Patent Document

CROSS-REFERENCE TO RELATED APPLICATION 
   This application is a divisional of, and claims priority to, U.S. patent application Ser. No. 11/633,856, filed Dec. 5, 2006. 

   STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable. 
   BACKGROUND OF THE INVENTION 
   The present invention relates to plumbing valves such as faucets. More particularly it relates to such valves which are controlled by a joystick type handle control. 
   A wide variety of plumbing control valves are known which use a single lever handle to control volume and mixing. Typically the handle extends through the top or front of a valve housing with its inner end linked to sliding and/or rotating plates or other control structures. The outer end of the handle is designed to be gripped by the consumer. See e.g. U.S. Pat. Nos. 1,798,530, 2,850,042, 3,512,547, 3,548,878, 3,693,660, 4,357,957, 4,916,966, 5,095,934, 6,209,581 and 6,286,808. 
   However, a problem with many of these designs is that pressure on the control handle during actuation can eventually cause the handle connection to loosen, which can allow the handle to inadvertently actuate or wobble. Further, over time some of these devices require a relatively large force to cause movement of the valve components, which can expedite degradation of valve internal components. Even where this is not the case, many of these designs are undesirably susceptible to wear and tear. 
   Still other of these designs do not effectively preclude environmental water, soap and dirt from entering the valve. Again, this can adversely affect performance. 
   In other developments, there have been some attempts to provide such control handles which mimic the aesthetic appearance and feel of an aviation or video game joystick. However, existing prior art designs suffer from one or more deficiencies (e.g. those noted above). 
   In still other developments there have been attempts to mount faucets in hidden enclosures associated with lavatories. For example, Kohler Co. markets a Purist™ bathroom cabinet in which the outlet for its faucet is integrated inside the cabinet. However, that system uses a conventional control handle to control outlet flow. 
   Thus, a need still exists for improved single handle plumbing valves, particularly those which present a joystick-type feel and appearance and/or which are capable of being integrated into cabinets and other box-like housings. 
   SUMMARY OF THE INVENTION 
   In one aspect the present invention provides a faucet that has a housing, a first inlet port for supplying water to the faucet, an outlet port for delivering water from the faucet, a control valve suitable to control the flow of water from the inlet port to the outlet port, a lever linked to the control valve for controlling the control valve, a joystick handle linked to the lever so as to permit relative axial movement there between, and a biasing member positioned outside the housing between the lever and joystick so as to resiliently bias the joystick away from the control valve. Typically, there is also a second inlet port for supplying water to the faucet which has a different water temperature than water supplied to the first inlet port, wherein the control valve controls both volume of water delivered out the outlet port, and the mix of water delivered out the outlet port deriving from the first inlet port versus the second inlet port. 
   In preferred forms the joystick handle has a domed inward end which rides against a complementary recess in a cover element, the cover element has an essentially central aperture through which extends at least part of the domed end, and the lever has an inward end which has a ball. 
   Some embodiments of the invention are particularly suitable to be mounted in a box with the handle (and possibly a portion of an outlet nozzle) projecting out a front of the box. The box could be a compact counter top mounted box, or could be a cabinet having storage shelving. 
   In another aspect the invention provides a faucet which has a housing, a first inlet port for supplying water to the faucet, an outlet port for delivering water from the faucet, a control valve suitable to control the flow of water from the inlet port to the outlet port, a lever linked to the control valve for controlling the control valve, a joystick handle linked to the lever, a ball positioned along the lever for movement there along, and a biasing member positioned outside the housing between the ball and joystick so as to resiliently bias the ball towards the control valve. Again, these principles can be applied to a mixing valve with multiple inlets and a valve that controls both volume and water temperature. 
   In preferred forms there is a sliding disk between the ball and housing that slides as the lever is tilted, as well as a bearing positioned between the housing and sliding disk. Most preferably the bearing is formed of an acetal copolymer. 
   In other preferred forms there is a set screw axially fixing the lever to the joystick, the faucet is in the form of a lavatory spout suitable to be mounted on a counter top, and the ball has a cavity housing a coiled spring. 
   One important advantage of the present invention is that the spring provides a resilient loading to the joystick, or from the joystick. Further, when a sliding disk is used to cover the connection between the handle, the lever and the control valve, the disk can be provided with a self-lubricating bearing. In any event, it helps seal out water, debris and cleaning solutions. 
   The resiliency of the joystick connection also minimizes wear on the internal moving parts, while providing an aesthetically pleasing feel. Importantly, the location for a spring outside the main housing facilitates assembly and maintenance. 
   Another advantage of the resilient connection is that it reduces the likelihood of cracking the cabinet or other associated supporting box. For example, the associated mirror of the cabinet may be somewhat fragile. The extra give provided by the spring is an important safeguard in reducing excess pressure. 
   Yet another advantage of the present invention is that when these faucets are used with aesthetically pleasing cabinet and other box housings, with appropriate positioning of an outlet nozzle a user can only see the joystick control and an exiting water stream. Particularly where the nozzle creates a laminar flow, this creates a highly desirable aesthetic appearance. 
   These and still other advantages of the present invention will be apparent from the detailed description which follows and the accompanying drawings. Hence, the following claims should be looked to in judging the full scope of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a bathroom storage cabinet and adjacent lavatory, where a plumbing valve of the present invention has been integrated therewith; 
       FIG. 2  is a fragmentary cross-sectional view taken generally along line  2 - 2  of  FIG. 1 ; 
       FIG. 3  is an enlarged sectional view of detail portion  3 - 3  of  FIG. 2 ; 
       FIG. 4  a view similar to  FIG. 1 , but with the  FIG. 1  cabinet replaced by a different more compact counter top mountable housing; 
       FIG. 5  is a schematic illustration of how a joystick of the present invention controls water flow and temperature; 
       FIG. 6  is an exploded perspective view of the  FIG. 4  faucet, excluding the spout; 
       FIG. 7  a perspective view of a third embodiment, in the form of a faucet with a joystick control, positioned adjacent a lavatory; 
       FIG. 8  is an exploded perspective view of the faucet of  FIG. 7 ; 
       FIG. 9  is a cross-sectional view taken along line  9 - 9  of  FIG. 7 ; and 
       FIG. 10  is a cross-sectional view similar to  FIG. 9  but with the faucet handle in a different “on” position. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring first to  FIGS. 1-6 , there is shown a sink  12  and a cabinet  16  having a faucet  14  associated therewith. The internal central portion of the cabinet  16  can contain plumbing connections and most of the parts of the faucet. The sides  18  of the cabinet can be in the form of swing-out hide-away shelves. 
   Faucet  14  includes a front  20 , which can be part of cabinet  16  (e.g. a mirrored front surface of cabinet  16 ) or can otherwise be part of a faucet housing. A outlet spout  22  is connected to the faucet  14 , and a mixing valve cartridge  24  is in fluid communication with spout  22 . 
   The precise mixing valve used is not critical provided that it can be controlled by joystick movement. For example, the mixing valve of U.S. Pat. No. 6,209,581, incorporated herein by reference, could be used to control water flow from hot and cold inlets to the outlet spout  22 . Alternatively, one could select other commercial ceramic mixing valves such as the Kerox Model GN-40A, which is advertised to be suitable for use with joystick control. 
   In any event, the cartridge should be able to accept a conventional hot water inlet connection  26  and cold water inlet connection  28 , and be connectible to a mixed water outlet tube  30 . Further, the control disks or other structures of the valve should be suitable to be activated by pivoting (or other movement) of the stick lever  32 . Further, in accordance with the present invention, a joystick type faucet handle  34  is then mounted to stick lever  32  (in this embodiment to permit relative axial movement there between). 
   A cover  42  is positioned between the joystick handle  34  and front  20 , and a biasing element  38  (in the form of a spring) is positioned outside front  20  between joystick handle  34  and stick lever  32 . Biasing element  38  biases handle  34  outward, and thus domed skirt  40  attached thereto against a corresponding recess in cover  42 . 
   Biasing element  38  is shown as a coil spring. However, other biasing structures are possible such as leaf springs, spring washers, elastomeric materials, and other resilient compressible elements such as a gas diaphragm. 
   There is also a gasket  44  between front  20  and cover  42 . Cover  42  also includes an approximately central aperture  46  through which extends at least part of domed skirt  40 . 
   Other elements include O-ring  48 , collar  50 , spring washer  52 , and nut  54 . Nut  54  is threadably engaged with casing  56  to provide an outer limit for mixing valve cartridge  24 , among other things, and screws  58  fix cover  42  to casing  56 . 
   Split nut  60  provides an inside limit for handle  34 . O-ring  62  reduces or eliminates any wobble in handle  34  and provides the user with a more positive control. Casing  56  can also include couplings (not shown) which connects inlet connections  26  and  28 , and outlet tube  30 , to corresponding ports on mixing valve cartridge  24 . 
   As best seen in  FIG. 6 , front  20  can include a mirrored surface  64  and back plate  66 , as well as corresponding bracket  68 , with shoulder screws  70  and springs  72  which connect to casing  56  to further support faucet  14 , and provide stress relief on front  20 . 
   Mixing valve cartridge  24  can include a triangular opening  74 , which allows faucet handle  34  to control temperature and flow. As suggested by  FIG. 5 , it is preferred that the mixing cartridge be such that a central upper stick position will be the off position. As the stick moves forwardly/downwardly, the volume increases. As it moves to the left the temperature of the resulting water increases. As it moves to the right the temperature decreases. Of course, with appropriate selection of a different mixing valve, rotational movement alone, and/or various combinations of pivoting and rotation could control the valve. 
   In the alternative embodiment of  FIG. 4  there is sink  82  and faucet  84  in a more compact housing arrangement  86  which is counter mounted. Apart from this, faucet  84  is similar to faucet  14  except that spout  22  here is preferably positioned somewhat differently. Thus, the “box” need not be a medicine cabinet or other large cabinet type structure. 
   In the embodiment of  FIGS. 7-10  there is shown a third stand-alone faucet embodiment. There is a sink  92  and a faucet  94  mounted on the rear of the sink  92 . 
   Faucet  94  has an outer housing  96  and an outlet spout  98 . Mixing valve cartridge  124  can be the same as mixing valve cartridge  24  in the other embodiments. A joystick type handle  100  is connected to a stick  132 . 
   Here, instead of the spring biasing the handle away from the lever, biasing element  104  biases a ball  106  against sliding disk  110 . Biasing element  104  can be a coil spring as shown, although other resilient members are possible such as leaf springs, spring washers, resilient members comprised of elastomeric materials, or other compressible elements such as a gas diaphragm, and other biasing elements. 
   There is also a bearing  108  contacting both the ball  106  and the sliding disk  110 . Bearing  108  can have an outer surface  112  complementary with an inner surface  114  of sliding disk  110 . Bearing  108  can be made of an acetal copolymer, such as Celcon®, which allows bearing  108  to have excellent wear resistance, and have high flexural fatigue strength, toughness and creep resistance. Bearing  108  and sliding disk  110  slidingly engage housing  96  as faucet handle  100  is actuated. Set screw  116  threads into handle  100  and is compressed against stick  132 . 
   Nut  154  is threaded into housing  96 . Couplings  118  allows connection between hot and cold inlet lines ( 120 , only one shown) to corresponding ports on bottom of mixing valve cartridge  124 . Depending on the position of faucet handle  100 , water is discharged out the bottom discharge outlet of mixing valve cartridge  124  and outlet spout  98 . O-ring  122  seals the mixed water from leaking out between couplings  118  and outlet spout  98 . 
   Here the resilience is between the handle  100  and the ball  106 . This is particularly important as ball  106  holds the sliding disk  110  in place while still permitting easy sliding so as to cover the opening in the valve regardless of position. 
   While the preferred embodiments of the present invention have been described above and/or depicted in the drawings, the present invention can be further modified within the spirit and scope of this disclosure. Hence, the claims should be looked to in order to judge the full scope of the invention. 
   INDUSTRIAL APPLICABILITY 
   The present invention provides faucets having joystick type controls with improved characteristics.

Technology Category: 4