Abstract:
A ball valve unit for shutting off the flow of fluids flowing in heating and plumbing systems. The ball valve unit includes a ball valve and a main section including a flange formed integrally with the main section. A chamber is formed in the main section for receiving the ball of the ball valve. The main section is made of brass in order to prevent galvanic action between ball valve unit and the heating/plumbing system.

Description:
RELATED APPLICATIONS 
     The present application is a continuation of U.S. patent application Ser. No. 10/097,762, filed Mar. 14, 2002. 
     CROSS REFERENCE TO RELATED APPLICATIONS 
     This Patent Application claims priority from U.S. Provisional Patent Application Serial No. 60/300,345, filed on Jun. 22, 2001 and U.S. Provisional Patent Application Serial No. 60/300,622, filed on Jun. 25, 2001, the contents of which are incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     This invention relates generally to ball valves, and more particularly to a flanged end ball valve of unitary construction. 
     Traditionally, a ball valve is used in plumbing and heating applications to shut off the flow of water or other fluid during replacement or repair of an in-line appliance or piece of equipment, such as a circulating pump. As shown in FIG. 1, typically, a ball valve used in a plumbing and heating application includes a separate flange  2 , a conventional ball valve  4 , and a copper nipple  6  and copper adapter  8  that connect the flange  2  to the conventional ball valve  4 . The ball valve  4  is attached to the plumbing or heating system with copper tubing  10 . The in-line appliance (not shown) is attached to the flange  2 . Alternatively, an iron nipple  12  has been used to connect the flange  2  to the ball valve  4 , and a copper adapter  14  has been used to connect the ball valve  4  to the copper tubing  10 , as shown in FIG.  2 . 
     As shown in FIGS. 1 and 2, in the conventional methods, there are several potential leak paths. Also, there are areas of galvanic action between dissimilar metals. Further, installation of the flange, the nipples, and the adapters in this type of configuration is time consuming and expensive. 
     The conventional method shown in FIG. 3 includes an iron flange  16  that includes a screwdriver slot ball valve. The flange  16  is connected to a second iron flange  18 . A copper adapter  20  connects the iron flange  18  to copper tubing  10 . In this configuration, since the flange  18  is made of iron, there is an area of galvanic action between the iron flange  18  and the copper adapter  20 . Also, there are several potential leak paths. Further, this configuration is complex, which increases the cost and installation time. 
     FIG. 4 shows another conventional configuration. This configuration includes an iron flange  30  connected to a copper tube  32  via a copper adapter  34 . In this conventional configuration, it is not possible to isolate an in-line appliance, thereby making repair and replacement of the in-line appliance burdensome. Also, there are several potential leak paths. Further, there are areas of galvanic action between the copper adapter  34  and the iron flange  30 . 
     SUMMARY OF THE INVENTION 
     The present invention provides a ball valve unit that reduces the cost and time required to replace in-line appliances such as pumps. 
     The ball valve unit of the present invention also reduces the number of joints and flanges, thereby reducing the volume of the plumbing system and the number of leakage paths. 
     Further, the present invention also provides a ball valve unit that prevents the cracking of brittle iron flanges and prevents galvanic action. 
     The present invention comprises a main section, a flange for connecting the ball valve unit to an appliance, wherein the flange is integrally formed with the main section, a ball valve, a chamber formed in the main section for accommodating the ball of the ball valve, and a handle for actuating the ball valve. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other features and advantages of the present invention will be more fully understood from the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawings in which: 
     FIG. 1 shows a first conventional system. 
     FIG. 2 shows a second conventional system. 
     FIG. 3 shows a third conventional system. 
     FIG. 4 shows a fourth conventional system. 
     FIGS. 5A and 5B show cross-sectional views of one embodiment of the ball valve unit of the present invention. 
     FIGS. 6A and 6B show cross-section views of a second embodiment of the ball valve unit of the present invention. 
     FIGS. 7A and 7B show a third embodiment of the ball valve unit of the present invention. 
     FIGS. 8A and 8B show a fourth embodiment of the ball valve unit of the present invention. 
     FIGS. 9A and 9B show a fifth embodiment of the ball valve unit of the present invention. 
     FIGS. 10A and 10B show a sixth embodiment of the ball valve unit of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 5A shows a cross-sectional view of one embodiment of the present invention. As shown in FIG. 5A, the single flanged ball valve unit, according to the present invention, is designated by reference number  50 . It comprises a handle nut  52 , a washer  54 , a stem  56 , a ball  58 , a body  60 , a handle  62 , a packing gland  64 , seats  66 , and a stem seal  68 . The body  60  comprises a main section  70  and an end cap  72 . The main section  70  includes a chamber  74  adapted to accommodate the ball  58  and seats  66 , a stem hole  76  to receive the stem  56  and stem seal  68 , and a flange  78  to be positioned juxtaposed an inline appliance or equipment, such as a circulating pump (not shown). The ball valve unit  50 , preferably, is 600 PSI rated for use with water, oil or gas. The inner diameter of the chamber  74  is substantially equal to the inner diameter of the end cap  72 , thereby maximizing flow through the ball valve unit. FIG. 5B shows a side view of the flange  78 . 
     The main section  70  and flange  78  are of unitary construction and preferably made from cast or hot forged brass. Since plumbing and heating systems typically comprise brass or copper tubing, this prevents the occurrence of electrolysis and galvanic action at the junction of the ball valve unit and the system tubing. Also, brass is a much softer alloy than traditional iron used for the flanges currently on the market that often crack when slightly over tightened. 
     The ball  58  is preferably made of Brass/Hard Chrome Plate and fits between seats  66 , preferably made from Teflon® or PTFE. The ball  58  is actuated with a blow-out proof stem  56  preferably made of Brass (ASTM B124-C37700). The ball  58  is actuated with a handle  62 , preferably made of stamped steel with a vinyl coating. 
     The stem  56  is sealed with a stem seal  68 , preferably made from Teflon® or PTFE, and an adjustable packing gland  64 , preferably Brass (ASTM B124-C37700). 
     The end cap  72 , preferably Brass (ASTM B124-C37700), is a threaded NPT (National Pipe Thread) connection, a Sweat (copper tubing) connection or a PEX (Cross Link Polyethylene) connection. The end cap  72  can be of varying sizes such as ½″, ¾″, 1″, 1¼″, 1½″ and 2″. The end cap  72  can be an (NPT) ANSI BI.20.1 threaded end (½″-2″), an ANSI B16.18 solder end (½″-2″), or a PEX insert end (½″-1″). 
     When the ball valve unit is installed, the flange  78  is bolted to, for example, an iron flange that is part of a circulating pump (not shown). A rubber gasket  82  (preferably made of neoprene) forms the seal between the two flanges. The rubber gasket can be part of the flange  78  or the pump. The gasket stops two unlike metals from touching each other, thus eliminating galvanic action. Preferably, the flange  78  is substantially flat so that it will fit different size appliances. The flange  78  is consistent in size to fit most manufacturers smaller sized circulating pumps. A preferred length and thickness of the flange is 4⅛″ and ⅜″, respectively. 
     FIG. 6A shows a cross-section of a second embodiment of the ball valve unit of the present invention. The second embodiment is substantially similar to the first embodiment. As shown in FIG. 6A, the second embodiment includes a wing-shaped handle  90  to allow for easy actuation of the valve. FIG. 6B shows a side view of the flange  78 . 
     FIGS. 7A and 7B show a third embodiment of the ball valve unit of the present invention. As shown in FIG. 7A, the ball valve unit  100  includes similar components as the ball valve unit  50  of the first embodiment. Specifically, the ball valve unit  100  comprises, inter alia, ball valve  102 , main section  104 , handle  106 , end cap  108 , and flange  110 . In addition, the ball valve unit  100  includes a drain valve  120 . The drain valve  120  is used to drain the system in the vicinity of the ball valve  102 . The drain valve  120  comprises a ball valve  122  that is actuated by a handle  124 . The ball valve  122  is housed in extension tubing  126  that is fitted to the main section  104  of the ball valve unit  100 . A hose (not shown) can be attached to the extension tubing for draining the system. The extension tubing  126  preferably is made from cast or hot forged brass. 
     FIGS. 8A and 8B show a fourth embodiment of the ball valve unit of the present invention. The fourth embodiment is substantially similar to the third embodiment and includes a wing-shaped handle  200 , as shown in FIGS. 8A and 8B. 
     FIGS. 9A and 9B show a fifth embodiment of the ball valve unit of the present invention. The fifth embodiment is substantially similar to the third embodiment. In the fifth embodiment, the drain valve  120  positioned between the flange  110  and ball valve  102 , as shown in FIGS. 9A and 9B. 
     FIGS. 10A and 10B show a sixth embodiment of the ball valve unit of the present invention. The sixth embodiment is substantially similar to the fifth embodiment and includes a wing-shaped handle  300 . 
     The present invention, without the addition of any additional components, can be used to quickly and easily replace plumbing components and appliances such as pumps. The appliance can be changed by simply closing the ball valves and loosening bolts in the flanges on each side of the appliance. The appliance will then drop out and a new one can be placed back in, thereby minimizing installation problems. 
     Further, because the ball valve is formed integral with the flange, the number of joints is reduced, thereby reducing the volume of the system and the number of leak paths. 
     Although the invention has been described with respect to various embodiments, it should be realized this invention is also capable of a wide variety of further and other embodiments. For example, the handle  62 ,  90 ,  106 ,  200 ,  300  can be a different type than those shown in FIGS. 5A-10B. In addition to brass, the body  60  and main section  70  can be made of any material that reduces galvanic action, for example, copper, PVC, or bronze. Also, in the embodiments shown in FIGS. 7A-10B, a bleeder valve can be used in addition to, or in place of, the drain valve.