Patent Publication Number: US-8113446-B2

Title: Showerhead for emergency fixture

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. application Ser. No. 12/146,025, filed Jun. 25, 2008, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     The present invention relates to a showerhead for emergency fixture. 
     It is generally known to provide a showerhead for an emergency fixture. Such a showerhead is typically configured to release a spray of water to soak a user in an emergency situation (e.g., to extinguish a fire, to rinse off a dangerous substance, etc.). 
     It would be advantageous to provide a showerhead for emergency fixture. It would also be advantageous to provide a showerhead that creates a more uniform spray pattern. It would also be advantageous to provide a showerhead that provides a more uniform spray pattern from a single outlet to reduce the chance of blockage from dirt or other deposits in the water. It would be desirable to provide for a showerhead for emergency fixture having one or more of these or other advantageous features. To provide an inexpensive, reliable, and widely adaptable showerhead for emergency fixture that avoids the above-referenced and other problems would represent a significant advance in the art 
     SUMMARY 
     One embodiment of the invention relates to an apparatus for controlling a flow of fluid in an emergency fixture. The apparatus comprises a first control element at least partially located in the body and configured to impart rotation into the fluid flow. The first control element comprises an inlet that receives fluid, and an outlet that divides the fluid flow into at least a first portion and a second portion. The outlet comprises a first outlet portion and a second outlet portion. The first outlet portion guides the first portion of the flow out of the first control element as an axial flow. The second outlet portion provides rotation to the second portion of the flow relative to the axial flow. 
     The present invention also relates to a method of controlling a flow of fluid in an emergency fixture. The method comprises providing a showerhead having a first control element; providing a fluid flow to the inlet of the showerhead; flowing the fluid flow into the first flow control element and separating the fluid flow into a first flow portion and a second flow portion; flowing the first flow portion through a first outlet on a path coaxial with an axis of the first control element; and flowing the second flow portion through a second outlet on a path rotating relative to the axis of the first control element. 
     The present invention further relates to an emergency fixture configured to deliver a fluid. The emergency fixture comprises a valve; a showerhead coupled to the valve and having a body, a flow volume control element and a flow rotation control element. The flow volume control element is configured to control the volume of the fluid flow. The flow rotation control element is located downstream from the flow volume control element and is configured to impart rotation into the fluid flow. The flow rotation control element comprises an inlet that receives fluid from the flow volume control element and an outlet. The outlet comprises a first outlet portion defining a bore for a first portion of the fluid flow, and a second outlet portion defining an annular opening circumscribing the bore of the first outlet portion and for a second portion of the fluid flow. At least one member extends across the annular opening and has a deflection surface angled relative to the direction of the first portion of the flow so that liquid deflects off the deflection surface during use. The first outlet portion guides the first portion of the flow out of the flow rotation control element as an axial flow, and wherein the second outlet portion provides rotation to the second portion of the flow relative to the axial flow. 
     The present invention further relates to various features and combinations of features shown and described in the disclosed embodiments. Other ways in which the objects and features of the disclosed embodiments are accomplished will be described in the following specification or will become apparent to those skilled in the art after they have read this specification. Such other ways are deemed to fall within the scope of the disclosed embodiments if they fall within the scope of the claims which follow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an emergency fixture (shower) including a showerhead assembly according to an exemplary embodiment mounted flush to the ceiling. 
         FIG. 2  is an exploded view of a showerhead assembly according to an exemplary embodiment. 
         FIG. 3  is a top plan view of a flow regulator for the showerhead assembly of  FIG. 2  according to one exemplary embodiment. 
         FIG. 4  is a cross section of a flow diverter of  FIG. 2  according to an exemplary embodiment taken along line  4 - 4 . 
         FIG. 5  is a top plan view of a flow rotation control element for the showerhead assembly of  FIG. 2  according to an exemplary embodiment. 
         FIG. 6  is a cross section of the flow rotation control element of  FIG. 5  taken along line  6 - 6 . 
         FIG. 7  is a cross section of a portion of the flow rotation control element of  FIG. 5  taken along line  7 - 7 -showing an angled deflection surface according to an exemplary embodiment. 
         FIG. 8  is a cross section of a portion of the showerhead assembly of  FIG. 2  schematically showing the fluid flow through the flow diverter and flow rotation control element according to an exemplary embodiment. 
         FIG. 9  is a top view of the main body of the showerhead assembly of  FIG. 2  schematically showing the first and second fluid paths through the inlet and throat portions of the nozzle formed by the main body. 
         FIG. 10  is a cross section of a portion of the main body of the showerhead assembly of  FIG. 2  schematically showing the fluid flow through the nozzle according to an exemplary embodiment. 
         FIG. 11  is an isometric view of an apparatus for testing an emergency fixture. 
         FIG. 12  is a side view of the showerhead assembly of  FIG. 2  mounted according to one exemplary embodiment. 
         FIG. 13  is a side view of the showerhead assembly of  FIG. 2  mounted according to another exemplary embodiment. 
         FIG. 14  is a side view of a free-standing emergency fixture (shower) including a showerhead assembly according to an exemplary embodiment. 
     
    
    
     Before explaining a number of preferred, exemplary, and alternative embodiments of the invention in detail it is to be understood that the invention is not limited to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION OF EXEMPLARY AND PREFERRED EMBODIMENTS 
     Before proceeding to the detailed description of the preferred and exemplary embodiments, several comments can be made about the general applicability and the scope thereof. 
     First, while the components of the disclosed embodiments will be illustrated as a showerhead designed for an emergency shower fixture, the features of the disclosed embodiments have a much wider applicability. For example, the showerhead design is adaptable for other applications requiring a desired spray pattern/quantity of water, such as residential, commercial, and industrial installations. 
     Second, the particular materials used to construct the exemplary embodiments are also illustrative. For example, injection molded acrylonitrile butadiene styrene (“ABS”) are an exemplary method and material for making the nozzle and spinner, and injection molded acetal plastic are an exemplary method and material for making the flow control (with the o-ring being EPDM rubber), but other materials can be used, including other thermoplastic resins such as polypropylene, high density polyethylene, other polyethylenes, polyurethane, nylon, any of a variety of homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, etc. Also, other molding operations may be used to form these components, such as blow molding, rotational molding, etc. Components of the showerhead can also be manufactured from cast or forged metal including but not limited to stainless steel or aluminum. 
     Referring to  FIG. 1 , an emergency fixture  10  is shown as an emergency shower according to an exemplary embodiment. Such fixtures  10  are often provided in laboratories or other environments where hazardous conditions due to fire or chemicals may be present. In such environments, where the eyes or body of any person may be exposed to corrosive or otherwise hazardous materials, emergency fixtures  10  provide quick drenching or flushing of the body. Emergency fixtures  10  may include an eyewash station (not shown) to flush the eyes of a user and/or an overhead showerhead  16  that drenches the body of a user. Emergency fixtures  10  are generally controlled by a valve  12  activated by a mechanism (shown as a pull cord in  FIG. 1 , but may be a lever, button, or the like), that allows water or another substance flow through plumbing  14  to emerge from the eyewash station and/or showerhead  16 . According to various exemplary embodiments, the plumbing  14  for emergency fixture  10  may be wholly exposed, partially exposed, or may be concealed within the walls and ceiling. For example as shown in  FIGS. 1 and 12 , the showerhead  16  may be recessed into the ceiling and a shroud and trim plate or other trim piece  18  may be mounted to trim out the hole. According to another exemplary embodiment, as shown in  FIGS. 13 and 14 , the showerhead  16  may be mounted below the ceiling (e.g., on a free-standing unit) and the trim piece  18  may be a bowl coupled to the showerhead  16 . 
     Referring now to  FIG. 2 , a showerhead assembly  16  is shown that provides a more uniform spray pattern, and is intended to meet both United States (e.g., local, state and/or federal) and new European specifications and provide an improved washdown through a single outlet. Showerhead assembly  16  includes a main housing or body  20 , a flow volume control element  40 , a diverter  50 , and a flow rotation control element  60 . Flow volume control elements  40  and diverter  50  are held within flow rotation control member or element  60  which is, in turn, held within main body  20 . Flow volume control element  40 , diverter  50 , and flow rotation control element  60  alter the flow of water supplied to showerhead assembly  16 . 
     Referring to  FIGS. 2 and 10 , main body or housing  20  includes a head portion  34 , a neck portion  35  and a bell portion  36 . Head portion  34  may include threads to couple showerhead assembly  16  to plumbing  14  (e.g. with a threaded coupling). A trim piece (shown in  FIG. 13 ) may be provided that is coupled to main body  20  with additional threaded protrusions  38 . Main body  20  includes a bore  22  that extends from head portion  34 , through neck portion  35  to bell portion  36 . Bore  22  has a first portion that receives the flow rotation control element  60  and a second portion, downstream from the first portion, that forms a nozzle  26  (shown best in  FIG. 10 ). 
     Referring to  FIGS. 2 ,  9 , and  10 , longitudinal recesses or grooves  24  are formed in the first portion of bore  22 . According to an exemplary embodiment, four grooves  24  are formed in bore  22  spaced evenly around bore  22 . At least one of grooves  24  receives a projection  64  on flow rotation control element  60  to inhibit the rotation of flow rotation control element  60  relative to main body  20  during operation of showerhead assembly  16 , as will be described in more detail below. Grooves  24  further provide drainage notches to facilitate the passage of air and/or water through bore  22  between flow rotation control element  60  and main body  20 . Sufficient drainage is desirable to reduce stagnant water pooling within showerhead assembly  16  which may provide conditions for the growth of mold, bacteria, or other undesirable organisms. 
     Referring now to  FIG. 3 , flow volume control element  40  is shown according to one exemplary embodiment. Flow volume control element  40  is a flow regulator configured to maintain a generally constant flow rate at a range of pressures. One exemplary flow regulator is an L-Type flow regulator, model number 58.6668.1 commercially available from NEOPERL Inc of Waterbury, Conn. Flow volume control element  40  includes an outer member  42  with a central opening and an inner member  44  that nests within outer member  42 . A resilient member, such as o-ring  46 , is trapped between the end walls of inner member  44  and outer member  42  on the downstream side of flow volume control element  40 . As the pressure difference across flow volume control element  40  increases (e.g., between the upstream and downstream sides) the o-ring  46  is forced into the central opening of flow volume control element  40 , thereby reducing (i.e., controlling) the flow rate of liquid through flow volume control element  40 . As the pressure difference is reduced, o-ring  46  retracts from the central opening and forces inner member  44  upstream. Flow  80  ( FIG. 10 ) through flow volume control element  40  is further obstructed by spokes  48  on inner member  44 . The size and/or number of spokes  48  on a control member  40  may be decreased or increased to increase or decrease the flow through the control member  40 . According to a preferred embodiment, flow volume control element  40  limits the flow rate to between approximately 17 and 24 gallons per minute (gpm). For example, at a low pressure such as 20 psi, flow volume control element may limit the flow to 17 gpm. At a higher pressure such as 50 psi, flow volume control element may limit the flow to 24 gpm. 
     According to other exemplary embodiments, flow volume control element  40  is not be housed within main body  20  and may be provided further upstream from showerhead assembly  16 . According to other exemplary embodiments, flow volume control element  40  may be a different volume control element such as a valve. 
     After passing through flow volume control element  40 , the water passes through diverter  50 . Diverter  50  is configured to redirect the flow  80 . Referring now to  FIG. 4 , diverter  50  is a cup-shaped member with an end wall  52 , one or more side openings  54 , and a flange  56 . Diverter  50  is housed within second control element  60  with flange  56  resting on an interior shoulder or ledge  65  of second control element  60 , as shown in  FIG. 6 . Water flowing through diverter  50  hits end wall  52  and is redirected through side openings  54 . According to an exemplary embodiment, four openings  54  are provided spaced equally about the circumference of diverter  50 . The flow  80  through diverter  50  is shown schematically in  FIG. 8 . 
     Referring now to  FIGS. 5-7 , second control element (or flow rotation element)  60  is shown according to one exemplary embodiment. Second control element  60  imparts a rotation on at least a portion of the flow passing through showerhead assembly  16 . Second control element  60  is a generally tubular member with an inlet  62  that receives flow volume control element  40  and diverter  50 , and an outlet  66 . According to one exemplary embodiment, two projections  64  protrude outward from opposite sides of second control element  60 . Projections  64  are longitudinal elements that are received in grooves  24  formed in bore  22  of main body  20 . As second control element  60  imparts a rotation on the flow, an opposite rotational force is in turn applied to second control element  60 . With projections  64  seated in grooves  24 , second control element  60  is restrained from rotating relative to main body  20 . According to other exemplary embodiments, second control element  60  may be restrained from rotating relative to main body  20  with another mechanism. For example, second control element  60  may be restrained with an adhesive, a fastener, or some other suitable mechanism. An inwardly extending shoulder or ledge  65  provides a surface upon which diverter  50  rests, as shown best in  FIG. 8 . 
     Outlet  66  of second control element  60  includes a first outlet portion  68  (e.g., port, aperture, orifice, opening, etc.) and a second outlet portion  70  (e.g., port, aperture, orifice, opening, etc.). First outlet portion  68  forms a generally bore (e.g., cylindrical, conical, elliptical, rectangular, etc.) aligned with the longitudinal axis of second control element  60 . Second outlet portion  70  defines an annular opening circumscribing first outlet portion  68 . One or more radial members  72  extend across second outlet portion  70 . Radial members  72  form an angled deflection surface  74 , shown best in  FIG. 7 . According to a preferred embodiment, angled deflection surface  74  has an angle θ between 10 degrees and 80 degrees According to a particularly preferred embodiment, angled deflection surface  74  has an angle θ of approximately 40 degrees. 
     Referring to  FIGS. 6 ,  7  and  8 , outlet  66  divides the flow  80  into a first portion  82  and a second portion  84 . First flow portion  82  is a generally axial flow, passing through first outlet portion  68  and flowing parallel to the longitudinal axis of second control element  60 . Second flow portion  84  passes through second outlet portion  70 . Second flow portion  84  is redirected by angled deflection surfaces  74  (shown in  FIG. 7 ) so that it rotates about first flow portion  82 , as shown best in  FIG. 9 . 
     Referring now to  FIG. 10 , axial first flow portion  82  and rotating second flow portion  84  pass from second control element  60  into nozzle  26 . Nozzle  26  includes an inlet portion  28 , a throat,  30 , and an outlet portion  32 . Inlet portion  28  has an initial cross-section approximately the same size as the cross-section of bore  22  proximate to second control element  60 . The cross-section of inlet portion  28  narrows as the downstream distance from second control element  60  increases. Throat  30  provides a minimum cross-section of nozzle  26 . The cross-section of outlet portion  32  expands as the downstream distance from throat  30  increases until it opens into bell section  36 . 
     At least a portion of second flow portion  84  flows along the walls of nozzle  26 . Proximate to second control element  60 , second flow portion  84  comprises a generally stable (e.g., organized, even, predictable, etc.) flow. As second flow portion  84  passes downstream, through throat  30 , it becomes an unstable, turbulent flow. The unstable flow causes second flow portion  84  to disperse and diverge as it passes from throat  30  to outlet  32  and out of showerhead assembly  16  to drench a user. First flow portion  82  continues generally along the longitudinal axis of nozzle  26  and forms the inner portion of the spray pattern while second flow portion expands to create the outer portion of the spray pattern. 
     By using a single large opening (e.g., outlet  32 ) to expel water from showerhead assembly  16  instead of a larger head with multiple outlets to direct water to specific areas, there is a reduced chance for dirt or other particles in the water to block the outlet and reduce the effectiveness of emergency fixture  10 . Further, a single large outlet  32  is effected less than multiple smaller outlets to corrosion build up. 
     To assure that the water emerging from showerhead  16  sufficiently covers the body of a user, the spread and pattern of the spray is intended to be carefully controlled. For example, European Standard EN15154-1 requires that plumbed-in body showers pass a test procedure involving water falling onto an apparatus including a series of circles, shown in  FIG. 11 . At a distance 700 mm below the shower head, 50±10% of the water falls in a circle 400 mm in diameter. Further the water falling within a 100 mm circle and the water falling in annular areas between the 100 mm circle and the 200 mm circle, the 200 mm circle and the 300 mm circle, and the 300 mm circle and the 400 mm circle must each deviate by less than 30% from the mean value. Still further, 95% of the water must fall within a circle 800 mm in diameter. 
     For purposes of this disclosure, the term “coupled” shall mean the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. Such joining may also relate to mechanical, fluid, or electrical relationship between the two components. 
     It is also important to note that the construction and arrangement of the elements of the showerhead as shown in the preferred and other exemplary embodiments are illustrative only. Although only a few embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and/or omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the appended claims.