FLOW CONTROL PORTS FOR A THERMOSTATIC MIXING FAUCET

Abstract: Two flow control ceramic discs (22 and 24) for a thermostatic valve (10) has ports to adjust water flow from a closed to a full open position. Ceramic disc (24) has a contoured inlet (32) that has a wide section (92) and narrow section (90) that provide varying flow adjustment with respect to the other port (30). The contoured port provides for increased capacity of mixing adjustment for the thermostatic element (70) during different manual flow adjustments.

Description: FLOW CONTROL PORTS POR A THERMOSTATIC MIXING FAUCET TECHNICAL FIELD The field of this invention relates to a thermostatically controlled mixing valve and more particularly to a thermostatic controlled mixing valve with a volume control feature incorporated therein. BACKGROUND OF THE DISCLOSURE Mixing valves are well known and common in the plumbing field. These valves provide a flow of mixed water from separate hot and cold water supplies. Secondly, thermostatic control for handle mixer valves are well known. One reason for thermostatic control is to eliminate constant readjustment of the valve when the temperature of the hot water supply fluctuates. The temperature of the hot water supply may vary substan¬ tially. Furthermore, the pressure within the cold water line may also vary thus changing the proportions of hot and cold water flow and thereby fluctuating the tempera¬ ture of the mixed water. Known thermostatic valves have packaging problems and are often significantly bulkier than standard mixing valves that do not incorporate the thermostatic regulation. This bulkiness is due to the flow path that has always been used for thermostatic faucets, namely the supply inlets approach the centrally located thermostatic valve from a radially outer posi¬ tion. When thermostatic valves are incorporated into mixer valves, the volume or flow control valves may be installed either downstream or upstream from the thermo- static valve element. When the flow is regulated downstream of the thermostatic element within the mixed water flow, installation of non-return valves are needed in order to prevent the possibility of communication between the hot water supply and the cold water supply, . When volume control of the hot and cold water supplies is upstream of the thermostatic valve before the water is mixed, the return valves are not needed. For this economic reason, most thermostatic mixing valves have the volume control upstream of the thermostatic element. However when the flow is regulated with respect to the hot and cold water supplies, the thermo¬ static device is unable to maintain the constant temper¬ ature due to the variations of the flow rates. It is well known that when hot and cold water supply pressures are approximately equal or with the hot supply pressure being only slightly lower than the cold water pressure, the difference in flow rate or variation between the hot and cold water supplies is increased when the total flow is reduced and the rise in temperature can sometimes become significant. On the other hand, if the hot water supply pressure is substantially lower than the cold water supply pressure, as in often the case due the increased corrosion of the hot water pipelines, the difference in the flow rate or variation of the flow rate between the hot and cold water supplies is de¬ creased as the total flow rate is reduced. Contoured apertures in a pair of disc plate valves have been known to contour the water flow profile between the hot and cold water supplies. However, these plate valves are set to move both rotatably and trans¬ lationally with respect to each other to mechanically control both the total flow rate and the temperature mix of the hot and cold water. What is needed is a compact thermostatic valve that is easily assembled and controls the temperature of the mixed water output. What is also needed is a thermostatic control built into a valve with flow control that provides proper thermostatic control at all flow rates. SUMMARY OF THE DISCLOSURE In accordance with one aspect of the inven¬ tion, a thermostatic mixing valve includes a base having two supply ports for connection with hot and cold water supplies. A handle body is rotatably mounted onto the base and operably connected to a first valving surface with a first and second inlet passage therethrough for hot and cold water supplies. The first valving surface is operably positioned adjacent the two supply ports for controlling total flow rate of the water into the mixing valve. A second annular valving surface is axially movable within the handle between a firεt seat in proximity to a first axial end of the annular valving surface and a second seat in proximity to a second axial opposite end of the annular valving surface for control¬ ling relative proportion of fluid from said firεt and second inlets. The first inlet paεεage paεεes axially by the first seating surface within radial extent of the annular valving surface and has a downstream end in fluid communication with the first seat and the firεt axial end of the annular valving surface to provide a first flow path between the first seat and the annular valving εurface from radially within the annular valving εurface to radially outside of the annular valving surface to a mixing chamber. The εecond inlet paεsage pasεes axially by the firεt εeating surface and through the interior of the annular valving surface within radial extent of the annular valving surface and has a downstream end in fluid communication with the second seat and the εecond axial end of the annular valving εurface to provide a εecond flow path between said second seat and said annular valving εurface from radially within the annular valving εurface to radially outεide of the annular valving εurface to the mixing chamber. The first inlet paεεage iε εealed with reεpect to the second inlet pasεage from the εupply portε to the mixing chamber and within the interior of the annular valving εurface. A thermostat element is axially movably disposed within the mixing chamber and operably connect¬ ed to the annular valving surface to move the annular valving surface axially between the first and second seats for controlling the relative flow from the first and second inlet passageε into the mixing chamber in response to the temperature of fluid in the mixing chamber. The mixing chamber is in fluid communication with an outlet. Preferably, the thermostatic mixing valve includes an internal body section having an upper annular flange that forms the second seat above an annular downstream end of the second inlet passage. The internal body section has an annular lower flange forming the firεt εeat below an annular downεtream end of the first inlet pasεage. The internal body εection has an annular middle flange forming a seal with the annular valving εurface to seal the annular downstream end of the reεpective inlet passages from each other within the radial confines of the annular valving surface. In one embodiment, the internal body section has a central outlet pasεage extending therethrough in fluid communication with the mixing chamber. The thermostat element extendε axially down into the outlet paεεage of the internal body εection and iε connected to said annular valving surface through a collar member with the collar member having apertures therethrough to provide flow of fluid from said first inlet passage through the mixing chamber and into the outlet pasεage that is operably connected to the outlet. In accordance with another aspect of the invention, a thermostatic mixing valve has a cold water inlet port and a hot water inlet port in communication with a base having two εupply ports. A handle body is rotatably mounted onto the base and is operably connect¬ ed to a first valving surface with two inlet paεεages therethrough that are operably positioned adjacent the two supply ports for controlling total flow rate into the housing. A thermoεtat element iε operably connected to a second valving surface to move the second valvmg surface between a first and second seat for controlling the relative flow from the first and second inlet passages in response to the temperature of fluid in the mixing chamber. The ports and the first valving εurface are incorporated in two concentrically mounted plates that can be rotated with respect to each other and provided with openings therethrough for the controlled pasεage of the fluid through the two plates. At least one of the openings is shaped to modify the ratio of fluid flow through the first and second inlet passages such that the modification counterε the tendency toward a varia¬ tion in the ratio of the flow rateε through the first and εecond inlet paεεageε as a consequence of only the change of flow rates through the firεt and εecond inlet paεsages. In one embodiment, the reεpective cold water paεεage is throttled less than the hot water passage during motion of the movable plate from full flow position to a closed position. In an alternate embodi¬ ment, the respective hot water pasεage iε throttled leεs than the cold water passage during motion of the movable plate from full flow position to a closed position. In another embodiment, the respective hot water passage resiεtance to fluid flow increases with the reciprocal displacement angle of the plates from the maximum flow poεition toward the closing position, while the resiεtance in the respective cold water passage remains subεtantially conεtant. Alternatively, the respective cold water passage resistance to fluid flow increases with the reciprocal displacement angle of the plates from the maximum flow position toward the closing position, while the resiεtance in the respective hot water passage remains substantially constant. In this fashion, a compact thermostatic cartridge is available. The cartridge can be housed in a mixer valve flow regulator with volume or flow rate control diεc plates that have contoured apertures to aεεure εet flow ratioε between the hot and cold water εupplieε independent of the total flow rate through the diεc plateε. BRIEF DESCRIPTION OF THE DRAWINGS Reference now is made to the accompanying drawings in which: Figure 1 iε a εide segmented view of a thermo¬ static mixing valve in accordance with one embodiment of the invention; Figure 2 is a plan view of a fixed plate for the flow rate regulation shown in figure 1; Figure 3 is a plan view of the movable plate shown in figure 1; Figure 4 is a plan view of the two plates εhown in an operating and fully open poεition; Figure 5 iε a view εimilar to figure 4 with the plates shown in the partially cloεed position; Figure 6 illustrates a second embodiment of the fixed plate; Figure 7 illustrates a third embodiment of the fixed plate; Figure 8 is a cross sectional view taken along lines 8-8 shown in figure 7 and showing the movable plate in the fully open position; and Figure 9 is a view similar to figure 8 illus- trating a modified profile of the port through the fixed plate shown in figure 8 with the movable plate moved to a partially closed position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to figure 1 and 2, a thermostatic mixing valve 10 includeε a handle body 12 that iε rotatably mounted in piping fixture or other suitable piping fixture 14. The piping fixture 14 includes a cold water supply 16 and hot water supply 18. The handle body 12 is rotatably mounted to a faucet base 17 that is affixed within the fixture 14. The mixing valve includes a flow rate control valve 20 that includes two ceramic disc plates 22 and 24. Fixed ceramic disc plate 22 is mounted in base 17. Rotatable ceramic disc plate 24 is mounted to a bottom of a cartridge assembly 25. The cartridge assembly 25 includes a thermostatic con- trolled second valve 26 is mounted downstream from the flow control valve 20 within the handle body 12 to control the temperature of the mixed water flowing to an outlet pasεage 28. The thermostatic valve is described in detail in PCT Publications WO 95/30940 and 95/30939 and is incorporated herein by reference. The fixed ceramic disc plate 22 haε reεpective cold and hot εupply portε 30 and 32 and a centrally located mixed water outlet port 34. The ceramic diεc plate 24 iε affixed to the rotatable handle body 12 via an internal body member 36 of the cartridge aεεembly 25 for rotation with the handle body 12. The movable ceramic disc plate 24 has a cold water inlet 38 and hot water inlet 40 and a centrally located outlet aperture 42 that is in constant alignment with outlet port 34 of fixed ceramic disc plate 22. The rotation of the handle body 12 rotates the ceramic disc plate 24 with reεpect to diεc plate 22 εelectively align or misalign the inletε 38 and 40 with inletε 30 and 32 to control the total flow rate of the hot and cold water. The detailε of the contour of the supply ports 30 and 32 and the inlets 40 and 42 through the two ceramic disc plates 22 and 24 is described in more detail as follows. The internal body member 36 has a hot water inlet pasεage 44 aligned with the hot water inlet 40 and a cold water inlet paεεage 46 aligned with the cold water inlet 42. A central mixed water outlet 43 is in alignment with outlets 42, 34 and 28. The passage 44 has an annular shaped downstream end 48 adjacent an annular valve seat 50 in internal body member 36 and the axial lower end 52 of thermostatically controlled valve 26 which is annular in shape. The pasεage 46 has an annular shaped downstream end 54 adjacent an annular valve seat 56 and the axial upper end 58 of the annular shaped valve 26. Valve seat 56 is secured to the internal body member 36. The pasεage 46 paεεes axially through the annular valve 26 within itε radial confines. The internal body member 36 has an intermediate seal seat 60 that εeats a εeal 62 that seals off the passage 44 from 46 within the axial extent of the annular valve 26. The annular valve 26 is affixed to a collar 64 via a threaded engagement. A spring 66 biaεeε the valve 26 to engage the seat 56 and close off passage 46. The collar extends above the internal body section and is operatively affixed to body section 68 of thermostatic element 70. The thermostatic element has an expanding piston leg 72 that engages a safety spring release seat 74 that is mounted in adjustment handle 76. The adjuεt¬ ment handle 76 is screwed onto handle body 12 with an appropriate εeal 75 for mechanically raiεing and lower¬ ing the thermoεtatic aεεembly 70 within the cartridge aεsembly 25. The body section 68 may extend into the central outlet passage 42 of the internal body 36. The cartridge asεembly 25 maintains its structural integrity because the annular valve 26 is entrapped between the internal body valve seat 50 and the upper seat 56. The thermoεtatic element 70 iε affixed to the collar which in turn is affixed to the annular valve 26. The spring element 66 is also en¬ trapped between the internal body 36 and the valve 26. The water flow from the cold water supply 16 passes up through the control valve 20 and axially upward through the internal body member with the cold water pasεing radially outward through the adjuεtably εized gap 78 between the εeat 50 and annular valve 26 and into mixing chamber 80. The flow path from the hot water supply 18 passeε through the control valve 20 and axially upward through the internal body member with the hot water paεεing radially outward through the adjuεta¬ bly sized gap 79 between the seat 56 and annular valve 26 to mixing chamber 80. The water thereafter is mixed and passes back radially inwardly to the center outlet passage 42 and out of the cartridge 25 and mixing valve 10. The thermoεtatic adjustment automatically slides the valve 26 axially to adjust the size of the two gaps 78 and 79. The specific internal construction of the thermostatic element 70 is well known in the art and is commercially available. The volume control valve 20 when in the closed position prevents any communication between water supplies 16 and 18 and thus the faucet need not be provided with non-return valves. Reference now is made to figures 3-10 for a more detailed description of the ceramic disc plates 22 and 24 and the shape and operation of the ports 30 and 32 in the fixed plate 22 and inlets 38 and 40 in ' the movable plate. For ease of illustration, the two plates are shown as having different diameters but it is under¬ stood that the diameters of the respective plates are not critical to the invention and they may have the same diameter. As was described earlier, the reduction of the flow in most circumεtanceε cauεeε a riεe in the tempera¬ ture of the mixed water and it is thiε riεe that muεt be corrected. Figure 2 shows the two ports 30 and 32. Ports 30 has the usual arched shape with constant width. Opening 32 however haε a particular configuration diεcloεing one embodiment of the invention. Section 90 has a constant and reduced width and expands into section 92 with an enlarged width. As shown in figure 3, the movable plate 24 has two inletε 38 and 40 whoεe configuration iε the uεual one with an arch of conεtant width. Figure 4 show the two plates superimposed onto each other at the full flow condition with the ports 30 and 32 fully aligned with inlets 38 and 40. As the movable plate iε rotated to the position shown in figure 5, the free cross-section through the ports 30 and inlet 38 varies directly in proportion to the displacement angle as is usually found in volume control valves. On the other hand, the hot water passage through port 32 and inlet 40 is throttled a greater proportion because at the start of the diεplacement, the wider part 92 waε covered by movable plate 24 until as εhown in figure 5 only the narrower part remainε uncovered with respect to inlet 40. Consequently, the hot water supply flow volume is reduced or throttled at the beginning of the regulation action by a greater amount than the throt¬ tling of the cold water supply flow. This difference in throttling counteracts the tendency toward a rise in the temperature of the mixed water in terms of diminishing the mixed water flow rate. The width and extent of the sectionε 90 and 92 can be profiled εo as to compensate in the best fashion, the tendency toward a rise in the temperature of the mixed water and to enable the thermo¬ εtatic device to correct any reεidual variation. If one now considers that port 30 and inlet 38 are used for the passage of the hot water supply flow and port 32 and inlet 40 are used for the cold water supply flow, the identical behavior and compensation can be provided if the rotation of the movable valve diεc iε in the reverεe direction. In thiε situation, as the movable plate is rotated in this reverse direction, the free crosε-εection through the ports 30 and inlet 38, now εupplying hot water, varies directly in proportion to the displacement angle as is usually found in volume control valves. On the other hand, the pasεage through port 32 and inlet 40 (now εupplying cold water) is throttled a lesεer proportion because at the start of the displacement, the narrower section 90 is covered by movable plate 24 until only the wider section 92 remains uncovered with respect to inlet 40. Consequently, the hot water supply flow volume is reduced or throttled at the beginning of the regulation action by a greater amount than the throttling of the cold water supply flow to achieve the same effect as before deεcribed. Furthermore, it εhould be noted that although the contoured port 32 is shown in fixed plate 22, the same effect can be achieved with the port 40 in the movable disc plate being contoured instead. It should also be understood that the εame effect can be accomplished by contouring either port 30 or inlet 38 provided that the contour is in the reverse fashion so that the hot water supply is throttled more than the cold water supply i.e. that the cold water is throttled less than the hot water supply as the valves are moved from the full on position toward the closed position. While previous discuεεion has been limited to one port opening, it iε foreεeen that both portε in the εame plate can be contoured or one contoured port can belong to one plate while the other contoured port can belong to the other plate. Furthermore, the ports of both plates may be cooperatively contoured to achieve the desired results of changing the ratio of flows. Figure 6 illustrates an embodiment of plate 122 similar to the one εhown in figure 3 . The port 132 however has a gradual variable width. In the case, the resultant effect is the same as in the preceding case, but is more regularly sloped along the pertinent diε¬ placement arc of the two plates. The above discuεεed examples diεclose plates for unproportional variation of the flow for the hot and cold waters by varying the width of at leaεt one port to vary the free cross-sectional overlap offered between the water supply and the internal passage through the valve. Another fashion to accomplish the unproportional variation iε to vary the reεistance in one pasεage relative to the other paεεage. Referring to figures 7 and 8, the width of port 232 at face 233 in plate 222 is uniform as shown in figure 7. However as shown in figure 8, the port 232 is steeped such that at the opposite face 236, a reduced or throttled open area 235 existε which emptieε out into region 237 at face 233. The resistance againεt the flow keeps increasing gradually as the free crosε-εection of the pasεage εhifts from directly over throttled section 237 toward only the distal end 239 of region 237. The result is εubstantially identical to the one accom¬ plished by the variation of the width of the port in itε various regions. The port can be further modified as shown in figure 9 where the port 332 has throttled region 335 that opens up into region 337. The floor 341 of region 337 is sloped from region 235 to distal end 339 to achieve a variation rate that may be more desir- able in particular circumstances. The configurations illustrated in figureε 6-9 can be aεεociated with the variationε in the cross¬ section of the portε rather than uεed aε a εubεtitution of the variation in width. In other wordε, the variouε featureε my be combined with each other to produce the variation in relative flow rateε. In this fashion, a thermostatic valve for a mixing faucet is able to correct the temperature of the outlet water for more varieties of plumbing conditions and water supplies. The invention increases the viabil¬ ity of thermostatic control valves where its mere action without the inventive concept is not εufficient to maintain the outlet water at the preselected or desired temperature. Other variationε and modificationε are poεsi- ble without departing from the scope and spirit of the preεent invention aε defined by the appended claimε.

Claims: CLAIMS The embodimentε in which an excluεive property or privilege is claimed are defined as follows: 1. A thermostatic mixing valve characterized by: a base having two supply ports; a rotatable handle body mounted onto said base and operably connected to a first valving surface with two inlet pasεageε therethrough that are operably poεitioned adjacent said two supply ports for control¬ ling volume flow into said housing; a second annular valving surface axially movable within said handle between a first seat in proximity to a firεt axial end of the annular valving εurface and a second seat in proximity to a second axial oppoεite end of the annular valving εurface for control¬ ling relative proportion of fluid from said first and εecond inlets; εaid first inlet pasεages pasεing up through said firεt εeating εurface within radial extent of εaid annular valving surface and having a downstream end in fluid communication with said first seat and said firεt axial end of εaid annular valving surface to provide a first flow path between said first seat and said annular valving surface from radially within said annular valving εurface to radially outεide of εaid annular valving εurface to a mixing chamber; εaid εecond inlet passage pasεing up through εaid first seating surface and through the interior of said annular valving surface within radial extent of said annular valving εurface and having a downstream end in fluid communication with said second seat and said second axial end of said annular valving surface to provide a εecond flow path between said second εeat and εaid annular valving εurface from radially within εaid annular valving εurface to radially outεide of εaid annular valving εurface to εaid mixing chamber; εaid first inlet passage being sealed within the interior of εaid annular valving εurface with respect to said second inlet pasεage from said supply ports to said mixing chamber; a thermostat element axially movably dispoεed with the mixing chamber and operably connected to said • annular valving surface to move said annular valving surface axially between said first and second seats for controlling the relative flow from the first and second inlet pasεageε into εaid mixing chamber in reεponεe to the temperature of fluid in εaid mixing chamber; said mixing chamber in fluid communication with an outlet exiting therefrom; said portε and εaid firεt valving surface being incorporated in two concentrically mounted plates that can be rotated with respect to each other and provided with openingε therethrough for the controlled passage of the fluid through the two plates; at least one of the opening is shaped to modify the ratio of fluid flow through the firεt and second inlet passages such that it counters the tendency toward a variation in the ratio of the flow rates through the first and second inlet passages as a conse- quence of only the change of total flow rate through the firεt and second inlet passages. 2. A thermostatic mixing valve as defined in claim 1 further characterized by: the reεpective openings for cold water paεεage are throttled more quickly than the openingε for hot water paεεage during motion of the movable plate from full flow poεition to a closed position. 3. A thermostatic mixing valve as defined in claim 1 further characterized by: the respective openings for hot water pasεage are throttled more quickly than the openings for cold water pasεage during motion of the movable plate from full flow poεition to a closed position. 4. A thermostatic mixing valve aε defined in claim 1 further characterized by: the respective hot water pasεage resistance to fluid flow increases with the reciprocal displacement angle of the plates from the maximum flow position toward the closing position, while the resistance in the respective cold water passage remains subεtantially constant. 5. A thermostatic mixing valve as defined in claim 1 further characterized by: the reεpective cold water paεsage resistance to fluid flow increases with the reciprocal displacement angle of the plates from the maximum flow position toward the closing poεition, while the resiεtance in the reεpective hot water passage remains substantially constant. 6. A thermostatic mixing valve having a cold water inlet port and a hot water inlet port character¬ ized by: a base having two εupply portε; a rotatable handle body mounted onto εaid baεe and operably connected to a firεt valving εurface with a hot water and cold water inlet paεsage therethrough that are operably positioned adjacent said two supply ports for controlling volume flow into said housing; a thermostat element operably connected to a movable second valving surface that is movable between firεt and εecond seats for controlling the relative flow from the cold and hot water inlet passages in response to the temperature of fluid in a mixing chamber; said ports and said firεt valving εurface being incorporated in two concentrically mounted plateε that can be rotated with reεpect to each other and provided with openingε therethrough for the controlled passage of the fluid through the two plates; at least one of the opening is shaped to modify the ratio of fluid flow through the hot and cold water inlet passages such that it counters the tendency toward a variation in the ratio of the flow rateε through the hot and cold water inlet paεεageε aε a conεequence of only the change of total flow ' rate through the firεt and εecond inlet paεεageε. 7. A thermoεtatic mixing valve as defined in claim 6 further characterized by: the respective openings for the cold water inlet paεεage are throttled more quickly than the openings for hot water inlet pasεage during motion of the movable plate from full flow position to a closed position. 8. A thermostatic mixing valve as defined in claim 6 further characterized by: the respective openings for hot water passage are throttled more quickly than the openings for cold water inlet passage during motion of the movable plate from full flow position to a closed position. 9. A thermostatic mixing valve as defined in claim 6 further characterized by: the respective hot water inlet passage resiε¬ tance to fluid flow increases with the reciprocal displacement angle of the plates from the maximum flow position toward the closing position, while the resiε¬ tance in the reεpective cold water inlet paεsage remains substantially constant. 10. A thermoεtatic mixing valve as defined in claim 6 further characterized by: the respective cold water inlet passage resiεtance to fluid flow increases with the reciprocal displacement angle of the plates from the maximum flow position toward the closing position, while the resiε¬ tance in the reεpective hot water inlet paεsage remains subεtantially conεtant.

Inventors: KNAPP ALFONS, KNAPP, ALFONS
Applicants: KNAPP ALFONS, MASCO CORP, KNAPP, ALFONS, MASCO CORPORATION
Application year: 1996
Main classification: G05D23
IPC codes: F16K1, F16K3, F16K11, G05D23