Abstract:
A water inlet system for a washing machine including a main body, at least one insert and a valve assembly. The main body is made of a first material. The at least one insert is spin welded to the main body. The at least one insert is made of a material substantially the same as the first material. The valve assembly is mechanically coupled and sealed with the insert. The valve assembly has a valve body made of a second material, with the first material and the second material being different.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a non-provisional application based upon U.S. provisional patent application Ser. No. 61/671,211, entitled “MIXING CHAMBER CONNECTING SYSTEM IN A WASHING MACHINE”, filed Jul. 13, 2012, which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to fluidic connecting systems, and, more particularly, to connector devices and methods for fluid conveying systems in a washing machine. 
     2. Description of the Related Art 
     Water inlet devices are used to provide a mixing chamber and a vacuum break in the inlet water supply that disperses water from an inlet supply hose into the tub of a washing machine. The water is directed to a load of clothes, which are located in the bottom of the tub or along the sidewall of the tub. 
     The typical automatic clothes washer or dishwasher for home use is equipped to carry on a series of operations in sequence. The series of operation is most commonly referred to as a cycle. A typical cycle includes fill and rinse elements, each of which utilize a water inlet device, such as a mixing chamber and vacuum break, to supply water to the washer. A washing machine includes a housing in which the mechanical operating devices are mounted. It is typical to include a motor assembly for causing motion within the washing device and water control valves for turning on the hot and cold water as necessary under the control of a controller. The water control valves may be associated with the mixing chamber and water vacuum break 
     The desirability of a vacuum break prevents water from re-entering the water supply source, thereby preventing the contamination of the water source. The mixing chamber allows the hot and cold water to be mixed prior to being discharged into the associated machine. 
     What is needed in the art is a simple cost effective way of connecting water control valves to a mixing chamber associated with a vacuum break. 
     SUMMARY OF THE INVENTION 
     The present invention provides an efficient connection system and method for the connection of water flow control valves to a mixing chamber for use with a washing machine. 
     The present invention in one form is directed to a water inlet system for a washing machine including a main body, at least one insert and a valve assembly. The main body is made of a first material. The at least one insert is spin welded to the main body. The at least one insert is made of a material substantially the same as the first material. The valve assembly is mechanically coupled and sealed with the insert. The valve assembly has a valve body made of a second material, with the first material and the second material being different. 
     The present invention in another form is directed to an insert system for use with a water inlet system of a washing machine. The water inlet system has a main body made of a first material and a valve assembly made of a second material. The insert system includes at least one insert spin welded to the main body. The at least one insert is made of a material substantially the same as the first material. The valve assembly is mechanically couplable and sealable to the insert, with the first material and the second material being different. 
     An advantage of the present invention is that it allows a valve with locking features to be mated to an insert of a different material, while the insert is cost effectively spun welded to a mixing chamber body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is an exploded perspective view of an embodiment of a water inlet system of the present invention; 
         FIG. 2  is a perspective view of an embodiment of an insert used in the water inlet system of  FIG. 1 ; 
         FIG. 3  is a partially sectioned view of the insert of  FIG. 2 ; 
         FIG. 4  is a perspective view of one embodiment of a valve assembly used with the water inlet system of  FIGS. 1-3 ; 
         FIG. 5  is a partially sectioned side view of the water inlet system of  FIGS. 1-4 ; and 
         FIG. 6  is a perspective view of another valve assembly assembled with another embodiment of the insert of the water inlet system of  FIG. 1 . 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, and more particularly, to  FIG. 1 , there is shown a water inlet system  10 , which includes a mixing chamber  12  and a vacuum break  14  connected to mixing chamber  12 , for use in a washing machine (not shown). Valves  16  and  18  are fluidically connected to mixing chamber  12  by way of inserts  20  and  22 . Mixing chamber  12  is made of a material such as polypropylene (although it could be of other materials, such as polycarbonate) and the body of valves  16  and  18  are made of another material such as nylon. Since the body of valves  16 ,  18  are made of a material different than the material of mixing chamber  12  then valves  16  and  18  cannot be spun welded to mixing chamber  12 . To overcome this problem inserts  20  and  22  are made from the same material (or substantially the same material) as mixing chamber  12  so that inserts  20  and  22  can be spin welded to mixing chamber  12 . For example, the inserts  20 ,  22  are made of polypropylene; however, the inserts  20 ,  22  can be made of a thermoplastic polymer that is substantially similar to polypropylene so as to create a viable spin welded seal. 
     The latching details of inserts  20  and  22  can alternately be molded into mixing chamber  12 . For example, the locking features of inserts  20  and  22  can be part of the mold that forms mixing chamber  12 , thereby eliminating inserts  20  and  22 . An advantage of spin welding inserts  20  and  22  to mixing chamber  12  is that it reduces the complexity of the molding of mixing chamber  12 . The faces of inserts  20  and  22  are oriented in opposite directions as shown in the drawings, although other orientations are contemplated. 
     Now, additionally referring to  FIGS. 2 and 3 , details of inserts  20  and  22  are illustrated. Inserts  20  and  22  may be identical, although it is also contemplated that they may be differently configured, to for example, preclude an inadvertent assembly of an incorrect part. Insert  20 ,  22  includes a substantially cylindrical contact surface  24 , a spin weld interface  28  and a locking attribute  30 . Surface  24  is brought into contact with and interior surface of mixing chamber  12 , also known as main body  12  as inserts  20  and  22  are spun to cause the melting of the contacting materials together. The materials being either the same or substantially the same. It is contemplated that surface  24  may have a slight taper and that the corresponding receiving opening in main body  12  would have a corresponding taper. Spin weld interface  28  are two indents that allow a spinning apparatus (not shown) to spin insert  20 ,  22  and apply pressure to mixing chamber  12  causing the material of mixing chamber  12  and insert  20 ,  22  to melt from the friction of the pressure and spinning motion. After a predetermined amount of pressure and spinning at a predetermined speed, insert  20 ,  22  is stopped in a preferred rotational position relative to mixing chamber  12  and the heat from the process dissipates and the contacting material of insert  20 ,  22  and mixing chamber  12  are fused to form a waterproof connection. 
     As can be seen in  FIG. 3  insert  20 ,  22  has a locking attribute  30 . Locking attribute  30  interacts with a locking protrusion or tab  36  ( FIG. 4 ) of valves  16 ,  18 . Locking attribute  30  may be a resilient finger that is only attached to insert  20 ,  22  along the left portion of locking attribute  30  as seen in  FIG. 3 . Alternatively, locking attribute  30  can be attached along the walls to form an inclined ramp of a higher resiliency. There is a cavity below locking attribute  30  to allow for movement and/or deformation of locking attribute  30  as tab  36  moves along the surface thereof. Tab  36  initially moves in a longitudinal direction  32 , then is rotated in direction  34 . As tab  36  passes the end of locking attribute  30 , locking attribute  30  springs up to preclude the removal of valve  16 ,  18  therefrom. Although inserts  20  and  22  can be identical, it is also contemplated that inserts  20  and  22  may be minor images of each other and that the interfacing portions of valves  16  and  18  may likewise be minor images to thereby ensure that the proper valve is connected to the proper insert. Other keying regimes are also contemplated. 
     Valve assemblies  16  and  18  are respectively positioned so as to move in a longitudinal direction  26  relative to inserts  20 ,  22  and valves  16  and  18  are respectively secured to inserts  20  and  22 . Now, additionally referring to  FIG. 4  details can be seen as to how valve assemblies  16  and  18  lock to inserts  20  and  22  and thereby to mixing chamber  12 . Valve assemblies  16  and  18  each have locking tabs  36  and seals  38 . A male portion of valve assembly  16 ,  18  with seal  38  thereabout enter into a corresponding opening in insert  20 ,  22 . As valve assembly  16 ,  18  is inserted into insert  20 ,  22  locking tab  36  moves in direction  32 , then is moved in direction  34  until locking tab  36  is positioned in locking attribute  30  thereby precluding the removal of valve assembly  16 ,  18  from insert  20 ,  22 . Locking attribute  30  is positioned and shaped to interact with a back edge of locking tab  36  to preclude removal. A forward edge of locking tab  36  is beveled to allow a rotational movement of valve assembly  16 ,  18 , the shape may also cause the material around locking tab  36  to flex as it is rotated into position in direction  34 . The angular amount of rotation may be approximately 45° . While locking attribute  30  and locking tab  36  serve to preclude removal, it is also contemplated that these elements can also be arranged so that valve assembly  16 ,  18  can be removed from mixing chamber  12 . 
     Now, additionally referring to  FIG. 5 , a partially sectioned view is shown as to how valve assembly  16 ,  18  is connected to insert  20 ,  22  allowing the fluidic connection between valve assembly  16 ,  18  with mixing chamber  12 . Seal  38  may have elements, such as annular features that correspond to reciprocal features to thereby ensure a leak-proof connection. 
     Now, additionally referring to  FIG. 6 , there is illustrated another embodiment of a valve assembly, here denoted as  116 ,  118 , having a snap feature  136 . Inserts  120 ,  122  are connected to main body  112 , and inserts  120 ,  122  have locking features  130  oriented relative to mixing chamber  112 . In this embodiment valve assembly  116 ,  118  is pressed into mixing chamber  112  in a longitudinal direction  126 , and snap features  136  are aligned with locking features  130  to ensure the proper positioning and securing of the two together. 
     While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.