WATERWAY ASSEMBLY FOR A FAUCET

A waterway assembly for a faucet including a plurality of tubular assemblies. Each tubular assembly includes a collar overmolded onto an end thereof and press fit onto a barbed fitting of an adapter.

BACKGROUND AND SUMMARY OF THE DISCLOSURE

The present invention relates generally to plumbing fixtures and, more particularly, to a waterway assembly for a faucet.

Waterway assemblies for use within faucets are known in the art. For example, U.S. Pat. No. 8,365,770 to Thomas et al. discloses a faucet including a molded waterway assembly having a plurality of tubes overmolded within a valve interface member. U.S. Pat. No. 8,944,093 to Veros et al. discloses a fluid delivery device including a waterway assembly, a valve assembly, and a waterway adapter that fluidly couples the waterway assembly to the valve assembly. U.S. Pat. Nos. 8,365,770 and 8,944,093 are expressly incorporated herein by reference.

According to an illustrative embodiment of the present disclosure, a waterway assembly for a faucet includes a waterway adapter having a body with a valve interface member and a plurality of downwardly extending connecting tubes, each having a plurality of securing members. A plurality of flexible tubular members are formed of a polymer and have opposing first and second ends. A collar is overmolded around the first end of each flexible tubular member, wherein the connecting tubes of the waterway adapter are received within the first ends of the flexible tubular members.

According to another illustrative embodiment of the present disclosure, a waterway assembly for a faucet includes a waterway adapter having a body with a valve interface member and a plurality of connecting tubes, the plurality of connecting tubes including a hot water connecting tube, a cold water connecting tube, and a water outlet connecting tube. The waterway assembly further includes a plurality of tubular assemblies, each of the tubular assemblies including a flexible tubular member formed of a polymer and having opposing first and second ends, and a collar supported by the first end of the flexible tubular member. The plurality of flexible tubular members include a hot water inlet tubular member, a cold water inlet tubular member, and an outlet water tubular member. The hot water connecting tube is received within the first end of hot water inlet tubular member, the hot water connecting tube expanding an inner diameter of the first end of the hot water inlet tubular member by at least 20 percent. The cold water connecting tube is received within the first end of cold water inlet tubular member, the cold water connecting tube expanding an inner diameter of the first end of the cold water inlet tubular member by at least 20 percent. The outlet water connecting tube is received within the first end of outlet water tubular member, the outlet water connecting tube expanding an inner diameter of the first end of the outlet water tubular member by at least 20 percent.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, which are described herein. The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to the precise form disclosed. Rather, the embodiments selected for a description have been chosen to enable one skilled in the art to practice the invention. Although the disclosure is described in connection with water, it should be understood that additional types of fluids may be used.

With reference initially toFIGS. 1-5, an illustrative waterway assembly10for a faucet12includes an adapter14having a body16supporting a valve interface plate18. The adapter14is illustratively molded from a polymer, such as a glass fiber reinforced polysulfone, to form unitary body16. A mixing valve20is illustratively coupled to the valve interface plate18. A handle21for manipulation by a user is illustratively coupled to a movable valve element22of the mixing valve20(FIG. 1). More particularly, movement of the valve element22controls water flow within the mixing valve20from a hot water inlet port23aand a cold water inlet port23b,to a mixed water outlet port23c.Additional details of an illustrative mixing valve20are provided in U.S. Pat. No. 7,753,074, the disclosure of which is expressly incorporated herein by reference.

A plurality of connecting tubes24extend downwardly from the body16of the adapter14and are in fluid communication with openings26in the valve interface plate18. More particularly, a hot water connecting tube24a,a cold water connecting tube24b,and a water outlet connecting tube24care fluidly coupled with a hot water opening26a,a cold water opening26b,and an outlet water opening26c,respectively. The hot water opening26a,the cold water opening26band the outlet water opening26care in fluid communication with corresponding hot water port23a,cold water port23b,and outlet water port23cin the mixing valve20.

The body16of the adapter14is configured to be received within a hub28of the faucet12, and illustratively includes support rails30for engaging an inner surface of the hub28. The connecting tubes24are illustratively nipples including a plurality of annular securing members, such as radially outwardly extending ribs or barbs32(FIG. 6).

The illustrative waterway assembly10further includes a plurality of flexible tubular assemblies34, including opposing first and second ends36and38, which are coupled to the adapter14. The flexible tubular assemblies34illustratively include a hot water inlet tubular assembly34a,a cold water inlet tubular assembly34b,and a water outlet tubular assembly34c,which are fluidly coupled to the connecting tubes24a,24b,24c,respectively, of the adapter14. Hot water from a hot water source (not shown) is supplied from the hot water tubular assembly34ato the hot water inlet port23aof the mixing valve20, and cold water from a cold water source (not shown) is supplied from the cold water tubular assembly34bto the cold water inlet port23bof mixing valve20. Illustratively, operation of the mixing valve20through the handle21moves the valve element22to control the flow rate and mixing (temperature) of water supplied from the hot water inlet tubular assembly34aand the cold water inlet tubular assembly34bto the mixed water outlet port23cand the water outlet tubular assembly34c,in a known manner.

With reference toFIGS. 7-9, each of the tubular assemblies34includes a tubular member or tube40extending between opposing first and second ends42and44, and illustratively formed of a polymer, such as polyethylene. The tubular members40illustratively include a hot water inlet tubular member40a,a cold water inlet tubular member40b,and a water outlet tubular member40c.Cylindrical reinforcing collars or cuffs46are coupled to the first ends42of the tubular members40, and quick connect fittings48are coupled to the second ends44of the tubular members40. More particularly, the collars46and fittings48are illustratively formed of a polymer, such as polyethylene, overmolded onto the tubular member40. Each respective collar46a,46b,46cillustratively concentrically receives the first end42of one of the respective tubular members40a,40b,40c,while each respective fitting48a,48b,48cillustratively concentrically receives the second end44of one of the respective tubular members40a,40b,40c.

The fittings48aand48bon the tubular members40aand40bare illustratively configured to fluidly couple the second ends38of the hot and cold water inlet tubular assemblies34aand34bwith conventional fluid couplings, such as hot and cold water stops (not shown). A nut50a,50bmay concentrically receive the tubular member40a,40band cooperate with the fittings48a,48b.The fitting48con the tubular member40cis illustratively configured to fluidly couple the second end38of the water outlet tubular assembly34cto a water outlet, such as a sprayhead (not shown). O-rings52may be coupled to the fitting48cfor providing a fluid seal. After overmolding, each assembly34(e.g., tubular member40, collar46, and fitting48) may be cross-linked to form a completed PEX tubular assembly34.

The first ends42of the tubular members40and associated collars46of the tubular assemblies34are illustratively press-fit onto the barbs32of the connecting tubes24to achieve a sealed joint without the need for additional sealing components, such as o-rings, gaskets, and/or crimped secondary collars or ferrules. In an illustrative embodiment, the connecting tubes24and the tubular members40(and associated collars46) have different material properties, wherein the connecting tubes24have a greater hoop strength than the first ends36of the tubular assemblies34. As such, the connecting tubes24maintain their general shapes, while expanding the first ends42of the tubular members40.

Illustratively, the first end36of each tubular assembly34is pressed on the respective connecting tube24with a diameter expansion of the first end42of the tubular member40of at least 20 percent. In one illustrative embodiment, the diameter expansion of the first end42of the tubular member40is at least 40 percent. Further illustratively, the diameter expansion of the first end42of the tubular member40is at least 50 percent. The diameter expansion of the tubular member40depends upon the resistance provided by the collar46which, in turn, is dependent upon the material and the wall thickness (T) of the collar46(FIG. 12).

In one illustrative embodiment, the tubular member40is ⅜ inch tubing, such that the inner diameter (ID) of the tubular member40is approximately 0.235 inches (FIG. 9). The outer diameter (ODC) of the collar46is illustratively 0.430 inches (FIG. 11), while the wall thickness (T) of the collar46is illustratively 0.048 inches (FIG. 12). As shown in the illustrative embodiment ofFIG. 6, a base diameter (BD) of each connecting tube24is 0.310 inches (+/−0.003 inches), a first barb32aouter diameter (OD1) is 0.335 inches (+/−0.003 inches), and a second barb32bouter diameter (OD2) is 0.370 inches (+/−0.003 inches). An illustrative inner diameter (CD) of the connecting tube24is illustratively 0.220 inches.

In the illustrative embodiment, the diametric expansion of the tubular member40due to the first barb32ais 42 percent (0.335-0.235/0.235), while diametric expansion of the tubular member40due to the second barb32bis 57 percent (0.370-0.235/0.235). Illustratively, the dimensions ID, OD1and OD2are fixed by crosslinking prior to insertion of the connecting tube24into the tubular member40. The collars46reinforce the first ends42of the tubular members40, thereby allowing for greater radial or diametric expansion from the connecting tubes24.

Crosslinking imparts a “memory” to the polymeric tubing's original dimensions, and upon deformation of the same, will tend to resort back to the original dimension when crosslinked upon the application of a transforming force. Using this shape-memory feature facilitates sealing engagement between the first end42of the tubular member40and the associated barbs32of the connecting tube24.

An illustrative method of manufacturing the waterway assembly10includes providing polymeric tubular member40, overmolding polymeric collar46on the first end42of tubular member40, overmolding polymeric fitting48on the second end44of the tubular member40to define tubular assembly34, and then crosslinking the tubular assembly34. Each such tubular assembly34has its first end36press fit onto one of the connecting tubes24of the adapter14. It should be appreciated that the number and arrangement of the tubular assemblies34and associated connecting tubes24may vary. The finished waterway assembly10is then inserted within the hub28of the faucet12. The mixing valve20is then fluidly coupled with the valve interface plate18and secured within the hub28by a coupler, such as a mounting nut (not shown).

As used in the present application, the term “overmold” means the process of injection molding a second polymer over a first polymer, wherein the first and second polymers may or may not be the same. In one illustrative embodiment, the composition of the overmolded polymer may be such that it is capable of at least some melt fusion with the polymeric tube. There are several means by which this may be affected. One of the simplest procedures is to ensure that at least a component of the polymeric tube and that of the overmolded polymer is the same. Alternatively, it would be possible to ensure that at least a portion of the polymer composition of the polymeric tube and that of the overmolded polymer is sufficiently similar or compatible so as to permit the melt fusion or blending or alloying to occur at least in the interfacial region between the exterior of the polymeric tube and the interior region of the overmolded polymer.

In an illustrative embodiment, the tubular members40and the collars46are made from high density polyethylene which is crosslinked. PEX is known to contain crosslinked bonds in the polymer structure changing the thermoplastic into a thermoset. Crosslinking may be accomplished during or after the molding of the part. There are three classifications of PEX, referred to as PEX-A, PEX-B, and PEX-C. PEX-A is made by the peroxide (Engel) method. In the PEX-A method, peroxide blended with the polymer performs crosslinking above the crystal melting temperature. The polymer is typically kept at high temperature and pressure for long periods of time during the extrusion process. PEX-B is formed by the silane method, also referred to as the “moisture cure” method. In the PEX-B method, silane blended with the polymer induces crosslinking during molding and during secondary post-extrusion processes, producing crosslinks between a crosslinking agent. The process is accelerated with heat and moisture. The crosslinked bonds are formed through silanol condensation between two grafted vinyltrimethoxysilane units. PEX-C is produced by application of an electron beam using high energy electrons to split the carbon-hydrogen bonds and facilitate crosslinking.

Crosslinking imparts shape memory properties to polymers. Shape memory materials have the ability to return from a deformed state (e.g. temporary shape) to their original crosslinked shape (e.g. permanent shape), typically induced by an external stimulus or trigger, such as a temperature change. Alternatively, or in addition to temperature, shape memory effects can be triggered by an electric field, magnetic field, light, or a change in pH, or even the passage of time.

Additional details on overmolding and crosslinking of fluid carrying components are provided in U.S. Pat. Nos. 8,220,126 and 8,844,111 to Yunk et al., the disclosures of which are expressly incorporated by reference herein.