Patent Publication Number: US-11028942-B2

Title: Fluid control valve

Description:
This application is a continuation of U.S. patent application Ser. No. 15/319,418 filed Dec. 16, 2016, now U.S. Pat. No. 10,088,074, the disclosure of which is incorporated herein by reference. U.S. patent application Ser. No. 15/319,418 is a 371 of PCT/GB2015/051774 filed Jun. 17, 2015, which claims priority of United Kingdom Patent Application No. 1410799.9 filed Jun. 17, 2014. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to fluid control and management. In particular, it relates to valves or regulators for controlling a flow of fluid, such as, but not limited to, taps and faucets. 
     Taps of the type mounted to baths, basins and sinks typically have a tap body mounted above the surface of the bath, basin or sink which tap body has a threaded body portion which extends below the surface such that the tap body is securable to the surface by means of a correspondingly threaded back nut. The tap body further includes at least one elongate supply pipe for operative connection to a water supply. A single tap has a single supply pipe and a mixer tap has two such pipes, conventionally referred to as “threaded tails”. Typically, the elongate supply pipes are metal pipes having threaded connections to the threaded body portion. In mounting of the tap to the surface, the supply pipes are screwed into the tap body, the braided or flexible supply pipes and threaded body portion of the tap body are inserted through an aperture in the surface and the threaded nut is applied from underneath the surface to the threaded body portion and tightened to grip the tap body to the surface. The required connections to the water supplies are then made, typically using a compression fitting or a push-fit coupling. 
     Water regulations typically require that a shut-off or service valve is provided close to the tap so that the water supply can be easily closed to allow for replacement of washers etc., as necessary. However, by the time that washers need replacing, the bath, basin or sink has been installed and invariably enclosed within an enclosure such as within bath panels, a sink unit or basin vanity unit, giving exceptionally limited accessibility to the service valves. The present invention seeks to overcome this problem in taps and faucets, but also to provide a means for control of fluids in fluid lines generally. 
     SUMMARY OF THE INVENTION 
     In its broadest sense, the present invention provides a fluid control valve comprising a valve body having an inlet, for operative connection to a supply of pressurised fluid, and an outlet and defining a fluid flow path therebetween; and a first valve adjustable under the control of a first valve actuator between a first, or closed, position in which flow of fluid through the first valve is prevented and a second, or open, position in which flow of fluid through the first valve is permitted. The valve is characterised in that: the fluid control valve further comprises a second valve associated with the inlet or intermediate the inlet and the first valve, wherein the second valve comprises a second valve body and a second valve actuator adapted such that the first valve actuator bears against the second valve actuator in each of said first and second positions to urge the second valve into an open configuration allowing flow of fluid; and further wherein the fluid control valve is arranged such that the first valve actuator is adjustable to a third position in which the first valve actuator is spaced from the second valve actuator by a separation sufficient to allow fluid pressure at the inlet to cause the second valve to close, preventing flow of fluid through the fluid control valve. 
     Preferably, the second valve actuator is a rod. 
     Preferably, the second valve body and the second valve actuator are formed as a unitary element. 
     Advantageously, the unitary element has substantially the form of a poppet or mushroom valve. 
     Preferably, the unitary element comprises an axially fluted or flanged stem. 
     Preferably, the axial flutes or flanges are longitudinal flutes or flanges radially dimensioned to provide a close fit between the unitary element and the inner cylindrical wall or surface of the valve housing. 
     Suitably, the unitary element is formed of an alloy or polymeric material, preferably a polyoxymethylene. 
     Suitably, the first valve is a screw-down valve, gate valve, needle valve or globe valve, preferably a screw-down or globe valve. 
     Suitably, the first valve actuator is manually operatable actuator, such as a lever or wheel, or a pneumatically or electrically operatable actuator. 
     Preferably, the first valve includes a valve seat and a valve head including a valve gear to which is mounted a washer for adjustment of a separation between the washer and the valve seat as the first valve head is rotated between the first and second positions; and wherein the washer or a washer mounting bears against the second valve actuator as the valve head is adjusted between the first and second positions to cause the second valve to open and becomes spaced from the second valve actuator in the third position. 
     Preferably, the valve seat is demountable from the fluid control valve body. 
     Preferably, the second valve further comprises biasing means to apply a biasing force to the second valve sufficient to bias the valve into a rest or closed position in which the flow of fluid through the valve body is prevented. 
     Advantageously, the valve is in the form of a tap or faucet. 
     Preferably, the inlet is in the form of a tail for operative connection to a fluid supply and the outlet is in the form of a tap body having a spout. 
     Preferably, the tap body includes a valve seat and the tap head includes a tap gear to which is mounted a washer for adjustment of a separation between the washer and the valve seat as the tap head is rotated between the first and second positions; and wherein the washer or a washer mounting bears against the second valve actuator as the tap head is rotated between the first and second positions to cause the second valve to open and is spaced from the second valve body actuator in the third position by an amount sufficient to allow the second valve to close under the pressure of fluid at the inlet. 
     Preferably, the valve seat is demountable from the tap body. 
     Preferably, the first valve is mounted to the actuator. 
     Preferably, the valve body is demountable to the tap body. 
     Preferably, the valve body includes a threaded stem and has an enlarged head, wherein the tap body is securable to the enlarged head. 
     Preferably, the tail is formed integrally with the valve body. 
     Preferably, the valve body includes a first valve seat wherein the first valve seat is demountable to the tap body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects of the present invention will now be described in further detail, by way of example only, with respect to the accompanying drawings, in which: 
         FIG. 1  is an exploded, part cross-sectional view of a first embodiment of a fluid control valve in accordance with the present invention in the form of a tap; 
         FIG. 2  is a side view of the tap of  FIG. 1  in a first or operatively open configuration; 
         FIG. 3  is a side view of the tap of  FIG. 1  in a second or operatively closed configuration; 
         FIG. 4  is an exploded cross-sectional view of a modification of the tap of  FIG. 1 ; 
         FIG. 5  shows, in cross-section and plan views, certain components of the tap of  FIG. 4 ; 
         FIG. 6  is a cross-sectional view of a second embodiment of a tap in accordance with the present invention in a disassembled configuration; and 
         FIG. 7  is a cross-sectional view of the tap of  FIG. 6  in an assembled configuration. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring initially to  FIGS. 1 to 3 , there is shown a first embodiment of a fluid control valve in accordance with the present invention in the form of a tap assembly. The tap assembly  10  includes a threaded tail  11  of an inlet for operative fluid connection to a source of water by means of a compression coupling in a conventional manner. The tap is mountable in a conventional manner to a surface, such as the surface of a bath, basin or sink as appropriate, by means of a threaded nut  12  with a washer  13  interposed therebetween. 
     In accordance with the present invention, tap assembly  10  has two principal elements, tap body  14  and valve body  15 . Tap body  14  includes a tap head including a rotatable handle  20  for adjustment, in a conventional manner, of a tap gear  21  (commonly known as a rising spindle), to the lower surface of which is mounted a washer  22 . In a conventional manner, tap washer  22  bears against a tap seat  23  to allow flow of water through the tap body from the inlet through spout  24 . 
     As shown, in preferred embodiments of the present invention, tap seat  23  is formed on a demountable cylindrical tap seat body  25  having a throughbore to allow for the passage of fluid therethrough. By providing the seat  23  on a demountable and therefore replaceable element, the tap seat can be readily replaced when life-expired without requiring replacement of the entire tap. This forms another aspect of the present invention. Tap seat body  25  is mountable to tap body  14  by means of a threaded male portion  26  formed to seat body  25  engageable with a correspondingly threaded female throughbore  27  formed within tap body  14  (threads omitted for clarity). 
     Valve body  15  includes a cylindrical valve housing  30  having an enlarged head which, in use, sits above the surface to which the tap is mounted, and a threaded outer surface forming tail  11  of the tap and having an inner cylindrical surface, which is stepped at a lower portion thereof such that the upper portion  32  of valve housing  30  is of greater internal diameter than the lower portion  33 . Upper portion of valve housing  30  is dimensioned for sealable receipt of a lower portion of tap seat body  25 . An O-ring seal  31  is provided to the lower portion of tap seat body  25  for provide a fluid seal between the two components. 
     Lower portion of valve housing  30  is formed with a frusto-conical seat surface  34 . Valve body  15  further includes a valve plug  35  which bears, in use, against frusto-conical seat surface  34  to define a valve, closing the flow of fluid through valve body  15  as will be described further below. 
     A generally conical or frusto-conical valve plug  35  is mounted on a valve guide rod  40  by means of mutually cooperating threads and is secured in position with a nut  41 . Valve plug  35  and its associated guide rod  40  are constrained to move axially within valve housing  30  by means of one or more stem guides  42 . In the embodiment shown in  FIG. 1 , a single stem guide  42  is provided. In use, stem guide  42  bears against shoulder  43  formed in the stepped inner cylindrical surface of valve housing  30 . A simple rubber O-ring washer  44  retains the guide rod  40  to stem guide  42  and thereby retains the valve plug and guide rod assembly within the valve housing. 
     In the embodiment of  FIG. 4 , a pair of stem guides  42  are provided in a spaced relationship. This acts to ensure more positive axial movement with less risk of off-axis movement to guide rod  40 . Alternative arrangements will be readily apparent to the skilled person. As shown in  FIG. 5 , stem guide  42  is suitably formed with a generally star-shaped appearance, such that there is as little interference with the flow of fluid as possible. 
     As shown in  FIGS. 1 to 3 , the entire tap is assembled by fitting tap seat body  25  to tap body  14 ; engaging valve body  15  with tap body  14  and securing the two components together with grub screws  45  passing through apertures formed in sidewalls of tap body  14  engaging recesses formed in valve body  15 . 
     The operation of the tap will now be described in further detail, with particular reference to  FIGS. 2 and 3 .  FIG. 2  shows the tap of the present invention in a normal operative configuration. The tap is operable in a conventional manner. Tap handle  20  is rotatable into a closed configuration (usually by rotation on a clockwise direction) until washer  22  bears against tap seat  23 , thereby closing the flow of water through the tap body to spout  24  and defining a first configurational position for the tap. Rotation of handle  20  in the reverse direction, lifts washer  22  away from engagement with the tap seat  23  into a second configurational position, thereby allowing flow of water to spout  24 . 
     Tap handle  20  is rotatable between a first configurational position in which tap washer  22  bears against tap seat  23  as described above; through a second configurational position in which tap washer  23  is spaced from tap seat  23  to allow flow of water through the tap; and to a third configurational position in which tap washer  23  is spaced further from the tap seat  23 . In both of the first and second configurational positions, tap washer  23  bears against the upper end of valve guide rod  40 . 
     The length of rod  40  is selected such that valve plug  35  is spaced from its valve seat surface  34  in both of these configurations to allow water to flow through valve body. The length is also selected such that, in the third configurational position, tap washer  22  is spaced from the upper end of valve guide rod  40  or contacts the rod but provides substantially no force against the rod. Accordingly, in the third configurational position, the pressure of water within the feed pipe to tail  11  of the tap bears against the outer surface of valve plug  35  and causes it to close against valve seat surface  34 , thereby closing the tap assembly  10  from admission of water. 
     In this third configuration, the inside of the tap assembly downstream of valve  34 , 35  is open to atmosphere rather than water pressure. As such, tap body  14  can be removed from valve body  15  following removal of grub screws  45 . 
     With tap body  14  removed, maintenance can be carried out. For example, washer  22  can be replaced, valve seat  23  can be re-ground if necessary or tap seat body  25  replaced completely if life-expired. 
     Alternatively, the system of the present invention allows the development of a range of designs of tap bodies attachable to a common valve body  15 , providing a simple mechanism for replacement of taps. 
     In contrast to the systems of the prior art, disconnection of the pressurised water flow to the tap is automatic rather than requiring the homeowner to operate a shut-off valve, with such valves often being in an inconvenient location, especially in the case of bath taps where the valve may be behind bath panels or tiles. 
     Additionally, the system of the present invention finds advantages in the construction industry. A “utility” design of tap body can be used during construction to test the pipework and can be replaced shortly before completion with the final tap body, thereby avoiding damage to possibly expensive tap bodies or theft. 
     Reinstatement of the water supply is simply the reverse process. The tap body  14  is located over the head of valve body  15  and secured thereto by grub screws  45 . Handle  20  of the tap is then rotated towards the closed position. When washer  22  contacts rod  40  and begins to bear against it (second configurational position), valve plug  35  is caused to move away from its closed position against valve seat surface  34 , thereby allowing admission of water to the tap. Further rotation of the handle takes the handle to the first configurational position where washer  22  bears against seat  23  to close the tap. 
     In preferred modifications (not illustrated), valve plug  35  and valve guide rod  40  are formed as a unitary element. Suitably, the unitary element is moulded (cast) or machined from a material compatible with the fluid with which the valve is intended to be used. For example, the unitary element may be cast or machined from an alloy, such as brass or from a polymeric material. Polyoxymethylene is a particularly preferred material, a resilient material compatible with many fluids, especially so with water. Polyoxymethylene is suitable for both machining or moulding and provides a smooth surface which exhibits low limescale adhesion. 
     In particularly preferred embodiments, the valve guide rod part of the unitary element is provided with longitudinal flutes or flanges radially dimensioned to provide a close fit between the unitary element and the inner cylindrical wall or surface of valve housing  30 . By this means, stem guides  42  are unnecessary and may be omitted. The unitary element is advantageously formed with suitable retention means for axially retaining the element within valve housing  30 . 
     It will be appreciated that alternative constructions can be envisaged within the scope of the present invention including other valve designs, such as ceramic disc valves and other quarter turn valve assemblies. It will also be appreciated that the valve may be activated by rotation about any axis, not merely co-axially with a rising spindle valve and/or may act through a lever arrangement. 
     One alternative embodiment is illustrated in  FIGS. 6 and 7 . Where features are common to the embodiment described above, the same reference numerals are used, with the addition of the prefix  1  (eg,  10  becomes  110 ). In the embodiment shown, compared with the first embodiment, tap body  114  and tap seat body  125  are formed as a unitary component. It will be appreciated that the components may equally well be constructed with a demountable tap seat body as described above. 
     Valve body  115  is generally cylindrical in form and is attachable to tap body  114  in the same manner as described above and includes an O-ring seal  116  forming a seal between valve body  115  and a tail of valve seat body  125 . In this embodiment, as shown, the valve is in the form of a demountable valve unit  136 . Valve unit  136  is suitably attachable to valve body  115  by means of mutually cooperating threaded surfaces  137 , 138  and fluidly sealed by means of a washer  139 . Similarly, valve unit  136  includes a threaded tail for operative connection to the water supply. 
     In this embodiment, valve unit  136  includes a valve  150  (shown schematically) of the one-way or non-return type arranged in its reverse orientation such that its permitted direction of flow is opposite to that of the flow of water through the tap. Accordingly, at rest, without tap head  114  attached to valve body  115 , valve  150  prevents the flow of water from the water supply. 
     Non-return valves typically include a valve plug which is held in a closed configuration against a small biasing force, usually of a spring, but optionally of a resilient polymeric member. The flow of water in the normal desired direction opens the valve against the biasing force and a back flow causes the valve to close. 
     In the tap  110  of this embodiment, a rod  140  is provided (omitted from  FIG. 6  for clarity) which, in normal use of the tap (between the first and second positional configurations), rod  140  is pushed by washer  122  to bear against valve  150  within valve unit  136  to urge the valve into the open position. Accordingly, with the tap closed, rod  140  bears against the valve and the valve is open. As the tap is opened, rod  140  continues to bear against the valve  150  retaining it in the open position against the biasing force. As the tap handle  120  is further rotated (from the second configuration to the third configuration), the separation between washer  122  and valve  150  exceeds the length of rod  140 . Rod  140  ceases to bear against, and therefore open, valve  150 , which consequently closes under the biasing force. The supply of water to the tap body is thus terminated and continued rotation of the handle allows the handle to be removed, for replacement of the washer, or allows the tap head  110  to be removed for replacement or repair. 
     Although described and illustrated in the context of a tap of the type used with a sink, basin or bath, it will be appreciated that the fluid control valve is equally suitable for use in other fields where control over the flow of fluids is required, such as in medical applications, dental applications, hydraulic or compressed air machinery and other plumbing installations, such as radiator valves, allowing disconnection of radiators; other vessels such as water tanks, expansion tanks and so on from their isolating valves without having to drain the entire heating system; and also pumps and flow meters.