Abstract:
A frost proof sillcock system for diverting water away from a building when a tubular body of a sillcock is broken and allowing an individual to easily repair a broken sillcock. The frost proof sillcock system generally includes an outer tube fluidly connected to a supply pipe within a building and a sillcock removably connected within the outer tube. If the sillcock ruptures, the water is diverted outside of the building by the outer tube. The sillcock is replaced by rotating the sillcock to disconnect from the outer tube thereby allowing a replacement sillcock to be installed.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    I hereby claim benefit under Title 35, United States Code, Section 119(e) of U.S. provisional patent application Ser. No. 61/529,993 filed Sep. 1, 2011. The 61/529,993 application is currently pending. The 61/529,993 application is hereby incorporated by reference into this application. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable to this application. 
       BACKGROUND OF THE INVENTION 
       [0003]    1. Field of the Invention 
         [0004]    The present invention relates generally to a frost proof sillcock and more specifically it relates to a frost proof sillcock system for diverting water away from a building when a tubular body of a sillcock is broken and allowing an individual to easily repair a broken sillcock. 
         [0005]    2. Description of the Related Art 
         [0006]    Any discussion of the related art throughout the specification should in no way be considered as an admission that such related art is widely known or forms part of common general knowledge in the field. 
         [0007]    Frost proof sillcocks are utilized in geographical areas where freezing temperatures are encountered. A frost proof sillcock is designed so that the valve is positioned inside the building and thereby stops the flow of water inside of the building that is not subject to freezing temperatures. The handle and the spout are positioned outside of the building, with the tubular body of the frost proof sillcock extending into the interior of the building to be fluidly connected to the water supply of the building. A properly installed frost proof sillcock will angled downwardly toward the spout so that water within the tubular body may be drained when the valve is closed. U.S. Pat. No. 4,022,243 to Edwards illustrates a conventional frost proof sillcock. 
         [0008]    One problem with conventional frost proof sillcocks is that they are still susceptible to freezing up when a hose or other device is fluidly connected to the spout thereby preventing drainage of the water from the tubular body. When water within a conventional frost proof sillcock freezes, the tubular body is subject to being ruptured and when the user turns the water one via the handle the water escapes via the rupture into the interior of the building causing water damage. Another problem with conventional sillcocks is that replacing them is difficult, costly and time consuming typically requiring the services of a plumber. 
         [0009]    Because of the inherent problems with the related art, there is a need for a new and improved frost proof sillcock system for diverting water away from a building when a tubular body of a sillcock is broken and allowing an individual to easily repair a broken sillcock. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    The invention generally relates to a frost proof sillcock which includes an outer tube fluidly connected to a supply pipe within a building and a sillcock removably connected within the outer tube. If the sillcock ruptures, the water is diverted outside of the building by the outer tube. The sillcock is replaced by rotating the sillcock to disconnect from the outer tube thereby allowing a replacement sillcock to be installed. 
         [0011]    There has thus been outlined, rather broadly, some of the features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and that 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 or to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein: 
           [0013]      FIG. 1  is a front upper perspective view of the present invention installed within a building. 
           [0014]      FIG. 2  is a front upper perspective view of the present invention. 
           [0015]      FIG. 3  is an exploded front upper perspective view of the present invention. 
           [0016]      FIG. 4  is an exploded side cutaway view of the present invention. 
           [0017]      FIG. 5  is a partially exploded side cutaway view of the present invention. 
           [0018]      FIG. 6  is a side cutaway view of the present invention installed within a building. 
           [0019]      FIG. 7  is a side cutaway view of the present invention illustrating a ruptured frost proof sillcock with the water flowing outside of the building. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A. Overview. 
       [0020]    Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views,  FIGS. 1 through 6  illustrate a frost proof sillcock system  10 , which comprises an outer tube  50  fluidly connected to a supply pipe  16  within a building and a sillcock  20  removably connected within the outer tube  50 . If the sillcock  20  ruptures, the water  11  is diverted outside of the building by the outer tube  50 . The sillcock  20  is replaced by rotating the sillcock  20  to disconnect from the outer tube  50  thereby allowing a replacement sillcock  20  to be installed. 
       B. Outer Tube. 
       [0021]      FIGS. 2 and 3  best illustrate the outer tube  50  which is comprised of an elongated structure. The outer tube  50  may be comprised of various materials such as but not limited to metal, plastic or composite materials. It is preferable that the outer tube  50  has a circular cross sectional shape to correspond with conventional sillcocks  20  that typically have a circular inner tube  22 . However, the outer tube  50  may have various cross sectional shapes such as but not limited to square, rectangular, oval, hexagonal and the like. 
         [0022]    The outer tube  50  has a length sufficient to extend completely through a wall  12  from the outside surface  13  thereof to the inside surface  14  of the wall  12  as illustrated in  FIGS. 1 ,  5 ,  6  and  7  of the drawings. When installed within a wall  12 , the outer tube  50  preferably is included downwardly from the inside surface  14  to the outside surface  13  of the water  11  to facilitate draining of the outer tube  50  and the sillcock  20 . 
         [0023]    The outer tube  50  includes an outer opening  56  that is exposable outside of a wall  12 . The outer opening  56  discharges water  11  that is received within the outer tube  50  because of a ruptured sillcock  20  due to freezing or other type of damage. For example, if the sillcock  20  incurs a ruptured opening  15  due to freezing of water  11 , building movement or other cause, water  11  flowing from the ruptured opening  15  is diverted outside of the building through the interior of the outer tube  50  to outwardly from the outer opening  56  of the outer tube  50  instead of into the wall  12  or inside of the building. 
         [0024]    The interior width of the interior of the outer tube  50  is larger than the exterior width of the sillcock  20  to provide a space for water  11  to be received and discharged from within the interior of the outer tube  50  when the sillcock  20  is damaged resulting a ruptured opening  15 . The space between the outer tube  50  and the inner tube  22  is preferably sufficient to allow a normal unobstructed flow of water  11  from the sillcock  20 . 
         [0025]    The outer tube  50  is fluidly connectable to a supply pipe  16  within a building to provide pressurized water  11  to the sillcock  20  as illustrated in  FIGS. 1 ,  2 ,  5 ,  6  and  7  of the drawings. The supply pipe  16  may be directly connected to the outer tube  50  or a second coupler  60  may be connected between the supply pipe  16  and the outer tube  50 . If a second coupler  60  is used, the second coupler  60  may be integrally formed within the outer tube  50  or attached to the outer tube  50 . 
         [0026]    The outer tube  50  includes an inner flange  52  that is positioned outside of the wall  12  of the building preferably adjacent to the outside surface  13  of the wall  12  as best illustrated in  FIGS. 3 ,  5 ,  6  and  7  of the drawings. The inner flange  52  preferably extends around the entire outer opening  56  of the outer tube  50  as illustrated in  FIG. 3  of the drawings, however, the inner flange  52  may only partially extend around the outer opening  56  of the outer tube  50 . For example, the inner flange  52  could extend from a lower-middle portion to an upper end of the outer tube  50  thereby leaving a discharge port for the water  11  to escape from in the lower portion of the outer opening  56 . The inner flange  52  preferably includes a pair of third apertures  54  that are aligned with the first apertures  29  of the outer flange  28  and the second apertures  46  of the spacer  40  to receive corresponding fasteners  18  to secure the same to the wall  12 . 
       C. Sillcock 
       [0027]    The sillcock  20  may be comprised of any conventional outdoor faucet capable of dispensing water  11  for outdoor watering needs (e.g. watering a garden, watering a lawn, washing a vehicle, cleaning a building, providing water  11  to animals, etc.). The sillcock  20  is preferably comprised of a frost proof sillcock  20  wherein the control valve  25  is positioned within a warmer area of the building to prevent freezing of the water  11  behind the control valve  25 . U.S. Pat. No. 4,022,243 to Edwards illustrates a conventional frost proof sillcock  20  and is hereby incorporated by reference. 
         [0028]    The sillcock  20  includes a spout  24  (preferably male threaded) for connecting a hose  19  or other outdoor irrigation device to the spout  24 . The sillcock  20  further includes a handle  26  connected to a valve stem  23  that extends through the inner tube  22 , wherein the valve stem  23  is connected to the control valve  25  to open and close the control valve  25 . As is well known in the technology of sillcocks  20 , when the user rotates the handle  26 , the valve stem  23  is rotated thereby causing the control valve  25  to open and close based upon the direction of rotation. The sillcock  20  further preferably includes an outer flange  28  that includes a pair of first apertures  29  as illustrated in  FIG. 3  of the drawings. The inner tube  22  of the sillcock  20  is comprised of an elongated tube that is fluidly connected between the spout  24  and the outer tube  50  to provide pressurized water  11  from the supply pipe  16  to the spout  24  as controlled by the handle  26 . 
         [0029]    The sillcock  20  is preferably removably positioned and fluidly connected within the interior of the outer tube  50  as illustrated in  FIGS. 1 ,  2 ,  6  and  7  of the drawings. While it is preferable that the sillcock  20  is removably positioned within the outer tube  50 , it can be appreciated that non-removable versions may be utilized in combination with the outer tube  50 . 
         [0030]    The sillcock  20  is preferably concentrically positioned within the outer tube  50  as best illustrated in  FIGS. 2 ,  5 ,  6  and  7  of the drawings. The inner tube  22  of the sillcock  20  is positioned within the interior of the outer tube  50  with the inner end  21  of the sillcock  20  fluidly connected to and sealed with respect to the outer tube  50 . The exterior perimeter of the inner tube  22  is distally spaced from an interior perimeter of the outer tube  50  to provide a passage for the water  11  to flow out of in the event a ruptured opening  15  within the inner tube  22  is created. 
       D. Couplers. 
       [0031]    The sillcock  20  includes a first coupler  30  which may be integrally formed or attached to the inner end  21  of the inner tube  22  as illustrated in  FIGS. 3 through 7  of the drawings. The outer tube  50  includes a second coupler  60  which may be integrally formed or attached to the end of the outer tube  50  opposite of the inner flange  52  as illustrated in  FIGS. 1 through 7  of the drawings. 
         [0032]    The first coupler  30  is removably and fluidly connectable to the second coupler  60  as illustrated in  FIGS. 5 through 7  of the drawings. The first coupler  30  includes a first coupler end  32  that preferably extends into the inside of the inner end  21  of the sillcock  20  as illustrated in  FIGS. 4 and 5  of the drawings. The second coupler  60  includes a first end  62  that is positioned within the outer tube  50  and a second end  64  opposite of the first end  62  that fluidly connects to the supply pipe  16 . The supply pipe  16  maybe an pipe within the building that supplies water  11 . 
         [0033]    A seal  38  (e.g. O-ring) is attached to the perimeter of the second coupler end  34  of the first coupler  30  to form a seal  38  within the interior surface of the outer tube  50  or the interior passage of the second coupler  60  when the sillcock  20  is installed within the outer tube  50  as illustrated in  FIGS. 6 and 7  of the drawings. The seal  38  prevents the passage of water  11  around the connection of the first coupler  30  and the second coupler  60 . 
         [0034]    The first coupler  30  and the second coupler  60  are preferably comprised of quick couplers to allow for the efficient removal of an existing sillcock  20  and replacement with a new sillcock  20 . The first coupler  30  is preferably rotatably connected and disconnected with respect to the second coupler  60  by a connecting member  66  (e.g. threading, inwardly extending portion) of the second coupler  60  engaging a helical groove or channel within the second coupler end  34  of the first coupler  30 . 
       E. Check Valve. 
       [0035]    A check valve  70  is fluidly connected to the outer tube  50 . The check valve  70  may be directly connected within the outer tube  50  or connected within the second coupler  60  as illustrated in  FIGS. 4 through 7  of the drawings. The check valve  70  is opened when the sillcock  20  is connected to the outer tube  50  wherein an engaging member  36  within the first coupler  30  engages the check valve  70  thereby allowing water  11  to flow from the supply pipe  16  to the sillcock  20 . The check valve  70  is closed when the sillcock  20  is disconnected from the outer tube  50  thereby preventing water  11  to flow from the supply pipe  16  to the sillcock  20  thereby allowing replacement of the sillcock  20  without having to turn off the water  11  inside of the building (e.g. house, commercial building). As illustrated in  FIGS. 6 and 7 , the check valve  70  is opened when the first coupler  30  is connected to the second coupler  60  thereby allowing water  11  to flow from the supply pipe  16  to the sillcock  20 . As illustrated in  FIG. 5  of the drawings, the check valve  70  is closed when the first coupler  30  is disconnected from the second coupler  60  thereby preventing water  11  to flow from the supply pipe  16  to the sillcock  20 . 
         [0036]      FIGS. 4 through 7  illustrate an exemplary check valve  70  having a bulbous shape that fits within a valve seat  68  within the second coupler  60  and includes a bias member  72  (e.g. spring) forcing the check valve  70  closed. However, various other types of check valves  70  may be utilized such as but not limited to a ball check valve  70 , a diaphragm check valve  70 , a swing check valve  70 , or a stop-check valve  70 . 
       F. Spacer. 
       [0037]      FIG. 3  best illustrates the spacer  40  having a center opening  42  positionable over the sillcock  20  and a discharge opening  44  extending downwardly forming a C-shaped structure. The center opening  42  is sufficient in size to receive the inner tube  22  of the sillcock  20  as illustrated in  FIGS. 6 and 7  of the drawings. The discharge opening  44  extends downwardly to the exterior perimeter of the spacer  40 . The spacer  40  may be comprised of various types of materials such as but not limited to plastic, metal and composite material. 
         [0038]    The spacer  40  is positioned between the inner flange  52  of the outer tube  50  and the outer flange  28  of the sillcock  20  to provide sufficient space for the water  11  discharged through the interior of the outer tube  50  to escape outwardly through the discharge opening  44 . The discharge opening  44  preferably extends downwardly thereby allowing all or at least a significant portion of the water  11  within the interior of the outer tube  50  to flow out via gravity thereby preventing the accumulation of water  11  within the outer tube  50 . The thicker the spacer  40  is, the greater the discharge opening  44  will be, so either the spacer  40  may have an increased thickness or more than one spacer  40  may be utilized. 
       G. Operation of Preferred Embodiment. 
       [0039]    In use, the user creates a hole within the wall  12  of the building (either new construction or existing construction) sufficient in size to receive the outer tube  50 . The hole is preferably angled downwardly from the inside surface  14  of the wall  12  to the outside surface  13  of the wall  12  to facilitate draining of water  11  from the sillcock  20  and the outer tube  50 . The outer tube  50  is inserted through the wall  12  until the inner flange  52  engages the outside surface  13  of the wall  12  as illustrated in  FIG. 5  of the drawings. The user then fluidly connects the supply pipe  16  from within the building to the second coupler  60  of the outer tube  50  (wherein the supply pipe  16  is initially closed for the flow of water  11  by closing the appropriate valve) as further shown in  FIG. 5  of the drawings. As discussed previously, the supply pipe  16  may be connected directly to the outer tube  50  utilizing various connecting systems (e.g. threaded connection, brazing, welding, etc.) or indirectly via the second coupler  60  which is illustrated in  FIGS. 4 through 7  of the drawings. 
         [0040]    After the outer tube  50  is properly positioned within the wall  12 , the user then positions the spacer  40  over the sillcock  20  and then inserts the inner tube  22  of the sillcock  20  into the interior of the outer tube  50  as illustrated in  FIGS. 6 and 7  of the drawings. The user presses the sillcock  20  inwardly such that the first coupler  30  engages the second coupler  60 . The user then rotates sillcock  20  approximately ninety-degrees clockwise resulting in the first coupler  30  mating with the second coupler  60 . As the first coupler  30  mates with the second coupler  60  drawing the first coupler  30  inwardly with respect to the second coupler  60 , an engaging member  36  (e.g. a pin extending crosswise within the first coupler  30 ) engages an end portion of the check valve  70  forcing the check valve  70  open against the biasing force of the bias member  72  as illustrated in  FIGS. 6 and 7  of the drawings. The user then secures the present invention by extending fasteners  18  (e.g. bolts, screws) through the apertures  29 ,  46 ,  54  into the wall  12  thereby preventing movement of the sillcock  20  and the outer tube  50 . 
         [0041]    The user may utilize the sillcock  20  as they normally would by rotating the handle  26  counterclockwise to dispense water  11  through the spout  24  and clockwise to stop the flow of water  11  which opens/closes the control valve  25  within the sillcock  20  respectively. As illustrated in  FIGS. 6 and 7  of the drawings, the control valve  25  is still positioned within a warm position within the building but is inside of the position of the check valve  70 . The user may also attached a hose  19  or other fluid transfer device to the male threading of the spout  24  (or connecting to the spout  24  via a different connection system) as illustrated in  FIG. 7  of the drawings. 
         [0042]    In a situation where the user leaves the sillcock  20  turned on thereby providing water  11  throughout the inner tube  22 , the spout  24  and the hose  19 , a ruptured opening  15  can occur when the water  11  within the inner tube  22  becomes frozen as illustrated in  FIG. 7  of the drawings. A ruptured opening  15  can also occur in situations where the sillcock  20  is turned off but the hose  19  is left attached to the spout  24  thereby preventing the draining of the sillcock  20  which in turn keeps water  11  within the inner tube  22 , the spout  24  and the hose  19  which can result in a ruptured opening  15  within the inner tube  22  as illustrated in  FIG. 7  of the drawings. Once the inner tube  22  has a ruptured opening  15 , water  11  provided from the supply pipe  16  is allowed to escape through the ruptured opening  15  (assuming the control valve  25  is turned on). The water  11  that escapes through the ruptured opening  15  is collected and transferred within the interior of the outer tube  50  to outside of the building via the outer opening  56  and the discharge opening  44  within the spacer  40  as illustrated in  FIG. 7 . By discharging the water  11  from the ruptured opening  15  outside of the building, the damage to the building from the water  11  is prevented which ordinarily would have happened with a conventional system. 
         [0043]    After the user determines the sillcock  20  is damaged, they can easily replace the sillcock  20  by removing the fasteners  18  and then rotating the sillcock  20  approximately ninety-degrees counter-clockwise thereby releasing the first coupler  30  from the second coupler  60 . Once the first coupler  30  is released from the second coupler  60 , the engaging member  36  is removed from the check valve  70  thereby allowing the bias member  72  to force the check valve  70  closed thereby preventing the flow of water  11  from the supply line until the sillcock  20  is replaced. The check valve  70  also prevents the user from having to find the appropriate valve within the building and closing the valve to stop the flow of water  11  which is conventionally done. The user then replaces the sillcock  20  by inserting a replacement sillcock  20  into the outer tube  50  such that the first coupler  30  is fully connected to the second coupler  60  thereby allowing continued operation of the sillcock  20 . 
         [0044]    Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described above. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. In case of conflict, the present specification, including definitions, will control. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive. Any headings utilized within the description are for convenience only and have no legal or limiting effect.