Abstract:
A flow-through valve is provided and includes a housing connecting first and second ends to allow fluid flow from the first end to the second end. The first end includes first and second inlet ports, while the second end portion includes an outlet port. The flow-through valve further includes a valve cartridge including a first fixed disk having an opening thereon, a first moveable disk in fluid communication with the first fixed disk, a second fixed disk having an opening thereon and a second moveable disk in fluid communication with the second fixed disk. The fixed disks and moveable disks may be configured within the valve cartridge to independently adjust the hot/cold water flow or the temperature/flow rate.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates to a flow-through valve assembly for a faucet, and more particularly to a two-handled flow-through valve assembly alternately configurable to provide adjustment of the hot and cold water or the flow rate and temperature. 
   Various valves to control the flow of hot and cold water are known for residential applications such as kitchen or lavatory fixtures or bath/shower fixtures. Such conventional valves operate in one of two modes—a hot/cold water control mode or a temperature/flow rate mode. However, such valves are not readily configurable to operate in either mode. Accordingly, there is a need for a valve design which may be adapted to provide either control mode. 
   Conventional valves include a radial outlet or discharge from the valve body so water flows axially into and radially out from the valve. As such, conventional valves limit the shape of the faucet and the placement of the valve. Accordingly, there is a need for a flow-through valve design in which water flows axially into and out from the valve. 
   SUMMARY OF THE INVENTION 
   The present invention provides a flow-through valve including a valve housing having an outer cylindrical wall connecting first and second axially offset end portions to allow in-line fluid flow from the first end portion to the second end portion. The housing includes first and second inlet ports while the end portion includes an outlet port for discharging the fluid. In addition, the flow-through valve includes a valve cartridge having a first fixed disk disposed in the housing having an opening therethrough and a first moveable disk disposed in the housing and in fluid communication with the first fixed disk. The first moveable disk is rotatable within the valve housing and cooperates with the first fixed disk to selectively control fluid flow rate from the first inlet port to the outlet port. The first moveable disk includes a first actuating arm extending radially outwardly therefrom for selectively rotating the first moveable disk. 
   The valve cartridge further includes a second fixed disk disposed in the housing having an opening therethrough and a second moveable disk disposed in the housing and in fluid communication with the second fixed disk. The second moveable disk is rotatable within the valve housing and is operable to cooperate with the second fixed disk to selectively control fluid flow rate from the second inlet port to the outlet port. The second moveable disk further includes a second actuating arm extending radially outwardly therefrom for selectively rotating the second moveable disk. 
   In one configuration, the rotating disks are configured to provide a hot/cold control valve wherein manipulation of a first rotating disks adjusts the flow rate of hot water through the valve assembly and adjustment of the second rotating disks controls the flow rate of cold water through the valve assembly. The valve assembly is alternatively configurable so as to provide a flow/temperature valve control wherein manipulation of the first rotating disk controls the flow rate of water through the valve assembly and manipulation of the second rotating disk controls the temperature of the water flowing through the valve assembly. 
   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 
       FIG. 1  is a top perspective view of a valve assembly in accordance with the principles of the present invention; 
       FIG. 2  is a bottom perspective view of the valve assembly of  FIG. 1 ; 
       FIG. 3  is an exploded perspective view of the valve assembly of  FIG. 1  configured as a hot/cold control valve; 
       FIG. 4  is an exploded perspective view of the valve assembly of  FIG. 1  configured as a flow/temperature control valve; 
       FIG. 5  is an exploded perspective view of the valve assembly of  FIG. 1  configured coupled to supply lines; 
       FIG. 6  is an assembled perspective view of the valve assembly of  FIG. 5  coupled to the supply lines; 
       FIG. 7  illustrates a first preferred embodiment of a faucet assembly utilizing the valve assembly of the present invention; and 
       FIG. 8  illustrates a second preferred embodiment of a faucet assembly incorporating the valve assembly of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
   With reference to  FIGS. 1–6 , a valve assembly  10  is provided and includes a valve body  12  and a valve cap  14 . The valve body  12  includes a first and second bore  16   c ,  16   h  formed through a bottom portion  20 , whereby the first and second bores  16   c ,  16   h  enable fluid communication between the valve body  12  and a pair of water supply lines  22 ,  24  (as seen in  FIGS. 5 and 6 ). In addition, a valve cartridge  26  is supported within valve body  12  to selectively control water supplied through the valve assembly  10  and discharged from an outlet port  28  formed through the valve cap  14 . 
   The valve body  12  includes the bottom portion  20  and first and second arms  30 ,  32  integrally formed therewith. As best shown in  FIGS. 3 and 4 , the bottom portion  20  is a generally cylindrical body having the first and second bores  16   c ,  16   h  formed therethrough in a generally diametric relationship. The first and second arms  30 ,  32  extend from the bottom portion, whereby each arm  30 ,  32  includes an arcuate surface  34  defining a portion of a cylindrical wall extending axially upward from bottom portion  20 . In this manner, the first and second arms  30 ,  32  cooperate with the bottom portion  20  to define an interstitial space  36  operable to receive the valve cartridge  26 , as will be discussed further below. 
   The valve cap  14  includes a first and second cylindrical portion  38 ,  40 , a central bore  42  formed therethrough, and a pair of flanges  44 . The first cylindrical portion  38  is disposed adjacent the second cylindrical portion  40  and is adapted to retain a seal  46 , as best shown in  FIG. 1 . The flanges  44  extend from the second cylindrical portion  40  and define recesses  48  therebetween. The recesses  48  are operable to receive the first and second arms  30 ,  32  of the valve body  12 , when the valve  10  is assembled. A pair of tabs  39  extend from the second cylindrical portion  40  in recesses  48  and engage apertures  35  formed through first and second arms  30 ,  32 . In this manner, the valve cap  14  may be releasably coupled to the valve body  12 . The valve cartridge  26  is disposed between the second cylindrical section  40  of the valve cap  14  and the bottom portion  20  of the valve body  12  and is operable to control an amount of fluid flowing through the first and second bores  16   c ,  16   h , as will be discussed further below. 
   With reference to  FIG. 3 , a first embodiment of the valve cartridge  26  is provided and includes a first and second rotatable disk  50 ,  52 , a first, second, and third stationary disk  54 ,  56 ,  58 , and a first and second disk driver  60 ,  62 . The first and second rotatable disks  50 ,  52  are generally cylindrical members and include a pair of ears  68  extending from an outer edge thereof. The first rotatable disk  50  includes first and second bore  64   h,    66   c  while the second rotatable disk  52  similarly includes a first and second bore  64   c,    66   h.  The first bores  64   h,    64   c  include a generally arcuate surface  70  disposed opposite a straight or planer surface  72 , whereby the arcuate surface  70  cooperates with the straight surface  72  to form the shape of a semicircular aperture. The second bores  66   c,    66   h  are formed adjacent the first bores  64   c,    64   h  and include an arcuate surface  74  formed between a pair of straight surfaces  76 , as best shown in  FIG. 3 . The pair of straight surfaces  76  cooperate with the arcuate surface  74  to form a generally quartercircular or triangular-shaped aperture. 
   The first, second, and third stationary disks  54 ,  56 ,  58  each include a generally circular main body  78 , a pair of flanges  80 , and a pair of bores  82   c ,  82   h . The flanges  80  extend from the main body  78  and serve to form a pair of recesses  84  therebetween, as best shown in  FIG. 3 . The recesses  84  engage arms  30 ,  32  to align the first, second, and third stationary disks  54 ,  56 ,  58  with the valve body  12  and prevent rotation therebetween. Specifically, the recesses  84  receive the first and second arms  30 ,  32  of the valve body  12  and serve to prevent rotation of the first, second, and third stationary disks  54 ,  56 ,  58  relative to the valve body  12  through the engagement of the arms  30 ,  32  with the flanges  80 . In this manner, the recesses  84  concurrently prevent rotation of the disks  54 ,  56 ,  58  and help align the valve cartridge  26  with the valve body  12 . The bores  82   c ,  82   h  are formed in a diametric relationship and generally include a quartercircular or triangular shape similar to that of the second bores  66   c ,  66   h  of the first and second rotatable disks  50 ,  52 . 
   The first and second disk drivers  60 ,  62  include a central bore  86  and first and second extensions  88 ,  90 . The central bore  86  of the first and second disk drivers  60 ,  62  receive the first and second rotatable disks  50 ,  52 , respectively for rotation therewith. Specifically, an inner surface of bore  86  includes a pair of slots  92  formed opposite one another, whereby the slots  92  receive the ears  68  of the rotatable disks  50 ,  52 . In this manner, the engagement between the ears  68  and the slots  92  serves to selectively fix the rotatable disks  50 ,  52  for co-rotation with the disk drivers  60 ,  62 . To rotate the disk drivers  60 ,  62 , and ultimately the rotatable disks  50 ,  52 , a force is applied to the first and second extensions  88 ,  90  to rotate rotatable disks  50 ,  52 . 
   As previously discussed, the valve cartridge  26  is disposed between the valve cap  14  and the bottom portion  20  once assembled. To assemble the valve cartridge  26  to the valve body  12 , the rotatable disks  50 ,  52 , stationary disks  54 ,  56 ,  58 , and disk drivers  60 ,  62  are stacked in a predetermined relationship relative one another. Specifically, the first stationary disk  54  is placed adjacent the bottom portion  20  with a gasket  94  disposed therebetween. The gasket  94  effectively seals an area around the bores  16   c ,  16   h  of the valve body  12  and the bores  82   c ,  82   h  of the stationary disk  54 , whereby the gasket  94  allows fluid flow from the bottom portion  20  to the stationary disk  54  but prevents leakage therefrom. The first stationary disk  54  is aligned with the bottom portion  20  such that the bores  82   c ,  82   h  of the disk  54  align with the bores  16   c ,  16   h  of the valve body  12 . As previously discussed, the interaction between the recesses  84  and the arms  30 ,  32  facilitates alignment of the first disk  54  with the valve body  12  and further ensures proper alignment of the bores  82   c ,  82   h  with the bores  16   c ,  16   h.    
   Once the first stationary disk  54  is in place, the first disk driver  60  and first rotatable disk  50  are rotatably assembled to the valve body  12 , whereby the first rotatable disk  50  is fixedly received by the central bore  86  of the first disk driver  60 , as previously discussed. The first and second extensions  88 ,  90  are assembled to the valve body  12  such that they are free to rotate between the first and second arms  30 ,  32 , as best shown in  FIG. 1 . In this regard, a range of motion is defined between the first and second arms  30 ,  32 , whereby a first position is established when the first extension  88  contacts the first arm  30  of the valve body  12  and a second position is established when the second extension  90  contacts the first arm  30  of the valve body  12 . 
   Once the first disk driver  60  and first rotatable disk  50  are assembled, the second stationary disk  56  is aligned with the valve body  12 . The second stationary disk  56  is assembled to the valve body  12  in the same manner as the first stationary disk  54 , whereby the recesses  84  align with the first and second arms  30 ,  32  to align the bores  82   c ,  82   h  with the bores  16   c ,  16   h  and further to prevent rotation between the second stationary disk  56  and the valve body  12 . The second disk driver  62  and second rotatable disk  52  are assembled to the valve body  12  in the same manner as the fist disk driver  60  and first rotatable disk  50 , whereby the first and second extensions  88 ,  90  are assembled to the valve body  12  such that they are free to rotate between the first and second arms  30 ,  32 . Again, a range of motion is defined between the first and second arms  30 ,  32 , whereby a first position is established when the first extension  88  contacts the first arm  30  of the valve body  12  and a second position is established when the second extension  90  contacts the first arm  30  of the valve body  12 . 
   The third stationary disk  58  completes the installation of the valve cartridge  26  to the valve body  12 , whereby the recesses  84  of the disk  58  are aligned with the first and second arms  30 ,  32  of the valve body  12  to properly align the bores  82   c ,  82   h  of the disk  56  with the bores  16   c ,  16   h  of the lower portion  20 . To maintain the relationship between the rotatable disks  50 ,  52 , stationary disks  54 ,  56 ,  58 , and disk drivers  60 ,  62 , the valve cap  14  fixedly engages the first and second arms  30 ,  32  of the valve body  12 . Specifically, the arms  30 ,  32  are received by the recess  48  of the valve cap  14 , whereby tabs  39  fixedly engage the apertures  35  formed in the first and second arms  30 ,  32 . In addition, an O-ring  95  is disposed between the valve cap  14  and the third stationary disk  56  to prevent fluid from escaping therebetween, and further to ensure that the fluid may be received through the central bore  42  of the valve cap  14 . 
   With reference to  FIGS. 5 and 6 , a coupling  100  is operable to connect the valve assembly  10  within a faucet neck  110 . The coupling  100  includes a valve housing  101  and a cap  103 . The valve housing  101  is generally cylindrical in shape with a portion of the sidewalls removed to afford access to the valve assembly  10  and specifically the extensions  88 ,  90 . In this manner, valve housing  101  is similar to valve body  12 . The cap  103  secures the valve body  12  within the valve housing  101 . A threaded interface  107  is provided between the valve housing  101  and the cap  103 . A set of external threads  105  is also provided on cap  103  to connect the coupling  100  within the faucet neck  110 . 
   As can be appreciated from the above description, each disk  50 ,  52 ,  54  must seal at the interface with the adjacent disk(s) to provide proper functioning of the valve cartridge. For this reason, the use of a ceramic valve disk is presently preferred. However, one skilled in the art will recognize the other types of valve disks which provide adequate sealing at the disk interface may be utilized in the present invention. 
   With reference to the Figures, the operation of the valve assembly  10  will be described in detail. The valve assembly  10  is operable to control the temperature of a flow of water entering the bottom portion  20  through bores  16   c  and  16   h . Specifically, the valve assembly  10  regulates the flow of hot and cold water entering the bores  16   c  and  16   h  respectively to provide a desired output temperature through the bore  42  of the valve cap  14 . 
   To control the flow of hot and cold water, the rotatable disks  50 ,  52  are rotated counter-clockwise from a first position to a second position to selectively align the bores  66   c ,  66   h  with the bores  16   c ,  16   h  of the bottom portion  20 . Specifically, to allow a flow of cold water to reach the outlet bore  42  of the valve cap  14 , the first disk driver  60  is rotated generally from the first position to the second position by applying a force to the first extension  88 . Rotation of the disk driver  60  causes concurrent rotation of the first rotatable disk  50 , whereby sufficient rotation of the disk  50  causes the bore  66   c  to align with the first bore  16   c  of the bottom portion  20 , thereby allowing a flow of cold water to enter the valve body  12 . As the first extension  88  rotates from the first position to the second position, the flow of cold water through the bore  66   c  increases to a maximum when the extension  88  reaches the second arm  32  due to the shape of the bore  66   c . Once the first extension  88  contacts the second arm  32 , the first rotatable disk  50  is in the fully open position and the maximum amount of cold water is permitted to flow to the outlet bore  42 . The configuration of bore  64   h  allows hot water to flow through first rotatable disk  50  irrespective of its angular position. 
   To provide a flow of hot water to the outlet bore  42 , the second disk driver  62  is rotated between the first and second positions by applying a force to the second extension  90 . Rotation of the disk driver  62  causes concurrent rotation of the second rotatable disk  52 , whereby sufficient rotation of the disk  52  causes the bore  66   h  to align with the second bore  16   h  of the bottom portion  20 , thereby allowing a flow of hot water to enter the valve body  12 . As the second extension  90  rotates from the first position to the second position, the flow of hot water through the bore  66   h  increases to a maximum when the extension  88  reaches the second arm  32  due to the shape of the bore  66   c . Once the second extension  90  contacts the second arm  32 , the second rotatable disk  52  is in the fully open position and the maximum amount of hot water is permitted to flow to the outlet bore  42 . The configuration of bore  64   c  allows cold water to flow through second rotatable disk  52  irrespective of its angular position. 
   In passing through the bores  66   c ,  66   h  of the respective rotatable disks  50 ,  52 , the hot and cold water ultimately reach the outlet bore  42  via the bores  64   c ,  64   h  formed in the first and second rotatable disks  50 ,  52 . Specifically, when the first rotatable disk  50  is in the first position, thereby not allowing a flow of cold water to reach the outlet bore  42 , a flow of hot water is permitted to flow through the first rotatable disk  50  and reach the second rotatable disk  52  via the bore  64   h  formed in the first rotatable disk  50 . In this regard, a stream of hot water may be selectively adjustable when the first rotatable disk  50  is in the first position. The same relationship exists with respect to a flow of cold water. When the first rotatable disk  50  is in the second position, thereby allowing a flow of cold water to reach the outlet bore  42 , and the second rotatable disk  52  is in the first position, thereby not allowing a flow of hot water to reach the outlet bore  42 , the cold water will reach the outlet bore  42  via the bore  64   c  of the second rotatable disk  52 . In this manner, the first and second rotatable disks  50 , 52 , provide the valve assembly  10  with the ability to independently control the flow of hot and cold water exiting the bore  42 . 
   In the foregoing description, it should be understood that the flow of water entering through the first and second bores  16   c ,  16   h  is permitted to flow through the bores  82   c ,  82   h  formed in the stationary disks  54 ,  56 ,  58 , whereby the bores  82   c ,  82   h  are aligned with the bores  16   c ,  16   h  of the bottom portion  20 . In this regard, the bores  82   c ,  82   h  provide a path for the water to pass between the rotatable disks  50 ,  52  and ensure that the water reaches the outlet bore  42  of the valve cap  14 . 
   With reference to  FIG. 4 , a second embodiment of the valve assembly  10   a  is provided, whereby the valve assembly  10   a  is operable to independently set the temperature and the flow rate of a outlet flow through the assembly  10 . In view of the substantial similarity in structure and function of the components associated with the valve assembly  10  with respect to the valve assembly  10   a , like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified. 
   The valve assembly  10   a  includes the same components as the valve assembly  10  except for modifications to the first and second rotatable disks  50 ,  52 . In this regard, a detailed description of the common components is foregone. The first rotatable disk  50   a  is operable to control the flow rate at which the water is allowed to flow through the valve body  12 . To accomplish adequate flow control, a first and second bore  64   c ,  64   h  are formed through the first rotatable disk  50   a . The first and second bores  64   c ,  64   h  are formed diametrically opposed to one another and include a generally quartercircular or triangular-shaped aperture, as best shown in  FIG. 4 . When the extension  88  of the first driver  60  is in contact with the first arm  30 , the flow is essentially restricted from passing through the first rotatable disk  50   a . As a force is applied to the extension  88 , the first disk driver  60  causes rotation of the first rotatable disk  50   a . As the first extension  88  approaches the second arm  32  of the valve body  12 , the bores  64   c ,  64   h  begin to align with the first and second bores  16   c ,  16   h  of the bottom portion  20 , thereby allowing a flow of water through the first disk  50   a . Once the extension  88  contracts the second arm  32 , the first rotatable disk  50   a  is in the fully open position and the maximum flow of water through the first rotatable disk  50   a  is achieved. 
   To control the temperature of the water flow, the second rotatable disk  52   a  includes bores  66   c,    66   h  formed adjacent each other and include a generally triangular shape, as best shown in  FIG. 4 . When the extension  90  is in contact with the first arm  30 , cold water is permitted to flow through the first bore  66   c.  As a force is applied to the extension  90 , the second rotatable disk  52   a  is caused to rotate, thereby allowing the second bore  66   h  to align with the second bore  16   h  of the bottom portion  20 . When the bore  66   h  aligns with the second bore  16   h  of the bottom portion  20 , a flow of hot water is permitted to flow through the second rotatable disk  52   a.  When the extension  90  is positioned such that it is disposed generally between the first and second arms  30 ,  32  a mixture of hot and cold water flows through the second rotatable disk  52   a,  thereby providing a generally warm stream of water exiting the outlet bore  42 . Once the extension  90  contacts the second arm  32 , the bore  66   c  is no longer aligned with the first bore  16   c  of the bottom portion  20  while the second bore  66   h  is perfectly aligned with the second bore  16   h  of the bottom portion  20 . In this regard, when the extension  90  contacts the second arm  32 , the flow of water will be at its hottest temperature. In this manner, the first and second disks  50   a,    52   a  allow for independent adjustment of both the temperature and flow rate of the water exiting the outlet bore  42 . 
   In the foregoing description, it should be understood that the flow of water entering through the first and second bores  16 ,  16   h  is permitted to reach the first and second rotatable disks  50   a ,  52   a  due to the bores  82   c ,  82   h  formed in the stationary disks  54 ,  56 ,  58  when aligned with the bores  16   c ,  16   h  of the bottom portion  20 . In this regard, the bores  82   c ,  82   h  provide a path for the water to pass between the rotatable disks  50   a ,  52   a  and ensure that the water reaches the outlet bore  42  of the valve cap  14 . 
   With reference to  FIGS. 7–8 , the valve assembly  10  is shown incorporated into a faucet assembly  104 . It should be understood that while the valve assembly  10  is shown assembled to the respective faucets  104 , that the valve assembly  10   a  could also be substituted in its place due to the fact that the overall dimensions of the valve assembly  10  are comparable to the overall dimensions of the valve assembly  10   a . Thus, the present invention provides a valve assembly that may be re-configured for a given faucet application in a simple manner. The faucet assemblies  104  each include a first and second handle  106 ,  108 , whereby the handles  106 ,  108  are fixedly attached to the first and second extensions  88 ,  90  of the first and second disk drivers  60 ,  62 . In this regard, applying a force to the handles  106 ,  108  will essentially transmit the force to the rotatable disks  60 ,  62 , thereby rotating the rotatable disks  50 ,  52  and control the hot/cold water flow or alternatively control the temperature and flow rate through the outlet bore  42 . In addition, the outlet bore  42  is aligned with a neck  110  of the faucet  104 , whereby the neck  110  of the faucet  104  is operable to transport the water flow to a predetermined location where the water exits the faucet  104  via an outlet port  112 . 
   The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.