Abstract:
A side spray diverter valve with anti-siphoning and flow regulation of the water diverted to the spray head. A ported valve plunger sliding in a sleeve admits water from the inlet to the spout in one position while a lower O-ring seals the spray outlet. In the other position, the sleeve has axially directed ports which screen and trap particulates in the water over a predetermined size. The flow rate of screened water to the spray is regulated by the lower O-ring pressing against grooves in the wall of the sleeve.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates generally to valves for diverting the flow of fluid from one outlet to another, and more particularly to a side spray diverter valve used in plumbing faucets with a separate hose-connected side spray.  
         [0002]     Diverter valves are known in the prior art for a faucet which directs water to either the faucet spout or to a spray nozzle connected to the faucet assembly by a hose. When the spray nozzle is activated, the corresponding drop in water pressure in the spray hose activates the diverter valve so as to divert the water from the normal faucet spout through which it is flowing to the spray nozzle outlet. The water supply is usually from both a hot water line and a cold water line, usually associated with a mixing valve to adjust the water temperature, although a diverter valve could operate with only a single source of water under pressure.  
         [0003]     A number of diverter valves or transfer valves are known in the prior art, which have been designed to meet the problems associated with residential water supplies. One problem is that of particulate material in the water. Although the usual residential faucet spout is fitted with an aerator having filters to trap particulate matter, this is not effective in the case of particulate matter passing through the diverter valve which can become trapped between the moving parts and interfere with proper operation. Another problem for diverter valves connected to an outlet attached to a hose, which could become immersed in a sink of dirty water, is the requirement that the diverter valve be of an anti-siphon type. This requirement is found in American Society of Sanitary Engineering (A.S.S.E.) standard no. 1025 stating that there be no back-siphonage of water through the spray or hose when the control valve of the spray is defective or open and a vacuum is applied to the faucet inlet. Further requirements are that a diverter valve meet high temperature and water pressure requirements, that it meet minimum flow requirements both at the faucet spout outlet and at the hose spray outlet when the spray is activated, and that it shall not permit more than a specified leakage at the spout outlet when the hose spray is activated. Therefore, the diverter valve should be constructed in such a manner that it meet these requirements and have provisions for reducing possibility of particulate matter blocking flow passages and affecting the performance of the diverter valve.  
         [0004]     A prior art diverter valve is known in U.S. Pat. No. 2,587,961 issued Mar. 4, 1952 to Bletcher et al., who disclose a transfer valve which incorporates an anti-siphonic means to prevent water from flowing backwards from the spray outlet into the water supply line should a vacuum condition occur. The transfer valve incorporates a pressure actuated control valve to divert water at the inlet into the spray outlet when the spray head is actuated, and a separate check valve to prevent flow through the spout outlet should pressure in the water inlet be reduced.  
         [0005]     U.S. Pat. No. 2,949,933 issued Aug. 23, 1960 to Moen discloses a spray diverter valve suitable for a water faucet with an inlet mixture of hot and cold water, comprising a sleeve with inlet ports registering with the water supply mixing chamber, and a valve seat controlling flow to the spout outlet. An unrestrained valve piston opens and closes the flow to the spout outlet in response to pressure changes when the spray handle is actuated. Flow to the spray outlet takes place around a piston with a flexible downwardly flaring skirt. Also, pressure in the inlet causes the skirt to seal against the inner surface of the sleeve and movement of the valve seat to eliminate suction through the inlet. The possibility of particulate matter becoming lodged in the clearances introduces the possibility of malfunctions of either the movable valve seat or the piston.  
         [0006]     U.S. Pat. No. 4,934,402 issued Jun. 19, 1990 to Tarnay et al. addresses the problem of possible malfunction of the foregoing Moen type diverter valve by reversing the orientation of the skirt on the piston to provide a positive seal, and providing a separate bypass channel to the spout outlet so that there is no flow past the piston, thereby eliminating the possibility of particulates jamming the valve. The bypass channel includes a precision size orifice so that any particulate matter that passes through the orifice will not be trapped. The Tarnay diverter valve requires the addition of another valve and valve seat, thereby adding to the cost of the prior art valves shown by Moen and Bletcher. Since there is a fixed restriction in the bypass line, there is no flow regulation to the spray head. This means that there will be greater flow of water to the spray head at higher pressure resulting in excess flow, and lower flow at lower pressure, resulting in insufficient flow.  
         [0007]     Accordingly, one object of the present invention is to provide an improved diverter valve for diverting flow from a spout outlet to a spray outlet when the spray head is actuated, which also incorporates protection against siphoning contaminated water through the spray outlet to the water supply when water inlet pressure is reduced.  
         [0008]     Another object of the invention is to provide an improved diverter valve which reduces possibility of jamming any moveable parts with particulate matter.  
         [0009]     Another object of the invention is to provide an improved diverter valve with flow regulation to the spray outlet when the spray head is actuated.  
         [0010]     Another object of the invention is to provide an improved diverter valve with a minimum of working parts suitable for general use in a variety of diverter valve applications.  
       SUMMARY OF THE INVENTION  
       [0011]     Briefly stated, the invention comprises a valve sleeve with an upper valve seat, radially directed ports into the sleeve from a water inlet, axially directed ports through the sleeve from the water inlet, a lower valve seat, and flow regulating grooves in the wall of the sleeve. A valve plunger within the sleeve has a valve head for sealing the upper valve seat to the spout, a lower valve head for sealing the lower valve seat to the spray outlet plunger ports which admit water from the radially directed ports in the sleeve to the spout when the plunger is in an upper position, and through the axially directed ports in the sleeve past the lower valve seat to the spray outlet when the plunger is in the lower position. In the latter position, the lower valve head regulates flow past the flow regulating grooves, while the axially directed ports in the sleeve screen and prevent the entry of larger particulate matter into the flow regulating grooves.  
         [0012]     In its preferred form, the invention comprises a diverter valve adapted to be received within a faucet assembly having at least one water inlet, a spout outlet and a spray outlet, the diverter valve comprising a cylindrical valve sleeve having a sleeve wall defining a central passage therethrough, the central passage communicating at an upper end thereof with the spout outlet and at a lower end thereof with the spray outlet, a central wall portion of the sleeve wall communicating on the outer surface thereof with at least one water inlet, the central wall portion having a plurality of radially directed inlet ports and a plurality of axially spaced, axially directed inlet ports, a spout valve seat defined by the sleeve wall at the upper end of the central passage, a spray valve seat defined by the sleeve wall, the spray valve seat being axially spaced from the spout valve seat on the other side of the central wall portion, and a plurality of circumferentially spaced flow regulating grooves defined in the sleeve wall between the spray valve seat and the lower end of the central passage. Inside the sleeve is a cylindrical valve plunger having a plunger wall dimensioned to slide axially with close clearances within said sleeve wall, the plunger having a transfer chamber closed at opposite axial ends of the plunger wall, a lower valve head arranged to seal the spray valve seat when the plunger is in an upper axial position, an upper valve head arranged to seal the spout valve seat when the plunger is in a lower axial position, a plurality of plunger inlet ports and a plurality of plunger outlet ports defined in the plunger wall and communicating with the transfer chamber, the plunger inlet and plunger outlet ports being axially spaced from one another and arranged to register with the upper end of the central passage and with the radially directed inlet ports respectively when the plunger is in the upper position so as to admit water from the water inlet through the transfer chamber to the spout outlet, and to be blocked when the plunger is in the lower position, the axially directed inlet ports being arranged to screen and admit a screened flow of water between the sleeve and plunger to the spray outlet, the lower valve head being adapted to cooperate with the flow regulating grooves to regulate the screened flow when the plunger is in the lower position. 
     
    
     Drawing  
       [0013]     The invention, together with other objects and advantages thereof, will be better understood by reference to the following description, taken in connection with the accompanying drawing, in which:  
         [0014]      FIG. 1  is a simplified elevation view of the faucet assembly with side spray,  
         [0015]      FIG. 2  is an elevation view, in cross section, of a side spray diverter valve according to the present invention showing the water inlet valves and spray valve in schematic form,  
         [0016]      FIG. 3  is an enlarged elevation view in cross section, of the diverter valve assembly with diverter valve plunger in an upper position for flow to the spout,  
         [0017]      FIG. 4  is a view of the valve of  FIG. 3  with the plunger in a lower position for regulated flow to the spray valve outlet, and  
         [0018]      FIG. 5  is plan view in cross section, taken along lines V-V of  FIG. 4 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]     Referring to  FIG. 1  of the drawing, a faucet assembly, shown generally at  10  is of the temperature mixing type having a faucet spout  12 , hot and cold water inlet connections  14 ,  16  respectively controlled by handles  18  and  19 . An alternate prior art arrangement might use a single handle to control both rate of flow and temperature of the water. A diverter valve (not shown) in accordance with the present invention is mounted inside a faucet assembly base  20 . A side spray nozzle  22  is connected to a spray outlet  24  opposite the outlet to spout  12  by a flexible hose  26 . A sink receptacle  28  with a drain (not shown) is provided for waste water from spout  12  or spray  22 . The spray  22  is actuated by a spray handle  30  actuating an internal valve (not shown). The foregoing is a description of a well-known type of residential sink application with separate hose-connected side spray according to the prior art.  
         [0020]     Referring now to  FIG. 2  of the drawing, a cross sectional view is shown of a diverter valve assembly indicated generally at  32 , which is located inside of or a part of a valve body  34 . The valve body  34  may take many forms according to the manufacturer of the particular faucet assembly  10 . The size and configuration of valve body  34  is not a material part of the present invention. The diverter valve assembly  32  is a unit which is inserted into valve body  34 . The hot and cold water inlets  14 ,  16  are supplied through valves  38 ,  40  respectively at water system pressure, which can vary between 20 to 100 psi according to the type of system. The valves  38 ,  40  are controlled by handles  18 ,  19  respectively. The upper end of valve body  34  comprises a spout outlet  42  leading to spout  12  which is open to atmospheric pressure. Spout  12  usually includes an aerator with a filter to catch particulate matter flowing through the open spout outlet  42 . The lower end of valve body  34  forms part of the spray outlet  24  connected through a valve  44  in the spray nozzle  22 .  
         [0021]     In accordance with the present invention, the diverter valve assembly  32  is disposed in a cylindrical bore in the valve body  34 , and comprises a cylindrical valve sleeve  46  with a plunger  48 . Plunger  48  is arranged to move between an upper and a lower position within sleeve  46  to function in a manner to be described.  
         [0022]     Referring now to  FIG. 3  of the drawing, an enlarged view is shown of the valve sleeve  46  with the valve plunger  48  in an uppermost position. Sleeve  46  is sealingly disposed within a cylindrical bore  50  of valve body  34 , and comprises a cylindrical body with axially spaced upper and lower flanges  52 ,  54  bridging a hot water inlet port  56  and cold water inlet port  58  cut in the wall of valve body  34  and supplied by hot water and cold water lines  14 ,  16  respectively. Hot and cold water inlets  56 ,  58  lead to a circumferential mixing chamber  60  partially defined by a reduced diameter section  62  of the valve sleeve  46 .  
         [0023]     The water inlet mixing chamber  60  is sealed by an upper O-ring  64  and lower O-ring  66  disposed in circumferential grooves in flanges  52 ,  54  respectively.  
         [0024]     In accordance with the present invention, a first set of circumferentially spaced, radially directed ports  68  are located around sleeve  46  and a set of circumferentially spaced, axially directed ports  70  are located on the sleeve below ports  68 .  
         [0025]     Radially directed ports  68  are relatively large and of ample size to accommodate full flow rate from mixing chamber  60  to the spout outlet. Axially directed ports  70 , on the other hand, are carefully sized to limit flow and to limit admission of particulate matter over a pre-selected size. For example, a typical diverter valve sleeve would have ten such axially directed ports  70  with a diameter of 0.039 inches designed to screen the flow and prevent the admission of particulates larger than that dimension, while permitting a screened flow of particles smaller than that dimension.  
         [0026]     The interior of the sleeve  46  comprises a cylindrical passage  72 . In order to shut off the flow of water to spout  42 , the upper end of passage  72  is formed with a valve seat  74 . In order to shut off the flow of water to the spray outlet, a lower valve seat  76  is formed on the inner sleeve wall. Lastly, flow regulating grooves  78  are formed longitudinally along the inner surface of the sleeve wall.  
         [0027]     Referring now to the construction of plunger  48 , the plunger comprises a cylindrical member with an upper flanged valve head  80  and a lower flanged valve head  82  disposed on either end of a cylindrical reduced diameter plunger wall  84 . Plunger wall  84  has a first set of circumferentially spaced plunger ports  86  and a second set of circumferentially spaced plunger ports  88 . Ports  86 ,  88  are axially spaced so that when plunger  48  is in the upper position shown, ports  86  are above the valve seat  74  on the upper end of the central passage  72 , while ports  88  register with radially directed inlet ports  68 .  
         [0028]     Referring now to  FIG. 4  of the drawing, reference numbers are the same as in  FIG. 3 , but plunger  48  is indicated in the lower position. In this position, inlet ports  86 ,  88  are blocked by the sleeve wall. Upper valve plunger O-ring  81  is seated on spout valve seat  74 . Lower valve plunger O-ring  83  is unseated, but is acting in conjunction with the flow regulating grooves  78  as shown in  FIG. 5 .  
         [0029]      FIG. 5  is a view taken in cross section through V-V. The lower diverter housing  36  encloses a lower sleeve wall extension  55 , in which precisely formed flow regulating grooves  78  extend longitudinally. The O-ring  83  acts in cooperation with flow regulating grooves  78  in a known manner to regulate the flow by bulging or expanding into the grooves  78  under increased pressure differential across the O-ring to reduce the opening so as to maintain a substantially constant flow. The flow regulating grooves  78  are of such dimension that particulates smaller than those trapped by axially directed ports  70  will pass through the grooves  78  without becoming lodged in the grooves.  
       Operation  
       [0030]     When water is supplied to inlet chambers  60  under pressure, plunger  48  rises to the upper position shown in  FIG. 3 , so that water can flow freely through the registered inlet ports  68 ,  88  into the transfer chamber inside valve plunger  80  and out ports  86  to spout outlet  42 . In this position, valve head  82  with lower O-ring  83  is seated on lower valve seat  76 .  
         [0031]     When the spray valve is actuated, so that pressure in the spray outlet  24  is reduced, the areas on the respective valve heads  80 ,  82  are such that valve plunger  48  moves to the lower position shown in  FIG. 4 . In this position, flow to the spout outlet  42  is cut off by valve  80  with O-ring  81  seated on upper valve seat  74 . Water flow from the mixing chamber  60  is blocked from flowing through the radially directed ports  68  and constrained to flow through the axially directed ports  70 , and through the flow regulating grooves  78  to the spray outlet  24  as indicated by the flow arrow. Particulate matter larger than the selected size admitted through axially directed ports  70  is held temporarily in the mixing chamber  60  and not allowed to pass through ports  70  into the flow regulating grooves  78 , where it could jam the movement of plunger  48 . If the inlet pressure in the mixing chamber  60  varies, the pressure differential changes across O-ring  83  to regulate the flow so as to hold it substantially constant in a manner known in the art. Any large particulates screened out by ports  70  and trapped in chamber  60  will later be flushed out through the spout outlet when the spray is shut off.  
         [0032]     Should the inlet pressure drop below a pre-determined value, while the spray valve is open, the areas on the plunger are such that the plunger will rise to seat on valve seat  76  to block flow of any contaminated water into the inlet, providing an anti-siphoning action.  
         [0033]     Other modifications will occur to those skilled in the art. Although two water supply lines are shown for hot and cold water, the arrangement will work equally well with a single water supply line.  
         [0034]     While the valve heads are shown supplied with O-rings, they obviously could be of another type of valve head designed to cooperate with the valve seats. For example, while lower O-ring  83  performs a dual function of sealing with valve seat  76  in the upper position and regulating the flow with grooves  78  in the lower position, a beveled valve head could perform the former sealing function, while an O-ring could perform the latter flow regulating function.  
         [0035]     Other modifications will occur to those skilled in the art, and it is desired to secure in the appended claims all such modifications as fall within the true spirit and scope of the invention.