US20040117906A1 - Faucet with underbody - Google Patents

Abstract

A faucet body (10) is molded from a plastic material and coupled to an underbody that is likewise molded from a plastic material. The unitary faucet body includes a spout portion (12) and a base portion (14). The underbody comprises a manifold (40) including an inlet (48) and an outlet (50). An end body (24) is coupled to the manifold and to the base portion. The end body includes means for coupling the faucet body to the manifold. A valve (96) is coupled to the end body. Alternatively, the faucet spout and base can be molded as a unitary structure using a lost core method, thereby eliminating the need for a separate manifold.

Description

• The present invention relates generally to faucets having an underbody and a faucet body that fits over the underbody and, in particular, to faucets that use a common underbody with multiple faucet body configurations. The faucet body and underbody can be molded together as a unitary structure using lost core methodologies. The invention is further related to faucets that have a reduced number of waterway parts and use the end bodies to hold a cartridge seal and orient the cartridge. In addition, the invention relates to faucet bodies that are molded from plastic and can be mounted on a sink deck without an intervening putty plate.[0001]
BACKGROUND AND SUMMARY OF THE INVENTION
• Conventional faucets are made using a brass casting that is machined to provide water inlets and a water outlet. A finishing cover, usually made of chrome plated metal, is used to cover the finished casting and provide a more pleasing appearance. A brass faucet is polished and plated. In some cases, the spout is formed from brass tubing that is plated, bent to the desired shape, and joined to a casting. Unfortunately, casting and machining brass is expensive in terms of time, labor, and material.[0002]
• Another disadvantage with conventional faucets is related to the brass composition. Some brass compositions contain lead that can leach out of the brass into the water passing through the faucet. It would be advantageous, therefore, to provide an alternative material that would be cheaper to produce while eliminating the possibility of lead leaching into the drinking water.[0003]
• The present invention overcomes these and other disadvantages by providing a faucet body molded from a plastic material and coupled to an underbody that is likewise molded from a plastic material. The use of a molding process is cheaper that casting and machining, and the use of plastic material eliminates the possibility of lead leaching into the drinking water. In preferred embodiments, the plastic faucet body is covered with a metallic coating to provide a more pleasing appearance.[0004]
• According to the present invention, a two-handled faucet assembly comprises a unitary faucet body, a manifold, at least one end body, and a valve. The unitary faucet body includes a spout portion and a base portion, wherein the spout portion includes a water passage and the base portion includes at least one hole for receiving the end body. The manifold includes in inlet and an outlet and the end body is coupled to the manifold and to the base portion. The end body further includes means for coupling the faucet body to the manifold. The valve is coupled to the end body.[0005]
• According to one aspect of the invention, the manifold includes a first portion coupled to the faucet body base portion and a second portion coupled to the spout portion. The faucet body portion defines a pair of end body-receiving holes and includes an alignment feature disposed adjacent each end body-receiving, hole to prevent improper alignment of the end body relative to the manifold.[0006]
• According to another aspect of the invention, the end body includes a first retainer nut and a second retainer nut, the first retainer nut retaining the end body in the end body-receiving hole. The first and second retainer nuts cooperate to couple the faucet assembly to a sink deck.[0007]
• One embodiment of the invention is formed using lost core technology. The faucet includes a spout having a first water passage and a base having a second water passage in fluid communication with the first water passage. The spout and base are molded as a unitary structure around a fusible core that is later removed from the unitary structure, the void left by the fusible core defining the first and second passages.[0008]
• Other features and advantages of the invention will become apparent from the following portion of this specification and from the accompanying drawings, which illustrate a presently preferred embodiment incorporating the principles of the invention.[0009]
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a top view of a faucet body for use with the present invention.[0010]
• FIG. 2 is a front view of the faucet body of FIG. 1.[0011]
• FIG. 3 is a bottom view of the faucet body of FIG. 1.[0012]
• FIG. 4 is a section view taken along line[0013]4-4 of FIG. 2.
• FIG. 5 is a section view taken along line[0014]5-5 of FIG. 1.
• FIG. 6 is an end view of an underbody for use with the invention.[0015]
• FIG. 7 is a front view, partially broken away, of the underbody of FIG. 6.[0016]
• FIG. 8 is a bottom view of the underbody of FIG. 6.[0017]
• FIG. 9 is a partial section view taken along line[0018]9-9 of FIG. 7.
• FIG. 10 is a front view, partially broken away, of an assembled faucet incorporating the faucet body and underbody of the present invention.[0019]
• FIG. 11 is a side view of an end body.[0020]
• FIG. 12 is a section view taken along the longitudinal axis of the end body of FIG. 11.[0021]
• FIG. 13 is a top view of the end body of FIG. 11.[0022]
• FIG. 14 is an exploded perspective view of a valve for use in the present invention.[0023]
• FIG. 15 is a section view taken along the longitudinal axis of the valve of FIG. 14.[0024]
• FIG. 16 is a bottom view of the stem of the valve in FIG. 14.[0025]
• FIG. 17 illustrates an alternative embodiment of the invention manufactured using a lost core method.[0026]
DETAILED DESCRIPTION
• FIGS.[0027]1-5 illustrate afaucet body10 according to the present invention. Thefaucet body10 is preferably injection molded as a single piece using gas assisted injection molding techniques and then coated or plated as desired to provide a pleasing finish acceptable to consumers. Thefaucet body10 includes aspout portion12 and abase portion14. As illustrated in FIG. 3, thebase portion14 further includes a perimetral seal-receivingchannel16, a pair of fastener-receivingmembers18, and a pair of end body-receivingbores20. Each of the end body-receivingbores20 includes a plurality ofribs22 spaced around the perimeter of theirrespective bores20 and projecting inwardly therefrom. Preferably, each bore includes fiveribs22 spaced at 60° intervals around the perimeter, with a gap in the spacing provided at the point closest to thespout portion12. Theribs22 provide support and alignment for a hexagonal portion of an end body24 (FIG. 10), and prevent the end body from rotating in thebore20.
• As illustrated in FIG. 4, the[0028]spout portion12 includes awater passage26 and achannel28 for receiving a pop-up knob30 (FIG. 10) for operating a drain sub-assembly (not shown). Thespout portion12 includes anoutlet32 with internal or external threads for coupling an aerator34 (FIG. 10) to thespout portion12. Thewater passage26 includes astepped inlet36 that extends through thebase portion14 and into thespout portion12. Thewater passage26 continues from thestepped inlet36 through thespout portion12 to theoutlet32.
• A[0029]water manifold40 according to the present invention is illustrated in FIGS.6-9. Thewater manifold40 includes abase46, a pair ofwater inlets48 and awater outlet50, preferably molded as a unitary piece. Thebase portion46 includes afirst end54 and asecond end56, with thefirst end54 including a pair of fastener-receivingholes58 and acentral bore60. Eachinlet48 includes a tubular member62 extending from theoutlet50. When thewater manifold40 is mounted in thefaucet body10, the tubular members62 extend to the end body-receivingbores20 to engage anend body outlet66, as illustrated in FIG. 10. Themanifold outlet50 includes a tube with astepped sidewall70 that is configured to match and engage thestepped inlet36 of thewater passage26. An O-ring can be installed between themanifold outlet50 and the steppedinlet36 to ensure a watertight seal.
• The[0030]base portion46 is configured to fit in thebase portion14 of thefaucet body10, with the fastener-receivingholes58 aligned with the fastener-receivingmembers18. The underbody40 is attached to thebase portion14 by fasteners, such as screws, that are passed through the fastener-receivingholes58 to engage the fastener-receivingmembers18. When the underbody40 is attached to thebase portion14, thecentral bore60 aligns with thechannel28 to allow the pop-upknob30 to pass through thefaucet body10 andwater manifold40 to engage the drain sub-assembly (not shown). In preferred embodiments, the first and second ends54,56 are contoured to match and abut the perimeter of thefaucet body10 to provide additional stability for the mountedwater manifold40.
• The[0031]end body24, as illustrated in FIGS.11-13, includes an externally threaded tubularlower portion76 and anupper portion78 having anoutlet66 and upper and lowerhexagonal flanges80 extending around the perimeter of theupper portion78. Thehexagonal flanges80 are sized to engage theribs22 in the end body-receivingbore20 so that theoutlet66 is directed to engage theunderbody water inlet48. The separation between the upper andlower flanges80 provides longitudinal stability to theend body24.
• The[0032]upper portion78 also includesinternal threads84,external threads85, a cappingwall82 that caps thelower portion76, and a bow tie-shapedwater inlet86. The bow tie-shape is “closed” by a firstarcuate member86athat extends between the two upper arms of the bow tie and a secondarcuate member86bthat extends between the two lower arms of the bow tie, thereby forming a pair of generally triangular openings. The bow tie shape of thewater inlet86 is defined by upwardly extendingsidewalls88 and includes an bow tie-shapedfloor90 with a pair oftriangular holes94 passing through the cappingwall82 to the tubularlower portion76. Thesidewalls88 and thefloor90 cooperate to receive and support a resilient bow tie-shaped seal92 (FIG. 14).
• A[0033]valve96 for use with theend body24 is illustrated in FIGS.14-16. Thevalve96 includes astem98, ahousing100, and avalve disk102 and is held in position by a nut engaging theinternal threads84. An O-ring104 can be installed with thevalve96 to provide a watertight seal. Thestem98 includes asplined portion108 and abase plate110. Thebase plate110 extends radially outwardly from the perimeter of thestem98 and includes a bow tie-shapedprojection114 depending downwardly from theplate110. The bow tie-shapedprojection114 is substantially similar in size and configuration to the bow tie-shapedinlet86 and is disposed on theplate110 to align with theinlet86 when thevalve96 is in the closed position. Askirt116 depends downwardly from the edge of the bow tie-shapedprojection114 in twosegments120,122 where the edge of theprojection114 coincides with the edge of theplate110. Eachsegment120,122 includes abreak124,126, respectively, for receiving thevalve disk102. Preferably, thebreaks124,126 are not the same size and are not located on a common diameter of theplate110 to prevent misalignment of thevalve disk102.
• The[0034]valve disk102 is a generally circular plate having a pair oftriangular holes128 and a pair oftabs132,134 extending radially from thedisk102. Thedisk102 is sized and configured to allow thedisk102 to fit snuggly against theskirt segments120,122. Thetabs132,134 fit in thebreaks124,126, respectively, in theskirt segments120,122 to provide for proper alignment of thedisk102 on thestem98. When thedisk102 is properly installed, the disktriangular holes128 are disposed outside the bow tie-shape of theprojection114. Thus, when the disktriangular holes128 are aligned with the inlet triangular holes94, thevalve96 is in the open position. When thevalve stem98 is rotated 90°, the disktriangular holes128 are no longer aligned with the inlet triangular holes94. Instead, the remaining unbroken portion of thedisk102 is aligned with the inlet triangular holes94, thereby blocking flow of water through thevalve96, and thevalve96 is closed.
• The[0035]water manifold40 is coupled to theend bodies24 by inserting theend body outlets66 into thewater inlets48 to form an underbody. The underbody is then assembled with thefaucet body10 by inserting theend bodies24 in the end body-receivingbores20 and threading a retaining nut106 (FIG. 10) onto theexternal threads85 of theend body24 to abut thebase portion14 of thefaucet body10. Alternatively, theend bodies24 can be retained in thefaucet body10 by a hub and handle combination, wherein the hub is configured to threadedly engage theexternal threads85 of theend body24. Thebase46 of thewater manifold40 is then attached to thefaucet body10 by screws or other fasteners. The retaining nuts, thehexagonal flanges80, and the screws cooperate to hold the underbody firmly in place in thefaucet body10. Adding the desired handles and hubs to operate and cover the valves completes the faucet assembly. The faucet assembly is mounted to a sink deck by inserting theend bodies24 through holes in the sink deck and threading retaining nuts140 (FIG. 10) onto theend bodies24.
• The resulting faucet assembly is relatively inexpensive to produce and assemble, thereby providing a cost advantage to the manufacturer. In addition, the faucet assembly includes fewer parts than a conventional faucet, thereby reducing the number of parts in inventory for additional cost savings. Moreover, the underbody can provide a common base for use with other faucet body designs, allowing for faster development of new faucet designs and providing a marketing advantage to the manufacturer.[0036]
• It will be understood by one of ordinary skill in the art that the fasteners may not be necessary and the underbody can be coupled to the faucet body by just the end bodies. The geometry of the underside of the faucet body can be designed to conform to the shape of the underbody to prevent movement of the underbody once the underbody is in position within the faucet body and prevent the end bodies from separating from the manifold. The retainer nuts would couple the underbody to the faucet.[0037]
• In an alternative embodiment of the invention, illustrated in FIG. 17, the[0038]entire faucet body210, including thespout portion212 and thebase portion214, is molded as a single unit using lost core methodologies. The lost core method includes the step of forming a core member (not shown), from a fusible material that defines the contours of the internal passages of the spout and base. The core member is then positioned in a mold of the faucet body and plastic is injected into the mold. After the plastic solidifies, the faucet body is removed from the mold and the core member is melted from the interior of the faucet body. The void caused by the removal of the core defines the internal passage of the spout and base. Of course, an important consideration in the choice of fusible material is its ability to retain its shape during the molding process, yet melt out of the interior of the plastic faucet body without damaging the faucet body. Several advantages flow from the use of lost core methodologies, such as the reduction in the number of parts, a reduction in the number of assembly steps, and a reduction in inventory costs.
• A faucet with underbody has been described with respect to a presently preferred embodiment. However, it will be understood that various modifications can be made within the scope of the invention as claimed below[0039]

Claims (10)

1. A two-handled faucet assembly comprising:

a unitary faucet body having a spout portion and a base portion, the spout portion including a water passage and the base portion including at least one hole for receiving an end body;

a manifold having in inlet and an outlet;

at least one end body coupled to the manifold and to the base portion, the end body including means for coupling the faucet body to the manifold; and

a valve coupled to the end body.

2. The faucet assembly ofclaim 1 wherein the manifold includes a first portion coupled to the faucet body base portion and a second portion coupled to the spout portion.

3. The faucet assembly ofclaim 1 wherein the body portion defines a pair of end body-receiving holes and includes an alignment feature disposed adjacent each end body-receiving hole to prevent improper alignment of the at least one end body relative to the manifold.

4. The faucet assembly ofclaim 3 wherein the at least one end body includes a first retainer nut for retaining the end body in the at least one end body-receiving hole.

5. The faucet assembly ofclaim 4 wherein the at least one end body includes a second retainer nut, the first and second retainer nuts cooperating to couple the faucet assembly to a sink deck.

6. A two-handled faucet assembly comprising:

a molded one-piece faucet body having a spout and a base portion with a water passage with an inlet, the base portion including at least one hole for receiving an end body;

a molded underbody having a base portion, a water inlet and a water outlet, the underbody being coupled to the faucet body with the underbody water outlet engaging the base water passage inlet.

7. The faucet assembly ofclaim 6 further including at least one end body coupled to the water inlet, wherein the at least one end body includes a first retainer nut for coupling the at least one end body to the faucet body.

8. The faucet assembly ofclaim 7 wherein the at least one end body includes a second retainer nut, the first and second retainer nuts cooperating to couple the faucet assembly to a sink deck.

9. The faucet assembly ofclaim 6 wherein the base portion includes a plurality of alignment ribs disposed adjacent the at least one hole, the alignment ribs facilitating proper alignment of the end body relative to the underbody.

10. A faucet assembly comprising:

a spout having a water passage;

a base having an underbody, the underbody including a water passage in fluid communication with the spout water passage, the spout and base being molded as a single unit; and

at least on valve coupled to the base for controlling a flow of water to the spout.

A faucet assembly comprising:

a spout having a first water passage; and

a base having a second water passage in fluid communication with the first water passage, the spout and base being formed as a unitary structure using a lost core technique.

A faucet assembly comprising:

a spout having a first water passage; and

a base having a second water passage in fluid communication with the first water passage, the spout and base being a unitary structure molded around a fusible core, wherein the fusible core is removed from the molded unitary structure to provide the first and second passages.

Images