Patent Publication Number: US-11384851-B2

Title: Cartridge assembly for diverting flow

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX 
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     BACKGROUND OF THE INVENTION 
     The average modern home uses a water heater to supply hot water through the various faucets in the home. Unfortunately, the farther a faucet is from the water heater, the longer it takes hot water to work its way from the heater to the faucet. This is especially true in the morning when the pipeline is filled with once hot water that has cooled overnight. When hot water is desired in the morning, a common practice in many households is to open the hot water handle and flush out the cooled water. The volume of water flushed out by this practice may range from half a gallon to more than two gallons, depending on the temperature setting of the water heater, ambient temperature, pipe diameter, and length of pipe between the heater and the faucet. This common morning practice results in a substantial loss of clean, potable water. In 2018, there were 128 million households in the United States. If each household had flushed one gallon of cooled water every morning that year, the loss of clean, drinkable water would have been 47 billion gallons, enough water to supply the needs of 400,000 average-sized households for one year. 
     There are currently some solutions that minimize, if not eliminate, the need to flush clean, potable water down the drain. A demand-type water heater is one solution. This device can be installed near the area of use and heats water through a heating element operated by electricity or gas, providing hot water almost immediately. But there are drawbacks. Because of their low flow rate, more than one device would typically be needed to service a home. And while kitchen sinks generally have one or more electrical outlets below the sink, allowing a demand-type water heater to be installed out of sight, bathroom sinks typically do not. The effort to install electrical outlets or a separate gas line may discourage individuals from installing demand-type water heaters. Other barriers which may discourage installation are the initial cost of the system and the additional operating/energy consumption costs. 
     Another solution is a water heater recirculating system, which recirculates cooled water in a hot water pipeline back to the water heater to make hot water continuously available. This solution also requires electricity (unless the system is gravity fed) but does not require that the system be installed near the area of use. As with the demand-type water heater, the initial cost and the additional operating/energy consumption costs are barriers which may discourage the average individual from installing a recirculating system. 
     While still another solution could be to educate the public and encourage that cooled water not be flushed but, instead, captured, temporarily stored, and put to later beneficial use, adding this task to a household&#39;s daily morning activities would likely be a burden for most, especially families hurrying to prepare for work or get their children ready for school. 
     What is needed is a faucet having a cartridge assembly that will allow cooled water in a hot water pipeline to be regulated to flow along one flow path and hot water, once available, to be regulated to flow along another flow path. The cooled water could be directed to flow into a container placed under the sink, where the water would be captured and stored for later use. The hot water could be directed to flow out of the faucet spout for immediate use. The faucet would not require electrical outlet installations, ongoing operating/energy consumption costs, or much user effort. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention provides a cartridge assembly having a cartridge shell. The cartridge assembly permits flow from a flow source to be regulated by the cartridge assembly to flow along a first flow path or along a second flow path. Flow along the first flow path enters the cartridge shell through a first end and exits through at least one opening in the cartridge shell. Flow along the second flow path enters the cartridge shell through the first end and is diverted to exit through the first end. 
     In an exemplary embodiment, a cartridge assembly includes a cartridge shell. The cartridge shell includes a first end and a second end. The cartridge shell includes one opening between the first end and the second end. The cartridge assembly includes a stem. The stem is operable to be at least partially disposed within the cartridge shell. The cartridge assembly includes a moveable disk. The moveable disk is operable to be disposed within the cartridge shell. The moveable disk includes one opening. The moveable disk also includes a cavity. The cartridge assembly includes a fixed disk. The fixed disk is operable to be disposed within the cartridge shell. The fixed disk includes two openings, a first opening and a second opening. 
     In an exemplary embodiment, the moveable disk abuts the fixed disk such that the cavity in the moveable disk abuts the fixed disk. The stem is operable to be connected to the moveable disk so that rotation of the stem causes rotation of the moveable disk relative to the fixed disk. Flow entering the cartridge assembly flows either through the first end in the cartridge shell, through the first opening in the fixed disk, through the opening in the moveable disk, and exits through the opening in the cartridge shell or flows through the first end in the cartridge shell, through the first opening in the fixed disk, into the cavity in the moveable disk where the flow is diverted through the second opening in the fixed disk, and exits through the first end in the cartridge shell. 
     In an exemplary embodiment, the moveable disk and the fixed disk are configured such that movement of the moveable disk relative to the fixed disk creates a first zone of control and a second zone of control. Under the first zone of control, flow from a flow source is regulated through a range of stem rotation from a completely-closed position, which does not permit any flow to exit through the opening in the cartridge shell, to a completely-open position at a counterclockwise rotation of the stem of ninety degrees (90°), which permits a maximum flow to exit through the opening in the cartridge shell. Under the second zone of control, the flow is regulated through a range of stem rotation from a completely-closed position, which does not permit any flow to exit through the first end of the cartridge shell, to a completely-open position at a clockwise rotation of the stem of ninety degrees (90°), which permits a maximum flow to exit through the first end of the cartridge shell. Under the first zone of control, the flow is regulated by the cartridge assembly through the first end of the cartridge shell, through the first opening in the fixed disk, through the opening in the moveable disk, and through the opening in the cartridge shell. Under the second zone of control, the flow is regulated by the cartridge assembly through the first end of the cartridge shell, through the first opening in the fixed disk, into the cavity in the moveable disk where the flow is diverted through the second opening in the fixed disk, and through the first end of the cartridge shell. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a perspective view of a cartridge assembly installed in a valve body according to an exemplary embodiment; 
         FIG. 2  is an exploded perspective view of the cartridge assembly of  FIG. 1 ; 
         FIG. 3  is a bottom plan view of the cartridge assembly of  FIG. 1 ; 
         FIG. 4A  is a cross-sectional view of the cartridge assembly of  FIG. 3  along the line  4 - 4 , rotated counterclockwise ninety degrees (90°); 
         FIG. 4B  is a cross-sectional view of the cartridge shell of  FIG. 4A ; 
         FIGS. 5A-5D  are views of the base seal of  FIG. 2 - FIG. 5A  is a top plan view,  FIG. 5B  is a bottom plan view,  FIG. 5C  is a front elevational view, and  FIG. 5D  is a side elevational view; 
         FIGS. 6A-6D  are views of the moveable disk of  FIG. 2 - FIG. 6A  is a top plan view,  FIG. 6B  is a bottom plan view,  FIG. 6C  is a front elevational view, and  FIG. 6D  is a side elevational view; 
         FIGS. 7A-7D  are views of the fixed disk of  FIG. 2 - FIG. 7A  is a top plan view,  FIG. 7B  is a bottom plan view,  FIG. 7C  is a front elevational view, and  FIG. 7D  is a side elevational view; 
         FIGS. 8A-8C  are top plan views of the moveable disk of  FIG. 2  in operable relation to the fixed disk of  FIG. 2 - FIG. 8A  is a view of the moveable disk and the fixed disk in a completely-closed position,  FIG. 8B  is a view of the moveable disk and the fixed disk in a completely-open position at ninety degrees (90°) clockwise rotation of the moveable disk relative to the fixed disk; and  FIG. 8C  is a view of the moveable disk and the fixed disk in a completely-open position at ninety degrees (90°) counterclockwise rotation of the moveable disk relative to the fixed disk. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     An exemplary embodiment of a cartridge assembly  10  is shown in  FIGS. 1-4A . In the illustrated embodiment, as shown in  FIG. 1 , the cartridge assembly  10  is installed in a valve body  12 . In the illustrated embodiment, as shown in  FIGS. 2 and 4A , the cartridge assembly  10  includes a cartridge shell  14 , a stem  18 , a stem seal  16 , a stem collar  26 , a retaining clip  38 , a moveable disk  20 , a fixed disk  22 , a base seal  24 , and a cartridge shell seal  28 . Cartridge assemblies and valve bodies are well known in the art; therefore, only the relevant components of the cartridge assembly  10  and the valve body  12  will be described in greater detail. 
     In the illustrated embodiment, as shown in  FIG. 4A , the cartridge shell  14  includes a first end  30  and a second end  32 . In the illustrated embodiment, as shown in  FIG. 4B , the cartridge shell  14  includes an exterior  34  with a generally cylindrical shape. The cartridge shell  14  includes an interior  36  with a generally cylindrical shape. The cartridge shell  14  includes an opening  40  extending from the interior  36  through the exterior  34  between the first end  30  and the second end  32  of the cartridge shell  14 . Additionally, in the illustrated embodiment, as shown in  FIG. 3 , the cartridge shell  14  includes two recesses  48   a ,  48   b  arranged one hundred eighty degrees (180°) apart on the inner periphery of the cartridge shell  14 . The cartridge shell  14  can be formed of plastic, metal, or any other suitable material. 
     In the illustrated embodiment, as shown in  FIG. 1 , the valve body  12  includes a first end  11  and a second end  13 . The valve body  12  includes an inlet tube  15 . The inlet tube  15  is connected to the second end  13  of the valve body  12 . The valve body  12  includes an outlet tube  17 . The outlet tube  17  is connected to the second end  13  of the valve body  12 . The valve body  12  includes an exterior  46  with a generally cylindrical shape. The valve body  12  includes an interior (not shown) with a generally cylindrical shape. The interior of the valve body  12  generally corresponds to the exterior  34  of the cartridge shell  14 . The valve body  12  can be formed of plastic, metal, or any other suitable material. 
     In an exemplary embodiment, as illustrated in  FIGS. 5A-5D , the base seal  24  includes a top side  80  and a bottom side  82 . The base seal  24  includes a first opening  84   a  extending from the top side  80  through the bottom side  82 . The base seal  24  includes a second opening  84   b  extending from the top side  80  through the bottom side  82 . Additionally, in the illustrated embodiment, the base seal  24  includes two lugs  86   a ,  86   b  arranged one hundred eighty degrees (180°) apart on the periphery of the base seal  24  for engagement with the recesses  48   a ,  48   b  on the inner periphery of the cartridge shell  14 , as shown in  FIG. 3 . The base seal  24  can be formed of neoprene or any other suitable material. 
     In an exemplary embodiment, as illustrated in  FIGS. 6A-6D , the moveable disk  20  includes a top side  50  and a bottom side  52 . The moveable disk  20  includes a cavity  56  on the bottom side  52 . The moveable disk  20  also includes one opening  54  extending from the top side  50  through the bottom side  52 . In the illustrated embodiment, the opening  54  is configured such that the moveable disk  20  presents an open-mouth shape when viewed in plan view, as shown in  FIGS. 6A and 6B . The moveable disk  20  can be formed of ceramic material or any other suitable material. 
     In an exemplary embodiment, as illustrated in  FIGS. 7A-7D , the fixed disk  22  includes a top side  60  and a bottom side  62 . The fixed disk  22  includes a first opening  64   a  extending from the top side  60  through the bottom side  62 . The fixed disk  22  includes a second opening  64   b  extending from the top side  60  through the bottom side  62 . Additionally, the fixed disk  22  includes two lugs  66   a ,  66   b  arranged one hundred eighty degrees (180°) apart on the periphery of the fixed disk  22  for engagement with the recesses  48   a ,  48   b  on the inner periphery of the cartridge shell  14 . The fixed disk  22  can be formed of ceramic material or any other suitable material. 
     In the illustrated embodiment, as shown in  FIG. 4A , the stem  18  includes a first end  42  and a second end  44 . A handle (not shown) is connected to the first end  42  of the stem  18 . The second end  44  of the stem  18  is operably connected to the top side  50  of the moveable disk  20 . The bottom side  52  of the moveable disk  20  abuts the top side  60  of the fixed disk  22 . The bottom side  62  of the fixed disk  22  abuts the top side  80  of the base seal  24 . The first opening  84   a  in the base seal  24  is aligned with the first opening  64   a  in the fixed disk  22 . In the illustrated embodiment, the second opening  84   b  in the base seal  24  is aligned with the second opening  64   b  in the fixed disk  22 , as shown in  FIG. 4A . 
     In an exemplary embodiment, a flow source is connected to the inlet tube  15  of the valve body  12 . The inlet tube  15  abuts the first opening  84   a  in the base seal  24 . The outlet tube  17  abuts the second opening  84   b  in the base seal  24 . Rotation of the handle causes rotation of the stem  18 . Rotation of the stem  18  causes rotation of the moveable disk  20  relative to the fixed disk  22 . In an exemplary embodiment, as illustrated in  FIG. 8A , when the handle and the stem  18  are in a completely-closed position, the opening  54  in the moveable disk  20  is not aligned with the opening  64   a  in the fixed disk  22  nor does the opening  54  in the moveable disk  20  overlap any portion of the opening  64   a  in the fixed disk  22 . Further, in the completely-closed position, the cavity  56  in the moveable disk  20  is aligned with the second opening  64   b  in the fixed disk  22 , but the cavity  56  is not aligned with the first opening  64   a  in the fixed disk  22  nor does the cavity  56  overlap any portion of the first opening  64   a  in the fixed disk  22 . 
     In the completely-closed position, the handle, stem  18 , and moveable disk  20  are at zero degrees (0°) of rotation. As the handle and the stem  18  are rotated in a clockwise direction from the completely-closed position, the cavity  56  in the moveable disk  20  begins to overlap the first opening  64   a  in the fixed disk  22 . As the handle and the stem  18  are further rotated, the amount of overlap increases. In an exemplary embodiment, as illustrated in  FIG. 8B , when the handle and the stem  18  are rotated to a completely-open position at a handle and stem  18  rotation of approximately ninety degrees (90°) in the clockwise direction, the cavity  56  in the moveable disk  20  is aligned with both of the openings  64   a ,  64   b  in the fixed disk  22 . 
     In an exemplary embodiment, as the handle and the stem  18  are rotated in a counterclockwise direction from the completely-closed position, the opening  54  in the moveable disk  20  begins to overlap the first opening  64   a  in the fixed disk  22 . As the handle and the stem  18  are further rotated, the amount of overlap increases. In an exemplary embodiment, as illustrated in  FIG. 8C , when the handle and the stem  18  are rotated to a completely-open position at a handle and stem  18  rotation of approximately ninety degrees (90°) in the counterclockwise direction, the opening  54  in the moveable disk  20  is aligned with the first opening  64   a  in the fixed disk  22 . 
     In an exemplary embodiment, the moveable disk  20  and the fixed disk  22  are configured in the cartridge assembly  10  to create two (2) zones of control. Under the first zone of control, flow from a flow source enters the inlet tube  15  and is regulated through a range of counterclockwise rotation of ninety degrees (90°) of the stem  18  from the completely-closed position to a completely-open position. The first zone of control regulates the flow through the first end of the cartridge shell  30 , through the first opening  84   a  in the base seal  24 , through the first opening  64   a  in the fixed disk  22 , through the opening  54  in the moveable disk  20 , and through the opening  40  in the cartridge shell  14 . Under the second zone of control, the flow enters the inlet tube  15  and is regulated through a range of clockwise rotation of ninety degrees (90°) of the stem  18  from the completely-closed position to a completely-open position. The second zone of control regulates the flow through the first end of the cartridge shell  30 , through the first opening  84   a  in the base seal  24 , through the first opening  64   a  in the fixed disk  22 , into the cavity  56  in the moveable disk  20  where the flow is diverted through the second opening  64   b  in the fixed disk  22 , through the second opening  84   b  in the base seal  24 , through the first end of the cartridge shell  30 , and through the outlet tube  17 . 
     One of ordinary skill in the art will now appreciate that the cartridge assembly permits flow from a flow source to be regulated by the cartridge assembly to flow along a first flow path or along a second flow path. Flow along the first flow path enters the cartridge shell through a first end and exits through at least one opening in the cartridge shell. Flow along the second flow path enters the cartridge shell through the first end and exits through the first end. Although the cartridge assembly has been shown and described with reference to particular embodiments, equivalent alterations and modifications are within the scope of the cartridge assembly. The cartridge assembly is limited only by the scope of the following claims in light of their full scope of equivalent alterations and modifications.