Patent Publication Number: US-4582253-A

Title: Spray aerator

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to spray aerator devices for attachment to faucets, and particularly of the type that can be manually operated to either an aeration mode or a spray mode. In the former instance, an aerated stream of water is delivered from the spray aerator; in the latter instance, a non-aerated spray is delivered from the spray aerator. 
     Spray aerator devices generally are well-known, and commonly have various problems of manufacture, assembly and/or operation associated therewith. Such devices may require the molding of intricate shapes of plastic parts and excessive numbers of such parts, thereby increasing the cost of manufacture and requiring excessive assembly operations. In particular, such devices usually require the use of threaded interconnections between various parts, screws and/or other elaborate fastening means which also increase the cost of manufacture and assembly, the time required for assembly, and require exact axial alignment of threaded parts to obtain proper assembly. Representative of prior art spray aerators are the devices disclosed in U.S. Pat. Nos. 2,989,249; 2,990,122; 3,286,935; 3,334,818; 3,520,481; 3,524,591; 3,623,670; 3,680,791; 3,682,392; 3,706,418 3,722,798; 3,768,735; 3,786,995; 3,884,418; 3,902,671; 4,221,337; and 4,221,338. 
     SUMMARY OF THE INVENTION 
     The spray aerator of the present invention serves to eliminate the above disadvantages, providing relatively few plastic parts of relatively simple moldable shapes, and particularly requiring no threaded interconnections between parts nor screw connections to fully assemble the invention. The spray aerator of the present invention accordingly can be manufactured and assembled economically, easily and very quickly. 
     The spray aerator of the present invention includes a water conduit pipe for mounting at its upper end (through swivelling means if desired) to a faucet and having lateral water passages through the conduit pipe wall short of the bottom of the pipe. A spray housing slides on the pipe and first and second housing insert means also are slidably mounted on the conduit pipe inside the spray housing. The second housing insert defines a first chamber above the first housing insert, the spray housing wall and first housing insert define a second chamber therebetween, and means are provided to interconnect the first and second chambers. The first housing insert also defines a third chamber inwardly thereof, and sealing ring means are provided adjacent the first and third chambers. Snap retainer means, essentially tubular in configuration, are provided to snap over the lower closed end of the conduit pipe and hold the spray housing and first and second housing inserts (and sealing ring means) on the conduit pipe. A collapsible diametrical notch in the lower closed end of the conduit pipe, as well as one or more beveled surfaces relative to the lower closed pipe end and the snap retainer, facilitate snapping of the snap retainer onto the lower closed pipe end, and an inwardly directed flange at the upper end of the snap retainer snaps into an encircling groove in the lower closed pipe end to lock the snap retainer in place. The spray housing further has an inwardly extending ledge about its lower end and a spray insert means snaps upwardly over and is retained by the ledge. The spray insert has spray openings about its periphery entering into the second chamber, and the sprayer insert inner portion forms a housing for and retains an aerator assembly positioned below the third chamber. The snap retainer also has respective surfaces to form respective stops for the spray aerator in its aeration and spray modes as it is manually shifted therebetween. When the spray aerator is positioned in the spray mode, water flows from the conduit pipe through its lateral wall passages sequentially into the first chamber, the second chamber and thence through the spray openings in the spray insert member. In the aerator mode, water flows from the conduit pipe through its lateral wall passages sequentially into the third chamber and thence through the aerator assembly. The snapping of the spray insert means into the spray housing, and the snapping of the snap retainer over the lower closed pipe end, form the attachment means to maintain the spray housing, spray insert member, aerator assembly and housing inserts in assembled condition and retained upon the conduit pipe. 
     To assemble the aerator, the aerator assembly is mounted in the spray insert member, and sequentially the spray housing is slid onto the lower end of the conduit pipe, the housing insert members are slid onto the lower pipe end, the snap retainer is snapped over the lower pipe end, and the spray insert member with aerator assembly is snapped into the spray housing. The assembly of the spray aerator is thereby quickly and easily completed and held against dislodgement from the lower pipe end. 
     Other details and advantages of the present invention are disclosed in the drawing and following detailed description. 
    
    
     BRIEF DESCRIPTION OF DRAWING 
     The single FIGURE illustrates a cross-sectional view of the invention taken along its central axis and showing on respective sides of the central axis the separate spray and aeration modes of the invention. 
    
    
     DETAILED DESCRIPTION OF INVENTION 
     Referring to the drawing, spray aerator 10 of the present invention is shown in cross-section. The drawing to the right side of central axis x--x illustrates the spray aerator in the aeration mode solely, and the drawing to the left side of central axis x--x illustrates the spray aerator in the spray mode solely. The parts on both sides of the central axis are identical, the only difference between the right and left sides being the vertical displacement of certain members in relation to conduit pipe 11. All parts of spray aerator 10 take a generally circular configuration in planes perpendicular to central axis x--x, and the spray aerator is constructed essentially of plastic parts. 
     Conduit pipe 11 has water conduit 12 extending axially from upper end 13 of the pipe to a position 14 at which a plurality of openings 15 extend laterally through the side wall of pipe 11. The lower end 16 of pipe 11 is closed. As shown, the upper end 13 of pipe 11 may be an enlarged ball 13a that is retained within and allowed to swivel in respect to socket and faucet attachment 17. In this manner the spray aerator may be provided with a swivelling capability if desired. Socket 17 includes lower curved retaining surface 18, recess-mounted sealing ring 19 and upper snap-in ring 20 that retains sealing ring 19 in position. Washer 21 overlies snap-in ring 20, and snap-in ring 20, configured as shown, assures that sealing ring 19 will not be displaced or lost as might be the case if only a washer were used for retention. The ball-retaining member 17 includes threads 22 (male or female) for connection to an overlying faucet (not shown). 
     At the lower closed end 16 of conduit pipe 11 is formed split 16a constituting a collapsible notch passing diametrically through pipe 11a from one side to the other. Also at lower end 16 of pipe 11 is provided retaining groove 23 encircling the pipe. Snap retainer member 24, generally of open tubular configuration and flexible, is snapped onto the lower pipe end 16 and retained thereon. Snap retainer 24 has upper end horizontal circular surface 25 and inwardly directed circular flange 25a surrounding the central opening at the upper end of snap retainer 24. Inwardly directed flange 25a fits within retaining groove 23 after snap retainer 24 has been snapped onto lower end 16 of pipe 11. Flange 25a has beveled surface 25b and lower pipe end 16 has beveled surface 16b below retaining groove 23. The combination of beveled surfaces 25b and 16b (or the beveling of at least one of the two surfaces), the flexibility of snap retainer 24, and the collapsibility of notch 16a,act together to allow snap retainer 24 to be pushed and cammed onto lower pipe end 16 from below. As surface 25b rides up surface 16b, flange 25a is stressed outwardly and the pipe material on opposite sides of notch 16a is stressed radially inwardly to close the notch 16a. Flange 25a as it is pushed upwardly then snaps into retaining groove 23, and notch 16a then is free to open back up to the position shown. Snap retainer 24 also has a few integral legs 26 extending downwardly and spaced about the periphery of the lower end of snap retainer 24, the legs 26 terminating at bottom surfaces 26a and water passage spaces 27 being provided between legs 26. 
     It should be understood that the mating of snap retainer 24 with lower pipe end 16 is illustrated with exaggerated spacing therebetween to facilitate understanding of the above description. Snap retainer 24 is locked onto the lower pipe end 16 solely by the above-described construction and snap-action, and generally serves as a very simple and speedy fastening means to retain the other parts of the spray aerator upon conduit pipe 11. Snap retainer 24 further provides two stops to respectively define the spray mode and aeration mode of the spray aerator, all as more fully described hereafter. 
     Spray housing 28 is slidable upwardly and downwardly on conduit pipe 11, having upper end 29 with circular opening 30 therein that is only slightly larger than and encircles pipe 11. Circumferential side wall 31 of spray housing 28 extends downwardly from upper end 29 and encircles conduit axis x--x at a distance therefrom. Spray housing 28 at its open lower end has an inwardly extending circumferential retaining ledge 32. The optional curvature 33 on a portion of spray housing side wall 31 provides finger placement means to slide the spray housing 28 upwardly on pipe 11 to operate the present invention to the aeration mode as hereinafter described. 
     Also slidable upwardly and downwardly on conduit pipe 11 is first housing insert 34 positioned within spray housing 28 and having upper end 35 with a central opening 36 which also is only slightly larger than and encircles the pipe 11. Circumferential side wall 37 of first housing insert 34 extends downwardly from upper end 35 and encircles the conduit axis x--x at a distance spaced outwardly from conduit pipe 11 and spaced inwardly from spray housing side wall 31, the first housing insert 34 also being open at its lower end 38. Sealing ring 39 is positioned within central opening 36, to seal upper end 35 and pipe 11 against the passage of water therebetween, and cup-shaped member 40 internal and contiguous to first housing insert 34 has its upper end 40a serving to retain sealing ring 39 in position as shown. 
     Also positioned in central opening 30 of upper end 29 of spray housing 28 is water-sealing ring 41, ring 41 being held in position by second housing insert 42. Second housing insert 42 is likewise slidable upwardly and downwardly on conduit pipe 11, second housing insert 42 having upper end 43 with central opening 43a only slightly larger than and encircling pipe 11 and having downwardly extending circumferential side wall 44 spaced from and encircling pipe 11 to define a first chamber 45 between pipe 11 and side wall 44. The upper end 43 of second housing insert 42 is seated against the upper end 29 of spray housing 28 and the lower end 46 of second housing insert 42 sits upon upper end 35 of first housing insert 34. A plurality of grooves or notches 47 surrounding pipe 11 are positioned in the upper peripheral surface of first housing insert 34 and provide passage means interconnecting first chamber 45 to a second chamber 48 defined between side wall 37 of first housing insert 34 and side wall 31 of spray housing 28. 
     At the bottom of spray housing 28 is positioned spray insert member 49 surrounding axis x--x, the peripheral edge 50 of which is snapped from below past, and rests upon, inwardly extending retaining ledge 32 of spray housing 28. Spray housing 28 has sufficient flex at its lower end to permit circumferential edge 50 to be snapped past circumferential ledge 32. Spray insert member 49 has an outer peripheral circumferential portion having numerous spray openings 51 opening from below the spray aerator into second chamber 48. Spray insert member 49 further has integral inner and upwardly extending cylindrical flange 52 which serves as a housing for and supports aerator assembly 53 by inner ledge 54. Aerator assembly 53 generally is of a well-known type, for example as disclosed in Bock U.S. Pat. No. 4,345,719 for &#34;Water Aerator&#34;, issued Aug. 24, 1982, which patent is incorporated herein by reference, and includes diffuser basket 55, screens 56, air entrance opening 57 and overlying washer 58. The lower end 38 of first housing insert 34 (with its cup-shaped member 40) rests upon washer 58 in the assembled condition of the spray aerator as shown. The side wall 37 of first housing insert 34, with contiguous cup-shaped member 40, defines a third chamber 59 extending inwardly thereof and above aerator assembly 53. 
     To assemble the spray aerator of the present invention, which can be done manually or automatically, the spray housing 28 may be slid through its central opening 30 onto conduit pipe 11 from the lower end. Sequentially, sealing ring 41, second housing insert 42, first housing insert 34, sealing ring 39, and cup-shaped member 40 are likewise slid onto conduit pipe 11 through their central openings, and snap retainer 24 is then snapped over lower pipe end 16 as above described to retain the above referenced parts on pipe 11. Aerator assembly 53 is then positioned within cylindrical flange 52 of spray insert 49, and the edge periphery 50 of the spray insert member is then snapped upwardly past inwardly extending retaining ledge 32 of spray housing 28 to complete the assembly. 
     The simplicity of the above assembly will be apparent, no screw-threaded interconnections between plastic parts nor screws or other elaborate fastening means are required, and it is solely the snap retainer 24 snapped over lower pipe end 16 and spray insert 49 snapped into the spray housing 28, that hold the spray housing 28, spray insert member 49, aerator assembly 53 and housing inserts 42 and 34 in assembled condition and retained upon the conduit pipe 11 of the spray aerator. The assembly can be carried out with great speed and simplicity, and there is no required exact axial alignment of mating threaded parts as is common in the prior art. 
     Turning now to the operation of the assembled spray aerator described above, the assembly of the spray housing 28, spray insert member 49, aerator assembly 53 and housing inserts 42 and 34 can be manually shifted upwardly on conduit pipe 11 to define the aeration mode (see drawing to the right side of axis x--x) or can be shifted downwardly on pipe 11 to define the spray mode (see drawing to the left side of axis x--x). 
     In the spray mode, upper horizontal surface 25 of snap retainer 24 provides a stop against further downward travel of first housing insert 34 and its cup-shaped member 40, the surface 25 abutting against upper end 40a of member 40 as shown. In this position, water passing down conduit 12 of pipe 11 exits lateral openings 15 through the pipe side wall into first chamber 45, then through grooves 47 in first housing insert 34 into second chamber 48, and from second chamber 48 out the bottom of the spray aerator through spray openings 51 in spray insert member 49. In this spray mode, no water can find its way into third chamber 59 and out through aerator assembly 53. 
     In the aeration mode, the bottom surfaces 26a of legs 26 of snap retainer 24 provide a stop against any further upward movement of the aerator assembly 53, by abutting against the diffuser basket 55 inner rim or a gasket or flow restrictor thereon. In this position, water passing down conduit 12 of pipe 11 exits lateral openings 15 through the pipe side wall into third chamber 59. The water then passes through spaces 27 between legs 26 of snap retainer 24, and down through aerator assembly 53 and out the bottom of the spray aerator of the present invention. In this aeration mode, maintained by the friction of sealing rings 41 and 39 against conduit pipe 11, no water can find its way into first and second chambers 45 and 48 and out through spray opening 51. 
     It is understood that various changes and modifications may be made in the foregoing embodiment without departing from the spirit and scope of the invention as hereafter claimed.