Patent Publication Number: US-6220279-B1

Title: Faucet assembly

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a faucet assembly, and particularly relates to structure of components of a faucet assembly which facilitate the rapid and easy installation of the components with a counter top or deck. 
     One type of currently-available faucet assembly is referred to as a “widespread” faucet and includes a spout and a pair of valve handles which are spaced from each other on a support platform such as a counter top or a deck. The faucet assembly also includes an underbody which is formed by a pair of spaced end bodies which are threaded on the exterior thereof and which are linked to a center body by a pair of fluid conduits. The center body is formed with a chamber which communicates with the conduits and with an opening formed in the top of thereof. The underbody is located beneath the deck. A pair of valves are located in respective ones of the end bodies with each valve having a stem extending above the top of the respective end body, and above the deck for assembly with a respective one of the valve handles. Hot and cold water enters at the bottom of the end bodies and the handles are used to control the valves and allow water to flow to the center body and from the spout in a conventional manner. 
     The faucet assembly includes a shank which has an axial opening therethrough and a threaded exterior from a first end nearly to a second end thereof. The first end of the shank is threadedly secured into a threaded opening in the bottom of the spout. The second end of the shank is reduced in size and has an O-ring mounted on the exterior thereof for eventual insertion into the top opening of the center body in communication with the chamber thereof. 
     Three spaced holes are formed through the deck for eventual receipt, from the bottom of the deck, of upper portions of the spaced end bodies and, from the top of the deck, the shank of the spout. The shank of the spout is initially positioned, from the top of the deck, through a center one of the three holes in the deck together with washers and a decorative flange on the top of the deck and a slotted washer at the underside of the deck. A locknut is threadedly attached to the threaded exterior of the shank, near the second end thereof, which extends below the deck and is tightened to secure the spout and the shank with the deck. In this arrangement, the reduced second end of the shank with the O-ring is exposed below the deck awaiting assembly of the other component parts of the faucet assembly. 
     A valve is assembled within each end body with the stem of the valve extending above the top of the end body. A locknut and a washer are assembled about the threaded exterior of each end body, near the bottom of the threaded exterior just above the conduit which is assembled therewith. The underbody is manipulated to move the upper ends of the end bodies, from the underside of the deck, through the respective holes in the deck. Also, the second end of the shank, with the O-ring, is guided into the top opening of the center body. Prior to, and during, this manipulation of the underbody, care must be exercised to insure that the exposed second end of the shank and the O-ring are not damaged. From the top of the deck, a washer and an internally threaded trim flange are positioned over the extended stem and the top of the exterior threaded portion of the end body. 
     For proper assembly of the faucet assembly, the top of each stem must be located a prescribed distance above the top of the deck, when the valve is in the closed position. To properly locate each stem as necessary, the underbody has to be held while measurements are made to insure that the stem height is appropriate. This is a tedious maneuver at best and necessitates movement of the second end of the shank within the opening of the center body during the adjustment period. 
     Once the desired height of the stems is obtained, and with the threaded trim flanges being in place, the locknuts on the bottom of the threaded exterior of the end bodies are threadedly moved upward to locate the respective washers against the underside of the deck and tightened in that location to firmly secure the faucet assembly with the deck. 
     In view of the techniques employed in assembling the faucet assembly as described above, there is a need for a faucet assembly having component structure which eliminates concern for damage to the second end of the shank, and facilitates relatively easy installation of the faucet assembly with the height stems being readily attainable without tedious manipulations of the components. 
     SUMMARY OF THE INVENTION 
     It is, therefore, an object of this invention to provide a faucet assembly having structure which facilitates relative easy and efficient assembly of components thereof with a deck. 
     Another object of this invention is to provide a faucet assembly having structure which facilitates the attainment of precisely and quickly locating, mounting and securing components thereof with a deck. 
     Still another object of this invention is to provide a faucet assembly having structure which facilitates the assembly of components thereof in such a manner as to minimize any opportunity for damage to the components during the assembly process. 
     With these and other objects in mind, this invention contemplates a faucet assembly for assembly with a deck which includes a spout, a center body and a shank secured at one end thereof to the spout and extending axially through an axial passage of the center body. Means are provided for securing the spout, the center body and the shank in assembly with the deck. 
     This invention further contemplates a faucet assembly for assembly with a deck including an end body formed with a first threadless fastening structure and an element formed with a second threadless fastening structure. The first and second fastening structures are formed to be cooperative and complementary when assembled to retain the end body and the element together in a threadless manner on a first side of the deck. Means are provided for securing the end body on a second side of the deck opposite the first side thereof. 
     Other objects, features and advantages of the present invention will become more fully apparent from the following detailed description of the preferred embodiment, the appended claims and the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the accompanying drawings: 
     FIG. 1 is an exploded perspective view showing components of a faucet assembly in accordance with certain principles of the invention; 
     FIG. 2 is a sectional view showing the components of FIG. 1 in assembly in accordance with certain principles of the invention; 
     FIG. 3 is a front view of an underbody of the faucet assembly of FIG. 1 in accordance with certain principles of the invention; 
     FIG. 4 is a end view showing a center body of the underbody of FIG. 3 in accordance with certain principles of the invention; 
     FIG. 5 is a sectional view showing features of the center body of FIG. 4 in accordance with certain principles of the invention; 
     FIG. 6 is a sectional view showing features of the center body of FIG. 4; 
     FIG. 7 is a sectional view showing a shank in accordance with certain principles of the invention; 
     FIG. 8 is a perspective showing a retainer in accordance with certain principles of the invention; 
     FIG. 9 is a side view showing a trim flange in accordance with certain principles of the invention; 
     FIG. 10 is a top view showing the trim flange of FIG. 9 in accordance with certain principles of the invention; 
     FIG. 11 is a sectional view showing the trim flange of FIG. 9 in accordance with certain principles of the invention; 
     FIG. 12 is a top view showing the trim flange of FIG. 9 in preliminary assembly with an end body in accordance with certain principles of the invention; 
     FIG. 13 is a top view showing the trim flange of FIG. 9 in final assembly with the end body of FIG. 12 in accordance with certain principles of the invention; 
     FIG. 14 is a sectional view showing the end body, the retainer, the trim flange and a lock nut in assembly with a deck; and 
     FIG. 15 is a perspective view showing the shank in assembly with a spout and aligned with the opening of the center body for insertion therein. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 1 and 2, a faucet assembly  30  includes a spout  32  and a shank  34  attached to the bottom of the spout. The faucet assembly  30  also includes an underbody  36  (FIG. 3) having a center body  38 , a first end body  40 , a second body  42  and a pair of conduits  44  for providing fluid communications between the end bodies and the center body. Also included are a pair of lock nuts  45  and a pair of washers  47 . The faucet assembly  30  further includes a first retainer element  46 , a first trim flange  48 , a second retainer element  50 , a second trim flange  52  and a fastener nut  54 . Also shown is a faucet assembly support such as, for example, a portion of the top of a counter top, referred to as a deck  56 . The deck  56  is formed with holes therethrough identified as a center hole  58  and two side holes  60  and  62  located and equally spaced on opposite sides of the center hole. 
     Referring to FIG. 3, each of the end bodies  40  and  42  are formed with an axial passage  64  (FIGS. 1 and 12 through  15 ) which extends through the body from a first axial end to a second axial end thereof. Each of the end bodies  40  and  42  are formed with an axially short top section  65 , a threaded upper section  66 , a hexagonal intermediate section  68  and a lower section  70 . An annular groove  72  is formed around each of the end bodies  40  and  42  between the upper section  66  and the top section  65  which is formed with a top surface  74 . The top section  65  is formed with a prescribed diameter and the annular groove  72  is formed with a diameter which is less than the prescribed diameter, with both diameters being measured with respect to the axis of the respective end body  40  or  42 . 
     Referring to FIGS. 4,  5  and  6 , the center body  38  is formed with an axial passage  76  which extends therethrough from a first axial end  78  to a second axial end  80 . The passage  76  is formed with a first cylindrical chamber  82  of a prescribed diameter extending axially inward from the first end  78 , a second cylindrical chamber  84  at a diameter smaller than the prescribed diameter, and a four-sided opening  86  at the second end  80 . The opening  86  is formed with two opposing, spaced flat sides  88  and  90 , and with two opposing, spaced rounded sides  92  and  94 . The center body  38  is formed with a pair of transaxial passages  96  which communicate with the axial passage  76 . An axially-aligned notch  98  is formed on the exterior of the central body  38  to provide an open clearance for a drain stem (not shown). 
     Referring to FIG. 7, the shank  34  is formed with an axial opening  100  which extends from a first axial end  102  toward, but not through, a second axial end  104 , which is closed. The shank  34  is formed with a first section  106  which is cylindrical in external shape and which extends from the first end  102  with a prescribed diameter. An intermediate or second section  108  of the shank  34  extends from the first section  106  and is formed with an external diameter which is less than the prescribed diameter. A third section  110  extends axially from the second section  108  to the second end  104  of the shank  34 . 
     The opening  100  is formed by a first chamber  112  of a prescribed diameter and a second chamber  114  of a diameter less than the prescribed diameter of the first chamber. The first section  106  of the shank is formed externally with threads  116  near the first end  102 , and an annular groove  118  near an inboard end of the first section for receiving an O-ring  120  (FIGS. 1,  2  and  15 ). A plurality of transaxial passages  122  are formed through the shank  34  and communicate with the chamber  114 . The exterior of the second section  108  is formed with an annular groove  124  for supporting an O-ring  126  (FIGS. 1,  2  and  15 ). As shown in FIGS. 1 and 15, the exterior of the third section  110  of the shank  34  is a formed in a four-sided cross-sectional shape with two flat surfaces  128  and  130  on opposite sides thereof, and two rounded sides  132  and  134  on the remaining opposite sides thereof. The rounded sides  132  and  134  are formed with threads. The four-sided cross-sectional shape of the third section  110  is complementary to the four-sided opening  86  formed in the end  80  of the center body  38 . 
     The retainer element  46  is shown in FIG.  8  and is formed in a circular stepped configuration including a ledge  136  having a flat upper surface  138 . A circular riser  140  extends upward from the ledge  136  and is formed with a flat upper surface  142 . A cylindrical opening  144  is formed through the retainer element  46  in an axial direction and is formed with a diameter which is essentially the same as the outside diameter of the upper section  66  of the end bodies  40  and  42 . 
     As shown in FIGS. 9 and 11, the trim flange  48  is formed externally with an upper section  146  having a cylindrical shape which extends from a top axial end  148  to its integral junction with a lower section  150  of the flange which flares radially outward and downward to a bottom axial end  152 . As shown in FIGS. 10 and 11, the trim flange  48  is formed internally with a passage  154  which extends through the flange from the top end  148  to the bottom end  152 . The portion of the passage  154  which is contiguous with the upper section  146  is formed as a cylindrical chamber  156  of a prescribed diameter, while a lower portion of the lower section  150  is formed as a cylindrical chamber  158  of a diameter greater than the prescribed diameter. The chamber  158  is formed with a diameter essentially equal to the outside diameter of the riser  140  of the retainer element  46 , and provides a nest for ultimate receipt of the riser therein. 
     A platform  160  is formed as an integral part of the trim flange  48  between the chambers  156  and  158 . A hole  162  is formed through the platform  160  and is shaped by the overlapping formation of a first circular hole portion  164  of a prescribed diameter and a second circular hole portion  166  of a diameter smaller than the prescribed diameter. The prescribed diameter of the first circular hole portion  164  is essentially the same as the prescribed diameter of top section  65  of the end bodies  40  and  42 , while the prescribed diameter of the second circular hole portion  166  is essentially the same as the diameter of the annular groove  72  of the end bodies. 
     When assembling the components of the faucet assembly  30 , the lock nuts  45  are threadedly positioned onto the upper sections  66  of the end bodies  40  and  42 , and are moved to a position adjacent the intermediate section  68  as shown in FIG.  1 . The washers  47  are then positioned over the upper sections  66  and are moved to engagement with the top of the lock nuts  45 . The underbody  36  is then maneuvered to axially align the end bodies  40  and  42  with the holes  60  and  62  of the deck  56 , and the underbody is moved toward the underside of the deck. The end bodies  40  and  42  are moved into the holes  60  and  62  to the extent that the top section  65 , the annular groove  72  and a small upper portion of the upper section  66  of each end body extends above the top surface of the deck  56  as shown in FIGS. 2 and 14. 
     In the description below, since the end bodies  40  and  42  are identical, since the retainer elements  46  and  50  are identical, and since the trim flanges  48  and  52  are identical, only the assembly steps of the end body  40 , the retainer element  46  and the trim flange  48  will be described. However, it is to be understood that the end body  42 , the retainer element  50 , and the trim flange  52  are assembled in the same manner. 
     The retainer element  46  is then positioned over the extend upper end of the end body  40  with the underside of the element resting on the upper surface of the deck  56 . Referring to FIG. 12, the trim flange  48  is then manipulated so that the larger first circular hole portion  164  thereof is aligned axially with the extended portion of the end body  40 . The trim flange  48  is then moved downward to allow the extended portion of the upper section  66  to be located in the larger first circular hole portion  164 . Eventually, the underside of the trim flange  48  rests on the upper surface  138  of the ledge  136  of the retainer element  46  and the riser  140  thereof nests in the chamber  158  of the trim flange. At this juncture in the assembly, the annular groove  72  of the end body  40  is aligned laterally with the platform  160  of the trim flange  48 . It is noted that the axial height of the annular groove  72  is essentially the same as the axial height of the platform  160   
     Referring to FIG. 13, the trim flange  48  is then moved in the direction of the arrow whereby the portion of the platform  160 , which is adjacent with the smaller second circular hole portion  166 , is moved fully into the annular groove  72  to the extent allowed by the radial depth of the groove. This arrangement now precludes any axial movement of the end body  40 . Thereafter, the washer  47  is moved axially over the upper section  66  of the end body  40  and is positioned against the underside of the deck  56 . The lock nut  45  is then threadedly moved toward the underside of the deck  56  and eventually engages the washer  47  and is tightened in this position. With the end body  42 , the retainer element  50 , the trim flange  52 , and the respective washer  47  and lock nut  45  assembled in the same manner, the underbody  36  is now firmly secured with the deck  56  with the center body  38  being below and in axial alignment with the center hole  58  formed in the deck. 
     It is noted that this assembly process is performed with relative ease and efficiency. It is also noted that the sensitive shank  34  was not in place during the assembly of the underbody  36 , the retainer elements  46  and  50 , and the trim flanges  48  and  52  with the deck  56 . Thus, the assembly of these components could take place without concern for damage to the shank  34 . 
     Referring to FIG. 15, the spout  32  and the shank  34  are located above the deck  56  and axially aligned with the center body  38  with the four-sided configuration of the third section  110  of the shank being aligned with the four-sided configuration of the opening  86  of the center body. The third section  110  of the shank  34  is moved into and through the axial passage  76  of the center body  38  from the first axial end  78  thereof, and eventually through and beyond the opening  86  as shown in FIG.  2 . In this position, the O-ring  120  is located near the bottom of the center body chamber  82  and the O-ring  126  is located near the top of the center body chamber  84 . The transaxial passages  122  of the shank  34  are aligned with the transaxial passages  96  of the center body  38  eventually to allow the flow of fluid therethrough. 
     When assembling the shank  34  with the center body  38 , the bottom of the spout  32  will rest on the top of the deck  56 . Due to manufacturing tolerances in making the various components of the faucet assembly  30  such as, for example, the spout  32 , the shank  34  and the center body  38 , the axial length of the shank is controlled in manufacturing thereof. This results in a clearance gap  168  in the bottom of the chamber  84  of the center body  38  to insure that the bottom of the shank does not engage the bottom of the chamber  84  before the bottom of the spout  32  seats onto the top of the deck  56 . 
     Thereafter, the fastener nut  54  is threadedly assembled with the threaded portions of the third section  110  of the shank  34  to firmly secure the spout  32  and the shank  34  with the underbody  36  and the deck  56 . This completes the assembly of the components of the faucet assembly  30  which is now firmly secured to the deck  56 . 
     During assembly of the shank  34  with the center body  38 , the shank is maneuvered from the top of the deck where it can be easily manipulated by the installer and readily inserted into the center body  38 . The installer does not have to initially install the spout  32  and the shank  34  with the deck  56 , and thereby avoids potential damage to the sensitive shank during assembly of the underbody  36  with the deck. 
     It is noted that the assembly process could be performed in sequences other than the sequence described above without departing from the spirit and scope of the invention. 
     The structure of the components of the faucet assembly  30  as described above facilitate an easy and efficient assembly of the components in a time-saving process. 
     In general, the above-identified embodiments are not to be construed as limiting the breadth of the present invention. Modifications, and other alternative constructions, will be apparent which are within the spirit and scope of the invention as defined in the appended claims.