Patent Publication Number: US-10323395-B1

Title: Tub and shower valve replacement system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     N/A. 
     FIELD OF THE INVENTION 
     The present invention relates generally to the field of plumping fixtures and systems, and more particularly to methods and systems for tub and shower valve replacement. 
     BACKGROUND OF THE INVENTION 
     Replacement of older two- and three-handle tub and shower valves can be done using a conventional valve repair kit, which includes a front plate that is usually oval-shaped and football sized. These plates offer little room to do piping and are very difficult to install when a valve is positioned low, near the tub spout of a tub and shower. They look undesirable and are difficult to install in. 
     As such, considering the foregoing, it may be appreciated that there continues to be a need for novel and improved devices and methods for shower and bath valve replacement. 
     SUMMARY OF THE INVENTION 
     The foregoing needs are met, to a great extent, by the present invention, wherein in aspects of this invention, enhancements are provided to the existing model of devices and methods for shower and bath valve replacement. 
     In an aspect, a valve repair system can include:
         a) a main plate;   b) a plurality of fastener members, which are configured to secure the main plate around an opening in a wall;   c) a replacement valve, which is configured to connect to existing wall piping;   d) a front cover plate, which is usually supplied with a replacement valve, in a conventional valve replacement kit; and   e) a plurality of cover plate fasteners;   such that the valve to plate spacers are configured to be positioned between the replacement valve and the main plate;   wherein the front cover plate is mounted in front of the main plate, and is tightened in place with the cover plate fasteners, such that the front cover plate is tightened against the main plate with the cover plate fasteners, such that the replacement valve is pulled in towards the main plate.       

     In a related aspect, the valve repair assembly can further include:
         at least two valve to plate spacers;   such that the valve to plate spacers are locked tightly between the main plate and the replacement valve.       

     In a related aspect, the valve repair assembly can further include:
         at least one plate standoff, which is mounted between the main plate and a fastener member in the plurality of fastener members.       

     There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto. 
     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of parts a valve repair system prior to installation in a bathroom, according to an embodiment of the invention. 
         FIG. 2  is a perspective view of a valve repair system installed in a bathroom, according to an embodiment of the invention. 
         FIG. 3  is a perspective view of a valve repair kit, according to an embodiment of the invention. 
         FIG. 4  is a cross-sectional side view of a valve repair system installed in a bathroom, according to an embodiment of the invention. 
         FIG. 5A  is a perspective view of a main plate of a valve repair kit, according to an embodiment of the invention. 
         FIG. 5B  is a perspective view of a main plate of a valve repair kit, according to an embodiment of the invention. 
         FIG. 6A  is a perspective view of a pipe holder of a valve repair kit, according to an embodiment of the invention. 
         FIG. 6B  is a perspective view of a pipe holder of a valve repair kit, according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Before describing the invention in detail, it should be observed that the present invention resides primarily in a novel and non-obvious combination of elements and process steps. So as not to obscure the disclosure with details that will readily be apparent to those skilled in the art, certain conventional elements and steps have been presented with lesser detail, while the drawings and specification describe in greater detail other elements and steps pertinent to understanding the invention. 
     The following embodiments are not intended to define limits as to the structure or method of the invention, but only to provide exemplary constructions. The embodiments are permissive rather than mandatory and illustrative rather than exhaustive. 
     In the following, we describe the structure of an embodiment of a valve repair system  100  with reference to  FIG. 1 , in such manner that like reference numerals refer to like components throughout; a convention that we shall employ for the remainder of this specification. 
     In an embodiment a valve repair system  100 , as shown in  FIGS. 1 and 2 , can include:
         a) A valve repair kit/assembly  110 , including:
           i. a main plate  112 ;   ii. a plurality of fastener members  114 , which are configured to secure the main plate  112  around an opening  162  in a wall  160 , which fastener members  114  can typically be made of a metal or in some cases from a high-strength composite;   iii. a plurality of main plate screws  116 , which can be made from a metal, such as stainless steel;   iv. a plurality of plate standoffs  115 , which are mounted between the main plate  112  and the fastener members  114 , such that each main plate screw  116  protrudes through a main plate aperture  513  (as shown in  FIGS. 5A and 5B ) and a central aperture  335  (shown in  FIG. 3 ) of a plate standoff  115 , and screws into a fastener member  114 ; and   v. at least two valve to plate spacers  118 ; and   
           b) a replacement valve kit/assembly  120 , including:
           i. a replacement valve  122 , which is configured to connect to existing wall piping;   ii. a front cover plate  124 , which for example can be round or oval/football shaped. The front cover plate is usually supplied as a part of a conventional replacement valve kit  120 ; and   iii. a plurality of cover plate fasteners, which can be cover plate screws  126  or cover plate push-lock fasteners  126 , or some other type of cover plate locking fastener  126 ;   
           wherein the main plate  112  is secured to the wall with the fastener members  114 ;   such that the valve to plate spacers  118  are positioned between the replacement valve  122  and the main plate  112 ;   wherein the front cover plate  124  is mounted in front of the main plate, and is tightened in place, with cover plate screws  126  screwed through cover plate apertures  125 , via a main valve aperture  113  of the main plate  112 , such that the cover plate screws  126  are screwed into apertures  123  of the replacement valve  122 , such that the front cover plate  124  is tightened against the main plate  112 , such that the replacement valve  122  is pulled in towards the main plate  112 , such that the valve to plate spacers  118  are locked/sandwiched tightly between the main plate  112  and the replacement valve  122 ;   such that if the replacement valve  122  is installed as a floating installation, the replacement valve  122  is tightly secured to the main plate  112  that is tightly secured to the wall  160 , such that the floating installation of the replacement valve  122  is converted to a stabilized installation;   wherein the main plate  112 , the valve to plate spacers  118  and the plate standoffs  115  can be made from a plastic material, such as ABS.       

     In a related embodiment,  FIG. 2  shows a perspective view of the valve repair system  100  installed in a bathroom. The valve repair system  100 , can also be referred to as the goof plate update  100 , the goof plate system  100 , or the goof plate repair system  100 . 
     In a related embodiment, as shown in  FIG. 3 , the main plate  112  can further include at least one standoff holder  315  connected to an inner side of the main plate  112 , which at least one standoff holder  315  is configured to receive an outer end of a plate standoff  115 . The main plate  112  can further include a standoff guide protrusion  316 , located inside the at least one standoff holder  315 , which standoff guide protrusion  316  inserts into a central aperture  335  of the outer end of the plate standoff  115 , to stabilize the plate standoff  115 . 
     In a related embodiment, as shown in  FIG. 3 , the main plate  112  can further include at least one spacer holder  318  connected to an inner side of the main plate  112 , which at least one spacer holder  318  is configured to receive an outer end of a valve to plate spacer  118 . The spacer holder  318  can include a spacer guide protrusion  319 , located inside the spacer holder  318 , which inserts into a receiving aperture  319  of the outer end of the valve to plate spacer  118 , to stabilize the valve to plate spacer  118 . 
     In a related embodiment, as shown in  FIGS. 1, 4, 6A, and 6B , an inner side of the main plate  112  can further include a pipe connector  119  that is positioned adjacent to a pipe aperture  117  of the main plate  112 , which pipe connector  119  is configured to receive a connection end  612  of a pipe holder  410 , such that a holder end  614  is configured to attach to a tub pipe  140 , to stabilize the tub pipe  140 . 
     In a related embodiment, as shown in  FIGS. 1, 4, 6A, and 6B , the valve repair system  100  can include:
         a) a pipe connector  119 , positioned adjacent to a pipe aperture  117  of the main plate  112 ; and   b) a pipe holder  410 , comprising a connection part  412  and a holder part  414  connected to the connection part  412 ;   wherein the pipe connector  119  is configured to receive the connection part  412 , such that the holder part  414  is configured to attach to a tub pipe  140 , when the tub pipe  140  protrudes through the pipe aperture  117 , to stabilize the tub pipe.       

     In a related embodiment,  FIG. 4  shows a cross-sectional side view of the valve repair system  100  installed in a bathroom. 
     In a related embodiment, the valve repair system  100  can be configured to provide an effective and inexpensive way to replace a conventional 3-handle scald allowing tub and shower valve, without having to redo a whole new tub surround or bathroom, and provides for a much easier installation than using conventional oval style plates in this situation. 
     In an embodiment, a method of replacing a valve can include:
         a) Breaking a hole in the in the wall around an existing/old, irreparable, 3-handle tub and shower valve;   b) Removing the existing valve and tub spout from that area;   c) Installing a new, modern, single handle anti scald valve and tub spout, while connecting to the existing pipes that feeds the shower head. This valve may be secured to the structure of the wall or may be left “floating” and only supported by the piping;   d) Securing the plate to the wall with the fasteners, standoffs and screws. The new valve would have to be piped properly so that the valve and tub spout pipe line up accordingly with the holes in the plate;   e) A seal can be made around the plate using customer supplied vinyl caulking. The valve to plate spacers can be provided in case the installer has decided to leave the valve floating in the wall. While utilizing the valve to plate spacers one can secure the floating valve to the secured plate. This is done by putting the spacers in between the back of the plate and face of the pipes that feed the valve on the left and right; and   f) The cover plate provided by the valve manufacturer is then screwed into the valve while pulling the valve towards the plate and “sandwiching” the valve to plate spacers therefore snugging up the floating valve permanently.       

     Here has thus been described a multitude of embodiments of the valve repair system  100 , and methods related thereto, which can be employed in numerous modes of usage. 
     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention, which fall within the true spirit and scope of the invention. 
     Many such alternative configurations are readily apparent, and should be considered fully included in this specification and the claims appended hereto. Accordingly, since numerous modifications and variations will readily occur to those skilled in the art, the invention is not limited to the exact construction and operation illustrated and described, and thus, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.