In one embodiment, a frost-free sillcock is provided. The sillcock has a single handle which rotates to control the temperature of the discharged fluid. The handle also moves axially toward and away from a mounting surface to control the volume of fluid discharged from the sillcock. Furthermore, the sillcock has valve components disposed on the inside of the mounting surface which can be serviced from outside of the mounting surface.

BACKGROUND

The present invention relates to a sillcock, and more specifically to a frost-free mixing sillcock with a replaceable cartridge.

In many geographic areas, freezing temperatures cause problems with sillcocks as a result of the water within the sillcock freezing. Since water expands when it freezes, the expansion can cause components of the sillcock to become damaged. To avoid this problem, some sillcocks come with an elongated stem that, when installed, places its valve components inside the building, thus preventing the water from sitting near the exterior of the building and the freezing temperature. The placement of the valve components on the inside of the building requires any servicing of the valve components to be done from the inside of the building. Consequently, if the valve components are disposed behind a finished interior wall, access to the valve components is not convenient and servicing the valve components becomes a difficult project.

SUMMARY

In one embodiment, a frost-free mixing sillcock is provided. The sillcock has a single handle which rotates to control the temperature of the discharged fluid. The handle also moves axially toward and away from a mounting surface to control the volume of fluid discharged from the sillcock. Furthermore, the sillcock has valve components disposed on the inside of the mounting surface which can be serviced from outside of the mounting surface.

DETAILED DESCRIPTION

In one embodiment, a frost-free mixing sillcock10is provided as shown inFIGS. 1A-1C. The sillcock10includes a valve body12, a body sub-assembly14, and a handle16. The valve body12is located at a distal end of the sillcock10and includes two inputs18and a single output19(FIG. 2). A hot water line is attached to one of the inputs18and a cold water line is attached to the other input18. The valve body12is attached to the body sub-assembly14. The sillcock10is mounted on a mounting surface20of a building or house22.

Now referring toFIG. 2, an exploded view of the components of the sillcock10are shown. A cartridge24is disposed partially within the valve body12and partially within the body sub-assembly14. The cartridge24is attached to a shaft26. The cartridge24fits into the output19of the valve body12such as to form a water tight seal.

Now referring toFIGS. 3A-3E, the cartridge24is shown in various views. The cartridge24includes a cartridge shell28, a piston30and may include one or more grommets32. The shell28includes two ports34that align with the inputs18of the valve body12when the cartridge24is assembled into the valve body12. The grommet32is located on the shell28about the ports34and provides a seal so that water can flow through the valve body12and into the cartridge shell28.

Referring now toFIGS. 4A and 4B, the cartridge24installed within the valve body12is shown. The cartridge24may also include an alignment mechanism36and an assembly mechanism40. The alignment mechanism36, shown in the drawings as a protrusion37along a portion of the cartridge shell28and a notch38in the valve body12, allows the cartridge24to be removed for inspection, maintenance or replacement, and then reconnected in a uniform manner that aligns the cartridge24, and piston30within the valve body12. The assembly mechanism40allows the cartridge24to be removed from and replaced into the valve body12with ease. Specifically, the assembly mechanism40allows the cartridge24to be removed without need to access the connection point between the body sub assembly14and the valve body12. The figures illustrate one such assembly mechanism40. A pair of snap wings are used to hold the cartridge24within the valve body12. The wings are compressed within the opening19of the valve body12and the ends of the wings engage the end of the opening19. When the cartridge24is removed, axial force is applied to the cartridge24, whereby the ends of the wings cam against the end of the opening19, thereby allowing removal of the cartridge24.

The piston30is attached to the shaft26with a connection pin42or other connection mechanism. Preferably the connection mechanism is easily removable, thereby allowing easy change of the cartridge24. The piston30is moved by the shaft26in two directions, in and out of the cartridge shell28and rotating about its axis within the shell28. The piston30includes two portions. The first portion44is solid all around the axis of the piston30and aligns with the shell ports34when the piston30is moved into the cartridge shell28. The second portion46is partially solid with a gap48formed about one quarter to one half of the total circumference of the piston30. The second portion46aligns with the shell ports34when the piston30is pulled outward away from the shell28. Preferably the piston30includes a stop that prevents the piston30from totally withdrawing from the cartridge shell28. It is also preferable that the shaft26includes a stop that limits the distance the piston30travels into the cartridge shell28. The second portion46is designed such that it can be rotated between two positions, with a stop preventing further rotation in each of the respective directions. When the piston30is rotated fully to a first temperature position, a solid portion50(FIG. 5) of the second portion46of the piston30aligns with a first port34in the cartridge shell28, while the gap48aligns with the other port34in the cartridge shell28. When the piston30is rotated to the second temperature position, the solid portion50aligns with the second port34in the cartridge shell28, while the gap48aligns with the first port34. When in one of these two temperature positions, either the hot water line or the cold water line is fully open. To mix the hot water and the cold water, the piston30is rotated to a position in between the full open positions, thereby opening each line a portion of the way. The total flow of water can be controlled by moving the piston30in and out of the cartridge shell28. When the piston30is all of the way in the cartridge shell28, or as far in as provided by the stop, the water flow is shut off. When the piston30is pulled outward away from the cartridge shell28, as far as provided for by the stop, the flow is at its maximum. Positioning the piston30in between these two positions allows for controlling the flow of water.

Referring now toFIG. 5, a cross-sectional view of the assembly of the sillcock10is shown. The piston30connects to the shaft26, which rotates within the body sub-assembly14. The handle16is fitted to an end52of the shaft26, which allows for the easy turning of the shaft26as well as moving the shaft26outward away from the cartridge shell28or inward toward the cartridge shell28. The movement of the shaft26, either rotationally or axially, moves the piston30likewise. Movement of the handle16rotationally controls the temperature of the water, while movement of the handle16axially controls the flow of water. The handle16may include a handle cap54with a temperature-direction indicator, such as, for example, a color coded indicator. O-rings and a retention nut56are also used to provide a water-tight passageway.

To operate the sillcock10, the handle16is pulled outward away from the side of the house22, or other attachment area. Water flows from the valve body12and enters the cartridge shell28through the ports34. The water continues through the shell28and through the piston30and then flows out the end of the piston30and through the slots (not shown) in the shaft26. Water flows around the shaft26and then out the spigot58. The temperature of the water can be controlled by turning the handle16, a first direction for hot water and a second direction for cold water. Additionally, flow of water can be controlled by moving the handle16in and out with respect to the point of attachment.

The sillcock10allows for a single entrance point into the house22, or other attachment area. Since the valve body12is located within the home22, water can be mixed and flow out through a single freeze-proof faucet58. Additionally, since the sillcock10includes an attachment mechanism (retention nut56) that allows for removal of the cartridge24through a single opening in the front of the faucet, the cartridge24can be removed for maintenance, inspection, and replacement with relative ease. The alignment feature (alignment mechanism36) allows a cartridge24that has been removed to be replaced in the correct alignment, thereby ensuring the ports34align with the valve body inputs18.

In a second embodiment, a frost-free mixing sillcock60is provided.FIG. 6shows a perspective view of the sillcock.FIG. 7shows a cross-sectional view of the sillcock60, with a magnified view of the spout end shown inFIG. 8and a magnified view of the valve body end shown inFIG. 9.FIG. 10shows an exploded view of a fluid mixing assembly61of the sillcock60. Referring toFIGS. 6-10, the sillcock60includes a spout62, spout tube64and a valve body66. As with the first embodiment discussed above, the spout62, when installed, is disposed on the outside of the house or building upon which it is mounted. The spout tube64is a conduit that connects the spout62with the valve body66. When installed, the majority of the spout tube64and the valve body66are disposed on the inside of the house (or building).

At a front end68of the spout62, a handle70is disposed. The handle70is operable to move axially toward and away from the spout62to adjust the flow rate of the fluid that is discharged from an outlet72of the spout62. Additionally, the handle70is operable to rotate to adjust the temperature of the fluid that is discharged from the outlet72of the spout62.

The handle70is attached by a fastening member74to a stem76disposed in the spout62and in the spout tube64. The stem76is held in place by a retaining nut78which is screw threaded onto the front end68of the spout62. The stem76is hollow and allows air to pass therethrough. The stem76is also disposed within a cartridge retainer80, which in turn, is disposed within the spout62and the spout tube64. The cartridge retainer80is a hollow conduit that has a drain hole82disposed near and aligned with the outlet72of the spout62. The cartridge retainer80is held in place by the retaining nut78.

A cartridge86is disposed on an interior end84of the cartridge retainer80. The cartridge86comprises an inner shell88and an outer shell90. The inner shell88is disposed within the outer shell90. Additionally, the inner shell88has two ports92,93disposed therethrough which align with two ports94,95disposed through the outer shell90. The ports92,93,94,95allow fluid to flow from the valve body66into the cartridge86. When installed, the cartridge86sits within the valve body66.

On an outer surface96of the inner shell88, a pair of grommets98are disposed. The grommets98provide a seal between the outer shell90and a piston110. On an outer surface100of the outer shell90, a pair of check valves102and a pair of shouldered O-rings104are disposed. The check valves102prevent fluid from being siphoned back into the fluid supply lines (not shown) which are connected to inlets106,107of the valve body66. The O-rings104provide a seal between the valve body66and the outer shell90.

The inner shell88is attached to the cartridge retainer80using an assembly mechanism108similar to the one described above with respect to the first embodiment.

The piston110is disposed, at least partially, within the inner shell88. The piston110is a hollow conduit having a pair of apertures112,113, which when aligned with the ports92,94and93,95, respectively allow fluid to flow into the piston110and toward the spout62. The apertures112,113of the piston110are offset to correspond to the offset positions of the ports92,94and93,95. The piston110is disposed between a back plug114and a stem plug116. The stem plug116is attached to the stem76which is in turn connected to the handle70. This allows the movement of the handle70to move the piston110in a corresponding manner. For example, if the handle70is rotated clockwise, the piston110will rotate clockwise. If the handle70is pulled axially away from the spout62, the piston110will move axially in the same direction.

Furthermore, the piston110includes a vent tube118which is disposed axially through the piston110and into the stem76. The vent tube118allows any air pressure that may build up behind the back plug114to vent to the atmosphere at the front end68of the spout62by virtue of an air conduit formed by the vent tube118and stem76.

In operation, the handle70begins flush against the front end68of the spout62. A hot water supply pipe is connected to inlet106and a cold water supply line is connected to inlet107of the valve body66. As a result of the handle70being flush against the front end68of the spout62, the piston110is positioned axially rearward such that apertures112,113of the piston110are not aligned with the ports92,94and93,95of the inner shell88and the outer shell90of the cartridge86. More specifically, aperture113will be positioned to the left (referring toFIG. 6) of the ports93,95and aperture112will be positioned. to the left of the ports92,94. In this position, a wall120of the piston110will cover the ports92,93, thereby preventing any water flow into the piston110. Hot water flows through inlet106, into the valve body66and into ports92,94. However, as discussed above, the hot water is prevented from flowing into the piston110because, in this position, the wall120of the piston110covers the port92. Similarly, the cold water enters inlet107, flows into the valve body66and into ports93,95, but is prevented from entering the piston110because the wall120of piston110, in this position, covers port93. Even if the handle70is rotated, there will be no water flow into the piston110(and ultimately out of the spout62) until the handle70is moved axially away from the front end68of the spout62.

As the handle70is slowly pulled axially away from the front end68of the spout62(assuming that the handle70is in a rotationally centered position), the attached stem76, stem plug116, piston110, vent tube118and back plug114all move axially with the handle70. As this occurs, the aperture113begins to partially align with the port93and the aperture112begins to partially align with the port92. As this happens, hot water slowly flows into the piston110through the aperture112and cold water slowly flows into the piston110through the aperture113. The hot and cold water mix within piston110and flow around the stem plug116, into a cavity122formed between the stem76and the cartridge retainer80. The mixed water continues to flow through the cavity122, out through the drain hole82, and out through the outlet72of the spout62.

During the axial movement of the piston110, the inner shell88and the outer shell90remain stationary. The farther the handle70is pulled axially away from the front end68of the spout62, the more the apertures112,113align with the ports92,93respectively and the greater the flow rate out of the outlet72of the spout62. The handle70may be pulled axially away from the front end68of the spout62until a stop124of the stem76abuts the retaining nut78. At this point, the spout is discharging maximum flow because the apertures112,113are fully aligned with the ports92,93respectively.

At any time while the water is flowing (at any axial position of the handle70), the temperature of the discharged water can be controlled by rotating the handle70in either direction. When the handle70rotates in a first direction, the discharging water becomes colder and when the handle is rotated in a second, opposite direction, the discharging water becomes hotter. This is a result of the apertures112,113being rotated in and out of alignment with the ports92,93respectively. For example, as the handle70is rotated in a first direction, the piston110is rotated in a corresponding manner and direction. As the piston110rotates, the aperture113becomes more fully aligned rotationally with the port93while the aperture112becomes less aligned rotationally with the port92. As a result, proportionally, more cold water enters the piston110than hot water, and the discharging water becomes colder. The opposite occurs when the handle70is rotated in the opposite direction. As a result of this design, at any given discharging water flow (determined by how far the handle70is pulled away from the front end68of the spout62), the temperature of the discharging water can be varied. In other words, the temperature of the discharging water is completely independent from the flow rate of the discharging water.

The embodiment shown inFIG. 6also allows the cartridge86to be serviced from the outside of the house instead of from the inside of the house. Often repairing or replacing any of the cartridge components requires access from the interior of the house since that is where the valve body66and the cartridge86are disposed. However, the embodiment shown inFIG. 6allows the cartridge86to be removed from the outside.

To remove the cartridge86, the handle70is first unattached from the stem76by removing the fastening means74. With the handle70removed, the retaining nut78can be unscrewed from the front end68of the spout62. The stem76can then be axially pulled to remove the back plug114, vent tube118, piston110and stem plug116. These components can then be serviced if needed and replaced back in a reverse step manner. However, if servicing is needed on the cartridge86, the cartridge retainer80can then be axially pulled to remove the inner shell88, outer shell90, grommets98, check valves102, and O-rings104. After servicing, the parts are reassembled in the same manner, just taking the above steps in reverse order.

Finally,FIGS. 11 and 12show two other possible designs for the valve body66.FIG. 11shows an embodiment in which the inlets106,107are disposed on a rear end126of the valve body66. However, the interior of the valve body would be substantially similar to that shown inFIG. 6.FIG. 12shows a valve body in which two flexible inlet connections106,107are disposed off of the rear end126of the valve body66. The flexible inlets106,107give the installer greater flexibility and makes installation easier.