Modular Spray Assembly for Low Flow Shower Heads
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Solution Overview
Problem
Conventional shower spray heads are unable to provide sufficient spray performance at low inlet flow rates, such as less than about 0.90 GPM, which is a challenge in water conservation efforts.
Innovation Solution
A modular spray assembly that includes a stator, an impeller, a rotor, and a cover, designed to create a unique water spray pattern through rotary and orbital motion, even at low inlet flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spray heads are used, then device complexity is low, but spray performance deteriorates at low inlet flow rates
Solution Approach 1:
The patent employs dynamic components including a rotatable impeller with vanes that rotate to direct water flow, and an eccentric rotor that orbits and rotates to distribute water through multiple nozzles. These dynamic mechanisms transform the kinetic energy of incoming water into rotational motion, enabling effective spray distribution at low flow rates without requiring complex electronic controls or multiple independent pump systems.
Solution Approach 2:
The invention utilizes hydraulic principles by using the kinetic energy of the incoming water flow to drive the impeller and rotor mechanisms. The water flow itself powers the spray distribution system through hydraulic action on the impeller vanes and rotor surfaces, eliminating the need for separate mechanical pumps or complex valve assemblies while maintaining effective spray performance at low inlet flow rates.
2Loss of substance
If low inlet flow rates are used for water conservation, then water consumption is reduced, but spray performance becomes insufficient
Solution Approach 1:
The patent changes the operational parameters by using an eccentric rotor mechanism that creates orbital motion, increasing the effective coverage area of the spray. The rotor's eccentric orbit combined with its rotation distributes water droplets over a larger surface area, compensating for the reduced flow rate and maintaining adequate spray performance for water conservation applications.
Solution Approach 2:
The invention adds dimensional complexity to the spray pattern through the eccentric orbital motion of the rotor. Instead of a simple radial spray pattern, the rotor's orbit creates a three-dimensional spray distribution that covers a larger effective area, allowing low flow rates to be distributed more effectively across the target surface.
3Area of stationary object
If water is distributed over a larger surface area, then spray performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple nozzles and spray distribution mechanisms into a single integrated rotor assembly. The eccentric rotor combines orbital motion and rotation in one component, with multiple nozzles positioned around its perimeter, creating a unified mechanism that distributes water over a large surface area without requiring multiple separate nozzle assemblies or complex control systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular spray assembly maintains effective spray performance at low inlet flow rates, distributing water over a larger surface area and preventing numbing sensations, while providing a massaging sensation similar to conventional spray heads operating at higher flow rates.
Implementation Method 1
The impeller can rotate responsive to the inlet receiving the flow of fluid
Implementation Method 2
The rotor can rotate eccentrically relative to the impeller by the second bearing
Data Source
AI summary
A modular spray assembly for a spray head includes a stator having an inlet that can receive a flow of fluid. The modular spray assembly includes a cover coupled to the stator and having a first bearing disposed in the stator. The modular spray assembly includes an impeller rotatably coupled to the first bearing, in which the impeller includes a second bearing. The modular spray assembly includes a rotor rotatably coupled to the second bearing. The rotor can rotate eccentrically relative to the impeller by the second bearing. The impeller can rotate responsive to the inlet receiving the flow of fluid.