Patent Publication Number: US-2005127664-A1

Title: Integral barbed fitting

Description:
RELATED APPLICATIONS  
      The present application is a non-provisional application claiming priority from provisional application Ser. No. 60/524,544 filed Nov. 24, 2003 and entitled INTEGRAL BARBED FITTING. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates to pipe fittings, specifically to a barbed fitting for use in a faucet assembly.  
     BACKGROUND OF THE INVENTION  
      The use of plastic piping systems has grown in popularity in the areas of light commercial, residential, manufactured/modular housing, recreational vehicle and recreational marine industries. Plastic pipes and fittings are less expensive than their copper equivalents and can be installed more quickly without the need of professional plumbers. In addition, plastic offers superior resistance to corrosion and degradation under aggressive water conditions. The primary piping systems currently use rigid chlorinated polyvinyl chloride (CPVC) pipe and semi-flexible, cross-linked polyethylene (PEX) pipe.  
      Current faucet designs require that a connection fitting be installed on the end of a supply pipe or hose to produce a water tight, threaded seal to the faucet inlet shank. These connection fittings typically rely on an end loaded elastomeric material that can deteriorate over time resulting in supply line leaks. These connection fittings are also costly, increase installation time and require time to connect the fitting to the faucet. Additionally, many plumbing codes discourage the use of elastomeric seals for in-wall applications and frequently require the installation of an access panel if such fittings are used.  
      Therefore, there is a need in the art for secure, long lasting connection for water supply lines to a faucet.  
     SUMMARY OF THE INVENTION  
      The present invention provides a new and improved coupling for direct connection of supply tubing to a faucet assembly. In the illustrated embodiment, a barbed fitting is integrated with a valve body. The barbed fitting includes standard male barb geometry at one end and a bonded spin weld nipple at another end. In a preferred embodiment, the bonding is accomplished by spin welding the barbed fitting directly to the valve body. By spin welding the barbed fitting to the valve body, the barbed fitting becomes an integral part of the valve body and not a detachable component. This process reduces overall component and labor costs for installation and manufacturing of a faucet assembly. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a perspective side view of a faucet assembly incorporating an embodiment of the present invention;  
       FIG. 2  is bottom view of the faucet assembly according to  FIG. 1  taken along line  2 - 2 ;  
       FIG. 3  is a perspective view of a barb fitting according to the present invention and a supply end of a valve body;  
       FIG. 4  is a cross-sectional view of a valve body including a barbed fitting according to the present invention;  
       FIG. 5  is a cross-sectional view of a valve body according to  FIG. 4  taken along line  5 - 5 ; and,  
       FIG. 6  is a cross-sectional view of a valve body including a straight barbed fitting according to the present invention. 
    
    
     DETAILED DESCRIPTION  
      Turning now to the figures,  FIGS. 1 and 2  show a faucet assembly  10  incorporating the present invention. In the disclosed embodiment, the faucet assembly  10  includes valve bodies  12   a ,  12   b . Each valve body  12   a ,  12   b  has attached thereto a supply line  15  for supply both hot and cold water to the faucet assembly  10 . Valve body  12   a  and  12   b  are in communication with each other via cross-pipe  16 . Cross-pipe  16  includes two outlet connectors  18 ,  19 . Outlet connector  18  supplies water to an overhead shower and outlet connector  19  supplies water to the tub spout  14 . Valve bodies  12   a  and  12   b  are structurally similar in view of their orientation within the faucet assembly  10 , therefore, for purposes of discussion, the valve bodies  12   a ,  12   b  will be generally referred to as valve body  12 . Valve body  12  further includes a control knob  17  for controlling the amount of water allowed to enter the cross-pipe  16  through valve body  12 . Valve body  12  includes threads  13  for securing the faucet assembly  10 . Water is supplied to the valve body  12  through supply line  15  which is connected to the valve body  12  through use of barbed fitting  20 . The barbed fitting  20  is integrated with the valve body by the method of the present invention as described in detail below, however, other bonding methods may be employed. The barbed fitting  20  allows for direct connection of PEX tubing to the valve body  12 . In addition, the barbed fitting  20  as well as other faucet assembly components may be connected using the friction weld process. For example, the valve body  12  may be friction welded to cross-pipe  16  and a barbed fitting  20  can be friction welded to the outlet connector  18  if so desired. The components of the faucet assembly  10  are constructed from any plastic type material that can be spin-welded. Preferably, the material is a glass filled polypropylene. In the alternative, the components may be fabricated from brass or other metallic alloys appropriate for use in potable water supply lines.  
      Turning now to  FIG. 3 , the barbed fitting  20  is shown prior to being friction welded to a valve body  12 . The barbed fitting  20  includes a spin-weld nipple generally shown as reference character  22  that includes a male peripheral wall portion  23  and a male inlet end shown generally as reference character  24  having a plurality of barbs  25  (one shown). Although barbs are shown on the male inlet end  24 , any other means that conforms to the standard specifications for attaching PEX tubing may be employed. The male peripheral wall portion  23  additionally acts as a bonding surface during the friction weld process. The barbed fitting  20  incorporates a 90° elbow (as shown) between the barbed end and the spin-weld nipple end. However, the barbed fitting may also be straight or angular depending on the desired plumbing. In the case where the 90° angle barb is employed, the design is such to permit a lock nut to slip over the fitting  20  and screw onto the shank threads  13  for securing the assembly  10  to a wall or deck.  
      Referring now to  FIGS. 4-6 , a closer view of a valve portion of the faucet assembly  10  is shown illustrating a valve body  12  including the barbed fitting  20 . The valve body  12  includes threads  15  for securing a valve assembly and a control knob  17  to adjust the amount of water allowed to pass through the valve body  12  into the cross-pipe  16 . Threads  21  act to secure a renewable seating element (not shown). In addition, the valve body  12  includes a hollow body portion defined by female internal peripheral wall  26  which additionally acts as a bonding surface. The female peripheral wall  26  extends from threads  16  to the butt end  28  of the valve body  12 . The female peripheral wall  26  includes a taper from the threads  16  to the butt end  28 . The diameter of the internal peripheral wall  26  increases as it extends from threads  13  to the butt end  28  of the valve body  12  thus creating a tapered geometry.  
      The hollow body portion defined by the female internal peripheral wall  26  is united with the barbed fitting  20  at a joint indicated generally by reference character  30 . The joint being formed using the process of the present invention. The peripheral male wall portion  23  of the barbed fitting  20  mates with the female peripheral wall portion  26  such that an integral bond is formed between the male wall portion  23  and the female wall portion  26 . It must be understood that the male and female wall portions  23 ,  26  can be reversed, i.e., the male wall portion  23  can be made as part of the valve body  12 .  
      In the preferred process of the present invention, the valve body  12  is positioned or chucked into a spinning apparatus which is operative to produce a relative rotation between the valve body  12  and the barbed fitting  20 . The male peripheral wall portion  23  of the barbed fitting  20  is inserted into the female peripheral wall portion  26  of the valve body  12  until such surfaces are in contact with each other. As noted, during the welding of the barbed fitting  20  to the valve body  12 , the male and female peripheral wall portions  23 ,  26  are used as bonding surfaces to form the weld.  
      To effect the weld, the barbed fitting  20  is rotated such to a speed which generates enough friction to melt the respective materials. Preferably, the barbed fitting  20  is rotated at a speed of about 1,500 rpm. It should be noted that either the valve body  12  or the barbed fitting  20  can be held stationary while the mating portion is spun. During the spinning process, the vale body  12  and barbed fitting  20  are brought together under pressure. Preferably, the pressure applied is about 80 psi. Once enough heat is generated during the spinning process to friction weld the parts together, the spinning is stopped such that the parts are aligned in a predetermined position. Such predetermined position is preferably one that the orientation of the angled fittings is correct for standard plumbing. The machine used to perform the process of the present invention is one that can friction weld the parts as described. Once such machine is a custom made Phoenix Spin Welder. However, any machine that is within the knowledge of one of ordinary skill in the art will suffice. Once the weld is formed and the spinning subsides, the parts are allowed to cool, thus forming an integral bond between the male peripheral wall portion of the barbed fitting  20  and the female peripheral wall portion of the valve body  12 .  
       FIG. 5  shows the valve body  12  with an integrated cross pipe  16  and barbed fitting  20 . The valve body  12  further includes a male portion  40  which is used to connect the cross pipe  16  to the valve body  12 . The male portion  40  is inserted into the cross pipe  16 . Using the friction weld process described above, a weld is formed between the outer peripheral wall  42  of the male portion  40  and the internal wall  44  of the cross pipe. Preferably, during the process the cross pipe  16  is held stationary while the valve body is rotated. Even though such method is preferred, the valve body  12  can be held stationary while the cross pipe  16  is rotated depending on the configuration of the piping and ease of operation to perform the process.  
       FIG. 6  shows the valve body  12  integrally bonding a straight barbed fitting  46 . This fitting is friction welded using the process of the present invention. The fitting  46  possess all of the components of the elbow fitting except it has a straight configuration rather than including a 90° elbow. Even though only an elbow fitting and straight fitting are shown, the barbed fitting can be designed to include any angle or bend depending on the desired plumbing. Like the elbow fitting, the straight fitting  46  includes a male portion  47  including an outer peripheral wall surface  48 . The peripheral wall surface  48  contacts the internal female peripheral wall portion  26  of the valve body  12  to form a friction weld bond by way of the process described above.  
      Although the components of the faucet assembly  10  are described as being spin-welded together, in an alternative embodiment, the invention also contemplates integrating the faucet assembly  10  parts together through other means as well. Such other means include sonic welding, hot plate welding and one-piece fabrication. Sonic welding and hot plate welding are processes that are common and known to those of ordinary skill in the art. These alternate methods of fabrication preserve the simplicity and flexibility of the preferred embodiment.  
      In the case of one-piece fabrication, the barbed fitting may be incorporated into the valve body by casting a valve body (where the faucet assembly is made of metal alloy components) including a barbed fitting. In the case of thermoplastic material, the barbed fitting can be integrated with the valve body through molding or any other means as known to those of ordinary skill in the art of plastics.  
      In any of the above embodiments, the barbed fitting becomes in integral part of the faucet shank. This allows supply lines to be connected directly to the faucet without the need for any transitional couplings.  
      Although the barbed fitting is shown is connection with a tub/shower divettet, the fitting  20  may be employed in any wall mount or ledge mount, kitchen or lavatory faucet (either at a 90° angle, straight or some angular variation thereof) designs or any other plumbing connection as apparent to those of ordinary skill in the art in view of this disclosure.  
      While the exemplary embodiments of the invention have been described with a degree of particularity, it is the intent that the present invention include all modifications and alterations from the disclosed design falling with the spirit or scope of the appended claims.