Abstract:
A ball valve cartridge is disclosed. It is especially well suited for freezeless hydrant applications and any other application where it is positioned remotely from a handle or other actuating element. The cartridge contains a ball valve element and an internal stem with a key for rotating the ball valve element between open and closed positions. The stem has rotational stop elements that limit rotational movement of the stem and the ball valve element. In a yard hydrant application, a drain valve can be added to regulate the opening and closing of the drain hole. It has an operational range of a quarter turn or ninety degrees.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is a ball valve cartridge especially adapted for use in applications where it is actuated by a remotely positioned handle, such as in freezeless wall hydrants or faucets and yard hydrants. 
     2. Description of the Prior Art 
     The field of valves for regulating and controlling fluid flow is certainly well developed. Self-draining yard hydrants and freezeless wall faucets, wall hydrants, sillcocks or bibcocks, are also well known. 
     Yard hydrants are described in many US Patents, including U.S. Pat. No. 4,372,339. Freezeless wall hydrants are also described by many U.S. Patents, including my prior U.S. Pat. No. 5,158,105. 
     A freezeless sillcock with ceramic disk valve elements is described in U.S. Pat. No. 6,880,573. This device has an operating range constituting only one quarter of a turn of an actuator handle. However, the components of the ceramic disk are contained within a cartridge and, in a commercial embodiment of this invention, the disks are under heavy compression exerted by very strong springs. That makes this unit subject to failure due to spring failure, as well as failure of the disks themselves. Ceramic has a very different co-efficient of expansion than steel and brass and copper and, in extreme temperatures such as those encountered in the freezeless application under consideration, this may lead to failure, as well. Ceramic disk cartridges can retain water so that freezing may lead to catastrophic failure. The flow rate through ceramic disk valve elements is generally less than the flow rate through a comparable ball valve element. Flow rate is also limited in ceramic valve elements by size limitations imposed by the ceramic material itself. Ceramic disk valve elements are more prone to sediment blockage than ball valve elements. Ceramic valve elements are made of ceramics while ball valve elements can be made of almost any material including, without limitation, brass, stainless steel, iron, PVC, Delrin, nylon and so on. 
     Generally speaking, the machining of ceramic parts can leave flaws which can cause premature failure of those parts. Ceramic parts generally cost more than do metal parts. Because ceramics are so hard, mating surfaces tend to wear more quickly than mating surfaces of parts made from other materials. The hardness of ceramics makes them generally more difficult to machine. Ceramics require more expensive abrasive materials and must be machined more slowly than metal to avoid damage. 
     It is submitted that there is a need for a cartridge style valve that is actuated over a quarter turn, like the ceramic freezeless ceramic disk valve hydrant mentioned above, that is more reliable, easier to produce, less expensive, and more resistant to extreme temperature fluctuations such as those encountered in freezeless hydrant applications. 
     SUMMARY OF THE INVENTION 
     The instant invention is based upon the discovery of a new ball valve and, specifically, one that is contained within a cartridge so that it can be positioned remotely from a handle or other actuating element. The cartridge contains a ball valve element and an internal stem with a key for rotating the ball valve element between open and closed positions. The stem has rotational stop elements that cooperate with rotational stops inside the cartridge to limit rotational movement of the stem and the ball valve element. In a yard hydrant application, a drain valve can be added to regulate the opening and closing of the drain hole in cooperation with the water valve operation. The cartridge itself is very compact and permits the positioning of the ball further from the actuator than prior art ceramic disk cartridges, thereby increasing the freeze resistance of a hydrant including the ball valve cartridge. 
     It is, therefore, an object of the invention to provide an improved ball valve especially adapted for actuation by a remote handle, such as in a freezeless hydrant application. 
     It is another object to provide an improved freezeless hydrant including the ball valve cartridge. 
     It is a further object of the invention to provide a hydrant with an easily replaceable valve mechanism. 
     It is yet a further object of the invention to provide a hydrant with the preferred quarter turn operation that is better than the prior art freezeless hydrants including ceramic disk cartridges. 
     Other objects and advantages will be apparent to one skilled in the art from the description herein, reference being made to the attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         FIG. 1A  is an exploded view showing elements of a valve stem assembly for use with a ball valve cartridge according to the invention in a freezeless hydrant application. 
         FIG. 1B  is an exploded view of a freezeless wall hydrant tube including a vacuum breaker mechanism. 
         FIG. 1C  is an exploded view showing the elements of a ball valve cartridge according to the invention. 
         FIG. 2  is a cross sectional view showing the ball valve cartridge seated in a valve seat of a hydrant tube, with the ball valve open. 
         FIG. 3  is a cross section view showing the ball valve cartridge seated in a valve seat of a hydrant tube, with the ball valve closed. 
         FIG. 3A  is a cross sectional view, taken along the line  3 A- 3 A of  FIG. 3 . 
         FIG. 4  is a view, partially in cross section, showing a second embodiment of a ball valve cartridge seated in a freezeless yard hydrant with a drain hole valve. 
         FIG. 5  is a split cross sectional view showing the relative rotational positions for the ball valve and the drain hole valve of the hydrant shown in  FIG. 4  when water flow is shut off. 
         FIG. 6  is a split cross sectional view showing the relative rotational positions for the ball valve and the drain hole valve of the hydrant shown in  FIG. 4  when water flow is beginning. 
         FIG. 7  is a split cross sectional view showing the relative rotational position for the ball valve and the drain hole valve of the hydrant shown in  FIG. 4  when water flow is at full rate. 
         FIG. 8  is a side view of a ball suitable for use in a ball valve cartridge according to the invention. 
         FIG. 9  is a side view of a second embodiment of a ball suitable for use in a ball valve cartridge according to the invention. 
         FIG. 10  is a side view of a third embodiment of a ball suitable for use in a ball valve cartridge according to the invention. 
         FIG. 11  is a side view of a fourth embodiment of a ball suitable for use in a ball valve cartridge according to the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now in more detail to the drawing figures, a freezeless sillcock according to the invention comprises an actuator indicated generally at  10  in  FIG. 1A , a sillcock tube indicated generally at  12  in  FIG. 1B  and a ball valve cartridge indicated generally at  14  in  FIG. 1C . The actuator  10  comprises a handle  16  ( FIG. 1A ) which is drivingly connected to a stem  18  by a fastener  20 . Torque imparted to the handle  16  is transmitted to the stem  18  through torque surfaces  22  on the stem  18  which are engaged by corresponding surfaces (not shown) on the handle  16 . A packing nut  24 , packing  26  and washers  28  secure the stem  18  within the sillcock tube  12  ( FIG. 1B ). At the distal end  30  ( FIG. 1A ) of the stem  18 , a torque transmitting element is provided for transmitting torque from the stem  18  to the cartridge  14 . The torque transmitting element shown is a fastener  32  although any torque transmitting element will suffice. 
     The sillcock tube  12  ( FIG. 1B ) is threaded as indicated at  34  at the distal end to engage a valve seat (not shown). A wrench hex  36  is provided near the distal end, adjacent to a flared portion  38  of the tube  12  in which the cartridge  14  ( FIG. 1C ) will be received. At the proximal end of the tube  12  ( FIG. 1B ), an internally threaded portion  40  is provided for receiving the packing nut  24  ( FIG. 1A ). An externally threaded hose bib  42  is also provided at the proximal end of the tube. A vacuum breaker assembly, indicated at  44 , is connected to the proximal end of the tube to prevent back-siphonage of water. A flange  46  is provided for securing the sillcock tube to a structure. 
     The components of the cartridge  14  ( FIG. 1C ) are contained within a housing comprised of a cartridge body  50  and a cartridge base  52  which is provided with external threads  54  to engage corresponding threads (not shown) provided on the cartridge body  50 . The cartridge body base  52  includes a rotational stop in the form of hex surfaces  56  to engage corresponding surfaces provided inside the distal end of the tube  12  ( FIG. 1B ) so that relative rotation between them is prevented. O-rings  58  ( FIG. 1C ) are used on the lower end of the cartridge base  52  to sealingly engage the tube  12  ( FIG. 1B ). A check valve  60  ( FIG. 1C ) is received, largely in the cartridge base  52 . Packing  62  and a ring  64  cooperate to provide a sealing connection between the cartridge body  50  and the cartridge base  52 . 
     An internal stem  66  is provided with a key  68  ( FIGS. 2 and 3 ) to engage a keyway or slot  70  ( FIG. 1C ) in a “T” ball  72 . Although a T ball is shown in  FIG. 1C , other balls, including the balls shown in  FIGS. 8 ,  9 ,  10  and  11  may certainly be employed. O-rings  74  provide a sliding seal between the internal stem  66  and the interior of the cartridge body  50 . The internal stem  66 , with O-rings  74  in place, is inserted into the cartridge body  50  so that a bore, indicated at  76 , is exposed outside of the cartridge body  50  for engagement with the stem  18  ( FIG. 1A ) and the fastener  32  (or other torque transmission mechanism). Also exposed is an upper circumferential slot  78  which is engaged by a clip  80  to hold the internal stem  66  in place during assembly. The clip  80  prevents the stem  66  from moving axially in the cartridge body  50  towards the cartridge base  52 . 
     The ball  72  is supported between an inlet washer  82 , a pair of outlet washers  84  and the key  68  ( FIGS. 2 and 3 ) on the internal stem  66 . The washers  84  are carried in recesses in the cartridge body  50 , as can be seen in  FIGS. 2 and 3 . 
     The internal stem  66  further includes an axial stop  86  which takes the form of a disk. The stop  86  prevents the stem  66  from moving axially in the cartridge  14  away from the cartridge base  52 . The internal stem  66  further includes a rotational stop  88  which takes the form of a key. The stop  88  cooperates with the cartridge body  50 , as described below with reference to  FIG. 3A , to limit the rotational movement of the stem  66  and, at the same time, the ball  72 . 
     Referring now to  FIGS. 2 ,  3  and  3 A, further details concerning the ball valve cartridge  14  will be described. In  FIG. 3A , a pair of ears or shoulders  90  depend from the inside of the cartridge body  50  and they cooperate with the rotational stop  88  on the internal stem  66  to limit rotation of the internal stem to a range of about ninety degrees. In the position shown in  FIGS. 3 and 3A , the ball  72  prevents fluid from flowing through the ball valve cartridge  14 . When the internal stem  66  is rotated ninety degrees from the position shown in  FIGS. 3 and 3A , by a remote actuator acting on the stem  18 , for example, the key  68  acting through the slot  70  will cause the ball  72  to rotate ninety degrees also, bringing side discharge ports  92  in the ball  72  into alignment with side discharge ports  94 . In this position of the ball  72  which is shown in  FIG. 2 , pressurized fluid can enter and flow through the check valve  60  (which would change the appearance of the elements of the check valve although this is not reflected in  FIG. 2 , or  FIG. 4 , for that matter), into and through a fluid inlet port  96  of the ball  72 , through ball discharge ports  92 , through cartridge discharge ports  94  and into and through the hydrant tube  12 . This corresponds with a maximum flow rate through the cartridge  14 . Intermediate positions of the internal stem  66  will provide intermediate flow rates with full adjustability. 
     The axial position of the stem  66  within the cartridge body  50  is maintained, in part, by co-action between the axial stop  86  of the stem  66  and a shoulder  98 . This co-action prevents the internal stem  66  from moving away from the cartridge base  52 . When the cartridge elements are inserted into the cartridge base  52  and the cartridge body  50 , and the base  52  and the body  50  are assembled, the elements inside including the check valve  60  and the ball  72 , act to maintain the axial stop  86  of the internal stem in contact with the internal shoulder  98  on the cartridge body  50 . The check valve is seated on an internal shoulder  99  on the cartridge base  52 . Thus, the axial location of the ball  72  and the internal stem  66  are determined and maintained by the shoulders  98  and  99  and, in the embodiment shown in  FIGS. 2 and 3 , as well as the embodiment shown in  FIG. 4 , the check valve  60 . The internal stem  66 , the ball  72  and the check valve  60  are held captive between the shoulders  98  and  99 . 
     When the hydrant tube  12  is secured into a valve seat (not shown) as by threads  34 , for example, it will be well seated and the hex  36  can be used to apply torque to the tube to better seat it. Once the hydrant tube  12  is seated in the valve seat, it can stay there. The cartridge assembly  14 , when it is attached to the stem  18 , can be inserted into and removed from the proximal end of the hydrant tube  12 . When the cartridge assembly  14  is inserted into the tube  12  and advanced to the position shown in  FIGS. 2 and 3 , it is seated against a shoulder seat  100  formed inside the tube  12  and O-rings  58  provide a seal between the inside of the tube  12  and the outside of the cartridge assembly  14 . Relative rotation between the cartridge assembly  14  and the hydrant tube  12  is prevented by co-action between the cartridge base hex surfaces  56  and corresponding internal flat surfaces  101  inside of the hydrant tube  12 . Thus, when torque is applied to the internal stem  66  of the cartridge assembly  14  enough to cause it to rotate, the stem  66  and the ball  72  rotate relative to the cartridge body  50  and the cartridge base  52 . 
     A ball valve cartridge  102  is shown in  FIG. 4  in combination with a self draining feature suitable for a yard hydrant application. The ball valve cartridge  102  is similar in many respects to the cartridge  14  and like reference numerals have been used to refer to like parts between the cartridges. A housing  103  is provided with a drain hole indicated at  104  through water is to be drained when the hydrant is not in use. The housing  103  has an internally threaded opening indicated at  106  for attaching the housing  103  to a source for fluid under pressure. Typically, this connection will be underground and below the frost line. At an upper end, the housing  103  has an internally threaded outlet  108  that cooperates with an externally threaded end  110  of a discharge conduit  112  to support the conduit  112  relative to the housing  103 . This connection, again, typically, will be underground and below the frost line. The discharge conduit extends upwardly through the ground to a discharge outlet (not shown) and a support for an actuator (not shown) for the ball valve cartridge  102 . 
     The cartridge  102  includes an internal stem  114  which includes a portion inside of the cartridge body  50  that is the same as the corresponding portion of the internal stem  66  ( FIGS. 1C ,  2 ,  3  and  3 A). The portion of the stem  114  that is outside of the cartridge body  50  terminates in a torque input region  116  for receiving torque transmitted to it from an external stem  118  through a coupler  120 . Fasteners  122  connect the coupler  120  to the external stem  118  and to the internal stem  114  in torque transmitting connections so that torque applied to the external stem  118  is transmitted to the internal stem  114  to operate the ball valve cartridge  102  substantially as described above for the operation of the ball valve cartridge assembly  14 . 
     Secured to the external stem  118  is a hemispherical valve element  124  which is supported adjacent to the drain hole  104  in sealing engagement with a washer  126  which surrounds the drain hole  104  on the inside of the housing  103 . The stem  114  is centered in the housing  103  at the distal end by co-action between the housing  103  and the cartridge base  52  and is centered, at the proximal end, by a perforated disk  128 . The disk can be secured to the stem  114  and made of a resilient material so that it can be withdrawn from the conduit  112  for repair or replacement of the cartridge  102 . This will provide a good sliding seal between the valve element  124  and the washer  126 . 
     With the stem  114  in the position shown in  FIG. 4 , the drain hole is closed by the valve element  124  and the ball valve is in a full flow position with the discharge ports  92  of the ball  72  aligned with the discharge ports  94  of the cartridge body  50 . This condition is represented in  FIG. 7  which shows the ball  72  with discharge ports  92  aligned with cartridge discharge ports  94  and the valve element  124  completely closing off the drain hole  104 . As the stem  114  is rotated from the position represented in  FIGS. 4 and 7  to the position represented in  FIG. 6 , the valve element  124  keeps the drain hole  104  closed or blocked but the flow of water through the ball  72  and out of the cartridge body  50  is getting restricted. As the stem  114  is rotated from the position represented in  FIG. 6  to the position represented in  FIG. 5 , the valve element  124  reaches an angular orientation where it opens the drain hole  104 , just as the flow of water through the ball  72  and out of the cartridge body  50  is stopped. This sequence of operation occurs over the brief angular rotation of a total of about ninety degrees or a quarter turn of a handle (not shown). Of course, the ball valve cartridge may be combined with other, different, hydrant draining mechanisms including those that are known and those that are yet to be invented. 
     Referring now to  FIGS. 8 through 11 , the ball  72  and other balls with alternative designs, all for use in a ball valve cartridge according to the present invention or in any ball valve, for that matter, are illustrated. 
     Ball  72  is shown in  FIG. 8  and it has fluid inlet  96  which is in fluid communication with two transverse fluid outlets  92 , each one having an axis that is at right angles to the axis of the fluid inlet  96 . The keyway  70  cooperates, as described above, with a key to, first of all, keep the ball  72  oriented in the cartridge body  50  ( FIGS. 2 ,  3  and  4 ) and, also, to transmit torque to the ball  72  to cause it to rotate from a closed position to an open position and back again. Fluid discharge openings  94  in the cartridge body  50  are suitably sized, shaped and positioned, relative to the fluid discharge openings  92  in the ball  72  so that fluid can flow out of the openings  92  and out of the openings  94 . 
     A ball  130  is shown in  FIG. 9  and it has a fluid inlet  132  which is in fluid communication with two semi-transverse fluid outlets  134 , each one having an axis that forms an angle with the axis of the other discharge opening of about eighty degrees. With the fluid inlet  132 , the fluid outlets form something resembling a Y-shaped passageway. A keyway  136  cooperates, as described above, with a key to, first of all, keep the ball  130  oriented in, for example, a cartridge body and, also, to transmit torque to the ball  130  to cause it to rotate from a closed position to an open position and back again. Fluid discharge openings in a cartridge body would be suitably sized, shaped and positioned, relative to the fluid discharge openings  134  in the ball  130  so that fluid can flow out of the openings  134  and out of the discharge openings in the cartridge. This design reduces turbulence inside the ball and would be well suited for high flow rates. 
     A ball  140  is shown in  FIG. 10  and it has a fluid inlet  142  which is in fluid communication with a transverse fluid outlet  144 . The outlet  144  has an axis which forms a right angle with the axis of the inlet  142 . A keyway  146  cooperates, as described above, with a key to, first of all, keep the ball  140  oriented in, for example, a cartridge body and, also, to transmit torque to the ball  140  to cause it to rotate from a closed position to an open position and back again. A fluid discharge opening in a cartridge body would be suitably sized, shaped and positioned, relative to the fluid discharge opening  144  in the ball  140  so that fluid can flow out of the opening  144  and out of the discharge opening in the cartridge. 
     A ball  150  is shown in  FIG. 11  and it has a fluid inlet  152  which is in fluid communication with a semi-transverse fluid outlet  154 . The axis of the fluid outlet  154  forms an angle with the axis of the fluid inlet  152  and that angle is an obtuse angle. A keyway  156  cooperates, as described above, with a key to, first of all, keep the ball  150  oriented in, for example, a cartridge body and, also, to transmit torque to the ball  150  to cause it to rotate from a closed position to an open position and back again. A fluid discharge opening in a cartridge body would be suitably sized, shaped and positioned, relative to the fluid discharge opening  154  in the ball  150  so that fluid can flow out of the opening  154  and out of the discharge opening in the cartridge with minimal turbulence. This design reduces turbulence inside the ball  150  and would be well suited for high flow rates. 
     It will be appreciated that considerable departures from the specific details of the embodiments of the invention described above, are possible without departing from the spirit and scope of the inventions as it is defined in the following claims.