Abstract:
A sprinkler system formed by an injection molding process is provided, as well as a device to install, remove and/or maintain the sprinkler system. The sprinkler system includes a sprinkler having a body portion defining a substantially hollow central portion for allowing water to pass therethrough. The hollow central portion extends from a distal end of the body portion to a proximate end of the body portion. The sprinkler system also includes a housing connected to the sprinkler. The housing includes at least one outer wall and a cover portion transverse with the at least one outer wall which defines an interior space. The sprinkler can be at least partially located within the interior space. Also disclosed is a device for maintaining a sprinkler system.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS  
       [0001]    This application claims priority under 35 U.S.C. § 120 to U.S. application Ser. No. 10/104,055 filed Mar. 25, 2002, which is hereby incorporated by reference in its entirety. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    Field Of The Invention. The present invention relates to sprinkler systems, preferably made from an injection molded plastic material.  
           [0003]    Sprinkler systems are known in the art. However, until recently, safety regulations have required them to be made of metal. That is, in the past, safety regulations for sprinkler systems required they be run in steel pipe, using metal sprinkler systems having metal trigger mechanisms. In addition, sprinkler systems had to be installed by licensed installers. These old safety regulations made installation very expensive and prohibitive for residential use in everything but the largest houses. With new safety regulations, however, sprinkler systems can now be run in plastic pipe.  
         SUMMARY OF THE INVENTION  
         [0004]    One object of the invention is to overcome the disadvantages of the known art described above. Another object of the invention is to provide a cost-effective method of adding a sprinkler system to a residential, commercial or light commercial building. Yet another object of the invention is to provide an inexpensive, injection-molded plastic device, that can be made from a number of different plastics, with a number of ways to turn a sprinkler system on. Still another object of the invention is to provide a sprinkler that is simple and dependable. Yet another object of the invention is to provide a sprinkler that is aesthetically pleasing. Yet another object of the invention is to provide a sprinkler where components are easily replaceable.  
           [0005]    In order to achieve the foregoing and further objects, there has been provided according to one aspect of the invention, a sprinkler, preferably formed by an injection molding process, that includes a molded plastic body portion made of an injection molded plastic having a substantially hollow central portion for allowing water to pass therethrough, the hollow portion extending from a distal end to a proximate end of the molded plastic body; a diffuser head portion preferably located in the vicinity of the distal end of the hollow central portion; a sealing portion made of an injection molded elastomeric material in proximity to the hollow central portion; and a link portion. When the link reaches a predetermined temperature the link portion is activated to start the flow of water out of the sprinkler.  
           [0006]    In one preferred embodiment, the diffuser head portion is rotatable. In another preferred embodiment, the sealing portion is located in the vicinity of the proximate end of the hollow central portion. The sealing portion can be mounted on an insert that can be inserted into the sprinkler system with threads or with tabs. Preferably, the insert and the sealing portion are formed in a multi-shot injection molding process.  
           [0007]    According to another aspect of the invention, there has been provided a sprinkler system that includes: a sprinkler as described above; at least one conduit adapted for transporting water from a water source to the sprinkler; and a connector for joining the hollow portion of the body portion with the at least one conduit.  
           [0008]    According to another aspect of the invention, there has been provided a sprinkler formed by a two-shot injection molding process that includes a molded plastic body portion comprising an injection molded plastic having a substantially hollow central portion for allowing water to pass therethrough, the hollow portion extending from a distal end to a proximate end of the molded plastic body; a diffuser head portion comprising an injection molded plastic and located proximate to the distal end of the hollow central portion, wherein one or both of the molded plastic body or diffuser head portion is formed in a first shot in a multi-shot injection molding process; a sealing portion made of an injection molded elastomeric material in proximity to the hollow central portion, the sealing portion is formed in a second shot in a multi-shot injection molding process; and a link portion. When the link reaches a predetermined temperature the link portion is activated to start the flow of water out of the sprinkler.  
           [0009]    According to yet another aspect of the invention, there has been provided a method for forming a sprinkler described above by a two-shot injection molding process that includes providing a first mold configured in the shape of a molded plastic body portion, or providing a first mold configured in the shape of a diffuser head portion; injection molding, as a first shot, a first plastic material into the first mold to form a body portion or a diffuser head portion; providing a second mold configured to provide, with the body portion or diffuser head portion, a void having a cross sectional area bounded by the body portion or diffuser head portion and the second mold surface; injection molding, as a second shot, a material into the void to form a sealing portion; and providing a link portion, wherein when the link reaches a predetermined temperature the link portion is activated to start the flow of water out of the sprinkler.  
           [0010]    A sprinkler system is also provided. The sprinkler system desirably includes a sprinkler having a body portion defining a substantially hollow central portion for allowing water to pass therethrough. The hollow central portion extends from a distal end of the body portion to a proximate end of the body portion. The sprinkler system also includes a housing connected to the sprinkler. The housing includes at least one outer wall and a cover portion transverse with the at least one outer wall which defines an interior space. The sprinkler can be at least partially located within the interior space.  
           [0011]    In embodiments of the sprinkler system, the housing can be integral with the sprinkler, or removably connected to the sprinkler. The housing can also include a lip, which outwardly extends from the distal portion of the outer wall that is opposite the cover portion. The at least one outer wall can also define at least one opening. The at least one opening typically has a first face and a second face, and an engagement portion adjacent to the first face of the at least one opening. The engagement portion may be directly adjacent the opening, or adjacent to the plane of the first face of the opening but a distance from the opening. The engagement portion generally does not extend the entire length of the opening.  
           [0012]    The sprinkler system, including the sprinkler and housing, are preferably molded, and more preferably injection molded. These components may be injection molded from a wide variety of materials including resins, plastics, and metals.  
           [0013]    The sprinkler can also be of the type previously described. The body portion of the sprinkler can include a diffuser head portion located in the vicinity of the distal end of the hollow central portion, a sealing member made of an elastomeric material in proximity to the hollow central portion, and a link portion. When the link reaches a predetermined temperature, the link portion is activated to start the flow of water out of the sprinkler. The link portion may be activated by melting, softening, breaking, or by other activation methods.  
           [0014]    The housing of the sprinkler system may include one outer wall that is generally circular or oval in shape. Alternatively, the housing may include a plurality of outer walls to provide a polygonal shaped housing, such a squared or rectangulared housing.  
           [0015]    Also provided is a sprinkler housing that includes at least one outer wall, and a cover portion transverse with the at least one outer wall which defines an interior space. The at least one outer wall defines at least one opening having a first face for engaging an object applying force against the housing in a first direction, and a second face for engaging an object applying force in a second direction. The housing can further include an engagement portion adjacent to the first face of the at least one opening for engaging an object applying force in a third direction. In one embodiment, the first direction may be counterclockwise, the second direction may be clockwise, and the third direction may be a direction perpendicular to the first and second directions.  
           [0016]    The object used to apply force against the housing is a sprinkler device. The device includes a distal end, a proximal end, and at least one tab extending from the proximal end for operable engagement with the at least one opening of the housing. The at least one tab is desirably configured to engage the first face, the second face and the engagement portion of the housing. This will permit the tabs to rotate the housing, and lull or push the housing using the device. The device can be configured so that the distal end can be removably coupled with a handle. The device can also be circular and hollow in nature so that it may fit over the sprinkler when located within the housing, or it may be shaped in other ways such as, but not limited to, a U-shaped configuration to allow the device to extend over the sprinkler to engage the housing.  
           [0017]    The sprinkler housing and the device may be made by molding a material by the application of heat and pressure in the form of the housing or device, and solidifying the material. Many alternative molding methods may be used, but the desired method of molding is injection molding. Likewise, a wide variety of moldable materials may be used including resins, plastics, and metals.  
           [0018]    Further objects, features and advantages of the present invention, will become readily apparent from detailed consideration of the preferred embodiments which follow.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]    [0019]FIGS. 1 a - 1   e  depict a sprinkler according to a preferred embodiment of the invention.  
         [0020]    [0020]FIGS. 2 a  and  2   b  depict a sprinkler according to another preferred embodiment of the invention.  
         [0021]    [0021]FIGS. 3 a  and  3   b  depict a sprinkler according to another preferred embodiment of the invention.  
         [0022]    [0022]FIG. 4 depicts a sprinkler system according to another preferred embodiment of the invention.  
         [0023]    [0023]FIG. 5 depicts the body portion of the sprinkler according to another preferred embodiment of the invention.  
         [0024]    [0024]FIG. 6 is an isolated view of the sealing system to another preferred embodiment of the invention.  
         [0025]    [0025]FIG. 7 depicts a sprinkler according to another preferred embodiment of the invention.  
         [0026]    [0026]FIGS. 8 a  and  8   b  depict a sprinkler according to another preferred embodiment of the invention.  
         [0027]    [0027]FIG. 9 depicts a sprinkler system according to another preferred embodiment of the invention.  
         [0028]    [0028]FIGS. 10 a  and  10   b  depict a replaceable seal according to a preferred embodiment of the invention.  
         [0029]    [0029]FIG. 11 is a top view of the top of diffuser head portion according to a preferred embodiment of the present invention.  
         [0030]    [0030]FIGS. 12 a - 12   c  depict a sprinkler system in accordance with another embodiment of the invention as described herein.  
         [0031]    FIGS.  13  depicts a device for installation, removal, and/or maintenance of a sprinkler system in accordance with the teachings described herein.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0032]    The present invention provides an inexpensive, preferably injection-molded plastic device, that can be made from a number of different plastics, with a number of ways to turn a sprinkler system on. The sprinkler head is made of a suitable plastic, preferably formed by an injection molding process. The sprinkler includes a molded plastic body portion  10  preferably made of an injection molded plastic having a substantially hollow central portion  11  for allowing water to pass therethrough. The hollow portion extends from a distal end  12  to a proximate end  13  of the molded plastic body portion  10 . The body portion  10  can be made of any suitable plastic, preferably a heat resistant plastic, such as polyacetal, sold under the trade name, Delrin™, polysulphone, nylon and other well known heat resistant plastics. The body portion  10  preferably is made by an injection molding process, in particularly, a multi-shot injection molding process described more fully below.  
         [0033]    The sprinkler also includes a diffuser head portion  16  located in the vicinity of, and preferably adjacent to, the distal end  12  of the hollow central portion  11 . The diffuser head portion  16  functions as a water diffuser to spray water in a desired pattern. The materials of the diffuser head portion  16  can be the same or different as the body portion, and preferably are the same. The sprinkler also includes a sealing portion or member  14  that is made of an injection molded elastomeric material in proximity to the hollow central portion. The sealing portion  14  or member can be made of any material capable of forming a sealing fit between the body portion and diffuser head portion or between the body portion and the retainer portion  15  (FIG. 1).  
         [0034]    Also included is a link portion  25 . The link portion  25  is constructed such that when the link reaches a predetermined temperature, the link portion is activated to start the flow of water out of the sprinkler diffuser head. The link portion can be a lead-meltable link that would melt at about 165° F. The link portion may also be a “mousetrap-type” device that has a bimetal link, or a memory metal link, such as nitinol, that deflects at a given temperature, allowing the link portion to activate the sprinkler system. In another embodiment, the body portion  10  also may include an extension or projection shown as  21  in FIGS.  1  to  3 , that acts to support the link  25 .  
         [0035]    According to one preferred embodiment, there is provided a retainer  15  (shown only in FIG. 1) that forms a water tight seal with the body portion along with the elastomeric material. This embodiment is described in more detail below.  
         [0036]    Between the body portion  10  and the diffuser head portion  16  or retainer  15 , a sealing member  17  is positioned. The sealing member provides a water-tight seal, when the sprinkler is not in use, to protect against leakage.  
         [0037]    As stated above, a goal of this invention is to make the sprinkler as simple and dependable as possible. Along those lines, the applicant has found that a multishot injection molding process is especially suitable. Multi-shot processes, per se, are known in the art, and examples can be found in “Injection Molding Alternatives: A Guide for Designers and Product Engineers,” Section 5.5: “Multicomponent Molding” by Jack Avery (Hanser Gardner Publishers, 1998, pages 113-117); “Process Selection For Multi-Shot Molding” by Mike Tolinski (Molding Systems, volume 56 number 1, January 1998, p 30-35); “Multi-Shot Values” by P. Coates, (Plastics and Rubber Weekly, No.1789, 4 th  June 1999, p.7); “Case Study for Multi-Shot” by J. Hahn, (Antec *99 Conference Proceedings, New York City, May 2-6, 1999 p.406; and “Multi-Shot Injection Moulding” by J. Tinson, (Med.Device Technol., No.3, April 1998, p.26-8), all of which are incorporated by reference their entireties.  
         [0038]    In a typical multi-shot process, the object to be molded is made from more than one material. A first material is injected into a first mold to form a first molded object. The first molded object is then removed from the first mold, and inserted into a second mold, typically by rotating the movable portion of the mold from the first mold to the second mold, into which a second material to be molded is injected to form the final molded object. The final molded object is thus a combination, e.g., laminate, of the first and second materials. Additional analogous molding steps using third, fourth and additional materials can also be employed. These steps preferably all occur within the same molding cycle.  
         [0039]    If a multi-shot injection molding is used in the present invention, the body portion  10  and/or diffuser head portion  16  preferably is formed in a first mold. According to this embodiment, a suitable plastic is injected into the mold to form the body portion and/or diffuser head portion. The body portion and/or the diffuser head portion then is removed from the first mold and moved into position with the second mold. The second mold and the body portion and/or the diffuser head portion form a cavity in the shape of the sealing portion. The elastomer forming the sealing portion is then injection molded into the cavity to form the sealing portion.  
         [0040]    Afterwards, the composite body and/or diffuser head portion and sealing portion are removed from the second mold. If the body portion or the diffuser head portion was formed separately, the composite can then be fitted with the body portion and/or diffuser head portion, either before or after installation. The link is then added to form the sprinkler.  
         [0041]    The present invention will now be described with reference to the non-limiting embodiments described in FIGS.  1 - 13 .  
         [0042]    [0042]FIGS. 1 a - e  show a molded hard plastic body portion with a hole through the center of threaded area  18 . The hole (i.e., hollow central portion  11 ) through the center of the molded area, through which the water runs, will have at its bottom a sealing portion elastomer, preferably formed from a second-shot injection molding process, to seal the central portion  11  and to help insure against leakage. In this embodiment, the sealing member is a soft, pliable elastomer that does not hold the water pressure. It is thus supported up by retainer  15  that can be held in place with a fusible link  25 , usually a metal link that melts at about 165 degrees F. The retainer  15  can be made out of metal or plastic, whichever is the most efficient and economical. The retainer can be made to stay attached or to fall free when the water pressure causes it to open.  
         [0043]    The body portion preferably has a slot  19  in which to snap in the diffuser head portion  16  water diverter that hangs below the center of the threaded area. The diffuser head portion diverter will be arranged to cause the water to divert in a uniform manner to cover the area that the sprinkler is designed to sprinkle.  
         [0044]    The sprinkler is activated when the fusible link  25  is activated, such as by melting. The retainer will be dropped, or forced, out of position by the water pressure, causing the sealing member to deflect and then burst as the retainer drops away. The water then flows freely in the diverter and is spread (sprinkled) around the room.  
         [0045]    The sprinkler may be a factory-molded part. The body portion would preferably be replaced with the sealing member in it after each activation. This would help assure a good seal and a uniform device for increased dependability. In a preferred embodiment, to replace the sealing member, the plastic body portion  10  is unthreaded from the sprinkler system. A new plastic body portion with sealing member  14  is then threaded into the sprinkler system, the diffuser head  16  is replaced and the retainer portion with a link portion is put back into position.  
         [0046]    [0046]FIGS. 2 a - b  show another preferred embodiment. The sprinkler in FIG. 2 has a moveable diffuser head portion  16 . In this embodiment, the sprinkler diffuser head portion  16  can be retracted back up into the body portion  10 , and is held in place with a link portion, such as a fusible pin. As FIGS. 2 a - b  depict, a sealing member  17  is located between the diffuser head and the body portion to form a water tight sealing relationship. When the heat reaches the temperature to activate the link portion, such as by melting the fusible pin, the diffuser head  16  drops down a sufficient distance, preferably about two inches, releasing the seal, and turning the water on within the sprinkler. The sprinkler according to this embodiment may be reusable. To reset the sprinkler, one would push the diffuser head back into location and put in a link member, such as a new meltable, or fusible, pin, and it would be resealed.  
         [0047]    As noted above, one object of the invention is to provide a more aesthetically pleasing sprinkler. This is accomplished by the embodiment shown in FIGS. 2 a - b  in that the sprinkler is substantially mounted flush with the ceiling and is thus significantly less obtrusive and noticeable.  
         [0048]    In FIGS. 2 a - b,  the hard plastic threaded body portion may be a smooth, glued-together body. In this case, the threaded body has projection  21  with a hole in it for receiving a link portion, such as a meltable pin. The diffuser head portion in this embodiment has an extended shaft or portion  20  that has a stop  22  at the top, and a sealing member  17  in the form of an O-ring seal at the bottom. The stop includes radially extending members  22   a.  The O-ring sealing member is pushed up into the threaded body and then retained there by putting a pin through the threaded body under the diffuser.  
         [0049]    The water pressure pushes down on the O-ring seal, which can be molded in a multi-shot injection molding as part of the diffuser head portion  16 . The fusible portion that keeps the diffuser in place also holds the O-ring seal in place because it is all one body. When the fusible portion is activated, such as by melting, the water pressure will force the O-ring seal and the diffuser in a downward direction. This mechanism will fall until the stop hits the bottom of the threaded body retainer. At that point, full water pressure comes from the threaded body portion  10 , and the stream will hit the diffuser head portion  16  and be diffused around the room in the area to be sprinkled. As noted above, in this embodiment, the threaded body portion  10  is substantially flush with surface of the ceiling, such that the diffuser head portion is held in place at the surface of the ceiling, thus making it aesthetically less noticeable obvious than a normal sprinkler system. However, when the link is released, it will drop down to the predetermined extended shaft length on the diffuser and operate as a normal suspended sprinkler system.  
         [0050]    According to another embodiment of the application as shown in FIGS. 4, 7,  9  and  11  the diffuser head portion  16  has a stop  22  with radially extending members  22   b  that are angled and preferably elongated in the longitudinal direction. Upon activation, the diffuser head portion drops down as described above. When the flow of water strikes the angled members  22   b,  the diffuser head will rotate and assist in dispersing the water, particularly in the area close to the sprinkler. FIG. 11 shows a top view according to this embodiment.  
         [0051]    Another alternative embodiment is shown in FIGS. 3 a - b.  In FIGS. 3 a - b,  the link portion is a bimetal or nitinol trigger mechanism. It can be used in the embodiment shown in FIGS. 1, 2,  4 ,  7 ,  8  and described above and below. For example, if it is configured in a manner similar to FIG. 1 (not shown), it would be the second-shot molded sealing member and retainer portion as described with reference to FIG. 1. The link portion would be like a trigger mechanism having a short, post-like strip of either bimetal or nitinol, shown as  25  in FIGS. 3 a - b.  The trigger mechanism would pop out like a mousetrap and allow the retainer portion that is holding the sealing member in place to be released. The sealing member would then blow off, and the water would be distributed by the diffuser head portion that is snapped in underneath it.  
         [0052]    If this embodiment is constructed in a manner that is similar to FIGS. 2 a - b  (as shown in FIGS. 3 a - b ) or e.g., FIG. 4, the threaded or tabbed body portion  10  includes a longer projecting member  21  that receives a bimetal, or memory metal, activating rod that is wedged between the diffuser head portion  16  and the end of the projection  21  of the threaded body portion  10 . When a temperature reaches a predetermined set point, the bimetal, or memory strip, deflects, causing the bottom end to kick out, which will cause the diffuser head portion to drop due to gravity and water pressure and the water will begin to flow.  
         [0053]    The diffuser head portion  16  can be made in various ways to cause the water flow to spread a desired amount depending on the room size and the sprinkler rating. It will also need to accommodate normal household water pressures that may be lower than a normal sprinkler water pressure.  
         [0054]    In another preferred embodiment shown in FIGS.  4 , and  7 - 9 , the body portion  10  is not required to be threaded into the sprinkler system. Instead, the body portion can include tabs  31  that can be inserted into slots in the sprinkler system  50  and rotated to lock the body portion into place in the sprinkler system  50 . FIG. 5 shows ¼ turn lock slots  32  according to a preferred embodiment. FIG. 7 depicts the body portion  10  with tabs  31  before insertion into the sprinkler system.  
         [0055]    The sprinkler system can include a support  40 , preferably made of metal, that is connected to the rest of the sprinkler system  50  having hollow portions  51 , as shown in FIGS. 4, 5 and  9 . While the metal support is shown as having slots for receiving the tabs  31 , the metal support can also have threads instead of slots for supporting body portions that are threaded such as those embodiments shown in FIGS.  1  to  3 .  
         [0056]    In embodiments where the body portion  10  is held by a locking tab and slot, it may be somewhat more difficult to nest the proximate portion  13  of the body portion  10  against the sprinkler system  50 . In these “threadless” embodiments, it is preferable to have an additional sealing member  60  that is located at the interface of the proximate end  13  of the hollow central portion  11  of the body portion and the sprinkler system  50 . This additional sealing provides a water-tight seal between the proximal end  13  of the body portion  10  and the sprinkler system  50 . This additional sealing member is preferably replaceable. This can be in lieu of or in addition to the sealing member  14  or  17  located at the interface of the distal end  12  and the diffuser head portion  16  or retainer  15 . FIG. 4 shows an embodiment with seal  17  and FIGS.  8 - 9  show embodiments with no sealing member between distal end  12  and diffuser head portion  16 .  
         [0057]    In a preferred embodiment, the additional sealing member  60  includes two components, a seal  61  and a support surface  62 . The seal can be made of a thin elastomeric material, such as the material forming sealing portion  14  that can deflect and burst by the water pressure in the sprinkler system  50 . To support the seal  61  before activation, a support surface  62  is provided, that is preferably coextensive with the area of the hollow central portion  11  of the body portion  10 . See, e.g. FIG. 8 a.  In a preferred embodiment, the support surface  62  is a split cover as shown in FIGS. 4, 5,  8  and  9 . In particular FIG. 8 a  shows a top view of the split cover  62  with score  63 . FIG. 8 b  shows split cover in both the intact and a ghost view of one half of the split cover after activation. In an alternative embodiment shown in FIG. 12 a,  the seal  61  is supported by the top  22   c  of stop  22  of the extended shaft  20 .  
         [0058]    Before activation, the support surface  62  is supported by the top  22   c  of stop  22  where it is held place by link portion  25 . Upon activation, the stop  22   c  can no longer support the support surface. As a result, the water pressure in the sprinkler system ruptures the seal and the support surface allowing water to be dispersed by the diffuser head portion.  
         [0059]    In one preferred embodiment, the seal can be mounted on a threaded insert  70  for ease of replacement as shown in FIG. 10. To reset the sprinkler head after activation, the body portion  10  is removed by aligning the tabs  31  with slots  32  to remove the body portion and diffuser head. The threaded insert  70  with seal  61  is then unscrewed and replaced with a new insert with an intact seal. A new supporting surface  62  is placed over the body portion and the body portion is inserted back into the slots of the sprinkler system and twisted into place.  
         [0060]    In another embodiment, the seal  61  is mounted on a tabbed insert  80 . In this embodiment, the insert  80  uses locking tabs  82  to hold the seal  61  in position before activation. An additional seal, such as an O-ring  81  is used to provide a water-tight seal between the insert  80  and the remainder of the sprinkler system  50 . Thus, instead of screwing in the insert for replacement of the seal  61 , the insert is simply pushed in and twisted into place.  
         [0061]    In both of these embodiments, the insert and seals  61  and/or O-ring seal  81  can be made by a multi-shot process as described above.  
         [0062]    In a separate embodiment, the sprinkler system includes a housing  41 , preferably made of a plastic and being integral with the plastic body portion  10 , as shown in FIGS. 12 a - c.  While the housing  41  and plastic body portion  10  are preferred to be one plastic entity (e.g., an integral injection-molded fire sprinkler system), the housing  41  can be made of a material different from the body portion  10 , and may also be separate from the body portion  12 . Under these circumstances, the housing  41  may be connected to the plastic body portion  10  by methods known in the art (e.g., adhesive, fasteners, couplings). The housing  41  allows the sprinkler to be retracted within the housing as shown in FIGS. 12 a  and  12   c,  to provide an aesthetically pleasing appearance. The housing  41  can also include a lip  42 , allowing the sprinkler to be mounted substantially flush with the ceiling (not shown) to make the fire sprinkler system significantly less obtrusive and noticeable. The lip  42  also conceals any gaps, spaces or other defects between the mounting surface and the fire sprinkler system, which often result from irregular cuts in the ceiling tile or finished surface. The housing  41 , as well as the sprinkler system, can also be colored to blend or match with its surroundings and be more aesthetically appealing.  
         [0063]    As discussed, the housing  41  can be connected to or integral with the plastic body portion  10  of the sprinkler, and the housing  41  can also be utilized to install and remove the sprinkler system. In such embodiments, it is preferable that the housing  41  include a distal circumference  43 , from which the optimal lip  42  may outwardly extend. The housing  41  also preferably includes a proximal circumference  44  adjacent to the housing cover portion (e.g., cap)  45  which desirably encloses the cavity formed by the housing wall. The proximal circumference  44  can include tab openings  46  for use with a device for installing, removal, and/or maintenance of the sprinkler system. In the preferred embodiment, the housing is circular, but the housing may be any shape including rectangular so long as a sprinkler can fit therein.  
         [0064]    A device  75  useful for such applications is shown in FIG. 13. The device  75  may be considered a tool to remove or install sprinkler systems that are connected to the water supply by tabs or threads. The device  75  has a distal end  76  that can be connected to handles of various lengths. For example, in one embodiment the device&#39;s distal end  76  can be connected to a short handle for easy installation or removal when in near proximity to the sprinkler system. In other embodiments, the device may be connected or coupled to an extension handle at the distal end  76  for easy installation or removal of the sprinkler system from ground level or other distance. FIG. 13 shows a preferred embodiment of the device  75  as being a hollow cylindrical tool (various handles not shown), although the device may take other forms.  
         [0065]    The device  75  also includes a proximate end  77  with one or more tabs  78  that extend therefrom. In one embodiment, the proximate end  77  is circular, open-ended, and has a diameter to fit within the housing  41 . Desirably, the tabs  78  extend from the proximate end  77  a sufficient distance to engage the openings  46  of the housing  41  when inserted therein. When the preferred embodiment is inserted for use, the proximate end  77  slides over the sprinkler system&#39;s diffuser head portion  16  until the proximate end&#39;s surface  77   a  reaches the backside of the cap  45   a  and fits within the proximate circumference  43  of the housing  41 . The tabs  78  then fit within the tab openings  46 . FIG. 12 b  shows that the tab openings  46  are designed such that the tabs  78  fit within the tab openings  46  differently when the device  75  is being used to install the sprinkler system than when it is being used to remove the sprinkler system. When the device  75  is being used to install the sprinkler system, the tabs  78  slide into the tab openings  46  and any clockwise torque on the sprinkler system tool  75  engages a first face of the opening and allows the entire sprinkler system to be turned clockwise for tightening of threads or tabs  31 . Any force towards the distal end  76  during installation allows the device  75  to be drawn away from the sprinkler system without being attached to the sprinkler system. For sprinkler system removal, the tabs  78  also slide into the tab openings  46 , but the tab opening is designed such that any counter-clockwise torque against the housing will engage a second face of the opening to loosen the sprinkler system. Any force towards the distal end  76  of the device  75  when loosening the system will engage the engagement portion  49 , permitting the housing  41 , together with the sprinkler head, to be pulled away from the ceiling. Other embodiments of the device can be appreciated by the teachings herein. A non-exhaustive example is a device that does not include a cavity that encloses the sprinkler when in use, such as a U-shaped device with two arms extending from the distal end, each arm having a tab for insertion into the tab openings. Further, the housing and device may have only a single mating tab and tab opening.  
         [0066]    The sprinkler system, including the sprinkler and the housing, as well as the device, may be manufactured by a molding process. Preferably, the components of the sprinkler system and device are molded by an injection molding process where moldable material, such as a plastic, metal or other resinous material is injected within a mold using heat and pressure. The material is then solidified, generally by a cooling process, although chemical setting agents may also be used in some embodiments.  
         [0067]    While a number of preferred embodiments of the present invention have been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. As used herein and in the following claims, articles such as “the,” “a” and “an” can connote the singular or plural.