Patent Application
20060049267
1. Field of the Invention
The present invention relates generally to faucets and bypass valves for use in home or industrial water distribution systems that supply water to various fixtures at different temperatures through different pipes. More particularly, the present invention relates to faucets having bypass valves that are thermostatically controlled so as to automatically bypass water that is not at the desired temperature for use at the fixture. Even more particular, the present invention relates to faucets having an integral thermostatically controlled bypass valve.
2. Background
Home and industrial water distribution systems distribute water to various fixtures, including sinks, bathtubs, showers, dishwashers and washing machines, that are located throughout the house or industrial building. The typical water distribution system brings water in from an external source, such as a city main water line or a private water well, to the internal water distribution piping system. The water from the external source is typically either at a cold or cool temperature. One segment of the piping system takes this incoming cold water and distributes it to the various cold water connections located at the fixture where it will be used (i.e., the cold water side of the faucet at the kitchen sink). Another segment of the piping system delivers the incoming cold water to a water heater which heats the water to the desired temperature and distributes it to the various hot water connections where it will be used (i.e., the hot water side of the kitchen faucet). At the fixture, cold and hot water either flow through separate hot and cold water control valves that are independently operated to control the temperature of the water into the fixture by controlling the flow rate of water from the valves or the water is mixed at a single valve that selectively controls the desired temperature flowing into the fixture.
A well known problem common to most home and industrial water distribution systems is that hot water is not always readily available at the hot water side of the fixture when it is desired. This problem is particularly acute in water use fixtures that are located a distance from the hot water heater or in systems with poorly insulated pipes. When the hot water side of these fixtures is left closed for some time (i.e., overnight), the hot water in the hot water segment of the piping system sits in the pipes and cools. As a result, the temperature of the water between the hot water heater and the fixture lowers until it becomes cold or at least tepid. When opened again, it is not at all uncommon for the hot water side of such a fixture to supply cold water through the hot water valve when it is first opened and for some time thereafter. At the sink, bathtub or shower fixture located away from the water heater, the person desiring to use the fixture will either have to use cold or tepid water instead of hot water or wait for the distribution system to supply hot water through the open hot water valve. Most users have learned that to obtain the desired hot water, the hot water valve must be opened and left open for some time so that the cool water in the hot water side of the piping system will flow out ahead of the hot water. For certain fixtures, such as dishwashers and washing machines, there typically is no method of “draining” away the cold or tepid water in the hot water pipes prior to utilizing the water in the fixture.
The inability to have hot water at the hot water side of the fixture when it is desired creates a number of problems. One problem is having to utilize cold or tepid water when hot water is desired. This is a particular problem for the dishwasher and washing machine fixtures in that hot water is often desired for improved operation of those fixtures. As is well known, certain dirty dishes and clothes are much easier to clean in hot water as opposed to cold or tepid water. Even in those fixtures where the person can let the cold or tepid water flow out of the fixture until it reaches the desired warm or hot temperature, there are certain problems associated with such a solution. One such problem is the waste of water that flows out of the fixture through the drain and, typically, to the sewage system. This good and clean water is wasted (resulting in unnecessary water treatment after flowing through the sewage system). This waste of water is compounded when the person is inattentitive and hot water begins flowing down the drain and to the sewage system. Yet another problem associated with the linability to have hot water at the hot water valve when needed is the waste of time for the person who must wait for the water to reach the desired temperature.
The use of bypass valves and/or water recirculation systems in home or industrial water distribution systems to overcome the problems described above have been known for some time. The objective of the bypass valve or recirculation system is to avoid suppling cold or tepid water at the hot water side of the piping system. U.S. Pat. No. 2,842,155 to Peters describes a thermostatically controlled water bypass valve, shown as
U.S. Pat. No. 5,623,990 to Pirkle describes a temperature-controlled water delivery system for use with showers and eye-wash apparatuses that utilize a pair of temperature responsive valves, shown as
A recirculating system for domestic and industrial hot water heating utilizing a bypass valve is disclosed in U.S. Pat. No. 5,572,985 to Benham. This system utilizes a circulating pump in the return line to the water heater and a temperature responsive or thermostatically actuated bypass valve disposed between the circulating pump and the hot water heater to maintain a return flow temperature at a level below that at the outlet from the water heater. The bypass valve, shown in
Despite the devices and systems set forth above, many people still have problems with obtaining hot water at the hot water side of fixtures located away from the hot water heater or other source of hot water. Boosted, thermally actuated valve systems having valves that are directly operated by a thermal actuator (such as a wax filled cartridge) tend not to have any toggle action. Instead, after a few on-off cycles, the valves tend to just throttle the flow until the water reaches an equilibrium temperature, at which time the valve stays slightly cracked open. While this meets the primary function of keeping the water at a remote faucet hot, leaving the valve in a slightly open condition does present two problems. First, the lack of toggle action can result in lime being more likely to build up on the actuator because it is constantly extended. Second, the open valve constantly bleeds a small amount of hot or almost hot water into the cold water piping, thereby keeping the faucet end of the cold water pipe substantially warm. If truly cold water is desired (i.e., for brushing teeth, drinking, or making cold beverages), then some water must be wasted from the cold water faucet to drain out the warm water. If the bypass valve is equipped with a spring loaded check valve to prevent siphoning of cold water into the hot water side when only the hot water faucet is open, then the very small flow allowed through the throttled-down valve may cause chattering of the spring loaded check valve. The chattering can be avoided by using a free floating or non-spring loaded check valve. It is also detrimental to have any noticeable crossover flow (siphoning) from hot to cold or cold to hot with any combination of faucet positions, water temperatures, or pump operation.
U.S. Pat. No. 6,536,464 describes an under-the-sink thermostatically controlled bypass valve and water circulating system with the bypass valve placed at or near a fixture (i.e., under the sink) to automatically bypass cold or tepid water away from the hot water side of the fixture until the temperature of the water reaches the desired level. The system described in the co-pending patent application includes a single small circulating pump that is placed between the water heater and the first branching in the hot water supply line which supplies the fixture having a bypass valve so as to pressurize the hot water piping system and facilitate bypassing of the cold or tepid water.
The public is accustomed to purchasing faucets for lavatories, bathtubs, showers, kitchen sinks and etc. that can be readily repaired, usually by removing a top-mounted handle and bonnet, and replacing al faucet washer or other seal or seat. In recent designs, the sealing action occurs within a replaceable cartridge, which can be easily replaced by the home repair person. None of the known prior art devices include the use of an integral thermostatically controlled bypass valve to bypass water as described above. However, for a thermal by pass valve to be included in a faucet, it is necessary that it meet the same expectation for ease of repair as the standard faucet. There are several advantages to location of the thermal by pass valve within the faucet itself and being accessible from the top, which include: (1) elimination of the clutter resulting from extra hoses located below the sink and the need to do plumbing and maintenance below the sink; (2) elimination of the under-the-sink hoses, which by their very presence add potential leak paths at each end of each hose; (3) a new feature that a faucet manufacturer can use to define its top-of-the-line faucet, which can stimulate sales to those customers who like to have the latest in convenience; and (4) the bypass valve can be serviced by the home repair person or, if desired, professional plumber in a standing position in a manner which is already learned from the maintenance of existing design faucets.
The water control fixture having a thermostatically controlled bypass valve of the present invention solves the problems and provides the benefits identified above. That is to say, the present invention provides a water control fixture, such as a faucet, having an integral thermostatically controlled bypass valve to automatically bypass cold or tepid water away from the hot water side of the fixture until the temperature of the water reaches the desired level. The thermostatically controlled bypass valve of the present invention is adaptable to a wide variety of faucet designs. A single small circulating pump can be placed between the water heater and the first branching in the hot water supply line which supplies a fixture having a bypass valve to pressurize the hot water piping system and facilitate bypassing of the cold or tepid water.
In the primary embodiment of the present invention, the water control fixture is a faucet or solenoid operated valve, such as used on laundry washing machines, having a bypass valve and is generally comprised of a standard faucet with a thermally sensitive actuating element, such as a wax-filled cartridge actuator, disposed in the interior of the faucet body. The actuating element has an actuating body and a rod member, the rod member being configured to operatively extend from the actuating body to seal against, or operate as a spool valve, a passage located in the separating wall to prevent water flow through the passage. A bias spring is located in the faucet body to urge the rod member toward the actuating body so as to open the passage. A check valve is located in the faucet body to prevent flow of water from the cold water side to the hot water side.
The present invention also describes a water circulating system for distributing water to a water control fixture, such as a faucet, that is configured for utilizing hot and cold water. The faucet has a hot water inlet and a cold water inlet. The hot water heater supplies hot water to the faucet through the hot water piping system that interconnects the hot water heater with the hot water inlet at the faucet. The system also has a source of cold water, such as the city water supply or a local well, for supplying cold water to the faucet through the cold water piping system that interconnects the source of cold water with the cold water inlet at the faucet. The source of cold water also supplies water to the hot water heater for distribution through the hot water piping system. As such, when the bypass valve located in the faucet is bypassing water the hot and cold water circulating systems form a loop. A faucet having a thermostatically controlled bypass valve interconnects the hot water piping system to the hot water inlet and the cold water piping system to the cold water inlet. The faucet's bypass valve is configured to bypass water from the hot water piping system to the cold water piping system until the water in the hot water piping system rises to a preset temperature value. The bypass valve can comprise the elements and be configured as described above. A single, small pump can be used in the hot water piping system to pump water through the hot water piping system to the hot water inlet on the fixture. In the preferred embodiment, the single pump is a low flow and low head pump. If necessary, a check valve can be used to pass water around the pump when the flow rate in the hot water piping system exceeds the flow rate capacity of the pump. An orifice can be located in the discharge of the pump to achieve the desired steep flow-head curve from available stock pumps A mechanism for cyclically operating the pump can be used to reduce electrical demand and wear and tear on the pump and bypass valve. In addition, a flow switch can be connected to the pump for detecting the flow rate of the water in the hot water piping system and for shutting off the pump when the flow in the hot water piping system exceeds the flow rate capacity of the bypass valve.
Accordingly, the primary objective of the present invention is to provide a faucet or other water control fixture having a thermostatically controlled bypass valve that is suitable for bypassing water from a hot water piping system to a cold water piping system at a fixture until the temperature of the water in the hot water piping system rises to a preset level for use at the fixture.
It is also an important objective of the present invention to provide a faucet or other water control fixture having a thermostatically controlled bypass valve that utilizes a thermally sensitive actuating element having a rod member configured to operatively open and close a passage between the hot and cold sides of the bypass valve based on the temperature of the water adjacent to the fixture.
It is also an important objective of the present invention to provide a faucet having a thermostatically controlled bypass valve that includes a check valve in the bypass valve to prevent the flow of water from the cold water piping system to the hot water piping system when the bypass valve is cold and thus in an open condition.
It is also an important objective of the present invention to provide a water circulating system utilizing a faucet having a thermostatically controlled bypass valve located therein and a pump in the hot water piping system to circulate water from the hot water piping system to the cold water piping system through the faucet's bypass valve until the temperature of the water in the hot water piping system reaches a preset level.
It is also an important objective of the present invention to provide a faucet or other water control fixture having a thermostatically controlled bypass valve that is adaptable to a wide variety of faucet or other fixture designs.
In the drawings which illustrate the best modes presently contemplated for carrying out the present invention:
With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, the preferred embodiments of the present invention are set forth below. The enclosed figures and drawings are illustrative of the preferred embodiments and represent a preferred way of configuring the present invention. Although specific components, materials, configurations and uses are illustrated, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein.
In the accompanying drawings of the various preferred embodiments of a water control fixture of the present invention, the water control fixture is shown as faucet 10. However, other water control fixtures may be adaptable to the thermal bypass valve features described herein (i.e., solenoid valve used on home laundry washing machines). A typical water distribution system 12 utilizing faucet 10 of the present invention is illustrated in
The preferred system 12 of the present invention utilizes a small circulating pump 26 of the type used in residential hot water space heating. A very low flow and low head pump is desirable because a larger (i.e., higher head/higher flow) pump mounted at the typical domestic water heater 18 tends to be noisy. This annoying noise is often transmitted by the water pipes throughout the house. In addition, if the shower (as an example) is already in use when pump 26 turns on, whether the first start or a later cyclic turn-on, the sudden pressure boost in the hot water line 20 from a larger pump can result in an uncomfortable and possibly near scalding temperature rise in the water at the shower head or other fixture in use. The smaller boost of a “small” pump (i.e., one with a very steep flow-head curve) will result in only a very small and less noticeable increase in shower temperature. In the preferred embodiment, the single, small pump 26 needs to provide only a flow of approximately 0.3 gpm at 1.0 psi pressure. In accordance with pump affinity laws, such a “small” pump requires a very small impeller or low shaft speed. The inventors have found that use of a very small impeller or low shaft speed also precludes formation of an air bubble in the eye of the impeller, which bubble may be a major cause of noise. Such a small steep curve pump may, however, constitute a significant pressure drop in the hot water line 20 when several fixture taps are opened simultaneously (such as a bathtub and the kitchen sink). To avoid reduced flow in those installations having a relatively low volume pump, a check valve 28 can be plumbed in parallel with pump 26 or incorporated within the pump housing, to pass a flow rate exceeding the pump's capacity around pump 26. When pump 26 is powered and flow demand is low, check valve 28 prevents the boosted flow from re-circulating back to its own inlet. With check valve 28 plumbed around pump 26, it is advantageous to place an orifice 30 in the pump discharge to provide a simple manner to achieve the desired very steep flow-head curve from available stock pump designs. A single pump 26 located at or near the water heater 18 in its discharge piping will boost the pressure in the hot water pipes somewhat above that in the cold water pipes (i.e., perhaps one to three feet of boost). With this arrangement only one pump 26 per plumbing system (i.e., per water heater 18) is required with any reasonable number of remote faucets 10 (i.e., the typical number used in residences) equipped with bypass valves. This is in contrast to those systems that require multiple pumps, such as a pump at each fixture where bypassing is desired.
If desired, pump 26 can operate twenty-four hours a day, with most of the time in the no flow mode. However, this is unnecessary and wasteful of electricity. Alternatively, pump 26 can have a timer 32 to turn on the pump 26 daily at one or more times during the day just before those occasions when hot water is usually needed the most (for instance for morning showers, evening cooking, etc.) and be set to operate continuously for the period during which hot water is usually desired. This still could be unnecessary and wasteful of electricity. Another alternative is to have the timer 32 cycle pump 26 on and off regularly during the period when hot water is in most demand. The “on” cycles should be of sufficient duration to bring hot water to all remote fixtures 10 that are equipped with a bypass valve, and the “off” period would be set to approximate the usual time it takes the water in the lines to cool-down to minimum acceptable temperature. Yet another alternative is to equip pump 26 with a normally closed flow switch 34 sized to detect significant flows only (i.e., those flows that are much larger than the bypass valve flows), such as a shower flowing. For safety purposes, the use of such a switch 34 is basically required if a cyclic timer 32 is used. The switch 34 can be wired in series with the motor in pump 26. If the switch 34 indicates an existing flow at the moment the timer calls for pump 26 to be on, the open flow switch 34 will prevent the motor from starting, thereby avoiding a sudden increase in water temperature at the fixture 10 (i.e., particularly if it is a shower) being utilized. The use of such switch 34 accomplishes several useful objectives, including reducing electrical power usage and extending pump life if hot water is already flowing and there is no need for the pump to operate, avoiding a sudden temperature rise and the likelihood of scalding that could result from the pump boost if water is being drawn from a “mixing” valve (such as a shower or single handle faucet) and allowing use of a “large” pump (now that the danger of scalding is eliminated) with its desirable low pressure drop at high faucet flows, thereby eliminating the need for the parallel check valve 28 required with a “small” pump.
By using a time-of-day control timer 32, pump 26 operates to maintain “instant hot water” only during periods of the day when it is commonly desired. During the off-cycle times, the plumbing system 12 operates just as if the faucet 10 having bypass valves and pump 26 were not in place. This saves electrical power usage from pump operation and, more importantly, avoids the periodic introduction of hot water into relatively un-insulated pipes during the off-hours, thereby saving the cost of repeatedly reheating this water. The time-of-day control also avoids considerable wear and tear on pump 26 and the bypass valve in faucet 10. Considerable additional benefits are gained by using a cyclic timer 32, with or without the time-of-day control. In addition to saving more electricity, if a leaky bypass valve or one not having toggle action is used, there will be no circulating leakage while the pump 26 is cycled off, even if the valve fails to shut off completely. Therefore, a simple (i.e., one not necessarily leak tight) valve may suffice in less demanding applications. Having the leakage reduced to just intermittent leakage will result in reduced warming of the cold water line 16 and less reheating of “leaking” re-circulated water.
The bypass valve assemblies 36 utilized with the present invention have a thermally sensitive actuating element 38, an example of which is shown in
Because the bypass valve 36 has little or no independent “toggle action,” after a few cycles of opening and closing, the valve tends to reach an equilibrium with the plumbing system, whereby the bypass valve 36 stays slightly cracked open, passing just enough hot water to maintain the temperature constantly at its setting. In particular plumbing systems and at certain ambient conditions, this flow is just under that required to maintain a spring loaded check valve cracked continuously open. In such a situation, the check valve chatters with an annoying buzzing sound. To avoid this occurrence, the spring may be removed from the check valve, leaving the poppet free floating. In the event that the hot water is turned full on at a time when the bypass valve 36 is open, thereby lowering the pressure in the hot water line 20, and so inducing flow from the cold water line 16 through the open bypass valve 36 to the hot side, the free floating poppet will quickly close. There is no necessity for a spring to keep this check valve closed prior to the reversal in pressures.
Although not entirely demonstrated in early tests, it is believed that beneficial “toggle” action can be achieved with a bypass valve 36 of very simple mechanical design. If the motion of the thermal actuator 38 is made to lag behind the temperature change of the water surrounding it by placing suitable insulation around the actuator 38 or by partially isolating it from the water, then instead of slowly closing only to reach equilibrium at a low flow without reaching shutoff, the water temperature will rise above the extending temperature of the insulated actuator 38 as the valve approaches shutoff, and the piston 44 will then continue to extend as the internal temperature of the actuator 38 catches up to its higher surrounding temperature, closing the valve 36 completely. It is also believed that an insulated actuator 38 will be slow opening, its motion lagging behind the temperature of the surrounding cooling-off water from which it is insulated. When actuating element 38 finally begins to open the valve 36 and allow flow, the resulting rising temperature of the surrounding water will again, due to the insulation, not immediately affect it, allowing the bypass valve 36 to stay open longer for a complete cycle of temperature rise. Such an “insulated” effect may also be accomplished by use of a wax mix that is inherently slower, such as one with less powdered copper or other thermally conductive filler. An actuator 38 to be installed with insulation can be manufactured with a somewhat lower set point temperature to make up for the lag, allowing whatever valve 36 closing temperature desired.
An additional benefit of utilizing pump 26 in system 12 is that shut-off of a toggle action valve upon attainment of the desired temperature is enhanced by the differential pressure an operating pump 26 provides. If pump 26 continues to run as the water at the faucet 10 cools down, the pump-produced differential pressure works against re-opening a poppet type bypass valve 36 in faucet 10. If pump 26 operates cyclically, powered only a little longer than necessary to get hot water to faucet 10, it will be “off” before the water at valve 36 cools down. When the minimum temperature is reached, the thermal actuator 38 will retract, allowing the bias spring to open valve 36 without having to fight a pump-produced differential pressure. By-pass flow will begin with the next pump “on” cycle. An additional benefit to the use of either a time-of-day or cyclic timer 32 is that it improves the operating life of thermal actuator 38. Because use of either timer 32 causes cyclic temperature changes in valve 36 (as opposed to maintaining an equilibrium setting wherein temperature is constant and the actuator 38 barely moves), there is frequent, substantial motion of the piston 44 in thermal actuator 38. This exercising of actuator 38 tends to prevent the build-up of hard water deposits and corrosion on the cylindrical surface of actuator piston 44 and face of poppet 42, which deposits could render the valve 36 inoperable.
Also inside valve 36 can be an over-travel spring (not shown) disposed between the first side 52 of the actuator body 48 and a stop located inside valve 36 to prevent damage to a fully restrained actuator 38 if it were heated above the bypass valve's maximum operating temperature and to hold the actuator 38 in place during operation without concern for normal tolerance. Use of an over-travel spring, which is not necessary for spool-type valves, allows movement of the actuator body 48 away from the seated poppet 42 in the event that temperature rises substantially after the poppet 42 contacts its seat. Without this relief, the expanding wax could distort its copper can, destroying the calibrated set point. The over-travel spring also holds the bias spring, rod member 40 and actuator body 48 in place without the need to adjust for the stack-up of axial tolerances. Alternatively, actuator 38 can be fixedly placed inside valve 36 by various mechanisms known in the art, including adhesives and the like. Over-travel spring, if used, can be held in place by various internal configurations commonly known in the art, such as a molded seat.
As there are a great many configurations and brands of faucets 10, there are several different preferred designs of bypass valve 36 placement and arrangement to accommodate these many faucet configurations. For purposes of illustrating the present invention, various specific examples are set forth below. The following examples are representative of the types of uses to which the integral or in-faucet bypass valve 36 is suitable. The examples are for illustrative purposes only and are not intended to restrict the invention to particular uses, sizes or materials used in the examples.
For instance, there are several basic types of faucet assemblies, including those that have a single handle faucet assembly that mixes the hot and cold water and delivers a flow of water out the single spout based on the user's movement of the faucet's valve assembly. Another common type of faucet assembly is the dual handle, single spout faucet assembly that has separate handles for the hot and cold water. As with the single handle assembly, the hot and cold water are mixed prior to the spout based on the user's selection of the amount of flow of hot and/or cold water. A third, older arrangement is the use of completely separate faucets for hot and cold water. Although the different manufacturers of faucets may utilize different arrangements of valving components, different valving mechanisms and/or different valves to water supply line connections, the bypass valve system of the present invention is adaptable to all such known configurations. As set forth below, the primary selection in the use of the bypass faucet assembly of the present invention is whether to place the bypass valve in a stationary portion of the faucet, such as the hot water piping leading to the faucet or in a housing or block portion of the faucet, or to place the bypass valve in the moveable valving of the faucet. Selection of which location to place the bypass valve assembly will often be dictated by economics, preferences, limitations on the amount of space available, the current design of the faucet and/or the willingness to change.
Single Handle Faucets w/ Bypass Valve in Stationary Block
As is well known, single handle faucets, an example of which is shown as fixture body 60, faucet 10 without its decorative covering, in
The single handle faucet body 60 with spherical ball valving means 64, shown in
Another example of a single handle water control fixture is shown as 110 in
Single Handle Faucets; W/ Bypass Valve In Moveable Valving
This family of valves may utilize either a moveable perforated hollow spherical ball 64, as shown in
The previous simple hollow sphere, now 134 (shown in
The two inlet ports on ball body 135, shown as 156 for the hot water inlet port and 158 for the cold water inlet port on
There are several major advantages to this arrangement. These advantages include: (1) the complete ball 134 is easily replaced to fix a malfunctioning bypass valve 36; (2) for retrofit, the original ball 64 can be removed and replaced with the new valve-in-ball 134. No other changes need be made to the existing faucet 10 (however, a booster pump 26 located near the hot water heater 18 in the hot water line 20 does of course need to be installed). This is particularly advantageous where it would be very difficult or impractical to replace an existing complete faucet valve, such as a shower valve installed behind a tiled wall.
While the hollow ball 64 of the Delta faucet (and other clone faucets) provides an adequate space in a convenient location for installation of the bypass valve 36, a miniaturized version of the bypass valve 36 can also be fitted into the replaceable cylindrical valving cartridges of other brands of single handle faucets with an action characterized by oscillating movement about a vertical centerline to adjust water temperature. Such a valving action to control mixing is commonly used in Price-Pfister, Sterling, American Standard, Moen, and Kohler faucets, among others. These faucets use a push-pull or tipping lever action to operate the on-off function within the same (usually) cylindrical cartridge. On some configurations, it is likely that space would have to be made by lengthening these cylindrical faucet cartridges, which would in turn call for a compensating change to the faucet central housing.
In the position shown in
The bypass valve 36 components (consisting of bias spring 226, shuttle 218, actuator piston 228 and actuator 230) are enclosed within the tubular portion of spool 204. Shuttle 218 is located (floats) between bias spring 226 and actuator 230. Shuttle 218 has a central cruciform shaped member with an integral elastomer sleeve 232 attached to the four legs of the cruciform. Four axial passages within the sleeve 232 and around the cruciform are thus provided. This elastomer sleeve 232 is in contact with and seals against the inner surface of tubular spool 204. When thermal actuator 230 is heated to its actuation temperature, it “suddenly” extends piston 228 outward, moving shuttle 218 (to the left in
Two bleed holes 234 and 236 are so located through the wall of tubular spool 204 as to line up with hot water inlet 210 and cold water inlet 208, respectively, when the manually operated spool 204 is pushed all the way into housing 206 (the off position). Further, bleed hole 236 is axially located slightly closer to the bias spring end of spool 204. O-rings 238 seal spool 204 and retaining clip 240 holds sleeve 222 within housing 206.
In
When sufficient cooled off water has passed through the valve 200 to bring “hot” water to and through the valve 200, actuator 230 will be warmed to its actuation temperature and will expand, forcing shuttle 218 against bias spring 226. This axial movement will result in elastomer sleeve 232 covering cold bleed hole 236. Boosted hot water pressure internal to sleeve 232 will hold sleeve 232 outward against the inner wall of tubular spool 204, effectively sealing bleed hole 236, and stopping the bypass flow until the valve cools down, causing bias spring 226 to force shuttle 218 back against piston 10 into contracting actuator 230, again opening cold bleed hole 236.
The elastomer sleeve 232 has a second function, that of acting as a check valve. When any faucet in the plumbing system is opened, the resulting flow may induce a substantial pressure drop in the associated plumbing line (either hot 20 or cold 16, depending on which faucet was opened). If a bypass valve 36 is open at such a time, such a pressure difference may cause sufficient water may leak through as to constitute a nuisance. If the lowered pressure is on the hot water line 20, no “leak” will occur as the higher pressure of the cold water inside the sleeve 232 will hold it against the inner wall of tubular spool 204 in the vicinity of hot bleed hole 234, effecting a seal. If the lowered pressure is on the cold side, the valve 200 will allow cooled off water from the hot water line 20 to bypass into the cold water line until warm water arrives at the valve 200, at which time the shuttle 218 will shift and cut off the bypass.
Dual Handle, Single Spout Faucets
Although two handle, single spout faucets might have been expected to fade out of demand in favor of the more convenient single handle faucets, the two handle faucets (shown as 10 in
Most modem two handle faucets utilize a cartridge design in a pair of valve member 166, shown in
The major difference of concern in this matter between single handle single spout and two handle single spout faucet designs is that in the single handle central block, it is possible to create the connecting passages (bypass) by simply drilling cross holes, as discussed above. With two separate hot and cold faucet valves located four inches apart, some kind of cross conduit for the bypass must be added. There seem to be two approaches to directing the water from the hot and cold faucets to a confluence and out to the single spout. American-Standard, Oasis, La Bella and some Price-Pfisters use a large brass casting that includes the spout, both hot and cold faucet housings, and a cored cast passage connecting all of this together. Adding a thermal bypass valve 36 to such a two handle faucet set would require the addition of an additional cored cast passage to accomplish the bypass function between hot and cold lines. Delta, Moen, Kohler, and some Price Pfister two handle single spout valves use brazed-in copper tube manifolds instead of cored cast passages. These would require the addition of a tubular cross passage brazed in. The Delta two handle single spout valve has a somewhat different valving action which makes it much more difficult to fit in a thermal valve cartridge. This new passage (cored or brazed tubular) needs to connect to the vertical hot and cold “pipe” members below their existing side port to the spout. These faucet sets generally do not have sufficient vertical space under the polished bezel to accommodate the extra passage. This will require addition of some vertical length to the skirt of the valve bezel.
The operation of the bypass valve 36 inside of faucet 10 of the present invention is summarized on the chart shown as
If the hot water valve is turned on with the thermal element 88 open as in mode IVB above, pressure in the line 20 to the hot water side of faucet 10 will drop below the pressure in the cold water line 16. This differential pressure, higher on the cold side, will load check valve 96 in the “closed” direction allowing no cross flow. This is mode IVC in the outline on
MODE I: Water In Hot Water Supply Line Hot, Pump On.
A. Hot and cold faucet valves full open
Pressure drops from hot and cold flow about equal. Actuator element 26 stays closed. No leak or recirculation in either direction.
B. Hot and cold faucet valves fully closed
Thermal actuator 88 keeps valve 36 closed. No recirculation.
C. Hot faucet valve fully open, cold faucet valve closed
Actuator element 88 closed. Check valve 96 closed. No recirculation. No leak.
D. Hot faucet valve closed, cold faucet valve fully open
Actuator element 88 closed. No recirculation. No leak.
E. Hot and cold faucet valves both partially open in any combination
Actuator element 88 closed. No recirculation. No leak.
MODE II: Water in Hot Water Supply Line Hot, Pump Off.
A. Hot and cold faucet valves full on
Pressure drops from hot and cold flow about equal. Actuator element 88 stays closed.
B. Hot and cold faucet valves fully closed
Thermal actuator 88 keeps valve 36 closed. No recirculation.
C. Hot faucet valve fully open, cold faucet valve closed
Thermal actuator 88 closed. Check valve 96 closed. No recirculation. No leak.
D. Hot faucet closed, cold faucet fully open
Thermal actuator 88 closed. No recirculation. No leak.
E. Hot and cold faucets both partially open in any combo
Thermal actuator 88 closed. No recirculation. No leak.
MODE III: Water in Hot Water Line Cooled Off, Pump On.
A. Hot and cold faucet valves full open
Flow-induced pressure drops about equal, valve 36 stays open and allows recirculation hot to cold until tepid water is exhausted and hotter water closes thermal actuator 88. If both faucet valves are at same sink, they are mixing hot and cold anyway. If faucet valves being manipulated are at remote sinks on the same plumbing branch, this short time tepid-to-cold leak will probably not be noticeable. If faucet valves being manipulated are on remote branches of plumbing, the mixing would have no effect.
B. Hot and cold faucet valves fully closed
Thermal actuator 88 open, get desired tepid-to-cold recirculation until hot line heats up.
C. Hot faucet valve fully open, cold faucet valve closed
Thermal actuator 88 open but pressure drop in hot line may negate pump pressure, stopping recirculation. Check valve 96 stops cold to hot leak.
D. Hot faucet valve closed, cold faucet valve fully open
Thermal actuator 88 open, get tepid to cold recirculation until hot line heats up.
E. Hot and cold faucets both partially open in any combination
Could get tepid to cold leak. If faucet valves at same sink don't care as mixing hot and cold anyway. If at remote sinks probably not noticeable. Tepid to cold leak would be short term.
MODE IV: Water In Hot Water Supply Line Cooled Off, Pump Off.
A. Hot and cold faucet valves full open
Flow-induced pressure drops about equal, valve 36 stays open and may allow recirculation (leak) hot to cold until tepid water is exhausted and hotter water closes thermal actuator 88. Don't care, if both faucets are at same sink as are mixing hot and cold anyway. If faucet valves being manipulated are at remote sinks on the same plumbing branch, this short time tepid-to-cold leak would probably not be noticeable. If faucets being manipulated are on remote branches of plumbing, mixing would riot be noticeable.
B. Hot and cold faucet valves fully closed
Thermal actuator 88 open, no recirculation.
C. Hot faucet valve fully open, cold faucet valve fully closed
Thermal actuator 88 open. Check valve 96 closed. No leak
D. Hot faucet valve closed. Cold faucet valve fully open
Valve 36 open, tepid to cold recirculation until thermal actuator 88 heats up and closes.
E. Hot and cold faucet valves both partially open, in any combo
Could get tepid to cold leak. If faucet valves at same sink, don't care as mixing hot and cold anyway. If at remote sinks probably not noticeable. Tepid to cold leak would be short term.
Several further enhancements have been developed for the thermal valve actuator 88, which are applicable to all of the above-described faucets are shown in
The most direct method to overcome sticking due to mineral buildup is to optimize actuator force in both directions. Buildup of precipitated minerals on the exposed outside diameter of the extended piston 44 tends to prevent retraction, requiring a strong bias spring 106. This high bias spring force subtracts from the available extending force however, thereby limiting the force available to both extend the piston 44 against the mineral sticking resistance and to effect an axial seal between poppet and seat.
When water temperature is high, the piston 44 is extended so that its surface is exposed. Deposition also occurs primarily at high temperatures, so that buildup occurs on the piston outside diameter, resulting in sticking in the extended position when the growth on the piston outside diameter exceeds the guide 186 interior diameter. Significantly more than half of the available actuator force thus can most effectively be used to compress the bias spring 106, resulting in a maximum return force.
While there is shown and described herein certain specific alternative forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to the dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use.
With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, and particularly with reference to the embodiment of the present invention illustrated in
At the first end 314 (the hot water side) is first inlet port 318 and first discharge port 320 and at the second end 316 (the cold water side) is second inlet port 322 and second discharge port 324. Conversely, the radial ports can be the inlet ports and the axial ports can be the discharge ports. As discussed in detail below, the first 318 and second 322 inlet ports connect to the hot and cold water distribution system and first 320 and second 324 discharge ports connect to the hot and cold water valves on the fixture (i.e., sink, shower, bathtub or etc.) with which the bypass valve 310 is utilized. The use of both an inlet 318 and discharge 320 ports on the hot side distinguish the present invention from other known bypass valves, which utilize a single port, and provide significant benefits for bypass valve 310. The bypass valve 310 of the present invention reduces the number of plumbing fittings (at least one tee) and plumber time for installation by allowing it to be connected simply with swivel nut hoses. Because the “tee” function is internal to valve body 312, hot water flowing to the open fixture valve flows through valve body 312, around the thermal actuator body, allowing immediate response to rising temperature. Conversely, if the tee is an external pipe fitting remote from the thermal bypass valve, response will be slowed. This use of an integral tee shortens time in which water can be siphoned from cold to hot, eliminating the need for an internal check valve. Hot water flowing through valve body 312 to an open fixture also allows placement of a screen inside the valve body 312 such that it is swept clean. The use of the second port on the hot side also allows placement of a retaining pin without the need for an extra seal. The use of two ports on the cold side (i.e., inlet port 322 and discharge port 324) also eliminates the use of an external tee and further simplifies and reduces the cost of installing the bypass valve 310. In addition, two ports on the cold side also facilitate the use of a retaining slot for holding a check valve, if one is used.
As best shown in
For ease of installation of the bypass valve 310 by the user, each of the four ports (318, 320, 322 and 324) on valve body 312 have one-half inch straight pipe threads for use with the swivel nuts that are commonly found on standard connection hoses that fit the typical residential faucet. The threads on all four ports are molded with flats or axial slots 348 interrupting the threads to prevent a user from attempting to mount valve body 312 directly to “hard” plumbing with female taper pipe threads. The swivel nuts on the connection hoses seal with hose washers against the ends of the four ports, as opposed to common pipe fittings that seal at the tapered threads. These four ports can be marked “hot in”, “hot out”, “cold in”, and “cold out” as appropriate to provide visual indicators for the do-it-yourself installer so as to avoid confusion. In the preferred installation of bypass valve 310, inlet port 318 connects to the hot water angle stop at the wall and the discharge port 320 connects to the hot water faucet. Inlet port 322 connects to the cold water angle stop and discharge port 324 connects to the cold water faucet. In actuality, the two hot hoses can be interchanged on the two hot ports (ports 318 and 320), as can the two cold hoses on the cold ports (ports 322 and 324).
Thermally sensitive actuating element 326 is preferably of the wax filled cartridge type, also referred to as wax motors, having an integral piston/poppet rod member 350, as best shown in
Although not entirely demonstrated in early tests, it is believed that beneficial “toggle” action can be achieved with a bypass valve 310 of very simple mechanical design. If the motion of the thermal actuator 326 is made to lag behind the temperature change of the water surrounding it by placing suitable insulation around the actuator 326 or by partially isolating it from the water, then instead of slowly closing only to reach equilibrium at a low flow without reaching shutoff, the water temperature will rise above the extending temperature of the insulated actuator 326 as the valve approaches shutoff, and the piston 350 will then continue to extend as the internal temperature of the actuator 326 catches up to its higher surrounding temperature, closing the valve 310 completely. It is also believed that an insulated actuator 326 will be slow opening, its motion lagging behind the temperature of the surrounding cooling-off water from which it is insulated. When actuating element 326 finally begins to open the valve 310 and allow flow, the resulting rising temperature of the surrounding water will again, due to the insulation, not immediately affect it, allowing the bypass valve 310 to stay open longer for a complete cycle of temperature rise. Such an “insulated” effect may also be accomplished by use of a wax mix that is inherently slower, such as one with less powdered copper or other thermally conductive filler. An actuator 326 to be installed with insulation can be manufactured with a somewhat lower set point temperature to make up for the lag, allowing whatever valve 310 closing temperature desired.
Also inside valve body 312 is an over-travel spring 330, disposed between the first side 358 of the actuator body 354 and a stop located inside valve body 312 to prevent damage to a fully restrained actuator 326 heated above the bypass valve's 310 maximum operating temperature and to hold the actuator 326 in place during operation without concern for normal tolerance. Over-travel spring 330 allows movement of the actuator body 354 away from the seated poppet 351 in the event that temperature rises substantially after the poppet 351 contacts seat 342. Without this relief, the expanding wax would distort its copper can, destroying the calibrated set point. The over-travel spring 330 also holds the bias spring 328, rod member 350 and actuator body 354 in place without the need to adjust for the stack-up of axial tolerances. Alternatively, actuator 326 can be fixedly placed inside valve body 312 by various mechanisms known in the art, including adhesives and the like. Over-travel spring can be held in place by various internal configurations commonly known in the art, such as a molded seat. In the preferred embodiment, however, over-travel spring 330 abuts against screen 332, which is held in place by cantilevered retention pin 334. Screen 332 can be a small wire fabric, mesh-type screen that is shaped and configured to fit within the first end 314 of valve body 312. Screen 332 is utilized to keep hard water lime particles and other detritus out of bypass valve 310 and to act as a seat for the over-travel spring (as explained above). Screen 332 is positioned inside valve body 312, as shown in
In an alternative embodiment of the present invention, a snap-in cartridge check valve 336 is located in the second end 316 of valve body 312, as shown in
In order to achieve the desired circulation flow, a single circulating pump 366 is utilized as part of a water circulating system 367, as shown in
If desired, pump 366 can operate twenty-four hours a day, with most of the time in the no flow mode. However, this is unnecessary and wasteful of electricity. Alternatively, pump 366 can have a timer 374 to turn on the pump 366 daily at one or more times during the day just before those occasions when hot water is usually needed the most (for instance for morning showers, evening cooking, etc.) and be set to operate continuously for the period during which hot water is usually desired. This still could be unnecessary and wasteful of electricity. Another alternative is to have the timer 374 cycle pump 366 on and off regularly during the period when hot water is in most demand. The “on” cycles should be of sufficient duration to bring hot water to all remote fixtures that are equipped with a bypass valve 310, and the “off” period would be set to approximate the usual time it takes the water in the lines to cool-down to minimum acceptable temperature. Yet another alternative is to equip pump 366 with a normally closed flow switch 376 sized to detect significant flows only (i.e., those flows that are much larger than the bypass valve 310 flows), such as a shower flowing. For safety purposes, the use of such a switch 376 is basically required if a cyclic timer 374 is used. The switch can be wired in series with the pump motor. If the switch indicates an existing flow at the moment the timer calls for pump on, the open flow switch will prevent the motor from starting, thereby avoiding a sudden increase in water temperature at the fixture (i.e., a shower) being utilized. The use of such a switch accomplishes several useful objectives, including reducing electrical power usage and extending pump life if hot water is already flowing and there is no need for the pump to operate, avoiding a sudden temperature rise and the likelihood of scalding that could result from the pump boost if water is being drawn from a “mixing” valve (such as a shower or single handle faucet) and allowing use of a “large” pump (now that the danger of scalding is eliminated) with its desirable low pressure drop at high faucet flows, thereby eliminating the need for the parallel check valve 370 required with a “small” pump.
By using a time-of-day control timer 374, pump 366 operates to maintain “instant hot water” only during periods of the day when it is commonly desired. During the off-cycle times, the plumbing system operates just as if the bypass valves 310 and pump 366 were not in place. This saves electrical power usage from pump operation and, more importantly, avoids the periodic introduction of hot water into relatively uninsulated pipes during the off-hours, thereby saving the cost of repeatedly reheating this water. The time-of-day control also avoids considerable wear and tear on pump 366 and the bypass valves 310. Considerable additional benefits are gained by using a cyclic timer 374, with or without the time-of-day control. In addition to saving more electricity, if a leaky bypass valve or one not having toggle action is used, there will be no circulating leakage while the pump is cycled off, even if the valve fails to shut off completely. Therefore, a simple (i.e., one not necessarily leak tight) valve may suffice in less demanding applications. Having the leakage reduced to just intermittent leakage will result in reduced warming of the cold water line and less reheating of “leaking” recirculated water. In addition, shut-off of a toggle action valve upon attainment of the desired temperature is enhanced by the differential pressure an operating pump provides. If pump 366 continues to run as the water at the bypass valve 310 cools down, the pump-produced differential pressure works against re-opening the valve. If pump 366 operates cyclically, powered only a little longer than necessary to get hot water to bypass valve 310, it will be “off” before the valve 310 cools down. When the minimum temperature is reached, the thermal actuator 326 will retract, allowing the bias spring 328 to open the valve 310 without having to fight a pump-produced differential pressure. Bypass flow will begin with the next pump “on” cycle. An additional benefit to the use of either a time-of-day or cyclic timer 374 is that it improves the operating life of thermal actuator 326. Because use of either timer 374 causes cyclic temperature changes in valve 310 (as opposed to maintaining an equilibrium setting wherein temperature is constant and the actuator barely moves), there is frequent, substantial motion of the piston 350 in thermal actuator 326. This exercising of actuator 326 tends to prevent the build-up of hard water deposits and corrosion on the actuator piston 350 and poppet face, which deposits would render the valve 310 inoperable.
In the preferred embodiment, bypass valve 310 is manufactured from a one-piece molded valve body 312 that is configured as described above with fin guides 338, internal shoulder 340, passage 337, retaining pin hole 344 and retaining slot 346 for ease of manufacture and reduced manufacturing costs. The bias spring 328, wax cartridge actuating element 326 with its piston/poppet rod member 350, the over-travel spring 330 and screen 332 are placed into the “hot” axial port (the first inlet port 318) in that order. Screen 332 is pushed against the over-travel spring 330 compressing it, thereby making room for insertion of the retaining pin 334 through the retaining pin hole 344 at the “hot” radial port (the first discharge port 320). The cartridge check valve 336, if utilized, is inserted into the “cold” axial port (the second inlet port 322) and snaps into place in retaining slot 346.
Installation of the bypass valve 310 of the present invention is also made easy by manufacturing the valve 310 in the configuration as set forth above. As discussed, valve body 312 is molded with four ports (designated as 318, 320, 322 and 324) to allow installation with commonly used under-sink (as an example) vinyl hoses or flexible metal pipe, shown as 378 in
The operation of the bypass valve 310 of the present invention is summarized on the chart shown as
If the hot water valve is turned on with the thermal element 326 open as in mode IVB above, pressure in the line 386 to the hot water side of faucet 380 will drop below the pressure in the cold water line 388. This differential pressure, higher on the cold side, will load check valve 336 in the “closed” direction allowing no cross flow. This is mode IVC in the outline on
MODE I: Water In Hot Water Supply Line Hot, Pump On
A. Hot and cold faucet valves full open Pressure drops from hot and cold flow about equal. Actuator element 326 stays closed. No leak or recirculation in either direction.
B. Hot and cold faucet valves fully closed Thermal actuator 326 keeps valve 310 closed. No recirculation.
C. Hot faucet valve fully open, cold faucet valve closed Actuator element 326 closed. Check valve 336 closed. No recirculation. No leak.
D. Hot faucet valve closed, cold faucet valve fully open Actuator element 326 closed. No recirculation. No leak.
E. Hot and cold faucet valves both partially open in any combination Actuator element 326 closed. No recirculation. No leak.
MODE II: Water in Hot Water Supply Line Hot, Pump Off
A. Hot and cold faucet valves full on Pressure drops from hot and cold flow about equal. Actuator element 326 stays closed.
B. Hot and cold faucet valves fully closed Thermal actuator 326 keeps valve 310 closed. No recirculation.
C. Hot faucet valve fully open, cold faucet valve closed Thermal actuator 326 closed. Check valve 336 closed. No recirculation. No leak.
D. Hot faucet closed, cold faucet fully open Thermal actuator 326 closed. No recirculation. No leak.
E. Hot and cold faucets both partially open in any combo Thermal actuator 326 closed. No recirculation. No leak.
MODE III: Water in Hot Water Line Cooled Off, Pump On
A. Hot and cold faucet valves full open Flow-induced pressure drops about equal, valve 310 stays open and allows recirculation hot to cold until tepid water is exhausted and hotter water closes thermal actuator 326. If both faucet valves are at same sink, they are mixing hot and cold anyway. If faucet valves being manipulated are at remote sinks on the same plumbing branch, this short time tepid-to-cold leak will probably not be noticeable. If faucet valves being manipulated are on remote branches of plumbing, the mixing would have no effect.
B. Hot and cold faucet valves fully closed Thermal actuator 326 open, get desired tepid-to-cold recirculation until hot line heats up.
C. Hot faucet valve fully open, cold faucet valve closed Thermal actuator 326 open but pressure drop in hot line may negate pump pressure, stopping recirculation. Check valve 336 stops cold to hot leak.
D. Hot faucet valve closed, cold faucet valve fully open Thermal actuator 326 open, get tepid to cold recirculation until hot line heats up.
E. Hot and cold faucets both partially open in any combination Could get tepid to cold leak. If faucet valves at same sink don't care as mixing hot and cold anyway. If at remote sinks probably not noticeable. Tepid to cold leak would be short term.
MODE IV: Water In Hot Water Supply Line Cooled Off, Pump Off
A. Hot and cold faucet valves full open Flow-induced pressure drops about equal, valve 310 stays open and may allow recirculation (leak) hot to cold until tepid water is exhausted and hotter water closes thermal actuator 326. Don't care, if both faucets are at same sink as are mixing hot and cold anyway. If faucet valves being manipulated are at remote sinks on the same plumbing branch, this short time tepid-to-cold leak would probably not be noticeable. If faucets being manipulated are on remote branches of plumbing, mixing would not be noticeable.
B. Hot and cold faucet valves fully closed Thermal actuator 326 open, no recirculation.
C. Hot faucet valve fully open, cold faucet valve fully closed Thermal actuator 326 open. Check valve 336 closed. No leak
D. Hot faucet valve closed. Cold faucet valve fully open Valve 310 open, tepid to cold recirculation until thermal actuator 326 heats up and closes.
E. Hot and cold faucet valves both partially open, in any combo Could get tepid to cold leak. If faucet valves at same sink, don't care as mixing hot and cold anyway. If at remote sinks probably not noticeable. Tepid to cold leak would be short term.
In an alternative embodiment of the present invention, the bypass valve 310 is incorporated into a fixture, such as faucet, shower or bathtub (as well as washing machines and dishwashers) for use in a water circulating system 367. In the alternative embodiment, the fixture would utilize the same internal components described above with the same schematic connections to the hot and cold inlet and discharge ports. The valve components may be installed into a housing integral with (or contained in a bezel covering) a valve for a sink, shower, bathtub or appliance. Utilization of the alternative embodiment would reduce installation costs by eliminating the extra set of hoses, thereby also eliminating four additional potential leak sources (i.e., the two ends of each of the two eliminated hoses).
While there is shown and described herein certain specific alternative forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to the dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use.
This application is a continuation of copending U.S. patent application Ser. No. 10/006,970 filed Dec. 4, 2001, which is a continuation in part of U.S. Pat. No. 6,536,464 having a patent application Ser. No. 09/697,520 filed Oct. 25, 2000, and claims priority based on U.S. Provisional Application No. 60/251,122 filed Dec. 5, 2000, all of which are incorporated in their entirety by this reference.
| Number | Date | Country | |
|---|---|---|---|
| 60251122 | Dec 2000 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10006970 | Dec 2001 | US |
| Child | 11203913 | Aug 2005 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 09697520 | Oct 2000 | US |
| Child | 10006970 | Dec 2001 | US |
