Patent Publication Number: US-2006016001-A1

Title: Ceramic diverter for tub spout

Description:
TECHNICAL FIELD  
      This invention relates generally to a diverter for a tub spout. More particularly, this invention relates to a diverter for diverting water from a tub spout to a showerhead, and particularly uses a pair of relatively rotating ceramic discs for diverting that water.  
     BACKGROUND OF THE INVENTION  
      Bathtubs are common features of full residential bathrooms. However, due to considerations including but not limited to time, many persons frequently prefer instead to bathe in showers. In homes with larger bathrooms, a separate shower stall may be provided. However, many smaller homes do not have the space for a separate shower stall. In such homes, the area adjacent the tub includes a tub spout, a showerhead, and both a hot and a cold water handle. A single hot and cold water handle open corresponding hot and cold water valves to provide water to both the tub spout and the shower head. To accomplish this with a single hot and cold water handle, however, it is necessary to provide a means for diverting water from the tub spout to the shower head, and then back to the tub spout.  
      Commonly, a single diverter valve is provided for this purpose. Such a diverter valve includes a stem that is mounted through an orifice in the top of the tub spout. The stem is vertically movable between a raised and a lowered position. When the user wishes to bathe in the bathtub, the stem is placed in its normal, lowered position. When the stem is in this position, mixed cold and hot water move into an axial water channel that is disposed within the tub spout. That water then exits the tub spout through its discharge end, and fills the tub.  
      In contrast, when the user wishes to shower, the stem is pulled upwardly into its raised position. When the stem is moved into this raised position, a valve attached to the stem is moved into contact with a valve seat. The pressure of the water entering the tub spout forcibly maintains contact between the valve and the valve seat. This contact between the valve and the valve seat closes off the water channel within the tub spout. As a result, the water is diverted to a flow path that leads to the shower head.  
      While such diverter valves are generally suitable, they do exhibit certain shortcomings. Particularly, for example, in their raised position, some of these prior art stem-type diverter valves fail to completely seal off the flow of water through the tub spout. As a result, while the great majority of the mixed hot and cold water flows through the shower head, a small amount of that water leaks through the valve and valve seal, and flows out of the discharge end of the tub spout. This is undesirable, as it results in the waste of some of the water, and of some of the energy used to heat and transport that water.  
      Diverter valves and conventional water valves including ceramic discs are described in many prior art patents. These patents include U.S. Pat. No. 5,775,373. At column 3, lines 17-21, of this patent, the diverter valve is described as including a movable ceramic valve disc and a fixed ceramic valve disc. Column 4, lines 39-53 appears to disclose that the movement of this ceramic valve disc causes water to be diverted from the tub spout to the showerhead. Another relevant patent is U.S. Pat. No. 5,904,336. At column 7, beginning at line 60, this patent includes a description of a water valve including a movable ceramic disc, and a stationary ceramic disc. In addition, this patent appears to describe, at column 1, lines 36-52, the structures of three additional prior art water valves that are said to include relatively rotating ceramic discs. These three additional patents are U.S. Pat. Nos. 3,780,758, 3,831,621, and 5,174,324.  
      U.S. Pat. No. 5,752,541 is directed to a diverter valve. At column 2, lines 52-55, this patent discloses a valve of a ceramic disc type. This valve seems to be of a conventional lift style (column 2, lines 53-55), operated with a stem.  
      U.S. Reissue Pat. No. 37,888, and U.S. Pat. Nos. 4,328,830, 6,575,196, 5,983,938, and 6,183,636 describe water valves with two ceramic discs (&#39;888 patent, col. 4, lines 19-20) (&#39;830 patent, column 3, lines 19-25) (&#39;196 patent, column 8, lines 37-47 and 59-69) (&#39;938 patent, col. 12, lines 49-59) (&#39;636 patent, column 3, lines 50-64). These ceramic discs appear to be used in connection with valves for conventional lavatory faucets, or in connection with lavatory faucets with spray heads, without any diverter valves.  
      Further related patents include U.S. Pat. Nos. 6,405,756, 6,517,720 and 6,634,380.  
      In view of the shortcomings of the prior art, it would thus be desirable to provide a diverter valve that completely seals off the flow of water through a tub spout.  
     SUMMARY OF THE INVENTION  
      One aspect of the invention is a water diverter. The water diverter comprises, in combination, a tub spout having an inlet port and an outlet port.  
      The water diverter also includes a cartridge for installation at the outlet port of the tub spout. The cartridge includes both a first ceramic disc with orifices, and a second ceramic disc with orifices. These first and second ceramic discs are rotatable relative to each other.  
      The first and second ceramic discs are movable between a first position and a second position. In this first position, the orifices of the first and second ceramic discs are substantially aligned. When the orifices of the first and second discs are aligned, those orifices permit flow of the water to the outlet port of the tub spout.  
      In the second position, the orifices of the first and second ceramic discs are substantially non-aligned. When the orifices of the first and second discs are substantially non-aligned, the non-alignment of the orifices prevents the flow of the water to the outlet port of the tub spout. Instead, the water is diverted to a shower head.  
      In yet another aspect of the invention, the first and second ceramic discs are positioned, i.e., fully contained within, the cartridge. The cartridge is installed at the outlet port of the tub spout.  
      In yet another aspect of the invention, the first disc is stationary, and the second disc rotates relative to the first disc.  
      In a still further aspect of the invention, the second disc is rotatable in a single plane relative to the first disc.  
      In yet another aspect of the invention, the rotation of the first disc relative to the second disc totals approximately 90 degrees.  
      In another aspect of the invention, the orifices of the first ceramic disc comprise a pair of segmented orifices. Each of the two segmented orifices preferably has a shape and creates an opening approximately equal to one-quarter of a circle.  
      Similarly, in yet another aspect of the invention, the orifices of the second ceramic disc comprise a pair of segmented orifices. Each of the two segmented orifices in the second ceramic disc also preferably has a shape and creates an opening approximately equal to one-quarter of a circle. As a result, the total opening through the nozzle created by the two segmented orifices comprises about one-half of a circle.  
      Other objects, advantages, and aspects of the present invention will become apparent upon reading the following description of the drawings and detailed description of the invention.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a perspective view of the assembled water diverter assembly of the invention;  
       FIG. 2  is an exploded view of the water diverter assembly of  FIG. 1 ;  
       FIG. 3  is a perspective view of a portion of the water diverter of  FIGS. 1 and 2 , including the handle, stator, and first (stationary) disc;  
       FIG. 4  is a perspective view of another portion of the water diverter of  FIGS. 1 and 2 , including the bascule and the second (movable) disc;  
       FIG. 5  is a cross-sectional view of the cartridge of the invention, and showing the first and second discs in their so-called first position;  
       FIG. 6  is a cross-sectional view of the cartridge of the invention, and showing the first and second discs in their so-called second position;  
       FIG. 7  is a partial sectional view of the cartridge of the water diverter assembly, taken along section lines  7 - 7  of  FIG. 5 , and showing the first and second discs in their so-called first position.  
       FIG. 8 a  partial sectional view of the cartridge of the water diverter assembly, taken along section lines  8 - 8  of  FIG. 6 , and showing the first and second discs in their so-called second position. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION  
      This invention may be made in many different forms. The following drawings and description describe a preferred embodiment of the invention. It will be understood that the description is to be considered as but one example of the principles of the invention. The description is not intended to limit the broadest aspect of the invention to the illustrated embodiment.  
      As may be seen in  FIG. 1 , the invention is a water diverter  10 . In this embodiment shown in  FIG. 1 , the water diverter  10  includes a tub spout  12 . The tub spout has an outlet port  14 . The outlet port  14  is the distal end of the tub spout  12  from which water passing through the tub spout  12  is discharged into the tub. The tub spout  12  also has an inlet port  16 . The inlet port  16  is at the opposite distal end of the tub spout  12 , and is the point at which municipal or other supply water enters the tub spout  12 .  
      In one aspect of the invention, the water diverter  10  may comprise, in combination, the tub spout  12  having an inlet port  16  and an outlet port  14 .  
      The water diverter  10  also includes a separate, discrete cartridge  18  for installation at the outlet port  14  of the tub spout  12 . The cartridge  18  has a main body portion, or handle  20 . Preferably, the handle  20  includes a pair of tabs  22  and  24 . These tabs  22  and  24  are integrally formed on the exterior surface of the handle  20 . The tabs  22  and  24  may be grasped by the consumer, and such grasping facilitates the turning of the handle  20 , in a manner and for a purpose to be described later.  
      The handle  20  has threads  26  formed on its upper, exterior surface. These threads  26  are mated to complementary threads (not shown) within the interior surface at the outlet port  14  of the tub spout  12 . In this way, the cartridge  18  may be firmly—and removably—secured to the outlet port  14  of the tub spout  12 .  
      The cartridge  18  includes at least two ceramic flakes  28  and  30 , also known as discs  28  and  30 . The discs  28  and  30  are, in this embodiment, virtually identical in size, shape, and configuration to each other. In this embodiment, each of the discs  28  and  30  has a diameter of approximately ⅝ inch (0.625 inch), and a thickness of approximately ⅛ inch (0.125 inch).  
      Each of these ceramic discs  28  and  30  include orifices. Particularly, first ceramic disc  28  includes an orifice  32  and an orifice  34 . Second ceramic disc  30  includes an orifice  36  and an orifice  38 .  
      These first  28  and second ceramic discs  30  have relatively smooth surfaces. Moreover, as may be seen in  FIG. 2 , the first  28  and second ceramic discs  30  are positioned adjacent to each other. The first ceramic disc  28  is rotatably movable relative to the second ceramic disc  30 . Low friction is created by such relative, rotatable movement, primarily because of the relatively smooth surfaces of the first  28  and second ceramic discs  30 .  
      Upon such relative rotatable movement, the first ceramic disc  28  and second ceramic disc  30  are movable between a first position and a second position. In this first position, as may be seen in  FIGS. 5 and 7 , the orifices  32  and  34  of the first ceramic disc  28  are substantially aligned with the orifices  36  and  38  of the second ceramic disc  30 . Moreover, when the orifices  32  and  34  of the first ceramic disc  28  are aligned with the orifices  36  and  38  of the second ceramic disc  30 , as shown in  FIGS. 5 and 7 , those orifices permit full and free flow of the water to the outlet port  14  of the tub spout  12 .  
      The second position of discs  28  and  30  is shown in  FIGS. 6 and 8 . The second position is attained by grasping the tabs  22  and  24  of the handle  20 , and rotating the handle  20  approximately 90 degrees. In this second position, as may be seen in  FIGS. 6 and 8 , the orifices  32  and  34  of the first ceramic disc  28  are substantially non-aligned with the orifices  36  and  38  of the second ceramic disc  30 . When the orifices  32 ,  34  of the first ceramic disc  28  are substantially non-aligned with the orifices  36 ,  38  of the second ceramic disc  30 , such non-alignment of the orifices  32 ,  34  with orifices  36 ,  38  prevents the flow of the water to the outlet port  14  of the tub spout  12 . Instead, the water is diverted to a shower head (not shown). Such diversion of the water from the spout to the shower head, using prior art diverters, is a process that is well-known in the art.  
      It will be understood that in the embodiment shown in the FIGURES, including  FIGS. 2 and 3 , the first  28  and the second  30  ceramic discs are positioned, i.e., fully contained within, the cartridge  18 . In particular, the first ceramic disc  28  is retained within a stator  40 . The stator  40  is positioned and securely held within the top of the main body portion or handle  20 .  
      As may best be seen in  FIG. 4 , the second ceramic disc  30  is retained within a bascule  42 . The bascule  42  is positioned and securely held within the bottom of the main body portion or handle  20 .  
      Normally, the first  28  and second ceramic discs  30  are in their so-called first position, as shown in  FIGS. 5 and 7 . When in this first position, water that enters the inlet port  16  of the tub spout  12  is discharged through both the outlet port  14  and cartridge  18 , and into the tub.  
      However, when the user grasps the tabs  22  and  24 , and turns the handle  20  one-quarter turn, the bascule  42  rotates with the handle  20  a full quarter turn, or 90 degrees. As a result, the second ceramic disc  30  is also moved a full 90 degrees. While the handle  20 , the bascule, and the second ceramic disc  30  move this full quarter turn, the stator  40  and the first ceramic disc  28  remain stationary. As a result, the first ceramic disc  28  and the second ceramic disc  30  move to their second position, as shown in  FIGS. 6 and 8 .  
      From the above description, it will be understood that in this embodiment, the first ceramic disc  28  is stationary, and the second ceramic disc  30  rotates relative to the first disc  28 . It will be understood, however, that all that is necessary is that the first  28  and second ceramic discs  30  be rotatable relative to each other. Accordingly, it is also possible that the first ceramic disc  28  may be movable, and that the second ceramic disc  30  be stationary.  
      As may best be seen in  FIG. 1 , the cartridge  18  is installed at the outlet port  14  of the tub spout  12 .  
      In this embodiment, the ceramic discs  28  and  30  are coaxial. In other words, the discs  28  and  30  are disposed substantially parallel to each other. As a result of this orientation, the second ceramic disc  30  is rotatable in a single plane relative to the first ceramic disc  28 .  
      Referring again to  FIGS. 5 and 6 , and to the ceramic discs  28  and  30 , and their orifices  32 ,  34 ,  36 , and  38 , it may be seen that the pair of orifices  32  and  34  of the first ceramic disc  28  are segmented orifices. Each of the two segmented orifices  32  and  34  preferably has a shape of, and creates an opening approximately equal to, one-quarter of a circle.  
      Similarly, the segmented orifices  36  and  38  of the second ceramic disc  30  also preferably have the shape of, and create an opening approximately equal to, one-quarter of a circle. As a result, when the discs  28  and  30  are in their first position, as shown in  FIGS. 5 and 7 , a total opening of somewhat less than one-half of a circle is created by the two segmented orifices  28  and  30 .  
      Included as additional components of the water diverter  10  and the cartridge  18  are a pair of substantially identical elastomeric washers  44  and  46 . These washers  44  and  46  assist in preventing leakage within the cartridge  18 .  
      The cartridge  18  can include a rectifier  48  and a nut  50 . The rectifier  48  includes a screen-like element, and provides for a smoother flow of water from the outlet port  14  and into the tub. The first nut  50  includes threads on its exterior. These threads on the nut  50  engage complementary threads (not shown) on the bottom, interior walls of the handle  20 . In this way, the nut  50  and rectifier  48  serve another function, i.e., they together aid in keeping all of the components of the cartridge  18  within that cartridge  18 .  
      A metal washer  52  seals the connection between the outlet port  14  of the tub spout  12  and the cartridge  18 .  
      Finally, a second nut  54  is secured to the top of the cartridge  18 , and particularly the top of the handle  20 . This second nut  54  also includes threads upon its exterior. These threads on the exterior of the second nut  54  engage complementary threads (not shown) on the upper, interior walls of the handle  20 .  
      While specific embodiments have been illustrated and described, numerous modifications are possible without departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.