Patent Publication Number: US-6983898-B2

Title: Showerhead with optical lens feature

Description:
RELATED APPLICATION 
   The subject matter disclosed herein is related to the subject matter contained in U.S. patent application Ser. No. 10/443,405, titled SHOWERHEAD WITH GROOVED WATER RELEASE DUCTS. 

   FIELD OF THE INVENTION 
   The present invention relates generally to shower fixtures. More particularly, the present invention relates to a showerhead. 
   BACKGROUND OF THE INVENTION 
   The prior art is replete with showerhead designs. Conventional showerheads utilize unmodified free flow water pressure to generate a spray of water. Water exiting a traditional showerhead is sent in a single direction by the force of the water pressure created in the supply plumbing. Such systems tend to consume a substantial amount of fresh water, most of which is wasted. Furthermore, most known showerheads produce a relatively narrow shower of water rather than distributing the water over a wide area. Such narrowly focused showerheads do not produce an effective stream of water that efficiently provides a wide area of water coverage to the person taking the shower. In addition, traditional showerheads are merely designed to provide a stream or spray of water to the user. Such showerheads are not designed to provide pleasant visual effects to the user during use. 
   BRIEF SUMMARY OF THE INVENTION 
   A showerhead according to the present invention produces an efficient and effective shower of water in a manner that conserves water. In contrast to many prior art designs, the showerhead distributes water over a relatively wide area without relying on wasteful free flow water pressure obtained directly from the supply plumbing. 
   In addition, a showerhead according to the invention employs an optical lens feature that provides pleasant visual effects to the user. The optical lens feature, combined with the cascading water, creates an invigorating and enjoyable showering environment. 
   Certain aspects of the present invention may be carried out in one form by a showerhead having a fluid distribution element for releasing fluid from a fluid source. The fluid distribution element includes: an interior side facing the fluid source and an exterior side opposite the interior side; and one or more ducts formed within the fluid distribution element, each having an inlet hole for receiving fluid from the fluid source, and a groove connected to the inlet hole, the groove being configured to laterally transport fluid across the fluid distribution element from the inlet hole toward a fluid release point on the exterior side. 
   Certain aspects of the present invention may be carried out in one form by a showerhead having an optical lens element configured to receive incident light rays, refract the incident light rays, and create exiting light rays that illuminate outgoing fluid emitted from the showerhead. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in conjunction with the following Figures, wherein like reference numbers refer to similar elements throughout the Figures. 
       FIG. 1  is a perspective view of a showerhead, showing its water distribution side; 
       FIG. 2  is a perspective view of the showerhead of  FIG. 1 , showing its water spray nozzle side; 
       FIG. 3  is a three-dimensional perspective rendition of the water distribution side of the showerhead shown in  FIG. 1 ; 
       FIG. 4  is a three-dimensional perspective rendition of a showerhead, showing the translucent/transparent characteristics of the showerhead; 
       FIG. 5  is a plan view of the water distribution side of the showerhead shown in  FIG. 1 ; 
       FIG. 6  is a plan view of the water spray nozzle side of the showerhead shown in  FIG. 1 ; 
       FIG. 7  is a side view of the showerhead shown in  FIG. 1 ; 
       FIG. 8  is an elevation view of the showerhead shown in  FIG. 1 ; 
       FIG. 9  is a sectional view of the showerhead (with the water distribution plate removed) as viewed from line A—A in  FIG. 5 ; 
       FIG. 10  is a sectional view of the showerhead (with the water distribution plate installed) as viewed from line A—A in  FIG. 5 ; 
       FIG. 11  is a perspective view of a water distribution plate; 
       FIG. 12  is a perspective view of a detailed portion of the water distribution plate shown in  FIG. 11 ; 
       FIG. 13  is a sectional view of a detailed portion of the water distribution plate shown in  FIG. 11 ; 
       FIG. 14  is a plan view of the opposite side of the water distribution plate shown in  FIG. 11 ; 
       FIG. 15  is a partial cutaway view of a feed valve assembly suitable for use with the showerhead shown in  FIG. 1 ; 
       FIG. 16  is a sectional view of the feed valve assembly (in a water distribution mode) as viewed from line B—B in  FIG. 15 ; 
       FIG. 17  is a sectional view of the feed valve assembly (in a water spray mode) as viewed from line B—B in  FIG. 15 ; 
       FIG. 18  is a schematic representation of a portion of a water distribution plate with water droplets formed thereon; 
       FIG. 19  is a schematic perspective view of a fluid duct, with shape planes defined therein; 
       FIG. 20  is an elevation view of the first and third shape planes shown in  FIG. 19 ; and 
       FIG. 21  is an elevation view of the second and fourth shape planes shown in FIG.  19 . 
   

   DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     FIG. 1  is a perspective view of one side of a showerhead  100 , and  FIG. 2  is a perspective view of the other side of the showerhead  100 .  FIG. 1  shows the water distribution side of the showerhead  100 , while  FIG. 2  shows the water spray nozzle side of the showerhead  100 .  FIG. 3  is a three-dimensional perspective rendition of the water distribution side of the showerhead  100 , showing the contoured/textured water distribution surface  102  of the showerhead  100 . 
   In typical installations, the showerhead  100  is attached to a plumbing feature, e.g., a water pipe, that protrudes from a wall. Of course, the showerhead  100  may be installed in any number of alternate mounting configurations. The showerhead  100  may be connected to the water pipe via a suitable conduit, which may include one or more interconnected pipes, hoses, or the like. The showerhead  100  may include a suitably configured mounting element  104 , e.g., a swivel joint, a telescoping joint, a ball joint, or a rotating joint. The mounting element  104  allows the user to adjust the position of the showerhead  100  and, consequently, the direction of the exiting water flow. In one embodiment, mounting element  104  incorporates a feed valve assembly for directing water flow to either a water distribution element or a water spray nozzle (described in more detail below). Although not a requirement of the invention, the showerhead  100  may include a flow valve (not shown) for controlling the flow of fluid entering showerhead  100 . The flow valve may be utilized in conjunction with existing hot and cold water valves (or a combined hot and cold water regulator) to provide an added measure of water flow control. 
   Although the showerhead shown and described herein includes a side-mounted water feed, the present invention is not so limited. Indeed, the features described below can also be extended for use in connection with a top-mounted showerhead and with other configurations and arrangements that may not be specifically addressed herein. 
   The showerhead  100  is suitably configured to support at least two modes of operation: (1) the gentle distribution of water droplets over a relatively wide area; and (2) a stream or spray of water as typically produced by conventional showerheads. In the first operating mode, water is routed within the showerhead  100  for release by a water distribution element  106  (upon which the water distribution surface  102  is formed). The water distribution element  106 , and certain aspects thereof, are shown in  FIGS. 11-14 . In the second operating mode, water is routed within the showerhead  100  to a water spray nozzle  108 . In the example embodiment, the water spray nozzle  108  is located on one side of the showerhead  100 , and the water distribution element  106  is located on the opposite side of the showerhead  100 . 
   In the example embodiment, the particular mode of operation is selected by rotating the main body of the showerhead  100  such that the appropriate side is facing the user. The rotating action results in the selectable engagement of a feed valve assembly  110 , which may be incorporated into the mounting element  104 .  FIG. 15  is a partial cutaway view of the feed valve assembly  110 ,  FIG. 16  is a sectional view of the feed valve assembly  110  (in the water distribution mode) as viewed from line B—B in  FIG. 15 , and  FIG. 17  is a sectional view of the feed valve assembly  110  (in a water spray mode) as viewed from line B—B in FIG.  15 .  FIG. 15  also depicts the feed valve assembly  110  operating in the water distribution mode. 
   Briefly, the feed valve assembly  110  includes an outer section  112  (which also serves as the fluid inlet for the showerhead  100 ) coupled to an inner section  114 . The inner section  114  is designed to rotate within the outer section  112 . In the practical embodiment, the inner section  114  can be formed as an integral part of the main body section of the showerhead  100 . In practice, the feed valve assembly  110  may include washers, seals, O-rings, or other features to prevent fluid leakage. The feed valve assembly  110  may also include structure or elements that temporarily “lock” the showerhead into the proper operating position. 
   The outer section  112  receives the incoming fluid at an inlet  116 . As best shown in FIG.  16  and  FIG. 17 , the height of the inlet  116  decreases at a neck  118  formed within the outer section  112 . The neck  118  directs the fluid flow into the inner section  114 . The inner section  114  includes two inlet channels formed therein (designated by the reference numbers  120  and  122 ). Inlet channel  120  represents the fluid inlet for the water spray nozzle  108 , and inlet channel  120  represents the fluid inlet for the water distribution element  106 . In the example embodiment, the two inlet channels are distinct and separate. When the main body of the showerhead  100  is rotated into the position shown in  FIG. 16 , the inner section  114  swivels such that the inlet channel  122  becomes aligned with the necked portion of the inlet  116  formed within the outer section  112 . This positioning allows the incoming fluid to be directed into the inlet channel  122  and, ultimately, to be released by the fluid distribution element  106 . In contrast, when the main body of the showerhead  100  is rotated into the position shown in  FIG. 17 , the inner section  114  swivels such that the inlet channel  120  becomes aligned with the necked portion of the inlet  116 . This allows the incoming fluid to be directed into the inlet channel  120  and, ultimately, to be sprayed from the fluid spray nozzle  108 . 
   The showerhead  100  need not include the spray nozzle  108  and the dual-action feed valve assembly  110 . For example,  FIG. 4  depicts an alternate embodiment that only incorporates a fluid distribution element.  FIG. 4  is a three-dimensional perspective rendition of a showerhead, showing the translucent (or transparent) characteristics of the showerhead. In this embodiment, the fluid inlet, which is incorporated into the mounting element  104 , directs the fluid into the fluid chamber formed within the main body of the showerhead. 
     FIG. 9  is a sectional view of the showerhead  100  (with the water distribution plate removed) as viewed from line A—A in  FIG. 5 ,  FIG. 10  is a sectional view of the showerhead  100  (with the water distribution plate installed) as viewed from line A—A in  FIG. 5 , and  FIG. 11  is a perspective view of the water distribution element  106  separated from the showerhead  100 . In accordance with one practical embodiment, the showerhead  100  is formed by coupling the water distribution element  106  to a main body portion  124  of the showerhead  100  as shown in FIG.  10 . 
   Although the figures depict a generally round showerhead body, the present invention is not limited to any specific shape or size. The showerhead  100  generally includes a hollow body (which is formed by the main body portion  124  and the water distribution element  106  in the example embodiment), a fluid chamber  126  within the hollow body, and the fluid distribution element  106 . Each of these components is described in more detail below. 
   The hollow body, and the main body portion  124  in particular, provides the structural foundation for the showerhead  100 . The main body portion  124  is preferably formed from a translucent (clear or colored) or transparent material such as plastic or resin. In accordance with one practical embodiment, the main body portion  124  is formed from an optical grade plastic. Although not a requirement of the present invention, the main body portion  124  may be integrally formed as a one-piece unit. In the illustrated embodiment, the hollow body of the showerhead  100  is circular in shape and its height is substantially less than its diameter. For example, the showerhead  100  may have an overall diameter of approximately 11-12 inches, and a height of approximately 0.4 to 0.6 inches. As mentioned above, the hollow body includes a fluid inlet for receiving incoming fluid such as water. In practical applications, the fluid inlet is coupled to a joint, a conduit, a pipe, or a suitable fixture that provides water to the showerhead  100 . The size, shape, and/or location of the fluid inlet on the showerhead  100  may vary from unit to unit depending upon the desired fluid flow characteristics, fluid chamber size, back pressure specifications, showerhead size, and other practical considerations. 
   Referring again to  FIG. 10 , the fluid chamber  126  is defined by the interior side of the fluid distribution element  106 , and by a thin cavity formed within the main body portion  124 . The fluid chamber  126  is suitably configured to receive fluid from the fluid inlet  116  via the inlet channel  122  (see FIG.  16 ). The hollow body is sized and shaped such that the fluid chamber  126  is relatively flat and thin. This configuration allows the fluid chamber  126  to be quickly filled and pressurized with fluid. In addition, the relatively low volume defined by the fluid chamber  126  ensures that water is conserved during operation of the showerhead  100 . 
   The fluid distribution element  106  is attached to the main body portion  124  such that it forms an exterior surface of the showerhead  100 . A practical embodiment utilizes a translucent (clear or colored) or transparent fluid distribution element  106 . In this regard, the fluid distribution element  106  and the main body portion  124  can be formed from the same material, e.g., plastic, optical grade plastic, resin, plexiglass, or the like. Briefly, the fluid distribution element  106  is suitably configured to release fluid obtained from the fluid chamber  126  in a gentle dripping action. The interior side of the fluid distribution element  106  faces the fluid chamber  126  and the exterior side of the fluid distribution element  106 , which is opposite the interior side, is textured with one or more fluid-releasing protrusions. The interior side is shown in  FIG. 11  (with a detail view in FIG.  12 ), and the exterior side is shown in FIG.  14 . 
   The fluid distribution element  106  includes one or more protrusions on its exterior side, as best shown in FIG.  3 . In the illustrated embodiment, the protrusions are arranged as a plurality of raised and concentric rings  128 . Each of the rings  128  has a curved convex surface when viewed in cross section (see FIG.  13 ). As described in more detail below, the “peaks” of the rings serve as the fluid release points due to the transport of fluid across the fluid distribution element  106 . The fluid distribution element  106  also contains a number of “valleys” or depressions formed between the protrusions. As shown in  FIG. 3 , the example embodiment includes circular valleys formed between two concentric rings. In lieu of such rings, the fluid distribution element  106  may employ a number of raised bumps, a raised serpentine segment, intersecting protrusions, shapes having varying heights, and the like. 
   The fluid distribution element  106  includes a number of ducts  130  formed therein. FIG.  12  and  FIG. 13  contain detailed views of the ducts  130 . Generally, each duct  130  provides a fluid path from the fluid chamber  126  to the fluid distribution surface  102  of the showerhead  100 . In this regard, the fluid chamber  126  serves as a fluid source for the fluid distribution element  106 . The fluid enters each duct  130  at the interior side of the fluid distribution element  106  and exits each duct  130  at the exterior side of the fluid distribution element  106 . Each duct  130  includes an inlet hole  132  that terminates at the interior surface of the fluid distribution element  106 , and a duct outlet  134  that terminates at the exterior surface of the fluid distribution element  106 . The inlet holes  132  receive the fluid from the fluid chamber  126  and the ducts  130  transport the fluid to (or near) the fluid release points on the exterior side. In the example embodiment, the inlet holes  132  are arranged in a circular pattern as viewed from the interior side of the fluid distribution element  106  (see FIG.  14 ). The projected outline/perimeter of each duct outlet  134  is shown in  FIG. 5 ; from this view, each duct outlet  134  has a teardrop shape. 
   The interior side of the fluid distribution element  106  may include one or more channels  135  formed therein (see FIG.  14 ). These channels  135  direct the flow of fluid from the inlet of the showerhead  100  to various points within the fluid chamber  126 . The channels  135  can be sized and shaped to promote uniform fluid pressure within the fluid chamber  126  such that drops are evenly formed across the fluid distribution element  106 . 
   Although the specific size, shape, and configuration of each duct  130  may vary from one practical embodiment to the next, and/or vary within the fluid distribution element  106  for a given practical embodiment, the preferred duct configuration is depicted in the drawings of the example embodiment. Each duct  130  generally includes the inlet hole  132 , a tapered outlet section  136  connected to the inlet hole  132 , and a groove  138  connected to the inlet hole  132 . The groove  138  is also connected to the tapered outlet section  136 . These features of the duct  130  are shown in FIG.  12  and FIG.  13 . The groove  138  and the tapered outlet section  136  combine to form the duct outlet  134  at the exterior side of the fluid distribution element. Notably, the inlet hole  132  represents the narrowest portion of duct  130 , and the area of the duct outlet  134  is greater than the area of the inlet hole  132 . 
   In the example embodiment, the tapered outlet section  136  has a partial-cone shape. As shown in FIG.  12  and  FIG. 13 , the coned portion of the duct  130  flares outward from the inlet hole  132 . The groove  138  intersects a side of the tapered outlet section  136  and creates an extended spout or flute for the duct  130 . The groove  138  is suitably configured to laterally transport fluid across the fluid distribution element  106  from the inlet hole  132  toward the respective fluid release point on the fluid distribution surface  102 . As depicted in  FIG. 5 , each groove  138  extends radially outward from the respective inlet hole  132  (alternate configurations may be utilized, and this specific layout is not intended to limit or otherwise restrict the scope of the invention). As described above, the fluid distribution element  106  includes a number of protrusions (e.g., raised rings  128 ) that facilitate the collection and release of fluid. In the preferred practical embodiment, the grooves  138  extend across the raised rings  128  and terminate at or near the peaks on the raised rings  128 . Consequently, the water seeps into the inlet hole  132 , clings to the walls of the tapered outlet section  136 , and the groove  138  directs the water to the drip ring protrusions. This positioning of the grooves  138  relative to the protrusions facilitates the desired drop formation and cascade pattern. 
     FIG. 19  is a schematic perspective view of an example duct  130 , along with four imaginary shape planes that can be used to define the shape and dimensions of the duct  130 . The first shape plane (designated by the letter “A”) corresponds to the groove portion of the duct  130 . The second shape plane (designated by the letter “B”), third shape plane (designated by the letter “C”), and fourth shape plane (designated by the letter “D”) generally define the tapered outlet section  136  of the duct  130 . The third shape plane opposes the first shape plane, and the second and fourth shape planes oppose each other. 
     FIG. 20  is an elevation view of the first and third shape planes shown in  FIG. 19 , and  FIG. 21  is an elevation view of the second and fourth shape planes shown in FIG.  19 . The diameter d of the inlet hole  132  is approximately 0.093 inches, the width W at the widest portion of the duct  130  is approximately 0.543 inches, and the width w at the tapered outlet section  136  is approximately 0.422 inches. The length l of the sidewall of the tapered outlet section  136  is approximately 0.199 inches, the length L of the sidewall of the groove portion is approximately 0.292 inches, and the height h of the inlet hole  132  is approximately 0.100 inches. The tapered outlet section  136  forms an angle θ with the horizontal reference line and the groove portion forms an angle α with the horizontal reference line. In the example embodiment, θ is approximately 40 degrees and α is approximately 25 degrees. It should be appreciated that the shape and dimensions of the ducts  130  can vary to suit the needs of the particular embodiment. 
   The shape of each duct  130  can be further visualized in conjunction with the following description of one suitable manufacturing process. First, a relatively small pilot hole is drilled into the fluid distribution element  106  at a point located between two adjacent raised rings  128 . A portion of this pilot hole will correspond to the inlet hole  132  of the finished duct  130 . Next, a countersink is formed in the end of the pilot hole corresponding to the exterior side of the fluid distribution element  106 . A portion of the countersink shape will correspond to the tapered outlet section  136 . Finally, the groove  138  is formed such that it intersects the side of the countersink. 
   As mentioned previously, the fluid distribution element  106  includes at least one protrusion extending beyond the point where fluid seeps through the inlet holes  132 . In this regard, the protrusions provide a texturized outer surface for the fluid distribution element  106 . In the normal operating orientation, water is released at a relative high point before traveling through the ducts  130  and onto the protrusions. Eventually, the water drops from the relative low points (the fluid release points) defined by the protrusions. 
   The creation of a substantially uniform and distributed back pressure of fluid within the fluid chamber  126 , in conjunction with the configuration of the fluid distribution element  106 , facilitates the even release of fluid droplets across the face of the showerhead  100 . Relying upon the surface tension of the fluid and the configuration of the ducts  130 , the fluid distribution element  106  transports the fluid from the inlet holes  132  located above the textured drip point on the face of the fluid distribution element  106 . The result is the formation of a droplet as the fluid travels to the fluid release points defined by the peaks of the protrusions. The drops are forced in a relatively slow manner from the face of the fluid distribution element  106  by both gravity and by continuing seepage from the fluid chamber  126 . This surface tension effect and the formation of droplets is depicted in FIG.  18 . Notably, the droplet size can vary depending upon the specific texturing of the fluid distribution element  106 . For instance, larger bumps, peaks, raised ridges, or texturing can generate larger droplets, and smaller bumps, peaks, raised ridges, or texturing can generate smaller droplets. Generally, the size and shape of each protrusion in the texture pattern can be designed such that it retains more or less water before releasing the droplet. 
   The showerhead  100  can also include an optical lens element that is configured to receive incident light rays, refract the light rays, and create exiting light rays that illuminate outgoing fluid emitted from the fluid distribution element  106 . In the example embodiment, the optical lens element is incorporated into the body of the showerhead  100 . For example, both the main body portion  124  and the fluid distribution element  106  can be formed from a translucent or transparent material that accommodates the transmission and propagation of light. In the illustrated embodiment, the optical lens element is integral to the fluid distribution element  106 . More particularly, the raised concentric rings  128  serve as the optical lens element, where each ring  128  can be considered to be a separate lens component. Accordingly, the protrusions on the fluid distribution element  106  are configured to distribute the water and form droplets in a predictable manner, and to provide the optical lens effect. 
   As shown in  FIG. 3 , each of the raised rings  128  has a convex external surface. In practice, the convex shape of the rings  128  produces the optical lens effect for refracting and focusing light. As depicted in FIG.  13  and  FIG. 18 , the interior side of the fluid distribution element  106  may also include a pattern of raised concentric rings that matches the pattern on the opposite side. Consequently, each ring  128  can be realized as a ring-shaped lens having two opposing convex surfaces.  FIG. 18  includes a schematic representation of how incident light rays (shown as vertical and parallel arrows) are received and refracted by the fluid distribution element  106 . In practice, the optical lens feature of the showerhead  100  can focus or direct the light rays toward the fluid release points on the fluid distribution element  106 . In this manner, droplets of water can be illuminated as they are being formed on the fluid distribution element  106  and as they are released from the showerhead  100 .  FIG. 18  depicts two droplets being illuminated by light rays focused by the raised concentric rings  128  of the example embodiment. 
     FIG. 4  is intended to illustrate the translucent or transparent nature of the showerhead  100 . If the entire hollow body of the showerhead  100  is formed from a translucent material, then incident light rays can enter the fluid distribution element from any number of directions. The incident light ray can be natural sunlight and/or generated by one or more lighting fixtures. The incident light can be white or, if generated artificially, colored or polarized using appropriate lenses. The body of the showerhead  100  may be formed from a colored translucent material such that the spectrum of the incident light is modified as it passes through the optical lens element. Furthermore, fluid and/or bubbles passing through the hollow body of the showerhead  100  can modify the characteristics of the exiting light rays, resulting in varied optical effects experienced by the user. 
   As water drips from the showerhead  100 , the optical lens element concentrates light on the water droplets, thus creating a scintillating, sparkling, flickering, and/or “firefly” effect as the water is released from the showerhead  100 . Indeed, the showerhead  100  itself can also be illuminated to provide a lamp or glowing effect. Different visual effects can be generated depending upon the orientation, intensity, color, and configuration of the light source or sources. These lighting effects can enhance the showering experience for the user. 
   The present invention has been described above with reference to a preferred embodiment. However, those skilled in the art having read this disclosure will recognize that changes and modifications may be made to the preferred embodiment without departing from the scope of the present invention. These and other changes or modifications are intended to be included within the scope of the present invention, as expressed in the following claims.