Abstract:
A system for mounting a faucet assembly to the exterior portion of a dwelling is provided. A mounting sleeve is employed that is associated with a tube of a faucet assembly that is generally positioned outside of a dwelling. The tube is rigidly interconnected to a mounting sleeve that is supported by a bracket that allows for selective adjustments. That is, the mounting sleeve may be selectively offset from the interior surface of the dwelling, thereby accommodating exterior building surfaces with irregular shapes such as stone, brick, mortar, stucco, etc. The mounting system provides additional rigidity to the faucet assembly/dwelling interconnection.

Description:
[0001]    This application is related to U.S. patent application Ser. No. 14/078,780, Nov. 13, 2013, which claims the benefit of U.S. Provisional Application No. 60/726,144, filed Nov. 14, 2012. The entire disclosure of which is incorporated by reference herein. 
         [0002]    This application is also related to U.S. patent application Ser. No. 12/649,800, now U.S. Pat. No. 8,281,800, filed Dec. 20, 2009, which is a continuation of U.S. patent application Ser. No. 12/115,223, now U.S. Pat. No. 8,151,821, filed May 31, 2012, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/947,902, filed Jul. 3, 2007, the entire disclosures of which are incorporated by reference herein. 
     
    
     FIELD OF THE INVENTION 
       [0003]    Embodiments of the present invention are generally related to devices for securing faucets, wall hydrants, or other fluid delivery devices, to a building surface. One embodiment of the present invention is directed to a mounting assembly that secures a wall faucet to an uneven building surface. 
       BACKGROUND OF THE INVENTION 
       [0004]    Wall faucets are often found mounted to the exterior of a dwelling. Wall faucets include a flange designed to interconnect to an exterior dwelling surface. The wall faucet also includes a fluid delivery tube interconnected to the dwelling&#39;s water source on one end and to a valve-controlled hose bib at the other end. Traditionally, flanges are directly mounted to the exterior building surface, e.g., siding, which may provide a strong and stable interface for the wall faucet flange. Siding, however, is not the only common exterior building surface employed. For example, often wall faucets must be interconnected to stone, brick, mortar, stucco, etc., which is difficult to interconnect to, and which may not provide a sound wall faucet interconnection. 
         [0005]    Commonly, a plurality of elongated screws are used to interconnect the faucet flange to a mounting surface, which is acceptable if the faucet flange is abutted to the mounting surface. If, however, the faucet flange must be spaced from the mounting surface, because, for example, a stone exterior surface is present, longer screws must be used to reach the interior surface. This mounting method results in an unstable wall faucet as loads are reacted some distance from the connection point. One of ordinary skill in the art can envision that a hose interconnected to the wall faucet is subject to forces generated by moving or pulling the hose. Over time, these forces will weaken the interconnection of the faucet to the dwelling and may cause the faucet flange to dislocate from the exterior building surface. If a faucet assembly should separate from the dwelling, water, insects, or other outdoor contaminants can enter the dwelling. The wall faucet could also separate from the fluid supply line, thereby causing water/mold damage. To address these issues, grout, mortar, or other formable substances are used to secure the fluid tube and faucet flange to the exterior building surface. This additional work increases the time and cost of installation, and is a temporary fix. 
         [0006]    Devices in the prior art have been used to offset a faucet flange from an interior building surface to accommodate a brick exterior. For example, the hose bib supporter of PerfectSett made by JCT Innovations, LLC includes a rectangular shaped face offset from a plate interconnected to the outer surface of the wall, board, or sheathing of a building. The face provides a location for interconnection of a faucet assembly. One drawback of the PerfectSett device is it does not provide selective adjustments and only accommodates exterior building surfaces of a predetermined and consistent thickness. 
         [0007]    Thus it is a long felt need in the field of outdoor plumbing to provide a stable interconnection scheme for attaching wall faucets to the exterior surface of a dwelling. The following disclosure describes an improved system and method for interconnecting a wall faucet to an exterior building surface that addresses and overcomes the problems of the prior art. 
       SUMMARY OF THE INVENTION 
       [0008]    Some aspects of the various embodiments of the present invention described herein can generally be categorized as improvements or modifications to the inventions described in the U.S. Patent Application Publication No. 2014/0131545, which is the publication of U.S. patent application Ser. No. 14/078,780. That is, the concepts discussed herein can be used with the inventions and concepts described in U.S. Patent Application Publication No. 2014/0131545. 
         [0009]    It is one aspect of embodiments of the present invention to provide a wall faucet support. One embodiment of the present invention employs a mounting sleeve associated with a fluid tube of the wall faucet. The mounting sleeve is interconnected to a supporting bracket that interconnects to an interior building surface, thereby increasing wall faucet stability. The mounting sleeve secures the fluid delivery tube and provides a location for interconnection of a faucet flange by way of a sleeve flange. Some embodiments of the present invention employ a selectively adjustable mounting sleeve such that the faucet flange may be selectively spaced from the outer surface of the dwelling and not interconnected directly to it. Other embodiments contemplate a fixed distance between the sleeve flange and the bracket, which is ideal for accommodating exterior building surfaces with consistent thicknesses, e.g., brick. 
         [0010]    It is another aspect of some embodiments of the present invention to provide a system for interconnecting a wall faucet to a building that increases mount stability. More specifically, embodiments of the present invention employ a bracket interconnected to an interior (or exterior) building surface. For example, the bracket of the invention may be interconnected to the inside or outside of any building member, such as 2×4 studs, sill plates, a concrete basement wall, a foundation member, headers, sheathing, etc. Interconnecting a bracket to a structural element improves the stability of the faucet assembly. That is, as opposed to prior art systems that interconnect a the faucet flange directly to an exterior building surface, the mounting sleeve employed in various embodiments of the present invention is maintained within a bracket, thus supplying a sufficient support to the faucet assembly. In such a manner the above-identified issues related to interconnecting a faucet to mortar, rock, stone, bricks, stucco, etc., are reduced if not eliminated. The method and associated apparatus of embodiments of the present invention for securing a tube within mounting sleeve, which is then interconnected to a rigidly interconnected bracket, is superior over prior art methods and systems of interconnection. 
         [0011]    It is another aspect of some embodiments of the present invention to provide a mounting system that allows for ease of faucet installation. More specifically, embodiments of the present invention may be installed before or after the siding or other exterior building surface is installed. The bracket that secures the mounting sleeve may be installed by the framers, siding installers, or plumbers. Guess work as to the location of the faucet is reduced. This aspect of the present invention is made possible because the faucet need not be initially installed to install the bracket and to locate the mounting sleeve. After installation of the mounting sleeve, it may be removed from the bracket and associated with the faucet tube and flange and interconnected to the bracket. 
         [0012]    It is still yet another aspect of embodiments of the present invention to provide a mounting system and method that provides the ability to selectively adjust the location of the faucet. More specifically, embodiments of the present invention provide a mounting sleeve adapted to move in relation to a fixed bracket. This aspect of the invention ultimately allows for the flange of the faucet to be offset (in various dimensions, but particularly along an axis perpendicular from the dwelling wall) from an interior or exterior wall of the dwelling to accommodate the thickness and surface texture of exterior building material such as stone, etc. In operation, if the faucet is not located as envisioned relative to the exterior building surface, readjustments are possible that do not require extensive structural modifications as would be necessary with prior art systems. 
         [0013]    It is another aspect of embodiments of the present invention to provide a faucet assembly attachment scheme that improves mounting options, wherein the faucet may be interconnected to an irregular surface easily. That is, as briefly described above; the mounting device of one embodiment includes an adjustable mounting sleeve that allows for selective adjustments of the location of the faucet flange, e.g., within a predetermined scope of dimensions from a first anticipated final position. Thus an installer can easily customize the location of the flange such that it is aesthetically pleasing and structurally stable. Embodiments of the present invention also employ a mounting sleeve with a measurement indication mechanism. Preferably, a linear scale is provided associated with each sleeve, e.g., imprinted thereon, molded thereto, etc., to facilitate the installation of a plurality of faucets about the exterior of a building. After one mounting sleeve is interconnected and correctly offset from a house, the remainder of mounting sleeves will be more quickly installed because the required offset is readily known by inspection of the linear scale. Installers will also be able to facilitate installation of mounting sleeves through experience by knowing generally how much offset should be used for a particular building surface, which will reduce time and cost of installing faucets. 
         [0014]    Embodiments of the present invention employ components that can be easily replaced. For example, if after installing the mounting sleeve relative to the bracket it is found the offset is incorrect, quick adjustments may be made. More specifically, it is contemplated that the length of the mounting sleeve can easily made to accommodate unique sizes of bricks, stone, etc. If this is difficult due, for example, to debris or grout residing in the grooves of the mounting sleeve, it can be discarded and a second replacement mounting sleeve can be interconnected to the existing bracket. 
         [0015]    It is yet another aspect of embodiments of the present invention to prevent water, debris, animals, insects, etc. from entering the dwelling through the faucet connection. That is, when a faucet of the prior art becomes loose or disconnects from the exterior of the dwelling, gaps form that allow the above-mentioned foreign objects to enter the dwelling. For example, gaps between the flange and the building surface allow moisture to penetrate between the faucet flange and the exterior building surfaces. Embodiments of the present invention provide a system and method that minimizes gaps between the external building surface and the faucet associated thereto. More specifically, as the mounting sleeve of embodiments of the present invention is of generally continuous shape (preferably cylindrical, but other shapes are contemplated), the installer can finish, with insulation, foam, mortar etc., up to the outer surface of the mounting sleeve, which reduces or eliminates gaps between the faucet assembly and the exterior building surfaces. A related aspect of the present invention is that the shape of the mounting sleeve and described finishing creates a cleaner appearance that is more aesthetically pleasing. 
         [0016]    It is another aspect of the present invention that the embodiments described herein are constructed of common materials, such as plastic, steel, aluminum, rubber (or other flexible materials), vulcanized rubber, wood, or any other common building materials that comply with applicable building codes. Preferably, the mounting sleeve and associated bracket are made of rigid plastic, which is non-corrosive and provides the needed rigidity to secure the faucet assembly. 
         [0017]    It is still yet another aspect of the present invention to provide a system that utilizes components that are customizable. More specifically, the mounting sleeves of embodiments of the present invention may be made of any color of plastic to blend in with the exterior building surface or wall faucet assembly, thereby adding to the aesthetically pleasing appearance of the finished assembly. 
         [0018]    It is another aspect of embodiments of the present invention to provide a mounting sleeve that can accommodate faucets having flanges of various shapes. More specifically, some faucets possess a handle laterally offset from the faucet outlet whereby access to the handle is improved. To further increase access and to remove obstructions between the faucet and the faucet outlet, the outlet may be angled as well such that the flow of water from the faucet outlet is at an angle relative to the vertical direction. Faucets of this type also may include an elliptical or oval handle that allows the user to more easily grip and turn the handle. Thus, one embodiment of the present invention includes a flange interconnected to the mounting sleeve adapted to receive faucet flanges that are other than circular. More specifically, the faucets described above, often have an elongated flange to accommodate an enlarged housing wherein the faucet outlet and handle are interconnected thereto. One can appreciate that a mounting sleeve having a mounting sleeve having a circular flange would not adequately accommodate this enlarged flange, thus embodiments of the present invention include an enlarged flange of any shape that is customizable to a faucet flange. It is a related aspect of the invention to provide a generic faucet flange that accommodates more than one type, make or model of faucet. Alternatively, one of skill in the art will appreciate that the faucet flange may be customized to fit only a specific faucet. 
         [0019]    It is another aspect of embodiments of the present invention to provide a wall faucet interconnection device, comprising: a mounting sleeve having a first end with a mounting flange and a second end, the mounting sleeve having a plurality of grooves positioned at least about a portion of an outer surface thereof; a bracket having a boss extending therefrom that interconnects with said mounting sleeve, said boss having a selectively deflectable tab that includes an end for selective engagement into a groove of said plurality of grooves; a locking ring that selectively interconnects to said boss, said locking ring restricting movement of said deflectable tab; and a seal with an inner portion that is adapted to interconnect to a fluid tube of the wall faucet to said mounting sleeve, and an outer portion that receives a clamp that compresses said seal about the fluid tube. 
         [0020]    It is still yet another aspect of embodiments of the present invention to provide a faucet assembly mounting device, comprising: a mounting sleeve having a first end with a means for supporting a faucet and a second end; a bracket having a boss extending therefrom that selectively interconnects to said mounting sleeve, said boss having a member for selective engagement with said mounting sleeve; and a locking device operatively interconnected to said boss, said locking device restricting movement of said member. 
         [0021]    It is another aspect of embodiments of the present invention to provide a wall faucet mounting system, comprising: a tube that includes a plurality of first locking members; a mounting bracket having a rear surface and an opening that extends through said mounting bracket; a bracket tube extending from said rear surface of said mounting bracket, wherein said bracket tube is in communication with said opening in said mounting bracket such that said tube is slidingly disposed within said mounting bracket, wherein said bracket tube comprises a first resilient member comprising a second locking member configured to releasably engage a respective one of said plurality of first locking members; and a locking device disposed about said bracket tube that restricts movement of said second locking members. 
         [0022]    The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detail Description, particularly when taken together with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions. 
           [0024]      FIG. 1  is an exploded perspective view of one embodiment of the present invention; 
           [0025]      FIG. 2  is a perspective view showing the mounting sleeve one embodiment of the present invention interconnected to a wall; and 
           [0026]      FIG. 3  is a partial side cross-sectional view showing one embodiment of the present invention interconnected to a wall. 
       
    
    
       [0027]    To assist in the understanding of the present invention the following list of components and associated numbering found in the drawings is provided herein: 
         [0000]    
       
         
               
               
             
               
               
             
           
               
                   
               
               
                 # 
                 Component 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 2 
                 Mounting sleeve 
               
               
                 6 
                 Building surface 
               
               
                 10 
                 Bracket 
               
               
                 14 
                 Tab 
               
               
                 18 
                 Groove 
               
               
                 22 
                 Locking ring 
               
               
                 26 
                 Seal 
               
               
                 30 
                 Fluid tube 
               
               
                 34 
                 Wall faucet 
               
               
                 38 
                 Mounting sleeve Inner Diameter 
               
               
                 42 
                 Faucet flange 
               
               
                 46 
                 Mounting flange 
               
               
                 50 
                 Hole 
               
               
                 54 
                 Offset indicator 
               
               
                 58 
                 Hole 
               
               
                 60 
                 Fastener 
               
               
                 61 
                 Outer surface 
               
               
                 62 
                 Interior building surface 
               
               
                 66 
                 Boss 
               
               
                 70 
                 Flange 
               
               
                 74 
                 Inner boss surface 
               
               
                 78 
                 Slot 
               
               
                 82 
                 Clamp 
               
               
                 84 
                 Fluid supply interface 
               
               
                 88 
                 Inner seal portion 
               
               
                 92 
                 Outer seal portion 
               
               
                 96 
                 Seal inner diameter 
               
               
                 98 
                 Outer diameter 
               
               
                 106 
                 Groove 
               
               
                   
               
             
          
         
       
     
         [0028]    It should be understood that the drawings are not necessarily to scale, but that relative dimensions can be nevertheless be determined thereby. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. 
       DETAILED DESCRIPTION 
       [0029]      FIGS. 1-3  show the mounting sleeve  2  of one embodiment of the present invention and the components used to interconnect the mounting sleeve  2  to a building surface  6 . The mounting sleeve  2  selectively interconnects to a bracket  10 . The bracket  10  includes at least one tab  14  for selective engagement with a groove  18  or grooves in the mounting sleeve  2 , which fixes the mounting sleeve  2  to the bracket  10 . The mounting sleeve  2  is further secured to the bracket  10  by providing a locking ring  22  that prevents the tabs  14  from disengaging from the grooves  18 , which would allow the mounting sleeve  2  to slide freely relative to the bracket  10 . A seal  26  is used to interconnect a fluid tube  30  associated with a wall faucet  34  to the inner diameter  38  of the mounting sleeve  2 , which secures the wall faucet  34  to the mounting sleeve  2 . A faucet flange  42  of the wall faucet  34  is also interconnected to a mounting flange  46  of the mounting sleeve  2 . 
         [0030]    The mounting sleeve  2  includes a mounting flange  46  at its first end adapted to interface with the faucet flange  42  associated with the wall faucet  34 . Accordingly, the mounting flange  46  includes a plurality of holes  50  or nut plates to receive fasteners (not shown) normally used to secure the faucet flange  42  to a wall, for example. Further, the mounting sleeve  2  includes offset  54  indicators that allow individuals to assess the distance between the mounting flange  46  and the bracket  10 . In this fashion, the mounting flange  46  is offset from the bracket  10  to accommodate the exterior building surfaces  6 , such as siding, stone, or brick. The mounting sleeve  2  may be hollow. Alternatively, the mounting sleeve  2  may include a plurality of inner walls or other structures that may engage the wall faucet fluid tube  30  to increase tube stability relative to the mounting sleeve  2 . 
         [0031]    The bracket  10  includes a plurality of holes  58  that receive fasteners  60  that interconnect the bracket  10  to an interior building surface  62 . The bracket  10  of one embodiment of the present invention includes an outwardly-extending boss  66  with the operatively interconnected tabs  14 . Tabs  14  may have inwardly extending projections that selectively engage the grooves  18  of the mounting sleeve  2 , which secures the mounting sleeve  2  to the bracket  10 . Although the wall mounting sleeve  2  is shown to extend generally perpendicular from the bracket  10 , one of ordinary skill in the art will appreciate that the mounting sleeve may be angled relative to the bracket so the associated fluid tube  30  is tilted a predetermined amount to ensure that fluid leaks from the wall faucet  34  when it is shut off. 
         [0032]    As the tabs  14  may disengage from the mounting sleeve grooves  18 , some prior art systems employ a glue to interconnect the tab  14  to the mounting sleeve  2 , e.g., fix the mounting sleeve  2  to the bracket  10 . One improvement to the prior art system employed by some embodiments of the present invention is the locking ring  22 . In operation, the locking ring  22  is positioned over the mounting sleeve  6  and the boss  66  and is situated over the tabs  14  so they cannot deflect outwardly, which would remove the tab ends from the groove  18 . The locking ring  22  may include a flange  70  that abuts an inner boss surface (see  FIG. 3 ) to prevent the locking ring  22  from sliding too far up the boss  66  to a position adjacent to the bracket, which could allow the tabs to be removed from the grooves  18 . The locking ring  22  may include a slot  78  to facilitate expansion of the locking ring  22 , and allow the locking ring  22  to slide over the boss  66 . Those of ordinary skill in the art will appreciate that a clamp  82 , e.g. c-clamp or band, may be used to ensure engagement of the tabs to the grooves instead of the locking ring. 
         [0033]    As described above, the mounting flange  46  is designed to receive and secure the faucet flange  42  that secures the wall faucet and the fluid supply tube  30 . To ensure a tight interconnection between the faucet tube  30  and the mounting sleeve  2 , the end adjacent to a fluid supply interface  84  of the faucet tube must also be secured. Embodiments of the present invention address this issue by providing the seal  26 . The seal  26  includes an inner seal portion and an outer seal portion  92 . The seal has inner diameter  96  that coincides with the outer diameter  98  of the fluid tube  30 . The inner seal portion  88  has an outer diameter  100  that coincides with the mounting sleeve inner diameter  38 . The outer seal portion  92  has an outer diameter equal to or greater than that of the mounting sleeve  2 . 
         [0034]    To secure the seal  26  to the mounting sleeve  2  and the fluid tube  30 , a clamp  82  is provided that when interconnected about the outer seal portion  92  will deform the seal  26  about the fluid tube  30 . When interconnected, the fluid tube  30  will be fixed via the inner seal portion  88  to the mounting sleeve  2 , which securely fastens both sides of the fluid tube  30  to the mounting sleeve  2 . The clamp  82  inner diameter may be selectively enlarged with finger pressure, for example, so that it can be received over the outer seal portion  92 . When pressure is removed, the clamp  82  will retract to compress the seal  26 . 
         [0035]      FIG. 3  illustrates the connection of the mounting sleeve  2  to an interior building surface  62 . In operation, an opening is created in the interior building surface  62 . A corresponding opening is also created in the outer building surface  6 , if needed. That is, in some situations, the outer building surface  6  is made of brick or stone, wherein the mounting flange may be integrated directly within the exterior building surface  6  and surrounded by mortar, for example. Next, the bracket boss  66  is placed within the opening in the building surface and the bracket  10  is interconnected to an outer side of the inner building surface  6  by way of the plurality of fasteners  62 . Alternatively, the boss can be made to extend away from the exterior building surface and concealed by stone and mortar, for example. The mounting sleeve  2  is then positioned through the opening in the outer building surface  6  and the mounting flange  46  is positioned adjacent to the outer building surface  6 , which moves the mounting sleeve  2  through the boss  66 . Once the predetermined offset between the mounting flange  46  and the outer surface  61  of the internal building surface  62  is achieved, the tabs  14  will be received by grooves  18  on the mounting sleeve  2 , which secures the mounting flange  46  at the predetermined offset. The locking ring  22  is then placed over the mounting sleeve  2  and the boss  66 , which maintains the tabs  14  within the grooves  18 . The wall faucet  34 , with interconnected fluid tube  30  is then received by the mounting sleeve  2  and the faucet flange  42  is abutted to the mounting flange  46 . The faucet flange is secured to the mounting flange  46  by at least one fastener  62 . Finally, the seal  26  is received over the supply interface  84  and positioned about the fluid tube  30 , wherein the inner seal portion  88  is placed between the mounting sleeve  2  and the fluid tube  30 . The clamp (not shown) is then positioned in a clamp groove  106  of the outer seal portion  92  to secure the fluid tube  30  to the mounting sleeve  2 . 
         [0036]    If the initially set offset is incorrect, the locking ring  22  may be removed from the boss  66  as the locking ring  22  is not glued or permanently attached to the boss  66 . After the locking ring  22  is removed, the mounting sleeve  2  may be selectively interconnected to the boss  66  at a different location. 
         [0037]    One of ordinary skill in the art will appreciate that the faucet mounting flange  46  may be made of various sizes and configurations to accommodate wall faucets  34  of other designs than that shown. Alternatively, the faucet mounting flange  42  may be made to accommodate only one type of wall faucet. 
         [0038]    The mounting sleeve  3  of some embodiments of the present invention is generally cylindrical, wherein counter from some prior art devices, a keyway or key is not employed. Thus, the mounting sleeve  2  can rotate freely within the bracket. This functionality allows the mounting sleeve to address non-ideal interconnection schemes. For example, the internal building surface to which the bracket  10  is interconnected may not be ideal (e.g., not level) wherein slight modifications to the orientation of the bracket may be required to ensure it is properly interconnected to the internal building surface  6 . If this is the situation, the bracket  10  may have to be rotated to allow for interconnection to the internal building surface  6 . Employing a mounting sleeve with a keyway will prevent the wall faucet to assume an ideal and aesthetically pleasing orientation when interconnected to the mounting flange. Stated differently, if a keyway is employed, the bracket must be oriented perfectly, or the mounting flange will be skewed as the mounting flange&#39;s orientation is dictated by the keyway or key. To enhance this functionality, one embodiment employs grooves that extend all, or substantially all, the way around the mounting sleeve. Such grooves will be engaged by the tabs, regardless of boss orientation. 
         [0039]    While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. In addition, one skilled in the art will appreciate that aspects of other inventions may be incorporated and are added in combination to the embodiments of the present invention disclosed herein. For example, aspects of the inventions disclosed in, for example, U.S. Pat. Nos. 6,142,172 and 6,431,204, both of which being incorporated by reference herein, which concern wall faucets, may be incorporated into embodiments of the present invention.