Abstract:
A control disk for a fluid valve has a disk body having at least one through hole, the body having an upper surface for contacting another control element of the valve and an opposed lower surface. The upper surface is formed with a raised undulating contact surface. The raised undulating contact surface defines pockets suitable for receiving a lubricant.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    Not applicable. 
       STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0003]    The present invention relates to plumbing valves. More particularly it relates to raised surface structures on control disks which facilitate the operation of such valves. 
         [0004]    One form of plumbing valve operates to control flow there through by rotation of a valve control handle. The handle drives a movable element over a stationary apertured disk. When the aperture aligns with a designated aperture or other path through or by the movable element, flow is permitted. This type of valve is often referred to as being of the non-rising type, as there is typically no axial movement of the moveable element. 
         [0005]    It is desirable in connection with plumbing valves to permit numerous operations, over numerous years, in a reliable fashion. This is made difficult to achieved because of the tendency of some contact parts in non-rise valves to wear, and the tendency of some parts to bind in the presence of grit or other contaminants in the water. 
         [0006]    Generally favorable wear and operation characteristics are provided by ceramic disks. Such disks are often used in volume control valves where a single type of water is controlled. They are also used in mixing valves where volume and the mix of hot and cold water are controlled by a single valve. Further, they are found in water distribution valves where one or more inputs are directed between multiple outlets (e.g. a bath spout versus a shower). See e.g. U.S. Pat. Nos. 4,651,770, 5,398,717 and 5,823,510. 
         [0007]    However, when the facing surfaces of the stationary and movable ceramic disks are in complete contact across the disks (except for the apertured areas). This results in the need for greater force to rotate the valve. Further, such forces can increase premature wear. 
         [0008]    There have therefore been some efforts to reduce the area of the ceramic disks that are in contact with each other. For example,  FIG. 1  depicts a prior art stationary ceramic disk  10  which has wheel, hub and spoke-shaped raised contact areas that are quite small relative to the overall top view area of that disk. While such a design reduces the frictional resistance between the two disks, all the contact force is focused along those limited contact areas. Over time this can still lead to premature wear. 
         [0009]    Hence, a need exists for further improved disk structures for use with valves of this type. 
       SUMMARY OF THE INVENTION 
       [0010]    In one aspect the present invention provides a control disk for a fluid valve. It has a disk body having at least one through bore, the body having an upper surface for contacting another control element of the valve and an opposed lower surface. The upper surface is formed with a raised undulating contact surface. 
         [0011]    In preferred forms the undulating surface extends adjacent a radial periphery of the disk around 360 degrees. The raised undulating surface defines pockets suitable for receiving a lubricant adjacent the undulating surface. 
         [0012]    There may be a first raised undulating ring adjacent a central portion of the upper surface and a second raised undulating ring adjacent a radial periphery of the disk. The first and second raised undulating rings may be interconnected by at least one linear spoke. 
         [0013]    In other preferred forms the control disk has at least one radial projection extending outward of a generally circular circumference to facilitate alignment in a control valve, the control disk is for use as a stationary control disk adjacent a rotatable valve member, and the raised undulating surface has a periodic contour. The disk may have one, two, three or more through apertures. 
         [0014]    In other aspects of the invention the disk is mounted in a plumbing control valve selected from the group consisting of volume control valves, mixing valves, and water distribution valves, preferably as part of a valve cartridge. The cartridge could have an outer housing, a rotatable spindle, a rotatable disk is within the housing and connected to the rotatable spindle, and a fixed disk in the housing. 
         [0015]    Advantages of the present invention in various embodiments include that friction is reduced between the two ceramic disks, while also minimizing the number of debris particles which get trapped between the ceramics causing an undesirable increase in operation torque. In this regard the contacted surface of the rotating member oscillates during rotation. 
         [0016]    Another advantage of the present invention is that the undulating raised surface provides an efficacious location for placing lubricant, which also promotes low operating torque. 
         [0017]    Yet another advantage of the present invention is that these disks can be used to replace existing stationary ceramic disks without further modification of some valves. 
         [0018]    These and still other advantages of the present invention will be apparent from the detailed description which follows and the accompanying drawings. Hence, the following claims should be looked to in judging the full scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is a top plan view of a prior art stationary ceramic disk; 
           [0020]      FIG. 2  is a perspective view of a water distributor valve using such a disk installed adjacent a bathroom area; 
           [0021]      FIG. 3  is a perspective view of the water distributor valve of  FIG. 2 , albeit rotated from the  FIG. 1  position; 
           [0022]      FIG. 4  is an exploded perspective view of the water distributor valve of  FIG. 3 ; 
           [0023]      FIG. 5  is a cross-sectional view taken along section line  5 - 5  of  FIG. 3 ; 
           [0024]      FIG. 6  is a top view similar to  FIG. 1 , but of a stationary ceramic disk of the present invention; 
           [0025]      FIG. 7  is a bottom perspective view of the ceramic disk of  FIG. 6 ; 
           [0026]      FIG. 8A  is a cross-sectional detail of region  8 A- 8 A of  FIG. 5 ; 
           [0027]      FIG. 8B  is a view similar to  FIG. 8A , but shown with lubricant differently positioned on a slightly different disk structure; 
           [0028]      FIG. 9  is a view similar to  FIG. 6  but of a second preferred stationary disk; 
           [0029]      FIG. 10  is a perspective view of a mixing valve using such a disk installed adjacent a bathroom area; 
           [0030]      FIG. 11  is an exploded perspective view of the mixing valve of  FIG. 10 ; and 
           [0031]      FIG. 12  is a view similar to  FIG. 9 , showing a preferred stationary disk for use with the  FIG. 10  embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0032]      FIG. 1  discloses a prior art stationary disk having an outer raised area  10  in the form of a wheel, and raised support spokes  12  leading to a raised hub area  14 . 
         [0033]    Turning now to embodiments of the present invention,  FIG. 2  shows a water distributor  20  used adjacent a bathtub  22 . While the fixture shown is a bathtub, it should be appreciated that the invention can be used with any plumbing fixture (e.g. shower; sink; lavatory). Spout  24  leads to an outlet  26  to deliver water from the distributor  20  to the bathtub  22 . 
         [0034]    Cartridge valve  30  is positioned in the water distributor. Cartridge valve  30  can divert an inlet fluid supply  34  (hot or cold water, or mixed) to one of three or a combination thereof, outlets  36 ,  38 ,  40 . We show outlet  36  leading to the bathtub  22 , outlet  38  leading to a shower head supply line, and outlet  40  leading to a personal shower supply line. 
         [0035]    Referring next to  FIGS. 3-5 , cartridge valve  30  includes an outer housing  42  configured for fluid communication with a supply of at least one of hot fluid and cold fluid, particularly at inlet fluid supply  34 . A rotatable spindle  46  is connected to housing  42 . A handle  83  can be mounted on the spindle  46 . 
         [0036]    Collar  48  is fixed axially to spindle  46  using split washers  50 . Legs  52  positively click into corresponding recesses (not shown) in upper cartridge housing  54  when inlet  34  is routed to one and only one outlets  36 ,  38 ,  40 . Otherwise legs  52  slide over a surface in upper cartridge housing  54  to continuously select varying combinations of two of the three outlets  36 ,  38 ,  40 . 
         [0037]    O-ring  56  provides a fluidic seal between upper cartridge housing  54  and housing  42 . Similarly, O-rings  58  provide a fluidic seal between upper cartridge housing  54  and spindle  46 . Further, spacer  60  maintains a correct orientation of spindle  46  axially. Nut  62  threadingly engages housing  42  to seat upper cartridge housing  54 , and other elements, within housing  42 . 
         [0038]    Fluid enters through inlet  34 , through apertures  64  in upper cartridge housing  54 , between bearing  66  and rotatable disk  68 , and through flow aperture  70  extending through rotatable disk  68  in an axial direction, to selectively discharge through one of, or a combination of two, outlets  36 ,  38 ,  40  depending on where the aperture  70  is relative to the stationary disk. A toe at the bottom of spindle  46  fits into a corresponding slot in the rotatable disk  68 , permitting the spindle to rotate the disk. 
         [0039]    Gasket  72  provides a fluidic seal between housing  42  and a fixed disk  74  within housing  42 . Fixed disk  74  has a first surface  76  oriented toward rotatable disk  68 , and a second surface  78  opposite first surface  76 . At least one flow aperture  79 , and in the embodiment shown three flow apertures  79 , fluidically corresponding to outlets  36 ,  38 ,  40 , extend through first surface  76  and second surface  78 , allow the fluid to be conducted from flow aperture  70  in rotatable disk  68  to one, or a combination of two, outlets  36 ,  38 ,  40 . 
         [0040]    Raised surfaces ( 80 ,  82 ,  84 ) are formed along the first surface  76 . Rotatable disk  68  contacts only those raised portions. This minimizes the contact area between fixed disk  74  and rotatable disk  68 . Note that many consumers (e.g. those with arthritis) are unable or don&#39;t want to use significant force to turn a plumbing valve on and off. This reduces the needed force. 
         [0041]    Moreover, as the disks rotate relative to one another the portion of the rotating disk that is contacted oscillates radially inward and outward, and thus any one given groove along the disk is not continuously contacted. This reduces wear and maintenance concerns. 
         [0042]    An additional improvement is best understood from  FIG. 6  and  FIGS. 8A and 8B . The raised undulating surfaces create pockets  86 . A lubricant (e.g. grease)  88  can be positioned in these pockets at the factory, or by a maintenance worker. Then, as the valve is used, this lubrication can slowly bleed to the joint between the disks, further reducing friction and wear. 
         [0043]    The raised undulating surfaces can be of varied shapes. For example there can be a first raised undulating surface  80  near the radial periphery of fixed disk  74 . This can circumscribe the perimeter of disk  74  for stability. The pattern of undulation can be uniform around the circumference, albeit this is not required. 
         [0044]    There can also be second raised undulating hub-like surface  82  located around center  92 . A plurality of linear raised spoke surfaces  84  can also be provided. Each of the flow apertures  79  can thus be bounded by undulating portions and a connecting linear portion. 
         [0045]    As shown in  FIGS. 8A and 8B , the lubricant  88  can be on either e inward facing pockets  86  or outward facing pockets (on the other side of the undulating surface). 
         [0046]      FIG. 9  embodiment shows a stationary ceramic disk  94  with a modified central undulating surface  96 . 
         [0047]    In the embodiments of  FIGS. 10-12  the valve  100  is a mixing valve. It feeds a basin  102  via a faucet  104  having a spout  106  configured for a fluid discharge  108 . A non-rising cartridge valve  110  is in fluid communication with spout  106 . Plumbing fixture  100  can be a bathtub, a vanity, and/or shower. 
         [0048]    In the specific embodiment shown in  FIGS. 10-12 , valve  110  is shown as a mixing valve which can mix a hot fluid inlet  112  and a cold fluid inlet  114  and discharge to outlet  116 . Non-rising cartridge valve  110  includes a housing  118  configured for fluid communication with a supply of at least one of hot fluid and cold fluid, particularly at inlets  112  and  114 , and housing  118  includes an axial direction  120 . 
         [0049]    A rotatable spindle  122  is connected to housing  118  and extends in axial direction  120 . Stop valves  124  are positioned at each inlet which allow for separate shut off/turn on of the hot and cold fluids during installation and/or in the event that valve  110  needs to be serviced. The inlet fluids flow into housing  118 , through corresponding stop valves  124 , and into pressure balance unit  126 . Pressure balance unit  126  regulates the pressure of the two fluid inlets, so that in the event of someone flushing a toilet or turning on another water valve within the plumbing system, there will not be a corresponding change in outlet  116  temperature. 
         [0050]    The fluid exits pressure balance unit  126  through outlets  128 ,  130  and flows through gasket  132 . A rotatable disk  136  is within housing  118  and is connected to rotatable spindle  122 . Rotatable disk  136  includes at least one first flow aperture  138 , and in the embodiment shown two flow apertures  138 , extending through rotatable disk in axial direction  120 . 
         [0051]    A fixed disk  140  is within housing  118 , and fixed disk  140  has a first surface  142  oriented toward rotatable disk  136 , and a second surface  144  opposite first surface  142  in axial direction  120 . At least one second flow aperture  146  extends through first surface  142  and second surface  144 . Undulating surfaces  148 ,  150 ,  152  extend from first surface  142 , and rotatable disk contacts the raised undulating surfaces  148 ,  150 ,  152 . Raised undulating surfaces  148 ,  150 ,  152  include at least one concave contour  154 , and a lubricating grease  88  can be in contact with at least some of the concave contours  154 . 
         [0052]    The undulating surfaces  148 ,  150 ,  152  include a first raised undulating surface  148  approximately at a perimeter of fixed disk  144  that circumscribe the perimeter. The first raised undulating  148  surface can have a periodic contour, as shown. 
         [0053]    After the fluids exit pressure balance unit  126  through outlets  128 ,  130  and flow through gasket  132 , they are present at second flow apertures  146  to be selectively mixed via first flow apertures  138  in rotatable disk  136 , as handle  156  rotatably actuates spindle  134  and disk  136 . Similarly, the raised undulating surface of the present invention can be incorporated into other valves such as a thermostatic valve, or any other rotational movement ceramic valve. 
         [0054]    While this invention has been described as having preferred designs, the present invention can be further modified within the spirit and scope of this disclosure. For example, undulations need not be curved, may only be undulating along contact surfaces rather than axially, and they can be in zig-zag form. 
         [0055]    Also, while the preferred disk is separate from the cartridge base, the term disk is also intended to cover structures where it is integral therewith. Hence, this patent is therefore intended to be broader than just the preferred embodiments. 
       INDUSTRIAL APPLICABILITY 
       [0056]    The present invention provides disks with raised undulating surfaces for use in plumbing valve.