Faucet handle hub

A valve assembly for a faucet including a valve cartridge having a valve stem and supported within a valve body, a handle operably coupled to the valve stem, a handle hub supported for rotation relative to the valve body, and a coupler operably coupling the valve stem with the handle hub.

BACKGROUND AND SUMMARY OF THE DISCLOSURE

The present invention relates to a valve assembly for a faucet and, more particularly, to a faucet valve assembly including a coupler between a valve stem and a handle hub.

Conventional faucet valve assemblies may include a lever coupled to a valve stem of a cartridge valve, with a handle hub covering at least the base of the lever and the top of the cartridge valve. In some valve assemblies, movement of the handle hub is facilitated by movement of the lever through an insert that is coupled to both the lever and the handle hub. In other valve assemblies, the lever and the handle hub may be manufactured as one piece. The handle hub may be affixed to a body of the valve assembly using an o-ring to prevent the handle hub from falling off the body. For the lever and the handle hub of such conventional valve assemblies to operate together, a very tight tolerance is required, which may result in an unpleasing aesthetic design, difficulty in manufacturing, difficulty in assembly and inconsistent function due to the normal dimensional variation of the mating components. As such, there is a need for a valve assembly which allows for a smoother movement of the valve assembly- and therefore a more efficient function.

According to an illustrative embodiment of the present disclosure, a valve assembly for a faucet includes a valve body defining a longitudinal axis, and a valve cartridge supported by the valve body. The valve cartridge includes a cartridge housing, a moveable valve member received within the cartridge housing, and a longitudinally extending valve stem operably coupled to the moveable valve member. A handle is operably coupled to the valve stem so that the valve stem rotates simultaneously with the handle. A handle hub is supported for rotation relative to the valve body. A coupler is supported by the cartridge housing and operably couples the valve stem with the handle hub. The coupler includes a coupler base and a coupler engagement member extending longitudinally from the coupler base and outwardly from the cartridge housing. The coupler base is disposed at least partially around the cartridge stem, and the coupler engagement member is coupled to the handle hub.

According to another illustrative embodiment of the present disclosure, a valve assembly for a faucet includes a cartridge housing, and a valve stem disposed within the cartridge housing and extending longitudinally away from the cartridge housing. A coupler is operably coupled to the cartridge housing. The coupler includes a coupler base and a coupler engagement member coupled to and extending longitudinally away from the coupler base. The coupler base is disposed at least partially around the valve stem and includes a lower slot to allow pivoting movement of the valve stem. The coupler engagement member includes a plurality of circumferentially spaced slots. A moveable valve member is received within the cartridge housing and includes a top face, a bottom face, a recess formed with the bottom face, and a stage supported by the top face. The stage is received within the lower slot of the coupler base and is operably coupled to a lower end of the valve stem. A lever is operably coupled to the valve stem so that the valve stem and the moveable valve member move concurrently with the lever. A handle hub includes a hub engagement member having a plurality of prongs that cooperate with the slots of the coupler engagement member so that the valve stem and the moveable valve member rotate simultaneously with the coupler engagement member and the handle hub.

According to a further illustrative embodiment of the present disclosure, a faucet assembly includes a valve body defining a longitudinal axis and including a hot water inlet, a cold water inlet, and a mixed water outlet. A valve cartridge is received within the valve body and includes a cartridge housing, a retainer including a hot water inlet, a cold water inlet, and a mixed water outlet in fluid communication with the hot water inlet, the cold water inlet, and the mixed water outlet of the valve body, respectively. The valve cartridge further includes a stationary valve member coupled to and positioned above the retainer, the stationary valve member including a hot water inlet aperture, a cold water inlet aperture, and a mixed water outlet aperture in fluid communication with the hot water inlet, the cold water inlet, and the mixed water outlet of the retainer, respectively, the stationary valve member further including a top face. A moveable valve member is positioned above the stationary valve member, the moveable valve member including a top face, a bottom face, a recess formed by the bottom face, and a stage disposed on the top face. The stage forms an opening, wherein the bottom face of the moveable valve member contacts the top face of the stationary valve member, and the recess is configured to be in selective fluid communication with at least one of the hot water inlet aperture, the cold water inlet aperture, and the mixed water outlet aperture of the stationary valve member. A coupler is received within the cartridge housing, and includes a coupler base and a coupler engagement member. The coupler base includes a groove receiving the stage of the moveable valve member and includes a through-hole. A valve stem is received within the coupler, a lower portion of the valve stem disposed within the groove formed by the coupler so that a lower end of the valve stem is received by the opening of the stage of the moveable valve member and is configured to move within the groove of the coupler. A pivot pin is received within the through-hole of the coupler base and supports the valve stem for pivoting movement. The coupler engagement member is coupled to and extends away from the cartridge housing and is disposed at least partially around the cartridge stem, the coupler engagement member defining a plurality of slots. A lever is coupled to the valve stem so that the valve stem and the moveable valve member move substantially simultaneously with the lever. A handle hub includes a hub engagement having a plurality of prongs that correspond with and couple with the slots of the coupler engagement member so that the valve stem and the moveable valve member rotate simultaneously with the coupler engagement member and the handle hub.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention.

Referring initially toFIG. 1, an illustrative valve assembly10is shown. In an illustrative embodiment, the valve assembly10may be coupled to a body (e.g., a hub or a delivery spout) of a faucet (such as a kitchen faucet including a pulldown sprayhead). In another illustrative embodiment, the valve assembly10may be coupled to a sink deck11for controlling water flow through the outlet of an adjacent faucet spout. The valve assembly10illustratively includes a handle12, a handle hub14, a handle or valve body16, and a mounting or coupling ring18. The handle12may comprise a conventional user input, such as a lever or knob. The coupling ring18couples the handle or valve body16to either the body of the faucet assembly or the sink deck11. The valve body16illustratively receives a valve cartridge22(FIG. 2), discussed below, which couples independently to the handle hub14and the handle12, so that when a user moves the handle12, components of the valve cartridge22(FIG. 2) also move to control water flow through the respective faucet assembly.

In an illustrative embodiment, the handle12of the valve assembly10may be rotated about an axis substantially parallel to a longitudinal axis17of the valve body16or about the longitudinal axis17of the valve body16. In a further illustrative embodiment, the handle12of the valve assembly10may be lifted in a direction substantially away from the coupling ring18of the valve assembly10for pivoting movement about an axis19orthogonal or perpendicular to the longitudinal axis17, as illustrated inFIGS. 1 and 5. In yet another illustrative embodiment, the handle12of the valve assembly10may be capable of both rotating about an axis substantially parallel to the longitudinal axis17of the valve body16and being lifted in a direction substantially away from the coupling ring18of the valve assembly10for pivoting movement about axis19. For example, in a faucet assembly having a single cartridge valve-style handle, the handle12of the valve assembly may be lifted to pivot about axis19to control the water flow velocity or rate of the faucet, wherein various angles of the lever correspond with various rates of water flow. In either a faucet assembly having a single cartridge valve-style handle or a faucet assembly having dual cartridge valve-style handles, the handle12of the valve assembly10may be rotated about axis17to control the temperature of the water flow for the respective faucet assembly. Further, in either a faucet assembly having a single cartridge valve-style handle or a faucet assembly having dual cartridge valve-style handles, the handle12of the valve assembly10may be rotated to control the water flow rate for the respective faucet assembly.

Referring now toFIGS. 2 and 3, an exploded perspective view of the valve assembly10illustrates the inner components of the valve assembly10. Illustratively, the handle12comprises a lever configured to sit within a hub groove141of the handle hub14so that a handle stem121passes through the handle hub14and engages with a cartridge valve stem20(FIG. 4). The handle hub14illustratively includes a cylindrical outer wall144configured to fit over the valve cartridge22and an inner arcuate wall145with prongs1431extending radially inward from the wall145(FIG. 3). The inner arcuate wall145and the prongs1431combine to form a hub engagement member143. The cartridge valve stem20illustratively includes an upper cartridge valve stem201with threading2011to engage with a cartridge valve stem body202to couple the upper cartridge valve stem201to the cartridge valve stem body202. The cartridge valve stem20(FIG. 4) also includes a stem cover203to fit on the outside of the cartridge valve stem body202.

The cartridge valve stem20is illustratively disposed within the center of the valve cartridge22and is surrounded by a cartridge valve coupler24. More particularly, the cartridge valve coupler24is disposed within the interior of the upper lip221(FIG. 2) of the valve cartridge22and interacts with the hub engagement member143(FIG. 3) of the handle hub14as described below. A retaining or bonnet nut38is fitted on the exterior of the upper lip221(FIG. 2) of the valve cartridge22to hold the valve cartridge22in place within the valve body16. The valve cartridge22may further include feet364to interact with sockets (not shown) within the valve body16of the faucet assembly to facilitate rotational orientation. In an illustrative embodiment, the valve cartridge22may include a hot water inlet361, a cold water inlet362, and a tempered or mixed water outlet363in an aperture disc or retainer36(FIG. 3) of the valve cartridge22. The inlets361,362and outlet363(FIG. 3) are present in illustrative embodiments where the valve assembly10controls the temperature of the water flow of the respective faucet assembly. In other illustrative embodiments, alternative inlets or outlets may or may not be present.

Still referring toFIGS. 2 and 3, the valve body16illustratively includes a friction groove161configured to hold an o-ring162when the valve assembly10is assembled. The o-ring162may be comprised of an elastic polymer, such as rubber, to facilitate a tight, friction fit connection between the valve body16and the handle hub14when the valve assembly10is assembled. The o-ring162keeps the handle hub14from falling off the valve body16while still allowing enough rotational movement of the handle hub14to operate the respective faucet assembly. In other words, the o-ring162retains the handle hub14on the valve body16in an axial direction while permitting rotation therebetween.

The valve body16is illustratively supported upon the coupling ring18. More particularly, in an illustrative embodiment, the lower lip163of the valve body16fits over a protruding lip181(FIG. 2) of the coupling ring18and may otherwise be removably or fixedly attached to the coupling ring18where the protruding lip181of the coupling ring18meets the lower lip163of the valve body16. In another illustrative embodiment, the coupling ring18may not include a protruding lip181and may otherwise couple to the valve body16through other means, such as, but not limited to, threading, welding, adhesive, or manufacturing the valve body16and the coupling ring18as one piece.

In an illustrative embodiment, the coupling ring18also includes a friction groove182(FIG. 3) configured to hold an o-ring183when the valve assembly10is assembled. The o-ring183may be comprised of an elastic polymer, such as rubber, to facilitate a tight, friction fit, liquid seal between the coupling ring18and the sink deck11(FIG. 1) or faucet body. In other embodiments, the coupling ring18may be manufactured as one piece with the respective faucet assembly deck or faucet body or otherwise fixedly attached to the respective sink deck11or faucet body.

Now referring toFIG. 4, a coupling structure of the valve assembly10is shown in further detail. More particularly, as discussed above, the coupling ring18supports the valve body16to hold the valve body16in a substantially upright position relative to the sink deck11(FIG. 1) or faucet body. The o-ring162is fitted within the friction groove161of the valve body16to facilitate the coupling of the valve body16with the handle hub14. The valve cartridge22is disposed within the valve body16and may be held in place via threading40and/or retaining nut38. In an illustrative embodiment, threading40and retaining nut38may be one piece, such as a bonnet nut. In another illustrative embodiment, threading40and retaining nut38may be formed in two pieces.

The cartridge valve stem20illustratively includes the stem cover203, the upper cartridge valve stem201, and the cartridge valve stem body202received within the center of the top of the valve cartridge22in such a way that allows the cartridge valve stem20to be extending from the valve cartridge22in a substantially upright direction. The cartridge valve coupler24illustratively includes a coupler base242(FIG. 7) and a coupler engagement member243extending longitudinally from the coupler base242(FIG. 7) and outwardly from a cartridge housing224. Illustratively, the coupler base242and the coupler engagement member243may be molded from a thermoplastic as a single component to form the cartridge valve coupler24. The coupler base242of the cartridge valve coupler24is illustratively disposed around the cartridge valve stem20just inside the upper lip221of the valve cartridge22. The cartridge valve coupler24is coupled to the valve cartridge22so that the coupler engagement member243extends beyond the upper lip221of the valve cartridge22in an arcuate manner around the cartridge valve stem20. The coupler engagement member243illustratively includes a plurality of circumferentially spaced slots241defined by tabs245.

The handle hub fits14illustratively fits over the top of the valve body16to friction fit to the valve body16via the o-ring162. An opening142(FIG. 3) formed by the handle hub14allows the cartridge valve stem20to pass through the handle hub14and engage with the handle12. The handle hub14couples with the valve body16in a manner that allows the cartridge valve coupler24to couple with the hub engagement member143(FIG. 3). Illustratively, the opening142(FIG. 3) of the handle hub14also receives the handle stem121of the handle12so that the handle12fits within the hub groove141. The handle stem121receives the cartridge valve stem20so that the stem cover203fits snugly within an interior surface of the handle stem121, holding the cartridge valve stem20in place within the handle stem121. For additional support, a handle engagement122may be inserted into the handle12to further secure the cartridge valve stem20within the handle12as described below in reference toFIG. 5.

Referring now toFIG. 5, the valve cartridge22is shown. In an illustrative embodiment, valve cartridge22is a closed mixing valve cartridge. The valve cartridge22includes a retainer or aperture disc36, which defines the hot water inlet361, the cold water inlet362, and the tempered or mixed water outlet363. The retainer36form fits with the valve cartridge body224via tabs365on the retainer36and the slots225on the valve cartridge22. When assembled, a stationary valve member or disc32is disposed within the valve cartridge22above the retainer36, and form fits with the retainer36via a protrusion366on the retainer36which fits into an opening325defined by the stationary valve member32. The interaction between the retainer36, the stationary valve member32and the valve cartridge22holds the stationary valve member32in place within the valve cartridge22.

Now referring toFIGS. 5 and 6, the stationary valve member32illustratively includes a hot water aperture321, a cold water aperture322, and a tempered or mixed water aperture323that correspond with (i.e., in fluid communication with) the hot water inlet361, the cold water inlet362, and the mixed water outlet363of the retainer36of the valve cartridge22respectively. A moveable valve member or disc34is also disposed within the valve cartridge22and sits on top of the stationary valve member32. Referring specifically toFIG. 6, the moveable valve member34illustratively includes a bottom face341and a top face342. The bottom face341touches and is configured to slide (translate) across a top surface324of the stationary valve member32. Additionally, the bottom face341of the moveable valve member34includes a recess3411that is capable of being in selective fluid communication with any or all of the hot water aperture321, the cold water aperture322, or the mixed water aperture323of the stationary valve member32. The top face342of the moveable valve member34defines a stage3421with an opening3422sized to fit a bottom portion2021of the cartridge valve stem body202, as discussed below and shown inFIGS. 7 and 8.

Referring again toFIG. 5, a pivot pin or pin rod42is disposed through the coupler base242and the stem body202so that each distal side of the pivot pin42is positioned on either side of the coupler base242and disposed through respective limiting grooves222within a sidewall223of the valve cartridge22. More particularly, the pivot pin42fits within a base through-hole2022and a stem through-hole2422to secure the cartridge valve stem body202in place within the valve cartridge22while allowing the stem body202to pivot relative to axis17(about transverse or perpendicular axis19), and also rotate about axis17. In the illustrative embodiment as shown inFIG. 5, retaining nut38and threading40are formed as one piece to make up a bonnet nut3840. When assembled, bonnet nut3840sits on nut shelf226so that the bonnet nut3840is retained by the valve cartridge22and facilitates the coupling of the valve cartridge22to the valve body16(FIG. 4).

Referring now toFIGS. 7 and 8, the bottom portion2021of the cartridge valve stem body202is illustratively disposed within a lower groove or slot2421formed by the coupler base242within the valve cartridge22. The lower groove2421is formed so that the bottom portion2021of the cartridge valve stem body202may pivot as the cartridge valve stem body202pivots during use of the valve assembly10. Additionally, the lower groove2421of the coupler base242is shaped to tightly accommodate the stage3421of the moveable valve member34so that the opening3422of the stage3421may stay in continuous contact with the bottom portion2021of the cartridge valve stem body202as it moves. The coupler base242continues through the top portion of the valve cartridge22as the base of cartridge valve coupler24. As a result, the coupler base242rotates as the cartridge valve coupler24rotates. As mentioned above, the upper cartridge valve stem201is threaded into the cartridge stem body202, and the upper cartridge valve stem201and the cartridge valve stem body202are disposed through the handle hub14and into the handle stem121of the handle12to form a friction fit coupling between the stem cover203of the cartridge valve stem20and the handle stem121so that the cartridge valve stem20moves as the handle12moves. For additional support, the handle engagement122may be inserted into the handle12to secure the upper cartridge valve stem201within the handle12. In an illustrative embodiment, the handle engagement122is screwed into the handle12using threading1221for a secure fit.

Still referring toFIGS. 7 and 8, valve assembly10may be coupled to the faucet body or sink deck11via a mounting shank (not shown) via threading164within the valve body16. Specifically referring toFIG. 8, the valve body16illustratively receives a hot water conduit26and a cold water conduit28that are in fluid communication with a hot water supply (not shown) and a cold water supply (not shown), respectively. When the valve assembly10is assembled and connected to the hot water supply, the hot water conduit26is in fluid communication with the hot water inlet361of the retainer36and the hot water aperture321of the stationary valve member32. Similarly, when the valve assembly10is assembled and connected to the cold water supply, the cold water conduit28is in fluid communication with the cold water inlet362of the retainer36and the cold water aperture322of the stationary valve member32. Now referring specifically toFIG. 7, the illustrative valve body16additionally houses a tempered or mixed water outlet30. When the valve assembly10is assembled, the mixed water outlet30is in fluid communication with the mixed water outlet363of the retainer36and the mixed water aperture323of the stationary valve member32.

As discussed above and shown inFIG. 7, the handle12is illustratively configured to move in a direction substantially away from the valve assembly10. In the resting position shown as shown by the solid line21, the recess3411of the moveable valve member34is in fluid communication with the mixed water aperture323of the stationary valve member32and the mixed outlet363of the retainer36. In this position, the hot water aperture321and the cold water aperture322of the stationary valve member are blocked by the bottom face341so that they are not in fluid communication with the recess3411. As a result, no fluid pathway exists between the respective water supplies (not shown) and the mixed water outlet30. In other words, the valve assembly10is not operating or is closed. As the handle12moves, the cartridge valve stem20moves with the handle12, causing the assembly formed by the cartridge valve stem20and the handle12to pivot about axis19defined by the pivot pin42, causing the bottom2021of the cartridge valve stem body202to move within the groove2421of the coupler base242. As the bottom2021of the cartridge valve stem body202moves with the handle12, the moveable valve member34slides or translates across the top surface along pathway99(FIGS. 5 and 6) to bring the recess3411of the moveable valve member34in fluid communication with the hot water conduit26and the cold water conduit28while remaining in fluid communication with the mixed water outlet30. In this position, the hot water conduit26and the cold water conduit28are in fluid communication with the mixed water outlet30via the recess3411of the moveable valve member34.

For example, when in operation, hot water may be supplied from the hot water supply (not shown) to the hot water conduit26, through the hot water inlet361of the retainer36, and through the hot water aperture321of the stationary valve member32into the recess3411of the moveable valve member34, then is released into the mixed water outlet30from the recess3411of the moveable valve member34via the mixed water aperture323of the moveable valve member34and the mixed water outlet363of the stationary valve member32. Similarly, when in operation, cold water may be supplied from the cold water supply (not shown) to the cold water conduit28, through the cold water inlet362of the retainer36, and through the cold water aperture of the322of the stationary valve member32into the recess3411of the moveable valve member34, then is released into the mixed water outlet30from the recess3411of the moveable valve member34via the mixed water aperture323of the moveable valve member34and the mixed outlet363of the stationary valve member32.

Referring again toFIGS. 7 and 8, as the cartridge valve stem20rotates with the handle12as described below, the moveable valve member34rotates according to lines97(FIGS. 5 and 6). When the valve assembly10is operational and the recess3411of the moveable valve member34is in fluid communication with the water supplies (not shown), rotation of the handle12about axis17determines the temperature of the water being disposed into the mixed water outlet30. For example, if the rotation of the handle12puts the recess3411in more communication with the hot water supply (not shown) than the cold water supply (not shown), then the water being disposed into the mixed water outlet30will be hotter than if the recess3411was in more communication with the cold water supply (not shown) than the hot water supply (not shown). The pivot pin42also serves as a temperature limit control. For example, if the handle12is rotated in one direction, eventually each of the distal ends of the pivot pin42will come into contact with a respective distal end of the limiting grooves222, preventing the handle12from being rotated any further in the same direction. If the handle12is rotated in the opposite direction, eventually each of the distal ends of the pivot pin42will come into contact with the opposite distal end of the limiting grooves222, preventing the handle12from being rotated any further in the same direction.

Referring now toFIG. 9, the interaction between the handle12, the cartridge valve stem20, the handle hub14and the cartridge valve coupler24is illustrated. More particularly, inFIG. 9, a cross-section of the valve assembly10is taken along line9-9ofFIG. 8, showing the interaction of the handle stem121, the cartridge valve stem body202, the stem cover203, the cartridge valve coupler24, and the hub engagement member143. As described above, the handle stem121passes through the opening142of the handle hub14to interact with cartridge valve stem20. The stem cover203of the cartridge valve stem20friction fits within the lever stem121and holds the cartridge valve stem20in place within the handle12. The cartridge valve stem20may be secured by the handle engagement122as shown inFIG. 5. The hub engagement member143extends below the lever stem121in a slight L-shape under the lever stem121to engage with cartridge valve coupler24.

FIG. 10further details the coupling between the hub engagement member143and the cartridge valve coupler24. The prongs1431of the hub engagement member143correspond with the slots241formed by the tabs245of the cartridge engagement member243of the cartridge valve coupler24. When the handle12is rotated or otherwise moved by a user, the cartridge valve stem20moves with the handle12due to the coupling relationship between the cartridge valve stem20and the lever stem121. The movement of the cartridge valve stem20causes the movement of the coupler base242within the valve cartridge22(FIGS. 7 and 8) as a result of the relationship between the cartridge valve stem20, the pivot pin29(FIGS. 5, 7 and 8), and the coupler base242. Because the coupler base242and the cartridge engagement member243form the cartridge valve coupler24as one piece, the entirety of the cartridge valve coupler24moves with the coupler base242. When the cartridge valve coupler24moves, the handle hub14moves because of the coupling relationship between the hub engagement member143and the cartridge engagement member243via the prongs1431and the slots241respectively. The described events happen substantially simultaneously with the movement of the handle12by the user.

FIG. 11offers another cross-section view of the interaction between the hub engagement member143and the cartridge engagement member243. As shown, a retainer44, such as a spring clip, is received around inner tabs244of the cartridge valve coupler24, illustratively between the inner tabs244and the cartridge engagement member243, to assist in retaining the connection between the cartridge valve coupler24and the valve stem20. More particularly, the spring clip44radially constricts the inner tabs244to tighten it against the valve stem20, thus increasing friction as the valve stem20moves.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exit within the spirit and scope of the invention as described and defined in the following claims. For example, although the invention has been described in detail with reference to a closed mixing valve cartridge, the invention may also be used in conjunction with an open mixing valve cartridge or any other type of valve for which a connection between a handle hub and a valve cartridge may be desired.