Patent Description:
The present disclosure relates generally to spray assemblies. More specifically, the present disclosure relates to a hand-held spray assembly. <CIT> discloses a sanitary fitting which has a rocker button and a jet shaper unit which can be controlled by means of a valve arrangement when the rocker button is manually actuated by pressure.

At least one embodiment relates to a spray assembly configured to provide a fluid in a plurality of spray modes. The spray assembly includes a plurality of shafts, a spray face, a lever assembly, and a plurality of sleeves. Each of the plurality of shafts is configured to selectively provide the fluid to a fluid outlet of the spray assembly. The spray face includes one or more nozzles that are configured to be moved between a pluralities of positions such that the spray face selectively provides the fluid in the plurality of spray modes. The lever assembly includes a lever that is configured to be selectively operable in a plurality of positions. At least one of the plurality of sleeves is configured to be operable by the lever to move the one or more nozzles of the spray face.

Another embodiment relates to a method of assembling a spray assembly. The method includes providing a plurality of shafts and coupling a spray face to a first shaft of the plurality of shafts. The first shaft is configured to sealably couple to a second shaft of the plurality of shafts, where the first shaft and the second shaft are made of a polymeric material and form a polymer-polymer seal therebetween. The first shaft is also configured to couple to a third shaft of the plurality of shafts. The method also includes providing a plurality of sleeves, at least one of the sleeves configured to couple to one or more of the plurality of shafts. The method also includes providing a lever assembly that is configured to couple to one of the plurality of shafts.

A third embodiment relates to a spray assembly. The spray assembly includes a first shaft, a spray face coupled to the first shaft, a valve selectively coupled to the first shaft, and a first spring having a first spring constant and positioned between the first shaft and the valve. The spray assembly also includes a second shaft coupled to the first shaft and a second spring having a second spring constant and positioned between the first shaft and the second shaft. The spray assembly also includes a first sleeve coupled to the second shaft and a third spring having a third spring constant and positioned between the second shaft and the first sleeve. The spray assembly also includes a lever assembly coupled to and configured to selectively operate the first sleeve in a plurality of positions. The first sleeve is configured to selectively operate the spray face and the third spring. The third spring is configured to selectively operate the second shaft. The second shaft is configured to selectively operate the valve and the second spring. The valve is configured to selectively operate the first spring. The first spring, the second spring, and the third spring are each configured to provide different resistances to operating the lever assembly such that the first spring, the second spring, and the third spring provide tactile feedback to a user as the user operates the lever between the plurality of positions.

Another embodiment relates to a spray assembly configured to provide a fluid in a plurality of spray modes. The spray assembly includes a plurality of shafts, a spray face, a lever assembly, and a plurality of sleeves. Each of the plurality of shafts is configured to selectively provide the fluid to a fluid outlet of the spray assembly. The spray face includes one or more nozzles that are configured to be moved between a plurality of positions such that the spray face selectively provides the fluid in the plurality of spray modes. The lever assembly includes a lever that is configured to be selectively operable in a plurality of positions. The lever assembly is structured to operate each of the plurality of shafts when operated through the plurality of positions. The lever assembly is structured to include a moving fulcrum such that the fulcrum changes as the lever assembly is operated through the plurality of positions. At least one of the plurality of sleeves is configured to be operable by the lever assembly to move the one or more nozzles of the spray face.

This summary is illustrative only and should not be regarded as limiting.

Traditional hand-held sprayers may be capable of providing different spray patterns (e.g., an aerate pattern, a shower pattern, a ring pattern, etc.). Most multi-mode sprayers, however, can be bulky and large to accommodate the various internal components required for switching between more than two spray modes (e.g., internal diverters, waterways, etc.). Slimmer, more compact sprayers may only be capable of providing two or less spray modes. Therefore, it would be advantageous to provide a hand-held sprayer that is capable of providing multiple spray modes (i.e., more than two) in a smaller or slimmer package that is more ergonomic and takes up less space, as compared to conventional multi-mode sprayers.

In addition, it would be advantageous to provide a hand-held sprayer that is easier to assemble and requires fewer parts, as compared to typical multi-mode hand-held sprayers.

Referring generally to the figures, a spray assembly <NUM> is shown according to an exemplary embodiment. The spray assembly <NUM> uses a lever <NUM> to rely on mechanical advantage to actuate a plurality of spray modes (e.g., three or more, etc.). The spray modes may include an aerate spray, a sweep spray, and a concentrated/stream spray, according to an exemplary embodiment. The internal structure includes various shafts/sleeves within a spray body <NUM> of the spray assembly <NUM> to direct the flow through different fluid passages.

The spray assembly <NUM> also includes a spray face <NUM> including dynamic spray nozzles that are capable of providing two or more spray modes. According to an exemplary embodiment, one or more spray nozzles of the spray face <NUM> may be manually moved directly or indirectly by the lever <NUM>, so as to dynamically provide different spray patterns from the spray face <NUM>. The spray nozzles may be made from an elastomeric material, and the spray assembly <NUM> may include an internal shaft coupled to the lever <NUM> that can selectively engage the spray nozzles to provide the dynamic movement. In this manner, the spray assembly <NUM> can, advantageously, provide for a plurality of spray modes using a smaller, or slimmer spray assembly design.

The spray assembly <NUM> may also include one or more springs for actuating a plurality of internal shafts. In some embodiments, each of the springs may have substantially equal spring constants. In other embodiments, two or more of the springs may have different spring constants. According to an exemplary embodiment, the spray assembly includes three springs, each having a different spring constant. In this arrangement, the springs are each configured to provide different resistances to actuating the lever <NUM>, such that the springs provide tactile feedback to a user as the user actuates the lever <NUM> between the plurality of spray modes. In this way, the spray assembly <NUM> can provide for a more intuitive and user friendly experience.

The spray assembly <NUM> may also include internal shafts, sleeves, and valves configured to be selectively actuated by the lever <NUM> or the springs such that the shafts, sleeves, and valves facilitate the fluid flow in the spray assembly <NUM>. The shafts, sleeves, and valves may be made of a polymeric material (e.g., plastic). In some embodiments, the shafts and sleeves may be coupled by a friction fit or snap-fit assembly. For example, a shaft may be snap-fit to another shaft, or a sleeve may be friction fit around a shaft. In other embodiments, the shafts, sleeves, and valves may be selectively and sealably coupled. In this arrangement, a first shaft may be sealably coupled to a second shaft where the seal between the first shaft and the second shaft is formed by a plastic-plastic seal such that the seal is formed substantially free of additional mechanical gaskets (e.g., without O-rings). This plastic-plastic seal advantageously allows for a smaller package spray assembly <NUM> because of the exclusion of mechanical gaskets. In some embodiments, the spray face <NUM> may include one or more plastic-plastic seals between the coupling of the shafts, sleeves, valves or any combination thereof. Additionally, the exclusion of mechanical gaskets reduces the steps involved in assembling the spray assembly <NUM>.

Referring now to <FIG>, a perspective view of the spray assembly <NUM> is shown according to an exemplary embodiment. The spray assembly <NUM> includes an outer sleeve <NUM> that extends at least partially between a sprayer first end <NUM> and a sprayer second end <NUM>. The outer sleeve <NUM> contains various components of the spray assembly <NUM>. In some embodiments, the outer sleeve <NUM> may be configured to have an ornamental exterior (e.g., brass, stainless steel, etc.). In additional embodiments, the ornamental exterior may be configured to match nearby fixtures in, for example, a kitchen environment. The spray assembly <NUM> may be incorporated as part of a faucet assembly, such as a pull-down faucet assembly in a kitchen, according to an exemplary embodiment. According to other exemplary embodiments, the spray assembly <NUM> may be a standalone sprayer. The spray assembly <NUM> may be used in a variety of different environments, including kitchens, bathrooms, showers, or other types of environments.

Still referring to <FIG>, a lever assembly <NUM> is positioned at the sprayer first end <NUM>. The lever assembly <NUM> includes a lever <NUM> that is disposed away from the outer sleeve <NUM>. The lever <NUM> is an elongated member that is configured to be operable in a plurality of positions. As shown in <FIG>, the lever is normally in a first position of the plurality of positions. An annular cover <NUM> is positioned atop the lever assembly <NUM>. An inlet portion <NUM> extends upwards from the annular cover <NUM>.

Referring now to <FIG>, cross section views and perspective views of various components of the spray assembly <NUM> are shown, according to an exemplary embodiment.

Referring now to <FIG>, a spray face <NUM> is shown coupled to a first shaft <NUM>. In some embodiments, the spray face <NUM> may be coupled to the first shaft <NUM> by a friction-fit coupling (e.g., press-fit/snap-fit). In other embodiments, the spray face <NUM> may be coupled to the first shaft <NUM> by an adhesive (e.g., glue, epoxy, etc.) or a fastener (e.g., bolt, pin, etc.) or over molded onto.

The spray face <NUM> may be made of a polymer or an elastic material (e.g., thermoplastic elastomer like Santoprene, silicone, etc.) or include portions that are made from an elastic material, such that at least a portion of the spray face <NUM> is selectively deformable (e.g., one or more spray nozzles, etc.). The spray face <NUM> is generally annular in shape and includes a plurality of nozzles <NUM> disposed about a perimeter of the spray face <NUM>. Each of the nozzles <NUM> is configured to receive a fluid through an inlet <NUM> and provide the fluid via an outlet <NUM>. The spray face <NUM> also includes an annular flange <NUM>. The annular flange <NUM> is configured to operate the nozzles <NUM> in a plurality of positions. As shown, the nozzles <NUM> and the annular flange <NUM> are in a first position of a plurality of positions. In the first position, the nozzles <NUM> are configured to provide fluid in a first pattern (e.g., a sweep pattern). In a second position, the nozzles <NUM> are configured to provide fluid in a second pattern (e.g., a stream pattern). In some embodiments, when the nozzles are in positions between the first position and the second position, the nozzles <NUM> are configured to provide fluid in a pattern that is between the first pattern and the second pattern (e.g., a part-stream-part-sweep pattern).

According to an exemplary embodiment, the nozzles <NUM> may be configured to be pointed in generally the same direction such that each of the nozzles has a central axis that are each parallel to each other. In another exemplary embodiment, the nozzles may be configured to be pointed in a hyperbolic paraboloid pattern such that the nozzles provide a spray pattern that is non-circular.

According to an exemplary embodiment, the first shaft <NUM> is made of a polymeric material or combinations of materials (e.g., PBT or polybutylene terephthalate like Celenex). Additionally, the first shaft <NUM> is generally tubular in shape such that the first shaft <NUM> is substantially coaxial with the spray face <NUM>. The first shaft <NUM> has a first end <NUM> and a second end <NUM>. The first shaft <NUM> also has a first passage <NUM> defined by annular wall <NUM>. The first passage <NUM> has an inlet portion <NUM> disposed at the first shaft first end <NUM>, a central portion <NUM> disposed between the first shaft first end <NUM> and the first shaft second end <NUM>, and an outlet portion <NUM> disposed at the first shaft second end <NUM>. The first passage <NUM> is configured to receive fluid at or near the inlet portion <NUM> and provide fluid at or near the outlet portion <NUM>.

The inlet portion <NUM> includes a coupling portion <NUM>. The inlet portion <NUM> also includes a radial ledge <NUM> that is positioned between the inlet portion <NUM> and the central portion <NUM>. The thickness of the annular wall <NUM> at the inlet portion <NUM> is less than the thickness of the annular wall <NUM> at the central portion <NUM> such that the passage <NUM> is wider at the inlet portion <NUM> and narrower at the central portion <NUM>.

The central portion <NUM> includes a plurality of grooves <NUM>. The central portion <NUM> has a radial lip <NUM> that is positioned between the central portion <NUM> and the outlet portion <NUM>. The thickness of the annular wall <NUM> at the central portion <NUM> is greater than the thickness of the annular wall <NUM> at the outlet portion <NUM> such that the passage <NUM> is wider at the outlet portion <NUM> and narrower at the central portion <NUM>.

The annular wall <NUM> includes a threaded portion <NUM> at the outlet portion <NUM>. The threaded portion <NUM> is shown to be configured as a female threaded portion, but in other embodiments, the threaded portion may be configured as a male threaded portion.

The first shaft <NUM> also includes a second passage <NUM>. The second passage <NUM> is generally annular in shape and is defined by annular wall <NUM> and annular wall <NUM> such that the second passage is substantially coaxial with the first passage <NUM>. The second passage <NUM> includes an inlet portion <NUM> and an outlet portion <NUM>. The inlet portion <NUM> of the second passage <NUM> is configured to receive fluid. The annular wall <NUM> has a substantially uniform thickness such that the outer diameter of the second passage <NUM> is substantially constant. The annular wall <NUM> extends further radially outward at the outlet portion <NUM> of the second passage <NUM> such that the thickness of the second passage <NUM> at the outlet portion <NUM> is less than the thickness of the second passage <NUM> at the inlet portion <NUM>. A radial ledge <NUM> is positioned between the inlet portion <NUM> and the outlet portion <NUM>. The outlet portion <NUM> is configured to provide fluid to the spray face <NUM>.

Referring to <FIG>, a first spring <NUM> is shown positioned in the inlet portion <NUM> of the first passage <NUM> of the first shaft <NUM>. The first spring <NUM> is configured to engage and be selectively compressed against the radial ledge <NUM>. The first spring <NUM> is configured to have a first spring constant "k<NUM>".

Referring to <FIG>, a second spring <NUM> is shown positioned in the inlet portion <NUM> of the second passage <NUM> of the first shaft <NUM>. The second spring <NUM> is configured to engage with and be selectively compressed against the radial ledge <NUM>. The second spring <NUM> is configured to have a second spring constant "k<NUM>". According to an exemplary embodiment, the first spring constant k<NUM> is less than the second spring constant k<NUM>. For example, the first spring constant k<NUM> may be about <NUM> N/m (<NUM> lbf/in. )+/- <NUM>% and the second spring constant k<NUM> may be about <NUM> N/m (<NUM> Ibf/in) +/- <NUM>%. In this arrangement, the first spring <NUM> and the second spring <NUM> may be actuated concurrently (e.g., experience an equal applied force) resulting in a greater deflection (e.g., compression) in the first spring <NUM> and a lesser deflection in the second spring <NUM>. In some embodiments, the first spring constant k<NUM> is substantially less than the second spring <NUM> constant k<NUM> such that the first spring <NUM> may be fully compressed while the second spring <NUM> is only partially compressed. Referring to <FIG>, a sealing flange <NUM> is shown coupled to an outer portion of the annular wall <NUM>. According to an exemplary embodiment, the sealing flange <NUM> is made of EPDM (ethylene propylene diene monomer) rubber. The sealing flange <NUM> is configured to sealably couple to at least the outer portion of the annular wall <NUM>.

Now referring to <FIG>, a valve shaft <NUM> is shown disposed within the first passage <NUM> of the first shaft <NUM>. In some embodiments, the valve shaft <NUM> is made of a Polyoxymethylene (POM), also known as acetal material. Additionally, the valve shaft <NUM> is generally cylindrical in shape. The valve shaft <NUM> has a first end <NUM> and a second end <NUM> opposite the first end <NUM>. The first end includes an extended portion <NUM> that defines an annular ledge <NUM>. The first end <NUM> has a greater diameter than the second end <NUM> such that a radial ledge <NUM> is positioned between the first end <NUM> and the second end <NUM>. The first spring <NUM> is configured to engage with and be compressed against the radial ledge <NUM>. The plurality of grooves <NUM> are configured to receive the second end <NUM> of the valve shaft <NUM>.

A sealing ring <NUM> (e.g., O-ring) is configured to couple to an exterior portion of the first end <NUM> of the valve shaft <NUM> and selectively engage with an interior portion of the annular wall <NUM> near the inlet portion <NUM> of the first shaft <NUM>. When the sealing ring <NUM> engages with the inlet portion <NUM>, the sealing ring <NUM> forms a fluid-tight seal between the first shaft <NUM> and the valve shaft <NUM> such that fluid is prevented from flowing through the first passage <NUM>.

Now referring to <FIG>, a second shaft <NUM> is shown positioned atop the first shaft <NUM>. In some embodiments, the second shaft <NUM> is made of a polymeric material. Additionally, the second shaft <NUM> is generally tubular in shape. The second shaft <NUM> has a first passage <NUM> defined by annular wall <NUM>. The second shaft <NUM> includes at least one flange <NUM> that is disposed radially inward from the annular wall <NUM>.

The flange <NUM> is configured to selectively engage with the annular ledge <NUM> of the valve shaft <NUM> such that when the flange <NUM> engages the annular ledge <NUM>, the valve shaft <NUM> is actuated axially downwards and the first spring <NUM> is compressed between the radial ledge <NUM> of the first shaft <NUM> and the radial ledge <NUM> of the valve shaft <NUM>. When the valve shaft <NUM> is actuated in this manner, the sealing ring <NUM> is configured to engage the first shaft <NUM> as described above.

The second shaft <NUM> also includes an annular sealing flange <NUM> that is disposed radially inward from the annular wall <NUM>. The annular sealing flange <NUM> is configured to selectively engage the sealing flange <NUM>. When the sealing flange <NUM> engages with the sealing flange <NUM> a fluid-tight seal is formed between the annular wall <NUM> of the first shaft <NUM> and the annular wall <NUM> of the second shaft <NUM> thereby prevented fluid from flowing from the first passage <NUM> of the second shaft <NUM> to the second passage <NUM> of the first shaft <NUM>.

The second shaft <NUM> also includes an annular shelf <NUM> that extends radially inward from the annular wall <NUM> and is disposed axially below the annular sealing flange <NUM>. The annular shelf <NUM> is configured to engage with the second spring <NUM> such that the second spring <NUM> may be selectively compressed between the annular shelf <NUM> and the radial ledge <NUM>. When the second shaft <NUM> is actuated axially downward, the annular shelf <NUM> compresses the second spring <NUM> with the radial ledge <NUM>.

The first passage <NUM> of the second shaft <NUM> is configured to receive fluid and selectively provide fluid to the first passage <NUM> of the first shaft <NUM> or the second passage <NUM> of the first shaft <NUM>, depending on the selected spray mode. According to an exemplary embodiment, in a first position (i.e., a normally open position), the flange <NUM> is engaged with the annular ledge <NUM> such that fluid may flow from the first passage <NUM> of the second shaft to the first passage <NUM> of the first shaft <NUM>. Also in the first position, the annular sealing flange <NUM> is engaged with the sealing flange <NUM> such that fluid may not flow from the first passage <NUM> of the second shaft <NUM> to the second passage <NUM> of the first shaft <NUM>. In a second position, annular sealing flange <NUM> is not engaged with the sealing flange <NUM> such that fluid may flow from the first passage <NUM> of the second shaft <NUM> to the second passage <NUM> of the first shaft <NUM>. Furthermore, the annular shelf <NUM> engages with and compresses the spring <NUM> into the radial ledge <NUM>.

The second shaft <NUM> also includes a tapered sealing flange <NUM>. The tapered sealing flange extends axially downward form the annular wall <NUM> and is configured to engage with the first shaft <NUM>. The engagement between the tapered sealing flange <NUM> and the first shaft <NUM> forms a fluid-tight polymer-polymer seal (e.g., plastic-plastic seal). This polymer-polymer seal advantageously does not include an additional sealing member or mechanical gasket (e.g., O-ring, gasket, etc.) such that the slim body design of the spray assembly <NUM> is maintained.

Referring to <FIG>, a third spring <NUM> is shown positioned axially above the second shaft <NUM>. The third spring <NUM> is configured to engage and be selectively compressed against a top portion <NUM> of the annular wall <NUM> of the second shaft <NUM>. The third spring <NUM> is configured to have a third spring constant "k<NUM>". In some embodiments, the third spring constant k<NUM> is greater than the second spring constant k<NUM>. For example, the third spring constant may be about <NUM> N/m (<NUM> Ibf/in. ) +/- <NUM>%. In this arrangement, the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> may be simultaneously actuated (e.g., experience an equal applied force), the second spring <NUM> deflects less than the first spring <NUM>, and the third spring <NUM> deflects less than the second spring <NUM>. In some embodiments, the first spring constant k<NUM> and the second spring constant k<NUM> are substantially less than the third spring constant k<NUM> such that the first spring <NUM> and the second spring <NUM> may be fully compressed while the third spring <NUM> is only partially compressed.

Referring to <FIG>, an inner sleeve <NUM> is shown positioned atop the third spring <NUM>, according to an exemplary embodiment. According to an exemplary embodiment, the inner sleeve <NUM> is made of a polymeric material. The inner sleeve <NUM> is generally tubular in shape and includes a central opening <NUM> defined by an annular wall <NUM>. The central opening <NUM> is at least partially radially outward from the first shaft <NUM>, the valve shaft <NUM>, and the second shaft <NUM>.

The inner sleeve <NUM> also includes an annular lip <NUM> that extends radially inward from annular wall <NUM>. The annular lip <NUM> is configured to engage with the third spring <NUM> such that the third spring <NUM> is selectively compressible between the annular lip <NUM> and the top portion <NUM> of the second shaft <NUM>.

The annular wall <NUM> has a proximal end <NUM> and a distal end <NUM>. The proximal end <NUM> is shown as having the same outer diameter as the distal end <NUM>. The proximal end <NUM> has a greater wall thickness than the distal end <NUM> such that the central opening <NUM> is wider at the distal end <NUM> and narrower at the proximal end <NUM>.

The annular wall <NUM> also has an end portion <NUM> disposed at the distal portion <NUM>. The end portion <NUM> is configured to selectively engage with the annular flange <NUM> of the spray face <NUM>. For example, when the inner sleeve <NUM> is in a first position, the end portion <NUM> may not engage with the annular flange <NUM> such that the annular flange is in a first position. When the inner sleeve <NUM> is in a second position, the end portion may engage with the annular flange <NUM> such that the end portion <NUM> operates the annular flange <NUM> from the first position to a second position. As the annular flange <NUM> is operated from the first position to the second position, the nozzles are operated through a plurality of positions, as described above.

According to an exemplary embodiment, the annular flange <NUM> may have a generally hyperbolic paraboloid shape such that each of the nozzles <NUM> are operated at different angles. In this arrangement, the nozzles <NUM> may have an original (e.g., un-operated) shape that is also generally hyperbolic paraboloidal in shape. According to an additional exemplary embodiment, the annular flange <NUM> may have a generally circular shape such that each of the nozzles <NUM> are operated uniformly. In this arrangement, the nozzles <NUM> may have an original shape that is also generally circular.

Referring to <FIG>, a lever assembly <NUM> is show positioned atop the inner sleeve <NUM>. The lever assembly <NUM> includes a lever <NUM> and a central opening <NUM>. The lever is configured to be operable in a plurality of positions. As shown, the lever <NUM> is in a first position (e.g., a normally open position).

Referring to <FIG>, a third shaft <NUM> is shown positioned atop the lever assembly <NUM> and extends through the central opening <NUM> of the lever assembly <NUM> and the central opening <NUM> of the inner sleeve <NUM> towards the inlet portion <NUM> of the first shaft <NUM>. The third shaft <NUM> is generally tubular in shape. In some embodiments, the third shaft is made of a polymeric material.

The third shaft <NUM> includes a first passage <NUM> defined by an annular wall <NUM>. The annular wall <NUM> has inlet portion <NUM> (also shown as inlet portion <NUM>). According to an exemplary embodiment, the inlet portion <NUM> has external male threads <NUM>. The male threads <NUM> are configured to be selectively coupled to a fluid supply (e.g., a household water supply) such that a fluid may flow into the first passage <NUM>. In other embodiments, the third shaft <NUM> may include an alternative coupling device such as female threads or a clip style retention device configured to selectively couple the third shaft <NUM> to the fluid supply. The inlet portion <NUM> is opposite an outlet portion <NUM>.

The outlet portion <NUM> of the annular wall <NUM> includes a coupling portion <NUM>. The coupling portion <NUM> is configured to couple to the coupling portion <NUM> of the first shaft <NUM>. For example, the coupling portion <NUM> of the third shaft <NUM> may couple to the coupling portion <NUM> of the first shaft <NUM> by a friction-fit (e.g., snap-fit) arrangement.

The outlet portion <NUM> may also include a mechanical gasket <NUM> (e.g., O-ring) disposed on an exterior surface of the annular wall <NUM>. The mechanical gasket <NUM> may engage with the exterior surface of the annular wall <NUM> and an interior surface of the annular wall <NUM> such that a fluid-tight seal is formed between the second shaft <NUM> and the third shaft <NUM>.

Referring to <FIG>, an annular cap <NUM> is shown positioned at least partially atop the third shaft <NUM> and the lever assembly <NUM>. The annular cap <NUM> may be coupled to the third shaft <NUM> and the lever assembly <NUM>. An outer sleeve <NUM> is positioned at least partially atop the annular cap <NUM>. The outer sleeve <NUM> is configured to at least partially surround the first shaft <NUM>, the valve shaft <NUM>, the second shaft <NUM>, the inner sleeve <NUM>, and the third shaft <NUM>. The outer sleeve <NUM> may also be configured to engage with or couple to the annular cap <NUM>. As shown in <FIG>, the outer sleeve <NUM> may be clamped or crimped by flanges <NUM> onto the annular cap <NUM>. In other embodiments, the outer sleeve <NUM> may be frictionally engaged with one or more of the annular cap <NUM>, the lever assembly <NUM>, or the inner sleeve <NUM>.

Now referring to <FIG> an annular cover <NUM> is shown positioned atop the annular cap <NUM>. The annular cover <NUM> may be configured to engage with or couple to the annular cap <NUM>. For example the annular cover <NUM> may be frictionally engaged with the annular cap <NUM>.

Referring to <FIG>, a spray head <NUM> is shown positioned in the outlet portion <NUM> of the first passage <NUM> of the first shaft <NUM>. The spray head <NUM> is generally tubular in shape and includes a threaded portion <NUM> that is configured to selectively engage with the threaded portion <NUM> of the first shaft <NUM>. The spray head <NUM> is configured as an aerator that receives a fluid from the outlet portion <NUM> and provides the fluid in an aerate spray pattern axially outward from the spray assembly <NUM>.

Referring to <FIG>, a flow chart <NUM> of a method of assembling the spray assembly <NUM> is shown, according to an exemplary embodiment.

At step <NUM>, the spray face <NUM> is coupled to the first shaft <NUM>. In some embodiments, the spray face <NUM> and the first shaft <NUM> are coupled together by an adhesive, epoxy, or other means. In other embodiments, the spray face <NUM> and the first shaft <NUM> are coupled together by a friction-fit interface (e.g., press-fit, snaps, etc.).

At step <NUM>, the first spring <NUM> is provided in the first passage <NUM> of the first shaft <NUM>. At step <NUM>, the second spring <NUM> is provided in the second passage <NUM> of the first shaft <NUM>.

At step <NUM>, the sealing flange <NUM> is coupled to an outer portion of the annular wall <NUM> of the first shaft <NUM>. In some embodiments, the sealing flange <NUM> may be coupled to the annular wall <NUM> by an adhesive, epoxy, or other chemical means. In other embodiments, the sealing flange <NUM> may be coupled to the annular wall <NUM> by a friction-fit method.

At step <NUM>, the valve shaft <NUM> is coupled to the sealing ring <NUM> and is provided in the first passage <NUM> of the first shaft <NUM> above the first spring <NUM>. In some embodiments, the sealing ring <NUM> may be coupled to the valve shaft <NUM> by an adhesive, epoxy, or other chemical means. In other embodiments, the sealing ring <NUM> may be coupled to the valve shaft <NUM> by a friction-fit method.

At step <NUM>, the second shaft <NUM> is provided above the first shaft <NUM>. The tapered sealing flange <NUM> is configured to form a fluid tight seal with the annular wall <NUM> of the first shaft <NUM>. At step <NUM>, the third spring <NUM> is provided above the second shaft <NUM>. At step <NUM>, the inner sleeve <NUM> is provided at least partially around the second shaft <NUM> and above the third spring <NUM>. At step <NUM>, the lever assembly <NUM> is provided above the inner sleeve <NUM>.

At step <NUM>, the third shaft <NUM> is provided at least partially within the central opening <NUM> of the lever assembly <NUM>. The third shaft <NUM> is also coupled to the first shaft <NUM> by first shaft coupling portion <NUM> and the third shaft coupling portion <NUM>.

At step <NUM>, the annular cap <NUM> is provided at least partially around the third shaft <NUM>. At step <NUM>, the outer sleeve <NUM> is provided at least partially around the inner sleeve <NUM>. The outer sleeve <NUM> is also at least partially coupled to the annular cap <NUM>. In an exemplary embodiment, the outer sleeve <NUM> is coupled to the annular cap <NUM> by crimping flanges <NUM> onto or into the annular cap <NUM>.

At step <NUM>, the annular cover <NUM> is provided at least partially above the annular cap <NUM>. The annular cover <NUM> may be coupled to the annular cap <NUM>. In this arrangement, the annular cover <NUM> is coupled to the annular cap <NUM> by friction-fit assembly.

At step <NUM>, the spray head <NUM> is coupled to the first shaft <NUM>. The spray head <NUM> is coupled to the first shaft <NUM> by spray head threads <NUM> and first shaft threads <NUM>.

Now referring to <FIG>, a cross section view of the spray assembly <NUM> in a first position of a plurality of positions is shown, according to an exemplary embodiment. In the first position, the spray assembly <NUM> is configured to receive a fluid (e.g., water) from a fluid source (e.g., a household water supply) at the spray assembly first end <NUM> and provide the fluid in an aerate spray pattern axially outward from the spray assembly second end <NUM>. For example, the fluid may follow a flow path such as flow path <NUM> shown in <FIG>. More specifically, the fluid may flow from the inlet portion <NUM>, through the first passage <NUM> of the third shaft <NUM>, through the first passage <NUM> of the second shaft <NUM>, through the first passage <NUM> of the first shaft <NUM>, through the spray head <NUM>, and axially outward from the spray assembly <NUM>.

In the first position, the lever <NUM> is in a normally open position (i.e., the lever <NUM> is not depressed). Also in the first position, the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> are configured to be in a steady-state position. The sealing flange <NUM> is engaged with the sealing flange <NUM> such that the fluid does not flow to the second passage <NUM> of the first shaft <NUM>.

Referring to <FIG>, a cross section view of the spray assembly <NUM> in a second position of the plurality of positions is shown, according to an exemplary embodiment. In the second position, the spray assembly <NUM> is configured to receive a fluid at the spray assembly first end <NUM> and provide the fluid at the spray assembly second end <NUM> in a sweep pattern. For example, the fluid may follow a flow path such as flow path <NUM> shown in <FIG>. More specifically, the fluid may flow from the inlet portion <NUM>, through the first passage <NUM> of the third shaft <NUM>, through the first passage <NUM> of the second shaft <NUM>, through the second passage <NUM> of the first shaft <NUM>, through the spray face <NUM>, and axially outward from the spray assembly <NUM>.

In the second position, the lever <NUM> is in a partially closed/depressed position. According to an exemplary embodiment, as the lever <NUM> is actuated from the first position to the second position, the first spring <NUM> is configured to provide a first resistance to actuating the lever. Additionally, the second spring <NUM> may provide a second resistance to actuating the lever. In an exemplary embodiment, the first resistance may be less than the second resistance because the spring constant of the first spring <NUM> is less than the spring constant of the second spring <NUM>. In an additional exemplary embodiment, the first resistance and the second resistance may be provided in series, concurrently, or partially concurrently. The resistances provided by the first spring <NUM> and the second spring <NUM> may be configured to provide tactile feedback to a user to indicate that the spray mode is changing. In the second position, the first spring <NUM> and the second spring <NUM> are configured to be at least partially compressed. The third spring <NUM> is configured to have a greater spring constant and therefore will not be compressed as much as the first spring <NUM> and the second spring <NUM>. The sealing flange <NUM> is no longer engaged with the sealing flange <NUM> such that the fluid may flow to the second passage <NUM> of the first shaft <NUM>.

Referring to <FIG>, a cross section view of the spray assembly <NUM> in a third position of a plurality of positions is shown, according to an exemplary embodiment. In the third position, the spray assembly <NUM> is configured to receive a fluid at the spray assembly first end <NUM> and provide the fluid at the spray assembly second end <NUM> in a concentrated stream pattern. For example, the fluid may follow a flow path such as flow path <NUM> shown in <FIG>. More specifically, the fluid may flow from the inlet portion <NUM>, through the first passage <NUM> of the third shaft <NUM>, through the first passage <NUM> of the second shaft <NUM>, through the second passage <NUM> of the first shaft <NUM>, through the spray face <NUM>, and outward from the spray assembly <NUM>.

In the third position, the lever <NUM> is in a fully closed/depressed position. According to an exemplary embodiment, as the lever is actuated from the first position to the second position, the third spring <NUM> may provide a third resistance to actuating the lever <NUM>. The third resistance may be provided concurrently or partially concurrently with the first resistance or the second resistance, or the third resistance may be provided serially after the first resistance and the second resistance. The resistances provided by the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> may be configured to provide tactile feedback to a user to indicate that the spray mode is changing. In the third position, the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> are each at least partially compressed. The sealing flange <NUM> is no longer engaged with the sealing flange <NUM> such that the fluid may flow to the second passage <NUM> of the first shaft <NUM>. The inner sleeve <NUM> is configured to actuate the annular flange <NUM> of the spray face <NUM> such that one or more of the nozzles <NUM> are deflected inward towards a central axis of the spray assembly <NUM>. When directed in this manner, the nozzles <NUM> are configured to provide a concentrated stream spray. When a user releases the lever <NUM>, the nozzles <NUM> will bias or return back to their original position.

In an exemplary embodiment, the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> may limit the movement of various internal components of the spray assembly <NUM>. For example, the first spring <NUM> may be configured to limit the movement of the valve shaft <NUM>, the second spring <NUM> may be configured to limit the movement of the second shaft <NUM>, and the third spring <NUM> may be configured to limit the movement of the inner sleeve <NUM>.

In other embodiments, each of the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> may be configured to be actuated sequentially, concurrently, or partially concurrently in any order of combination as the lever <NUM> is actuated from the first position (e.g., the open position) to the third position (e.g., the closed position). In these arrangements, the spring constant of the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> may be selected from a different set of values.

Referring to <FIG>, various views of the spray face <NUM> and connected components are shown, according to various exemplary embodiments. A side perspective view of a spray face of the spray assembly is shown in <FIG>.

<FIG> is a side perspective view of a first shaft <NUM> of the spray assembly, according to an exemplary embodiment. The second passage <NUM> of the first shaft <NUM> includes a plurality of channels <NUM> that are each configured to interface with one of the nozzles <NUM> of the spray face <NUM>.

<FIG> is a perspective view of the spray face <NUM> coupled to the first shaft <NUM> of the spray assembly <NUM>, according to an exemplary embodiment. Each of the nozzles <NUM> of the spray face <NUM> are configured to couple to the one of the plurality of channels <NUM> such that each of the nozzles <NUM> are in fluid communication with one of the plurality of channels <NUM>.

<FIG> is a cross section view of a spray assembly <NUM>, according to an exemplary embodiment, shown in a first position. The spray assembly <NUM> is structured to be coupled to a fluid supply and provide a fluid output. Accordingly, in some embodiments, the spray assembly <NUM> may include components that are similar to the components of the spray assembly <NUM>. For example, the spray assembly <NUM> includes a lever <NUM> to rely on mechanical advantage to actuate a plurality of spray modes (e.g., three or more, etc.). The spray modes may include an aerate spray, a sweep spray, and a concentrated/stream spray. The internal structure of the spray assembly <NUM> includes various shafts/sleeves within a spray body <NUM> of the spray assembly <NUM> to direct the flow through different fluid passages.

According to an example embodiment, the spray assembly has a first end <NUM> (e.g., a proximal end, an inlet end, etc.) and a second end <NUM> (e.g., a distal end, an outlet end, etc.) opposite the first end <NUM>. The first end <NUM> may be structured to fluidly couple to a fluid source and the second end <NUM> may be structured to provide the fluid output. The spray assembly <NUM> includes a lever <NUM> structured to actuate various valves, shafts, and/or sleeves within the spray assembly <NUM> to change a fluid flow path. As shown, the spray assembly <NUM> includes a central body <NUM>, an outlet body <NUM>, an inner sleeve <NUM>, an outer sleeve <NUM> and a spray face <NUM>. The spray assembly also includes a first shaft <NUM>, a second shaft <NUM>, and a third shaft <NUM>. The spray assembly <NUM> also includes one or more elastic members shown as springs <NUM>, <NUM>, and <NUM>.

The inner body <NUM> includes an inlet portion <NUM> disposed at the first end <NUM> of the spray assembly <NUM>. The inlet portion <NUM> include defines at least one thread <NUM> for coupling the spray assembly to a fluid source. The inner body <NUM> also defines a third pocket <NUM> structured to receive the third shaft <NUM>. The third pocket <NUM> also defines an inlet of a first channel <NUM> and a second channel <NUM>.

In some embodiments, an annular wall <NUM> extends radially outwards from the inner body <NUM> at the inlet portion <NUM>. The annular wall <NUM> is configured to contact and/or couple to the outer sleeve <NUM>.

The first channel <NUM> and the second channel <NUM> are each in fluid communication with the inlet portion <NUM>. In some embodiments, the first channel <NUM> and the second channel <NUM> are substantially parallel. The first channel <NUM> has a first channel inlet <NUM> disposed at the first end <NUM> of the spray assembly <NUM> and a first channel outlet <NUM> disposed at the second end <NUM> of the spray assembly <NUM>. In some embodiments, the first channel inlet <NUM> is in fluid communication with the inlet portion <NUM> via the third pocket <NUM>. The second channel <NUM> has a second channel inlet <NUM> disposed at the first end <NUM> of the spray assembly <NUM> and a second channel outlet <NUM> disposed at the second end <NUM> of the spray assembly <NUM>. In some embodiments, and as shown in <FIG>, the second channel <NUM> is disposed radially outward of the first channel <NUM>. In some embodiments, at least a portion of the second channel <NUM> extends circumferentially around the first channel <NUM>. For example, the second channel outlet <NUM> may extend circumferentially around the first channel outlet <NUM>.

The inner body <NUM> also defines a second pocket <NUM> (e.g., a central pocket) that is structured to receive the second shaft <NUM>. As shown, the second pocket <NUM> may extend at least partially through the first channel <NUM> and the second channel <NUM> such that a first flow path <NUM> defined by the first channel <NUM> and a second flow path <NUM> defined by the second channel <NUM> are defined around the second pocket <NUM>. The second pocket <NUM> may include an upper portion and a lower portion. The upper portion of the second pocket <NUM> may have a larger diameter than the lower portion such that a shoulder <NUM> is defined between the upper portion and the lower portion of the second pocket <NUM>. The spring <NUM> may contact and/or be biased against the shoulder <NUM>.

The inner body <NUM> may also include a first pocket <NUM> defined on an outer surface of the inner body <NUM>. The first pocket <NUM> may be an annular recess that is structured to receive at least a portion of the spring <NUM>. In some embodiments, the first pocket <NUM> also receives at least a portion of the first shaft <NUM>.

In some embodiments, the inner body <NUM> also includes a radial flange <NUM> that extends radially outward from the inner body <NUM>. The radial flange <NUM> is positioned opposite the first pocket <NUM>. In some embodiments, the radial flange <NUM> is structured to contact and/or couple to the outer sleeve <NUM>. In some embodiments, the radial flange <NUM> is structured to provide rigidity to the inner body <NUM> such that when the first shaft <NUM> is depressed by the lever <NUM>, the inner body <NUM> is substantially prevented from moving or deflecting.

In some embodiments, the inner body <NUM> is coupled to an outlet body <NUM>. In some embodiments, the outlet body <NUM> is coupled to the inner body <NUM> in a snap fit arrangement. For example, the outlet body <NUM> may include an annular notch <NUM> structured to receive at least a portion of the inner body <NUM>. In some embodiments, the annular notch <NUM> extends around the circumference of the inner body <NUM> (e.g., at the second channel outlet <NUM>). In some embodiments, the annular notch <NUM> only extends partially around the circumference of the inner body. In some embodiments, the inner body <NUM> is coupled to the outlet body <NUM> such that a fluid tight seal is formed therebetween. In some embodiments, the spray assembly <NUM> includes one or more sealing members (e.g., O-rings, gaskets, etc.) shown as sealing members <NUM>. The outlet body <NUM> includes an inner chamber <NUM> and an outer chamber <NUM>.

The inner chamber <NUM> is fluidly coupled to the first channel <NUM> at the first channel outlet <NUM>. In some embodiments, one of the sealing members <NUM> is positioned at or near the connection between the first channel <NUM> and the inner chamber <NUM> such that a fluid tight seal is formed between a surface of the inner body <NUM> and a surface the outlet body <NUM> and fluid can flow from the inner body <NUM> to the outlet body <NUM> along a first flow path (e.g., first flow path <NUM>). In some embodiments, fluid flows along the first flow path <NUM> such that the inner chamber <NUM> receives fluid from first channel <NUM> and provides a first spray mode (e.g., an aerate spray) as the fluid flows out of the inner chamber <NUM>. Accordingly, the first follow path <NUM> flows through at least the inner body <NUM> and the outlet body <NUM>. The inner chamber <NUM> may also include at least one thread <NUM>. The at least one thread <NUM> may be structured to receive at least one thread of a faucet attachment, for example a filter, an extension, and the like.

The outer chamber <NUM> is fluidly coupled to the second channel <NUM> at the second channel outlet <NUM>. In some embodiments, the outer chamber <NUM> is also fluidly coupled to the spray face <NUM>. In some embodiments, one of the sealing members <NUM> is positioned at or near the connection between the second channel <NUM> and the outer chamber <NUM> such that a fluid tight seal is formed between a surface of the inner body <NUM> and a surface of the outlet body <NUM> and fluid can flow from the inner body <NUM> to the outlet body <NUM> along a second (e.g., second flow path <NUM>, see <FIG>). Accordingly, the second follow path <NUM> flows through at least the inner body <NUM> and the outlet body <NUM>.

The inner sleeve <NUM> includes a proximal portion <NUM> and a distal portion <NUM>. The proximal portion <NUM> is positioned near the first pocket <NUM> and extends at least partially circumferentially around the inner body <NUM>. In some embodiments, and as described herein below, the proximal portion <NUM> may be operably coupled to the first shaft <NUM> and/or a portion of the inner body <NUM>.

The distal portion <NUM> is positioned near the outlet body <NUM> and extends at least partially circumferentially around the outlet body <NUM>. The distal portion <NUM> may include an extended portion <NUM> that selectively contacts an annular flange <NUM> of the spray face <NUM>. In some embodiments, the inner sleeve <NUM> is structured to be operable between a first position (as shown in <FIG>) and a second position (as shown in <FIG>). When the inner sleeve <NUM> is in the first position, the extended portion <NUM> does not contact the annular flange <NUM>. When the inner sleeve <NUM> is in the second position, the extended portion <NUM> contacts the annular flange <NUM>.

The outer sleeve <NUM> extends at least partially between the first end <NUM> and the second end <NUM>. The outer sleeve <NUM> at least partially contains the various components of the spray assembly <NUM>. In some embodiments, the outer sleeve <NUM> may be configured to have an ornamental exterior (e.g., brass, stainless steel, etc.). In additional embodiments, the ornamental exterior may be configured to match nearby fixtures in, for example, a kitchen environment.

The outer sleeve <NUM> is configured to at least partially surround the central body <NUM>, the outlet body <NUM>, the inner sleeve <NUM>, the spray face <NUM>, the first shaft <NUM>, the second shaft <NUM>, the third shaft <NUM>, and/or the springs <NUM>, <NUM>, and <NUM>. The outer sleeve <NUM> may also include an inner annular wall <NUM> that is configured to engage with or couple to the radial flange <NUM> of the inner body <NUM>, as described above. In some embodiments, the outer sleeve <NUM> may be coupled to the inner body <NUM> by a fastener (e.g., a screw, a bolt, etc.), by an adhesive, (e.g., glue, epoxy, etc.), by a snap fit arrangement, and/or by a molding process (e.g., over molding, etc.). In some embodiments, the outer sleeve <NUM> may be frictionally engaged with the inner body <NUM> and/or the inner sleeve <NUM>.

In some embodiments, the outer sleeve <NUM> has one or more openings shown as a proximal opening <NUM>, a distal opening <NUM>, and a lever opening <NUM>. The proximal opening <NUM> is structured to receive at least a portion of the inner body <NUM>. For example, the inlet portion <NUM> may at least partially extend through the proximal opening <NUM> such that the at least one thread <NUM> extends axially away from the proximal opening <NUM> of the outer sleeve <NUM>. The distal opening <NUM> is structured to allow fluid to flow out of the spray assembly <NUM>. For example, the distal opening <NUM> may allow fluid following the first flow path <NUM> and/or the second flow path <NUM> to flow out of the spray assembly <NUM>. The lever opening <NUM> is structured to receive the lever <NUM> such that the lever is operable to move between a plurality of positions (e.g., a first position, a second position, and a third position).

The spray face <NUM> is shown coupled to outlet body <NUM> at the outer chamber <NUM>. In some embodiments, the spray face <NUM> may be coupled to the outlet body <NUM> by a friction-fit coupling (e.g., press-fit/snap-fit). In other embodiments, the spray face <NUM> may be coupled to the outlet body <NUM> by an adhesive (e.g., glue, epoxy, etc.) or a fastener (e.g., bolt, pin, etc.) or over molded onto the outlet body <NUM>.

The spray face <NUM> may be substantially similar to or the same as the spray face <NUM>. For example the spray face <NUM> may be made of a polymer or elastic material or include portions that are made from an elastic material, such that at least a portion of the spray face <NUM> is selectively deformable. The spray face <NUM> is generally annular in shape and includes a plurality of nozzles <NUM> disposed about a perimeter of the spray face <NUM>. Each of the nozzles <NUM> is configured to receive a fluid through an inlet and provide the fluid via an outlet. The spray face <NUM> also includes an annular flange <NUM>. The annular flange <NUM> is configured to operate the nozzles <NUM> in a plurality of positions. As shown in <FIG>, the nozzles <NUM> and the annular flange <NUM> are in a first position of a plurality of positions. In the first position, the nozzles <NUM> are configured to provide fluid in a first pattern (e.g., a sweep pattern). In a second position as shown in <FIG>, the nozzles <NUM> are configured to provide fluid in a second pattern (e.g., a stream pattern). In some embodiments, when the nozzles are in positions between the first position and the second position, the nozzles <NUM> are configured to provide fluid in a pattern that is between the first pattern and the second pattern (e.g., a part-stream-part-sweep pattern).

The first shaft <NUM> is disposed at the first pocket <NUM>. In some embodiments, the first shaft <NUM> defines a first shaft inner volume <NUM> that is substantially hollow and structured to receive a first spring <NUM>. The first shaft <NUM> includes a domed portion <NUM> disposed at the lever <NUM>. The first shaft <NUM> is operable between a first position (as shown in <FIG>) and a second position (as shown in <FIG>). The first spring <NUM> is structured to bias the first shaft <NUM> to the first position. The first shaft <NUM> may be actuated (e.g., by the lever <NUM>) from the first position to the second position. For example, at least a portion of the lever <NUM> may contact the first shaft <NUM> at the domed portion <NUM> and depress the first shaft <NUM> by overcoming the biasing force of the first spring <NUM>.

In some embodiments, at least a portion of the first shaft <NUM> is operably coupled to the inner sleeve <NUM> such that, when the first shaft <NUM> is actuated from a first shaft first position to a first shaft second position, the first shaft <NUM> actuates the inner sleeve <NUM> from an inner sleeve first position to an inner sleeve second position.

The second shaft <NUM> is disposed at the second pocket <NUM>. In some embodiments, the second shaft <NUM> extends at least partially through the inner body <NUM> within the second pocket <NUM>. The second shaft <NUM> is pivotably coupled to the lever <NUM>. In some embodiments, the second shaft <NUM> includes an annular flange <NUM> that extends at least partially circumferentially around the second shaft <NUM>. The annular flange <NUM> is structured to contact the second spring <NUM> such that the second spring <NUM> is retained between the annular flange <NUM> and the shoulder <NUM> of the second pocket <NUM>. The second shaft <NUM> is operable between a first position (as shown in <FIG>) and a second position (as shown in <FIG>). The second spring <NUM> is structured to bias the second shaft <NUM> to the first position. The second shaft <NUM> may be actuated (e.g., by the lever <NUM>) from the first position to the second position. For example, the lever <NUM> may depress the second shaft <NUM> by overcoming the biasing force of the first spring <NUM>.

The third shaft <NUM> is disposed at the third pocket <NUM>. In some embodiments, the third shaft <NUM> extends at least partially through the inner body <NUM> within the third pocket <NUM>. In some embodiments, the third shaft <NUM> is a valve shaft structured to direct the fluid flow within the inner body <NUM>. For example, the third shaft <NUM> may be structured to selectively direct a fluid that enters the inner body <NUM> at the inlet portion <NUM> to at least one of the first channel <NUM> and the second channel <NUM>.

As shown in <FIG>, the third shaft <NUM> includes one or more sealing members (e.g., O-ring, gasket, etc.) shown as sealing members <NUM>. One or more of the sealing members <NUM> may be structured to form a fluid-tight seal between the third shaft <NUM> and the inner body <NUM>. In some embodiments, the third shaft includes a valve pin <NUM> disposed at the lever <NUM>. The valve pin <NUM> is structured to be actuated by a track portion <NUM> of the lever <NUM>. In some embodiments, the third shaft also includes a valve shaft <NUM> and a valve body <NUM>. In some embodiments, one or more of the sealing members <NUM> may form a seal between the valve body <NUM> and the valve shaft <NUM>. In some embodiments, the valve shaft <NUM> is operable between a first valve position (shown in <FIG>) and a second valve position (shown in <FIG>). That is, the valve shaft <NUM> is movable relative to the valve body <NUM>. In some embodiments, the third spring <NUM> is positioned between the valve shaft <NUM> and the valve body <NUM>. The third spring <NUM> is structured to bias the valve shaft <NUM> in the first valve position. In some embodiments, the lever may actuate the valve shaft <NUM> when the lever <NUM> is depressed. In some embodiments, the valve pin <NUM> follows the track portion <NUM> as the lever <NUM> is depressed thereby moving the valve shaft <NUM> from the first valve position to the second valve position. In the first valve position, the valve shaft <NUM> is structured to direct a fluid from the inlet portion <NUM> to the first channel <NUM>. For example, at least one of the sealing members <NUM> may form a seal between the valve shaft <NUM> and the inner body <NUM> such that a fluid is substantially prevented from flowing from the inlet portion <NUM> to the second channel <NUM>.

The lever <NUM> is disposed at the lever opening <NUM>. The lever <NUM> at least partially extends radially away from the outer sleeve <NUM>. The lever <NUM> is an elongated member that is configured to be operable in a plurality of positions. As shown in <FIG>, the lever <NUM> is normally in a first position of the plurality of positions. The lever <NUM> is structured to actuate the first shaft <NUM>, the second shaft <NUM>, and the third shaft <NUM> as the lever is operated through the plurality of positions. The plurality of positions may include a first position (shown in <FIG>), a second position (shown in <FIG>), and a third position (shown in <FIG>). The lever includes a distal flange <NUM> that extends axially towards the spray assembly second end <NUM>. The distal flange <NUM> is structured to contact the outer sleeve <NUM> such that the lever <NUM> is substantially retained at least partially within the outer sleeve <NUM>. In some embodiments, the lever <NUM> also includes a first flange <NUM>, a second flange <NUM>, and a track portion <NUM>. The first flange <NUM> is structured to contact the domed portion <NUM> of the first shaft <NUM> when the lever is operated from the second position to the third position. As the lever is operated from the second position to the third position, the first flange <NUM> may follow the curvature of the domed portion <NUM> such that the lever continuously contacts the first shaft <NUM>. The second flange <NUM> is structured to pivotably couple to the second shaft <NUM> such that the lever may selectively pivot about the second shaft <NUM>. The track portion <NUM> is structured to at least partially retain the valve pin <NUM> such that the track portion <NUM> actuates the valve pin <NUM> and the valve shaft <NUM> as the lever <NUM> is operated from the first position to the second position.

In the first position, the lever <NUM> is in a normally open position (i.e., the lever <NUM> is not depressed). Also in the first position, the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> are configured to be in a steady-state position. The first shaft <NUM>, the second shaft, <NUM>, and the third shaft <NUM> are each in a respective first position such that a fluid may flow along the first fluid path <NUM> (shown by a dotted line) from the inlet portion <NUM> to the first channel <NUM> and out of the spray assembly <NUM> via the outlet body <NUM>.

<FIG> is a cross section view of the spray assembly <NUM> of <FIG>, shown in a second position. In an exemplary embodiment, a user may actuate the lever <NUM> by applying a force (shown as force F) to at least a portion of the lever <NUM>. As the lever <NUM> is actuated from the first position to the second position, the lever pivots about the second shaft <NUM> and actuates the third shaft <NUM> (e.g., the valve shaft <NUM>). For example, as the lever <NUM> is pivoted about the second shaft <NUM>, a distal portion of the lever <NUM> is actuated radially inward, towards the inner body <NUM> (e.g., downward) and a proximal portion of the lever <NUM> is actuated radially away from the inner body <NUM> (e.g., upward). As the proximal portion of the lever <NUM> is actuated away from the inner body <NUM>, the valve pin <NUM> is retained within the track portion <NUM> such that the valve shaft <NUM> is actuated in the same direction (e.g., radially towards the lever <NUM>). In some embodiments, the third spring <NUM> may be compressed between the valve shaft <NUM> and the valve body <NUM> as the valve shaft <NUM> is actuated. Accordingly, as the lever <NUM> is operated the third spring <NUM> may provide a third resistance to actuating the lever. As the lever <NUM> is operated, the second spring <NUM> biases the second shaft <NUM> towards the lever <NUM>. Accordingly, as the lever <NUM> is operated the second spring <NUM> may provide a second resistance to actuating the lever. The second resistance may be substantially greater than the third resistance such that the second shaft <NUM> is substantially biased in a second shaft first position while the lever <NUM> is operated from the first lever position to the second lever position.

In an exemplary embodiment, the third resistance may be less than the second resistance. For example, the second spring <NUM> may have a higher spring constant (i.e., stiffness) than the third spring <NUM>. In some embodiments, the second resistance and the third resistance may be provided in series, concurrently, or partially concurrently. The resistances provided by the first spring <NUM>, the second spring <NUM>, and the third spring <NUM> may be configured to provide tactile feedback to a user to indicate that the spray mode is changing. As the lever <NUM> is operated from the first position to the second position, the second spring <NUM> is not substantially deflected such that the second shaft <NUM> is stationary and the lever pivots about the second flange <NUM> at the second shaft <NUM>. In some embodiments, the third spring <NUM> is full compressed by the lever <NUM> when the lever <NUM> is in the second position. In some embodiments, the first spring <NUM> is not compressed by the lever <NUM> because the first flange <NUM> does not contact the first shaft <NUM> until the lever <NUM> is in the second position. For example, the load of the lever <NUM> is the third shaft <NUM> and the stiffness of the third spring, the fulcrum is at the second shaft <NUM>, and a force F is applied to the lever (e.g., by a user) as shown in <FIG>.

In the lever second position, the lever <NUM> is in a partially closed/depressed position. In some embodiments, while the lever <NUM> is in the second position, the third spring <NUM> is fully compressed such that the valve shaft <NUM> is substantially prevented from being further actuated towards the lever <NUM>. The second spring <NUM> is substantially uncompressed and/or may be partially compressed such that the second shaft <NUM> remains in a second shaft first position. The first flange <NUM> may not yet contact or just contact the domed portion <NUM> of the first shaft <NUM> such that the first shaft <NUM> remains in a first shaft first position.

When the lever <NUM> is in the second lever position, the valve shaft <NUM> is in the second valve position. In the second valve position, the valve shaft <NUM> is structured to direct a fluid from the inlet portion <NUM> to the second channel <NUM> along a second flow path <NUM>. For example, At least one of the sealing members <NUM> of the valve shaft <NUM>, when the valve shaft <NUM> is in the second (e.g., open) valve position is structured to form a fluid tight seal with the valve body <NUM> such that the fluid may flow to the second channel <NUM> and is substantially prevented from flowing to the first channel <NUM>. In some embodiments, the fluid flows along the second flow path <NUM> such that the outer chamber <NUM> receives fluid from second channel <NUM> and through the spray face <NUM> as the fluid flows out of the outer chamber <NUM>.

<FIG> is a side perspective view of the spray assembly of <FIG>, shown in the second position. As shown, a plate <NUM> may be disposed on an outer surface of the inner body <NUM> to form a fluid tight seal thereon. The plate <NUM> may be positioned to enclose the first channel <NUM> such that fluid flowing along the first flow path <NUM> is substantially prevented from leaking out the side of the inner body <NUM>.

In some embodiments, and as shown in <FIG>, the first shaft <NUM> is operably coupled to the inner sleeve by a pin-track arrangement. For example, the first shaft <NUM> may include a pin <NUM>. The pin <NUM> may be structured to at least partially extend through a portion of the inner sleeve <NUM>. For example, the pin <NUM> may at least partially extend through a track portion <NUM> of the inner sleeve <NUM>. In some embodiments, the first shaft <NUM> is structured to operate the inner sleeve <NUM> from a first sleeve position to a second sleeve position when the first shaft is operated from a first shaft first position (shown in <FIG>) to a first shaft second position (shown in <FIG>).

<FIG> is a cross section view of the spray assembly <NUM> of <FIG>, shown in a third position. In an exemplary embodiment, a user may actuate the lever <NUM> from the second position to the third position by applying a force (shown as force F) to at least a portion of the lever <NUM>. As the lever <NUM> is operated from the second position to the third position (e.g., a fully closed/depressed position) the lever <NUM> pivots about the stationary valve pin <NUM> of the third shaft <NUM>. The lever <NUM> actuates the first shaft <NUM> and the second shaft <NUM> as the lever <NUM> is actuated from the second position to the third position. For example, as the lever <NUM> is pivoted about the valve pin <NUM>, the distal portion of the lever <NUM> is actuated radially inward, towards the inner body <NUM> (e.g., downward). As the distal portion of the lever <NUM> is actuated towards the inner body <NUM>, the first shaft <NUM> and the second shaft <NUM> are actuated radially away from the lever <NUM>. In some embodiments, the first spring <NUM> may be compressed between an inner surface of the first shaft <NUM> and the first pocket <NUM> as the first shaft <NUM> is actuated. In some embodiments, the second spring <NUM> is compressed between the annular flange <NUM> and the shoulder <NUM> as the second shaft <NUM> is actuated. Accordingly, as the lever <NUM> is actuated form the second position to the third position, the first spring <NUM> and the second spring <NUM> may provide a first resistance and a second resistance, respectively, to actuating the lever <NUM>. The first resistance may be provided concurrently or partially concurrently with the second resistance, or the second resistance may be provided serially after the first resistance. The resistances provided by the springs <NUM>, <NUM>, <NUM> may be configured to provide tactile feedback to a user to indicate that the spray mode is changing.

As the lever <NUM> is actuated from the second position to the third position, the fulcrum of the lever changes from the first flange <NUM> rotating around the second shaft <NUM> to the track portion <NUM> rotating around the valve pin <NUM>. The "load" of the lever <NUM> changes from the valve shaft <NUM> to the second shaft <NUM> and/or the first shaft <NUM>. The force applied by the user remains at the distal end of the lever <NUM>. Accordingly, the spray assembly <NUM> includes a moving fulcrum feature (e.g. changing from a location on the lever <NUM> corresponding to the second shaft <NUM> to the third shaft <NUM>) that is structured to assist in changing spray modes within the spray assembly <NUM>.

When the lever <NUM> is in the third lever position, the first shaft <NUM>, the second shaft <NUM>, and the third shaft <NUM> are each in a respective second position. For example, the valve shaft <NUM> is in the second valve position. In the second valve position, the valve shaft <NUM> is structured to direct a fluid from the inlet portion <NUM> to the second channel <NUM> along a second flow path <NUM>. The second shaft <NUM> is in a second shaft second position. The first shaft <NUM> is in a first shaft second position. When the lever <NUM> is in the third position, the springs <NUM>, <NUM>, <NUM> are each at least partially compressed. For example, when the lever <NUM> is in the third position (i.e., a fully closed/depressed position) the third spring <NUM> is fully compressed, the second spring <NUM> is at least partially compressed and/or is substantially more compressed compared to the lever second position, and the first spring <NUM> is at least partially compressed.

<FIG> is a side perspective view of the spray assembly of <FIG>, shown in the third position. In some embodiments, when the first shaft <NUM> is actuated from the first position to the second position (e.g., by the lever <NUM> as described above with respect to <FIG>), the pin <NUM> is structured to actuate the inner sleeve <NUM> from a first sleeve position to a second sleeve position by following the track portion <NUM>. In some embodiments, the pin <NUM> may actuate the inner sleeve <NUM> from the second sleeve position to the first sleeve position when the first shaft is returned to the first shaft first position.

In some embodiments and as shown in <FIG>, at least a portion of the first shaft <NUM> extends circumferentially around the radial flange <NUM> when the first shaft <NUM> is in the first shaft second position.

<FIG> is a detailed section view of the spray assembly of <FIG>, shown in the third position. When the inner sleeve <NUM> is actuated from the first sleeve position to the second sleeve position, the inner sleeve <NUM> is configured to actuate the annular flange <NUM> of the spray face <NUM> such that one or more of the nozzles <NUM> are deflected inward towards a central axis <NUM> of the spray assembly <NUM>. When directed in this manner, the nozzles <NUM> are configured to provide a concentrated stream spray.

Referring to <FIG> in general, when a user releases the lever <NUM>, the springs <NUM>, <NUM>, <NUM> will bias the first shaft <NUM>, the second shaft <NUM>, and the third shaft <NUM> back to the respective first positions, the first shaft <NUM> will actuate the inner sleeve <NUM> to the first position and the nozzles <NUM> will bias or return back to their original position.

As utilized herein with respect to numerical ranges, the terms "approximately," "about," "substantially," and similar terms generally mean +/- <NUM>% of the disclosed values, unless specified otherwise. As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms "approximately," "about," "substantially," and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

The term "coupled" and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If "coupled" or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of "coupled" provided above is modified by the plain language meaning of the additional term (e.g., "directly coupled" means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of "coupled" provided above. Such coupling may be mechanical, electrical, or fluidic.

Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above.

Claim 1:
A spray assembly (<NUM>) comprising:
an inner chamber (<NUM>) defining a first fluid outlet (<NUM>) for providing a fluid in a first spray mode of a plurality of spray modes; and
an outer chamber (<NUM>) disposed radially outward from the inner chamber (<NUM>);
a spray face (<NUM>) fluidly coupled to the outer chamber (<NUM>) and comprising one or more nozzles (<NUM>), the one or more nozzles (<NUM>) configured to be moved between a plurality of nozzle positions such that the spray face (<NUM>) selectively provides the fluid in at least a second spray mode and a third spray mode;
a plurality of shafts (<NUM>, <NUM>, <NUM>) configured to be selectively movable between a plurality of shaft positions such that the spray assembly (<NUM>) selectively provides the fluid in the plurality of spray modes;
a lever (<NUM>) configured to be selectively operable in a plurality of lever positions such that the lever (<NUM>) operates the plurality of shafts (<NUM>, <NUM>, <NUM>) in the plurality of shaft positions;
a moving fulcrum structured to change a location of a fulcrum of the lever (<NUM>) such that the fulcrum changes as the lever (<NUM>) is operated through the plurality of lever positions; and
a plurality of sleeves (<NUM>, <NUM>), a first sleeve (<NUM>) of the plurality of sleeves configured to move the one or more nozzles (<NUM>) of the spray face (<NUM>).