Abstract:
A diverter valve assembly having a machined brass housing that seats a diverter valve that has a stem portion, inlet portion and outlet portion. The outlet portion is tubular and has an arcuate sealing pad secured thereon by axial flanges and keys on the outlet section. The sealing pad is flexible and the tubular outlet portion is resiliently flexible to allow an interference fit in a cylindrical bore in the brass housing.

Description:
TECHNICAL FIELD 
     This invention relates to diverter valves and more particularly to diverter valves for directing water either to a tub spout or showerhead. 
     BACKGROUND F THE INVENTION 
     Diverter valves are commonly placed either in a tub spout or in a separate housing that is connected to a single handle valve or is interposed between hot and cold water valves above the tub spout. 
     Diverter valves are constructed such that they can seal off the conduit leading to the tub spout and force water to pass up through the shower riser and out through the showerhead. Some diverter valves are made to also positively seal the shower riser when water is directed to the tub spout. However, most of these designs either do not function properly allowing leakage or create added noise due to the water passing through the diverter housing from the inlet supply lines to either the shower riser or tub spout. 
     Some diverters are made such that they do not positively block the shower riser. An aspirator housing is mounted at the lower end of the shower riser to prevent water to rise to the showerhead. However, aspirators can either be noisy or not function properly and allow for leakage through the showerhead. 
     What is needed is a diverter valve assembly which is reliable and properly seals either the tub spout conduit or shower riser and does not provide additional noise due to the water flow therethrough. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the invention, a diverter valve assembly includes a housing having a cylindrical bore defined by a side wall thereabout. Two inlets are circumferentially spaced about the bore and extend through the side wall at first axial position and first and second outlets are circumferentially spaced about the bore at a second axial position spaced from the two inlets. 
     A rotatable valve member is mounted in the bore for rotating about the longitudinal axis of said bore. The rotatable valve member has a central passage therethrough with two inlets in fluid communication with the two inlets of the housing. The rotatable member has a seal member axially aligned with the outlets of the bore to selectively seal one of the first and second outlets Preferably, the rotatable valve member has an outlet circumferentially spaced from the sealing member and is selectively alignable with the other of the first and second outlets. The outlet in the rotatable valve member is in fluid communication via the central passage with the inlets in the rotatable member such that fluid passes from the inlets in the housing, through the inlets in the rotatable member, through the central passage, through the outlet of the rotatable member, and through the other of the first or second outlet of the housing. 
     The inlets in the housing are axially spaced between the inlets and the collar in the rotatable member such that the rotatable valve member functions as a baffle for water flowing in from the housing inlets. The housing and the rotatable valve member form an annular chamber upstream from the collar which fluidly connects the inlets of the housing with the inlets of the rotatable member. It is desirable that the inlets of the valve member are normally angularly positioned 90° from each of the inlets of the housing. In addition, it is preferable that the inlets in the housing are angularly displaced 90° from each of the outlets in the housing. The rotatable member also includes a circumferential collar which is axially spaced between the inlets and outlets of the bore for sealing the rotatable member against the bore to assure that most fluid passes through the inlets in the rotatable valve member and therethrough to assure that the valve member acts as a baffle to minimize noise due to water flow. 
     The seal member is desirably an elastomeric pad that has a semi-oblong arcuate free shape. The contour of the pad can be rendered by a central section of one radius and two side sections of larger radius with the centers of the radii displaced from each other. The central section is positioned on a tubular outlet section of the rotatable valve member such that there is an interference fit between the seal and the bore in the housing. Preferably the outlet section of the rotatable member is also elongated in cross-section to an oblong or elliptical like shape. For manufacturing ease, cross-sectional contour of the rotatable outlet section can be defined by a pair of radii opposed to each other, two radii opposed to each other, and a pair of inner and outer opposed radii that connect the aforementioned radii. The outer contour in cross-section is similarly manufactured with two pair of radii opposing each other. The outer radius of the tubular outlet section that seats the seal and the inner radius of the seal central section are different such that a gap is formed between the two when the seal is in a free state seated on the valve member. The gap is closed when the seal is flexed to form an interference with the housing. 
     Preferably the housing is machined from bar stock and the inlets in the housing are drilled. The bore in the housing can be stepped such that only the outlet section is reamed to a fine finish. The inlets and outlets having step shoulders for abutting a pipe received therein. The rotatable valve member has a stem section, a tubular inlet section, and a tubular outlet section axially spaced from each other. The tubular outlet section is flexible and seats the flexible seal pad. The tubular outlet section has two outward flanges with grooves therein which are positioned and sized to receive opposite side edges of the seal. The outlet section further has two lugs that are keyed with the seal to prevent axial movement of the seal with respect to the stem. Positioned radially opposite the seal on the outlet section are two other lugs that are sized to abut the side wall of the bore to provide the interference fit of the valve member and seal into the housing. 
     In this fashion, a diverter valve is provided without introducing excess torque so that the stem or valve member can be easily rotated between the two alternate positions that either block the tub spout outlet or block the showerhead outlet. In addition, the inlets and outlets are arranged to provide a baffle and minimize noise created by the water flowing through the diverter valve housing and valve member. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Reference now is made to the accompanying drawings in which 
     FIG. 1 is a perspective view of a showerhead and tub spout assembly incorporating the diverter valve assembly according to the invention; 
     FIG. 2 is a side elevational view of the diverter valve housing shown in FIG. 1; 
     FIG. 3 is a side elevational and partially segmented view of the diverter valve assembly; 
     FIG. 4 is a cross-sectional view of the rotatable valve member shown in FIG. 3; 
     FIG. 5 is a fragmentary cross sectional view taken along the lines 5--5 shown in FIG. 3; 
     FIG. 6 is a view similar to FIG. 5 of the valve member and seal member in the free state outside of the valve housing bore; 
     FIG. 7 is a view similar to FIG. 3 showing the valve member rotated 180°; 
     FIG. 8 is a fragmentary, cross-sectional view taken along the lines 8--8 shown in FIG. 3; 
     FIG. 9 is a fragmentary, cross-sectional view taken along the lines 9--9 shown in FIG. 7; 
     FIG. 10 is a top plan view of the seal member; and 
     FIG. 11 is an end view of the seal member shown in FIG. 10. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in FIG. 1, a showerhead 10 and tub spout 12 are mounted to conduits 14 and 16 that are often mounted behind a tile wall or a plastic wall that forms a shower/tub enclosure. The conduits 14 and 16 are mounted to outlets 18 and 20 of a diverter housing 22. The housing 22 has hot and cold water supply conduits 24 and 26 mounted at its two inlets 23 and 25. Supply conduits 24 and 26 lead to hot and cold water valve members (not shown). A diverter valve handle 28 is mounted at the front of housing 22. 
     Referring now to FIG. 2, the housing 22 is made from machined brass, commonly referred to as bar stock, that has outlets 18 and 20 drilled therein and threaded. Outlets 18 and 20 each have a shoulder 30 and 32 that prevents the pipe from being overly threaded into the housing 22. A central stepped bore 34 in the housing 22 extends to the front thereof circumscribed by side wall 35. The bore section axially coexistent with outlets 18 and 20 is reamed to a fine finish. An exterior threaded section 36 is sized to threadably receive a nut 38. The nut 38 secures a handle stop member 40 which has a central aperture 42 and seats two O-rings 44 and 45 which prevent leakage from the housing 22. The step member 40 abuts a washer 41. 
     A rotatable valve member 46 extends into the bore 34. Valve member 46 has a stem section 48 that has a central aperture 50 to receive a thread cutting screw (not shown) that mounts the valve handle 28. The stem section 48 has a flat 49 to form a D-shaped cross-section to non-rotatably engage valve handle 28 in a conventional fashion. Integral with the stem section 48 is a seating collar 54. Axially beyond the collar 54 is an integral tubular inlet section 52 that has two opposing inlets 56 leading to a central passage 60. A flexible baffle collar 62 circumscribes the downstream end of the tubular inlet section 52. The collar 62 is sized to form a close fit with wall 35 and central bore 34 as shown in FIG. 3. 
     The central passage 60 axially extends through an integral outlet section 64 that has a lateral outlet 66, open end 68 and a laterally extending slot 70. In addition, lugs 72, 74 are integrally formed on opposite axial sides of outlet 66. As shown in FIG. 9, lug 72 has a slot 72b to section the lug into two parts 72a and 72c to provide for more flexibility as discussed below. Lug 74 has two leg sections 78 which are used to guide the rotatable member 46 into the bore 34 and to prevent the member 46 from cocking so that lug 74 does not intrude into any of the outlets 18 and 20. 
     As more clearly shown in FIG. 5, the outlet section 64 has an elongated cross-section resembling an ellipse or oval. For manufacturing ease, the outlet section can be manufactured with two radius sections 84 and 86 having an outer radius that is smaller than the outer radius of two side radial sections 88 and 90. 
     The two larger radial sections 88 and 90 have axially and radially outwardly extending flanges 92 which form grooves 94. Two keys 80 and 82 are radially disposed opposite lugs 72 and 74. The keys 80 and 82 and grooves 94 seat a sealing pad 96. The sealing pad 96 is made from an elastomeric material such as Sanoprene and has an inner contour that is approximately semi-elliptical or semi-oval and can be manufactured from three integrally formed arced sections with the side arced sections 98 having an internal radius and a central section 100 having an internally smaller radius. The internally smaller radius is slightly larger than the outer radius of radial section 86. The differing radius of the internal surface of the sealing pad 96 and the outer radius of section 86 of the tubular outlet section 64 provides for a gap 102 when the pad 96 is seated in the free state as shown in FIG. 6. The bore 34 at the outlets 18 and 20 is dimensioned to provide an interference fit with the sealing member 96 and the tubular outlet section 64 with its lugs 72 and 74 such that the elastomeric pad section 100 flexes into a substantially semi-circular shape against the bore side wall 35 and closes the gaps 102 as shown in FIG. 5. In addition, there is some flexing of the tubular section 64 to provide for spring bias of the elastomeric pad 96 against the bore 34 at either of the outlets 18 and 20. Elastomeric pad 96 has its edges 104 sized to fit within grooves 94 and also has notches 106 sized to receive the keys 80 and 82 to prevent axial movement of the sealing pad 96 along the tubular outlet section 64. Flanges 92 prevent rotational or angular relative movement of the sealing pad 96 with respect to the tubular outlet section 64. 
     As shown in FIG. 3, when the sealing pad 96 is sealing outlet 18 of the housing, outlet 66 of outlet section 64 is aligned above the outlet 20 in the housing. Inlets 23 and 25 in housing 22 are axially spaced between the inlets 56 of the rotatable valve member and the flexible flange 62. Also, the tubular inlet section 52 has an outer radius sized to provide an annular chamber 53 therebetween. When water from either one or both of conduits 24 and 26 enter into inlets 23 and 25 of the housing, water flowing through the annular chamber and through the inlets 56 passes downstream through the central passage 60 of member 46 beyond the collar 62 and flows through outlets 66 and 20. 
     Handle 28 mounted on stem section 48 can be rotated such that member 46 is rotated to the position shown in FIG. 7 when a shower is desired. 
     Slot 72b in lug 72 and extending slot 70 positioned downstream of the flexible annular collar 62 provides for resiliency of the tubular outlet section 64 such that it can flex as shown in FIG. 5 when inserted into the bores 34 of housing 22. The flexing of the outlet section 64 and the elastomeric sealing pad 96 assure adequate sealing of either the outlet 20 or 18. 
     The curvature of the side section 98 provides that substantially other side sections 98 are spaced from the bore wall. The spacing of sections 98, resilient flexing of outlet section 64, and the elastomeric flexure of pad 96 also assure that the torque required to turn the valve member 46 is not undesirably high. 
     It should also be noted that in addition to the inlets 23 and 25 being axially displaced from inlets 56 as shown in FIGS. 3 and 7, they are radially positioned 90° with respect to each other such that the water is baffled within the annular chamber 53 before it flows into the inlets 56. The baffling of the water assures that the housing 22 and diverter valve assembly does not provide for undesirable noise which is common in many other diverter valve designs. Furthermore, the tubular outlet section 64 does not take a permanent compression but retains its resiliency to provide for a long durable diverter valve. 
     Variations and modifications of the present invention are possible without departing from the scope and spirit as defined in the appended claims.