Abstract:
An outlet box housing a stop valve that is connected to a water supply line of a building. The outlet box enables a user to control the internally housed stop valve by axial movement of a handle assembly linked to a handle on the valve. The outlet box has a faceplate with at least one aperture through which the handle assembly and water outlet line can pass. Valve inlet shanks (or adaptors) connect the stop valve to the water supply line and allow for quick and easy replacement of the stop valve.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of Invention 
         [0002]    The present invention is directed to a recessed wall-mounted outlet box having a stop valve connected to a water supply line and a push-pull handle assembly providing convenient, instantly accessible, manual control over the flow of inlet water through the valve. An alternative embodiment wherein the valve is controlled by turning the knob or faceplate is also disclosed. 
         [0003]    2. Description of Related Art 
         [0004]    Many different wall-mounted outlet boxes have previously been disclosed that contain valves for and provide access to one or more water supply lines and, sometimes, drain lines for household or commercial appliances such as, for example, washing machines, ice makers, toilets, and the like. In the past the valves used in many such outlet boxes were open and closed by rotating a hand wheel at the top of the valves. More recently, quarter turn ball valves have achieved widespread use because the handles on the valves move between fully open and fully closed positions by traversing an arc of only 90 degrees or less. Such prior art water outlet boxes are disclosed, for example, in U.S. Pat. Nos. 5,983,923, 6,125,881, and 6,234,193. 
       SUMMARY 
       [0005]    The present invention is a compact and aesthetically pleasing, recessed, wall-mounted outlet box with a push-pull handle assembly that controls the operation of a stop valve connected to a water supply line between fully open and fully closed positions. The outlet box comprises a housing that can be mounted to at least one stud or other frame member disposed proximally to a water supply line inside a wall, and desirably further includes a faceplate or escutcheon with apertures through which the handle assembly and water line extend, while simultaneously concealing the valve and conduit behind the faceplate for a more aesthetically pleasing appearance and also providing a means for quickly closing or opening the valve without any manual rotation of the outwardly extending portion of the handle assembly. This feature of the invention is particularly helpful to elderly, arthritic, or otherwise partially incapacitated users who may have much greater difficulty grasping and rotating a valve handle than simply pushing or pulling a knob on the handle assembly to open or close a valve. Another feature of this invention is that the valve is easily replaceable with just a screwdriver and will cause no damage to the surrounding material such as drywall. 
         [0006]    The handle assembly of the invention desirably comprises a pull rod, which is attached to the stop valve&#39;s handle and is linked to both the valve handle and the knob in such a way that pushing the knob toward the faceplate and the wall opens the valve and permits the flow of water through it, while pulling the knob outwardly from the wall and faceplate closes the valve to shut off water flow through the valve. Alternatively, it will be appreciated that stop valves can likewise be fabricated that will block fluid flow through the valve when the knob of the handle assembly is pressed inwardly toward the faceplate and wall, and that will allow the flow of water through the valve when the knob portion of the handle assembly is pulled away from the faceplate and the wall. 
         [0007]    The present invention can be provided or otherwise utilized with pre-installed stop valves having inlet valve shanks that are readily attachable to valve extensions having selected fittings for use with threaded hose or pipe connectors, with compression fittings or solder for attachment to copper tubing (for hot water lines), with glueable joints such as CPVC or PVC piping, or with hose barbs that are readily attachable by crimping or the like to flexible hoses such as those made of crosslinked polyethylene (“PEX”) pipe, or of other flexible materials. The outlet box of the invention desirably further comprises a retaining block and retainer clip that help secure the stop valve and valve inlet shank, respectively, in place relative to the valve housing. This feature enables the valve to be easily replaced. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The apparatus of the invention is further described and explained in relation to the following figures of the drawing wherein: 
           [0009]      FIG. 1  is a top front perspective view of a preferred embodiment of the outlet box of the invention with the knob of the handle assembly shown in the position where the valve handle is pushed rearwardly into the “valve open” position; 
           [0010]      FIG. 2  is a bottom rear perspective view of the outlet box of  FIG. 1 ; 
           [0011]      FIG. 3  is an exploded side elevation view of the outlet box of  FIG. 1 ; 
           [0012]      FIG. 4  is a front elevation view of the outlet box of  FIG. 1 ; 
           [0013]      FIG. 5  is a side elevation view of the outlet box of  FIG. 1 ; 
           [0014]      FIG. 6  is a cross-sectional top plan view taken along line  6 - 6  of  FIG. 5 ; 
           [0015]      FIG. 7  is a cross-sectional top plan view taken along line  7 - 7  of  FIG. 5 ; 
           [0016]      FIG. 8  is a cross-sectional side elevation view taken along line  8 - 8  of  FIG. 4 ; 
           [0017]      FIG. 9  is a cross-sectional side elevation view taken along line  9 - 9  of  FIG. 4 ; 
           [0018]      FIG. 10  is a top front perspective view of the outlet box of  FIG. 1  with the knob and pull rod of the handle assembly shown in the position where the valve handle is pulled forward into the “valve closed” position; 
           [0019]      FIG. 11  is a side elevation view of the outlet box of  FIG. 10 ; 
           [0020]      FIG. 12  is a top plan view of the outlet box of  FIG. 10  taken along line  12 - 12  of  FIG. 11 ; 
           [0021]      FIG. 13  is a cross-sectional side elevation view of the outlet box of  FIG. 10  taken along line  13 - 13  of  FIG. 10 ; 
           [0022]      FIG. 14  is a top perspective view of a PEX valve inlet shank; 
           [0023]      FIG. 15  is a top perspective view of a PEX valve inlet shank being inserted into the housing of the outlet box; 
           [0024]      FIG. 16  is a top perspective view of a PEX valve inlet shank being secured by a retaining clip within the housing of the outlet box; 
           [0025]      FIG. 17  is a top perspective view of the stop valve; 
           [0026]      FIG. 18  is a top perspective view of the stop valve being inserted into a PEX valve inlet shank seated within the housing of the outlet box; 
           [0027]      FIG. 19  is a top perspective view of the stop valve and PEX valve inlet shank being secured by a retaining block within the housing of the outlet box; 
           [0028]      FIG. 20  is a partially exploded side perspective view of a protective cap fitting onto the outlet box with a PEX valve inlet shank installed; 
           [0029]      FIG. 21  is a is a top perspective view of a copper valve inlet shank and snap ring being inserted into the housing of the outlet box; 
           [0030]      FIG. 22  is a is a top perspective view of a copper valve inlet shank being secured by a retaining clip within the housing of the outlet box; 
           [0031]      FIG. 23  is a is a top perspective view of the stop valve being inserted into a copper valve inlet shank seated within the housing of the outlet box; 
           [0032]      FIG. 24  is a is a top perspective view of the stop valve and copper valve inlet shank being secured by a retaining block within the housing of the outlet box; 
           [0033]      FIG. 25  is a bottom perspective view of an o-ring being attached onto the bottom of the copper valve inlet shank; 
           [0034]      FIG. 26  is a partially exploded side perspective view of a protective cap fitting onto the outlet box with the copper valve inlet shank installed; 
           [0035]      FIG. 27  is a front elevation view of an outlet box installed upside down on a stud; 
           [0036]      FIG. 28  is a front elevation view of two outlet boxes installed side-by-side on the same stud; and 
           [0037]      FIG. 29  is a front elevation view of an outlet box installed on a Hyco strap. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0038]    As depicted in  FIGS. 1-29 , stop valve  44  is desirably mounted inside housing  22  of outlet box  20 . Stop valve  44  can be any suitable stop valve, such as a quarter-turn stop valve or a push-pull gate valve. The external back side of housing  22  preferably comprises a plurality of reinforcing ribs  23 . Mounting plate  24  extends perpendicularly to the opening of housing  22  and has a plurality of nail or screw holes  26  for use in attaching outlet box  20  to studs or other proximal structural members of a supporting wall. Annular collar  28  projects forwardly and supports faceplate  32  by frictional engagement or by other similarly effective conventional attachment methods. Alternatively, faceplate  32  can be attached using, for example and without limitation, screws, tamperproof screws, or the like. According to one preferred embodiment of the invention, annular collar  28  and faceplate  32  are cooperatively configured and aligned, and mounting plate  24  is sufficiently recessed from the surface of the supporting wall that rear annular edge  35  of faceplate  32  as shown in  FIG. 3  sits substantially flush against the facing surface of the support wall when faceplate  32  is fully seated against and engaged with annular collar  28  of housing  22 . In a preferred embodiment, rear annular ridge  35  has bottom drip slot  27  and top drip slot  29 . Drip slots  27  and  29  allow for the detection of a leak in stop valve  44  after installation. Drip slot  27  is located at the bottom of rear annular ridge  35  for use in conventional installation, and drip slot  29  is located at the top of rear annular ridge  35  for use in upside down installation. Additionally, as seen, for example, in  FIGS. 20 and 26 , a protective cap  64  may be provided to fit in housing  22  in place of faceplate  32  prior to installation and during the rough-in construction process to protect the valve and, for example, during shipping and transportation. 
         [0039]    As seen, for example, in  FIGS. 3 ,  7 - 9 , and  13 , spaced-apart arcuate top and bottom attachment members  36  and  37 , respectively, are provided with outwardly facing textured sections  38  and desirably project rearwardly from faceplate  32 . Arcuate top and bottom attachment members  36  and  37  are preferably sized and configured to provide frictional sliding engagement with the inwardly facing surface of annular collar  28  for the releasable attachment of faceplate  32  to housing  22  of outlet box  20 . 
         [0040]    Referring to  FIGS. 14-19 , valve inlet shank  50  may be designed for use in applications involving piping made of polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), cross-linked polyethylene (PEX), WIRSBO PEX, or other materials. Valve inlet shank  50  acts as an adaptor for the connection of stop valve  44  to a building&#39;s water line. Valve inlet shank  50  has a distal end  54 , which can either be threaded, barbed, or designed for some other type of connection or coupling, depending on the type of piping to which valve  44  is to be connected. Distal end  54  is barbed for use with PEX or WIRSBO PEX piping. The barbs for PEX would be of a different design than those for WIRSBO PEX. A standard brass crimp can be used to connect a barbed distal end  54  to a building&#39;s PEX piping. A standard WIRSBO PEX expander ring can be used to connect to the piping in the building. Glue can be used to connect distal end  54  to a building&#39;s PVC or CPVC piping. Valve inlet shank  50  is disposed within housing  22  by inserting distal end  54  down through an opening  21  of housing  22 . Proximal flange opening  52  engages the interior surface of the bottom of housing  22 , thereby preventing valve inlet shank  50  from slipping through opening  21 . Retaining clip  42  secures inlet valve shank  50  in place and prevents it from lifting out of place during a replacement of stop valve  44 . 
         [0041]    Referring to  FIGS. 21-25 , valve inlet shank  55  and distal end  59  may be designed for use in applications involving copper piping. Valve inlet shank  55  acts as an adaptor for the connection of stop valve  44  to a building&#39;s water line. Valve inlet shank  55  has a distal end  59 , which can be soldered with copper sweat to connect it to a building&#39;s copper piping. Valve inlet shank  55  is disposed within housing  22  by inserting proximal opening  61  from the bottom of and up through opening  21  of housing  22 . Retaining ring  57  snaps under the proximal opening  61  and prevents valve inlet shank  55  from slipping through opening  21 . Retaining clip  42  secures inlet valve shank  55  in place and prevents it from lifting out of place during a replacement of stop valve  44 . 
         [0042]    Stop valve  44 , which is best seen in  FIGS. 3 ,  6 ,  8 - 9 ,  12 - 13 ,  18 - 19 , and  23 - 24 , is desirably mounted through opening  21  of housing  22  by inserting its downwardly projecting valve inlet  34  into proximal flange opening  52  of valve inlet shank  50  for PEX piping applications or into proximal opening  61  of valve inlet shank  55  for copper piping applications. O-rings  43  are mounted on valve inlet  34  of stop valve  44 . O-rings  43  work to seal valve inlet  34  to the interior diameter of valve inlet shank  50  or the interior diameter of valve inlet shank  55 . Referring to  FIGS. 14 and 25 , o-ring  49  is fitted onto valve inlet shank  50  or valve inlet shank  55 . O-ring  49  provides a seal between valve inlet shank  50  or valve inlet shank  55  and housing  22  at opening  21 . 
         [0043]    Referring to  FIGS. 3 ,  6 - 7 , and  12 , valve handle  60  is disposed on top of stop valve  44  and has an aperture  58 , which is a linkage that facilitates insertion of the proximal end of pull rod  46  into valve handle  60 . Knob  30  is attached to extended handle  62 , which passes through a first opening  31  on faceplate  32  and is attached to threaded end  48  of pull rod  46 . First opening  31  and extended handle  62  can be of any shape. In a preferred embodiment, first opening  31  and extended handle  62  are square-shaped. The square shape prevents extended handle  62  from being over-threaded onto pull rod  46  during assembly or unthreaded off of pull rod  46  while the valve is in the “on” position It also ensures correct handle thread engagement to properly align handle  60  with faceplate  32  for the valve “on-off” position. Faceplate  32  desirably has a second opening  33  through which a hose or other water connector can pass for threaded engagement to valve outlet  56  of stop valve  44 . 
         [0044]    Referring, for example, to  FIGS. 3 and 9 , top attachment member  36  sits just outwardly of retaining block  40 , which is attached to housing  22  by self-tapping screw  41  to act as a guide for pull rod  46  as it releasably engages and operates handle  60  of stop valve  44  within housing  22 . As seen, for example, in  FIGS. 19 ,  24 , and  25 , retaining block  40  also secures stop valve  44  in place within outlet box  20 . 
         [0045]    In an embodiment in which stop valve  44  is a quarter-turn valve, valve handle  60  opens and closes the valve with a 90 degree arc movement. Stop valve  44  can be conventionally or specially configured. In a conventional configuration, stop valve  44  is in the “open” position when looking down at stop valve  44  and valve handle  60  is clockwise 45 degrees from valve outlet  56  and in the “closed” position when valve handle  60  is 135 degrees from valve outlet  56 . In a special configuration, stop valve  44  is in the “closed” position when looking down at stop valve  44  and valve handle  60  is clockwise 45 degrees from valve outlet  56  and in the “open” position when valve handle  60  is 135 degrees from valve outlet  56 . In either configuration, pulling knob  30  aligns valve handle  60  with valve outlet  56 , while pushing knob  30  inwardly positions valve handle  60  transverse to valve outlet  56 . 
         [0046]    A user operates stop valve  44  of outlet box  20  by pulling knob  30  to either open or close the valve and either start or stop water flow, or by pushing knob  30  to achieve the opposite result. The effect of the particular action will depend on the valve configuration as described above.  FIGS. 1 ,  5 , and  6 - 9  depict knob  30 , extended handle  62 , and pull rod  46  pushed in and the valve in the open position for a special configuration or in the closed position for a conventional configuration.  FIGS. 10-13  depict the same components pulled out and the valve in the closed position for a special configuration or in the open position for a conventional configuration. Although not shown in the drawings, it will be appreciated by those of ordinary skill in the art upon reading this disclosure that an installation can be similarly configured wherein a different linkage will facilitate turning the valve off by rotating rather than pulling the handle, or even by rotating the faceplate. 
         [0047]    For example, in a special configuration for a quarter-turn valve, when a user pulls on knob  30 , extended handle  62  and pull rod  46  rotate valve handle  60  a quarter of a turn (90 degrees), thereby closing stop valve  44 . When a user pushes knob  30  into outlet box  20 , extended handle  62  and pull rod  46  rotate valve handle  60  a quarter of a turn in the opposite direction, thereby opening stop valve  44 . 
         [0048]    Stop valve  44  creates a watertight seal to valve inlet shanks  50  using o-rings  43 . Retaining block  40  allows the valve to be installed or replaced quickly by hand or by using a simple tool, such as a screwdriver. Stop valve  44  can simply be pushed into or pulled out of an inlet valve shank after removing retaining block  40 . Outlet box  20  can be mounted and connected to water lines during the construction of a building project to enable monitoring for water leaks. Should a water leak be discovered, stop valve  44  can be replaced before completion of construction such that the likelihood of wall damage after drywall installation is eliminated. 
         [0049]    Additionally, since outlet box  20  can be installed during the rough-in phase of construction, stop valve  44  and the water line can stay pressurized during the construction of a building. This feature provides the ability to test and monitor stop valve  44  for leaks and other problems before drywall installation. Also, by installing the valve in the rough-in phase, you eliminate the need to use a copper stub out, thus reducing wasted piping by eliminating the need for using stub outs. The ability to test and monitor stop valve  44  during construction also results in the decreased likelihood of crossed or dead water lines. Crossed water lines can occur, for example, when a hot or cold water line is connected to the opposite water outlet. Even in the event of a crossed or dead water line, the present invention provides for a quick remedy because the water lines can simply be reattached to the proper outlet while still in the rough-in phase of construction. The present invention also eliminates the need for the use of a compression joint in copper piping applications. In some copper piping applications, a stop valve would be connected to a compression joint, which under pressure from the water line can sometimes cause the valve to split at the attachment point. This type of valve failure is most commonly seen in ⅝ inch valves. 
         [0050]    The pull stop assembly provides for simple operation of stop valve  44  by simply pulling or pushing knob  30  while faceplate  32  is in place and provides an aesthetically pleasing appearance with no piping being visible outside of the wall. Additionally, faceplate  32  and knob  30  can be painted as desired to match the building&#39;s interior walls or decor. The smaller and more compact design takes up less space under or behind toilets, sinks, or appliances. Additionally, the more compact design uses less material and provides materials cost savings in comparison to larger valve boxes. The compactness of outlet box  20  provides for several installation advantages. For example, outlet box  20  can be mounted right-side up or upside down depending on the location and orientation of the building&#39;s water lines. Outlet box  20  can also be installed on a stud  65 , a block (not depicted), or a Hyco strap  66 . Additionally, two outlet boxes  20  can be installed side-by-side on one standard wooden stud to accommodate two proximally located (such as hot and cold) water lines.  FIG. 27  depicts outlet box  20  installed upside down on a stud  65 .  FIG. 28  depicts two outlet boxes  20  installed side-by-side on the same stud  65 .  FIG. 29  depicts outlet box  20  installed on a Hyco strap  66 . Also, two outlet boxes  20  can be installed upside down and side-by-side. 
         [0051]    The present invention can be made of plastic, metal, or any other suitable material. In particular, the valve inlet shank assembly for PEX and WIRSBO PEX piping applications can be made of a moldable polymeric material, copier, or copper alloy pursuant to ASTM standards. The valve inlet shank assembly for copper piping applications can be made of any standard copper pipe. Housing  22  and mounting plate  24  of outlet box  20  can be made of any metal or polymeric material suitable for the intended use, and preferably comprise a moldable polymeric material that is tough and resistant to cracking. 
         [0052]    In an alternative embodiment not shown in the figures, outlet box  20  could contain two independent pull-stop assemblies. Faceplate  32  of outlet box  20  could contain two openings  33  for water connectors from an appliance that has a separate water connection for hot and cold water. In this alternative embodiment, faceplate  32  could also contain two openings  31  through which two extended handles  62  can pass to connect to two pull rods  46 . A user could pull or push one or two knobs  30  to open or close one or two valves  44 . 
         [0053]    In another alternative embodiment not shown in the figures, outlet box  20  could contain two coincident pull-stop assemblies. Faceplate  32  of outlet box  20  could contain two openings  33  for water connectors from an appliance that has a separate water inlet for hot and cold water. In this alternative embodiment, however, one knob  30 , one extended handle  62 , and one pull rod  46  are manipulated to open or close two valves  44 . 
         [0054]    In yet another alternative embodiment not shown in the figures, faceplate  32  could contain one opening through which both the push-pull handle assembly and the water connector(s) could pass to connect to valve  44 . Also alternatively, faceplate  32  could feature a cutaway section from the bottom, sides, or top through which both the push-pull handle assembly and the water connector(s) could pass to connect to valve  44 . 
         [0055]    Possible applications of the present invention include services that have a cold water connection and those that include hot and cold water connections. In particular, possible applications include toilets, faucets, vanity sinks, lavatory cabinets, pedestal sinks, kitchen sinks, icemakers, washing machines, dishwashers, water coolers, and refrigerators. 
         [0056]    Other alterations and modifications of the invention disclosed herein will likewise become apparent to one of ordinary skill in the art upon reading this disclosure, and the inventors intend that the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which they are legally entitled.