Top down mounting system for faucet

[0001] This application claims the benefit of U.S. Provisional Application No. 60/373,277, filed Apr. 17, 2002.

[0002] The present invention relates to a top mounting system for faucets in which the faucet may be mounted from the top of the countertop or sink.

[0003] The installation of a faucet onto a countertop or sink is a difficult and time-consuming task. At least some of the installation must be done with the installer being in the confined and hard to work in area under the counter or sink. There is a need to provide a less cumbersome and complicated system of installing faucets or interchanging different faucet styles, such as single handle faucets and two handle faucets, onto a countertop or sink which can be done largely from the top of the countertop or sink. The present invention provides such a system.

[0004] The instant invention relates to a faucet containing a valve assembly for mounting on a sink ledge from above or the top of the sink ledge. The top mounting system includes a mounting plate for mounting on the top of the sink ledge containing means for attaching a faucet body housing to the mounting plate. The mounting plate has two vertical downwardly extending support rods which extend through access openings in the sink ledge and on which are mounted vertically movable clamping arms which are adapted to abut against the underside of the sink ledge, thereby clamping the mounting plate to the sink ledge. Rotation of the support rods, which are preferably threaded, effects movement of the clamping arms toward the underside of the sink ledge.

[0031] Referring to FIGS. 1–3, a top mounting faucet assembly 20 is shown in conjunction with a countertop or sink ledge 10, having access openings 11, 12 on which it is mounted. The top mounting faucet assembly includes a mounting plate 21, a tube waterway 40, a faucet body housing 90 with a base 92 and a spout 94, and a locking mechanism 100. An undercover plate (not shown) is connected to cover the underside of the spout 94 and the waterway 40.

[0032] In the embodiment illustrated in FIGS. 1 and 2 for a two-handle faucet, the waterway 40 is generally “T” shaped with two arms 42, 44 and a spout leg 46 extending from the arms 42, 44 to form a “T” shape. At the free end of the spout leg 46 is a discharge head 47 in which is disposed an aerator (not shown). The two arms 42, 44 of the waterway 40 are connected to valves 50, 52 that deliver water to the waterway 40. The waterway 40, including the arms 42, 44 and the spout leg 46 are disposed within the faucet body housing 90 as best shown in FIGS. 2 and 3.

[0033] The mounting plate 21 is mounted from the top of the sink or countertop 10, and sits on top of the countertop 10. It should be noted that the mounting plate 21 might also be mounted from the underside of the countertop 10. Extending downwardly from mounting plate 21 are two inlet water conduits 22, 23. Inlet water conduits pass through access openings 11, 12 in the countertop 10, and are connected to water supply tubes (not shown) under the countertop 10 or sink. Inlet water conduits 22, 23 receive, at their top ends 24, 25 tubes 54, 55 of waterway 40 which extend downwardly from valves 50, 52. Tubes 24, 25 carry hot and cold water from inlet water conduits 22, 23 to valves 50, 52.

[0034] To mount the faucet assembly 20 onto the countertop 10 water inlet conduits 22, 23, mounting plate locking members 60, 61, threaded members 70, 71, and securing members 80 and 82 of threaded members 70, 71, are inserted through the access openings 11, 12, and the mounting plate 21 is lowered until it rests on the countertop 10.

[0035] The mounting plate 21 locking members 60, 61 are vertically movably mounted on threaded members 70, 71 that are disposed coaxial with and adjacent to water conduits 22, 23, respectively.

[0036] When the mounting plate 21 is on the countertop 10, the threaded members 70, 71 are rotated to cause the mounting plate locking members 60, 61 to move up or down on the threaded members 70, 71. As best illustrated in FIG. 4 counterclockwise rotation of threaded members 70, 71 causes locking members 60, 61 to move downwardly or away from countertop 10 to an unlocked position. A clockwise rotation of threaded members 70, 71, as seen in FIG. 8, causes locking members 60, 61 to move upwardly or toward countertop 10 to a locked position.

[0037] In the locked position the tops 66, 65 of fingers 62, 63 of locking members 60, 61 abut the bottom or underside of countertop 10, thereby securing mounting plate 21 to countertop 10.

[0038] The locking members 60, 61 are prevented from rotating with the threaded members 70, 71 as they are turned, by guide surfaces 67, 68 of the locking members 60, 61. Guide surfaces 67, 68 abut against water inlet conduits upon rotation of the locking members. This causes locking members 60, 61 to ride up or down threaded members 70, 71 as these threaded members are rotated instead of rotating 360° with the rotation of the threaded members 70, 71.

[0039] Threaded members 70, 71 are stabilized and secured at their bottom portions by securing members 80, 82. The threaded members 70, 71 extend through apertures 83, 85 in securing members 80, 82. Securing members 80, 82 are mounted on water inlet conduits 22, 23 via apertures 84, 86 into which water conduits 22, 23 are inserted.

[0040] To remove the top mounting faucet assembly 20 from the countertop or sink ledge 10, threaded members 70, 71 are turned in a counter-clockwise manner, as illustrated in FIG. 4, moving the locking members 60, 61 downwardly away from the underside of the sink ledge 10. The water inlet conduits 22, 23, mounting plate locking members 60, 61, threaded members 70, 71, and threaded members securing or stabilizing members 80, 82 of mounting plate 21 are then pulled up through the access openings 11, 12 in the sink ledge 10.

[0041] As best seen in FIG. 5 in the unlocked or down position fingers 62, 63 of locking members 60, 61 are swiveled against the inlet water conduits 22, 23, and can be pulled out through access openings.

[0042] As seen in FIGS. 11 and 12, in the up or locked position fingers 62, 63 of locking members 60, 61 are swiveled away from inlet water conduits 22, 23 and their tops 66, 65 abut against the bottom or underside of countertop 10. In this position the fingers 62, 63 cannot be pulled through access openings 11, 12.

[0043] It is also possible that the water inlet conduits 22 and 23 may be threaded on the outer surface itself. This would then allow the mounting plate 21 to be installed in the conventional under-the-sink fashion using compatible nuts. Other known methods for under-the-sink attaching of the mounting plate 21 are envisioned as part of this invention.

[0044] In one embodiment, as illustrated in FIG. 13, the faucet body housing 90 is attached to mounting plate 21 by fastening members 35, 36 such as screws or bolts which pass through aligned openings 95, 96, 37, 38 in raised ears 33, 34, 93, 94.

[0045] In another embodiment the faucet housing 90 is attached to mounting plate 21 by a locking mechanism 100. The locking mechanism 100 is mounted on the mounting plate 21 by means of two spaced apart securing members 28, 29 extending upwardly from the mounting plate 21.

[0046] As shown in FIGS. 6–8, the attachment means 28, 29 of mounting plate 21 comprise an upwardly extending tab portion having a vertical body portion 28a and an inwardly angled arm 29a. The inwardly angled arm 29a has a sloping leading ledge 30.

[0047] In one embodiment, as illustrated in FIGS. 14–21, the locking mechanism 100 is comprised of a top cover 101 and a bottom cover 102. Two spring-loaded locking arms 106, 108 are located in the locking mechanism and movably extend out the two opposite open sides of the locking mechanism 100. As shown in FIGS. 14 and 19, the locking mechanism 100 further comprises spring pairs 109 and 110 that have one end located within openings 108a in the locking arms 106 and 108, and the other end resting against an inner wall 102a of the bottom cover 102. Also shown in FIG. 14, are linkages 113 and 114, having an outer end 113a and an inner end 114a. The outer ends 113a of linkages 113 and 114 are attached by pins 115, 118 to the locking arms 106 and 108. The inner ends 114a of the linkages 113 and 114 are similarly attached to an operating rod 112 via pins 116 and 117. The operating rod has a stop 112a on its upper surface that rides within a guide slot 101a within the top cover 101 of the locking mechanism 100.

[0048] When these locking arms 106, 108 are extended they engage securing members 28, 29 on the mounting plate 21. The locking arms 106, 108, being spring loaded, are normally in an extended position, as shown in FIGS. 15, 16 and 18. The spring loaded locking arms 106 and 108 have angled top surfaces 106a and bottom surfaces 106b. Once the mounting plate 21 is installed on top of the sink ledge or countertop 10, the locking mechanism 100 may be installed onto the mounting plate 21 by simply aligning the faucet body housing 90 over the mounting plate 21 and pressing the faucet body housing into place. As the locking mechanism 100 is pressed into position, the bottom sloping surfaces 106b abut the sloping leading ledge 30 of the mounting plate 21. This bottom sloping surface 106b assists the locking arms 106, 108 to retract into the locking mechanism 100. Once inserted, the locking arms 106, 108 spring back to their original extended position, thereby locking the faucet body housing 90 into position onto the mounting plate 21. After the locking arms 106, 108 are in place, the installer can then pull out or extend the operating rod 112, which, as shown in FIG. 19, drives the inner ends 114a of linkages 113, 114 downwards, further forcing locking arms 106, 108 outwards against the angled arm 29a of attachment means 28, 29. Once the linkages 113, 114 pass through horizontal, corresponding to when the stop 112a reaches the limit of guide slot 101a. This locks the locking arms 106, 108 in the fully locked position.

[0049] To retract the locking arms to a retracted position, as shown in FIGS. 17 and 21, so that the faucet body housing 90 can be removed from the mounting plate 21, an operating rod 112 is pushed inwardly into the locking mechanism 100 as shown by the arrow in FIG. 17. This, as shown in FIG. 19, causes linkage 113, 114, to swivel, which results in inward retraction of locking arms 106, 108 against the opening forces caused via springs 109 and 110. Upon release of inward force upon operating rod 112 springs 109, 110 force locking arms 106, 108 out of the sides of locking mechanism 100 and to their extended locking positions.

[0050] In a second embodiment a different locking mechanism 200 as illustrated in FIGS. 21 and 22 can be used in place of locking mechanism 100. This locking mechanism 200 also has two locking arms 206, 208 extending from its sides. Just as with locking mechanism 100, the locking arms 206, 208 are normally in an extended or locking position. The locking members 206, 208 are retained in a heel block 300 by means of a modified dovetail, with mating flanges 302 being inserted within slots 301 of the heel block 300. The slots 301 in the heel block 300 are wider than the mating flange 302 on the two locking arms 206, 208. As shown in FIG. 22, heel block 300 also comprises a central cylindrical guide having a threaded inner surface 307. Worm screw 304 is matingly received within the cylindrical guide. Hence, by rotating worm screw 304, an operator can move heel block 300 forwards and backwards. By so doing, the angled cam portion 306 of heel block 300 forces the locking arms 206, 208 between a locked position, when fully extended, and a retracted position, when the locking arms 206, 208 are drawn inwards within housing 202.

[0051] As shown in FIG. 22a, springs 303 are mounted behind heel 300 against housing 202. The springs 303 serve to provide some forward pressure on the heel block 300 as the heel block 300 is moved forward in order to lock locking arms 206, 208, effectively “snapping” locking arms 206, 208 into the locked position.

[0052] As worm screw 304 is rotated in a clockwise direction, heel block 300 is moved forward within housing 202. The locking arms 206, 208 will be forced out by the angled cam portion 306 of heel block 300, thereby locking the mechanism 200 to the securing members 28, 29.

[0053] A groove 305 on worm screw 304 rests in a tab 312 on the housings 201, 202 which allows the worm screw 304 to rotate without changing position. A lock 310 can be used to maintain the worm screw 304 in the locked position.

[0054] As illustrated in FIG. 24 the locking mechanism 100 may be secured to the faucet body housing 90 by screws 95 screwed into bosses 96–99 formed in the underside of faucet body housing 90. However, the attachment means may be employed.

[0055] FIG. 25 illustrates an alternative embodiment of a locking mechanism 400, similar to locking mechanism 100. As shown in FIG. 25, locking mechanism 400 comprises a top cover 410, and a housing 420. The top cover 410 has a body portion 411 having a slot 418 located therein. A ledge 413 extends downwards from the edges of the top cover 410 at each of the four corners. Mounting arms 412 extend outwards from the ledges 413 at the four corners of the top cover 410, the mounting arms 412 having mounting holes 414 for attaching the locking mechanism 400 to the faucet housing body 90. The top cover further has attachment holes 416 for securing the top cover 410 to the housing 420. As shown in FIG. 25, downwardly extending nodes 419 are located between the attachment holes 416.

[0056] The housing 420 comprises a main body portion 422 having upwardly extending supports 424 at the four corners of the housing 420, each support having a top surface 425. A slot 426 is located in the main body portion 422. Upwardly extending inner walls 428 form a partially enclosed passageway within the housing 420. Extending outwards from the inner walls 428 are attachment tabs 430 which correspond to the attachment holes 416 of the top cover 410. Inward of the attachment tabs 430 are retaining grooves 432.

[0057] Enclosed within the housing 420 is a cam bolt 440, linkage arms 460a and 460b, paired springs 470, and outwardly extending locking arms 480. The cam bolt 440 has an operating end 442 and an attachment end 444. A cylindrical shaft 446 runs between the operating end 442 and the attachment end 444. Attachment wings 448 having holes 450 extend outwards from the cylindrical shaft 446. A groove 452 is cut into the cylindrical shaft 446 adjacent the attachment end 444. A recess 454 is situated in the operating end 442 of the cam bolt 440 for receiving a tool to turn the cam bolt 440 in the desired direction.

[0058] The linkage arms 460a and 460b are attached to the cam bolt 440 via pins 462 at one end, and to the locking arms 480a and 480b at the other outside end. Although pins are described herein, other attachment means may be used for attaching the linkage arms 460 to the cam bolt 440. The locking arms 480a and 480b extend outwards from the housing 420, and are attached to the linkage arm 460a and 460b, respectively. The locking arms 480a, 480b comprise body portion 482 having a top surface 482a and a bottom surface 482b, and having downwardly sloping edges 484 at the outside end of the top surface 482a. The inside end of the body portion 482 has an attachment point 486 for receiving the linkage arms 460. Adjacent the attachment point 486 is recesses 488 for receiving the springs 470. Wing ledges 490 protrude outwards from the body portion 482 of the locking arms 480. The outside end of the bottom surface 482b also has an upwardly angled edge 492.

[0059] In operation, the top cover 410 is attached to the housing 420. Once attached, the downwardly extending ledge 413 and the upwardly extending support 424 form a guide slot 425a for receiving the locking arms 480a and 480b. The downward extending node 419 serves to lock the cam bolt 440 within the groove 432. The assembled locking mechanism 400 is then installed within the faucet housing body 90. Once the mounting plate 21 is installed on top of the sink ledge or countertop 10, the locking mechanism 400 may be installed onto the mounting plate 21 by simply aligning the faucet body housing 90 over the mounting plate 21 and pressing the faucet body housing 90 into place. As the locking mechanism 400 is pressed into position, the bottom sloping surfaces 492 of the locking arms 480 abut the sloping leading ledge 30 of the mounting plate 21. This bottom sloping surface 492 assists the locking arms 480 to retract into the locking mechanism 400. As the locking arms 480a and 480b retract, compressing the spring pairs 470 against the upwardly extending inner wall 428, the locking arms 480a and 480b rotate the wings 450 of the cam bolt 440 in a clockwise direction, thereby displacing the linkages 460a and 460b. When the cam bolt 440 is rotated in the clockwise direction, the linkages 460a and 460b pass through the slots 426 and 418, respectively. Once the locking arms 480a and 480b pass by the inwardly angled arm 29, the spring pairs 470 force the locking arms 480a and 480b into the extended position. The installer may next insert a suitable tool into the recess 454 to rotate the cam bolt 440 in a counterclockwise direction to lock the locking arms in the extended position. The top cover 410 and the housing 420 prevent the cam bolt 440 from rotating past the locked position, thereby preventing the linkage arms 460a and 460b from retracting the locking arms 480a and 480b via counterclockwise rotation.

[0060] Although the cam bolt 440 in the above-described embodiment is oriented in the horizontal direction, it is also envisioned that the locking arms 480a and 480b may be rotated using a cam bolt or other similar device placed in a vertical or other suitable orientation. Also, the cam bolt 440 may be used to extend the locking arms 480a and 480b without the use of the linkage arms 460a and 460b.

[0061] While the invention has been described in what is considered to be a preferred embodiment, other variations and modifications will become apparent to those skilled in the art. It is intended, therefore, that the invention not be limited to the illustrative embodiment.