Abstract:
A fluid valve assembly and method for assembling the same includes a valve body defining an inlet, an outlet and a fluid passage communicating fluid therebetween. A control member is positioned within the fluid passage and includes a central passage through which the fluid advances. A flow seat component is positioned in the valve body downstream of the flow control member and receives the fluid from the flow control member. A cap component is secured to a distal opening defined on the valve body. A quick-connect collet is retained within an opening defined on the cap component.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to water valves and, more particularly, to water valves incorporating a quick connect feature and used in household appliances such as dishwashers, icemakers and clothes washing machines. 
     BACKGROUND OF THE INVENTION 
     In recent years there has been an increasing desire to provide a water dispenser and automatic ice maker on a household refrigerator. In such an arrangement a valve assembly is typically provided having a single water inlet and a pair of water outlets. The valve assembly may have a pair of valves housed in the valve assembly, one dedicated to controlling flow to the ice maker and the other dedicated to controlling flow to the water dispenser. Typically, the refrigerator includes a first water supply line that is adapted to connect from one of the water outlets on the valve assembly to the ice maker. A second water supply line is similarly adapted to connect from the other water outlet on the valve assembly to the water dispenser. 
     In one arrangement, the water supply lines and the respective water outlets on the valve assembly are attached by way of a quick connect. A quick connect allows the supply lines to be easily connected to the water outlets without the requirement of fasteners or supplemental hand tools. In general, to couple a supply line to a water outlet on the valve assembly, an end of the supply line is simply inserted into a tube gripper or collet provided on the water outlet. Once inserted, the collet provides radial retention on a first portion of the supply line to maintain a connection. In some instances an o-ring may also be provided to encourage a water tight fit. If the supply line needs to be removed from the quick connect, an outer flange defined on the supply line is squeezed thereby reducing the radial retention force between the collet and the supply line and therefore allowing the supply line to be retracted from the collet interface. 
     While the quick connect feature provides the convenience of a simple connection, quick connects can be difficult to manufacture within the valve assembly. For example, current designs for quick connect water valves with dual flow controls incorporated in the outlets of the valve require two weld operations to install the quick connect geometry for each valve outlet. As a result, such a valve assembly requires four weld operations. Consequently, it is desirable to provide a valve configuration having a quick connect feature that is simpler and more cost effective to manufacture. 
     SUMMARY OF THE INVENTION 
     A fluid valve assembly includes a valve body defining an inlet, an outlet and a fluid passage communicating fluid therebetween. A control member is positioned within the fluid passage and includes a central passage through which the fluid advances. A flow seat component is positioned in the valve body downstream of the flow control member and receives the fluid from the flow control member. A cap component is secured to a distal opening defined on the valve body. A quick-connect collet is retained within an opening defined on the cap component. 
     According to other features, the valve assembly further includes an o-ring supported within the cap component. The o-ring is adapted to seat on an outlet defined on the flow seat component. The flow seat component defines an upstream cup supporting the flow control member. The flow seat component also defines a downstream cup having an intermediate portion and an annular collar radially stepped in from the intermediate portion. 
     A method of manufacturing a fluid valve includes slideably inserting a flow seat component within a valve body. The flow seat component captures a flow control member within the valve body. A cap component is positioned at a downstream opening defined on the valve body. The cap component is then welded to the valve body. The cap component captures the flow seat component within the valve body. The cap component captures a quick-connect collet arranged on a downstream opening. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1  is a front perspective view of a water valve constructed in accordance with the teachings of the present invention; 
         FIG. 2  is a cross-sectional view of the water valve shown in  FIG. 1  taken along line  2 - 2 ; 
         FIG. 3  is an enlarged detail of the cross-sectional view of the water valve of  FIG. 2  showing a valve body outlet assembly; and 
         FIG. 4  is a perspective view of a flow seat component for the water valve of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to  FIGS. 1 and 2 , there is shown an appliance water valve assembly  10 . The water valve assembly  10  includes a valve body  12 , a water inlet  14 A and a pair of water outlets  20  and  22 . During operation of the valve assembly  10 , water is selectively advanced from the water inlet  14 A, through the valve body  12 , and out the desired water outlet  20  and/or  22 . Alternatively, a water inlet  14 B may be used. 
     The exemplary valve assembly  10  shown in the drawings is particularly useful for supplying water to two separate appliance components such as an icemaker and a door-mounted cold water dispensing unit. It should be appreciated however, that the concepts of the present invention may also be utilized in the construction of water valve assemblies having a single outlet and/or water valve assemblies for use in other types of appliances such as dishwashers and clothes washers or even in the construction of water valve assemblies for non-appliance applications. 
     The water inlet  14 A is typically connected to a residential water line (not shown) thereby providing for a water flow to the valve assembly  10 . The inlet  14 A and the outlets  20  and  22  may be of the quick connect variety. Specifically, the inlet  14 A and the outlets  20  and  22  include a tube gripper or collet  24  annularly retained by an inlet cap component  14 A and outlet cap component  28  (as best illustrated in  FIGS. 1 and 2 ). The quick connect inlet  14 A and outlets  20  and  22  facilitate connection of an appliance water line (not shown) for delivering water to the desired appliance component. 
     The water valve assembly  10  further includes a pair of valve actuator assemblies  30  and  32  having an upper plate frame  34  and a lower plate frame  36 . For purposes of discussion, the operation and features associated with the actuator assembly  30  and outlet  20  of the valve assembly  10  will be described in greater detail. It is appreciated however, that the actuator assembly  32  and outlet  22  are similarly constructed and provide similar operation. 
     With specific reference now to  FIG. 2 , the water valve assembly  10  will be further described. The water valve assembly  10  generally includes field windings  40 , a biasing spring  42 , a solenoid armature  44 , a guide tube  46 , a valve seal  48 , a valve surface  50 , an outlet extension  52  and a valve body outlet assembly  54 . The valve seal  48  is retained in the solenoid armature  44 . The solenoid armature  44  is slideably carried in the guide tube  46  and is moveable to an open position away from the valve surface  50  for permitting water flow from an actuation chamber  58  to the valve outlet  20  and moveable to a closed position contacting the valve surface  50  for preventing water flow from the actuation chamber  58  to the valve outlet  20 . 
     When the field windings  40  are energized, the solenoid armature  44  is retracted to lift the valve seal  48  thereby permitting flow of water from the actuation chamber  58  into the valve body outlet assembly  54 , out the outlet  20  and into the water line of the appliance (not shown). When the field windings  40  are de-energized, the solenoid armature  44  is returned to the closed position by the biasing spring  42  and the valve seal  48  contacts the valve surface  50  thereby stopping the flow of water from the actuation chamber  58  into the valve body outlet assembly  54 . 
     With continued reference to  FIGS. 1 and 2  and further reference to  FIG. 3 , the valve body outlet assembly  54  will now be described in greater detail. The valve body outlet assembly  54  generally includes a valve body outlet  60 , a flow seat component  64 , the cap component  28  and the collet  24 . The flow seat component  64  defines an inlet  66 , an outlet  68  and a flow control chamber  70  for accepting water from the outlet extension  52 . The flow control chamber  70  is disposed within the valve body outlet  60  and retains a flow control member  74  and a noise reduction member or bullet  80 . The bullet  80  can be integral with the flow seat component  64  as illustrated in  FIG. 3  or can be a separate piece. An o-ring  82  is supported within the cap component  28  and is adapted to seat on the flow seat component  64  at the outlet  68 . 
     The flow control member  74  is made of flexible material such as ethylene propylene (EP) rubber, and has a central passage  86  defined therein. The flow control member  74  flexes or deforms in response to variations in inlet water pressure exerted on an upstream surface  88 . In particular, a higher inlet water pressure on the upstream surface  88  causes a greater amount of flexing or deformity of the flow control member  74 , thereby reducing the diameter of the central passage  86 . A lower inlet water pressure exerted on the upstream surface  88 , causes the flexing or deformity of the flow control member  74  to be reduced, thereby increasing the diameter of the central passage  86 . 
     The flow seat component  64  has an orifice  90  defined therein, and provides a surface  92  on which the flow control member  74  is supported. The bullet  80  reduces the amount of cavitation, and hence the amount of noise, generated by the flow of water being advanced through the valve assembly  10 . The bullet  80 , may be made of a plastic material such as polypropylene. The bullet  80  includes a bullet body  94  and a tip  96 . The bullet  80  extends toward orifice  90  of the flow seat component  64  and is centrally aligned in a central passage  100  of the flow seat component  64 . Since the bullet  80  is aligned with the central passage  100 , a direct flow path or line of advancement of the flow of water exists. 
     With continued reference to  FIGS. 1-3 , and further reference to  FIG. 4 , the flow seat component  64  will be described in greater detail. The flow seat component  64  generally includes an upstream cup portion  110 , defining the flow control chamber  70 , and a downstream cup portion  112 . The upstream cup portion  110  defines a series of recesses  114  for locating a series of fingers  118  of the flow control member  74 . In the exemplary configuration, three recesses  114  are formed for locating three fingers  118 . A radial rib  120  extends around a downstream portion of the upstream cup  110 . The radial rib  120  facilitates a press-fit or interference fit with an inner diameter ( FIG. 3 ) of the valve body outlet  60 . The downstream cup portion  112  defines an intermediate portion  124  and an annular collar  126 . The annular collar  126  is adapted to engage the o-ring  82  in an assembled position ( FIG. 3 ). The annular collar  126  is radially stepped in from the intermediate portion  124  and defines a radial ledge  130 . During operation, the radial ledge  130  of the flow seat component  64  is supported by an annular shoulder  134  defined by the cap component  28  ( FIG. 3 ). 
     Assembly of the valve body outlet assembly  54  will now be described. At the outset, the flow control member  74  is positioned into the flow control chamber  70  of the flow seat component  64 . The flow seat component  64  is then slideably inserted within the inner diameter of the valve body outlet  60  thus creating a press-fit at the radial rib interface  120 . Next, the cap component  28  is positioned against a downstream opening  138  on the valve body outlet  60  capturing the flow seat component  64  and the flow control member  74  therebetween. Next, the cap component  28  is connected, such as by a welding operation to the valve body outlet  60 . More specifically, a weld is created at an interface between a tapered female surface  140  of the cap component  28  and a tapered male surface  142  of the valve body outlet  60 . 
     According to the teachings of the present invention, only a single welding operation between the mating surfaces ( 140  and  142 ) of the valve body outlet  60  and the cap component  28  is necessary to manufacture (assemble) the valve outlet assembly  54 . 
     The valve body outlet  60  and the cap component  28  are fused together at the mating surfaces ( 140  and  142 ) in a welding operation. The welding operation serves to permanently affix the cap component  28  and the valve body  60 . 
     The welding operation may be, for example, a friction welding operation such as spin welding. Friction welding generally is a process for joining components in which sufficient heat for the melting and fusion of the components is generated by friction between the components. In this process, one of the members is held stationary while the other is rotated at a high speed. The members are then brought into contact under an axial force. The friction induced at the interface between the components produces heat so that the components (in the present invention, the cap component  28  and the valve body outlet  60 ) are melted and fused together. 
     Once the weld has been created, the o-ring may be slidably inserted into the outlet assembly  54 . The collet  24  may be squeezed at an upper end  146  defining a plurality of fingers  148  and slideably inserted (in an upward direction as viewed from  FIG. 3 ) into the cap component  28 . Once a radial ledge  150  defined around the upper end  146  of the collet  24  clears an inner diameter  152  of the cap component  28 , the upper end  146  of the collet  24  rebounds outwardly to a relaxed position ( FIG. 3 ). Once assembled, the radial ledge  150  limits downward motion of the collet  24  within the cap component  28 . 
     The configuration of the valve body outlet assembly  54  and the single welding operation described herein provides a cost effective method for manufacturing quantities of valves. 
     Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modification will become apparent to the skilled practitioner upon a study of the drawings, specification and following claims.