuator which operates a mix control apparatus, such as a rotatable sleeve, which is connected to a mix valve apparatus associated with the mixing chamber. The mix actuator and a fluid outlet are mountable on or above a work surface via a mounting apparatus, while the mixing chamber is mountable below the work surface. Furthermore, the mix control apparatus and an output conduit, between the fluid outlet and the mixing chamber, pass through a bore in the mounting means, so minimizing the footprint of the mixer tap assembly on the work surface.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to mixer taps, i.e. taps with a plurality of fluid inputs which are mixable to be ejected from one or more common outputs. For example, mixer taps are used on kitchen sinks to provide a single water supply with controllable temperature. The present invention is applicable to mixer taps having a pull-out or pull-down spray facility, i.e. where the or an additional fluid outlet is detachable from the main unit to give flexible user-directable flow. 
     2. Summary of the Prior Art 
     Mixer taps are well known. Typically, fluid input from a plurality of sources (usually hot and cold water supplies) is controllably conveyed to a mixing chamber, where the fluid is mixed and ejected through an output spout. Such mixer taps commonly use a single lever mixing valve to control the flow rate and temperature of the ejected water. Temperature is controlled by adjusting the ratio of hot to cold inputs received in the mixing chamber. A single lever mixing valve can control these two properties using a combination of rotational and tilting movements of an actuator operably connected to the control lever of the mixing valve. For example, the actuator (e.g. tap head) may be rotated to control temperature and tilted to control flow rate. This is conventional. 
     To give greater flexibility it is increasingly common to combine a side spray unit with the main mixer tap. Previously, separate side sprays were used, but when used with mixer taps these suffered from problems in efficiently delivering mixed water from the mixing chamber to the side spray. For example, one proposal incorporated an automatic diverter valve in the mixer tap to deflect water to a side spray when the side spray was operated. To fit in the mixer tap, the diverter valve was small, which meant that in time it was liable to become clogged with limescale and therefore reduce flow to the spray. By combining the side spray unit with the main tap, the problems caused by the diverter valve could be avoided. 
     In one combined proposal (known as a pull-out spray), a spray head is removably attached to the side of the tap beneath the mixing valve with a hose connecting the spray head to the valve. In another combined proposal (known as a pull-down spray), the main tap spout has a traditional goose neck configuration through which the tube that feeds the spray nozzle passes. The spray nozzle is removably attached to the mouth of the spout; when attached it operates as the main tap outlet, when detached (pulled down) it operates as a hand spray. Typically the connecting hose is longer than the spout to give flexibility of movement. 
     SUMMARY OF THE INVENTION 
     Combined arrangements of the sort described above often require large housings to contain the components. For example, it can be necessary for the tap housing to contain the valve apparatus and mixing chamber. Such large housings can be undesirable as they take up space and may not be aesthetically pleasing. Usually, the excess hose is looped under the work surface to stay out of sight. Thus, space must be made for the connecting hose to pass through the work surface twice, as well as to allow for the input supplies to the mixing chamber. This may give the tap assembly a large footprint on the work surface. 
     The present invention aims to address the problems mentioned above. At its most general, the invention provides a mixer tap assembly with a control mechanism for controlling input to and output from a mixing chamber where the control mechanism includes means for communicating through a work surface via the same path as an output fluid flow to allow components of the assembly such as the mixing chamber to be located below the work surface. Accordingly, the size of that part of the assembly to be mounted on or above the work surface, e.g. in view of the user during normal use, can be kept small and/or made more aesthetically pleasing. 
     There are many ways of controlling the output from the mixing chamber. One way is to indirectly control the output by controlling the input into the mixing chamber. Another way is to have separate control means for controlling the output independently of control of the input. 
     It is to be noted that the terms “above” and “below” as used hereafter refer to positions of elements relative to each other, and of course do not limit the components of the invention to a particular orientation relative to the earth. 
     Thus, in one aspect the present invention may provide a mixer tap assembly having: 
     a mixing chamber mountable below a work surface for mixing fluid receivable from two inputs which are in fluid communication with the mixing chamber; 
     a fluid outlet mountable on or above the work surface; 
     an output conduit in fluid communication with the mixing chamber to carry mixed fluid to the fluid outlet; 
     a flow controller operable to control fluid flow out of the mixing chamber into the output conduit; and 
     a mix controller operable to control fluid input received in the mixing chamber; wherein: 
     the flow controller has a flow actuator that is mountable on or above the work surface and arranged to operate flow control means which are communicable with the mixing chamber through the work surface to control fluid flow out of the mixing chamber; 
     the mix controller has a mix actuator that is mountable on or above the work surface and arranged to operate mix control means which are communicable with the mixing chamber through the work surface to perform the fluid input control; and 
     the flow control means, mix control means and output conduit share a common path through the work surface. 
     The mounting of components of the assembly above and below the work surface is normally achieved by using mounting means for attaching the assembly to the work surface. The mounting means may be a housing and backing nut on opposite sides of the work surface. The components of the assembly are positioned relatively above or below the mounting means of the assembly and are thus located above or below the work surface when the mounting means is attached to it. 
     The listed components of the assembly which are adapted to share a common path through the work surface normally do so by passing through a bore in the mounting means. Therefore, the present invention may also provide a mixer tap assembly having: 
     mounting means for attaching the assembly to a work surface; 
     a mixing chamber positioned below the mounting means for mixing fluid receivable from two inputs which are in fluid communication with the mixing chamber; 
     a fluid outlet positioned above the mounting means, which fluid outlet is located at the end of a spout; 
     an output conduit in fluid communication with the mixing chamber for carrying mixed fluid to the fluid outlet; and 
     a mix controller including mix valve means associated with the mixing chamber, the mix controller being operable to control the ratio of fluid received in the mixing chamber from the two inputs; 
     wherein the mix controller further includes a mix actuator positioned above the mounting means and arranged to operate mix control means which is communicable with the mix valve means to perform the fluid input control; and 
     wherein the mix control means and the output conduit pass through a bore in the mounting means. 
     Thus, the mixer tap assembly may be arranged to be mounted in a sink unit, e.g. a kitchen sink, with the mixing chamber under the sink surface, i.e. out of sight during normal use, so that preferably only the fluid outlet, flow actuator and mix actuator are on view. 
     The output conduit typically travels through a hole formed through the work surface (sink surface). The fluid outlet is preferably mountable over this hole to receive the output conduit. 
     Preferably, the assembly includes a housing mountable on the work surface. The housing preferably has any one or more or all of the flow actuator, mix actuator and fluid outlet mounted thereon. 
     Preferably, the fluid outlet is connected to the output conduit. For example, the fluid outlet may be a nozzle, e.g. a spray head nozzle mountable on the housing. The spray head nozzle may be detachable from the housing, e.g. to form a pull-out spray. 
     Preferably, the tap assembly includes a spout extending from the housing. In one arrangement, the spout may be provided with its own water supply from the mixing chamber. Alternatively, the fluid outlet may be located at, e.g. detachably mountable on, the end of the spout. The spout may form a passageway for the output conduit, so that the fluid outlet (spray head nozzle) is detachable from the end of the spout to form a pull-down spray. In a preferred embodiment, the spout has a goose-neck configuration. 
     Thus, the present invention is equally applicable to mixer tap assemblies where the spray unit doubles as the main fluid supply (pull-down sprays) and mixer tap assemblies having an independent spray unit and main fluid supply on a common housing. 
     Preferably, the flow and/or mix control means include a physical connection to the mixing chamber, e.g. directly to control valve or valves at the inputs and/or output of the mixing chamber. In this case, the output conduit and control means may pass through a common hole, e.g. a single hole, in the work surface. The output conduit therefore only passes through the work surface once, thereby reducing the footprint of the tap assembly compared with known devices. The footprint is further reduced by locating the mixing chamber (and hence its inputs) below the work surface. 
     Preferably, the flow controller is arranged to control fluid flow rate through the output conduit. In other words, it controls the volume of fluid delivered by the tap assembly per unit time. The mixing chamber may include an output valve operable by the flow controller, the output valve being arranged to control the flow rate of fluid out of the mixing chamber into the output conduit. Preferably the flow control means communicates e.g. by physical connection with the output valve. 
     Preferably, the mix controller is operable to control the relative proportion of fluid from each fluid input that is permitted into the mixing chamber. Preferably, the mix controller controls input to the mixing chamber independently of the flow controller&#39;s control of flow output from the mixing chamber. 
     Preferably, the mixing chamber includes an input valve at each of the two inputs, each input valve being arranged to control the flow rate of fluid from its respective input into the mixing chamber. The two inputs may carry hot and cold water respectively. Preferably, the valves are controlled in a complementary fashion, i.e. varying the relative proportion of fluid from each input while maintaining a constant input flow rate. For example, the input flow rate to the mixing chamber may be kept constant with the mix controller able to cause all of the flow to come from one or other of the inputs or as a mixture of the two. Preferably, the ratio of the mixture is variable in a continuous, e.g. linear, fashion. 
     Thus, while the flow controller may be operable to allow fluid to flow through the tap assembly, the mix controller may be operable to control the proportions of flow inputs into the mixing chamber, i.e. the mix controller may control the content of the fluid flowing through the tap. 
     Preferably, the output conduit is a flexible tube extending from the mixing chamber to the housing mounted on the work surface. The housing is preferably located over a hole in the work surface through which the output conduit (flexible tube) passes. As explained above, the output conduit may feed a spray head mounted on the housing or may extend through a main spout to feed a nozzle detachably mounted to the end of the spout. In both cases, it is preferable that the tube is extendable away from the housing, e.g. by being slidable relative to it (i.e. through it). This may be achieved by making the flexible tube longer than is necessary to reach the fluid outlet, with the excess length under the work surface when the tube is in a non-extended position. 
     Preferably, the flow and/or mix control means include physical connection to the valve or valves (e.g. cartridge valves) associated with the mixing chamber such that operation of the flow and/or mix actuator is directly transferred to operation of the valve or valves. Preferably, the physical connection of the control means extends through the same hole (i.e. the single hole) in the work surface as the output conduit that carries fluid to the fluid outlet. By sharing this space, the number of components on view to the user (i.e. above the work surface) can be kept to a minimum, which may improve the overall appearance of the tap assembly. 
     In one preferred embodiment, the flow and mix control means are upstanding sleeves rotatable about an axis. The sleeves are preferably operably connected to the valve or valves associated with the mixing chamber. In a most preferred configuration, the upstanding sleeves of the flow and mix control means are coaxial, i.e. concentric. The actuators may be rotatable rings coupled to their respective sleeve, each ring being rotatable by a protruding (e.g. radially protruding) lever. Preferably, the rotation axis of the sleeves is coaxial with the hole in the housing through which the output conduit is arranged to travel. Thus, the output conduit may pass through the actuator sleeves on it route from the mixing chamber below the work surface to the fluid outlet above the work surface. 
     A longitudinal (axially extending) opening is preferably formed in each sleeve to receive the output conduit. The circumferential extent of the opening is preferably selected to avoid interference with (i.e. constricting movement of or affecting flow through) the output conduit. The axial extent of the opening is preferably selected to avoid excessive bending of the output conduit as it travels through the sleeves and out of the housing. 
     Thus, the flow rate and mix ratio of fluid output from the tap may be controllable by two rotatable controllers. The rotatable controllers may be located on top of one another to permit easy user access. 
     Fluid may arrive in the mixing chamber from each input through a respective input cartridge valve, e.g. of the conventional ceramic disc type, with the mix controller arranged to control the cartridge valves. Typically, cartridge valves are operated (turned from off to full on) by rotating a control lever, e.g. through a quarter turn. Preferably, the control means of the mix controller is operably connected to the control levers of its respective cartridge valves. The operative connection may be geared to give the user increased control. 
     Fluid may exit from the mixing chamber into the output conduit through another cartridge valve, e.g. of the ceramic disc type, with the flow controller arranged to control this cartridge valve, e.g. in a similar way to the mix controller, described above. 
     The outputs of two input cartridge valves may be directly connected to, i.e. in fluid communication with, the input of an output cartridge valve. Thus, flow rate and mixing ratio of the output fluid flow can be controlled using three cartridge valves. 
     The flow and mix controllers may be combined. Such a combined mix/flow controller may include a common actuator for operating control means (which may be separate or combined) for controlling fluid input and output to the mixing chamber. 
     Preferably, the combined mix/flow controller includes both a common actuator and a common control means, thereby reducing the total number of components in the tap. The common actuator may be arranged to cause the common control means to exhibit different types of movement. A different type of movement may be associated with fluid input and output control. For example, the combined actuator may be horizontally rotatable and vertically tiltable. 
     Different types of movement preferably communicate to the control means which of flow or mix control is to be operated. This communication may be physical. For example, the common control means may be a upstanding sleeve capable of rotational motion about its axis and linear motion along its axis, e.g. up and down. 
     The sleeve may be operably coupled to a single-lever mixing cartridge, e.g. of the conventional type where output flow rate and input mix proportion are controlled by manipulating a single lever. The movement of the sleeve is therefore preferably translated into movement of the control lever. For example, rotation of the sleeve may cause rotation of the control lever, and up and down movement of the sleeve may cause tilting of the control lever. 
     Second and third aspects of the invention may provide a tap and work surface assembly, including a mixer tap assembly mounted on a work surface, and a method of assembling the same, respectively. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Examples of the present invention are discussed in detail with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a tap assembly according to a first embodiment of the invention; 
         FIG. 2  is a side view of the tap assembly of  FIG. 1 ; 
         FIG. 3  is a cross-section taken along the line A-A in  FIG. 2 ; 
         FIG. 4  is a close-up perspective view of the interior of the mixing chamber housing shown in  FIG. 1 ; 
         FIG. 5  is another perspective view of the interior of the mixing chamber housing of  FIG. 1 ; 
         FIG. 6  is a perspective view of a tap assembly according to a second embodiment of the invention; 
         FIG. 7  is a first cross-sectional view of the tap assembly of  FIG. 6 , in an “on” configuration; 
         FIG. 8  is a second cross-sectional view of the tap assembly of  FIG. 6 , in an “off” configuration; 
         FIG. 9  is a perspective view of a tap assembly according to a third embodiment of the invention; 
         FIG. 10  is a front view of the tap assembly of  FIG. 9 ; and 
         FIG. 11  is a cross-section taken along the line B-B in  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a tap assembly  10  according to one embodiment of the invention isolated from its mounting position, e.g. next to a sink. The tap assembly  10  has a mixing chamber housing  12  which receives two fluid inputs  14 , 16  which are connected to hot and cold water supplies (not shown) respectively via connectors  20 . The inputs  14 , 16  feed the base  15  of the mixing chamber housing  12 ; each input  14 , 16  supplies its own cartridge valve (not shown) inside the base  15 . An output conduit  18  carries mixed fluid away from the mixing chamber housing  12  to a fluid outlet  34  at the end of an output spout  32 . The output conduit  18  is a flexible pipe that loops around the bottom of the base  15  and passes through the interior of the output spout  32 , which is a hollow rigid pipe made of suitable material (e.g. stainless steel, brass, etc.), arranged in a goose-neck configuration. The output conduit  18  feeds fluid to the fluid outlet  34 , which is a conventional spray head. The fluid outlet  34  is detachably mounted to the output spout  32 , and can be pulled down, i.e. away from the spout  32 , to give the user flexibility in directing flow out of the outlet  34 . The output conduit  18  has extra length to accommodate this movement. 
     The mixing chamber housing  12  is connected to control housing  26  by an upstanding rigid tube  24 . In use, as shown in  FIG. 2 , the base of control housing  26  rests on the top of a work surface  42 , where it is secured in place by a backing nut  27 . The upstanding tube  24  extends through a hole (not shown) in the work surface  42  so that the mixing chamber housing  12  and the loop of output conduit  18  are located out of sight below the work surface  42 . 
     Tube  24  is hollow, and control housing  26  has a passageway therethrough to allow the output conduit  18  to travel from below the work surface  42  to the output spout  32  through the same hole in the work surface  42  as the tube  24 . The tube  24  has a cut-out opening  25  which allows the output conduit  18  to be fed in below the control housing  26 . A guiding tube  22  is attached to a ring  21  mounted on the tube  24  via a lug  23 . The guide tube  22  controls the orientation and angle at which the output conduit  18  enters the tube  24 . This prevents the edges of the cut-out hole  25  from interfering with the output conduit, and also prevents kinks from forming in the conduit. 
     Two radially protruding rotatable push levers  30 , 31  are mounted in the control housing  26  to communicate with the valves in the mixing chamber housing  12  as described below. The levers  30 , 31  rotate about a vertical axis extending through the tube  24 . The levers  30 , 31  are located on top of one another, and their connections in the housing are covered by respective trim covers  28 , 29 . The upper lever  31  is arranged to control flow rate (output volume), whereas the lower lever  30  is arranged to control mix ratio, i.e. the relative proportion of fluid received from inputs  14 , 16 . 
       FIG. 3  shows the mechanism by which the levers  30 , 31  communicate with the valves in the mixing chamber housing  12 . Lower lever  30  is operably coupled to the head  35  of an upstanding rotatable sleeve  36 . The base of sleeve  36  is connected to a annular block  46 , which has a depending lug  55  connected to a set of radially protruding teeth  64 , which are arranged to engage gears  58 , 60  associated with valve cartridges  52 , 54  for controlling the input mix ratio of fluid from inputs  14 , 16  (see  FIGS. 4 and 5 ). 
     Similarly, upper lever  31  is operably coupled to the head  37  of another upstanding sleeve  38  which lies inside and coaxial with sleeve  36  and tube  24 . The base  40  of sleeve  38  has a splined through hole  43  bored therein which receives a correspondingly splined projection  45  from coupling block  44 . Rotation of the sleeve  38  causes coupling block  44  to rotate. Coupling block  44  extends through annular block  46  and terminates in another set of radially protruding teeth  62  arranged to engage a gear  56  to operate a cartridge valve  50  associated with output flow rate (see  FIG. 4 ). 
     The valve cartridges  50 , 52 , 54  are housed in the base  15  of the mixing chamber housing  12 . A casing  17  attaches the base  15  to the tube  24  to prevent relative rotation therebetween, i.e. so that operating the levers  30 , 31  does not cause the entire mixing chamber housing  12  to rotate. Additionally, the cover  17  protects the gear connections, which protrude from the top of the base  15 . 
     The rotatable sleeves  36 , 38 , which act as physical control means that connect user operations above the work surface  42  to the control of valves below the work surface  42 , also have cut-out openings along their length to overlap with the cut-out opening in tube  24 . To allow for the rotation of the sleeves  36 , 38 , their cut-out openings have a wider circumferential extent. This means that they do not interfere with the output conduit  18 , even when rotated to control the cartridge valve(s). 
       FIGS. 4 and 5  show the operative connections in the mixing chamber housing  12 . The base of the housing contains three standard cartridge valves  50 , 52 , 54  of the ceramic plate type. As is conventional, each valve has an input in its base, and an output near the top, and flow through the cartridges controlled by a valve which is opened and closed by rotating a control lever which projects from the top of the valve. In the illustrated embodiment, gears  56 , 58 , 60  are mounted on and rotatable with the control levers of the cartridges. Inputs  14 , 16  are connected to the inputs of two of the cartridges  52 , 54 . The gears  58 , 60  of these cartridges  52 , 54  are operably connected to a common set of teeth  64 . This allows for the input cartridges to be controlled in a complementary fashion, i.e. the common set of teeth  64  rotate between two limits corresponding to 100% (full) supply from input  14  and 100% (full) supply from input  16 . Between these limits the cartridges  52 , 54  are open/closed in a linear (i.e. constant) fashion so that the total input volume remains constant and only the mix ratio (proportion of input  14  to input  16 ) varies. 
     The outputs of the two cartridges  52 , 54  connected to the inputs  14 , 16  are both connected to the input of the third valve cartridge  50 . Mixing of the fluids occurs at this point. The third valve cartridge  50  is operated to control the flow rate of mixed fluid out of the mixing chamber housing  12  (i.e. through output conduit  18 ). Thus, the set of teeth  62  which are operably connected to the gear  56  on the third valve cartridge  50  is arranged to move the gear between two limits corresponding to off, where no fluid flows through the cartridge (i.e. the valve is closed), and on, where the valve is fully open and maximum flow rate is achieved. 
       FIGS. 6 to 8  illustrate a second embodiment of the invention. Components which are the same as those illustrated in the first embodiment are given the same reference numerals and are not described again. 
     In the second embodiment, the three valve cartridges of the first embodiment are replaced by a conventional single lever-type mixer valve  74 , which is sits in an outer housing  71 , secured by a ring  79 . The inputs  14 , 16  and output conduit  18  are connected to the outer housing  71 , from where they are fed to the mixer valve  74 . A lever  76  is manipulated to permit fluid from the inputs  14 , 16  to enter a mixing chamber (not shown) in the mixer valve  74  in variable proportions. This is achieved by rotating the lever  76 . The same lever  76  is also tiltable to control the amount of fluid released from the mixer valve  74  into the output conduit  18 . 
     The mixer valve  74  is operated using an actuator lever  30  that is mounted on the control housing  26  above the work surface  42 . The actuator lever  30  is coupled to an upstanding sleeve  72  which extends between the control housing  26  and the mixer valve  74 . The sleeve  72  is rotatable and axially slidable relative to the tube  24  connecting the control housing  26  and mixer valve  74 . The actuator lever  30  is connected to the sleeve  72  via a V-shaped connector  73 . The actuator lever is pivoted at a fulcrum  33  to enable the sleeve  72  to be pulled up and down. The lever  30  and fulcrum mechanism  33  are mounted on a rotatable ring  28 , attached to the sleeve  72  so that the sleeve can be rotated by pushing the actuator lever  30 . 
       FIGS. 7 and 8  show the connection between the control lever  76  of the mixer valve  74  and the base  75  of the sleeve  72 . The control lever  76  is typically a box-like structure, and is contained within walls formed by the base of the sleeve  72  so that it is rotated with the sleeve  72 . Outward projections  78  on the control lever  76  are received in slanted slots  77  in the walls that contain the lever  76 . The slanted slots cause the lever to be tilted by the up and down movement of the sleeve  72 .  FIG. 7  shows an on configuration, where the sleeve  72  is at its lower position (actuator lever  30  pulled high) so that control lever  76  is tilted forward by the action of slot  77  against projection  78 .  FIG. 8  shows the off position with the sleeve  72  in its upper position (actuator lever  30  pushed down) where the control lever  76  stands upright. 
     As before, the sleeve  72  represents a physical control means connecting the actuator lever  30  with the mixer valve  74  and has a cut-out formed therein to enable the output conduit  18  to travel into the middle of tube  24 , through the work surface  42  via the same hole as the tube  24  and sleeve  72  to enter the output spout  32 . 
     A casing  70  attached the outer housing  71  to the tube  24  to prevent relative rotation therebetween, as described above. The casing  70  also protects the operative mechanism between the sleeve  72  and the control lever  76 . 
       FIGS. 9 to 11  illustrate a third embodiment of the invention, where the work surface which hides the mixer valve (i.e. the work surface through which the output conduit passes) is a vertical wall  102 , e.g. a stud wall for mounting in a kitchen or other suitable area. Again, parts in common with the first or second embodiments are given the same reference numbers. 
     In the tap assembly  100  of the third embodiment, the housing  26  includes a flat base plate  106  which can be mounted on the wall  102  using screws  108 . The output conduit  18  enters the cut out  25  in the tube  24  behind the wall  102  and is therefore guided horizontally through the wall into a conventional spout  104  to terminate at spray head  34 . 
     Similar to the second embodiment, the third embodiment uses the single lever mixer valve  74 , but in this case, the valve  74  is held in a horizontal configuration, with the lever  76  extending substantially horizontally. 
     The inner control sleeve  72  is movable axially (horizontally) and rotatably by the control lever  30  on the housing  26  using the same mechanism as the second embodiment.