Fluid handling – With casing – support – protector or static constructional... – Static constructional installations
Reexamination Certificate
1997-10-02
2001-07-31
Chambers, A. Michael (Department: 3753)
Fluid handling
With casing, support, protector or static constructional...
Static constructional installations
C137S359000, C137S801000, C004S590000
Reexamination Certificate
active
06267136
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to hardware associated with a secure, leak-free installation of a faucet set and gasket. The faucet set comprising valves and a spout is used for the delivery of service water from a water utility into a sink. The hardware prevents water leakage into the space below the sink through the installation gasket placed between the sink and the faucet set.
BACKGROUND OF THE INVENTION
Sinks have been installed in household and commercial kitchens, laundries, photography darkrooms, hospitals, etc. for many years. Sinks commonly have one or more bowl portions to contain water or other liquid and a flat, generally horizontal mounting flange portion around the periphery of the upper portion of the sink assembly. Such flanges often interact with a countertop and hold the sink in place. Additionally, in the mounting flange, two holes (
FIG. 1
holes
12
a
,
12
b
) having a diameter of about 1.5 inches are commonly formed for installation of a faucet set having separate hot and cold water service. Such faucet sets at a minimum, comprise one valve or one valve each for hot and cold water and a spout conveying hot, cold or mixed hot/cold water into the sink or bowl. Such mounting flanges typically also have a central hole (see
FIG. 1
, hole
12
c
) midway between the hot and cold service holes. The faucet can also contain other optional components that if present must be dealt with in installation. The faucet set is mounted on a flange typically using a sealing or leak preventing gasket between the sink mounting flange and the faucet set base. The faucet set is held in place by attachment means typically wing nuts threaded onto a threaded mating surface on both the hot and cold water intake ports. As the nuts are tightened, the gasket is compressed. Such a gasket is designed to seal the joint between the faucet set and the flange to ensure that no water can leak through the mounting holes into the space below the sink. Any such water leak can cause rust in ferrous metal members and can ruin any water sensitive item stored below the sink and can cause rot or other disintegration of wooden members in the sink area or counter assembly.
The faucet set as installed is secure against leaks through the seal formed by the gasket. However, when in use, water can begin to leak through the portion of the faucet set or sink even when a gasket is used. Such leaks occur because, as the faucet, spout and valves are manipulated, the sink mounting flange can flex. Such flexing can cause a gap to appear between the faucet set and gasket and can cause a second gap between the gasket and sink flange. Such a flexed flange can provide one or more paths for water to leak from the sink region into the cabinetry below the sink. Such loosening of the faucet set is more common in sinks having a relatively thin gauge metal ((i.e.)typically 23-20 gauge, about 0.7 mm to 0.9 mm, stainless steel) in the flange because flex in the flange occurs to a greater degree in thin gauge metal. More robust sinks made of thicker gauge material (20-17 gauge, about 1.0 mm to 1.5 mm) are somewhat more resistant to flex generated water leaks. However, any sink location depending on use and installation can have substantial loosening and leak occurrence depending on timing and severity of use.
Accordingly, a substantial need exists to provide a sink flange stiffener device that can reduce the tendency of such faucet set installations on sink flanges to leak when installed on flexible flanges.
Brief Discussion of the Invention
I have found a novel stiffener that can make an installation of a faucet set to mounting flange, using a gasket, more flex resistant and more secure against leaks. The stiffener is a sheet-like resilient member in two parts. The two parts
13
a
and
13
b
of the stiffener, when assembled have a central point or opening
14
formed by the ends
19
a
and
19
b
of the parts
13
a
and
13
b
. Ends
16
a
and
16
b
depart from planarity with the central point by less than 5° preferably less than 2°, preferably less than 1.8°. Each part can be arcuate or can include a discrete angle. The two part stiffener is installed opposite to the faucet set and gasket on the sink flange (
FIG. 1
) by securing the stiffener with the nuts. The two part stiffener generally has a mounting holes or apertures
18
a
and
18
b
for each of the hot and cold water intake ports. These holes in the stiffener and the stiffener surfaces are generally non-coplanar. In other words, the stiffener can be curved or can have a flat portion of the stiffener fixed at an angle to the other generally flat portion. The preferred two part stiffener after installation typically has dimensions of about 2 to about 2.5 inches in width, 11 to 12 inches in length and about ⅛ to ⅜ inches in thickness depending on material and modulus. Each part is about 2 to about 2.5 inches in width, 5 to 6 inches in length and about ⅛ to ⅜ inches in thickness depending on material and modulus. Each part comprises an intentionally formed non-coplanar surface and in each end the mounting apertures or holes for the installation are formed.
In a preferred mode, the two part stiffener of this invention can be used to repair leaking sink installations. When a sink installation is leaking, the removal of the faucets from the installation locus can be difficult. The two part stiffener of this invention is fashioned in two parts to permit the installation of the two parts without complete disassembly of the faucet set from the sink installation flange. In the repair of a leaking faucet set, the installation nuts are simply loosened to a degree that the two part stiffener can be inserted or slid into place in the installation. The two part stiffener is then secured in place using fasteners in place. Once the nuts are tightened, the non-coplanar aspect of the two part stiffener compresses the gasket and repairs the leakage.
The two part stiffener device of this invention should have sufficient stiffness to prevent the localized flexing around the faucet set that causes leakage. In other words when installed, the stiffener stabilizes the sink installation flange as the faucet set valves and spout are manipulated. The flange flexes so little, when stiffened by the object of the invention, that no leakage occurs. Such stiffness results from the resiliency or modulus of the material from which the stiffener is made. Further the degree of flex depends on the gauge of the stainless steel sink flange. Relatively thin gauged steel requires a significant stiffener while thicker steel flanges can be maintained leak free with a less thick stiffener depending on period and severity of use. In certain application, a stiffener with a modulus of less than 100,000 psi is acceptable. However, any modulus between 100,000 and 1.5 million psi may be required for complete leak prevention. Preferred sink stiffeners have a modulus of greater than 200,000 and preferably greater than 300,000 psi. The thickness of the stiffener depends on the modulus and the material from which it is made. Accordingly a stainless steel stiffener can have a relatively narrow thickness when compared to a stiffener with the same modulus prepared from an acrylic material. A modulus of 100,000 and a stainless steel member can be achieved with a substantially less thick part when compared to an acrylic stiffener.
The edges of each part of this stiffener can also comprise a reinforcing member or reinforcing means. Such reinforcing means can be introduced in the initial shaping of the stiffener. Alternatively, the reinforcing means can comprise separate ribs, bars or other reinforcing members on any portion of each of the stiffener parts, commonly the edge of the stiffener length. An important aspect of this stiffener is its portions that are non-coplanar with respect to other portions of the stiffener. This lack of coplanarity that when installed the stiffener is placed under stress resulting in a substantial strain. In a preflexed installation, the installation n
Burd, Bartz & Gutenkauf
Chambers A. Michael
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