Abstract:
A water control valve has a plurality of ports and a mixing chamber and a removable cartridge in the chamber for controlling water flow. A flushing plug is receivable in the chamber in place of the cartridge for enabling flushing and pressure testing of the ports. A retainer removably holds either the cartridge or the flushing plug in the chamber. A method of pressure testing and/or flushing a water control system includes the steps of removing a clip that holds a mixing cartridge in a valve body; removing the mixing cartridge from an opening in the valve body; inserting a flushing plug into the opening in the valve body; and replacing the clip to hold the plug in the opening in the valve body.

Description:
TECHNICAL FIELD  
         [0001]    The present invention relates to apparatus for use in the installation, flushing and pressure testing of a water control valve. In particular, the present invention relates to a flushing plug for use in the installation, flushing and pressure testing of a shower and tub control valve.  
         BACKGROUND OF THE INVENTION  
         [0002]    When a shower and tub water control valve is installed by a plumber, a cartridge is located in a central chamber in the valve body. The cartridge is insertable and removable through an opening in the valve body, for installation and replacement purposes. The chamber is open to the room through the opening in the valve body, when the cartridge is not in place. A horseshoe clip normally holds the cartridge in place in the valve body. When the cartridge is in place in the chamber in the valve body, the cartridge blocks flow of water out of the valve body through the opening, allowing fluid flow only along the flow paths established by the open or closed and hot or cold position of the cartridge. If the cartridge is not in place in the chamber in the valve body, water can flow out of the valve body through the opening and into the room in which the valve is being installed.  
           [0003]    The valve body has four ports that open into the chamber in which the cartridge is located. Four water pipes are soldered or otherwise connected to these four ports—hot and cold water inlets, a tub spout drop, and a shower riser.  
           [0004]    After the valve body is installed, the system is pressure tested. If the pressure test is conducted with the cartridge installed and in the closed position, only the hot and cold solder joints are tested; there is no water flow to the shower riser and the tub drop, and they are not pressurized. If the pressure test is conducted with the cartridge installed and in the open condition, so that the riser and the drop are pressurized, then water flows through the cartridge, which allows line trash in the cartridge.  
           [0005]    The system should also be flushed. If flush testing is done with the cartridge in place, line trash can accumulate inside the cartridge, causing friction, incorrect valve operation, etc.  
         SUMMARY OF THE INVENTION  
         [0006]    In one embodiment the present invention relates to an apparatus comprising a water control valve having a plurality of ports and a chamber interconnecting the ports and a removable cartridge receivable in the chamber for controlling water flow through the valve between the ports. The apparatus also includes a flushing plug receivable in the chamber in place of the cartridge for enabling flushing and pressure testing of the ports.  
           [0007]    In another embodiment the invention relates to apparatus comprising a water control valve having a plurality of ports, a chamber interconnecting the ports, a removable cartridge receivable in the chamber for controlling water flow through the valve between the ports, and a retainer that removably holds the cartridge in the chamber. A flushing plug is receivable in the chamber in place of the cartridge. The retainer is operative to removably hold the flushing plug in the chamber.  
           [0008]    In another embodiment the invention relates to apparatus comprising a valve body with a mixing chamber and a plurality of ports that open into the mixing chamber. A cartridge is insertable into the chamber through an opening for controlling fluid flow through the mixing chamber between the ports. A retainer is engageable between the valve body and the cartridge to retain the cartridge on the valve body. The apparatus includes a plug for plugging the opening when the cartridge is not inserted in the chamber, the retainer being engageable with the valve body and the plug to retain the plug on the valve body.  
           [0009]    In yet another embodiment, the invention relates to a method of pressure testing and/or flushing a water control system including a hot and cold mixing valve. The method includes the steps of removing a clip that holds a mixing cartridge in a valve body; removing the mixing cartridge from an opening in the valve body; inserting a flushing plug into the opening in the valve body; and replacing the clip to hold the plug in the opening in the valve body. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    The foregoing and other features of the present invention will become apparent to one skilled in the art to which the present invention relates upon consideration of the following description of the invention with reference to the accompanying drawings, in which:  
         [0011]    [0011]FIG. 1 is a schematic view of a tub and shower water supply system including a control valve in accordance with the present invention;  
         [0012]    [0012]FIG. 2 is a sectional view of the control valve of FIG. 1, taken through the hot and cold water inlets, with the valve cartridge installed;  
         [0013]    [0013]FIG. 3 is a sectional view of the control valve of FIG. 1, taken through the tub drop and shower riser, with the valve cartridge installed;  
         [0014]    [0014]FIG. 4 is a sectional view of the control valve of FIG. 1, taken through the hot and cold water inlets, with a flushing plug installed; and  
         [0015]    [0015]FIG. 5 is a sectional view of the control valve of FIG. 1, taken through the tub drop and shower riser, with the flushing plug installed. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0016]    The present invention relates to apparatus for use in the flushing and pressure testing of a water control valve. In particular, the present invention relates to a flushing plug for use in the flushing and pressure testing of a shower and tub control valve. The invention is applicable to various flushing plug constructions. As representative of the invention, FIGS. 1 and 4- 5  illustrate a flushing plug  10  in accordance with a first embodiment of the invention.  
         [0017]    The plug  10  is shown in use with a shower and tub control valve  12  that is part of a tub and shower water supply system  14 . The valve  12  includes a valve body  20  of a known type. The valve body  20  has a hot water inlet port  22 . A hot water supply pipe  24  is connected with the hot water inlet port  22  by a solder joint  26 . The hot water supply pipe  24  connects the valve body  20  with a hot water supply shown schematically at  28 . The hot water supply pipe  24  can alternatively be connected with the hot water inlet port  22  in another manner, for example, with a threaded connection.  
         [0018]    The valve body  20  also has a cold water inlet port  30 . A cold water supply pipe  32  is connected with the cold water inlet port  30  by a solder joint  34 . The cold water supply pipe  32  connects the valve body  20  with a cold water supply shown schematically at  36 . The cold water supply pipe  32  can alternatively be connected with the cold water inlet port  30  in another manner, for example, with a threaded connection.  
         [0019]    The valve body  20  has a shower outlet port  40 . A shower riser  42  is connected with the shower outlet port  40  by a solder joint  44 . The shower riser  42  connects the valve body  20  with a shower head shown schematically at  46 . The shower riser  42  can alternatively be connected with the shower outlet port  40  in another manner, for example, with a threaded connection.  
         [0020]    The valve body  20  also has a tub outlet port  50 . A tub drop  52  is connected with the tub outlet port  50  by a solder joint  54 . The tub drop  52  connects the valve body  20  with a tub spout shown schematically at  56 . The tub drop  52  can alternatively be connected with the tub outlet port  50  in another manner, for example, with a threaded connection.  
         [0021]    The four ports  22 ,  30 ,  40  and  50  in the valve body  20  are interconnected by a central chamber  60  (FIGS. 2 and 3) in the valve body. The central chamber  60  is defined by a cylindrical inner surface  62  of the valve body  20 . The surface  62  is centered on an axis  64  of the valve  12 .  
         [0022]    The valve body  20  also includes a cartridge port  66  defined by a cylindrical wall  68  having at its outer end an opening  70 . At its inner end the cartridge port  66  opens into the central chamber  60  of the valve body  20 . The interior of the cartridge port  66  is defined by the same cylindrical inner surface  62  as the central chamber  60 . A retaining clip groove  74  (FIG. 3) is formed on the outer side surface  76  of the wall  68  of the cartridge port  66 .  
         [0023]    The valve  12  also includes a cartridge  80 . The cartridge  80  is received in the cartridge port  66  and extends into the central chamber  60  of the valve body  20 . The cartridge  80  is operable to direct hot water, cold water, or a mixture of hot and cold water, in a known manner, to either the tub drop  52  or the shower riser  42 . The valve cartridge  80  fits closely within the cylindrical inner surface  62  of the valve body  20 .  
         [0024]    The valve  12  also includes a retainer for holding the cartridge  80  in the valve body  20 . In the illustrated embodiment, the retainer is a retaining clip  82 , although other form of retainer could be used in other embodiments, for example a screw. The clip  82  is a thin metal piece having an upside down U-shaped configuration when viewed in elevation. The clip  82  is received in the retaining clip groove  74  of the valve body  20  and also in a retaining clip groove  84  (FIG. 3) of the cartridge  80 . The engagement of the retaining clip  82  in the grooves  74  and  84  blocks removal of the cartridge  80  from the valve body  20 .  
         [0025]    The cartridge  80  is removable from the valve body  20 , through the opening  70 , by removing the clip  82  and pulling the cartridge out, in a direction along the axis  64 . When the cartridge  80  is not present in the valve body  20 , the central chamber  60  of the valve body  20  is open to the exterior of the valve  12 , through the opening  70  of the cartridge port  66 .  
         [0026]    The cartridge  80  when located in the valve body  20  controls, in a known manner, the flow of water between the various ports of the valve body. The cartridge  80  blocks flow of water out of the valve body  20  through the opening  70 , allowing fluid flow only along the flow paths established by the open/closed and hot/cold position of the cartridge. If the cartridge  80  is not in place in the chamber  60  in the valve body  20 , water can flow out of the valve body through the opening  70 , and into the room in which the valve  12  is being installed.  
         [0027]    After the valve body  20  is installed and the solder joints  26 ,  34 ,  44  and  54  (FIG. 1) (or other form of connection) are made, the system  14  is pressure tested to check the integrity of the four solder joints (or other form of connection). If the pressure test is conducted with the cartridge  80  installed and in the closed position, only the hot and cold solder joints  26  and  34  are tested. This results because with the cartridge  80  in the closed position, there is no water flow to the shower riser  42  and the tub drop  52 , so those lines are not pressurized and their solder joints  44  and  54  are not tested.  
         [0028]    If the pressure test is conducted with the cartridge  80  installed and in the open position, so that the riser  42  and the drop  52  are pressurized to test their solder joints  44  and  54 , the water must flow through the cartridge to reach the riser and the drop. Line trash in the water can accumulate in the small openings and passages in the cartridge  80 . Accumulation of line trash in the cartridge  80  can cause damage to the cartridge, or friction in or improper operation of the valve.  
         [0029]    After the valve body  20  is installed and the solder joints  26 ,  34 ,  44  and  54  are made, the system should also be flushed. Flush testing involves flowing water through all the joints and pipes and the valve body  20 , and flushing that water out through the shower riser  42  and the tub drop  52 . If the flush testing is conducted with the cartridge  80  in place in the valve body  20 , line trash can again accumulate inside the cartridge.  
         [0030]    Use of the flushing plug  10  facilitates pressure testing and flushing of the system without damaging the cartridge  80 . The flushing plug  10  (FIGS. 4 and 5) is preferably made from plastic, but could be made from another material, and may be molded as one piece. The plug  10  has a configuration adapted to replace the cartridge  80  in the valve body  20  and seal the opening  70 .  
         [0031]    Specifically, the plug  10  has a configuration similar to that of the cartridge  80  that it replaces. The illustrated plug has a cylindrical configuration including a cylindrical side wall  90  centered on the axis  64 . The side wall  90  has inner and outer side surfaces  92  and  94 .  
         [0032]    Specifically, the plug  10  has a generally cylindrical configuration including a cylindrical side wall  90  centered on the axis  64 . The side wall  90  has inner and outer side surfaces  92  and  94 .  
         [0033]    A tubular first section or outer end portion  96  of the plug  10  extends for about 50% of the length of the plug. An annular positioning flange  98  extends radially outward from the first section  96  of the plug  10 .  
         [0034]    A tubular second section  100  of the plug  10  extends from the first section  96  and has a thicker wall section than the first section. The outer diameter of the second section  100  of the plug  10  is selected so that the second section fits closely within the cartridge port  66  of the valve body  20 . A retaining clip groove  102  is formed in the outer surface of the second section  100  of the plug  10 . A tubular third section or inner end portion  104  of the plug  10  extends from the second section  100 . The outer diameter of the third section  104  of the plug  10  is selected so that the third section fits closely within the cartridge port  66  of the valve body  20 .  
         [0035]    A seal groove  106  is formed in the outer side surface  110  of the third section  104  of the plug  10 . The seal groove  106  is adapted to receive a suitable seal, such as the illustrated O-ring  108 , to seal between the inner surface  62  of the valve body  62  and the outer side surface  110  of the third section  104  of the plug  10 .  
         [0036]    The plug  10  has an inner wall  112 . The inner wall  112  extends radially within the second section  100  of the plug  10 . The inner wall  112  blocks fluid flow between the inner end portion  104  of the plug  10  and the outer end portion  96  of the plug, through the second section  100  of the plug.  
         [0037]    To use the flushing plug  10 , the cartridge  80  is first removed from the valve body  20  by removing the retaining clip  82  and pulling the cartridge out of the valve body through the opening  70 , in a direction along the axis  64 . The central chamber  60  of the valve body  20  is then open to the exterior of the valve  12 , through the opening  70 .  
         [0038]    The flushing plug  10  is inserted into the cartridge port  66  through the opening  70 . The flushing plug  10  moves into the valve body  20  until the positioning flange  98  on the plug engages the side wall  68  of the cartridge port  66 . This engagement blocks further inward movement of the plug  10  into the valve body  20 .  
         [0039]    The plug  10  is then in the position shown in FIGS. 4 and 5. The inner end portion  104  of the flushing plug  10  is located in the chamber  60  in the valve body  20 . The outer end portion  96  of the plug  10  projects from the valve body  20  through the opening  70 . The distance between the retaining clip groove  102  in the plug  10 , and the positioning flange  98 , is selected so that when the plug is inserted in the valve body  20  in place of the cartridge  80 , the retaining clip groove  102  in the plug aligns with the retaining clip groove  74  in the valve body, just as the retaining clip groove  84  in the cartridge  80  does when the cartridge is inserted. The retaining clip groove  102  on the plug  10  is thus located radially inward of (is aligned with) the retaining clip groove  74  on the side wall  68  of the cartridge port  66  when the flushing plug is installed in the valve body  20 .  
         [0040]    The retaining clip  82  is then inserted into the retaining clip groove  74  on the side wall  68  of the cartridge port  66  and into the retaining clip groove  102  on the flushing plug  10 . The engagement of the retaining clip  82  in the grooves  74  and  102  blocks removal of the flushing plug  10  from the valve body  20 . The positioning flange  98 , at the same time, blocks further movement of the flushing plug  10  into the valve body  20 .  
         [0041]    With the flushing plug  10  thus installed in the valve body  20 , the inner wall  112  of the flushing plug blocks fluid flow out of the central chamber  60  of the valve body  20  through the center of the flushing plug. The O-ring  108  on the exterior of the plug  10  blocks fluid flow out of the central chamber  60  of the valve body  20  along the exterior of the flushing plug  10 . The opening  70  in the valve body  20  is thereby sealed.  
         [0042]    A pressure test can then be conducted to check the integrity of the four solder joints  26 ,  34 ,  44  and  54 , (FIG. 1) in the system  14 . The pressure test is conducted with the flushing plug  10  in the valve body  20 . The shower riser  42  and the tub drop  52  are plugged or capped, in a known manner (not shown).  
         [0043]    Both the hot and cold water supplies  28  and  36  are turned on. Hot water under pressure flows into the valve body  20  through the hot water inlet port  22 . Cold water under pressure flows into the valve body  20  through the cold water inlet port  30 . The central chamber  60  is open, even though the flushing plug  10  is installed, because the plug does not cover any of the four ports in the valve body  20 . Therefore, the mixture of hot and cold water flows out of the central chamber  60  through the shower riser port  40  and the tub drop port  50 .  
         [0044]    Because the tub drop  52  and the shower riser  42  are plugged or capped, the water flowing into the system  14  is trapped and pressure builds up. The integrity of the hot and cold inlet solder joints  26  and  34  is tested, as well as the integrity of the riser and drop solder joints  44  and  54 . Since the cartridge is not in the valve body during this pressure testing, there is no possibility of line trash getting into the cartridge.  
         [0045]    Flushing of the parts after installation, to clear any line trash, is likewise conducted with the flushing plug  10  in the valve body  20 . The shower riser  42  and tub drop  52  are open (not plugged). Both the hot and cold water supplies  28  and  36  are turned on. Hot water under pressure flows into the valve body  20  through the hot water inlet port  22 . Cold water under pressure flows into the valve body  20  through the cold water inlet port  30 . The central chamber  60  is open, even though the flushing plug  10  is installed. Therefore, the mixture of hot and cold water flows out of the central chamber  60  through the shower riser port  40  and the tub drop port  50 .  
         [0046]    Because the tub drop  42  and the shower riser  52  are open, the water flowing into the valve body  20  flows through the central chamber  60  of the valve body and through all four ports  22 ,  30 ,  40  and  50 , past all four solder joints  26 ,  34 ,  44  and  54 . The water flows out of the valve body  20  through the shower riser  42  and the tub drop  52 . Thus, the valve body  20  and the associated pipes, are all flushed. Since the cartridge  80  is not in the valve body  20  during this flushing, there is no possibility of line trash getting into the cartridge.  
         [0047]    From the above description of the invention, those skilled in the art will perceive improvements, changes; and modifications in the invention. Such improvements, changes, and modifications within the skill of the art are intended to be included within the scope of the appended claims.