Faucet having magnetic spray head

Abstract

A faucet includes a spout defining a non-linear internal passage extending between an inlet and an outlet. The faucet includes a spray head movable between a docked position adjacent to the outlet region and an undocked position. The faucet includes a docking assembly positioned within the internal passage of the spout. The docking assembly includes a main body that engages a portion of the spray head. The docking assembly includes a top body that allows a flexible hose provided within the internal passageway to pass therethrough, and the top body secures at least one magnet within the passageway. The docking assembly includes an arm positioned between and securing the top body to the main body. The arm permits the top body to move relative of the main body when the docking assembly is positioned within the internal passage of the spout.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 63 / 780,036 filed on Mar. 28, 2025, the entire disclosure of which is incorporated herein in its entirety by reference.FIELD

[0002] The subject matter disclosed herein generally relates to a faucet having a magnetic spray head.BACKGROUND

[0003] Many kitchen faucets utilize a spray head that is connected to a flexible spray hose, and the spray head is removeable from the spout. The spray head may be removed and used by the user, and the spray head may be returned and docked with the end of the spout. Various mechanisms have been used to retract and dock the spray head to the spout including magnets and counterweights. There remains a need for an improved mechanism to secure the spray head to the spout.SUMMARY

[0004] Briefly, and in general terms, various faucets having a magnetic spray head are disclosed herein. In one embodiment, the faucet includes a spout defining a non-linear internal passage extending between an inlet region and an outlet region. The faucet includes a spray head that is movable between a docked position adjacent to the outlet region and an undocked position. The faucet includes a hose that extends through the non-linear internal passage and coupled to the spray head. The faucet includes a docking assembly located proximate to the outlet region. In one embodiment, the docking assembly includes a main body defining an inner bore and an outer bore, wherein the hose passes through the inner bore, and a portion of the spray head engages the main body when the spray head is in the docked position. The docking assembly includes a top body defining an inner bore and an outer bore, wherein the hose passes through the inner bore of the top body. The docking assembly includes an arm positioned between the top body and main body, wherein the arm secures the top body to the main body, and the arm permits the top body to move relative to the main body within the non-linear passage of the spout. The docking assembly includes at least one magnet secured within the inner bore of the top body.

[0005] In another embodiment, a docking assembly is positionable within an internal passage of a spout. The docking assembly includes a main body defining an inner bore and an outer bore, wherein the main body engages at least a portion of a spray head. The docking assembly includes a top body defining an inner bore and an outer bore, wherein a flexible hose provided within the faucet passageway passes through the inner bore. The docking assembly includes an arm positioned between the top body and main body, wherein the arm secures the top body to the main body, and the arm permits the top body to move relative of the main body when the docking assembly is positioned within the internal passage of the spout. The docking assembly includes at least one magnet is secured within the inner bore of the top body.

[0006] Other features and advantages will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate by way of example, the features of the various embodiments.BRIEF DESCRIPTION OF DRAWINGS

[0007] FIG. 1 is a perspective view of one embodiment of the magnetic spray head.

[0008] FIG. 2 is an exploded view of a portion of the magnetic spray head.

[0009] FIG. 3 is a perspective view of the magnetic spray head shown in FIG. 2.DETAILED DESCRIPTION

[0010] Briefly, and in general terms, various faucets having a magnetic spray head are disclosed herein. The faucet includes a docking assembly that is fixed within the bore of the spout outlet. The docking assembly positions a magnet within the spout outlet. The magnet captures and orients the spray head at the spout outlet. Additionally, the docking assembly is configured to permit the retainer-magnet assembly to be used in a wide variety of faucets configurations such as, but not limited to, faucets having a straight pipe as well as faucets having curved pipes with different curvatures. This allows a magnetic spray head to be utilized in a wide variety of faucet configurations.

[0011] FIG. 1 illustrates an exploded perspective view of one embodiment of a faucet 10. The faucet includes a spout 12 having a water outlet 14 and a water inlet 16. The water inlet is coupled to a water source (not shown). The flow of water in the faucet 10 is controlled by a faucet lever 18. A spray head 20 is positioned at the outlet 14 of the spout 12. The spray head 20 is connected to a flexible hose 26 (a portion of the hose shown) by a connector 24. The flexible hose 26 is positioned within the inner bore of the spout 12. The flexible hose 26 extends or retracts within the inner bore of the spout 12 as the spray head 20 is pulled away from the spout or returned to the spout outlet 14. As those skilled in the art will appreciate, the location the docking assembly within the spout outlet will vary depending on the shape and configuration of the spray head and the faucet outlet.

[0012] FIGS. 2-3 illustrate one embodiment of a docking assembly 28 removed from the spout outlet (not shown). The docking assembly 28 is a generally cylindrical structure having an inner wall defining an inner bore and an outer wall defining an outer bore. The docking assembly 28 includes a main body 28a, a top body 28b, an arm 28g positioned between the main body and top body. One end of the docking assembly (spray head holder) includes a lip 28d extending away from the outer wall, in which the lip engages the outlet of the spout, when the spray head holder is inserted into the faucet.

[0013] As shown in FIGS. 2-3, the main body 28a of the spray head holder 28 is a generally cylindrical structure having an inner wall defining an inner bore and an outer wall defining an outer bore. As shown in FIGS. 2-3, the inner and outer bores taper moving from the bottom of the main body 28a to the top of the main body. In another embodiment, the inner and outer bores are uniform. As those skilled in the art will appreciate, the inner and outer bores may have variable diameters depending upon the design and shape of the inner bore of the faucet and the configuration of the spray head. In FIG. 3, the top edge of the main body 28a is radiused to create a beveled edge. Also, as shown in FIGS. 2-3, the outer bore of the main body 28a includes a plurality of rectangular protuberances 30 that project from the outer bore.

[0014] In other embodiments, the outer bore of the main body includes one or more protuberances having different shapes, such as but not limited to, squares, circles, and ovals and may have varying heights (i.e., distance raised from the surface of the outer bore). In other embodiments, the outer bore is provided with no protuberances. In yet other embodiments, the outer bore is included with one or more channels that recess into the surface of the outer bore. In another embodiment, the outer bore includes protuberances and channels. As those skilled in the art will appreciate, the channels may be rectangular grooves or other shaped channels. In these embodiments, the protuberances and grooves may mate or engage with corresponding protuberances or grooves on the distal portion of the bore of the faucet. The protuberances and grooves may aid in securing the main body of the spray head holder within the inner bore of the faucet.

[0015] As shown in FIG. 2, one embodiment of the main body 28a includes multiple cut-outs so that the remaining portions of the main body in this area form a resilient member 28h. A protuberance 28c is provided on the resilient member 28h. The resilient member 28h allows a portion of the main body 28a to deflect or expand as the spray head 20 (or a portion of the spray head such as the spray head connector or flexible hose) enters the main body of the spray head holder to secure the spray head in a retracted position. As shown in the figures, the protuberance 28c has a circular shape. As those skilled in the art will appreciate, the protuberance may have different shapes, sizes, and depths. The protuberance 28c is sized and shaped to engage a portion of the distal portion of the outlet of the faucet and prevent too much clearance or play between the main body and the spray head when the spray head is retracted back to the distal end of the faucet outlet.

[0016] As shown in FIGS. 1 and 3, an arm 28g connects the main body 28a to a top body 28b. The arm 28g may be any length and / or width to accommodate the spray head, hose, ferrule, and strength of magnet, or the angle and / or bend of the faucet. The arm 28g allows flexibility of top body 28b relative to the main body 28a by allowing the spray head holder 28 to fit into different shaped spouts (i.e., the portion of the spout that received the spray head holder 28 does not necessarily need to be straight). Additionally, the arm 28g allows the top body and the main body to have different sizes (i.e., different inner and outer diameters as well as different wall thicknesses). This allows more design flexibility for the spray head holder while simplifying the design and manufacturing process.

[0017] As shown in FIGS. 2-3, the arm 28g is a generally rectangular member with a uniform width. In another embodiment, the arm (not shown) may have varying widths. For example, the midpoint of the arm may have a narrow width as compared to the ends of the arm that are connected to the main body and the top body. In another embodiment, the arm is thicker in certain areas to provide a more robust arm. As shown in the FIGS. 2-3, the arm 28g is a generally planar structure. In another embodiment, the arm (not shown) has a curved body to match or attempt to match the inner bore of the faucet. It is also contemplated that other embodiments of the arm may have different sizes, shapes, lengths, and widths. The top body 28b may move / deflect between approximately 5 degrees to approximately 85 degrees relative to the longitudinal axis of the main body 28a. In other embodiments, the top body 28b may less or more than the range of motion depending upon the selection of the material of the arm, the thickness, width, the length of the arm, or whether the arm has any narrowing (which renders such portion more bendable as compared other portions of the arm).

[0018] In another alternate embodiment (not shown), a plurality of arms is positioned between the main body and top body. In one exemplary embodiment, two arms are positioned between the main body and top body, and the arms secure the main body to the top body. In one embodiment, the arms are in spaced relation to each other (e.g., on opposite sides of the spray head holder). Alternatively, the arms may be positioned closer (e.g., on the same side of the spray head holder), which permits the top body to bend or move within the spout relative to the main body of the spray head holder.

[0019] The top body 28b has a generally cylindrical body having an inner bore and an outer bore. In one embodiment, the inner and outer bores of the top body 28b are generally smooth. In alternate embodiments, the outer bore of the top body includes one or more protuberances having different shapes, such as but not limited to, squares, circles, and ovals and may have varying heights (i.e., distance raised from the surface of the outer bore). In other embodiments, the outer bore is included with one or more channels that recess into the surface of the outer bore. In another embodiment, the outer bore includes protuberances and channels. As those skilled in the art will appreciate, the channels may be rectangular grooves or other shaped channels. In these embodiments, the protuberances and grooves may mate or engage with corresponding protuberances or grooves on the distal portion of the bore of the faucet. The protuberances and grooves may aid in securing the top body of the spray head holder within the inner bore of the faucet.

[0020] In various embodiments, the top body 28b includes one or more grooves that form one or more recessed rings in the inner bore. The recessed ring may be sized (height and depth) to engage and hold the edge of the annular snap joint 32. In other embodiments, the recessed rings are sized to hold O-rings or gaskets. Referring to FIG. 2, an annular snap joint 32, which is a planar ring member, is placed over the annular magnet 30 and engages a recess 28e in the top body 28b in order to secure the magnet 30 within the top body of the spray head holder 28.

[0021] The inner bore of the top body is sized to receive and engage the outer diameter of an annular magnet 30. As shown in FIG. 3, the top body 28b includes a lip 28f that receives the bottom edge of the annular magnet. That is, the lip 28f extends into the inner bore of the top body. When the annular magnet 30 is placed within the inner bore of the top body, the magnet rests on the lip 28f. The annular magnet 30 is secured within the top body 28b by the annular cap 32 at a first end of the top body and the lip 28f at the second end (opposite the first end) of the top body.

[0022] In an alternate embodiment, the top body (not shown) may include one or more prongs along the top edge of the top body, and the prongs extend into the inner bore of the top body (i.e., prongs extend into the bore substantially perpendicular to the longitudinal axis of the top body). The annular magnet is pushed past the prongs and secures the magnet within the top body between the prongs and the lip 28f of the spray head holder. In another embodiment, a lip (not shown) is provided along the top edge of the top body 28b. The annular magnet is pushed past the top lip, and the magnet within the top body between the top lip and the bottom lip 28f of the spray head holder. In yet another embodiment, the annular magnet is press fit (friction fitted) within the top body.

[0023] In yet another embodiment, at least one magnet is secured within the top body of the docking assembly. In various embodiments, one or more rectangular magnets may be affixed on the inner bore or the outer bore of the top body. These rectangular magnets may be generally planar or may have curved surfaces. Alternatively, an annular magnet may be divided into two or more pieces, and each piece is affixed to the top body. In these various embodiments, the magnets may be glued to the surface of the top body. Alternatively, the magnets may be friction-fitted (or glued) into channels or grooves provided on the top body. In other embodiments, the magnets may be placed into one or more pockets may be positioned on the inner or outer bore of the top body. The magnets may be secured into these pockets by friction-fit, glue, or individual caps, or an annular cap having a opening to allow the flexible hose to pass therethrough (wherein the annular cap covers all the magnets).

[0024] In various embodiments, the spray head holder 28 is provided with one or more indents and / or nodules on the inner surfaces of the main body and / or the top body to facilitate the proper orientation of the spray head 20 within the outlet 14 of the faucet 10 when the spray head is returned to the faucet outlet. In another embodiment, the polarity of the magnet retained in the spray head holder and the indents and / or nodules provided on the spray head holder

[0025] In various embodiments, one or more grooves, ridges, arms, or protuberances may be provided on the outer surfaces of the top body and the main body that may be engage corresponding ridges, grooves, or rings provided on the inner bore of the spout. These grooves, ridges, recesses, or protuberances may be used to secure the top body and main body within the inner bore of the spout. In another embodiment, the top body and the main body are fiction-fitted within the spout.

[0026] FIGS. 2-3 show the connector 22 that connects the spray head (not shown) to the flexible hose 26. The connector 22 is a cylindrical structure with a flat-top surface having an opening. The opening is sized to hold a ball 25 such that the connector 22 is rotatable about the ball. This ball-and-socket type connection allows the user to rotate and move the spray head. In one embodiment, the ball-and-socket connection allows the spray head to be rotated 360-degrees. In an alternate embodiment, the ball or socket portion of the ball-and-socket connection may be modified with one or more flat surfaces and / or protuberances that limits the rotation of the spray head between approximately at least five-degrees to less than 360-degrees.

[0027] In one embodiment, the interior portion of the connector 22 is threaded to engage the corresponding threads on the spray head 20. In another embodiment, the connector 22 is snap-fitted to the top of the spray head 20. In various embodiments, the connector and / or the ball are composed of metal. In another embodiment, the connector and / or ball are magnetized metal. In yet another embodiment, the connector and / or ball are composed of plastics or other composite materials. In yet another embodiment, the connector and / or ball are composed of plastics or other composite materials that is impregnated with metal.

[0028] As shown in FIGS. 2-3, the ball 25 is connected to a ferrule 24 that is used to secure the ball 25 to the hose 26. In one embodiment, the ferrule is a metal ferrule. In another embodiment, the ferrule is metal which is magnetized. In another embodiment, the ferrule is composed of plastics or other composite materials. In yet another embodiment, the ferrule is composed of plastics or other composite materials that is impregnated with metal.

[0029] In one embodiment, the annular magnet is a permanent magnet, such as neodymium, samarium-cobalt, and ferrite (ceramic) magnets, generate a persistent magnetic field without the need for external power. In another embodiment, the annular magnet is an electromagnet. In other embodiments, the annular magnet may have different polarities on different portions of the magnet. For example, the top and bottom surfaces of the magnet may have different polarities. Alternatively, opposing sides may have different polarities.

[0030] In various embodiments of the faucet, the magnet(s) provided within the docking assembly are attracted to a ferromagnetic component of the spray head. The component that may be ferromagnetic includes, but is not limited to, the spray head housing, components within the spray head (e.g., internal diffuser), a spray head connector, a specific piece of ferromagnetic material that is inserted into or applied to at least one portion of the spray head (e.g., a discrete piece of ferromagnetic tape or metal applied to the inner surface of the spray head. In another embodiment, the magnet(s) provided within the docking assembly are attracted to a ferromagnetic component provided on the flexible hose of the faucet. In one exemplary embodiment, a ferromagnetic collar is positioned around the outer surface flexible hose and at a spaced distance from the distal end of the flexible hose; that is, a predefined distance from the end of the hose that is coupled to the spray head so that the ferromagnetic surface on the hose is within the magnetic field of the magnet(s) provided in the top body of the docking assembly. In another exemplary embodiment, ferromagnetic material is impregnated into the flexible hose material. As those skilled in the art will appreciate, embodiments are contemplated where the magnet is placed within or positioned on the spray head or flexible hose and ferromagnetic material is provided on the top body of the docking assembly.

[0031] In operation, the spray head is docked with distal end of the spout in a first configuration. The docking assembly (via the magnet) is magnetically attracted to a ferromagnetic component on the spray head and / or the flexible hose to secure the spray head to the distal end of the spout. In a second configuration, the spray head and a portion of the flexible hose is moved away from the distal end of the spout. The user needs to pull the spray head with a sufficient amount of force to overcome the magnetic attraction of the components and any mechanical resistance of the docking assembly and the spray head.

[0032] Although an embodiment has been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the scope of the present disclosure. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. The accompanying drawings that form a part hereof show by way of illustration, and not of limitation, specific embodiments in which the subject matter may be practiced. The embodiments illustrated are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure.

[0033] Such embodiments of the inventive subject matter may be referred to herein, individually and / or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed. Thus, although specific embodiments have been illustrated and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.

[0034] It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Description of Embodiments, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure.

Claims

1. A faucet, comprising:a spout defining a non-linear internal passage extending between an inlet region and an outlet region;a spray head movable between a docked position adjacent to the outlet region and an undocked position;a hose extending through the non-linear internal passage and coupled to the spray head; anda docking assembly located proximate to the outlet region, the docking assembly comprising:a main body defining an inner bore and an outer bore, wherein the hose passes through the inner bore and a portion of the spray head engages the main body when the spray head is in the docked position;a top body defining an inner bore and an outer bore, wherein the hose passes through the inner bore of the top body;an arm positioned between the top body and main body, wherein the arm secures the top body to the main body, and the arm permits the top body to move relative of the main body within the non-linear passage of the spout; andat least one magnet is secured within the inner bore of the top body.

2. The faucet of claim 1, wherein the docking member further comprises a resilient member provided on the main body of the docking assembly.

3. The faucet of claim 1, wherein the top body and the main body have different inner bore diameters.

4. The faucet of claim 1, wherein the magnet is an annular magnet defining a central opening through which the hose passes, and the annular magnet is secured within the inner bore of the top body.

5. The faucet of claim 4, wherein the annular magnet is friction fitted within the inner bore of the top body.

6. The faucet of claim 4, wherein the annular magnet engages an annular ridge provided within the inner bore of the top body.

7. The faucet of claim 1, wherein the docking member further comprises an annular cap engages the top body to secure the at least one magnet within the top body.

8. The faucet of claim 1, wherein at least a portion of the spray head, the flexible hose, or a connector in fluid communication with the spray head and flexible hose includes a ferromagnetic material.

9. A docking assembly positionable within an internal passage of a spout, comprising:a main body defining an inner bore and an outer bore, wherein the main body engages at least a portion of a spray head;a top body defining an inner bore and an outer bore, wherein a flexible hose provided within the faucet passageway passes through the inner bore;an arm positioned between the top body and main body, wherein the arm secures the top body to the main body, and the arm permits the top body to move relative of the main body when the docking assembly is positioned within the internal passage of the spout; andat least one magnet is secured within the inner bore of the top body.

10. The faucet of claim 9, wherein the docking member further comprises a resilient member provided on the main body of the docking assembly.

11. The faucet of claim 9, wherein the top body and the main body have different inner bore diameters.

12. The faucet of claim 9, wherein the at least one magnet is an annular magnet defining a central opening through which the hose passes, and the annular magnet is secured within the inner bore of the top body.

13. The faucet of claim 12, wherein the annular magnet is friction fitted within the inner bore of the top body.

14. The faucet of claim 12, wherein the annular magnet engages an annular ridge provided within the inner bore of the top body.

15. The faucet of claim 9, wherein the docking member further comprises an annular cap engages the top body to secure the at least one magnet within the top body.

16. The faucet of claim 9, wherein at least a portion of the spray head, the flexible hose, or a connector in fluid communication with the spray head and flexible hose includes a ferromagnetic material.

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