AU2017219119A1 - Adjustable wall furniture for wall mounted taps - Google Patents

Abstract

Abstract An adjustable wall flange fitting for wall mounted taps, which includes a wall engaging base plate with a first aperture there through having a first axis, a resilient element captively retained with the plate to extend at least partially into the first aperture, and a longitudinally extending sleeve having a longitudinal axis corresponding to the first axis. The sleeve includes means to adjustably engage a spindle bonnet on a stuffing box assembly to provide a first linear range of adjustment along the longitudinal axis, and an outer body portion of constant external cross section configured to be slidably movable along the longitudinal axis within said first aperture against the captive resilient element to provide a second linear range of adjustment along the longitudinal axis. 28 2- 20 -- 21 ' -- _uuanuu -U

Description

Adjustable wall furniture for wall mounted taps

Technical Field [0001] The present invention relates to wall flange fittings for recessed wall mounted taps of the kind having breech bodies recessed within and secured to structural elements of the wall, to which a stuffing box assembly (“SBA”) with tap spindle is secured. The stuffing box assembly may include a ceramic disc or jumper valve flow control device.

[0002] Wall flange fittings of this kind are used to finish off and cover the opening in a wall surface through which the tap spindle will extend, and hide portions of the spindle and stuffing box assembly from view. More particularly, the invention relates to a new wall flange design that provides improved adjustability to accommodate a wider range of installation tolerances and variations.

[0003] The term wall and wall surface as used herein is intended to include non vertical surfaces.

Background [0004] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.

[0005] When building or renovating rooms with wall mounted taps of the kind discussed above, it is important that the breech bodies of the taps are accurately mounted behind the front face of the wall, so that once the stuffing box assembly with tap spindle is attached to the breech, it protrudes the desired target distance from the finished wall. This is because the existing wall flanges that are then attached to a threaded spigot that extends outwardly from the stuffing box assembly, which in combination with a lock nut type formation is generally referred to as the spindle bonnet, have very limited offset adjustment. As such, if the breech is mounted too shallow from the wall, the flange won’t be deep enough to extend to the wall. Conversely, if the breech is mounted too deep, the flange will be too long and extend too far over the spindle and foul with the handle that connects to the spindle.

[0006] In this regard existing wall flanges for wall mounted taps are usually of a fixed one piece construction including an internal connection portion for attachment to the stuffing box assembly, a base plate portion designed to engage the wall and hide the opening, and a sleeve element that extends integrally from the base plate toward the tap end to surround the spindle.

[0007] Even where breech locations are accurately set during original construction, it is common practice to renovate bathrooms at regular periods, during which changes in tile types and styles often mean changes in tile thickness, which can create problems whereby the breech bodies are no longer at the ideal offset from the inner wall surface. It is also common practice to renovate by retiling over existing tiles. In such instances significant offset problems are created. While there are some solutions available based on substituting components with longer spindles or using additional adaptors and the like, these represent costly options that do not provide fine adjustment, and which still only address the offset issue.

[0008] In this regard, if the breech bodies to which the stuffing boxes are attached are not oriented exactly square to the final inner wall assembly, the existing wall flanges will not sit flush against the wall and unsightly gaps will be created at the peripheral edges of the base plate portion adjacent the wall which will highlight the problem. Given variations that can occur after the breech bodies are installed, such as during installation of the inner wall, ora substructure below the tiles and subsequent installation of the tiles to that sub structure, problems of this kind can be difficult to avoid.

[0009] Rectification of any breech body misalignment of any kind after installation of the wall covering is not practical, and if it must be done it is time consuming and costly.

[0010] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

Summary [0011] According to the invention there is provided an adjustable wall flange fitting for recessed wall mounted taps, the fitting including: a wall engaging base plate with a first aperture there through having a first axis, a resilient element captively retained with the plate to extend at least partially into the first aperture, a longitudinally extending sleeve having a longitudinal axis corresponding to the first axis, the sleeve including means to adjustably engage a threaded spigot portion of a spindle bonnet on a stuffing box assembly to provide a first linear range of adjustment along the longitudinal axis, the sleeve also including an outer body portion of constant external cross section configured to be slidably movable along the longitudinal axis within said first aperture against the captive resilient element to provide a second linear range of adjustment along the longitudinal axis.

[0012] Preferably, the resilient element is in the form of a continuous o-ring type element which is held captive within an o-ring seat provided within a surface which defines the first aperture in a direction generally parallel to the first axis.

[0013] In most preferred forms the first aperture and outer body portion of constant cross section portion of the sleeve have generally circular cross sectional profiles. In common forms, the sleeve is generally cylindrical.

[0014] Preferably, the means provided on the sleeve to adjustably engage the spindle bonnet on a stuffing box assembly is in the form of an internal threaded region provided intermediate the ends of the sleeve. Desirably the constant cross section outer body portion of the sleeve extends towards the other end of the sleeve. In preferred forms, the end of the sleeve configured to be positioned proximal to the breech body, has a recess adapted to accommodate a lock nut formation behind the threaded spigot. This enables the sleeve to be positioned inwardly as far as possible as may be needed when the breech body is too shallowly located within the wall recess.

[0015] For embodiments designed for use with tap handles that do not cover the sleeve, the end of the sleeve adjacent the handle is closed except for an aperture sized to allow the spindle to extend therethrough. In other embodiments where the handle itself may include an outer sleeve portion that in use extends at least partially over the wall flange fitting sleeve, that end can be open. In such arrangements it is possible to have the internal thread that engages the threaded spigot offset between the two ends, enabling the sleeve to be used in two different orientations to further increase the adjustment that can be achieved.

[0016] In other embodiments of the sleeve for use with tap handles that do not cover the sleeve, the end of the sleeve may be closed by a separately formed cap element with aperture for the spindle. This may be removably securable with the sleeve by means of a threaded connection or similar and in some variations the sleeve may be configured to enable the cap to be attached to either end of the sleeve.

[0017] In preferred forms the base plate is generally planar, but in other embodiments may have a more complex profile viewed along the first axis.

[0018] The peripheral profile of the base plate can be any desired shape, but common profiles include circular and square.

[0019] Desirably, the base plate aperture size, the size and form of the captive resilient element and the size of constant cross section portion of the sleeve, are all optimised to enable sliding adjustment of the base plate along the constant cross section portion of the sleeve under an applied load, yet retain the base plate position relative to the sleeve when the load is removed.

[0020] Preferably, the base plate aperture size, the size and form of captive resilient element, and the size of constant cross section portion of the sleeve, are also configured with sufficient clearance between the constant cross sectional portion of the sleeve and aperture in the base plate to enable movement of the base plate relative to the constant cross sectional portion of the sleeve in axes that are not perpendicular to the first axis, to thereby accommodate situations where the spindle may not extend exactly perpendicular to the wall surface.

[0021] In some embodiments the sleeve may include a portion of constant cross section corresponding to the shape of the base plate aperture for sliding adjustment through the aperture and a portion of a different peripheral shape at an end remote from the base plate.

Brief Description of the Drawings [0022] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: [0023] Figure 1 is an exploded perspective view of the components of a first cylindrical embodiment wall flange according to the invention; [0024] Figure 2 shows two perspective views of the assembled wall flange of Figure 1 illustrated in two extreme operating positions indicating adjustment along the axis of the fitting; [0025] Figure 3 is a side view of the wall flange components of the previous Figures illustrating internal detail; [0026] Figures 4 is a side view of the assembled wall flange of the previous Figures illustrating angular variation of the base plate relative to the axis of the sleeve; [0027] Figure 5 is a sectional view of the wall flange of the previous Figures illustrating application where a breech body is located close to ideally relative to the wall; [0028] Figure 6 is a sectional view of the wall flange of the previous Figures illustrating application where a breech body is too deep to the wall [0029] ; Figure 7 is a sectional view of the wall flange of the previous Figures illustrating application where a breech body is too shallow to the wall [0030] Figure 8 is a sectional view of the wall flange of the previous Figures illustrating application where a breech body not set perpendicular to the wall; [0031] Figure 9 is an exploded perspective view of the components of a second square section embodiment wall flange according to the invention; [0032] Figure 10shows two perspective views of the assembled wall flange of Figure 9 illustrated in two extreme operating positions indicating adjustment along the axis of the fitting; [0033] Figures 11a and 11b compare a prior art fixed base plate fitting with the second embodiment wall flange with square base plate and square sleeve of Figures 8 and 9 which can be accurately aligned during installation; and [0034] Figures 12a and 12b compare a prior art fixed base plate fitting with a third embodiment wall flange with square base plate and cylindrical sleeve which can be easily and accurately aligned during installation.

Detailed Description [0035] Referring firstly to Figures 1 to 4, there is illustrated a first embodiment wall flange according to invention shown generally at 1. The wall flange 1 includes an outer wall engaging base plate 2 which has a first through aperture 3 which has a central axis 4. Captively retained within an o-ring seat 5, provided in a surface 6 parallel to the first axis 4, is a resilient o-ring 7.

[0036] A sleeve 8 is also provided which in this embodiment has an outer body 9 that is of constant cross section, configured so as to be slidably movable within the first aperture 3 along axis 4 against the o-ring 7. In this manner the sleeve 8 can be moved and resiliently retained anywhere between two extreme positions where the distal end 10 of the sleeve is either remote from, or adjacent, an outermost face 11 of the base plate 2 as exemplified in Figure 2.

[0037] Additionally, the size of the base plate aperture 3, the size and form of captive resilient o-ring 7, and the size of constant cross section portion 9 of the sleeve, are also configured with sufficient clearance between the constant cross sectional portion 9 of the sleeve and aperture 3 in the base plate to also enable movement of the base plate relative to the constant cross sectional portion of the sleeve in axes that are not perpendicular to the first axis 4 such as is illustrated in Figure 4. This enables the wall flange 1 to accommodate situations where the spindle may not extend exactly perpendicular to a wall surface.

[0038] The sleeve also includes means to adjustably engage with an SBA in the means of an internal threaded portion 12 as shown in hidden detail in Figure 3.

[0039] The operation and advantages of the wall flange of the invention are now described with reference to Figures 5 to 8.

[0040] Referring first to Figure 5 there is shown a cross sectional view of a tap assembly shown generally at 13 mounted to a wall 14 comprising a structural cladding board 15 to which an internal cladding 16, such as tiles, has been attached. The tap assembly includes a breech body 17 with connecting water pipe 18, an SBA shown generally at 19 with integral spindle 20, a wall flange of the invention shown generally at 1, and a tap handle 21.

[0041] The breech body 17 with connected water pipe 18 is usually secured to a structural portion of the wall, which for stud walls will typically be to a nogging or other horizontal frame element. Location of the breech body 17 relative to an inner surface 22 of the internal cladding 16 is very important, as this determines the offset of the tap handle 21 from outer surface of the wall.

[0042] As can be seen in Figure 5, there is shown an example of a breech that has been located in a close to ideal position relative to the wall, with the forward most portion of the breech body itself located within the thickness of the wall. This situation is accommodated with the wall flange of the invention as shown. This is done by securing the sleeve 8 to the threaded spigot of the spindle bonnet 23 of the SBA using the internal thread 12 as shown, the recess 24 accommodating the lock nut formation 25 on the SBA enabling the sleeve to sit as close in to the wall as needed. The base plate 2 is then slid back towards the wall until it engages the wall surface 22. In this particular situation the end of the sleeve Figure 6 illustrates how the same wall flange can accommodate the an extreme whereby the breech body has been set too deep into the wall. In this configuration, the sleeve 8 can extend right into the wall opening 26 to still engage the threaded spigot of the spindle bonnet 23, and the base plate 2 finishes up closer to the tap handle end of the sleeve as was illustrated in the right hand view of Figure 2. This would not be possible with a prior art single piece wall flange, as the end remote from the wall would be too close to, or foul with, the tap handle 21.

[0043] Figure 7 shows how the same fitting can also accommodate the other extreme in which the breech body has been located too shallowly within the wall recess. In this situation the sleeve 8 can be bought forward toward the tap handle a further amount almost approximating to the thickness of the base plate 2 as shown and still provide the desired appearance and function. However, it will be appreciated that with a fixed single piece wall flange of the prior art, the rear of the fitting would not be able to reach the wall.

[0044] Turning next to Figure 8, it illustrates how the wall flange of the invention can also accommodate installations where the spindle 20 does not protrude perpendicular to the inner wall surface 22. This can occur with or without the problems shown in Figures 5 and 6 and the operation is clear. As can be seen, the relative sizes of the aperture 3 of the base flange 2 and the outer sliding portion of the sleeve 8, along with the properties and size of the o-ring, have all been optimised to enable movement of the base plate relative to the constant cross sectional portion of the sleeve in axes that are not perpendicular to the first axis, which still holding the preferred orientation once in position.

[0045] This can be achieved in a number of different ways. However, in the example shown typical dimensions and approximate tolerances that have been found to work to provide translational and useful angular operation and are as follows:

Base Plate aperture size 31.40mm +/- 0.05

Sliding sleeve diameter 31.00mm +/- 0.05 O-ring Hole diameter 30.50mm +/- 0.05 O-ring cross sectional shape 2.00mm +/- 0.05

This provides for a typical maximum deflection of about 6mm at the plate edges or about 5 degrees.

[0046] It will be appreciated that the external dimensions of the sleeve will depend on the size and style of the tap and tap handle for which it is designed. For example, with tap handles of the kind including an outer sleeve with single radial pin or lever as commonly used with ceramic disc taps, the sleeve of the wall flange fitting may be narrower than fittings for taps with simple bar or cross tap handles.

[0047] In terms of providing a good range of adjustability for an example of one currently trending tap style as shown in the accompanying drawings, the following approximate dimensions have been found to work well. Sleeve length approximately 40mm. Base plate thickness approximately 10mm. Internal thread length approximately 10-15mm. Recess depth approximately 10mm or more.

[0048] Figures 9 and 10 show views of a second embodiment wall flange according to the invention where the base plate and the sleeve both have a square profile. It will be appreciated that with one piece prior art wall flanges having non circular profiles such as that shown in 10a and 11a, that there will be further limitation on adjustability and an even higher need for precision installation. This is because as the wall flange is screwed onto the spindle bonnet, the acceptable degree of engagement between the corresponding threads is limited to orientations where the integrally connected square flange is appropriately aligned, which may not correspond with engagement of the base plate with the wall surface as shown for example in 11a and 12a. With the two part wall flange of the invention where the sliding portion of the sleeve is cylindrical such as in 12b, alignment of the base plate is entirely independent of the connection to the spindle bonnet and so can be adjusted after connection of the sleeve to the SBA.

[0049] Accordingly, the invention provides numerous advantages over the prior art rigid wall flange fittings that secure to the spindle bonnet of an SBA, by enabling a single stock fitting to be used in a range of applications where the breech may not be located at the ideal depth relative to the wall. Preferred forms of the invention also enable the base plate to be mounted neatly flush with the wall, even when the spindle does not extend exactly square to the wall.

[0050] It will be appreciated that while most of the preferred embodiments illustrated use resilient elements in the form of continuous o-rings of circular shape to suit a circular aperture, other embodiments could use a different shape continuous ring to suit a correspondingly different shaped aperture such as shown in Figures 9 and 10. In other forms, instead of a continuous o-ring, a series of separate resilient elements may be disposed at spaced intervals around the aperture.

[0051] Additionally, while the preferred embodiments illustrated all have generally planar base plates consistent with current modern styling, these could be profiled as required. Similarly, while the illustrated sleeves are all of constant cross section, in other embodiments the sleeve could have a portion of its outer surface corresponding to the shape of the aperture in the base plate for sliding movement there through, but another portion of a different profile at or nearer the end remote from the base plate.

[0052] While the invention has been described with reference to various examples it will be appreciated by those skilled in the art that the invention is not limited to these particular examples and could be embodied within many other forms within the same inventive concept.

Claims (15)

1. Claims

   1. An adjustable wall flange fitting for recessed wall mounted taps, the fitting including: a wall engaging base plate with a first aperture there through having a first axis, a resilient element captively retained with the plate to extend at least partially into the first aperture, a longitudinally extending sleeve having a longitudinal axis corresponding to the first axis, the sleeve including means to adjustably engage a threaded spigot portion of a spindle bonnet on a stuffing box assembly to provide a first linear range of adjustment along the longitudinal axis, said sleeve also including an outer body portion of constant external cross section configured to be slidably movable along the longitudinal axis within said first aperture against the captive resilient element to provide a second linear range of adjustment along the longitudinal axis.
2. 2. An adjustable wall flange fitting according to claim 1 wherein the resilient element is in the form of a continuous o-ring type element which is held captive within an o-ring seat provided within a surface which defines the first aperture in a direction generally parallel to the first axis.
3. 3. An adjustable wall flange fitting according to claim 1 wherein the resilient element is in the form of one or more separate elements held captive within the base plate to extend at least partially into the first aperture.
4. 4. An adjustable wall flange fitting according to any one of the preceding claims wherein the first aperture and outer body portion of constant cross section portion of the sleeve have generally circular cross sectional profiles.
5. 5. An adjustable wall flange fitting according to any one of the preceding claims wherein the sleeve is generally cylindrical.
6. 6. An adjustable wall flange fitting according to any one of the preceding claims wherein the means provided on the sleeve to adjustably engage the spindle bonnet on a stuffing box assembly is in the form of an internal threaded region provided between ends of the sleeve.
7. 7. An adjustable wall flange fitting according to claim 6 wherein the internal thread region does not extend to the ends and is not located centrally along the axis of the sleeve.
8. 8. An adjustable wall flange fitting according to claim 6 or claim 7 wherein the internal thread region has a length of at least about 10 to 15mm.
9. 9. An adjustable wall flange fitting according to any one of the preceding claims wherein the end of the sleeve configured to be positioned proximal to the breech body has a recess adapted to accommodate a lock nut formation provided on the stuffing box assembly behind the threaded spigot.
10. 10. An adjustable wall flange fitting according to claim 8 wherein the recess has a depth in excess of 8mm.
11. 11. An adjustable wall flange fitting according to any one of the preceding claims configured for use with tap handles that do not cover the end of the sleeve, wherein the sleeve includes an end cover with central aperture for the spindle to extend through.
12. 12. An adjustable wall flange fitting according to claim 8 wherein the end cover is made separately from the sleeve and can be releasably connected to either end of the sleeve.
13. 13. An adjustable wall flange fitting according to any one of the preceding claims wherein the base plate aperture size, size and form of captive resilient element and size of constant cross section portion of the sleeve, are optimised to enable sliding adjustment of the base plate along the constant cross section portion of the sleeve under an applied load, yet retain the base plate position relative to the sleeve when the load is removed.
14. 14. An adjustable wall flange fitting according to any one of the preceding claims wherein the base plate aperture size, the size and form of captive resilient element, and the size of constant cross section portion of the sleeve, are configured with sufficient clearance between the constant cross sectional portion of the sleeve and aperture in the base plate to enable movement of the base plate relative to the constant cross sectional portion of the sleeve in axes that are not perpendicular to the first axis, to thereby accommodate situations where the spindle may not extend exactly perpendicular to the wall surface.
15. 15. An adjustable wall flange fitting according to any one of claims 1 to 3 and 6 to 12 when not dependent on claims 4 or 5, wherein the sleeve may include a portion of constant cross section corresponding to the shape of the base plate aperture for sliding adjustment through the aperture and a portion of a different peripheral shape at an end remote from the base plate.