AU2019229379A1 - An Improved Tap Assembly - Google Patents

Abstract

A tap assembly comprising: a body; a spindle assembly incorporating a spindle housing; a locking component; and a covering flange, wherein, when the tap assembly is assembled: the spindle assembly is mounted to the body with a portion, but not all, of the spindle housing located within the body; the locking component is mounted on the outside of a portion of the spindle housing which is not located within the body, and the covering flange is mounted to the outside of the locking component. Figure 1 Figure 2 Figure 3

Description

TECHNICAL FIELD [0001] The present invention relates to tap assemblies, and embodiments and variations of the invention may often be employed for use in water taps used in domestic applications (e.g. in hot and cold water taps for sinks, showers, baths and the like of bathrooms and laundries in homes, hotels, offices, etc.). However, no limitation is to be implied from this and the invention could also be employed in taps used in other applications.

BACKGROUND [0002] It is to be clearly understood that mere reference in this specification to any previous or existing products, devices, apparatus, systems, methods, ways of doing things, practices, publications or indeed to any other information, or to any problems or issues, does not constitute an acknowledgement or admission that any of those things, whether individually or in any combination, were known or formed part of the common general knowledge of those skilled in the field, or that they are admissible prior art.

[0003] In the field of taps and tap assemblies, and particularly for hot and cold water taps for sinks, basins, showers, baths and the like of bathrooms and laundries in homes, hotel rooms, offices, etc, it is often desired by e.g. the owner or occupant of the home or office or the like that the covering flange of the tap assembly be “slimline” in profile relative to the wall or other surface into which the tap assembly is mounted (i.e. the surface from which the tap spindle and handle extend). This is depicted in Figure 1.

[0004] The components of the tap assembly visible in Figure 1 are the handle 1, the spindle 2 and the covering flange 3. The tap handle 1 is mounted on the outer end of the spindle 2 (i.e. the handle 1 is mounted to the outer end of the portion of the spindle 2 which extends out from the surface in which the tap assembly is mounted). The spindle 2 also extends through a hole in the covering flange 3 and into/through the surface in which the tap assembly is mounted where it connects to other parts of the spindle assembly and operates the valve of the tap assembly. The

2019229379 12 Sep 2019 covering flange 3 (which happens to be circular in Figure 1 but which can have a range of shapes in a plane parallel to the surface in which the tap assembly is mounted) is essentially a cosmetic cover that conceals/hides other portions of the tap assembly, and also the hole in the surface in which the assembly is mounted, that would otherwise be visible and unsightly were these not covered (hidden from view) by the covering flange 3. The covering flange 3 shown in Figure 1 is “slimline” in the sense that it is thin in the dimension perpendicular to the surface in which the tap assembly is mounted (this is unlike some other non-slimline covering flanges (not shown) which have a shape that extends quite some way out in the direction perpendicular to the surface in which the tap assembly is mounted, often to conceal other parts of the tap assembly that extend out from within (i.e. proud of) the surface but which are located/hidden behind/within the non-slimline flange), and the covering flange 3 sits directly against that surface. This slimline appearance of the covering flange 3 when the covering flange 3 is mounted directly against (and in contact with) the surface is often considered to give tap assemblies such as this, when installed correctly as shown in Figure 1, a modern look, and this modern look is often strongly desired.

[0005] However, there are often difficulties in achieving this modern look, even where a tap assembly which is designed to provide this modern look is used. This is particularly so where a tap assembly which is designed to provide this modern look is required to be retrofitted into an older or pre-existing house or other building, and especially where the wall or other surface into which the tap assembly is to be mounted was not originally designed to receive or accommodate a tap assembly configured to provide this modern look. Generally, the same difficulties do not arise (or they do not arise as often) where a tap assembly which is configured to provide this modern look is required to be installed in a new-build house or other building because, in “new-builds”, the walls or other surfaces into which the tap assembly is to be mounted are (or can be) designed so as to accommodate such assemblies and allow the modern looked to be achieved.

[0006] It is thought that it may be desirable if a tap assembly could be provided which is configured to allow the above-mentioned modern look to be achieved (or more easily achieved) in situations where the tap assembly is required to be

2019229379 12 Sep 2019 retrofitted into an older or pre-existing house or other building in which the wall or other surface into which the tap assembly is to be mounted, and the existing plumbing, was not originally designed and/or installed/built in a manner to accommodate the kinds of tap assemblies that have previously been used to achieve the above-mentioned modern look..

SUMMARY OF THE INVENTION [0007] In one form, although not necessarily the only or the broadest form, the invention resides in a tap assembly comprising:

a body;

a spindle assembly incorporating a spindle housing;

a locking component; and a covering flange, wherein, when the tap assembly is assembled:

the spindle assembly is mounted to the body with a portion, but not all, of the spindle housing located within the body;

the locking component is mounted on the outside of a portion of the spindle housing which is not located within the body, and the covering flange is mounted to the outside of the locking component.

[0008] The spindle assembly may further incorporate a spindle and a valve portion, wherein the spindle is able to rotate relative to the spindle housing, and when the tap assembly is assembled, the valve portion may cooperate with features of the body to allow fluid to flow through the body when the spindle is turned one way and to prevent fluid from flowing through the body when the spindle is turned the other way.

[0009] When the tap assembly is assembled, the locking component may be mounted radially on the outside, relative to a longitudinal axis of the spindle, of the portion of the spindle housing which is not located within the body. Also, when the tap assembly is assembled, one side of the locking component may press against or towards the body in a direction parallel to the longitudinal axis, and the locking assembly may not extend in the opposite direction parallel to the longitudinal axis further than the end of the spindle housing.

2019229379 12 Sep 2019 [0010] A portion of the covering flange which engages with the locking component may do so radially on the outside, relative to the longitudinal axis, of the locking component.

[0011] The spindle housing may have an externally threaded portion, and when the tap assembly is assembled, a portion of the externally threaded portion of the spindle housing may be screwed into a corresponding internally threaded opening in the body.

[0012] The tap assembly may further comprise a sealing component which, when the tap assembly is assembled, is located on the outside of the portion of the spindle housing that is not within the body and between the body and the locking component. The sealing component may have an internal thread, and when the tap assembly is being assembled, the sealing component may be screwed onto an externally threaded portion of the spindle housing that is not located within the body. The locking component, which may have an internal thread, may then be screwed onto the said externally threaded portion of the spindle housing which is not located within the body, such that the sealing component is compressed between the locking component and the body.

[0013] The sealing component and the locking component may each be configured in such a manner that when the sealing component is compressed between the locking component and the body, the sealing component is also pressed radially inwards, relative to the longitudinal axis, into the threads on outside of the spindle housing. In some embodiments, the sealing component may have a sloped portion, and the locking component may also have a sloped portion which engages with the sloped portion on the sealing component when the tap assembly is assembled, and the slopes of the respective sloped portions may be such that, when the sealing component is compressed between the locking component and the body, this also causes the sealing component to be pressed radially inwards into the threads on outside of the spindle housing.

[0014] The locking component may have external threads thereon, and a portion of the covering flange which engages with the locking component may be internally threaded, such that the said portion of the covering flange screws onto the outside of

2019229379 12 Sep 2019 the locking component. The locking component may also have an internal thread so that it can be screwed onto an externally threaded portion of the spindle housing which is not located within the body, and the locking component may further have a number of flat surfaces on its radial/outer perimeter, which flat surfaces may be operable to allow the locking member to be gripped and turned by a tool. The locking component may further have a number of curved surfaces on its radial/outer perimeter, which are spaced in between the flat surfaces on the radial/outer perimeter, and the external threads in the locking component may be formed in the curved surfaces.

[0015] When the tap assembly is installed, the body may be positioned within a space or cavity behind a surface (e.g. a wall sheet or countertop surface or the like) from which the spindle of the spindle assembly extends. Also, when the tap assembly is installed, a portion of the spindle housing, which is not located within the body, may extend, in a direction parallel to the longitudinal axis of the spindle, some, but not all, of the way through the thickness of the surface from which the spindle extends.

[0016] When the tap assembly is installed, the locking component may be at least partially located within the thickness of the surface from which the spindle extends but it may not project out or proud from the said surface. And, when the tap assembly is installed, a portion of the covering flange which engages with the locking component may do so radially on the outside, relative to the longitudinal axis, of the locking component, i.e. at a location which is at least partially within the thickness of the surface, and an outer portion of the covering flange may come into contact with the outer face of the surface to give the oft-desired modern look.

BRIEF DESCRIPTION OF THE DRAWINGS [0017] Preferred features, aspects and variations of the invention and its various embodiments may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting, in anyway, the scope in the Summary of the Invention above. The Detailed Description will make reference to a number of drawings as follows:

2019229379 12 Sep 2019 [0018] Figure 1 shows an installed tap assembly having a modem look wherein the covering flange is slimline and sits directly against the surface in which the tap assembly is installed.

[0019] Figure 2 is a side view of a prior art tap assembly of the kind configured to provide the modern look (i.e. where the covering flange is slimline and sits directly against the surface in which the tap assembly is installed). This Figure shows the tap assembly installed in (and so that the tap extends horizontally out from) a vertical wall panel. Note that, in this Figure, a number of the components of the tap assembly (and also the wall panel in which the assembly is mounted) are shown as transparent in order that the other parts of the assembly may be seen. Note also that, in this Figure, the tap assembly is illustrated mounted to the wall panel in the manner which is usually possible in new-build scenarios (i.e. where the wall cavity and plumbing have been designed so as to accommodate this form of prior art tap assembly).

[0020] Figure 3 is similar to Figure 2 in that it is a side view of the same prior art tap assembly, again with a number of the components of the assembly (and also the wall panel) shown as transparent. However, unlike Figure 2 which shows this prior art tap assembly mounted to the wall panel in the correct manner which is usually possible in new-build scenarios, Figure 3 illustrates a problem (and the consequent incorrect installation of the tap assembly) that can sometimes occur where this prior art tap assembly is to be installed as a retrofit in an older or pre-existing house or building, which can prevent the covering flange from sitting directly against the surface (the wall panel in this case) in which the tap assembly is mounted. Hence, this prevents the desired aesthetic shown in Figure 1 from being achieved.

[0021] Figure 4 is, again, a side view of the same prior art tap assembly as in Figure 2, and in Figure 4 the tap assembly is installed correctly like in Figure 2; however Figure 4 shows a number of the components of the assembly that cannot be made out in Figure 2 and Figure 3.

[0022] Figure 5 is, yet again, a side view of the same prior art tap assembly as shown in Figure 2, Figure 3 and Figure 4. The wall panel is not shown in Figure 5. Figure 5 illustrates the function of a particular washer and a particular O-ring, which

2019229379 12 Sep 2019 are required to prevent certain undesirable flows of water through this prior art tap assembly.

[0023] Figure 6 is an exploded perspective view of a pair of tap assemblies, each in accordance with an embodiment of the present invention (the two tap assemblies shown in Figure 6 are actually identical to one another). The components of both of the tap assemblies are shown in exploded view relative to the surface in which the assemblies are mounted (which in this case is a wall panel adjacent to or above a bath, sink basin or the like).

[0024] Figure 7 is a side view of a single tap assembly in accordance with the same embodiment (and identical to) the two tap assemblies shown in Figure 6. The tap assembly in Figure 7 is also shown in exploded view relative to the surface in which the assembly is mounted. However, whereas Figure 6 shows the two assemblies exploded relative to a wall panel which is adjacent to or above a bath or sink or basin or the like, Figure 7 shows a single one of these tap assemblies exploded relative to a shower wall panel (i.e. a wall panel in which this shower tap and also the pipe leading to the showerhead is mounted).

[0025] Figure 8 is similar to Figure 5 except that the tap assembly depicted is the tap assembly in the embodiment of the invention shown in Figure 6 and Figure 7, not the prior art tap assembly shown in Figure 2, Figure 3, Figure 4 and Figure 5.

[0026] Figure 9 illustrates the operation of the compression lock-nut and dual sealing ring in the depicted embodiment and the way in which the (single) seal (created by the dual sealing ring) prevents essentially the same undesirable flows of water through the tap assembly as shown on the prior art tap assembly in Figure 5 (except that the prior art tap assembly requires a separate washer and O-ring to prevent these undesirable flows).

[0027] Figure 10 is a side on (partially cross-sectional and partially transparent) view of the spindle subassembly used in the embodiment of the tap assembly shown in Figure 6, Figure 7, Figure 8 and Figure 9. Note that the spindle subassembly used in this depicted embodiment of the inventive tap assembly is modified compared to the spindle assembly used in the prior art tap assembly shown in Figure 2, Figure 3, Figure 4 and Figure 5.

2019229379 12 Sep 2019 [0028] Figure 11 is a perspective view of the same modified tap spindle subassembly as shown in Figure 10.

[0029] Figure 12, Figure 13 and Figure 14 are perspective, end and side views, respectively, of the lock-nut used in the depicted embodiment of the inventive tap assembly.

[0030] Figure 15 is actually the same as Figure 13, and Figure 16 is a crosssectional side view of the lock-nut taken in the plane A-A in Figure 15, and both of these Figures show dimensions, thread specifications, and the like for this part in one very specific commercial embodiment.

[0031] Figure 17 and Figure 18 are both perspective views, from opposite sides respectively, of the dual sealing ring used in the depicted embodiment of the inventive tap assembly.

[0032] Figure 19 and Figure 20 are front and side views, respectively, of the dual sealing ring in Figure 17 and Figure 18. In Figure 19 and Figure 20, certain hidden details of the dual sealing ring are shown by the phantom dashed lines.

[0033] Figure 21 is a cross-sectional side view of the dual sealing ring showing the dimensions, thread specifications, and the like for this part in one very specific commercial embodiment, being the same embodiment as the lock-nut shown in Figure 15.

DETAILED DESCRIPTION [0034] As mentioned above, Figure 2 is a side view of a prior art tap assembly of the kind configured to provide the “modern look” described in the Background section above (i.e. where the covering flange is slimline and sits directly against the surface in which the tap assembly is installed). And in fact, Figure 2 shows the prior art tap assembly installed correctly so that the desired modern look and aesthetic (i.e. the look shown in Figure 1) is achieved. The fact that the prior art tap assembly depicted in Figure 2 is installed correctly to achieve the desired modern look is evident because the slimline covering flange 3 is positioned directly in contact with the outer surface of the wall panel W in which the tap assembly is installed.

2019229379 12 Sep 2019 [0035] The main components of the prior art tap assembly that are shown in

Figure 2 are:

- the tap handle 1,

- the spindle 2’ (note that in Figure 2, and hereafter, the reference number 2 designates the entire spindle assembly of this prior art tap assembly, which includes the spindle 2' itself, but which also includes the parts labelled 2” and 2’),

- the covering flange 3,

- the in-wall body 4,

- the lock-nut component 5,

- the flange nut 6,

- the sealing washer 7, and

- the wall panel W (e.g. the gyprock or tiled wall surface or the like in which the tap assembly is installed and from which the tap handle 1 and spindle 2’ extend - this wall panel W will generally be connected to and supported by the internal wall framing comprising e.g. studs, bracing, nogging etc., none of which are shown). Note that if Figure 2 were rotated 90° counterclockwise, so that the spindle 2’ instead extended vertically upwards relative to the outer surface of the panel W, the panel W would then effectively represent a horizontal surface such as e.g. a kitchen countertop or horizontal bathroom sink/basic top or the like, and this is indeed a way in which such tap assemblies can also be installed.

[0036] Although not shown in Figure 2, the prior art tap assembly also includes a secondary seal O-ring 8, as well as other O-rings 9 and 9’ which are required to seal the covering flange 3. See Figure 4. Note that the covering flange 3 also has a boss portion 3' on the inside thereof (again see Figure 4). One of the O-rings 9’ is located within this boss portion 3', to seal between the boss 3’ and the spindle 2’. The boss portion 3' is externally threaded and screws into one internally threaded end of the flange nut 6.

[0037] In Figure 2, the dashed lines extending out to the left-hand side from the end of the in-wall body 4 represent the hot or cold water piping (or a plumbing fitting connecting to such piping) that delivers the hot or cold water to the tap assembly (i.e.

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2019229379 12 Sep 2019 into the in-wall body 4). The water from this piping or plumbing fitting enters the inwall body 4 through an opening in the end of the in-wall body 4 (see Figure 4), as indicated by arrow A. Note that the opening which allows the flow of water into the inside of the in-wall body (as indicated by arrow A) could alternatively be located in the side wall of the in-wall body rather than in the end wall thereof. The way in which water flows within and through the tap assembly, and also certain undesirable flows which the tap assembly is designed to prevent, will be discussed further below. However, note that, because the in-wall body 4 is connected to the hot or cold water piping, and because this water piping is contained inside the wall cavity behind the wall panel W, it follows that the in-wall body 4 and certain other components of the prior art tap assembly are also located within the wall cavity (behind the wall panel W).

[0038] The in-wall body 4 is connected to, and it is held in place (at least partially) by such connection to, the piping or plumbing fittings through which the hot or cold water is delivered to and from the tap assembly. The spindle assembly 2 includes a component which is designated 2 in Figure 2. As can be seen, this component 2 of the spindle assembly is externally threaded. It can also be seen that the spindle 2' extends through an axial through-bore in the component 2, such that ends of the spindle 2' extend out from both sides of the component 2. The handle 1 attaches to one of the ends of the spindle 2' (so that turning the handle 1 turns the spindle 2’), and on the other end of the spindle 2', namely the end which projects out from the opposite side of the component 2, there is mounted (or there is located) the valve elements (these valve elements are generally designated by reference numeral 2'). It is these valve elements 2', which are located inside the in-wall body 4 when the tap assembly is assembled, that move when the tap handle 1 (and spindle 2’) is turned (when the tap is turned on or off) to control whether water is able to flow through the tap assembly. This will be understood by those skilled in this area.

[0039] The outward-facing end of the in-wall body 4, which faces towards the inside/back surface of the wall panel W, has an opening therein which is internally threaded with a diameter and thread configuration to match the diameter and external thread configuration on the component 2. Consequently, the external

2019229379 12 Sep 2019 threads on the outside of the component 2 screw into the internal threads in the end of the in-wall body 4 thereby connecting these two components together. However, the whole externally threaded length of the component 2 does not screw into the end of the in-wall body 4. Rather, a portion of the externally threaded length on the outside of the component 2 remains on the outside (i.e. projecting out to the right hand side in Figure 2) of the in-wall body 4. An internally threaded portion of the lock nut component 5 screws onto this remaining projecting threaded portion of the component 2 - i.e. the lock nut component 5 screws onto the portion of the component 2 which remains on the outside of the in-wall body 4. One of the functions of the lock nut component 5 is that it functions as a lock nut to help prevent the component 2 from unscrewing relative to the in-wall body 4.

[0040] Actually, before the lock nut component 5 is screwed onto this projecting portion of the component 2, the sealing washer 7 is first placed around the outside of the projecting threaded portion of the component 2, and then the lock nut component 5 is screwed on until the washer 7 is firmly squashed between the lock nut component 5 and the end of the in-wall body 4. The purpose of the sealing washer 7 will be discussed further below.

[0041] It will also be seen from Figure 2 that, on the exterior of the lock nut component 5, on the opposite end thereof to the washer 7 and in-wall body 4, there is an externally threaded portion. When the overall tap assembly is installed as shown in Figure 2, a portion of this externally threaded portion of the lock nut component 5 extends into (but not all the way through) the wall panel W. However, this external threaded portion on the lock nut component 5 does not itself screw into (or directly engage) the wall panel W. The component which extends through the full thickness of the wall panel W, and which may come into contact with the wall panel (in places on its outside, although it also may not directly contact the wall) is the flange nut 6. As can be appreciated from Figure 2, the flange nut 6 is internally threaded such that the lock nut component 5 is screwed into the flange nut 6. However, the threaded portion of the lock nut component 5 does not extend all the way through the flange nut 6 either. The flange nut 6 does, however, extend through the full thickness of the wall panel W, and in fact it projects slightly from both the inner and outer surfaces of the wall panel W. As mentioned above, the covering

2019229379 12 Sep 2019 flange 3 has a central boss 3’ formed on the inside thereof (i.e. on the side that faces the outer surface of the wall panel W) - this is shown in Figure 4 - and this cylindrical boss 3’ is externally threaded with a thread and diameter configured to screw into the threaded end of the flange nut 6 that projects from the outer surface of the wall panel W. Therefore, once the tap assembly has been assembled and installed (i.e. connected into the plumbing and secured in the wall panel), then as one of the final steps (typically before finally attaching the handle 1 to the spindle 2'), the covering flange 3 is screwed into the flange nut 6 such that the external perimeter portions of the flange 3 come into contact with the outer surface of the wall panel W to thereby give the desired modem look.

[0042] Turning now to Figure 3, as mentioned above, this illustrates a problem (and the consequent incorrect installation of this kind of prior art tap assembly) that can sometimes occur where this prior art tap assembly is to be installed as a retrofit in an older or pre-existing house or building, which can prevent the covering flange from sitting directly against the surface. Basically, the problem is that, in older or preexisting houses and buildings, the amount of space that exists behind the wall panel W, and more specifically between the existing water piping (or the so called combination”, being the piping which delivers the cold and hot water to respective taps - indicated by dashed lines) and the back or internal face/surface of the wall panel W is not large enough to properly accommodate the tap assembly. To illustrate this problem, in Figure 2 (which illustrates the prior art tap assembly installed correctly), the amount of space that exists between the water piping (or the “combination”) and the back/internal face of the wall panel W is indicated in as δ1. The amount of space indicated as δ1 is really (or almost) the minimum amount of space required to properly accommodate this prior art tap assembly if it is to be correctly installed. However, in Figure 3, which represents an old or existing building, the amount of space that exists between the pre-existing water piping (or the existing “combination”) and the back/internal face of the wall panel W, which is indicated in as δ2, is significantly less than δ1. In other words, the amount of space that exists between the existing water piping and the back/internal face of the wall panel W (δ2) in this older building is significantly less than the minimum amount of space (δ1) required to properly accommodate the prior art tap assembly. As a result, an attempt to install the prior art tap assembly, as shown in Figure 3, results in much of the

2019229379 12 Sep 2019 assembly being installed (or becoming located) further forward towards or though the outer surface of the wall panel W, with the consequent result that (even if the covering flange 3 is screwed all the way in as far as it can go into the flange nut 6, and in fact even if all components are screwed together to compact the assembly as much as possible) a significant gap (G) remains between the outer surface of the wall panel W and the inward permitter edges of the covering flange 3 that are supposed to contact the wall panel. Consequently, the tap assembly does not look the way it should (i.e. it does not achieve the modern look shown in Figure 1).

[0043] Another related problem can also arise in that the fact that the above will occur (i.e. the fact that it is not always possible to correctly installed the prior art tap assembly due to the lack of sufficient space between the water piping and the internal surface of the wall panel W in pre-existing buildings, with a consequent gap G therefore remaining between the outer surface of the wall panel W and the covering flange 3 when the tap assembly is installed) is not discovered until an attempt is actually made to install the prior art tap assembly (e.g. by a plumber, after the customer has already bought or specified the taps). And when this is discovered, and it is realised that the desired modern look cannot be achieved using this prior art tap assembly in these retrofit scenarios, these prior art tap assemblies are often returned to the manufacturer/supplier as defective or not fit for purpose, but the manufacturer/supplier is also often then unable to sell the tap assembly again (e.g. due to damage to surface finishes or the like caused during the failed first installation attempt) such that the returned tap assembly must be discarded, and this represents a financial loss to the manufacturer/supplier (for a problem that often was not of the manufacturer's/supplier’s doing - often the manufacturers/suppliers are not consulted about the appropriateness of the particular tap assembly for a desired installation prior to purchase - and manufacturers/suppliers typically also supply detailed product information and installation instructions, which make it clear that this prior art tap assembly may not be suitable for installation in all (and particularly in retrofit) scenarios, but these instructions are often simply discarded and not read by plumbers and installers).

[0044] Turning now to Figure 5, this Figure illustrates the way that (as mentioned above) water enters the in-wall body 4 through an opening in the end of the in-wall

2019229379 12 Sep 2019 body, as indicated by arrow A. Actually, it is perhaps more accurate to say that, when the tap is turned off, the sealing elements 2' engage with surfaces on the inside of the in-all body 4 to prevent water from entering the in-wall body 4 through the opening (i.e. the sealing elements prevent the flow of water indicated by arrow A). However, when the tap is turned on, the sealing elements 2' move or disengage so as to allow water to flow into the inside of the in-wall body 4 through the opening in the end of the on-wall body, as indicated by arrow A. Recall, however, that the opening through which water flows into the inside of the in-wall body could alternatively be located in the side of the in-wall body, rather than in the end. In any case, when the tap is turned on, water flows into the space inside the in-wall body 4 and it then exits the in-wall body 4 through an opening (not shown) which is generally located in the side wall of the in-wall body. After exiting the in-wall body 4, the water then proceeds to flow into and through piping leading to the water spout, showerhead, or other water outlet controlled by the tap assembly.

[0045] However, there are a number of sealing components provided in the prior art tap assembly to prevent undesired flows of water therethrough, some of which will now be explained. One of these undesirable flows is water that flows (or attempts to flow) between the exterior threaded surface of the component 2 and the internal threaded surface of the in-wall body 4 and which tries escape through any gap that exists between the in-wall body 4 and the lock nut component 5. This flow of water attempting to escape this way is indicated as B in Figure 5. Water that attempts to escape this way is, however, prevented from doing so by the washer 7, as indicated by the crossed arrow B'. However, because the washer 7 is only compressed in the longitudinal/axial direction, between the in-wall body 4 and the lock nut component 5, it may not necessarily also prevent water from continuing to flow in the longitudinal/axial direction along the threads between the in-wall body 4 and the component 2 i.e. “underneath” the washer 7 (i.e. through the space between the inside of the washer 7 and the threads on the outside of the component 2), as indicated by arrow C. This flow C that may continue underneath the washer 7 is prevented by the O-ring 8, as indicated by the crossed arrow C.

[0046] Turning now to Figure 6 and Figure 7, these show a tap assembly in accordance with an embodiment of the present invention (the two tap assemblies

2019229379 12 Sep 2019 shown in Figure 6 are identical to one another). In Figure 6, the components of both of the tap assemblies are shown in exploded view relative to the wall panel W in which the assemblies are mounted, which in the case of Figure 6 is a wall panel adjacent to or above a bath, sink, basin or the like. The water piping extending from (and through) the wall panel W which leads to the spout controlled by the two taps in Figure 6 is indicated as S. Figure 7 shows a single one of these tap assemblies, from the side, and exploded relative to a shower wall panel W (i.e. a wall panel W in which this shower tap assembly and also the pipes leading to the tap assembly, and from the tap assembly to the showerhead, are mounted). The water piping extending from the wall panel W which leads to the showerhead controlled by the tap in Figure 7 is indicated as S’.

[0047] The main components of the tap assembly shown in Figure 6 and Figure 7 are:

- the tap handle 10,

- the spindle 20 assembly (note that in Figure 6 and Figure 7, and hereafter, the reference number 20 designates the entire spindle assembly of the tap assembly in this embodiment, and the spindle assembly 20 includes the spindle 22 and also the parts labelled 24 and 26),

- the covering flange 30,

- the in-wall body 40,

- the lock-nut 50,

- the dual sealing ring 70, and

- the wall panel W.

[0048] The water piping that delivers water to, and from, the in-wall body 40 is shown, but not labelled, in Figure 6 and Figure 7.

[0049] Similar to the prior art tap assembly discussed above, in each tap assembly shown in Figure 6 and Figure 7, the in-wall body 40 is connected to, and it is held in place (at least partially) by its connection to the piping or plumbing fitting through which the hot or cold water is delivered to and from the tap assembly. The spindle assembly 20 includes a component which is designated 24 - see Figure 10 and Figure 11. As can be seen, this component 24 of the spindle assembly 20 (like component 2 above) is externally threaded. It can also be seen that the spindle 22

2019229379 12 Sep 2019 extends through an axial through-bore in the component 24, such that ends of the spindle 22 extend out from both sides of the component 24. The handle 10 attaches to one of the ends of the spindle 22 (so that turning the handle 10 turns the spindle 22), and on the other end of the spindle 22, namely the end which projects out from the opposite side of the component 24, there is mounted (or there is located) the valve elements (these valve elements are generally designated by reference numeral 26). It is these valve elements 26, which are located inside the in-wall body 40 when the tap assembly is assembled, that move when the tap handle 10 (and spindle 22) is turned (when the tap is turned on or off) to control whether water is able to flow through the tap assembly.

[0050] The forward-facing end of the in-wall body 40, which faces towards the outer surface of the wall panel W, has an opening therein which is internally threaded with a diameter and thread configuration to match the diameter and external thread configuration on the component 24. Consequently, the external threads on the outside of the component 24 screw into the internal threads in this end of the in-wall body 40 thereby connecting these two components (the component 24 of the spindle assembly 20 and the in-wall body 40) together. However, the whole externally threaded length of the component 24 does not screw into the end of the in-wall body 40. Rather, a portion of the externally threaded length on the outside of the component 24 remains on the outside (i.e. projecting out to the right hand side in the Figures) of the in-wall body 40. An internally threaded portion 52 on the smallest internal diameter portion of the lock nut 50 screws onto this remaining projecting threaded portion of the component 24 - i.e. the lock nut 50 screws onto the portion of the component 24 which remains on the outside of the inwall body 40. Similar to the lock nut component 5 above, one of the functions of the lock nut 50 is that it functions as a lock nut to help prevent the component 24 from unscrewing relative to the in-wall body 40. Actually, before the lock nut 50 is screwed onto this projecting portion of the component 24, the dual sealing ring 70 is first mounted (screwed) onto the outside of the projecting threaded portion of the component 24, and then the lock nut 50 is screwed on after it so that the dual sealing ring 70 becomes firmly squashed axially between the lock nut 50 and the end of the in-wall body 40, and also radially inward against the threads on the outer surface of

2019229379 12 Sep 2019 the component 24. The configuration of the lock nut 50 and the dual sealing ring 70, and the cooperation between these two components, will be discussed further below.

[0051] It will next be seen from Figure 12 through Figure 16 that, on the exterior perimeter of the lock nut 50, there are a number of flat faces 55. In this particular embodiment there are six of these flat faces 55 arranged in a manner to be easily engageable (and hence the lock nut 50 can be easily turned) by a spanner or socket wrench or the like. Spaced in between the respective flat faces 55 around the exterior perimeter of the lock nut 50 are a number (again six in this embodiment) of curved edge faces 56. Importantly, these curved edge faces 56 have threads cut or tapped or otherwise formed into them. The purpose and function of these curved and threaded edge faces 56 will be described further below.

[0052] As shown particularly in Figure 7 and Figure 8, when the tap assembly in this depicted embodiment is installed, the whole of the in-wall body 40 is positioned within the wall cavity behind the wall panel W. The open end of the in-wall body 40, which receives the component 24 of the spindle assembly, may be located close to or even in line with the internal surface of the wall panel W; however the in-wall body 40 generally does not extend much (if at all) into or through the thickness of the wall panel W. However, the component 24 of the spindle assembly which is received in that end of the in-wall body 40, and in particular the portion of the component 24 which projects beyond the end of the in-wall body, does extend some (but not all) of the way through the thickness of the wall panel W, i.e. into the opening O in the wall panel W which is formed to receive the tap assembly. Actually, where the tap assembly in accordance with the present embodiment is employed, the opening O which is formed in the wall panel W must have a diameter which is sufficiently large to receive the enlarged boss portion 32 on the covering flange 30. The reason for this will become apparent below.

[0053] As mentioned above, before the lock nut 50 is screwed onto the portion of the component 24 that projects from the in-wall body 40, the dual sealing ring 70 is mounted onto the outside of the projecting threaded portion of the component 24,and then the lock nut 50 is screwed on so that the dual sealing ring 70 is firmly squashed axially between the lock nut 50 and the in-wall body 40 and radially inward against the threads on the component 24. Once the lock nut 50 has been screwed

2019229379 12 Sep 2019 on thus, the covering flange 30 can be installed. This is done by initially sliding the covering flange 30 onto (or over) the spindle 22, so that the spindle 22 extends through the central circular opening in the covering flange 30. It will also be seen from Figure 7 in particular that on the inward-facing side of the covering flange 30 there is a boss portion 32. Note that the boss portion 32 on covering flange 30 is much larger than the boss portion 3' in the covering flange 3 of the prior art tap assembly. Also note that, unlike the boss portion 3' in the prior art tap assembly, which is a small-ish diameter and externally cylindrical boss 3’ extending around only very close to the outer surface of the spindle 2', the boss portion 32 on the covering flange 30 is much larger in diameter, with a radially internal face which is threaded, and the radially internal threaded face is spaced quite a distance away (outward) from the surface of the spindle 22. Importantly, the internal diameter and the thread configuration on the radially internal face of the boss portion 32 matches the external diameter and thread configuration on the curved edge faces 56 on the lock nut 50. Therefore, after the lock nut 50 has been screwed on as described above, and after the covering flange 30 has been initially slid onto the spindle 22, the covering flange can be finally installed in position by screwing the covering flange onto the outside of the lock nut 50, as shown in Figure 8.

[0054] Next recall from above that the component 24 of the spindle assembly, which is received in the end of the in-wall body 40, and in particular the portion of the component 24 which projects beyond the end of the in-wall body, extends some of (but not all of) the way through the thickness of the wall panel W. It should also be noted that the thickness of the lock nut 50 (i.e. it's dimension parallel to the thickness dimension of the wall panel W) is less than the thickness of the wall panel W. Therefore, when the lock nut 50 is screwed as far as it can be onto the component 24, such that an innermost surface of the lock nut 50 (in the axial direction) contacts the end of the in-wall body 40, no portion of the lock nut 50 remains or extends proud of the outer surface of the wall panel W. This, in turn, means that when the covering flange 30 is screwed all the way onto the outside of the lock nut 50, the inward side of the outermost perimeter edge of the covering flange 30 comes directly into contact with the outer surface of the wall panel W, as required in order to achieve the desired modern look.

2019229379 12 Sep 2019 [0055] It was mentioned above that, after the dual sealing ring 70 has been mounted onto the projecting portion of the component 24, the lock nut 50 is then screwed onto component 24 so that the dual sealing ring 70 is firmly squashed between the lock nut 50 and the end of the in-wall body 40, and also radially inward against the threads on the outer surface of the component 24. In order to understand this in more detail, it is useful to refer to Figure 12 through Figure 21. Referring to Figure 17 first, this figure clearly shows that the dual sealing ring 70 has an inwardfacing surface 72 with threads formed therein. These threads correspond in diameter and thread configuration to the external threads on the component 24. Therefore, the dual sealing ring 70 is actually installed/mounted onto the component 24 by being screwed on. Figure 17 also shows that on the outside of the dual sealing ring 70, there is a large diagonally sloping face 74. There is also a smaller diagonally sloping face 75 on the other side of the dual sealing ring, as shown in Figure 18. The angle of slope of the smaller diagonally sloping face 75 is slightly steeper than that of the face 74, and the maximum outer diameter of the sloping face 75 is smaller (i.e. the smaller face 75 terminates more inwardly) than the sloping face 74, as shown in Figure 20. When the dual sealing ring 70 is installed on (screwed onto) the component 24, the smaller sloping face 75 faces towards the in-wall body 40, and in fact, this sloping face 75 on the dual sealing ring 70 mates closely with a small or slightly sloping or bevelled internal edge surface in the very end of the opening in the in-wall body 40. Also, when the dual sealing ring is screwed onto the component 24, the larger diagonally sloping face 74 therefore faces away from the in-wall body 40. Then, when the lock nut 50 is screwed onto the component 24, a large sloping face 54 on inside of the lock nut 50, which has a size and angle of slope corresponding to that of the sloping face 74 on the dual sealing ring, comes into direct contact with the sloping face 74 on the dual sealing ring 70. As a result of this configuration and engagement between the dual sealing ring 70 and the lock nut 50, and in particular as a result of the pressure exerted on the dual sealing ring 70 as the lock nut 50 is screwed tightly on (whereupon the sloping face 54 on the lock nut 50 presses firmly against the sloping face 74 of the dual sealing ring) the dual sealing ring is consequently pressed firmly in both the axial direction, squashing the dual sealing ring 70 between the lock nut 50 and the end of the in-wall body 40, and also in the radially inward direction against the threads on the outer surface of the component 24.

2019229379 12 Sep 2019 [0056] It should be noted that the in-wall body 40 used in the depicted embodiment of the invention is essentially the same size as the in-wall body 4 used in the prior art tap assembly above, or at least its size in the longitudinal direction is about the same. However, as shown in Figure 8, the design of the tap assembly in this embodiment allows the modern look to be achieved despite the more limited space available (e.g. a space roughly the same as 52, which it will be recalled is insufficient to allow correct installation of the prior art tap assembly) behind the wall typical of older or pre-existing buildings. One of the main reasons this can be achieved is because the much larger (and longer in the longitudinal direction) lock nut component 5, and also the flange nut 6, of the prior art tap assembly, are replaced in the present embodiment by a single component, namely the much more compact (shorter in the longitudinal direction) lock nut 50. When the lock nut 50 is installed, there is no part of the lock nut 50 that extends any further forward in the axial direction than the component 24. Furthermore, the design of the covering flange 30 is modified so that the covering flange 30 screws directly onto the outside of the lock nut 50. And, yet further, the outer diameter of the threaded curved edge portions 56 of the lock nut 50 is larger than the outer diameter of the in-wall body 40, or in other words the in-wall body 40 has an outer diameter which is smaller than the outer diameter of the threaded curved edge portions 56 of the lock nut 50. The result of this is that the internal diameter of the internally threaded boss 32 on the covering flange 30 (which corresponds to the external diameter of the threaded curved edge portions 56 on the lock nut 50) is also larger than the external diameter of the in-wall body 40, meaning that, if necessary, the flange 30 can be screwed onto the lock nut 50 far enough for part of the boss 32 to extend out over/around the outside of the inwall body. All of this results in an overall tap assembly which, once fully assembled and installed, is much more compact in the axial direction, and therefore more likely to be able to be correctly installed in older or pre-existing buildings.

[0057] The tap assembly in the present embodiment is also able to prevent the undesirable flows described above and shown as B and C in Fig 5. This is achieved by the single dual sealing ring 70. The reason the single dual sealing ring 70 can replace the two sealing components which were required for this in the prior art tap assembly (namely the washer 7 and the O-ring 8) is because, on the one hand the dual sealing ring 70 is squeezed in the longitudinal direction between the lock nut 50

2019229379 12 Sep 2019 and the in-wall body 40 and therefore prevents the flow B (see B’) in Figures 5 and 9.

In addition, the tapering surfaces on the dual sealing ring 70 and the way the tapering surface on the lock nut 50 press against this forces the dual sealing ring 70 firmly into the threads on the outside of the component 24, which prevents the flow C (see C) in Figures 5 and 9.

[0058] In this specification, adjectives such as first and second, left and right, top and bottom, and the like may be used solely to distinguish one element or action from another element or action without necessarily requiring or implying any actual such relationship or order. Where the context permits, reference to an integer or a component or step (or the like) is not be interpreted as being limited to only one of that integer, component, or step, but rather could be one or more of that integer, component, or step, etc.

[0059] The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. The invention is intended to embrace all alternatives, modifications, and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above described invention.

[0060] In this specification, the terms ‘comprises’, ‘comprising’, ‘includes’, ‘including’, or similar terms are intended to mean a non-exclusive inclusion, such that a method, system or apparatus that comprises a list of elements does not include those elements solely, but may well include others elements not listed.

Claims (17)

1. A tap assembly comprising:

a body;

a spindle assembly incorporating a spindle housing;

a locking component; and a covering flange, wherein, when the tap assembly is assembled:

the spindle assembly is mounted to the body with a portion, but not all, of the spindle housing located within the body;

the locking component is mounted on the outside of a portion of the spindle housing which is not located within the body, and the covering flange is mounted to the outside of the locking component.

2. The tap assembly according to claim 1, wherein the spindle assembly further incorporates a spindle and a valve portion, the spindle is able to rotate relative to the spindle housing, and when the tap assembly is assembled, the valve portion cooperates with features of the body to allow fluid to flow through the body when the spindle is turned one way and to prevent fluid from flowing through the body when the spindle is turned the other way.

3. The tap assembly according to claim 1 or claim 2 wherein, when the tap assembly is assembled, the locking component is mounted radially on the outside, relative to a longitudinal axis of the spindle, of the portion of the spindle housing which is not located within the body.

4. The tap assembly according to claim 3 wherein, when the tap assembly is assembled, one side of the locking component presses against or towards the body in a direction parallel to the longitudinal axis, and the locking assembly does not extend in the opposite direction parallel to the longitudinal axis further than the end of the spindle housing.

5. The tap assembly according to claim 3 or claim 4 wherein, when the tap assembly is assembled, a portion of the covering flange which engages with the locking component does so radially on the outside, relative to the longitudinal axis, of the locking component.

2019229379 12 Sep 2019

6. The tap assembly according to any one of the preceding claims, wherein the spindle housing has an externally threaded portion, and when the tap assembly is assembled, a portion of the externally threaded portion of the spindle housing is screwed into a corresponding internally threaded opening in the body.

7. The tap assembly according to any one of the preceding claims, further comprising a sealing component which, when the tap assembly is assembled, is located on the outside of the portion of the spindle housing that is not within the body and between the body and the locking component.

8. The tap assembly according to claim 7, when dependent on claim 6, wherein the sealing component has an internal thread, and when the tap assembly is being assembled, the sealing component is screwed onto an externally threaded portion of the spindle housing that is not located within the body, and the locking component, which has an internal thread, is then screwed onto the said externally threaded portion of the spindle housing which is not located within the body, such that the sealing component is compressed between the locking component and the body.

9. The tap assembly according to claim 8, wherein the sealing component and the locking component are each configured in such a manner that when the sealing component is compressed between the locking component and the body, the sealing component is also pressed radially inwards, relative to the longitudinal axis, into the threads on outside of the spindle housing.

10. The tap assembly according to claim 9, wherein the sealing component has a sloped portion, and the locking component also has a sloped portion which engages with the sloped portion on the sealing component when the tap assembly is assembled, and the slopes of the respective sloped portions are such that, when the sealing component is compressed between the locking component and the body, this also causes the sealing component to be pressed radially inwards into the threads on outside of the spindle housing.

11. The tap assembly according to any one of the preceding claims, wherein the locking component has external threads thereon, and a portion of the covering flange which engages with the locking component is internally threaded, such that

2019229379 12 Sep 2019 the said portion of the covering flange screws onto the outside of the locking component.

12. The tap assembly according to claim 11, wherein the locking component has an internal thread so that it can be screwed onto an externally threaded portion of the spindle housing which is not located within the body, and the locking component also has a number of flat surfaces on its radial/outer perimeter, which flat surfaces are operable to allow the locking member to be gripped and turned by a tool.

13. The tap assembly according to claim 12, wherein the locking component also has a number of curved surfaces on its radial/outer perimeter, which curved surfaces are spaced in between the flat surfaces on the radial/outer perimeter, and the external threads in the locking component are formed in the curved surfaces.

14. The tap assembly according to any one of the preceding claims wherein, when the tap assembly is installed, the body is positioned within a space or cavity behind a surface (e.g. a wall sheet or countertop surface or the like) from which the spindle of the spindle assembly extends.

15. The tap assembly according to claim 14 wherein, when the tap assembly is installed, a portion of the spindle housing which is not located within the body extends, in a direction parallel to the longitudinal axis of the spindle, some, but not all, of the way through the thickness of the surface from which the spindle extends.

16. The tap assembly according to claim 15 wherein, when the tap assembly is installed, the locking component is at least partially located within the thickness of the surface from which the spindle extends but the locking component does not project out or proud from the said surface.

17. The tap assembly according to claim 16 wherein, when the tap assembly is installed, a portion of the covering flange which engages with the locking component does so radially on the outside, relative to the longitudinal axis, of the locking component, i.e. at a location which is at least partially within the thickness of the surface, and an outer portion of the covering flange comes into contact with the outer face of the surface.