Abstract:
A thermostatic valve incorporated within a plumbing system for regulating the flow of fluid. The thermostatic valve includes two valve assemblies operatively cooperating to preclude the flow of scalding water. The first valve assembly and second valve assembly respond to different fluid temperatures, as well as, over separate periods of time. The thermostatic valve can be incorporated in an “end-line” device such as a showerhead or faucet assemblies to create an “anti-scaled” plumbing fixture. The invention includes a valve housing having a first compartment and a second compartment, a fluid passageway, a first valve assembly, a second valve assembly, a first spring, a first stopper, a first flange, a first-thermostatic cylinder, a second spring, a second stopper, a second flange, a second thermostatic cylinder, and a third spring.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The present invention generally relates to a thermostatic fluid controller, and more particularly, to a thermostatic fluid controller for showerhead assemblies and faucet assemblies featuring two thermostatic cylinders for precluding water between different pre-determined temperatures for an increased closing time over a broader range of temperatures.  
         [0002]     Recent legislation requiring products to prevent accidents involving scalding water indicates an increased interest in devices that can control water, namely hot water. Scald-burn injuries can range from minor to life-threatening and can even cause death in certain cases. These injuries are frequently caused by water temperature fluctuation in the plumbing system. Occurrences such as toilets being flushed are common causes of water temperature fluctuations. As an example, when a toilet is flushed while a shower or faucet with a proper hot-to-cold water ratio is running, cold water is used to refill the tank of the toilet and, consequently, the water pressure, from the cold water pipes, decreases. The result is that less cold water is available for the hot/cold mix flowing to the shower, bathtub, or faucet, thereby causing the water mix to increase in temperature. In many instances, the temperature for hot water can be too hot in buildings that share a common boiler or water heater, i.e. apartment buildings, hospitals, or nursing homes. Frequently water temperatures in these residential and commercial water supplies can exceed 130° F., temperatures at which an adult can easily be scalded or burned. Children are especially vulnerable to being scalded from overly-hot bath or shower mix because they have thinner skin than adults. A child can sustain a third degree burn from exposure to 140 F water for a mere three seconds.  
         [0003]     The water temperature in buildings that share a common boiler or water heater is often kept higher than recommended so that a sufficient source of hot water is available to a great number of users at a given time. This means that a way to regulate the temperature at the “end-line” location in buildings with a large common boiler is critical.  
         [0004]     The serious consequences of over-hot water temperatures has caused a majority of states to enact legislation requiring new construction to incorporate anti-scald devices that feature a means of controlling maximum water temperatures delivered to the faucet and showerhead assemblies. These regulations, however, only apply to new construction and do not mandate the use of anti-scald fixtures in older buildings. Since the legislation applies only to new construction, many of the anti-scald devices currently known in the field relate to devices incorporated “in-line” or behind the walls adjacent to the showers, bathtubs or sinks, or are otherwise difficult to access and require the skill of a professional plumber.  
         [0005]     Such “in-line” devices are incorporated within the lines of the home or business plumbing systems. These devices are normally installed prior to the interior finishing and “dry-walling.” These devices often have a reset capability for normal use. However, when the device is damaged, defective, or is unable to be reset, it is very difficult to repair or replace the device without a trained plumber. Furthermore, the devices are incorporated behind the walls, so it is necessary to tear out portions of the wall to replace or repair the device. Such destruction can be very costly. Furthermore, a device that electronically controls the temperature of water often has a sensor component, which is mounted behind the wall of the shower. In situations of an electrical malfunction or short circuit, the electronic device is only accessible by a plumber. Such systems can lead to high repair costs.  
         [0006]     An “in-line” device is incorporated for use with existing faucet assemblies or showerhead assemblies, and is described in U.S. Pat. No. 5,584,432 (“&#39;432 patent”). The &#39;432 patent teaches a structure for blocking the flow of water using a shape memory alloy spring. The shape memory alloy spring stiffens at a specific temperature against a valve to preclude the flow of water from exiting the valve. The shape memory alloy spring softens at a second pre-determined temperature to enable the flow of water to exit the valve.  
         [0007]     The previously described regulating devices in the prior art are for “in-line” locations rather than “point-of-use” locations. The Safe Drinking Water Act amendments of 1996, 104 P.L. 182 (1996), distinguishes between point-of-entry and point-of-use devices in § 105. Point-of-entry devices are located at a plumbing systems “in-line” location, or in other words, located within the plumbing supply pipes. Point-of-use devices are located at the systems “end-line” location, or in other words, the apparatus the consumer uses.  
         [0008]     The present invention is an “end-line” device integrated into a unique faucet assembly or shower head assembly. The present invention offers an “end-line” anti-scald device providing relatively inexpensive scald prevention in both new and existing homes and/or commercial buildings. The invention&#39;s location in the water supply system, integrated into an “end-user” device offers inexpensive and efficient scald prevention. This “end-line” location offers a device that blocks the flow of excessively hot water and is located in a showerhead assembly or a faucet assembly. Previous devices are incorporated directly into the plumbing system behind the walls of a building. The present invention enables the user to incorporate an anti-scald system into pre-existing plumbing systems and can be easily replaced by the user. Replacement occurs by replacement of the unit at the end of the water line.  
         [0009]     The previous devices utilize a single thermostatic cylinder having a specific “ramp-up” time period. These devices do not account for instances where the change in fluid temperature instantly increases because the slow reaction time of the single thermostatic cylinder. Therefore, there is a need for thermostatic fluid controllers that regulate fluid flow when fluid temperature changes at a moderate rate and when fluid temperature changes at a high rate. The present invention solves this problem by incorporating a primary and secondary thermostatic cylinder system designed to operate at separate temperatures as well as over different temperature ranges.  
       SUMMARY OF THE INVENTION  
       [0010]     The present invention is directed to a thermostatic valve suitable for blocking the flow of water between predetermined temperatures that may be used in a plumbing system comprising, a valve housing having a first compartment and a second compartment, where the first compartment includes a first inlet end and a first outlet end, and the second compartment includes a second inlet end and a second outlet end; a fluid passageway which communicates between the first compartment and the second compartment; a first valve assembly which is housed within the first compartment and a second valve assembly which is housed within the second compartment, such that the first valve assembly responds to fluid temperature changes and the second valve assembly responds to fluid temperature changes, such that the first valve assembly and the second valve assembly operatively cooperate to preclude the flow of scalding fluid; the first valve assembly includes: a first spring associated with the valve housing which is proximate to the outlet aperture end; a first stopper which is biased by the first spring, such that a first face of the first stopper forms a first gap with the first outlet end; a first flange abuts a first shoulder in the first compartment, such that the first flange permits the flow of water between the first inlet end and the first outlet end; a first thermostatic cylinder having a first cylinder body, a first piston housing, and a first piston where the first cylinder body abuts the first flange, such that the first piston axially extends through the first piston housing from the first cylinder body, and the first cylinder body includes a first temperature sensitive wax, where the first temperature sensitive wax and the first piston axially cooperate to produce axial movement of the first stopper to substantially block the first outlet end; also, a second spring which biases the first cylinder body against said first flange; the second valve assembly includes: a second stopper which is biased by the second spring, such that the second stopper includes a second face forming a second gap with the second outlet end; a second flange which abuts a second shoulder in the second compartment, such that the second flange permits the flow of fluid between the second inlet and the second outlet end; a second thermostatic cylinder having a second cylinder body, a second piston housing, and a second piston, such that the second cylinder body abuts the second flange, where the second piston axially extends through the piston housing from the second cylinder body, the second cylinder body includes, a second temperature sensitive wax, such that the second temperature sensitive wax and the second piston axially cooperate to produce axial movement of the second stopper to substantially block the second outlet end; also, a third spring which biases the second cylinder body against the second flange, such that the third spring associates with the second compartment at the second inlet end.  
         [0011]     A method of supplying temperature regulated fluid, comprising the steps of flowing hot fluid from a second compartment having temperature regulated by a second valve assembly to a first compartment having temperature regulated by a first valve assembly, such that said second compartment and the first compartment communicate to form a fluid passageway; blocking hot fluid in the first compartment by the first valve assembly when the fluid temperature rises above a third predetermined temperature, where the first valve assembly includes a first thermostatic cylinder and a first stopper which axially associates with the first thermostatic cylinder to block hot fluid from flowing through the first compartment; releasing hot fluid from the first compartment by the first valve assembly when the fluid temperature drops below the third predetermined temperature, where the first thermostatic cylinder resets to its pre-response position to release the hot fluid; blocking hot fluid in the second compartment by the second valve assembly when the fluid temperature rises above a second predetermined temperature, where the second valve assembly includes a second thermostatic cylinder and a second stopper which axially associates with the second thermostatic cylinder to block hot fluid from flowing through the second compartment; releasing hot fluid from the second compartment by the second valve assembly when the fluid temperature drops below the second predetermined temperature, where the second thermostatic cylinder resets to its pre-response position to release hot fluid. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a cut-away cross section view of the thermostatic controller.  
         [0013]      FIG. 2  is a cut-away, partial close up view of the first valve assembly in the normally open position.  
         [0014]      FIG. 3  is a cut-away, partial close up view of the second valve assembly in the normally open position.  
         [0015]      FIG. 4  is a cut-away, partial close up view of the first valve assembly in the closed position.  
         [0016]      FIG. 5  is a cut-away, partial close up view of the second valve assembly in the closed position.  
         [0017]      FIG. 6  is a cut-away cross section view of the thermostatic controller where the first valve assembly and the second valve assembly are in the closed position, respectively.  
         [0018]      FIG. 7  is a cut-away cross section view of the thermostatic controller within a shower head, an alternate embodiment.  
         [0019]      FIG. 8  is a partially sectional pre-assembly exploded view of the thermostatic controller and the shower head thermostatic insert housing.  
         [0020]      FIG. 9  is a cut-away cross-sectional view of the thermostatic controller within a faucet, an alternate embodiment.  
         [0021]      FIG. 10  is a cut-away cross-sectional view taken along line  1 - 1  of  FIG. 9  of the first valve assembly and the second valve assembly detailed in a faucet assembly embodiment. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]     Referring to  FIG. 1 , the thermostatic valve  10  is situated within a valve housing  9 . The valve housing  9  includes a first compartment  11  and a second compartment  12 . A fluid passageway  3  communicates between first compartment  11  and second compartment  12  to allow fluid to flow from a second inlet end  19  to a first outlet end  1 . A first valve assembly  8  is housed within first compartment  11 . The first valve assembly  8  responds to a first predetermined temperature of fluid entering a first inlet end  2  of first compartment  11  to block first outlet end  1 . A second valve assembly  21  is housed within second compartment  12 . Additionally, the second valve assembly  21  responds to a second predetermined temperature of fluid entering second inlet end  19  to block second outlet end  20 .  
         [0023]      FIG. 2  shows an exploded view of first valve assembly  8 , which includes a first thermostatic cylinder  7 . The first thermostatic cylinder  7  includes a first cylinder body  55 , a first piston housing  56 , and a first piston  13 . The first cylinder body  55  is securely positioned against a first flange  15  by a second spring  17 . The first flange  15  abuts a first shoulder  57  as to keep first cylinder body  55  stationary against second spring  17 . A first temperature sensitive wax  43  is located in the first cylinder body  55 ; while, the first piston  13  axially extends from the first cylinder body  55  outward through first piston housing  56 . The first piston  13  axially associates between the first temperature sensitive wax  43  and a first stopper  4 . The first stopper  4  includes a first face  6 , while the first stopper  4  is biased by a first spring  14  to form a first gap  5  between first face  6  and first outlet end  1 . The first spring  14  is preferably compressed between the first outlet end  1  and first stopper  4 .  
         [0024]      FIG. 3  details the second valve assembly  21 , which includes a second thermostatic cylinder  53 . The second thermostatic cylinder  53  includes a second cylinder body  60 , a second piston housing  61 , and a second piston  54 . The second cylinder body  60  is securely positioned against a second flange  51  by a third spring  50  that is compressed against a spring catch insert  18  at second inlet end  19 . Second flange  51  abuts a second shoulder  58  as to keep second cylinder body  60  stationary against third spring  50 . A second temperature sensitive wax  44  is located in the second cylinder body  60 , while the second piston  54  axially extends outward from second cylinder body  60  through second piston housing  61 . The second piston  54  axially associates between the second temperature sensitive wax  44  and a second stopper  47 . The second stopper  47  includes a second face  49 , while the second stopper  47  is biased by second spring  17  to form a second gap  48  between second face  49  and a second outlet end  20  of the second compartment  12 .  
         [0025]      FIG. 4  shows the first valve assembly  8  blocking the flow of fluid from the first outlet end  1 . Preferably, the first spring  14  is a cylindrical coil spring of corrosion resistant steel with a spring rate which corresponds to a force exerted by the first temperature sensitive wax  43  when it expands to move first piston  13 . The first temperature sensitive wax  43  expands at a first predetermined temperature, such that first predetermined temperature sensitive wax  43  expands to axially associate with first piston  13 . Subsequently, at a third predetermined temperature, first piston  13  axially moves the first stopper  4  toward the first outlet end  1 . The first face  6  of first stopper  4  cooperates with the first outlet end  1  to substantially block fluid from flowing out the first outlet end  1 . Preferably, the first predetermined temperature is 113° F., where the first temperature sensitive wax  43  begins expanding. The expansion of the first temperature sensitive wax  43  results in a force upon first piston  13  at first predetermined temperature to axially engage with first stopper  4 . However, first spring  14  will prevent first stopper  4  from axially moving into contact with first outlet end  1 , thereby preventing any change in flow rate at first outlet end  1 . Preferably, when the third predetermined temperature of the first temperature sensitive wax  43  is 117° F., the first temperature sensitive wax  43  will significantly expand to axially move first stopper  4  to substantially engage first outlet end  1  and restrict flow of the fluid. In a preferred embodiment, the first valve assembly  8  substantially blocks the first outlet end  1  at a third predetermined temperature within a first time range of at least a minute. Preferably, the first valve assembly  8  will completely terminate the flow of fluid in passageway  3  at a fourth predetermined temperature of 120° F. in a second time range of 10 seconds. Alternatively, all predetermined temperatures in the can be adjusted to temperatures between 70° F. and 130° F. in order to preclude scalding.  
         [0026]      FIG. 5  shows the second valve assembly  21  blocking the flow of fluid from the second outlet end  20 . Preferably, the second spring  17  is a cylindrical coil spring of corrosion resistance steel with a spring force and spring rate selected to enable the second temperature sensitive wax  44  to overcome the second spring  17 . The second temperature sensitive wax  44  expands at a second predetermined temperature and axially moves the second piston  54 . Preferably, the second temperature sensitive wax  44  responds to a second predetermined temperature of 130° F. or greater to expand and axially move second piston  54  to engage second stopper  47 . Immediately, second piston  54  axially moves the second stopper  47  towards second outlet end  20 . Once the fluid temperature reaches 130° F., the second face  49  substantially engages the second outlet end  20  to block fluid from flowing out of second compartment  12 . Preferably, the second cylinder body  60  has a smaller volume than first cylinder body  55 , in order for the second temperature sensitive wax  44  to quickly expand upon temperatures of 130° F. or greater. Alternatively, the distance between second outlet end  20  and second piston  54  is relatively small to facilitate a quick engagement time between second stopper  47  and second outlet end  20 . Alternatively, the second temperature sensitive wax  44  can expand in response to temperatures between 100° F. and 200° F.  
         [0027]      FIG. 6  details the thermostatic valve  10  in the closed position, where both the first valve assembly  8  and the second valve assembly  21  are in the closed position. Between temperatures of 113° F. and 117° F., first valve assembly  8  initializes the axial movement of first stopper  4  to begin the closing process of first outlet end  1 . However, if temperatures were to rapidly heat to 130° F. or higher while the first valve assembly  8  was in the closing process, second valve assembly  21  would rapidly close the second outlet end  20  by second stopper  47  to prevent further fluid flow into the first compartment  11 .  
         [0028]     Alternatively, the first stopper  4  includes a plurality of weep holes  65  that allow the hot fluid to trickle out, as shown in  FIG. 6 . Consequently, cold fluid is able to cycle in after the first valve assembly  8  is in the closed position. Such cold fluid will cool the temperature of the fluid in the first compartment  12 , so that the first temperature sensitive wax  43  will cool and contract, thereby causing the first valve assembly  8  to open first outlet end  1 . Likewise, the second stopper  47  includes a plurality of weep holes  66  that allow hot fluid to trickle out. Consequently, cold fluid is able to cycle in after the second valve assembly  21  is in the closed position. Such cold fluid will cool the temperature of the fluid in the second compartment  12 , so that the second temperature sensitive wax  44  will cool and contract causing second valve assembly  21  to open second outlet end  20 .  
         [0029]      FIG. 7  and  FIG. 8  illustrates one preferred embodiment of the thermostatic valve  10  removably attached to a shower head  31 . In  FIG. 7 , the valve housing  9  includes a ball joint geometry end  22  that is rotatably mounted to a reciprocal ball joint geometry washer  26 . The reciprocal ball joint geometry washer  26  then removably is associated with retainer  27 , so that first outlet end  1  communicates with shower head second inlet end  34 . Fluid flow then departs through showerhead second outlet end  29  by a fluid spraying means  30 . Setting flow means  28  can also be associated with showerhead  31 .  
         [0030]      FIG. 8  illustrates the assembly of thermostatic valve  10  within a showerhead assembly  32 . First spring  14  is inserted into the valve housing  9  in order to attach to the first outlet end  1 . First stopper  4  is inserted such that first spring  14  surrounds first stopper  4  which causes first stopper  4  to abut against first outlet end  1 , as shown in  FIG. 7 . Next, first flange  15  is removably attached to the mid portion of valve housing  9  at a first shoulder  57 , as shown in  FIG. 2 . Also, the first flange  15  includes first flange apertures  16 , which permit fluid to flow from first inlet end  2  to first outlet end  1 . Then, first thermostatic cylinder  7  is inserted so that the first cylinder body  55  abuts first flange  15 ; and, second spring  17  is inserted so that second spring  17  surrounds the first cylinder body  55  and biases first thermostatic cylinder  7  against first flange  15 . Second stopper  47  is inserted to abut and secure second spring  17  against the second end of first thermostatic cylinder  7 . Next, second flange  51  is inserted against a second shoulder  58 , seen in  FIG. 3 , as to removably associate to second compartment  12 , also shown in  FIG. 3 . Also, second flange  51  includes second flange apertures  52  that permit fluid to flow from second inlet end  19  to second outlet end  20 . Second thermostatic cylinder  53  is inserted to abut second flange  51 . Third spring  50  is inserted so that third spring  50  surrounds the second cylinder body  60  and abuts to spring catch insert  18 . Finally, coupling sleeve  37  and insert cap  39  attach the thermostatic valve  10  to a water supply.  
         [0031]      FIG. 9  illustrates an embodiment where the thermostatic valve  10  in  FIG. 7  is housed within a faucet assembly  38 . A faucet housing  36  includes a faucet housing inlet aperture  41  that is removably associated with first outlet end  1 , so that fluid can flow between a fluid supply  24  and a faucet housing outlet aperture  33 . The assembly of thermostatic valve  10  remains the same as described in the showerhead assembly  32  and showerhead  31 .  
         [0032]      FIG. 10  illustrates a cross-sectional view taken along the line  1 - 1  and looking in the direction of the arrows. Valve housing  9  is situated so that first outlet end  1  operatively communicates with faucet housing inlet aperture  41 . The details of the first valve assembly  8  and second valve assembly  21  remain the same as described above.  
         [0033]     In operation, the first valve assembly  8  starts to react at a first predetermined temperature; however, the first spring  14  is coiled to deter axial movement of first stopper  4 , as shown in  FIG. 2 . The first thermostatic cylinder  7  is of the wax-filled or paraffin-filled type generally known in the art. The first thermostatic cylinder  7  is filled with a temperature sensitive wax  43  formulated to change from solid to liquid or from liquid to solid over a predetermined temperature range. As the temperature sensitive wax  43  changes state from solid to liquid, its volume increases. The increase in volume displaces the first piston  13  to extend outwards from the first piston housing  56 . Motion is transmitted from the first temperature sensitive wax  43  to first piston  13  in the first cylinder body  55 , as shown in  FIG. 4 . First piston  13  axially engages the first stopper  4 , while the first thermostatic cylinder  7  remains stationary biased against first flange  15 . Subsequently, first stopper  4  abuts first outlet end  1  to preclude the flow of fluid out of first outlet end  1 . In  FIG. 5 , the second thermostatic cylinder  53  responds to increases in temperature just as first thermostatic cylinder  7  described above.  
         [0034]     Once the temperature of the temperature sensitive wax  43  drops below the predetermined temperature range, the temperature sensitive wax  43  volume decreases to enable first spring  14  to axially bias first stopper  4  to form first gap  5 . Thus, first valve assembly  8  is reset to enable the flow of fluid out of first outlet end  1 . The second valve assembly  21  responds to temperature decreases just as first valve assembly  8  described above. The first temperature sensitive wax  43  may be formulated to produce a solid to liquid transition over a 4° change in temperature. The first temperature sensitive wax  43  may also allow selection of the transition temperature over a predetermined range of 113° F. to 120° F.  
         [0035]     The above has been provided for illustrative purposes only and is not intended to limit the scope of the invention of this application which is defined in the claims below. Accordingly, the description is provided for the purposes of teaching those skilled in the art the best mode for carrying out the invention