Abstract:
The invention relates to faucet assemblies having removable components such as hand sprayers and spray heads. More particularly, the invention relates to a method and apparatus for retracting removable components of faucet assemblies.

Description:
FIELD OF THE INVENTION 
   The invention relates to faucet assemblies having removable components such as hand sprayers and spray heads. More particularly, the invention relates to a method and apparatus for retracting removable components of faucet assemblies. 
   BACKGROUND AND SUMMARY OF THE INVENTION 
   Conventional sink units such as those used in kitchens and bathrooms generally include a faucet having a delivery spout and at least one valve for controlling hot and cold water supplies. Some faucets include additional features such as removable spray heads that can be extended from the faucet to allow a user to spray items that are difficult to place under the delivery spout of a conventional faucet. Some sinks may also include a removable hand sprayer that is positioned adjacent the delivery spout. The removable hand sprayer can be extended from the sink to allow a user to spray items in or around the sink. Both the removable spray head and the removable hand sprayer allow users to conveniently spray items without placing them directly under the delivery spout of a conventional faucet. 
   According to an illustrative embodiment of the present invention, an installation tool is configured to support a retraction coil for a sprayer of a sink, the sprayer being coupled to a liquid supply hose. The retraction coil has an inner coil diameter, and the liquid supply hose has an outer hose diameter, wherein the outer hose diameter is less than the inner coil diameter. The installation tool includes a substantially cylindrical tube having an outer tube diameter, an inner tube diameter, and first and second spaced apart ends, the outer tube diameter being less than the inner coil diameter such that the retraction coil is configured to receive the tube. The inner tube diameter is greater than the outer hose diameter such that the tube is configured to slidably receive the supply hose. The first end includes a first retainer configured to support a first end of the retraction coil and the second end includes a second retainer configured to support a second end of the retraction coil. 
   According to a further illustrative embodiment of the present invention, an installation tool is configured to support a retraction coil for a hose. The installation tool includes a substantially cylindrical tube having an outer wall extending between first and second spaced apart ends and defining a central aperture. A retraction coil has first and second spaced apart ends and is received over the tube. A first retainer is supported by the first end of the tube and is configured to engage the first end of the retraction coil, wherein the first retainer comprises a washer removably coupled to the first end of the tube. The washer includes a flange extending radially outwardly from the outer wall of the tube and a coupling member integrally formed with the washer and configured to couple with the tube. A second retainer is supported by the second end of the tube and is configured to engage the second end of the retraction coil. 
   According to yet another illustrative embodiment of the present invention, a method of installing a retraction coil on a hose for a faucet assembly is provided. The method includes the steps of providing an installation tube, a retraction coil positioned on the installation tube, and a retainer removably coupled to the tube and configured to support an end of the retraction coil. The method further includes the steps of inserting a free end of the hose through the tube, uncoupling the retainer from the tube, sliding the retainer over the hose to form a stop for the retraction coil, and removing the installation tube from the free end of the hose, leaving the retraction coil positioned around the hose. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above-mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
       FIG. 1  is a partial perspective view of an illustrative embodiment sink and faucet assembly, with the sink shown in phantom; 
       FIG. 2  is a side elevational view, in partial cross-section, of the hand sprayer, supply hose, and retraction coil of the faucet assembly shown in  FIG. 1 , with the hand sprayer shown in the retracted position; 
       FIG. 3  is a view similar to  FIG. 2 , with the hand sprayer shown in the extended position; 
       FIG. 4  is a partial perspective view of a further illustrative embodiment sink and faucet assembly, with the sink shown in the phantom; 
       FIG. 5  is a perspective view of an illustrative embodiment installation tool and retraction coil; 
       FIG. 6  is a partial exploded perspective view of the installation tool and retraction coil shown in  FIG. 5 ; 
       FIG. 7  is a partial perspective view of the installation tool and retraction coil of  FIGS. 5 and 6 , during an illustrative installation of the retraction coil on a hose; 
       FIG. 8  is a perspective view of the retraction coil of  FIGS. 5 and 6  installed on a hose; and 
       FIG. 9  is a partial perspective view similar to  FIG. 7 , during a further illustrative installation of the retraction coil on a hose. 
   

   Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplifications set out herein illustrate embodiments of the invention in several forms and such exemplification is not to be construed as limiting the scope of the invention in any manner. 
   DETAILED DESCRIPTION OF THE INVENTION 
   The embodiments discussed below are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. 
   An illustrative embodiment faucet assembly  10  and sink  11  is shown in  FIGS. 1–3 . Faucet assembly  10  includes base  12 , delivery spout  13 , hand sprayer  34 , and valve assemblies  16  and  18 . Delivery spout  13  is coupled to base  12  and includes an outlet  14 , illustratively including an aerator (not shown). Valve assemblies  16 ,  18  are also coupled to base  12 . Valve assembly  16  is coupled to supply line  24  at fluid coupling  42 . Supply line  24  carries liquid, illustratively hot water, from shut-off valve assembly  20  to valve assembly  16 . Similarly, valve assembly  18  is coupled to supply line  26  at fluid coupling  44 . Supply line  26  carries liquid, illustratively cold water, from shut-off valve assembly  22  to valve assembly  18 . Hose  28  is coupled between an outlet (not shown) of valve assembly  16  and an inlet (not shown) of delivery spout  13 . Similarly, hose  30  is coupled between an outlet (not shown) of valve assembly  18  and an inlet (not shown) of delivery spout  13 . Valve assemblies  16  and  18  include handles or levers  17  and  19 , respectively, that may be actuated by a user to regulate the flow of water to the delivery spout  13 . Moreover, the valve assemblies  16  and  18 , delivery spout  13 , and couplings therebetween may be of conventional design. 
   Outlet tube  32  is fluidly coupled on end  33  to hoses  28  and  30  proximate the delivery spout  13 . The opposing end of tube  32  is coupled to hose  35  through a fluid coupling  46 . The hose  35 , in turn, is coupled to removable hand sprayer  34 . Hand sprayer  34  may be extended from its original position to allow a user the spray items. Retraction coil  36  is positioned around hose  35  substantially along its length between first and second ends  41  and  43 . Retraction coil  36  illustratively comprises a compression spring formed from a continuous run of wire and includes a central aperture. As is known in the art, the compression spring is an open-coil helical spring that offers resistance to a compressive force applied axially. When a user extends hand sprayer  34  by pulling it upward, retraction coil  36  is compressed. When the user releases hand sprayer  34 , retraction coil  36  expands and retracts hand sprayer  34  to its original position. This process is described in greater detail below. 
   As shown in  FIGS. 1 and 2 , the illustrative hand sprayer  34  is positioned in base  38  in its retracted or default position. Base  38  is mounted to or formed in sink  11 . Hand sprayer  34  includes spray head  39 , lever  37 , and an internal valve assembly (not shown) actuated by lever  37  to control water flow through hand sprayer  34 . Base  38  includes a lower end  50  that extends below sink  11 . A fastener  40 , such as a nut, is positioned below sink  11  on end  50  of base  38  to couple base  38  to sink  11 . Both fastener  40  and base  38  include a central aperture having an inner diameter larger than the outer diameter of hose  35  to allow hose  35  to pass through both fastener  40  and base  38  during removal and retraction of hand sprayer  34 . In other embodiments (not shown), base  38  and hand sprayer  34  may be mounted in a countertop or any other suitable supporting surface positioned around the faucet. The hand sprayer  34  and base  38  may be of the type known in the art. 
   During operation of faucet assembly  10 , valve assemblies  20  and  22  are positioned in an open position to allow water to flow from a water source (not shown) such as a water heater or other conventional plumbing to valve assemblies  16  and  18 . A user moves levers  17  and  19  to actuate valve assemblies  16  and  18 , respectively. Water then passes through hoses  28  and/or  30  to the inlet (not shown) of delivery spout  13 . Water from the inlet then travels through delivery spout  13  and exits faucet assembly  10  via spray head  14 . The user can move levers  17  and  19  to actuate valve assemblies  16  and  18 , respectively, to adjust the flow rate and water temperature of the water exiting spray head  14 . 
   Hand sprayer  34  is shown in the retracted position in  FIG. 2 , and in the extended or removed position in  FIG. 3 . A retaining washer  48  having a central aperture with a diameter larger than the outer diameter of hose  35  is positioned on hose  35  between retraction coil  36  and lower end  50  of base  38 . Washer  48  is illustratively formed of a thermoplastic material, but may comprise any other suitable material. Washer  48  includes a body portion  47  and a radially outwardly extending flange or rim  49 . Flange  49  has an outer diameter greater than the inner diameter of retraction coil  36  such that the washer  48  serves as a first stop for the coil  36 . More particularly, flange  49  is positioned between first end  41  of retraction coil  36  and lower end  50  of base  38 . Body portion  47  of washer  48  extends inside retraction coil  36 . The opposing second end  43  of retraction coil  36  abuts fluid coupling  46  of tube  32 . Fluid coupling  46  has an outer diameter larger than the inner diameter of retraction coil  36 , thereby defining a second stop for the coil  36 . 
   In operation, the user lifts or removes hand sprayer  34  from base  38 , as shown in  FIG. 3 , and depresses lever  37  which actuates the internal valve assembly (not shown). Water then flows from end  46  of hose  28  to spray head  39  of hand sprayer  34 . As shown in  FIG. 3 , when hand sprayer  34  is lifted from base  38 , a length of hose  35  is extended through sink  11  and, as such, passes through base  38 , fastener  40 , end  50 , washer  48 , and retraction coil  35 . As shown in  FIGS. 1 and 2 , when hand sprayer  34  is in the retracted position, i.e., sitting in base  38 , hose  35  is hanging under sink  11  in a relaxed configuration and retraction coil  36  is uncompressed. When hand sprayer  34  is removed from base  38 , retraction coil  36  is compressed between coupling  46  of tube  32  and washer  48 , as shown in  FIG. 3 . When the user releases hand sprayer  34 , retraction coil  36 , which was compressed during extension of hand sprayer  34 , extends or decompresses to retract hose  35  and hand sprayer  34  and return them to the retracted position, as shown in  FIG. 2 . 
   Another illustrative embodiment faucet assembly is shown in  FIG. 4 . In the following description like reference numbers refer to similar components as detailed above with respect to the illustrative embodiment of  FIG. 1 . Faucet assembly  60  includes a base  62 , a delivery spout  68 , a spray head  70 , and levers  64  and  66 . Levers  64  and  66  are coupled to valve assemblies  16  and  18  to control the flow of hot and cold water, respectively, to spray head  70 . Spray head  70  is fluidly coupled to hose  72  which extends through delivery spout  68  to water outlet tube  76 . Retraction coil  74 , which is similar to retraction coil  36 , discussed above, is positioned around hose  72 . Retraction coil  74  includes a central aperture having an inner diameter larger than the outer diameter of hose  72 , thereby allowing hose  72  to slidably move within retraction coil  74 . A first end  75  of retraction coil  74  abuts the washer  48  which, in turn, abuts a lower surface  78  of the sink  11 . The opposing second end  77  of retraction coil  74  abuts the fluid coupling  81  of tube  76 . A user may remove or pull spray head  70  out of delivery spout  68 , as shown in  FIG. 4 . When spray head  70  is extended from delivery spout  68 , hose  72  extends through delivery spout  68  and compresses retraction coil  74  between the bottom surface  78  of sink  11  and water outlet tube  76 . When the user releases spray head  70 , retraction coil  74  extends or decompresses to pull hose  72  and spray head  70  back into the retracted position in delivery spout  68 . 
     FIGS. 5 and 6  illustrate installation tool  53  which is configured to be positioned within retraction coil  36  and to receive the hose  35 ,  72 . Installation tool  53  includes substantially cylindrical tube  51  having an outer wall  57  and a retaining flange  54 . Installation tool  53  is illustratively formed from a thermoplastic material, but may comprise any other suitable material. The outer diameter of tube  51  is less than the inner diameter of retraction coil  36 , thereby allowing retraction coil  36  to slide on or off of tube  51 . A retainer, illustratively flange  54  is formed on lower end  56  of tube  51  and engages or abuts retraction coil  36  when it is positioned on installation tool  53 . The outer diameter of flange  54  is greater than the inner diameter of retraction coil  36 . 
   Upper end  58  of tube  51  includes a plurality of apertures or notches  52  positioned around the circumference of tube  51 . In this embodiment, a retainer, illustratively washer  48  is coupled to upper end  58  of tube  51 , to secure retraction coil  36  on tube  51  ( FIG. 5 ). Washer  48  includes central aperture  59 , body  47 , and radially outwardly extending flange  49 . Washer  48  further includes coupling members, illustratively tabs or extensions  55  which are integrally formed with the body  47 . The diameter of aperture  59  is greater than the outer diameter of tube  51  to allow washer  48  to slide over tube  51 . Flange  49  extends outwardly from body  47  and has an outer diameter greater than the inner diameter of retraction coil  36 . Body  47  of washer  48  has an outer diameter less than the inner diameter of retraction coil  36 . Tabs  55  are configured to be received within notches  52  of tube  51  to releasably couple washer  48  to tube  51 , as shown in  FIG. 5 . When retraction coil  36  is positioned on installation tool  53  and washer  48  is coupled to upper end  58  of tube  51 , retraction coil  36  encircles body  47  of washer  48  and is compressed between flanges  49  and  54 . As such, retraction coil  36  may be stored on installation tool  53  before installation. 
   In an alternative embodiment (not shown), flange  54  on lower end  56  of tube  51  is replaced with a second removable washer  48  to support the lower end of retraction coil  36 . In this embodiment, lower end  56  of installation tool  53  is similar to upper end  58  and includes notches  52  to receive tabs  55  for releasably coupling washer  48  to lower end  56 . 
     FIGS. 7 and 8  illustrate a method of installing retraction coil  74  onto hose  72  using installation tool  53 . As detailed above, the inner diameter of tube  51  is greater than the outer diameter of hose  72 . To install retraction coil  74 , a user aligns first free end  80  of hose  72  with lower end  56  of tube  51 . The user then slidably passes hose  72  through the interior of installation tube  51  and couples first free end  80  of hose  72  to spray head  70 . Next, the user squeezes washer  48  to remove tabs  55  from notches  52  and slides washer  48  off of tube  51 . The coil  74  automatically expands along the hose  72 , pushing the washer  48  to a stop, illustratively the bottom surface  78  of sink  11 . The user then removes installation tube  51  from hose  72  by sliding it over hose  72  until the opposing second free end  82  of hose  72  passes through installation tube  51 . As the user slides installation tube  51  toward the second free end  82  of hose  72 , retraction coil  74  expands and extends along the length of hose  72 . After the user removes installation tube  51  from the free end of hose  72 , the user connects the second free end  82  to tube  76  through fluid coupling  81 . In this configuration, retraction coil  74  is positioned between washer  48  which abuts a bottom surface  78  of the sink  11 , such as a countertop, and fluid coupling  81 . 
   As shown in  FIG. 9 , another method of installing retraction coil  74  may be used to install retraction coil  74  on a hose  72  having only one free or uncoupled end  82 . In this case, the first end  80  of retraction coil  74  is illustratively coupled to spray head  70 . For this method the user first aligns upper end  58  of installation tube  51  with the free end  82  of the hose  72  and slides the free end  82  through the interior of installation tube  51 . The user then removes washer  48 , as discussed above, which causes the coil  74  to automatically expand along the length of the hose  72 . Next, the user slides installation tube  51  over the free end  82  of the hose  72  leaving retraction coil  74  positioned on the hose  72 . The free end  82  of the hose  72  is then coupled to the outlet tube  76  through fluid coupling  81 . 
   While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.