Patent Publication Number: US-2009223579-A1

Title: Water flow control device

Description:
RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/068,836, filed Mar. 10, 2008. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to an improved water flow control device and a method of installation thereof. More specifically, this invention relates to an improved water flow control device mounted between a water supply line and a nozzle enabling a user to regulate the amount of water flowing through the control device. 
     DESCRIPTION OF THE PRIOR ART 
     Water flow control devices, in particular for reducing the water flow in shower applications are known in the art and are used to help preserve water and save energy related to heating the water. For example, U.S. Pat. No. 4,191,332 to De Langis et al. discloses a shower head flow control device comprising a push/pull rod type valve mechanism for on/off control of the water flow. U.S. Pat. No. 5,613,639 to Storm et al. discloses an on/off control valve for showers using a cylindrical rod type valve mechanism. U.S. Pat. No. 4,522,232 to Ferguson discloses a shower flow controller comprising a horseshoe-shaped handle to allow the user to change the amount of water supplied to the shower head. U.S. Pat. No. 5,123,628 to Yu discloses a water saving valve comprising a spool rod type mechanism rotatable by a handle to regulate the quantity of water allowed to flow through the showerhead. U.S. Pat. No. 6,565,018 to Degeyter discloses a shower flow control device comprising a lever connected to a valve for quickly shutting off the flow of water through a shower head. 
     While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents all possess shortcomings that, if addressed, would prove beneficial to users of such devices. All prior art devices use some kind of lever or handle to manipulate a valve for regulating the amount of water that can flow through the device. However, all prior art water flow control devices leave the orientation of their levers or handles in relation to the user to chance. Typically, an installer will screw a water flow control device onto a water supply line until a snug and leak free fit is achieved, with no regard to the orientation of the handle. In the prior art, in relation to the user, the handle may end up to the left, to the right, on top, or underneath the shower head or anywhere in between. The orientation of the handle can be different every time it is installed. 
     In addition, many of the prior art devices allow the user to completely stop the flow of water before it reaches the nozzle or shower head even though the water may still be turned on at the main valves. If a user inadvertently forgets to also shut of the main valves, the water line between the main valves and the water flow control device could be left in a pressurized condition for potentially a long period of time. However, typical water supply lines are not intended to be left in a pressurized condition for any period of time and there is a strong possibility that leaks in the supply line may develop causing substantial water damage. 
     Furthermore, many prior art devices do not provide for an area on the handle or lever to apply text or graphics, which, for example, could be used for operating instructions or a marketing message. Especially the lack of instructive text or graphics in close proximity to the device limits the prior art devices&#39; effectiveness in public areas. 
     Still further, many prior art devices comprise many parts and are therefore rather expensive to manufacture and cannot be installed without the use of tools. 
     OBJECTS OF THE INVENTION 
     Accordingly, it is an object of this invention to provide an improved water flow control device that can be easily and cost-efficiently manufactured and that is easily mounted between a water supply line and a nozzle or shower head, whereby the water flow control device only comprises three separate main components and a total of five separate parts. 
     Another object of this invention is to provide for an improved water flow control device that enables a user to regulate the amount of water flowing through the device from a full flow condition to a reduced flow condition, whereby the device further prevents the user to completely shut off the flow of water to avoid the build-up of undesirable pressure inside the water supply line, and to prevent water from accumulating inside the water supply line where it would cool down below the temperature selected by the user at the main valves, causing a blast of cold water to come out of the nozzle once a full flow condition is reinstated. 
     Yet another object of this invention is to provide for an improved water flow control device, wherein the handle member comprises a display area for a text and/or graphical display. 
     Another object of this invention is to provide for a method of installing a water flow control device that ensures the correct, i.e., upright/vertical orientation of the handle member at every installation, whereby the front side of the handle faces the user and is located substantially over the shower head. 
     Yet another object of this invention is to provide for an improved water flow control device and method of installation thereof that promotes more widespread use of the device in public areas. 
     Still another object of the invention is to provide for an improved water flow control device that avoids unnecessary waste of water thereby preserving a limited natural resource as well as saving energy necessary to heat the water. 
     These and other objects and advantages of this invention will be apparent from the detailed description and drawings. What follows is a preferred embodiment of the present invention. To assess the full scope of the invention the claims should be looked to as the preferred embodiment is not the only embodiment within the scope of the invention. 
     SUMMARY OF THE INVENTION 
     The disclosed invention achieves its objectives by providing an improved water flow control device and a method of installation thereof. The present invention comprises a water flow control device for installation between a water supply line and a nozzle, shower head or the like, whereby its assembly and installation ensures that the handle to control the water flow is oriented the same way for every installation. 
     In one aspect of the invention an improved water flow control device is disclosed. More particularly, the improved water flow control device is adapted to be installed between a water supply line and a nozzle or shower head. The improved water flow control devices comprises a housing having an input end and an output end, said input end having an internal thread for coupling to the water supply line and said output end having an external thread for coupling to the nozzle, said housing further having a first bore connecting said input end and said output end, and between said input end and said output having a second bore perpendicular to and intersecting said first bore; a valve member having a third bore, said valve member rotatably disposed within said second bore; and a handle member removably coupled to said valve member for rotating said valve member between a full flow position and a reduced flow position. 
     In another aspect of the disclosed invention a method of installing a water flow control device is disclosed, wherein the method comprises the steps of coupling said input end of said housing to a water supply line; aligning said first bore of said housing substantially parallel to a horizontal plane; inserting a valve member into said second bore; and removably coupling a handle member to said valve member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself, and the manner in which it may be made and used, may be better understood by referring to the following description taken in connection with the accompanying drawings forming a part hereof, wherein like reference numerals refer to like parts throughout the several views and in which: 
         FIG. 1  shows a perspective view of the fully assembled preferred embodiment of the water flow control device of the present invention mounted between a water supply line and a shower head; 
         FIG. 2  shows a cross-sectional side view of the valve housing of the water flow control device of  FIG. 1 ; 
         FIG. 3  shows a cross-sectional front view of the valve member of the water flow control device of  FIG. 1 ; 
         FIG. 3   a  shows a cross-sectional side view of the valve member of the water flow control device of  FIG. 1 ; 
         FIG. 4  shows a rear view of the handle member of the water flow control device of  FIG. 1 ; 
         FIG. 4   a  shows a cross-sectional side view of the handle member of  FIG. 4 ; 
         FIG. 5  shows a cross-sectional rear view of the water flow control device in an full flow condition; 
         FIG. 6  shows a cross-sectional side view of the water flow control device in an full flow condition; 
         FIG. 7  shows a side view of the fully assembled water flow control device in a reduced flow condition; 
         FIG. 8  shows a cross-sectional front view of the water flow control device in a reduced flow condition; 
         FIG. 9  shows a cross-sectional side view of the water flow control device in a reduced flow condition; 
         FIGS. 10   a ,  10   b  and  10   c  illustrate the method of installing the three components of the water flow control device in the preferred embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT 
     Turning now to the Figures,  FIG. 1  is illustrative of a preferred water flow control device assembly  20  to control the amount of water flowing through the device incorporating the features of the present invention. In particular, it shows water flow control device  20  fully assembled and installed as part of shower system  10 , whereby water flow control device  20 , having a handle member  30  and a display area  34  is mounted between water supply line  11  and shower head  12 . 
     A. The Components of the Water Flow Control Device 
       FIGS. 2 through 4   a  show in detail the three components of the disclosed water flow control device  20 , that is, a housing, a valve member, and a handle member. Turning first to  FIG. 2 ,  FIG. 2  shows a cross-sectional view of a preferred embodiment of housing  21  having on one side an input end  26  through which, when connected to a water supply line, water will flow into the device, and on the opposite side, an output end  27  through which water will flow out of the device. Input end  26  further having an internal thread  22  and output end  27  further having an external thread  23 . Housing  21  also includes a water pathway  24  located therein and extending through the length of housing  21  from input end  26  to output end  27  for allowing the water to flow through the device. Housing  21  further comprising bore  25  located between input end  26  and output end  27 , whereby bore  25  intersects water pathway  24  in a perpendicular orientation. 
       FIG. 3  shows a cross-sectional front view of a preferred embodiment of valve member  40 . Valve member  40  having a cylindrical-shaped valve body  41  with an orifice  46  located in the center of valve body  41 . Valve body  41  further having a left slot  42   a  and a right slot  42   b  located at either one of the respective ends of valve body  41 . Located near each of the two ends of valve body  41  are recesses  43   a  and  43   b  for supporting o-rings  44   a  and  44   b , respectively. Furthermore, in the preferred embodiment of valve member  40 , at least one of the ends of valve body  41  includes a beveled or tapered surface  45  to facilitate the mounting of handle member  30  (shown in  FIGS. 4 and 4   a ).  FIG. 3  shows tapered surface  45  on the side of right slot  42   b.    
     To further facilitate the installation of handle member  30  (shown in  FIGS. 4 and 4   a ), in another embodiment (not shown) of valve member  40 , one end of valve body  41  would have a larger diameter than the other end of valve body  41 . In this embodiment, the ends of bore  25  near the outer surface of housing  21  would have to be counter sunk to a diameter appropriate for receiving and accommodating the larger diameter end of valve body  41 . During the installation of handle member  30 , the counter sink would prevent the handle prong from pushing the valve member through bore  25 , thereby exposing too much of the other end of valve member  41  past the surface of valve housing  21  making it more difficult to engage the tab of the handle prong with the slot of valve member  41 . Counter-sinking both ends of bore  25  to accommodate the larger diameter end of valve body  41  preserves the 90 degree turn of adjustment in order to align bore  25  parallel to a horizontal plane, as described below in the section regarding the installation of the water flow control device of this invention. 
     Referring now to  FIG. 3   a ,  FIG. 3   a  shows a cross-sectional side view of the preferred embodiment of valve body  41 , wherein centerline  47  of orifice  46  is offset with reference to vertical plane  49  and horizontal plane  48  of valve body  41 , whereby vertical plane  49  is perpendicular to horizontal plane  48  of valve body  41 . Horizontal plane  48  is further defined by and parallel to horizontally oriented left slot  42   a  and right slot  42   b  (not shown). More particularly, centerline  47  is oriented offset between vertical y-plane  49  and horizontal x-plane  48 . In the preferred embodiment, centerline  47  of orifice  46  is offset by approximately 45 degrees. This offset orientation of orifice  46  within valve body  41  facilitates the alignment of orifice  46  with water pathway  24  between a full flow condition, when handle member  30  is moved forward until it comes into contact with housing  21  (as shown in  FIG. 6  and further described below) and a reduced flow condition when handle member  30  is moved back until it comes into contact with housing (as shown in  FIG. 9  and further described below). If the centerline  47  of orifice  46  would not be offset, between vertical plane  49  and horizontal plane  48 , a full flow condition could not be achieved when handle member  30  is moved forward until it comes into contact with housing  21 . It is understood that other orientations are possible as long as the orientation of orifice  46  within valve body  41  facilitates the creation of a full flow condition and a reduced flow condition in a final assembly of water flow control device  20 , whereby it is preferred that a full flow condition be achieved when handle member  30  is moved forward until it comes into contact with housing  21  and a reduced flow condition be achieved when handle member  30  is moved back until it comes into contact with housing  21 . 
       FIGS. 4 and 4   a  show a preferred embodiment of handle member  30 , whereby  FIG. 4   a  provides a cross-sectional view of handle member  30 . Handle member  30  comprises a handle body  31  having a pair of handle prongs, i.e., left handle prong  32   a  and right handle prong  32   b . Left and right handle prongs  32   a  and  32   b  each include corresponding protruding tabs, i.e., left tab  33   a  and right tab  33   b  for removably engaging with left slot  42   a  and right slot  42   b , respectively, of valve body  41  shown in  FIG. 3 . Handle member  30  further having a front-side  35 , a back-side  36  and an underside  37 , whereby in the assembly of water flow control device  20 , front-side  35  is oriented to face the user as shown in  FIG. 1 . The preferred embodiment of handle member  30  further having a display area  34  located on front-side  35  of handle member  30  for displaying text and/or graphics. For example, the text and/or graphics displayed on display area  34  may include instructions on how to operate water flow control device  20 . 
       FIGS. 5 and 6  show a fully assembled preferred embodiment of water flow control device  20  in its full flow condition. During the operation of water flow control device  20 , a user can control the amount of water that is allowed to flow through water flow control device  20  by manipulating handle member  30 . With reference to  FIG. 6 , a cross-sectional side view of water flow control device  20 , moving handle member  30  forward, i.e., towards output end  27  will cause orifice  46  in valve member body  41  to align with water pathway  24  in a manner that allows the most amount of water to enter housing  21  through input end  26  and to flow through orifice  46  and out through output end  27 . More particularly, in its full flow condition, orifice  46  is aligned substantially parallel to water pathway  24 .  FIG. 5  shows a cross-sectional rear view of water flow control device  20  in its full flow condition, wherein orifice  46  and water pathway  24  are aligned in a manner allowing the most amount of water to pass through valve housing  21 , i.e., substantially the entire diameter of orifice  46  is exposed towards both input end  26  and output end  27 . In the preferred embodiment of water flow control device  20 , the range of motion of handle member  30  is restricted by valve housing  21 . For example, the full flow condition is achieved when the portion of handle underside  37  that is near handle front  35  comes in contact with valve housing  21 , as shown in  FIG. 6 . 
       FIGS. 7  though  9  show a preferred embodiment of water flow control device  20  in its reduced flow condition, whereby  FIG. 7  provides a side view of water control device  20  in its reduced flow condition. With reference to  FIG. 9 , a cross-sectional side view of water flow control device  20 , moving handle member  30  towards the input end  26  will cause orifice  46  in valve member body  41  to align with water pathway  24  in a manner that allows the least amount of water to enter housing  21  through input end  26  and to flow through orifice  46  and out through output end  27 . More particularly, and with reference to  FIG. 8 , showing a cross-sectional in its reduced flow condition, orifice  46  is aligned with water pathway  24  so as to create only a small opening through which water can enter orifice  46  from input end  26  and leave orifice  46  to output end  27 .  FIG. 8  shows a cross-sectional front view of water flow control device  20  in its full flow condition, wherein orifice  46  and water pathway  24  are aligned in a manner allowing the least amount of water to pass through valve housing  21 , i.e., only a small fraction of the diameter of orifice  46  is exposed towards both input end  26  and output end  27 . In the preferred embodiment of water flow control device  20 , the range of motion of handle member  30  is restricted by valve housing  21 . For example, the reduced flow position is achieved when the portion of handle underside  37  that is near handle back  36  comes in contact with valve housing  21 , as shown in  FIG. 9 . 
     It should be noted that in the preferred embodiment of water flow control device  20 , it is neither possible, nor desirable to completely stop the flow of water through housing  21 . This is to prevent any possibility that a user may leave shower system  10  with the water turned on at the main valves (not shown), while completely stopping the flow of water only through water flow control device  20  near shower head  12 . Doing so would leave water supply line  11  between the main valves and water flow control device  20  in a pressurized condition for potentially a long period of time. However, typical water supply lines are not intended to be left in a pressurized condition for any period of time and there is a strong possibility that leaks in the line may develop causing substantial water damage. Another advantage of not allowing the water flow to completely stop is that it prevents water from accumulating inside water supply line  11  where it would cool down below the temperature selected by the user at the main valves (not shown), causing a blast of cold water to come out of the nozzle or shower head  12  once a full flow condition is reinstated. 
     B. The Installation of the Water Flow Control Device 
       FIGS. 10   a  through  10   c  illustrate the claimed method of installing water flow control device  20  between water supply line  11  and shower head  12  (as shown in  FIG. 1 ) in order to ensure the correct orientation of water flow control device  20  for every installation. 
     Referring first to  FIG. 10   a , after having removed shower head  12  (not shown) from water supply line  11 , the installer first screws housing  21  onto water supply line  11  until a snug fit is achieved. More particularly, input end  26  with internal thread  22  is screwed onto the external thread of water supply line  11  leaving external thread  27  exposed to receive the internal thread of showerhead  12  (not shown). When installing shower heads and faucets, water control devices and other plumbing devices, it is common to apply plumbing tape onto the external threads of a line or device to facilitate an installation free of water leaks. 
     As pointed out above, prior art water flow control devices leave the orientation of their handles in relation to the user to chance. Typically, an installer will screw a water flow control device onto a water supply line until a snug and leak free fit is achieved, with no regard to the orientation of the handle. In the prior art, in relation to the user, the handle may end up to the left, to the right, on top, or underneath the shower head or anywhere in between. 
     Therefore, when mounting housing  21  to water supply line  11  it is critical to correctly orient housing  21  with reference to the user. More particularly, the housing should be oriented in a way that after the assembly of water control device  21  is completed, handle  30  is upright at a substantially 90 degree angle relative to the (horizontal) floor or some other horizontal reference line. When screwing a device, such as a water flow control device to a water supply line, especially if plumbing tape is applied to the external thread of the water supply line, the installer can screw the device to a snug fit and normally still has a 90 degree turn of adjustment available without compromising a leak free fit. Because the housing  21  is mounted to water supply line  11  prior to mounting handle  30  to valve member  40  disposed inside bore  25  of valve housing  21 , the installer is still able to take full advantage of the available 90 degree turn of adjustment to properly orient housing  21 . 
     In order to ensure that handle  30  will be positioned upright at a substantially 90 degree angle relative to the (horizontal) floor, the installer must, within the available 90 degree turn of adjustment, horizontally align both bore  25  of housing  21  with the (horizontal) floor or some other horizontal reference line  28  as shown in the detail drawing to  FIG. 10   a . The fact that handle  30  is not attached to water flow control device  20  until after housing  21  has been mounted and properly oriented is a critical improvement over the prior art, because fully assembled prior art devices may not be able to benefit from the available 90 degree turn of adjustment in order to obtain the preferred orientation of the handle member. A prior art device may end up with its handle underneath the shower head, and a 90 degree turn of adjustment is insufficient to correctly orient the handle. 
     In a next step, as shown in  FIG. 10   b , the installer may insert valve body  40  into bore  25  of housing  21 . However, the sequence is not critical and an installer may also insert valve body  40  before mounting housing  21  to water supply line  11  without compromising the proper orientation of handle  30 . Yet, what is critical is correct insertion of valve body  40  into bore  25 , to ensure that the handle  30  can achieve the desired full flow condition or reduced flow condition. Consequently, valve body  40  should be inserted so that when valve body  40  is disposed inside of bore  25 , from the perspective of a user facing output end  27  of mounted housing, left slot  42   a  is on the left side of housing  21  and right slot  42   b  is on the right side of housing  21 . Furthermore, in the preferred embodiment of tapered surface  45  must be located on top of right slot  42   b  and on the right side of housing  21  from the perspective of a user facing output end  27 , in order to assure correct orientation of valve body  40  and orifice  46  inside bore  25 . 
     In a final step, as shown in  FIG. 10   c , the installer attaches handle  30  to water flow control device  20  by engaging left tab  33   a  of left handle prong  32   a  with left slot  42   a  of valve body  40  and then sliding right handle prong  32   b  over housing  21  to engage right tab  33   b  of right handle prong  32   b  with right slot  42   b . While the particular sequence is not critical, to promote ease of installation, the installer may prefer to first engage left tab  33   a  with left slot  32   a  and then right tab  33   b  with right slot  42   b . Furthermore, tapered surface  45  may further facilitate the engagement of right tab  33   b  with right slot  42   b.    
     After full assembly of water flow control device  20 , the installer may mount shower head  12  to water flow control device  20  by screwing shower head  12  onto external thread  27 . The completed installation is shown if  FIG. 1 . 
     While  FIGS. 1-10   c  illustrate only one design of a water flow control device used by the preferred embodiment of the present invention, it should be understood that different sizes and shapes are obviously a matter of design choice. The improvements of the present invention can be incorporated in a variety of designs. 
     The foregoing description of the invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or to limit the invention to the precise form disclosed. The description was selected to best explain the principles of the invention and practical application of these principles to enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention not be limited by the specification, but be defined by the claims set forth below.