Patent Publication Number: US-10329749-B2

Title: Plumbing fixture fitting

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of U.S. Non-Provisional application Ser. No. 15/606,792, filed May 26, 2017, the entire disclosure of which is hereby incorporated by reference, which is a continuation application of U.S. Non-Provisional application Ser. No. 14/491,494, filed Sep. 19, 2014, the entire disclosure of which is hereby incorporated by reference, which claims the benefit of U.S. Provisional Application No. 61/880,829, filed Sep. 20, 2013, the entire disclosure of which is hereby incorporated by reference. 
    
    
     FIELD 
     The present invention relates generally to a plumbing fixture fitting, and, more particularly, to a plumbing fixture fitting that provides a spray mode with improved spray performance. 
     BACKGROUND 
     Plumbing fixture fittings that provide a spray mode are well known. Such plumbing fixture fittings are used in residential and commercial applications, such as in kitchens, laundry rooms, utility rooms, and various other locations. In recent years, legislation has been passed that limits the flow rate from plumbing fixture fittings in certain applications. Limiting the flow rate from plumbing fixture fittings can degrade the spray performance of the plumbing fixture fittings. However, users of plumbing fixture fittings still expect the same spray performance. 
     Difficulties can be encountered in designing plumbing fixture fittings with limited flow rates while maintaining the spray performance. 
     SUMMARY 
     The present invention provides a plumbing fixture fitting having a spray mode with improved spray performance. 
     In an exemplary embodiment, a faucet comprises a hub and a spout. The hub is operable to connect to a mounting surface. The spout includes a receptor and a wand. The receptor is operable to connect to the hub. The wand is operable to mount in the receptor. The wand is operable to pull away from the receptor. The wand includes a shell, a waterway, a diverter valve, and a spray face. The shell is operable to pull away from the receptor. The waterway is separately formed from the shell. The waterway is operable to be substantially disposed in the shell. The waterway includes an inlet region and an outlet region. The inlet region includes an inlet passage. The outlet region includes a first outlet passage and a second outlet passage. The inlet region is operable to connect to a water hose. The waterway includes a first conduit, a second conduit, and a third conduit disposed between the inlet passage and the first outlet passage and the second outlet passage. The waterway includes a diverter valve chamber. The diverter valve chamber is disposed between the first conduit and the second conduit and between the first conduit and the third conduit. The diverter valve is operable to be received in the diverter valve chamber. The diverter valve is operable to divert fluid flow between the first conduit and the second conduit and between the first conduit and the third conduit. The spray face is operable to connect to the outlet region of the waterway. The spray face includes an opening and a plurality of nozzles. The opening is operable to fluidly communicate with the second conduit and the first outlet passage and deliver water from the spray face in the form of a stream. The nozzles are operable to fluidly communicate with the third conduit and the second outlet passage and deliver water from the spray face in the form of a spray. The spray includes a plurality of streamlets. An average unbroken length of the streamlets is greater than approximately two inches at a flow rate of approximately thirty-seven thousandths gallons per minute. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a faucet according to an exemplary embodiment of the present invention; 
         FIGS. 2A-2B  are views of a wand for use in the faucet of  FIG. 1 - FIG. 2A  is an assembled perspective view, and  FIG. 2B  is an exploded perspective view; 
         FIGS. 3A-3E  are views of an assembled waterway and spray face for use in the faucet of  FIG. 1 - FIG. 3A  is a perspective view,  FIG. 3B  is a side elevational view,  FIG. 3C  is a bottom plan view,  FIG. 3D  is a cross-sectional view taken along the line  3 D- 3 D in  FIG. 3C , and  FIG. 3E  is a partial cross-sectional view taken along the line  3 D- 3 D in  FIG. 3C ; 
         FIGS. 4A-4D  are views of a waterway for use in the faucet of  FIG. 1 - FIG. 4A  is a perspective view,  FIG. 4B  is a side elevational view,  FIG. 4C  is a bottom plan view, and  FIG. 4D  is a cross-sectional view taken along the line  4 D- 4 D in  FIG. 4C ; 
         FIGS. 5A-5G  are views of a spray face for use in the faucet of  FIG. 1 - FIG. 5A  is a top perspective view,  FIG. 5B  is a bottom perspective view,  FIG. 5C  is a top plan view,  FIG. 5D  is a bottom plan view,  FIG. 5E  is a cross-sectional view taken along the line  5 E- 5 E in  FIG. 5D ,  FIG. 5F  is a cross-sectional view of a nozzle of the spray face, and  FIG. 5G  is a cross-sectional view of the nozzle of the spray face; 
         FIG. 6  is a graph showing a force of a spray delivered from the spray face of the wand of  FIG. 2A ; 
         FIG. 7  is a graph showing a velocity of a spray delivered from the spray face of the wand of  FIG. 2A ; 
         FIG. 8  is a graph showing a splash of a spray delivered from the spray face of the wand of  FIG. 2A ; 
         FIG. 9  is a graph showing an average unbroken stream length of a spray delivered from the spay face of the wand of  FIG. 2A ; 
         FIG. 10  is a graph showing a specific flow rate of a spray delivered from the spray face of the wand of  FIG. 2A ; 
         FIGS. 11A-11B  are views of a test setup for a wand spray splash test procedure— FIG. 11A  is a front view, and  FIG. 11B  is a top view; 
         FIG. 12  is a view of a test setup for a wand spray unbroken stream length test procedure; 
         FIGS. 13A-13B  are views of a streamlet- FIG. 13A  shows an unbroken stream length, and  FIG. 13B  shows a streamlet width; and 
         FIGS. 14A-14C  are views of streamlets- FIG. 14A  shows an end of an unbroken stream length,  FIG. 14B  shows an uncounted segment, and  FIG. 14C  shows a range of core and unbroken stream lengths. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention provides a plumbing fixture fitting having a spray mode with improved spray performance. In an exemplary embodiment, the plumbing fixture fitting is a faucet. However, one of ordinary skill in the art will appreciate that the plumbing fixture fitting could be a showerhead, a handheld shower, a body spray, a side spray, or any other plumbing fixture fitting. 
     An exemplary embodiment of a faucet  10  of the present invention is shown in detail in  FIG. 1 . In the illustrated embodiment, the faucet  10  includes a hub  12 , a spout  14 , and a handle  16 . The spout  14  includes a receptor  18  and a wand  20 . A base of the hub  12  is connected (either directly or indirectly) to a mounting surface (such as a counter or sink). An upstream end of the receptor  18  is connected to the hub  12 . In an exemplary embodiment, the upstream end of the receptor  18  is connected to a side of the hub  12 . In an exemplary embodiment, the upstream end of the receptor  18  is connected to a top of the hub  12 . An upstream end of the wand  20  is mounted in a downstream end of the receptor  18 . The wand  20  is operable to pull away from the receptor  18 . The wand  20  is operable to deliver water from the faucet  10 . The handle  16  is connected to the hub  12 . In an exemplary embodiment, the handle  16  is connected to the top of the hub  12 . In an exemplary embodiment, the handle  16  is connected to a side of the hub  12 . The handle  16  is operable to move relative to the hub  12 . 
     An exemplary embodiment of the wand is shown in detail in  FIGS. 2A-2B . In the illustrated embodiment, the wand  20  includes a shell  22  and a waterway  24 . The shell  22  is operable to pull away from the receptor  18 . The waterway  24  is formed separately from the shell  22 . The waterway  24  is substantially disposed within the shell  22 . 
     An exemplary embodiment of the waterway  24  is shown in detail in  FIGS. 3A-3E and 4A-4D . The waterway  24  includes an inlet region  26  and an outlet region  28 . The inlet region  26  includes an inlet passage  30 . The outlet region  28  includes a first outlet passage  32  and a second outlet passage  34 . In an exemplary embodiment, the first outlet passage  32  is inside the second outlet passage  34 . The inlet region  26  is connected to a water hose. The waterway  24  includes a first conduit  36 , a second conduit  38 , and a third conduit  40  disposed between the inlet passage  30  and the first outlet passage  32  and the second outlet passage  34 . The waterway  24  includes a diverter valve chamber  42 . The diverter valve chamber  42  is disposed between the first conduit  36  and the second conduit  38  and between the first conduit  36  and the third conduit  40 . 
     Additionally, in the illustrated embodiment, the wand  20  includes a diverter valve  44 . The diverter valve  44  is received in the diverter valve chamber  42 . The diverter valve  44  diverts flow between the first conduit  36  and the second conduit  38  and between the first conduit  36  and the third conduit  40 . 
     Further, in the illustrated embodiment, the wand  20  includes a spray face  46 . The spray face  46  is connected to the outlet region  28  of the waterway  24 . 
     An exemplary embodiment of the spray face  46  is shown in detail in  FIGS. 3A-3E and 5A-5E . The spray face  46  includes an opening  48  and a plurality of nozzles  50 . In an exemplary embodiment, the opening  48  is central and the nozzles  50  surround the opening  48 . In an exemplary embodiment, the nozzles  50  are integrally formed with the spray face  46 . The opening  48  fluidly communicates with the second conduit  38  and the first outlet passage  32  and delivers water from the spray face  46  in the form of a stream. The nozzles  50  fluidly communicate with the third conduit  40  and the second outlet passage  34  and deliver water from the spray face  46  in the form of a spray. The spray includes a plurality of streamlets. 
     An exemplary embodiment of the nozzles  50  is shown in  FIGS. 5F and 5G . At least one of the nozzles  50  includes an inlet section  52 , a converging section  54 , and a throat section  56 . The inlet section  52  has an inlet width w i  and an inlet length l i . In an exemplary embodiment, the inlet section  52  is generally cylindrical shaped. The throat section  56  has a throat width w t  a throat length l t . In an exemplary embodiment, the throat section  56  is generally cylindrical shaped. The inlet width w i  is greater than the throat width w t . As used herein, a width of a component (such as the inlet section  52  or the throat section  56 ) is the dimension of the largest straight line segment extending from one point on the surface of the component to another point on the surface of the component in any plane that intersects the central longitudinal axis of the component at a right angle. 
     In an exemplary embodiment, the ratio of the inlet width w i  to the throat width w t  is greater than approximately one and a half (1.5). In another exemplary embodiment, the ratio of the inlet width w i  to the throat width w t  is greater than approximately two (2.0). In another exemplary embodiment, the ratio of the inlet width w i  to the throat width w t  is greater than approximately three (3.0). 
     In an exemplary embodiment, the ratio of the inlet length l i  to the throat width w t  is greater than approximately one-quarter (0.25). In another exemplary embodiment, the ratio of the inlet length l i  to the throat width w t  is greater than approximately one-half (0.5). In another exemplary embodiment, the ratio of the inlet length l i  to the throat width w t  is greater than approximately one (1.0). 
     In an exemplary embodiment, the ratio of the throat length l t  to the throat width w t  is greater than approximately one-quarter (0.25). In an exemplary embodiment, the ratio of the throat length l t  to the throat width w t  is greater than approximately one (1.0). In another exemplary embodiment, the ratio of the throat length l t  to the throat width w t  is greater than approximately two (2.0). In another exemplary embodiment, the ratio of the throat length l t  to the throat width w t  is greater than approximately three (3.0). 
     In an exemplary embodiment, the throat width w t  is greater than approximately one hundredths of an inch (0.01 in) and less than approximately seven hundredths of an inch (0.07 in). In another exemplary embodiment, the throat width w t  is greater than approximately two hundredths of an inch (0.02 in) and less than approximately five hundredths of an inch (0.05 in). 
     In the illustrated embodiment, the converging section  54  extends between the inlet section  52  and the throat section  56 . The converging section  54  narrows from the inlet section  52  to the throat section  56 . In an exemplary embodiment, the converging section  54  is generally conical shaped. In an exemplary embodiment, the converging section  54  is generally parabolic shaped. However, one of ordinary skill in the art will appreciate that the converging section  54  could have any shape that provides a generally smooth transition from the inlet section  52  to the throat section  56 . 
     The converging section  54  has a convergence angle ca. As used herein, a convergence angle of a converging section  54  that is generally conical shaped is the included angle of the cone, and a convergence angle of a converging section  54  that is not generally conical shaped is the angle between tangents to opposing sides of the surface of the converging section  54  at the midpoint along the length of the converging section  54 . 
     In an exemplary embodiment, the convergence angle ca is less than approximately one-hundred twenty degrees (120°). In another exemplary embodiment, the convergence angle ca is less than approximately sixty degrees (60°). In an exemplary embodiment, the convergence angle ca is less than approximately thirty degrees (30°). In another exemplary embodiment, the convergence angle is less than approximately fifteen degrees (15°). 
     In the illustrated embodiment, the converging section  54  has a first converging portion  58  and a second converging portion  60 . The first converging portion  58  is adjacent the inlet section  52 , and the second converging portion  60  is adjacent the throat section  56 . The first converging portion  58  has a first convergence angle ca 1 , and the second converging portion  60  has a second convergence angle ca 2 . In an exemplary embodiment, the first convergence angle ca 1  is greater than the second convergence angle ca 2 . 
     In an exemplary embodiment, a force of the spray delivered from the spray face  46  is improved.  FIG. 6  is a graph showing the force of the spray delivered from the spray face  46 . The force was measured using a test procedure described in detail in Appendix A below. The test was conducted on the wand  20  of  FIG. 2A . 
     In an exemplary embodiment, the force of the spray is greater than approximately two ounces (2 oz) at a flow rate of approximately one and a half gallons per minute (1.5 gpm). In another exemplary embodiment, the force of the spray is greater than approximately two and an eighth ounces (2.125 oz) at a flow rate of approximately one and a half gallons per minute (1.5 gpm). In another exemplary embodiment, the force of the spray is greater than approximately two and a quarter ounces (2.25 oz) at a flow rate of approximately one and a half gallons per minute (1.5 gpm). 
     In an exemplary embodiment, a velocity of the spray delivered from the spray face  46  is improved.  FIG. 7  is a graph showing the velocity of the spray delivered from the spray face  46 . The velocity was calculated using a flow rate, a number of nozzles  50 , and a cross-sectional area of the throat section  56  of the nozzles  50 . The flow rate was measured using a standard flow meter. The test was conducted on the wand  20  of  FIG. 2A . 
     In an exemplary embodiment, the velocity of the spray is greater than approximately two-hundred fifty inches per second (250 in/sec) at a flowing pressure of approximately sixty pounds per square inch (60 psi). In another exemplary embodiment, the velocity of the spray is greater than approximately two-hundred sixty inches per second (260 in/sec) at a flowing pressure of approximately sixty pounds per square inch (60 psi). In another exemplary embodiment, the velocity of the spray is greater than approximately two-hundred seventy inches per second (270 in/sec) at a flowing pressure of approximately sixty pounds per square inch (60 psi). 
     In an exemplary embodiment, a splash created from the spray delivered from the spray face  46  is improved.  FIG. 8  is a graph showing the splash created from the spray delivered from the spray face  46 . The splash was measured using a test procedure described in detail in Appendix B below and shown in  FIGS. 11A-11B . The test was conducted on the wand  20  of  FIG. 2A . 
     In an exemplary embodiment, the splash created from the spray is less than approximately twenty percent (20%) at approximately one and a half gallons per minute (1.5 gpm). In another exemplary embodiment, the splash created from the spray is less than approximately fifteen percent (15%) at approximately one and a half gallons per minute (1.5 gpm). In another exemplary embodiment, the splash created from the spray is less than approximately ten percent (10%) at approximately one and a half gallons per minute (1.5 gpm). 
     In an exemplary embodiment, an average unbroken stream length of the streamlets delivered from the spray face  46  is improved.  FIG. 9  is a graph showing the average unbroken stream length of the streamlets delivered from the spray face  46 . The average unbroken stream length was measured using a test procedure described in detail in Appendix C below and shown in  FIGS. 12, 13A-13B, and 14A-14C . The test was conducted on the wand  20  of  FIG. 2A . 
     In an exemplary embodiment, the average unbroken stream length of the streamlets is greater than approximately two inches (2 in) at a flow rate of approximately thirty-seven thousandths gallons per minute (0.037 gpm). In another exemplary embodiment, the average unbroken stream length of the streamlets is greater than approximately two and a quarter inches (2.25 in) at a flow rate of approximately thirty-seven thousandths gallons per minute (0.037 gpm). In another exemplary embodiment, the average unbroken stream length of the streamlets is greater than approximately two and a half inches (2.5 in) at a flow rate of approximately thirty-seven thousandths gallons per minute (0.037 gpm). 
     The present invention provides a plumbing fixture fitting having a spray mode with improved spray performance. An exemplary embodiment in which the plumbing fixture fitting is a faucet has been described and shown in detail. As stated above, one of ordinary will appreciate that the plumbing fixture fitting could be a showerhead, a handheld shower, a body spray, a side spray, or any other plumbing fixture fitting. These other exemplary embodiments include a waterway and a spray face. The waterway and the spray face of the other exemplary embodiments may differ in some aspects from the waterway  24  and the spray face  46  of the faucet  10 . However, the waterway of the other exemplary embodiments includes an inlet region and an outlet region and passages and conduits for flowing water from the inlet region to the outlet region, and the spray face of the other exemplary embodiments includes nozzles for delivering water from the spray face in the form of a spray. At least one of the nozzles in the other exemplary embodiments includes the same structure as the nozzles  50  of the faucet  10 . 
     Similarly, the structure for supporting and/or housing the waterway and spray face of the other exemplary embodiments may differ in some aspects from the structure for supporting and/or housing the waterway  24  and the spray face  46  of the faucet  10  (such as the hub  12  and the spout  14 ). For example, the structure for supporting and/or housing the waterway and the spray face of a showerhead may include a showerhead housing that is mounted to a wall and attached to a water supply via a shower pipe; the structure for supporting and/or housing the waterway and the spray face of a handheld shower may include a handheld shower housing that is mounted to a wall via any of a variety of mechanical mounting mechanisms and attached to a water supply via a water hose; the structure for supporting and/or housing the waterway and the spray face of a body spray may include a body spray housing that is mounted to or within a wall and attached to a water supply via a water pipe; the structure for supporting and/or housing the waterway and the spray face of a side spray may include a side spray housing that is mounted to a mounting surface via an escutcheon and attached to a water supply via a water hose. 
     Appendix A—Wand Spray Force Test Procedure 
     Spray wand is mounted in sink with plane of spray face oriented vertically. Circular flat rigid target plate 4.5″ in diameter is mounted parallel to spray face at a distance 6″ from spray face with center of circle at same height as center of wand spray face. Target plate is rigidly connected to a high sensitivity (100 inch pounds capacity) torque-type load cell via a 10″ lever arm. (Spray target plate is rigidly mounted on cantilever supports. Cantilever supports for spray target are rigidly mounted to load cell.) Water is supplied to wand at temperature 100+/−5 deg F.+ and specified flowing pressure P 1 , P 2 , P 3 , etc up to about 125 psi. If necessary, height of wand is adjusted to ensure all jets from wand strike target plate. Flowing pressure, flow rate of water and force on target plate are recorded. (Note, technically, the raw load cell reading is a torque. Since the length of the lever arm is known, the corresponding applied force can be calculated.) 
     Appendix B—Wand Spray Splash Test Procedure 
     Customer Attribute: Spray that is focused and powerful but does not splash outside of the sink. 
     See  FIGS. 11A-11B  for test setup. 
     Test Methodology: 
     Splash Measurement Procedure: 1. Align 10 inch strip of water sensitive paper on front sink edge. Center strip with sink opening center. 2. Cover the strip to protect it from moisture. 3. Turn on sprayer with 60 psig static line pressure, cold water 50-60° F., hot water 130-140° F. 4. Mount the wand so that the spray face is aimed straight down and 8 inches away from 45 degree spray target. Spray face should be positioned 8 inches from sink front edge and center on sink opening. 5. Flow water through the faucet assembly at 60 psi static pressure using cold (ambient) and hot water (130-140 degrees F.). 6. Uncover the collector strip for 30 seconds. At the end of 30 seconds, turn water off. 7. Remove collector strip and analyze results. 
     Wand Spray Splash Analysis Procedure: 1. Find worst case 1 inch area along 10 inch strip (most splash (blue)). Take a photo or scan of this area. Create a 1 inch square with Snagit or any other screen capture program. 2. Open image in ImageJ or any other image processing and analysis program (ImageJ is available for download from the National Institutes of Health at: http://imagej.nih.gov/ij/download/). 3. Adjust recognition threshold (Image&gt;Adjust&gt;Threshold; set color space=RGB). Uncheck Blue “Pass” box. Adjust color ranges to fill in blue spots with red. 4. Draw a line across the width of the strip (known 1.0″ distance). 5. Set scale (Analyze&gt;set scale&gt;set to known distance=1.0, Units=Inches, set Global). 6. Using rectangle tool, draw a 1 inch square at the area of interest. 7. Analyze&gt;Analyze particles (set to Overlay masks, Display results, clear results, summarize&gt;OK). 8. Distribution of blue (wet) sections listed as % Area. 9. Use the % Area value when calculating Normalized Spray Splash per Normalized Spray Force (Attribute #PAxxx). 
     Appendix C—Wand Spray Unbroken Stream Length Test Procedure 
     Streamlet—Droplet Progression: Past work identified that maintaining an unbroken streamlet length is key to cleaning effectiveness and reducing splash. Better Cleaning, Less Splash: Core Zone—Unbroken Stream; Generally smooth. Transition Zone—Ligaments Form; Thin-Thick waves form; Diameter increase+decrease. Less Power, Splashier: Droplet Formation—Ligaments Form; Surface tension pulls ligaments into droplets; Diameters grow and slow. Droplet Growth—Droplets continue to grow and slow; Aerodynamic forces fracture droplets into smaller sets. 
     Test Setup: A test set up was designed to independently control influencing variables. 
     See  FIG. 12  for test setup. 
     Measurement Method: Using a scale placed in plane with the Streamlet, the parameters were measured directly from a photograph. See  FIG. 13A  for Unbroken Length. See  FIG. 13B  for Streamlet Width. Length measurements are rounded to the nearest 0.1″ increment. Using ImageJ software with digital zoom, 3-5 M-pixel camera resolution, 1/1000 sec. shutter speed, 400 ASA setting and side facing flash angle, while carefully accounting for parallax error, the method demonstrated 0.002″ diameter repeatability and similar accuracy. 
     Test Procedure: 1. Effort was made at the beginning of each series to extract all upstream air from the line. The system was run at approximately 480 mL/min for several minutes. Hoses were shaken to allow air to work out through the flow. 2. Flow was reduced to target flowrate (typically 218 mL/min, streamlet flowrate for 2B cleaning spray) and allowed to flow 6 minutes before measuring data. 3. Most streamlets displayed a fast and irregular bimodal pulsation. Several photos were taken at the breakup region to attempt to capture min. and max. limits. However, test data scatter is expected due to the difficulty in capturing limits. 4. Except where specifically noted, test lab cold water was used and the temperature was generally in 60° F.-68° F. range. 5. Due to the somewhat subjective length measurement, UL accuracy is considered to be within 0.1″. 
     Interpretation of Results: See  FIG. 14A  for End of Unbroken Length. For purposes of this test: Unbroken length is defined as the point where the neck is less than ½ the head of the forming droplet. See  FIG. 14B  for uncounted segment. A segment is counted into max unbroken length measurements only if it is longer than adjacent interrupted segments. The segment shown is not counted. See  FIG. 14C  for An example of Broad range of Core and Unbroken Lengths ( 16   a ), including Minimum UL, Maximum UL, and UL range. 
     One of ordinary skill in the art will now appreciate that the present invention provides a plumbing fixture fitting having a spray mode with improved spray performance. Although the present invention has been shown and described with reference to a particular embodiment, equivalent alterations and modifications will occur to those skilled in the art upon reading and understanding this specification. The present invention includes all such equivalent alterations and modifications.