Patent ID: 12215487

DETAILED DESCRIPTION

In one example embodiment of this disclosure, a tub spout faucet having an automatic temperature-controlled diverter for diverting water to a showerhead, and that has minimum back-flow pressure so that water does not undesirably divert to the showerhead until the diverter is actuated is disclosed.

A water control system includes a temperature controlled showerhead and a tub faucet having a temperature controlled valve. The faucet has a hot bypass mode, and a cold bypass mode. In the bot bypass mode, water flows through the faucet until its temperature reaches a predetermined temperature, and then the valve closes and operates as a diverter, directing the heated water to the temperature controlled showerhead. The faucet can be reset to allow water flow through the faucet regardless of water temperature to take a both. In the cold bypass mode, the faucet can be manually set to divert water to the temperature controlled showerhead, regardless of temperature, such as to provide a cold shower.

Referring now toFIG.1there is shown an example embodiment according to this disclosure depicting a water saving system10including a tub faucet12, a temperature controlled showerhead14, a water mixing valve15configured to receive a cold water from source16and hot water from source17, and plumbing18extending between these elements. The mixing valve15has a control19controllable by a user to establish a desired temperature of water that is provided to the tub faucet12and/or showerhead14through plumbing18.

The temperature controlled showerhead14has a flow control valve configured to restrict a flow of water through the showerhead as a function of water temperature, such that when the flow of water reaches a predetermined temperature the flow of water is restricted and/or blocked. The reset member allows the user to override the flow control valve and allow water to flow through the showerhead14regardless of water temperature, such as to take a shower. Applicant hereby incorporates the teachings of commonly assigned U.S. Pat. No. 8,434,693, filed Dec. 13, 2010 detailing an example of the showerhead14. In another embodiment, the showerhead14may be a conventional drip Navy-type showerhead, or a drip showerhead that can be manually reset to allow water to flow and which is automatically reset when water pressure is removed.

Advantageously, the tub faucet12includes a water saving valve22positioned in the faucet12and is configured to be positioned as a function of the water flowing through the faucet, and also has a manually settable override member24. The valve22is configured to restrict the flow of water through the faucet12when water flowing through the faucet reaches and exceeds a temperate threshold. In addition, when the valve22is closed, the water flow is automatically directed from the faucet12to the showerhead14. Thus, the valve22operates as both a temperature controlled valve and also as a tub spout diverter valve. The valve22also includes a manually operable override member24configured to disable the valve22such that wafer of any temperature can flow through and exit the valve22.

Referring toFIG.2, faucet12is shown according to one example embodiment of this disclosure.

Referring toFIG.3, cross sectional view of faucet12is shown having a valve22positioned therein. The valve22is shown in a first position allowing water to freely pass through the faucet12. Valve22is secured in a tubular faucet body26. Valve22comprises of an annular body front30threadably received into a proximal end of an annular main body32secured to faucet body26. An upstream port34is defined at a proximal opening of body front30. An annular middle body36has a proximal end annularly disposed about a distal end of main body32, and has a distal end threadably received in an annular end body38. A distal end of end body38has a downstream port40positioned at the outlet of faucet body26. An axially slidable sleeve42is axially positioned in the end body38.

A slidable piston50is axially and slidably disposed in the sleeve42. Piston50has a recessed middle portion52defined between a proximal O-ring54and a distal O-ring55, the recessed piston middle portion52forming an annular fluid passageway56extending between the piston middle portion52and an opposing inner wall58of sleeve42, as shown. When fluid is permitted to flow through valve22, a fluid path60extends from passageway56to an outwardly tapered proximal end62of sleeve42. An O ring64is provided in an annular outer recess at the proximal end62providing a fluid seal between the sleeve42and the end body38.

A spring64is annularly positioned in the distal end of end body38and in the distal end of the piston50. The spring64is compressed, and is engaged against an inner flange66at the distal end of end body38and a distal end of the piston50. The spring64is configured to bias the piston50proximally and away from the flange66. A spring68is annularly positioned in the distal end of end body38that encompasses the sleeve42and extends between an end flange of end body38and a flange of sleeve42. Spring68is configured to bias the sleeve42proximally. Seal69seals the sleeve42with respect to the end body38.

The temperature sensitive actuator70is axially and threadably received in an annular flange72defined at the distal end of middle body36. The actuator70may be a paraffin wax actuator. The actuator70has an actuator nose74that axially extends and pushes a proximal end of piston50when the temperature of water passing about the outer surface of actuator70, and through openings76defined each side of annular flange72, reaches and exceeds a predetermined temperature. As shown inFIG.4, the extension of the actuator nose74axially pushes the piston50distally such that proximal seal54of piston50extends into the sleeve42and closes the passageway56, thus preventing the flow of water through sleeve42and the valve22. Therefore, the closed valve22functions as an automatic diverter, and warmed fluid flow is automatically directed from the faucet12to the showerhead14.

An actuator spring78is a secondary spring positioned in the end body38, and is in the compressive state. Spring78is configured to counteract the sleeve42when manually put in manual cold bypass mode (FIG.5) to help the valve22reset each time to its original position in the hot bypass mode (FIG.3andFIG.4). The spring78engages the proximal end of sleeve42and extends to and against the distal end of middle body36. The spring78distally biases the sleeve42into the end body38as shown inFIG.3andFIG.4, but also permits the sleeve42to move proximal as shown inFIG.5when urged by the override member24to manually close the passageway56and prevent flow of fluid through valve22, regardless of the temperature of the fluid proximate the actuator70. Thus, water flow is manually directed from faucet12to the showerhead14at a temperature established by the mixer16.

Referring toFIG.5, the valve22is shown in the cold bypass mode. End body38includes a threaded annular extension80. Extension80is configured to receive a radially extending pin82extending through a collar84having 2 opposing tapered upper surfaces83, forming a cam. A lever85extends radially from a midsection of pin82each side of pin82, and rides upon the respective upper surface of the collar84causing the pin82to retract away from valve22when rotated counterclockwise. The pin82is further shown inFIG.6. The pin82has a distal tip portion86, and has a radially extending cam88configured to selectively engage a flanged surface92of sleeve42. A handle90is secured to the outer end of pin82by a fastener91. A spring94is defined between an annular pin flange96and an inner surface of a cap98. The cap98is threadably connected to the extension80. The spring94is configured to assist in returning the handle24to the hot bypass mode position when rotated clockwise.

FIG.7shows the cam88position in the hot bypass mode, corresponding toFIG.4. Upon rotation of the handle90and the cam88in the clockwise direction and laterally engages a flange92annularly defined about the proximal end of sleeve42as shown inFIG.8. As the handle90and cam88continue to rotate the cam88pushes the sleeve42proximally, as shown inFIG.9, such that piston50extends distally into sleeve42and closes passageway56, and thus restricts fluid flow in the valve22in the cold bypass mode. The pin85riding along the upper surface of collar84helps reduce friction between cam88and the surface of sleeve42during rotation. In the cold bypass mode, cold water is thus directed to showerhead14to provide a cold shower.

When the handle90is rotated counter-clockwise, from the position shown inFIG.9to the position shown inFIG.7, the cam88retracts from flange92and the spring78pushes the sleeve42back into the hot bypass mode such as shown inFIG.3andFIG.4, such that the piston50can move in response to the extended actuator nose74.

Advantageously, the valve22can operate to automatically deflect hot water to the showerhead14, referred to as the hot mode, or can be manually set to manually directed cold water to the showerhead14, referred to as the cold mode. In both modes, a significant water savings is obtained by preventing an excess amount of water being dispensed through the tub faucet to establish the shower mode with either hot or cold water.

Referring now toFIG.10, there is shown a perspective view of another embodiment of a tub faucet at100including an automatic temperature-controlled diverter for diverting water to a showerhead, which diverter creates minimum back-flow pressure so that water does not undesirably divert to the showerhead until the diverter is actuated.

The tub faucet can be reset with less than 10 lbs. of pressure and meets the American Disabilities Act (ADA) requirements

Reset Mode

FIG.10shows faucet100in the Reset Mode, which is defined as the mode when the faucet100is not in use, and when water flowing through the faucet100is below a predetermined temperature threshold at which point the faucet100would enter the Auto-Divert Mode (FIG.15).FIG.11shows a front view of faucet100, andFIG.12shows a side sectional view of the faucet100in the Reset Mode, taken along line12-12inFIG.11.FIG.13shows a side sectional view of the faucet100in the Reset Mode, taken along line13-13inFIG.11, andFIG.14is an enlarged view of a diverter valve shown inFIG.13.

The faucet100includes a diverter valve102positioned in a water flow channel104defined in an outer body105, shown in a first position. The channel104longitudinally extends through the faucet100from an inlet port106to an outlet port108. The valve102is configured to be automatically positioned in the channel104as a function of the temperature of water flowing through channel104.

Advantageously, in the Reset Mode, the structure of the diverter valve102is configured to create low back-pressure such that water from the source does not undesirably backflow up to the showerhead. For instance, when the source water pressure is at 100 psi, the diverter generates no more than 2 psi back-pressure, and preferably at or below 1.5 psi. This low back-pressure is achieved by the detailed design of the diverter valve102and how it interacts with the tub faucet housing, minimizing and avoiding surfaces that are perpendicular to the incoming water flow, the configuration and size of the various openings and passageways, and the configuration of the temperature controlled actuator including the anti-hammering mechanism.

As will be discussed shortly, the valve102is also manually positionable as a function of a longitudinally piston shaft110extending longitudinally in a distal end of the channel104. A vertically extending lever12is positioned at the distal end of faucet100and is pivotably connected to a distal end of shaft110at a pivot114. The pivot114is formed in a pivot coupler116threadably connected to a threaded distal end118of shaft110. A lower end120of lever112is pivotably connected to a distal end of faucet housing122at pivot124forming a leverage point. An upper end126of lever112can be grasped by a user and pulled outwardly to manually set the valve102in an arrangement such that the faucet is in a Manual Divert Mode and water is diverted to the showerhead14, such as to take a cold shower. The upper end126can also be pushed by a user toward the faucet housing122using less than 10 lbs. of force, meeting the ADA requirement, to set the valve102in a Manual Bypass Mode such that hot water continues to flow through the channel104regardless of water temperature to take a hot bath. This Manual Bypass Mode allows water to bypass the valve102, and is also referred to as an override position.

Referring toFIGS.12-14illustrating the Reset Mode, the valve102is configured to restrict the flow of water through the channel104when water flowing through the channel104reaches and exceeds a temperate threshold. When the valve102is closed, the water flow is automatically directed from the faucet100to the showerhead14. Thus, the valve102operates as both a temperature controlled valve and also as a tub spout diverter valve. The valve102is shown in a first position allowing water to freely flow in channel104from the inlet port106and freely pass around valve102to the outlet port108. Valve102is secured in the tubular outer body105.

Valve102comprises of an annular actuator adapter130having a proximal end threadably receiving a distal end of an annular actuator cap132. An annular piston diverter shield134has a proximal end threadably receiving a distal end of adapter130. Shield134is secured in a distal end of outer body105by a screw135, and a seal137provides a liquid seal about the screw135. A two piece annular piston shaft receiver is positioned in shield134, and comprises a distal piston shaft receiver136and a proximal piston shaft receiver138with a piston receiver seal140interposed between the two receivers. An outer receiver seal o-ring142provides a seal between the proximal shaft receiver138and an inner surface of shield134, and a piston gland o-ring144extends annularly about an inner wall of proximal shaft receiver138, located proximal of the distal piston shaft receiver136.

A thermal actuator150is threadably received through an opening152in the proximal end of actuator cap132. The actuator150may be a paraffin wax actuator, or other temperature sensitive actuator, such as a bi-metal spring. The actuator150has an actuator nose154that axially extends as water temperature increases, and responsively pushes a proximal end of a longitudinally movable piston156when the temperature of water passing about the proximal end of actuator150. Piston156has a proximal end positioned in adapter130and receiving the distal end of actuator150. A spring157is positioned within adapter130between a distal flange of adapter130and a proximal flange of piston156, and is in the compressive mode operative to retract piston156proximally. Piston156has a distal end extending through a distal opening of adapter130and into proximal shaft receiver138. Piston156has an annular shoulder158configured to be received in and engage the piston gland o-ring144

In the Reset Mode, there is spacing between the distal end of piston156and an inner surface160defined in an inner portion162of distal piston shaft receiver136. A pilot hole forming a passageway164is shown extending from the inner portion162through both the distal piston shaft receiver136and the proximal piston shaft receiver138. An annular outer piston body170encompasses the distal piston shaft receiver136, and has a plurality of parallel longitudinal openings172forming passageways from a distal side of the annular outer piston body170to a proximal side of the annular outer piston body170, openings172abutting a distal side of flange174of distal piston shaft receiver136. The seal140encompasses a periphery of flange174. An annular inner piston body176encompasses the distal end of outer piston body170. The passageway164and the openings172are configured to prevent hammering of the valve102by providing a hydraulic shock, and also to reduce the required force using lever112to reset the valve102in a Bypass Mode compliant with the ADA, as will be described in more detail shortly.

An annular piston body seal180is secured within outer piston body170, and securely encompasses the periphery of inner piston body176. The seal180is comprised of a resilient material, and specifically a material that is resistant to build-up of materials such as calcium and other materials over time as water flows past the seal180. In the Auto Divert Mode, as will be described shortly, the distal face of seal180is configured to be urged by actuator150against an opposing seal interface182, formed as an annular shoulder at the proximate end of body105, to provide a seal and also prevent leakage over time.

A shaft spring184encompasses piston shaft10and is compressed between a piston shaft receiver flange186formed distal of outer piston body170and a shaft bushing188. Bushing188extends in a distal opening of housing122and has a pair of bushing o-rings190positioned around the bushing188and providing a liquid seal between the bushing122and the housing122. A shaft o-ring192is positioned around piston shaft110and provides a liquid seal between the shaft110and the bushing188. A pair of body o-rings194are each positioned about a distal end of outer body105and form a liquid seal between the outer body105and the housing122. A tub spout water shaping grate196is secured in the outlet port108, and a grate o-ring198provides a liquid seal between the grate196and the housing122.

Auto-Divert Mode

Referring now toFIGS.15-17, the valve100is shown in the Auto-Divert Mode. When the temperature of water flowing through the channel104increases and reaches or exceeds a predetermined temperature, such as 90 degrees Fahrenheit, the actuator150heats up and actuator nose154responsively extends axially such that it engages and urges the piston156distally. The piston shoulder158, in turn, pushes and urges against the piston gland o-ring144, without extending further through the o-ring144, such that the distal piston shaft receiver136moves distally until the seal180engages seal interface182and seals the channel104. Distal piston shaft receiver136continues to urge seal180against the seal interface182to maintain a complete liquid seal, such that no fluid leaks past valve102, and thus water is prevented from flowing through the channel104. Consequently, the piston shaft110extends distally and urges the lever120outwardly from housing122such that the lever is substantially vertical. Therefore, the closed valve102functions as an automatic diverter, configured to prevent water from flowing through the channel104when in a second position as a function of a parameter, such as water temperature, and water flow is automatically directed from the faucet100to the showerhead14.

Bypass Mode

Referring toFIGS.18-20, the valve100is shown in the Bypass Mode. In this Bypass Mode, water is allowed to continue flowing through channel104regardless of the water temperature, allowing the faucet to fill a tub and allow a user to take a bath. The amount of force required by the user to put the valve100in the Bypass mode is less than 10 lbs. to meet the ADA requirements, which is 10 lbs., and the applied force may be as little as 6 lbs. when the water pressure at the inlet port is 120 pounds per square inch (psi).

This low user force is created due to numerous design features as will now be described in detail. This Bypass Mode is entered from the Auto-Divert Mode by a user providing a force to the upper portion126of lever120and toward the faucet100, such that the lever120rotates about pivot124to create a lever arm and a moment force. The user may conveniently use the palm of a hand, or other body part such as an arm or foot.

As the lever120is rotated toward the faucet100, the shaft110is responsively urged through the bushing188to urge the distal piston shaft receiver136proximal. Because the actuator tip154is already extended it provides a resistance to the piston156, such that the distal piston shaft receiver136is pushed proximal and the distal end of piston156is urged through the gland o-ring144and into the inner portion of the distal piston shaft receiver136.FIG.20shows an enlarged view, where the seal180is retracted from the seal interface182and water is allowed to resume flowing in the channel104and past the valve102, past the seal180.

Referring toFIGS.21-23, there is shown the valve102when the Bypass Mode is initiated. The force required to enter the Bypass Mode is reduced to meet the 10 lb. ADA requirement because upon pushing the lever120with such a small force, the shaft110initially pushes the distal piston shaft receiver136proximal such that shaft flange186is moved proximally until it engages (ater piston body170while the seal180maintains stationary, such that they separate from one another and create a spacing200between them. This created spacing200forms a flow passageway allowing water to flow from proximal of the valve102around seal140, through the spacing200and the openings172to reduce the pressure differential across the valve102. This differential pressure reduction may be referred to as enabling the distal piston shaft receiver136to pop-off. As the pressure differential is reduced, a lower force is required to then urge the seal180to separate from seal interface182and further reduce the pressure differential and open the channel to resume continuous flow through the channel104.

Together, the lever arm, and the differential pressure reduction mechanism allows the valve102to transition from the Auto-Divert Mode to the Bypass mode while meeting the ADA requirements.

Cold Mode

The valve102can be manually set in the position shown for the Auto-Divert Mode by the user to take a cold shower. The user simply pulls the upper portion126of lever120to manually pull the shaft110and the seal180forward. This causes the seal180to engage the seal interface182and the water pressure will maintain the seal, such that cold water is diverted to the showerhead14. In this mode, the actuator tip154is not extended since the water temperature is below the predetermined temperature threshold. The valve can be reset from the Cold Mode to the Reset Mode as described above, by a user imparting a force on the lever120that meets the ADA requirements.

In the Cold Mode, Bypass Mode. Or the Auto-Divert mode, the valve102will automatically move to the Reset Mode when water pressure is removed from the faucet100, such as using handle19, due to the shaft spring184pushing the valve102toward the inlet port.

Hammer Elimination

Hammering of the valve102is eliminated due to several features. Hammering is defined as the mechanical resonance of the valve102causing the valve102to repeatedly hit the seal interface182, which may sound like a jack hammer.

Referring back toFIGS.12-14, andFIGS.22-24, as the valve102transitions from the Reset Mode to the Auto-Divert Mode, or into the Cold Mode, the seal180will eventually engage the seal interface182. As shown inFIGS.22-24, the distal piston shaft receiver136will be pushed forward by the water pressure, causing it to be pulled ahead and in advance of the flange174. When the seal180engages the seal interface182to create a seal, water is disposed in a pocket defined between seal140and seal142and forms a hydraulic shock absorber. The water in this pocket can only flow through passageway164to spacing162such that the valve102can't hammer. This may be referred to as a sol-close such that the valve102won't mechanically resonate or hammer.

The passageway164extends from the inner portion of the distal piston shaft receiver136to the channel104, such that water is positioned in the space162between the piston156and inner surface160. As the seal180engages the seal interface182with momentum, the fluid in the space162also dampens the piston156from hammering in the distal piston shaft receiver136. The passageway164allows fluid to be transferred between the space162and the channel104to also form a hydraulic shock absorber.

Leak Proof Valve Seal

As previously detailed with respect toFIGS.15-17, the seal180is comprised of a resilient material and specifically a material that is resistant to the build-up of materials such as calcium and other materials over time as water flows past the seal180. The distal face of seal180is configured to be urged by actuator150against an opposing seal interface182, formed as an annular shoulder at the proximate end of body105, to provide a seal and also prevent leakage over time.

Universal Tub Spout Adapter

Referring toFIG.25, a rear perspective view of faucet100is shown including a universal pipe mounting adapter210secured in the proximal end of faucet100. There are four different embodiments of the universal adapter as will be detailed.

FIG.26illustrates a bottom view of the faucet100.

FIGS.27-30illustrate the first embodiment of the universal adapter210seen to include an annular snap lock receiver mount212configured as a sleeve and having a bottom anchor insert214, an annular compression plate216and an annular spacer plate218. A fastener220, such as a screw, is configured to secure the compression plate216to the pipe. An annular compression seal222also configured as a sleeve is axially positioned within the receiver mount212and is configured to make a liquid seal about a copper pipe inserted through the compression seal222. A pair of mount o-rings224are each annularly positioned about a distal end of the receiver mount212and are configured to provide a liquid seal between the receiver mount212and an inner flange230of body end232threadably received in the proximal end of outer body105, as shown inFIG.12. A receiver o-ring234provides a liquid seal between the body end232and outer body105. A mounting tab236has an insert238configured to receive the fastener211to secure the adapter210within the proximal end of faucet100. Mount212has an annular angled tab239configured to be inserted through mounting tab236and snapped into place behind the tab236in a tight fit such that o-ring seals224create a liquid seal. The fastener220is configured to threadably extend through compression plate216to secure the compression plate216about an annular pipe. Compression seal242creates a seal around the pipe by fasteners250compressing the receiver mount212against the annular compression plate216and an annular spacer plate218. Faucet100has a escutcheon plate244and a foam spacer246at the proximal end. As shown inFIG.29, four fasteners250, such as screws, are configured to each extend through a distal end of mount212to secure the mount212to compression plate216.

Referring toFIGS.31-34, there is shown a second embodiment of a universal mounting adapter250configured to be secured to galvanized pipe. This embodiment is similar to the adapter210ofFIGS.27-30, except that the sleeve type compression seal222is replaced with an annular galvanized pipe seal252that has the same inner diameter as receiver mount212, and axially extends only in the proximal end of the mount212.

Referring toFIGS.35-38, there is shown a third embodiment of a universal mounting adapter260configured to be attached to a threaded pipe stub.

Referring toFIGS.39-42, there is shown a fourth embodiment of a universal mounting adapter270configured to be attached to a threaded pipe stub, similar to adapter260but having a different threading.

Though the invention has been described with respect to a specific preferred embodiment, many variations and modifications will become apparent to those skilled in the art upon reading the present application. The intention is therefore that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.