Abstract:
A control disk insert for a one lever mixer valve ( 20 ) contains two preferably, planar disks, whereof one fixed control disk ( 24 ) has at least one opening zone for hot water and at least one opening zone for cold water. The movable control disk ( 22 ) facing the fixed control disk ( 24 ) and movable with two degrees of freedom can both completely close and continuously completely open the opening zones in the fixed control disk ( 24 ). The opening zones of the fixed control disk ( 24 ) and the opening zones of the moveable control disk ( 22 ) are constructed in such a way that the control disk ( 22 ) can be positioned to divert a non-contaminated fluid stream to a separate outlet for connection to various devices. Or, the opening zones of the fixed control disk ( 24 ) and the opening zones of the moveable control disk ( 22 ) are constructed in such a way that the control disk ( 22 ) can be positioned to send a pressure signal or pressure relief signal to an appliance.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of provisional patent application Ser. No. 60/647,252, filed 2005 Jan. 26 by the present inventor. 
     
    
     FEDERALLY SPONSORED RESEARCH 
       [0002]    Not Applicable 
       SEQUENCE LISTING OR PROGRAM 
       [0003]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    This invention relates to faucets which control the mixing of hot and cold water. More particularly, the invention relates to faucets of the foregoing type wherein a movable disk is both rotated and directed in a linear manner over a stationary disk by an operating spindle. In addition, the invention relates to a cartridge with at least one additional port which can be used for various applications. 
         [0006]    2. Prior Art 
         [0007]    There are problems with certain mixing valves which utilize movable and stationary disks (e.g. ceramic disks) in applications which relate to the use of water filtration systems. Prior art arrangements of these faucets and four port mixing valves (e.g. cartridges) appear to suffer from common disadvantages such as (a) cartridges are bulky and large. (b) cartridges require additional space and are specific to one unique application. (c) cartridges require numerous additional components. (d) they are more expensive to manufacture due to larger exterior components. (e) cartridges have small flow area at control surface interface of the additional filtration water communication port. (f) cartridges have rotatable activation at faucet handle. Control surface refers to where a movable control disk and a fixed control disk form a seal plane for mixing. 
         [0008]    Also, alternate cartridge designs that are used for water filtration applications require 5 port cartridges. Such a cartridge is described in U.S. Pat. No. 6,029,699 by Yoav Granot. The aforementioned patent employs small overlap area at the control surface interface of the diverting opening. Also, the large 5 port cartridge activates filter water mode by handle rotation, which is perhaps less than an intuitive approach. 
         [0009]    Other large and bulky cartridge designs do activate filter water by pushing downwards on a faucet handle as in U.S. Pat. No. 6,135,151 by David L. Bowers et al. While this cartridge design has the convenience of downward activation, and the cartridge requires one less flow line when compared to the cartridge described in U.S. Pat. No. 6,029,699 by Yoav Granot, the cartridge is complex, bulky and can only be used on very specific valve seats. 
         [0010]    Furthermore, The cartridge described in U.S. Pat. No. 6,135,151 by David L. Bowers et al defines disk members having defined therebetween a mixing chamber and a diverting cavity. Such arrangements result in limiting surface area for the overlapping cavity and results in more geometry restrictions on the underside of such movable control disks. 
         [0011]    3. Objects and Advantages 
         [0012]    Accordingly, several objects and advantages of the present invention are:
       (a) to provide a cartridge with a downward activation with reference to the faucet handle and a diverting fluid stream   (b) to provide a 4 port cartridge that can be used in filtration applications   (c) to provide a more conventional shaped 4 port cartridge   (d) to provide a 4 port cartridge requires a few additional components when compared to existing 3 port cartridges that are quite common   (e) to provide a cartridge that can be used to send water to a displacement type chiller that dispenses chilled, filtered or unfiltered cold water   (f) to provide a cartridge that can send a momentary or long duration pressure signal to control an appliance or mechanism   (g) to provide a cartridge that can vent a pressure buildup in order to control an appliance or mechanism       
 
         [0020]    Further objects and advantages are to provide a compact cartridge that may be suitable for applications that dispense hot or chilled water in kitchens. 
       SUMMARY 
       [0021]    The invention can be used in applications where the dispensing of filtered water is desired. The newly invented cartridge requires few additional parts when compared to typical 3 port cartridges. Such an invention would be well suited for the dispensing of Hot water by means of a displacement type heated water chamber similar to that of a commercial coffeemaker. Or, a similar displacement device could be used to chill water. Furthermore, both devices could be located in modern or gourmet kitchens where the dispensing of heated cooking water and chilled water are desired. In addition, the use of such a device to control appliances by way of a pressure signal communicated by the cartridge may be desirable. 
     
    
     
       DRAWINGS—FIGURES 
         [0022]    The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein: 
           [0023]      FIG. 1  is a cross-section through part of a mixer valve with a control insert according to the invention. 
           [0024]      FIG. 2  is a cross-section from a direction turned 80° relative to  FIG. 1  with the control rod rotated respectively. 
           [0025]      FIG. 3  is a bottom view of the moveable control disk e.g. the moveable control surface 
           [0026]      FIG. 4  is a top view of the moveable control disk 
           [0027]      FIG. 5  is a cross-section through the moveable control disk according to  FIG. 4   
           [0028]      FIG. 6  is a top view of the fixed control disk e.g. the fixed control surface 
           [0029]      FIG. 7  is a bottom view of the fixed control disk 
           [0030]      FIG. 8  is a cross-section through the fixed control disk according to  FIG. 6   
           [0031]      FIG. 9  is a cross-section through the fixed control disk according to  FIG. 6   
           [0032]      FIGS. 10 to 14  are diagrammatically positions of fixed and movable control disks. 
           [0033]      FIG. 15  is an exploded view of the valve of  FIG. 1 . 
       
    
    
     DRAWINGS 
     Reference Numerals 
       [0000]    
       
         
           
               20  cartridge 
               21  cartridge housing 
               22  movable control disk 
               23  bearing surface 
               24  fixed control disk 
               25  flange 
               26  valve seat 
               27  bearing surface 
               28  cavity 
               29  limit locus 
               30  rotative control rod device 
               32  cover seat 
               34  attachment 
               36  cavity 
               38  motion transmission element 
               40  o-ring 
               41  protrusion feature 
               42  protrusion feature 
               43  void 
               44  inlet cavity 
               45  void 
               46  inlet cavity 
               48  overpass chamber 
               50  mixing chamber 
               51  diverting outlet 
               53  seal 
               54  hot water inlet 
               58  cold water inlet 
               59  upper limit surface 
               60 A seal slot 
               60 B seal slot 
               60 C seal slot 
               60 D seal slot 
               61  moveable control surface 
               62  seal 
               63  seal slot 
               64  opening 
               66  opening 
               67  diverting chamber 
               68  opening 
               69  outlet 
               74  outlet 
               153  seal 
               144  outlet 
               145  inlet 
               148  inlet 
               174  inlet 
               253  seal 
               353  seal 
           
         
       
     
       DETAILED DESCRIPTION 
     Preferred Embodiment 
       [0083]    Referring to the attached drawings  FIG. 1  and  FIG. 2 , the present invention generally includes a cartridge  20 , a movable control disk  22 , a fixed control disk  24 , and a valve seat  26 . A bearing surface  23  is located above a flange  25 . A cartridge housing  21  is cylindrical, on the top. there is a cavity  28  of a smaller diameter. A rotative control rod device  30  is inserted in the cavity  28 . The control rod  30  swings through the central axis of a cover seat  32 , and includes an attachment  34 . The control rod  30  extends down and continuous in an attachment  34  from a cover seat  32 . The attachment  34  is placed in a corresponding cavity  36 . The cavity  36  is located in an upper portion of a motion transmission element  38 . A bearing surface  27  is located above transmission element  38 . The transmission element  38  provides a range of motion for the control rod  30 . An, O-ring  40  is beneath the transmission element  38  where said O-ring  40  seals transmission element  38  with the movable control disk  22 . The transmission element  38  is equipped with protrusion features  41  and  42  extending downward into voids  43  and  45  securing control disk  22  as illustrated in  FIG. 15 . There are also two inlet cavities  44 ,  46  and two outlet cavities  74  and  174  as illustrated in  FIGS. 1 and 2 . 
         [0084]    Referring to the  FIGS. 1 to 5 , the moveable control disk  22  is a smaller diameter than the aforesaid cartridge  20 . There is an overpass chamber  67  in the upper portion of the movable disk  22 . The transmission element  38  has protrusions  41  and  42  that can be inserted into voids  43 , 45  in the moveable control disk  22 . In addition, an o-ring  40  seals the moveable control disk  22  with the transmission element  38 . 
         [0085]    Together, these items are to be mounted in the cartridge  20  while moving freely relative to the fixed disk  24 . The moveable disk is free to move within the confines of the cartridge housing  21  with a notable difference from existing cartridges defined by inner cartridge housing  21  geometry limit locus  29 . Also, there is a mixing chamber  50  in the movable disk  22 . The mixing chamber  50  can be connected to hot water inlet  54  and cold water inlet  58  in the fixed control disk. 
         [0086]    A valve seat  26  inserts and engages at bottom of the cartridge  20  and positions the seals  53 ,  153 ,  253  and  353  interfacing the fixed disk  24 . The moveable disk  22  is subjected to the movement of the control rod  30  and is able to move and overlap the fixed disk  24 . The control rod  30  drives the moveable disk  22  and alters various positions of the moveable disk  22  in relation to the fixed disk  24  (see  FIGS. 10 to 14 ). The movable control disk has a lower limit surface that forms the movable control surface  61  as illustrated in  FIG. 3 . To provide for outlet  74  water flow, the movable control disk opening  66  connects to hot water inlet  54 , cold water inlet  58 , or a combination of both water inlets. All mixed water exits the fixed control disk  24  through outlet  69 . By way of the aforementioned connections, the movable control disk  22  is able to open or close or mix or deliver hot and cold water to outlet  74 . 
         [0087]    See FIGS.  1 , 2 , 6 , 7  and  15 . Below the movable control disk  22 , the fixed control disk  24  is secured in the cartridge by the position of the seals  53 , 153 , 253  and  353  only for the purpose of this example. The fixed disk will utilize common means for securing the fixed control disk in position. Common means refers to voids along a peripheral edge in a lower surface of a fixed control disk which engage securing protrusions located in a valve seat. The fixed control disk  24  has an upper limit surface  59  which forms the fixed control surface. The fixed control disk  24  has hot and cold inlet  54  and  58  that receive flow from inlet cavities  46  and  44 . The only diagrammatically represented fixed control disk  24  rest partly on the seals  53 , 153 , 253  and  353  and valve seat  26 . In  FIGS. 6 to 8 , the fixed disk  24  contains a diverting outlet  51 . The diverting outlet  51  is diametrically opposed to the cold water inlet  58 . 
         [0088]    In  FIG. 15  you can see seal slots  60 A, 60 B, 60 C, and  60 D in the valve seat  26 . A seal  62  covers seal slot  63  in order to prevent leakage between valve seat and all inlets and outlets. In doing so, all individual fluid paths are also sealed from each other as is accomplished by individual seals  53 , 153 , 253  and  353 . 
         [0089]    It is common practice to use a flat surface of two disks to form a seal plane by placing what we call control surfaces against each other to form a seal plain. In order to be clear, the term opening zone in a control surface means an opening in a control surface where an edge of said opening zone does not share an edge with a perimeter or boundary of said control surface. 
         [0090]    With reference to  FIG. 4 , and  FIGS. 10 to 14 , the interactions of the two control disks for mixing the two water flows and for setting the water quantity will now be described. A rotation of the movable control disk  22  leads to a temperature change, whilst a displacement of the movable control disk in a direction of an alignment passing through the center of the section  3  line in  FIG. 4  permits the choice of the water quantity. In  FIG. 12  the control disk is rotated counter clockwise to its end position and is simultaneously displaced to the left and upwards. The opening  64  of moveable control disk  22  frees the cold water inlet  58  of the fixed control disk  24 , which is to be connected with the cold water. Simultaneously, the opening  68  of moveable control disk  22  frees opening  51  in the fixed control disk, which is also connected to the cold water inlet. The water enters opening  64  and travels through a diverting channel  67 . The position of  FIG. 12  consequently means that the cartridge is in the diverting position and is sending water or sending a pressure signal to a water filter or alternate device. If the control disk  22  is now positioned downward to the right, then the situation is as shown in  FIG. 14 . Opening  66  frees opening  58  in the fixed control disk and allows the water to exit through outlet  69 . Thus,  FIG. 14  shows the control insert in the cold water position. 
         [0091]    If the control disk  22  is now positioned downward to the left, then the situation is as shown in  FIG. 13 . To an equal extent opening  66  frees the openings  54  and  58 . 
         [0092]    Thus,  FIG. 13  shows the control insert position with a 50% mixing ratio. 
         [0093]    If the moveable control disk  22  is moved upwards from the position in  FIG. 13  without turning it, the position shown in  FIG. 10  is obtained, in which the valve is closed in the central temperature position. In this closed position, control disk  22  can be rotated both clockwise and counterclockwise without the valve opening. In  FIG. 11 , the off position of the full hot orientation is displayed. 
       Alternative Embodiments 
       [0094]    There may be applications where a compact cartridge is able to channel hot or cold water to a another location.  FIG. 1  can also be a section through the hot water inlet  54  &amp; outlet  74 . Such a 5 port unit could have the fifth port diametrically opposed to the hot water inlet  144  that can utilize the diverting channel  67  in order to connect to a second diverting out port  174 . Using  FIG. 1  to replace the hot water cross section of  FIG. 2  is the simplest way to describe what a section that is 80 degrees away from the cold water position of  FIG. 1  would look like. A cartridge built without limit locus  29  being completely circular cross sectioned cartridge could allow for the dispensing of either stream or a mix of both streams. In the event that a mixing of both diverting streams is undesirable, a smaller limit locus or a groove in limit locus can facilitate downward activation occurring in only non-mixing positions. 
         [0095]    The newly invented cartridge could easily have the translation or volume controlling throw positions divided into two index-able positions to allow for a user interface that provides response feel to the user when pressing handle down. Part of the response throw could be momentary and then transition into a fixed position of outflow. This can be accomplished by use of indents with corresponding cavities located in the lever and interfacing parts. Use of a spring or incorporating geometry into a memory retaining polymer would suffice for such an application. 
         [0096]    In addition, the cartridge  20  can be seated on a surface that allows for, the first one of two diverting positions to be active, the second of two diverting positions to be active or both diverting positions to be active. 
         [0097]    Also, the cartridge can be used with one of the diverting ports functioning as a vent. This may be useful in applications where a filter unit can be relieved of pressure so as to change the filter unit. Similarly, one of the diverting chambers can be used to connect a vent to an appliance that builds pressure in a line where the relief of such pressure causes a desired functioning to occur. Such a device could be used to flush a toilet and promote good hygiene practices. In such an application, the movement of the faucet handle to wash ones hands could automatically flush a toilet. 
         [0098]    Additionally, the cartridge can be constructed using similar protrusion notches or pawls to secure and balance the fixed control disk to the valve seat as is done in current cartridge designs. Furthermore, the cartridge can be constructed using similar snap locking features that are currently used to secure the cartridge outer shell to the valve seat. 
         [0099]    Similarly, the cartridge can be constructed similar to existing 3 port cartridges requiring few additional parts. From an appearance standpoint, the main differences distinguishing this invention from other cartridges are related to the geometry of the control disks. 
         [0100]    When the invention is compared to other similar four or five port cartridges, the simplicity and therefor lower cost is desirable. 
         [0101]    When the alternate flow area overlap in the control surface of the newly invented cartridge is compared to other 4 or 5 port cartridges, the sound and performance may be more desirable. 
         [0102]    Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. 
         [0103]    Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by examples given. 
       Advantages 
       [0104]    The numerous advantages in the aforementioned items generally relate to diverting flow area, size, cost and versatility. The newly invented cartridge can be used in many different applications. Also, the cartridge can be used in applications where a cheaper alternative cartridge is desired. There may be numerous applications for which this cartridge may be preferred over the prior art. 
         [0105]    It is noteworthy to mention that such a cartridge can have numerous common parts with other similar cartridges so as to reduce the number of custom parts that are unique only to a 4 or 5 port application.