Note: Descriptions are shown in the official language in which they were submitted.
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FAUCET INCLUDING A MOLDED WATERWAY ASSEMBLY
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] The present invention relates generally to plumbing fixtures and,
more
particularly, to a faucet including a molded waterway assembly.
[0002] Single handle faucets typically include mixing valves that control
the flow of both
hot and cold water to a delivery spout. These faucets have found wide
acceptance and are
commonly constructed such that a handle or knob is movable in distinct
directions to adjust the
temperature (i.e., the mix of hot and cold water) and the flow rate of water.
[0003] Conventional mixing valves typically include a machined brass body
and
associated brass fittings. The brass body usually includes a hot water inlet,
a cold water inlet,
and a mixed water outlet. An adjustable valve element, typically either a
mixing ball or a
slidable plate, is manipulated by a handle to control the aforementioned
temperature and flow
rate of water. In conventional faucets, copper tubes are usually brazed to the
inlets and the
outlet(s) of the valve body and to associated fittings. Following the brazing
operation, an etching
or bright dip operation is typically performed to clean the metal surfaces of
contaminants.
[0004] It may be appreciated that such conventional mixing valves have
certain
disadvantages. For example, the cost of copper tubing and the additional
assembly cost
associated with the brazing and bright dipping operations may be significant.
The bright dipping
operation may also result in the undesirable deposit of metal on the valve
body. As such, it is
known that the use of plastic materials for waterways may reduce cost,
eliminate metal contact,
and provide protection against acidic and other aggressive water conditions.
The use of non-
metallic materials in plumbing fixtures is significant given the growing
concern about the quality
of potable water. The U.S. Environmental Protection Agency, NSF International
(National
Sanitary Foundation) and other health-related organizations are actively
seeking to reduce the
metal content (i.e., copper and lead) in water.
[0005] Previous plastic faucets have often attempted to use plastic in a
method similar to
brass, i.e., as both a structural component and a water conducting mechanism.
This has caused
some issues because the yield strength and stiffness of most plastics are not
similar to the
properties of brass. This may result in the need to use higher grade materials
that can be difficult
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to process. Alternatively, materials less suitable for structural applications
may be used in the
interest of cost and long term durability.
100061 According to an illustrative embodiment of the present disclosure,
a fluid delivery
device includes a waterway assembly having a first inlet fluid transport
component formed of a
polymer and with opposing first and second ends, and an outlet fluid transport
component
formed of a polymer and with opposing first and second ends. The waterway
assembly further
includes a base formed of a polymer and having an upper surface and a lower
surface and being
overmolded around the first end of the first inlet fluid transport component
and the first end of
the outlet fluid transport component. A valve assembly includes a first inlet
port in fluid
communication with the first inlet fluid transport component, and an outlet
port in fluid
communication with the outlet fluid transport component. The valve assembly
further includes a
lower surface facing the upper surface of the base and sealingly engaged with
the base. The
valve assembly further includes a movable valve member configured to control
the flow of water
from the first inlet port to the outlet port.
[0007] According to a further illustrative embodiment of the present
disclosure, a faucet
includes a holder, and a waterway assembly including a base supported by the
holder. A hot
water inlet tubular member includes a first end fluidly coupled to the base
and a second end
configured to be fluidly coupled to a hot water supply. A cold water inlet
tubular member
includes a first end fluidly coupled to the base and a second end configured
to be fluidly coupled
to a cold water supply. An outlet tubular member includes a first end fluidly
coupled to the base
and a second end. A valve assembly includes a hot water inlet port in fluid
communication with
the hot water inlet tubular member, and a cold water inlet port in fluid
communication with the
cold water tubular member. The valve assembly further includes an outlet port
in fluid
communication with the outlet tubular member, and a lower surface facing an
upper surface of
the base and sealingly couple with the base. The valve assembly also includes
a movable valve
member configured to control the flow of water from the inlet ports to the
outlet port. A locking
member is operably coupled to the valve assembly and is configured to secure
the valve
assembly to the waterway assembly.
[0008] According to a further illustrative embodiment of the present
disclosure, a fluid
delivery device includes a valve assembly having a lower surface and a first
locating element
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supported by the lower surface. The fluid delivery device further includes a
waterway assembly
having a first fluid transport component having opposing first and second
ends, and a second
fluid transport component having opposing first and second ends. A base
includes an upper
surface and a lower surface and is overmolded around the first end of the
first fluid transport
component and the first end of the second fluid transport component. The
waterway assembly
further includes a second locating element supported by upper surface of the
base and is
configured to cooperate with the first locating element of the valve assembly
to facilitate proper
orientation of the valve assembly relative to the waterway assembly.
100091 According to another illustrative embodiment of the present
disclosure, a faucet
includes a valve assembly, and a waterway assembly including a first inlet
fluid transport
component formed of a non-metallic material and having opposing first and
second ends, and an
outlet fluid transport component formed of a non-metallic material and having
opposing first and
second ends. The waterway assembly further includes a base formed of a non-
metallic material
and having an upper surface and a lower surface, the base being fluidly
coupled to the first end
of the first fluid inlet transport component, the first end of the outlet
fluid transport component,
and the valve assembly. An upper housing is formed of a non-metallic material
and includes a
spout having an outlet fluidly coupled to the outlet fluid transport
component, and a channel to
receive the outlet fluid transport component.
100101 According to a further illustrative embodiment of the present
disclosure, a
waterway assembly includes a plurality of flexible tubular members formed of a
polymer and
having opposing first and second ends. The waterway assembly further includes
a base formed
of a polymer and overmolded around the first end to the plurality of tubular
members.
[0011J According to yet another illustrative embodiment of the present
disclosure, a
waterway assembly includes a base including a plurality of openings. A
plurality of tubular
members formed of a cross-linked polymer includes opposing first and second
ends, the first
ends of the plurality of tubular members being received within the plurality
of openings of the
base.
[0012] According to a further illustrative embodiment of the present
disclosure, a fluid
delivery device includes a flow directing member, and a molded waterway
fluidly coupled to the
flow directing member. The molded waterway includes a base having an inlet
opening and an
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outlet opening, and a flexible tubular member fluidly coupled to the inlet
opening. A fluid
passageway extends from the inlet opening, through the flow directing member
and out of the
outlet opening wherein the fluid travels in a first direction through the
inlet opening and in a
second direction, different from the first direction, through the outlet
opening.
[0013] According to another illustrative embodiment of the present
disclosure, a base for
a waterway assembly includes an upper surface, a lower surface, a first inlet
opening in fluid
communication with the upper surface, and an outlet opening in fluid
communication with the
upper surface and positioned in spaced relation to the inlet opening. The base
is formed of a
cross-linked polymer.
[0014] According to a further illustrative embodiment of the present
disclosure, a
waterway assembly includes a plurality of flexible tubular members formed of a
polymer and
having opposing first and second ends. A valve interface member is formed of a
polymer and
overmolded around the first ends of the plurality of tubular members. The
valve interface
member includes a first surface, a second surface, a plurality of openings
extending into the first
surface and in fluid communication with the plurality of tubular members, a
seat defined by the
first surface and extending around the plurality of openings and configured to
seal with a valve
assembly to provide fluid communication between the plurality of openings and
the valve
assembly.
[0015] According to another illustrative embodiment of the present
disclosure, a
waterway assembly includes a base having a first surface, a second surface, a
plurality of
openings extending from the first surface to the second surface, and a seat
defined by the first
surface and configured to sealingly interface with a valve assembly. A
plurality of tubular
members are formed of a cross-linked polymer and include opposing first and
second ends, the
first ends of the plurality of tubular members being received within the
plurality of openings of
the base and extending from the second surface. A plurality of fluid couplings
are supported by
the second ends of the plurality of tubular members.
[0016] According to a further illustrative embodiment of the present
disclosure, a valve
interface member for a waterway assembly includes an upper surface, a lower
surface, a first
inlet opening extending into the upper surface, and an outlet opening
extending into the upper
surface and positioned in spaced relation to the inlet opening. A first flow
directing channel
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extends into the upper surface, extends outwardly from the first inlet
opening, and is in fluid
communication with the first inlet opening. A second flow directing channel
extends into the
upper surface, extends outwardly from the outlet opening, and is in fluid
communication with the
outlet opening. A valve assembly seat is supported by the upper surface and
extends around the
first flow directing channel and the second flow directing channel, wherein
the valve interface
member is formed of a cross-linked polymer.
100171 According to another illustrative embodiment of the present
disclosure, a
waterway assembly includes a plurality of tubular members formed of a polymer
and having
opposing first and second ends. A support plate includes a plurality of
openings aligned with the
first ends of the plurality of tubular members. The support plate has a plate
stiffness. A base is
formed of a polymer and has a base stiffness. The base is overmolded around
the first ends of
the plurality of tubular members and the support plate. The plate stiffness is
greater than the
base stiffness.
[00181 Additional features and advantages of the present invention will
become apparent
to those skilled in the art upon consideration of the following detailed
description of the
illustrative embodiment exemplifying the best mode of carrying out the
invention as presently
perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The detailed description of the drawings particularly refers to the
accompanying
figures in which:
[0020] Fig. IA is a perspective view of an illustrative embodiment faucet
of the present
disclosure mounted to a sink deck and fluidly coupled to hot and cold water
supply lines;
100211 Fig. 1B is a perspective view similar to Fig. 1A, showing another
illustrative fluid
coupling to hot and cold water supply lines;
100221 Fig. 1C is a perspective view similar to Fig. IA, showing a further
illustrative
coupling to hot and cold water supply lines;
[0023] Fig. 2 is a perspective view of the faucet of Fig. 1;
[0024] Fig. 3 is a perspective view similar to Fig. 2, with the escutcheon
removed to
show the molded waterway assembly, the holder, and the valve assembly;
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[00251 Fig. 4 is a perspective view similar to Fig. 3, with the undercover
removed to
reveal additional details of the molded waterway assembly;
[0026] Fig. 5 is an exploded perspective view, with a partial cut-away, of
the faucet of
Fig. 2;
[0027] Fig. 6 is a partial exploded perspective view of the faucet of Fig.
2, showing the
escutcheon, the bonnet, the guide ring, and the securing sleeve;
[0028] Fig. 7 is a diagrammatic view of an illustrative embodiment faucet
showing a
molded waterway assembly coupled to a valve assembly;
[0029] Fig. 8 is a cross-sectional view taken along line 8-8 of Fig. 2;
[0030] Fig. 9 is a detailed cross-sectional view of Fig. 8;
[0031] Fig. 10 is a partial exploded perspective view of the faucet of
Fig. 2, showing the
interface between the molded waterway assembly and the valve body;
[0032] Fig. ll is a top plan view of the base of the molded waterway
assembly;
[0033] Fig. 12 is a bottom plan view of the base of molded waterway
assembly;
100341 Fig. 13 is a diagrammatic cross-sectional view showing another
illustrative fluid
coupling arrangement for the waterway assembly;
[00351 Fig. 14 is a diagrammatic cross-sectional view similar to Fig. 13,
showing a
further illustrative fluid coupling for the waterway assembly;
[0036] Fig. 15 is a side elevational view, in partial cross-section, of a
further illustrative
embodiment faucet of the present disclosure;
[00371 Fig. 16 is a partial exploded perspective view of the faucet of
Fig. 15;
[0038] Fig. 17 is a detailed view of the cross-section of Fig. 15;
[00391 Fig. 18 is a perspective view showing the molded waterway assembly
of the
faucet of Fig. 15 supported by the sink deck;
100401 Fig. 19 is a partial perspective view of the molded waterway
assembly of Fig. 18;
100411 Fig. 20 is an exploded perspective view of the molded waterway
assembly of
Fig. 19;
100421 Fig. 21 is a partial exploded perspective view of the faucet of
Fig. 15, showing the
interface between the valve body and the molded waterway connection;
100431 Fig. 22 is a top plan view of the base of the molded waterway
assembly;
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[0044] Fig. 23 is a bottom plan view of the base of the molded waterway
assembly;
[0045] Fig. 24 is a diagrammatic view showing fluid flow in an
illustrative waterway
assembly;
[0046] Fig. 25 is a diagrammatic view showing fluid flow in another
illustrative
waterway assembly;
[0047] Fig. 26 is a diagrammatic view showing fluid flow in a further
illustrative
waterway assembly;
[0048] Fig. 27 is a partial perspective view of a further illustrative
molded waterway
assembly;
[0049] Fig. 28 is a cross-sectional view taken along line 28-28 of Fig.
27;
[0050] Fig. 29 is a cross-sectional view taken along line 29-29 of Fig.
27; and
[00511 Fig. 30 is a perspective view of a support plate of the molded
waterway assembly
of Fig. 27.
DETAILED DESCRIPTION OF THE DRAWINGS
[0052] The embodiments of the invention described herein are not intended
to be
exhaustive or to limit the invention to precise forms disclosed. Rather, the
embodiments selected
for description have been chosen to enable one skilled in the art to practice
the invention.
Although the disclosure is described in connection with water, it should be
understood that
additional types of fluids may be used.
[0053] Referring initially to Fig. 1A, an illustrative embodiment faucet
10 is shown
mounted to a sink or mounting deck 12 above a sink basin 14. The faucet 10 is
fluidly coupled
to hot and cold water supplies or sources 16 and 18 through conventional stops
20 and 22,
respectively. Hot and cold water risers 24 and 26 may fluidly couple the stops
20 and 22 to hot
and cold water inlet fluid transport components, or tubes 28 and 30,
respectively. While Fig. 1
illustrates hot and cold water risers 24 and 26 coupled to inlet tubes 28 and
30 through fluid
couplings 32 and 34, it should be appreciated that the inlet tubes 28 and 30
may extend
uninterrupted from the faucet 10 to the stops 20 and 22 through fluid
couplings 36 and 38, as
shown in Fig. 1B. Additionally, Fig. 1C shows an illustrative embodiment where
inlet tubes 28
and 30 are coupled behind the wall 40 to the plumbing system of the building
or house.
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[00541 Referring further to Figs. 2-6, the faucet 10 includes a holder 42
configured to be
secured to the sink deck 12. The holder 42 includes a pair of downwardly
extending legs 44 and
46, illustratively comprising hollow tubes having external threads 48 and 49,
respectively.
Securing members, illustratively nuts 50 and 51 are threadably received by
threads 48 and 49 of
legs 44 and 46. The nuts 50 and 51 are configured to secure the holder 42 to
the sink deck 12.
Supports 52 and 54 are coupled to the upper ends of legs 44 and 46 and are
connected by a
bridge member 56. The bridge member 56, in turn, supports a stand 58 in spaced
relation above
the supports 52 and 54.
[0055] With further reference to Fig. 5, the stand 58 illustratively
includes a cylindrical
outer wall 59 supporting a plurality of external threads 60. An upper end of
the wall 59 supports
a platform 62 surrounding a longitudinal opening 64. In one illustrative
embodiment, the holder
42 is molded from a polymer, such as a long-fiber reinforced thermoplastic
(LFRT) exhibiting
high dimensional stability and strong mechanical properties. One such LFRT is
Celstrang
available from Ticona of Florence, Kentucky. However, it should be noted that
the holder 42
may be formed of other suitable materials, such as stainless steel or brass.
100561 With reference to Figs. 4, 5, and 7, a molded waterway assembly 70
is supported
by the stand 58 of holder 42. The molded waterway assembly 70 illustratively
includes a valve
interface member or base 72 in the form of a puck or disk having a hot water
inlet opening 74, a
cold water inlet opening 76, and an outlet opening 78, all extending between
upper and lower
surfaces 80 and 82 (Fig. 10). The hot water inlet tube 28, the cold water
inlet tube 30, and an
outlet tube 66 are fluidly coupled to the openings 74, 76, and 78,
respectively, in the base 72. As
detailed herein, the tubes 28, 30, and 66 are illustratively formed of a
flexible non-metallic
material, such as a polymer.
100571 In the illustrative embodiment, the tubes 28, 30, 66 and the base
72 are formed of
compatible materials, such as polymers, and illustratively of cross-linkable
materials. As such,
the waterway assembly 70 is illustratively electrically non-conductive. As
used within this
disclosure, a cross-linkable material illustratively includes thermoplastics
and mixtures of
thermoplastics and thermosets. In one illustrative embodiment, the tubes 28,
30, 66 and the base
72 are formed of a polyethylene which is subsequently cross-linked to form
cross-linked
polyethylene (PEX). However, it should be appreciated that other polymers may
be substituted
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therefor. For example, the waterway assembly 70 may be formed of any
polyethylene (PE)(such
as raised temperature resistant polyethylene (PE-RT)), of polypropylene
(PP)(such as
polypropylene random (PPR)), or of polybutylene (PB). It is further envisioned
that the
waterway assembly 70 could be formed of cross-linked polyvinyl chloride (PVCX)
using silane
free radical initiators, of cross-linked polyurethane, or of cross-linked
propylene (XLPP) using
peroxide or silane free radical initiators.
[0058] With reference to Figs. 9, 10, and 12, the upper ends 84 of tubes
28, 30, and 66
are positioned within the openings 74, 76, and 78 of the base 72. Each opening
74, 76, and 78
includes a counterbore 74a, 76a, and 78a extending upwardly from the lower
surface 82 and
defining a stop surface 75 which cooperates with the upper ends 84 of the
tubes 28, 30, and 66,
respectively. In the illustrative embodiment, the base 72 is overmolded around
the upper ends 84
of the tubes 28, 30, and 66. More particularly, the base 72 is formed of a
polymer which is
molded over the previously formed tubes 28, 30, and 66, in the manner detailed
herein. The
overmold base 72 partially melts the upper ends 84 of the tubes, forming
couplings or bonds 86a,
86b, 86c between material of the base 72 and material of the tubes 28, 30, and
66 (shown
diagrammatically in Fig. 7). To facilitate the molding process, the openings
74, 76, and 78, and
thus tubes 28, 30, and 66, are illustratively aligned along a common center
axis 79 (Fig. 11).
Flow directing channels 109, 111, and 113 are formed within upper surface 90
of the base 72 and
are configured to facilitate fluid flow through openings 74, 76, and 78,
respectively (Figs. 10
and 11).
100591 As shown in Figs. 9 and 12, a support or reinforcing boss 110
illustratively
extends downwardly from the lower surface 82 of the base 72 and surrounds the
openings 74, 76,
and 78. The boss 110 provides additional support to the tubes 28, 30, and 66
coupled to the
base 72.
[0060] In the illustrative embodiment detailed herein, the base 72 is
formed of
polyethylene which has been overmolded around the tubes 28, 30, and 66 and
subsequently
cross-linked. It should be noted that reinforcing members, such as glass
fibers, may be provided
within the polyethylene of the base 72. While a polymer, such as cross-
linkable polyethylene, is
the illustrative material for the base 72, in certain embodiments other
materials may be
substituted therefore, such as brass or copper. Additionally, the tubes 28,
30, and 66 may be
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fluidly coupled to the base 72 in a variety of manners other than through
overmolding, such as
ultrasonic welding or heat staking.
[0061] With reference now to Figs. 13 and 14, illustrative alternative
means for coupling
the tubes 28, 30, and 66 are shown. For example, in Fig. 13, the upper ends 84
of tubes 28, 30,
and 66 include an enlarged portion 134 configured to be received within
cooperating
counterbores 135 formed within base 72. As may be appreciated, each enlarged
portion 135 is
retained intermediate a lip 136 formed within counterbore 135 of the base 72
and the lower
surface 102 of the valve assembly 100. The enlarged portion 135 may
illustratively be formed
integral with each tube 28, 30, 66, or as a separate component, such as an
overmold. As shown
in the further illustrative embodiment of Fig. 14, the upper ends 84 of the
tubes 28, 30, and 66
may include external threads 137 which threadably engage internal threads 139
formed within
base 72.
[0062] As detailed herein, the base 72 of the waterway assembly 70 is
illustratively
secured to the tubes through overmolding. The basic principle of overmolding
plumbing
connections on the tubes is well known. Exemplary overmolds are shown in U.S.
Patent No.
5,895,695, U.S. Patent No. 6,082,780, U.S. Patent No. 6,287,501, and U.S.
Patent No. 6,902,210
each listing William W. Rowley as an inventor.
[0063] In the present method, the tubes 28, 30, and 66 are illustratively
positioned within
a mold (not shown) wherein pins or mandrels slide into each respective tube
end 84 to prevent
collapsing thereof during the injection molding process. The mold receives the
parallel aligned
ends of the tubes 28, 30, and 66 and then receives a flowable polymer,
illustratively
polyethylene, which forms the appropriate base 72. As further detailed herein,
the upper ends 84
of the tubes 28, 30, 66 are aligned along a common axis 79 to facilitate
opening and closing of
portions of the mold. After the polymer sufficiently hardens, the mold is
opened to release the
base 72 and tubes 28, 30, and 66. Through overmolding, the end 84 of each tube
28, 30, and 66
partially melts and bonds with the overmolded material of the base 72 through
couplings 86a,
86b, and 86c. This makes a substantially monolithic waterway assembly 70.
[0064] As is known, polyethylene is flexible, or semi-rigid, and may be
cross-linked to
form PEX. Cross-linking polyethylene couples the individual molecule chains
together and
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prevents splitting. The curing or cross-linking process may use any one of
several different
technologies to form, for example, PEX-A, PEX-B or PEX-C. PEX-A is formed by
using
peroxide to cross-link polyethylene. More particularly, PEX-A is formed of a
polyethylene
having incorporated therein peroxide. Upon heating the peroxide polyethylene
above the
decomposition temperature of the peroxide, "free" radicals are produced to
initiate the cross-
linking process. PEX-B is formed by using silane to cross-link polyethylene.
PEX-B is formed
by using silane-grafted polyethylene which is then "moisture-cured" by
exposure to heat and
water, also known as sauna curing. PEX-C is formed of polyethylene which is
cross-linked by
bombarding it with electromagnetic (gamma) or high energy electron (beta)
radiation.
[00651 By overmolding, it is possible to obtain a material to material
bond, thereby
providing a substantially leak-proof coupling between the tubes 28, 30, and 66
and the base 72.
The resulting overmolded waterway assembly 70 is then cross-linked by means
known in the art,
e.g., peroxide cross-linking, silane cross-linking, radiation cross-linking,
etc. More particularly,
and as detailed above, cross-linking can be performed by a silane process or a
peroxide process,
or combinations thereof, wherein cross-linking is completed in a hot bath.
Each process has a
cross-linking catalyst that causes the polymer to crosslink when certain
temperature and pressure
and/or humidity are used. In the illustrative embodiment, the waterway
assembly (i.e., waterway
assembly 70) is passed under a radiation unit and the exposure causes cross-
linking. While
illustratively the final product 70 is cross-linked, in certain circumstances
it might be appropriate
to cross-link individual components 28, 30, 66, and 72. In a further
illustrative embodiment, the
material for the base 72 may be partially cross-linked prior to overmolding,
followed by further
cross-linking after coupling to the tubes 28, 30, and 66.
[0066] With reference to Fig. 2, the second ends 92 of each inlet tube 28
and 30
illustratively includes a fluid coupling 94, which may define couplings 32 and
34 shown in Fig.
I. Illustratively, each fluid coupling 94 includes an overmolded coupler 96
and cooperating
internally threaded nut 98. Additional details regarding illustrative
overmolded fluid couplings
is provided in U.S. Patent Nos. 5,895,695 and 6,287,501.
[0067] In one illustrative embodiment, the tubes 28, 30, and 66 may include
certain
additional features, such as corrugated walls for improved flexibility, as
detailed in U.S. Patent
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Application Publication No. US 2008/0178957, published July 31, 2008, entitled
"TUBE
ASSEMBLY".
100681 With reference to Figs. 5, 9, and 10, a valve assembly 100 is
supported by the
base 72 of the molded waterway assembly 70. More particularly, a lower surface
102 of the
valve assembly 100 sealingly engages a seal, illustratively a silicone gasket
103 received
intermediate the base 72 and the valve assembly 100. The gasket 103 is
received within a
channel 104 formed within lower surface 102 of the valve assembly 100 and
seals against a seat
105 formed by the upper surface of the base 72 (Fig. 10). The gasket 103
extends around the
flow directing channels 109, 111, and 113.
[0069] As shown in Fig. 10, first locating elements, illustratively
locating pegs 106a and
106b, are positioned on the bottom of the valve assembly 100 and extend
downwardly from the
lower surface 102. The pegs 106a and 106b are configured to be received within
second locating
elements, illustratively recesses 108a and 108b, formed within the upper
surface 80 of the base
72. The position of the pegs 106 within the recesses 108 facilitates proper
orientation of the
valve assembly 100 relative to the molded waterway assembly 70 and hence,
alignment with the
tubes 28, 30, and 66 and respective openings 74, 76, and 78, with appropriate
ports 116, 118, and
120 of the valve assembly 100. Engagement between the pegs 106 and the
recesses 108 may
also improve resistance to torque generated between the valve assembly 100 and
the base 72.
[0070] As shown in Figs. 9 and 10, the valve assembly 100 illustratively
includes a stem
112 that may be actuated by a handle 114 to selectively allow variable
temperature and flow rate
of water to be supplied to an outlet port 120 from a hot water inlet port 116
and a cold water inlet
port 118. The base 72 of the waterway assembly 70 fluidly couples the hot
water inlet port 116
to the hot water inlet tube 28, and fluidly couples the cold water inlet port
118 to the cold water
inlet tube 30. The base 72 also fluidly couples the outlet port 120 to the
outlet tube 66.
100711 With further reference to Fig. 9, the valve assembly 100
illustratively includes an
upper housing 126, a stem assembly 128, a coupling member 130, a carrier 132,
an upper disc
138, a lower disc 144, a seal 150, and a lower housing 152. The stem assembly
128 illustratively
includes a ball 160 molded from a thermoplastic material over a portion of the
stem 112. A
longitudinal extension or knuckle 162 extends downwardly from the ball 160.
The ball 160
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transmits motion of the stem 112 to the upper disc 138 through the extension
162 and the
carrier 132.
[0072] The upper disc 138 is positioned on top of the lower disc 144 to
control the
mixing of hot and cold water and the flow rate of water through the valve
assembly 100.
Illustratively, both the upper and lower discs 138 and 144 are constructed of
a ceramic material,
however, any suitable material may be used, such as stainless steel.
[0073] In a further illustrative embodiment, a temperature limiting member
164 is
received intermediate the coupling member 130 and the upper housing 126. The
temperature
limiting member 164 limits lateral pivoting movement of the stem 112 and the
extension 162,
and hence the maximum allowable temperature of water flowing through the valve
assembly 100.
[0074] Additional details of an illustrative valve assembly are provided in
U.S. Patent
Application Serial No. 11/494,889, filed July 28, 2006. While the illustrative
valve assembly
100 is of a movable disc variety, it should be appreciated that other types of
valve assemblies
may be substituted therefor. For example, a ball-type mixing valve assembly
may find equal
applicability with the present invention. Illustrative ball-type valve
assemblies are detailed in
U.S. Patent No. 4,838,304 to Knapp, U.S. Patent No. 5,615,709 to Knapp, U.S.
Patent No.
5,927,333 to Grassbergcr, and U.S. Patent No. 6,920,899 to Haenlein et al.
[0075] As shown in Figs. 5 and 6, an upper housing or escutcheon 170
includes wing
portions 172 and 174 which are received over the holder 42 and secured thereto
through
conventional fasteners. More particularly, hex bolts 176 and 178 are
illustratively received
within legs 44 and 46 and extend through apertures 180 and 182 formed in the
supports 52 and
54 and up into threaded apertures 184 and 186 formed in the bottom of the
wings 172 and 174.
The valve assembly 100, the base 72, and the holder 42 are all received within
a hub 187 of the
escutcheon 170.
[0076] With reference to Figs. 5 and 8, a spout 188 is formed by an upper
spout member
189 of the escutcheon 170 and a lower spout or undercover member 190. The
undercover
member 190 is illustratively coupled to the upper spout member 189 through
resilient snap
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fingers 191. A boss 192 having a central opening 193 on the undercover member
190 may be
aligned with a cooperating opening 194 formed in a boss 196 of the holder 42.
A fastener (not
shown) may be received within the aligned openings 193 and 194 to further
secure the
undercover member 190 to the holder 42 (Fig. 8).
[0077] The undercover member 190 illustratively includes a
channel 198 which receives
a portion of the outlet tube 66. The channel 198 extends from the hub 187 of
the escutcheon 170
to an outlet 199 of the spout 188. The outlet tube 66 rests in channel 198
when the spout 188 is
assembled. More particularly, upper spout member 189 conceals the channel 198
from the view
of an outside observer.
[0078] In one illustrative embodiment, the spout 188 is formed
of a non-metallic
material. More particularly, the upper spout member 189 and the undercover
member 190 may
be molded from a polymer, such as a thermoplastic or a cross-linkable
material, and illustratively
a cross-linkable polyethylene (PEX). Further illustrative non-metallic
materials include
polybutylene terephthalate (PBT) and thermosets, such as polyesters, melamine,
melamine urea,
melamine phenolic, and phenolic. Of course, the spout 188 may be formed of
traditional
metallic materials, such as zinc or brass. Additional details of a further
illustrative embodiment
I . spout is disclosed in U.S. Patent No. 7,717,133, issued May 18,
2010, entitled "SPOUT TIP
ATTACHMENT".
[0079] As detailed herein, a first end 84 of the outlet tube 66
is coupled to the base 72 of
the waterway assembly 70. The second end 92 of the outlet tube 66 is
illustratively coupled to
an overmold component 200. The overmold component 200 provides an interface
including a
sealing surface and is operably coupled to an aerator assembly 202 (Fig. 8).
Additional details
concerning the overmold component 200 are provided in U.S. Patent No.
7,748,409, issued July
6,2010, entitled "OVERMOLD INTERFACE FOR FLUID CARRYING SYSTEM".
[0080] With reference to Figs. 5 and 9, a locking sleeve or nut
204 is received over the
valve assembly 100 and waterway base 72, and threadably engages with the
external threads 60
of the holder 42. As shown in Fig. 9, lip 205 of locking sleeve 204 forces the
valve assembly
100 toward the base 72 of the waterway assembly 70, thereby compressing the
gasket 103 for
effecting a seal therebetween.
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[0081] Referring now to Figs. 5, 6 and 9, a guide ring 206 is
concentrically received over
the locking sleeve 204. The guide ring 206 includes a resilient body 208
having a slit 210
formed therein. A plurality of retaining tabs 212 extend upwardly from the
body 208. The
retaining tabs 212 of the guide ring 206 are configured to frictionally engage
with an inside
surface 214 of a bonnet 216 to retain the bonnet 216 in a fixed position
relative to the locking
sleeve 204.
[0082] Referring now to Figs. 15 and 16, a further illustrative embodiment
faucet 310 is
shown. The faucet 310 includes many of the same features identified above with
respect to
faucet 10. As such, similar components are identified with like reference
numbers.
[0083] The faucet 310 includes a holder 312 having a cylindrical outer
wall 314
supporting a stand 316. A securing member, illustratively a conduit 318 having
external threads
320, extends downwardly from the holder 312. A nut 322 and washer 324 may
threadably
engage the threads 320 of the conduit 318 for securing the holder 312 to the
sink deck 12. The
stand 316 includes a plurality of external threads 60 and a platform 62
surrounding a longitudinal
opening 64.
[00841 The holder 312 may be overmolded to an upper end 325 of the conduit
318.
Alternatively, the holder 312 may be secured to the conduit 318 in other
conventional manners,
such as locking rings or threads. Illustratively, the holder 312 is formed
from a polymer, such as
Celstran .
[0085] The holder 312 is received within an upper housing or escutcheon
326,
illustratively formed of brass. The housing 326 includes a hub 328 and a spout
portion 330. As
shown in Fig. 13, the spout portion 330 is configured to slidably receive a
conventional pull out
wand 332. Illustratively, the pull out wand 332 is Model No. 473 available
from Delta Faucet
Company of Indianapolis, Indiana. The pull out wand 332 includes a coupling
portion 334
configured to be received within the spout portion 330, a body 336 connected
to the coupling
portion 334, and a spray head 338. The second end of the outlet tube 66
illustratively includes an
overmolded coupling 339 which is configured to be fluidly coupled to the wand
332. The
overmolded coupling 339 illustratively includes annular grooves 341 configured
to receive
sealing members, such as o-rings (not shown). The coupling 339 may be formed
in a manner
similar to couplings 96 detailed above. A button 340 may be provided on the
wand 332 and is
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operably coupled to a diverter (not shown) to toggle between different modes
of operation, such
as a spray mode and a stream mode.
[0086] The molded waterway 70 is supported by the holder 312 and includes
tubes 28,
30, and 66 overmolded to a base 72, in a manner similar to the molded waterway
assembly 70
detailed above. The inlet tubes 28 and 30 are configured to extend through a
lower opening 342
defined by the wall 314 of the stand. The outlet tube 66 is configured to
extend through a side
opening 344 formed within the wall 314 and to the outlet 346 of the spout
portion 330.
[0087] As shown in Figs. 16, 20, and 23, a first registration element,
illustratively a
plurality of aligned ribs 347 extend downwardly from the lower surface 82 of
the base 72'. The
ribs 347 are configured to be received within a second registration element,
illustratively a notch
349 formed within the stand 316 to facilitate proper orientation of the
waterway assembly 70'
relative to the holder 312 (Fig. 16). It should be appreciated that the base
72' may be registered
relative to the stand 316 in a number of ways, including by providing the base
72' with an
asymmetrical shape configured to cooperate with mating elements on the stand
316.
[0088] The valve assembly 100 is sealingly coupled to the base in a manner
detailed
above with respect to the faucet 10. A bonnet 348 is received over the valve
assembly 100 and
the molded waterway assembly 70'. The bonnet 348 threadably engages the
external threads 60
of the holder 312. An annular lip 350 of the bonnet 348 engages the valve
assembly 100, thereby
securing the valve assembly 100 and the waterway assembly 70 to the holder 312
(Fig. 17).
[0089] With reference now to Figs. 24-26, various illustrative embodiments
of waterway
assembly 70 and cooperating flow directing member, illustratively valve
assembly 100, are
shown. In Fig. 24, the base 72 defines hot water inlet opening 74, cold water
inlet opening 76,
and outlet opening 78. Fluid passageways are defined by the inlet openings 74
and 76,
cooperating valve assembly 100, and outlet opening 78. Hot and cold water
travels in parallel
directions (as shown by arrows 352a and 352b) through the inlet openings 74
and 76. Valve
assembly 100 changes the water flow direction and redirects the mixed water
flow in a second
direction downwardly through the outlet opening 78 (as shown by arrow 354).
[0090] With further reference to Fig. 25, a further illustrative waterway
assembly 70 is
shown with two separate bases 72a and 72b. The separate bases 72a and 72b may
be utilized for
a widespread-type faucet. More particularly, hot water 352a enters through hot
water inlet
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opening 74 formed within base 72a where it is redirected through a flow
directing member,
illustratively a hot water control valve 100. The redirected hot water passes
in a second direction
downwardly (as shown by arrow 354a) and out through hot water outlet 358a to a
delivery spout
(as shown by arrow 356). Similarly, cold water enters through cold water inlet
opening 76 and is
redirected by a cold water outlet valve 100b. The redirected cold water then
exits the base 72b
through cold water outlet 358b in a second direction to the delivery spout. As
shown, the cold
water combines with the hot water prior to exiting the delivery spout.
[0091] Fig. 26 illustrates yet another illustrative embodiment waterway
assembly
wherein first and second bases 72a' and 72b' are provided for a centerset-type
faucet. The inlet
openings 74 and 76 are similar to those identified above with respect to Fig.
25. Similarly, hot
and cold water valves 100a and 100b are provided to control the flow of fluid
through the
respective inlets 74 and 76 to hot and cold water outlets 358a' and 358W,
respectively. The hot
and cold water outlets 358a' and 358W in Fig. 26 each include first and second
portions 360a,
360b and 362a, 362b, respectively, disposed at right angles to each other.
More particularly,
fluid flow in a first direction (as shown by respective arrows 352a, 352b) is
redirected from the
inlet 74, 76 to outlet 358a', 358W for exiting base 72a', 72b' in a second
direction (as shown by
arrow 362a, 362b) which is substantially perpendicular to the first direction.
The fluid flow from
the outlets 358a' and 358b' then combines and passes to the outlet of a
delivery spout (as shown
by arrow 366).
[0092] Referring now to Figs. 27-30, a further illustrative embodiment
waterway
assembly 470 is shown. The waterway assembly 470 includes many of the same
features
identified above with respect to waterway assembly 70. As such, similar
components are
identified with like reference numbers.
[0093] The molded waterway assembly 470 may be supported by a holder, such
as holder
42, 312 detailed above. Similar to waterway assembly 70, waterway assembly 470
includes
tubes 28, 30, and 66 overmolded with a valve interface member or base 472.
More particularly,
the molded waterway assembly 470 illustratively includes valve interface
member or base 472 in
the form of a puck or disk having a hot water inlet opening 474, a cold water
inlet opening 476,
and an outlet opening 478, all extending between upper and lower surfaces 480
and 482 (Fig.
28). An annular groove 483 may be formed within the base 472 to receive an o-
ring (not
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shown). Hot water inlet tube 28, cold watcr inlet tube 30, and outlet tube 66
are fluidly coupled
to the openings 474, 476, and 478, respectively, in the base 472. Hot water
inlet tube 28, cold
water inlet tube 30, outlet tube 66 and base 472 are illustratively formed of
a polyethylene which
is subsequently cross-linked to form cross-linked polyethylene (PEX). However,
it should be
appreciated that other polymers may be substituted therefor.
[0094] A valve assembly (not shown) is supported by the base 472 of the
molded
waterway assembly 470, in a manner similar to valve assembly 100 being
supported by the base
72 of the molded waterway assembly 70 as detailed above. A lower surface of
the valve
assembly may sealingly engage a seal, such as a silicone gasket received
intermediate the base
472 and the valve assembly. The gasket illustratively seals against a seat
formed by the upper
surface 480 of the base 472 and extends around the openings 474, 476, and 478.
[0095] The valve assembly interfacing with the base 472 may be of a Euro-
motion design
different from the valve assembly 100 detailed above. As such, the tubes 28,
30, and 66 are
arranged within the base 472 in a different configuration due to the Euro-
motion design of the
valve assembly. More particularly, the openings 474, 476, and 478 receiving
the tubes 28, 30,
and 66 are not aligned along a vertical plane, and the outlet tube 66 is no
longer positioned
intermediate the hot water inlet tube 28 and the cold water inlet tube 30.
[0096] Locating elements, illustratively recesses 484a, 484b and 484c are
formed within
the upper surface 480 of the base 472, and are configured to receive
cooperating locating
elements, such as pegs, of the valve assembly. The position of the pegs within
the recesses 484
facilitates proper orientation of the valve assembly relative to the molded
waterway assembly
470 and hence, alignment with the tubes 28, 30, and 66 and respective openings
474, 476, and
478, with appropriate ports of the valve assembly. Engagement between the pegs
and the
recesses 484 may also improve resistance to torque generated between the valve
assembly and
the base 472.
[0097] With reference to Figs. 27-29, the upper ends 84 of tubes 28, 30,
and 66 are
positioned within the openings 474, 476, and 478 of the base 472. Each opening
474, 476, and
478 includes a counterbore 474a, 476a, and 478a extending upwardly from the
lower surface 482
and defining a stop surface which cooperates with the upper ends 84 of the
tubes 28, 30, and 66,
respectively. In the illustrative embodiment, the base 472 is overmolded
around the upper ends
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84 of the tubes 28, 30, and 66. More particularly, the base 472 is formed of a
polymer which is
molded over the previously formed tubes 28, 30, and 66, in the manner detailed
herein. The
overmold base 472 partially melts the upper ends 84 of the tubes 28, 30, and
66, forming
couplings or bonds between material of the base 472 and material of the tubes
28, 30, and 66. In
one illustrative embodiment, the tubes 28, 30, and 66, and the base 472 are
all formed of
polyethylene which is cross-linked following the overmolding operation.
100981 The base 472 illustratively includes an internal support plate 490
to improve
rigidity and reduce deflection of the base 472 during high pressure loads
(e.g., high water
pressure between valve assembly and base 472). The reduced deflection of the
base 472 helps to
minimize any potential gap formed between the valve assembly and the base 472
during burst
testing. The minimized gap prevents the seal above the base 472 from migrating
away from the
pressure load and relieving to atmosphere. The support plate 490 also helps
provide for a
smooth or level upper surface 480 on the base 472.
[0099] The support plate 490 includes openings 494, 496, and 498 aligned
with openings
474, 476, and 478 of the base 472. Arcuate notches 500a, 500b, and 500c are
formed in the outer
edge 502 of the support plate 490 to align with locating recesses 484a, 484b
and 484c in the base
472 for receiving pegs of the valve assembly.
1001001 The base 472 is illustratively overmolded around the support plate
490.
Illustratively, the base 472 encapsulates the support plate 490 so that no
portion of the support
plate 490 is exposed or visible from outside of the base 472. The support
plate 490 is
illustratively formed of a material having a stiffness greater than that of
the overmolded base
472. For example, the PEX of the base 472 has a Modulus of Elasticity of
approximately 0.8
GPa, and the stainless steel of the support plate 490 has a Modulus of
Elasticity of approximately
180 GPa.
[00101] In the illustrative embodiment, the support plate 490 is formed of
a metal. More
particularly, the support plate 490 may be formed of stainless steel having a
thickness of
approximately 0.05 inches and an outer diameter of approximately 1.16 inches.
It should be
appreciated that materials other than metal, including polymers, may be used
for the support
plate 490 if having a stiffness greater than the material of the base 472.
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1001021 Although
the invention has been described in detail with reference to certain
preferred embodiments, variations and modifications exist within the spirit
and scope of the
invention as described and defined in the following claims.
