AU2010257265A1 - Valve assembly - Google Patents

Abstract

Valve assemblies having a cartridge assembly and a flow control member. The flow control member may be a removable insert or integrally formed within the cartridge assembly. The flow control member has a restricted fluid opening and is sized and shaped to modify the flow of fluid through a fluid port. The modified fluid flow provides a reduction in fluid pressure and better fluid mixing control of the valve assembly, such as in a shower or a faucet. r77-,~692 -- 90 - _ 30

Description

VALVE ASSEMBLY BACKGROUND This present disclosure generally pertains to valve assemblies that include a cartridge assembly and a flow control member. More particularly, the present disclosure relates to valve assemblies for showers, bathroom faucets or kitchen faucets. DESCRIPTION OF BACKGROUND ART Valve assemblies have desired features such as flexibility to operate with fluid inlets having unequal fluid pressures. While valve assemblies are attractive, there are many aspects in which improvement is sought. For example, there is a desire to provide control of mixing unequally pressured fluids using existing valve cartridge assemblies. There is also a desire to use ceramic disc valves for good reliability. There is a further desire to allow a flow control member to be easily inserted or removed for ease of manufacturing and servicing. There is an overall need to improve valve assemblies and overcome the deficiencies of the prior art. Prior art approaches include New Zealand Patent No. 248,664. This patent pertains to a water mixing unit having a housing with hot and cold water paths. The housing includes an external nozzle which reduces the cross sectional area of one flow path. The housing further includes a lower ceramic disc and a movable ceramic disc. Australian Patent No. 698,151 describes a thermostatic mixing valve that includes a fixed ceramic disc plate and a rotatable 1 ceramic disc plate. Each ceramic disc plate has a cold water inlet, a hot water inlet and an outlet. One inlet of the fixed ceramic disc plate has a narrowed shape such that the hot water supply flow volume is throttled by a greater amount than the cold water supply flow is throttled. U.S. Patent Application Publication No. 2010/0058534 relates to a pressure balancing spool mixing valve having a ceramic disc cartridge. The valve also includes a pressure balance sub-assembly having side housings with cylindrical openings to receive a stainless steel cylinder in which a stainless steel piston freely slides. The piston acts to compensate the flow due to water pressure fluctuations. U.S. Patent No. 7,264,221 pertains to a control valve assembly having a butterfly valve. The control valve assembly also includes a flow insert. The flow insert has a generally curved arcuate shape and acts to restrict the flow of fluid during the initial rotation of a valve disc. Other prior art includes the following. U.S. Patent No. 6,997,212 pertains to a sub-sea choke valve having an insert chamber that includes a flow trim with a throttling sleeve. The pressure reducing flow trim is positioned in the cartridge bore and has a restrictive opening whereby fluid from the body inlet enters the flow trim at a reduced pressure and passes through the body outlet. U.S. Patent No. 5,275,195 describes a valve cartridge having a pressure balancing spool. If the pressure in the fluid line increases, a shuttle moves toward the opening to close off the effective diameter of one opening and increase the effective diameter of another opening. 2 It has been determined that various characteristics of the prior art, such as these patents and patent applications, have shortcomings and undesirable attributes, results or effects. The exemplary embodiments disclosed herein recognize and address matters such as these to provide enhancements not heretofore available. Overall, the present disclosure more fully meets the need to have a flow control member that is easy to manufacture and service, to have a flow control member that can be used with ceramic disc valves, and to have a flow control member that can be used with existing valve systems without any redesign of the valve system. Furthermore, the present disclosure allows the user to more precisely control the mixing of fluids, such as controlling the temperature of water flowing out of a shower or faucet for example. SUMMARY One aspect or embodiment relates to an improved valve assembly that comprises a cartridge assembly and a flow control member. The cartridge assembly includes a housing, a seal plate having a fluid port, and first and second disc, the seal plate, first disc and second disc are engaged to provide fluid flow paths. For example, the second disc may be movable such that a fluid path opening through the first disc may be varied between fully blocked to fully open by the second disc. A flow control member further varies the opening of a fluid flow path, changing the flow rate to compensate for fluid inlets with disparate pressures, for example. 3 In accordance with another aspect or embodiment, the flow control member is a separate component that is insertable into a fluid port of the cartridge assembly. For example, the flow control member can be sized and shaped on a first end to closely fit within the surface opening profile of a water inlet port and on a second end to less closely fit within the fluid opening to avoid completely blocking fluid flow through the opening. The first end of the flow control member has a restricted opening profile, such as an arcuate slit with a central bore, for example. The restricted opening profile provides a restricted fluid flow path and may be sized and shaped as desired to achieve specific fluid flow control. The second end may be sized and shaped as desired to vary the fit within the fluid flow path to also achieve specific fluid flow control, for example. Alternatively, a flow control member may be integrally formed with a fluid port, such as forming a restricted opening profile within a water inlet port of a seal plate of a water valve assembly, for example. In still another aspect or embodiment, the valve assembly having a flow control member is part of a fluid delivery system. For example, the valve assembly may be used in a shower where hot and cold water having disparate pressures are mixed in the valve assembly and the mixed water is output through a showerhead. Alternatively, the valve assembly could be used in a kitchen or bathroom faucet, for example. It is the intention of at least one embodiment provide a valve assembly including a cartridge assembly having a housing, a seal plate having a fluid port, a first disc having an opening, and a second disc having at least one of a fluid 4 opening and a mixing cavity, and a flow control member in which the flow control member is positioned within at least one of the fluid port and the opening of the first disc, and in which the flow control member modifies the opening profile of at least one of the fluid port and the opening of the first disc, thereby altering the flow of fluid through at least one of the fluid port and the opening of the first disc. In another aspect or embodiment, the flow control member is a removable insert. In yet another aspect, the removable insert extends through portions of the fluid port of the seal plate and the fluid opening of the first disc. In yet another aspect, the removable insert extends through substantially all of the opening of the first disc and terminates just before the closest surface of the second disc. In a further aspect, the removable insert has a first end sized and shaped to substantially correspond to a portion of an opening profile of the fluid port. An aspect further includes a portion of the outer surface of the first end of the removable insert defines a perimeter that is substantially flush with a perimeter defined by a portion of an inner surface of the fluid port. In another aspect the first end further comprises a restricted fluid opening. Yet another aspect further includes the restricted fluid opening having a substantially arcuate shape. In another aspect, the removable insert has a second end sized and shaped to be positioned within the fluid opening of the first disc. In yet another aspect, the second end is sized and shaped such that a portion of the outer surface of the second end defines a perimeter that is substantially flush with a 5 perimeter defined by a portion of an inner surface of the opening of the first disc, in which there is a gap between a portion of the outer perimeter of the second end and a portion of the inner perimeter of the opening of the first disc, the gap allowing fluid to flow therethrough. In a further aspect, the second end has a substantially arcuate shape. Another aspect further includes wherein the first and second discs are ceramic. In another aspect, the first disc is stationary and the second disc is moveable. In yet another aspect, the flow control member is an integral portion of the seal plate. It is the intention of at least one embodiment to provide a fluid delivery system including a fluid inlet, a fluid outlet, a fluid adjustment member, and a valve assembly including a cartridge assembly having a housing, a seal plate having a fluid port, a first disc having an opening and a second disc having at least one of a fluid opening and a mixing cavity, and a flow control member in which the flow control member is positioned within at least one of the fluid port and the opening of the first disc, and wherein the flow control member modifies the opening profile of at least one of the fluid port and the opening of the first disc, thereby altering the flow of fluid through at least one of the fluid port and the opening of the first disc. In an aspect, the fluid delivery system is one of a shower, a bathroom faucet and a kitchen faucet. It is the intention of at least one embodiment to provide a flow control member including a first end sized and shaped to substantially correspond to an 6 opening profile of a fluid port, wherein a portion of the outer surface of the first end of the removable insert defines a perimeter that is substantially flush with a perimeter defined by a portion of an inner surface of the fluid port, and in which the first end further includes a restricted fluid opening, and a second end generally opposite with the first end. In an aspect, the second end is sized and shaped such that a portion of the outer surface of the second end defines a perimeter that is substantially flush with a perimeter defined by a portion of an inner surface of the opening of the first disc, in which there is a gap between a portion of the outer perimeter of the second end and a portion of the inner perimeter of the fluid port, the gap allowing fluid to flow therethrough. In another aspect, at least one of the restricted fluid opening and the second end has a substantially arcuate shape. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an exemplary embodiment of a fluid delivery system; FIG. 2 is a bottom cross-sectional view of the fluid delivery system of FIG. 1; FIG. 3 is a side cross-sectional view of the fluid delivery system of FIG. 1; FIG. 4 is a perspective view of an exemplary embodiment of a valve assembly; FIG. 5 is a bottom plan view of the valve assembly of FIG. 4; FIG. 6 is an exploded perspective view of the valve assembly of FIG. 4; 7 FIG. 7 is another exploded perspective view of the valve assembly of FIG. 4; FIG. 8 is a perspective bottom view of an exemplary embodiment of a seal plate; FIG. 9 is another perspective top view of the seal plate of FIG. 8; FIG. 10 is a perspective view of an exemplary embodiment of a first disc; FIG. 1 1A is a perspective view of an exemplary embodiment of a second disc; FIG. 11 B is a perspective view of another embodiment of a second disc; FIG. 12 is a perspective view of a partially assembled valve assembly of FIG. 4; FIG. 13 is a perspective view of an exemplary embodiment of a flow control member; FIG. 14 is a top plan view of the flow control member of FIG. 13; FIG. 15 is a bottom view of the flow control member of FIG. 13; FIG. 16 is a graphical view of various levels of occlusion of the fluid pathway without a flow control member; and FIG. 17 is a graphical view of various levels of occlusion of the fluid pathway with a flow control member. DETAILED DESCRIPTION Referring generally to the FIGURES an exemplary embodiment of a valve assembly generally designated 20 is shown. Among other benefits, valve 8 assembly 20 is configured to provide improved fluid mixing (e.g., mixing hot and cold water in a fluid delivery system such as shower or faucet, etc.). For example, an operator of a fluid delivery system is able to more precisely control the mixing of two or more fluid sources such as hot and cold, thereby allowing the operator to more accurately adjust/control the temperature of the fluid delivered by the fluid delivery system. Further, valve assembly 20 provides for use with ceramic disc valves and may be used with existing systems (e.g., avoiding any redesign of the valve system, etc.). Valve assembly 20 includes a cartridge assembly 30 and a flow control member 80 according to an exemplary embodiment. As will be discussed in more detail below, the flow control member 80 may be integral with the cartridge assembly 30 or a separate part insertable therein. Referring to FIGs. 1-3, valve assembly 20 is shown utilized in a fluid delivery system 90 that is a faucet including a fluid adjustment member 92. While the fluid delivery system 90 is shown as a faucet, it will be appreciated that the valve assembly may be utilized in any number of fluid delivery systems, including, but not limited to, showers, bathtubs, etc. Referring to FIGs. 4-7, cartridge assembly 30 includes a housing 40, a seal plate 50, a first disc 60, a second disc 70, and a flow control member 80 according to an exemplary embodiment. The cartridge assembly 30 has a first end 34 generally opposite a second end 36. The first end 34 of the cartridge assembly 30 is disposed proximate to fluid inlet and outlet sources, such as hot and cold water pipes and a faucet outlet, for example. The second end 36 of the 9 cartridge assembly 30 is disposed proximate to a control member of a fluid delivery system, such as a faucet control handle or knob, for example. Water flows into and out of the first end 34, having an opening profile defined by seal plate 50, first disc 60, second disc 70 and flow control member 80. Referring in particular to FIGs. 4 and 7, housing 40 defines a cavity 42 according to an exemplary embodiment. Cavity 42 (e.g., opening, chamber, hole, hollow area, etc.) is sized and shaped to receive and at least partially confine components of valve assembly 20. As shown, first disc 60 and second disc 70 are disposed within cavity 42 when the valve assembly 20 is assembled. While housing 40 is shown substantially cylindrical, other suitable shapes may be used. Referring further to FIGs. 4-7, seal plate 50 is disposed at first end 34 of cartridge assembly 30. Seal plate 50 is disposed to at least partially close off the end of housing 40 generally corresponding to the first end 34 of the cartridge assembly 30. A plurality of openings 52 in seal plate 50 provide for a fluid flow into and out of the valve. In the example embodiment shown, the openings 52 of seal plate 50 include a pair of fluid inlet ports 51A,B and a fluid outlet port 53. The fluid inlet ports 51A,B are intended to each be coupled to a fluid source. While the fluid sources may vary, one of the fluid inlet ports (e.g., 51A) is typically coupled to a cold water source while the other fluid inlet port (e.g., 51B) is typically coupled to a hot water source. As will be discussed in more detail later, the fluids entering fluid inlet ports 51A,B are mixed within a mixing chamber 32 of cartridge assembly 30. This resulting fluid mixture then flows out of the fluid 10 outlet port 53 to eventually be delivered to a user via fluid delivery system 90. Seal plate 50 can be formed from any industry standard material, including, but not limited to, metal, ceramic, plastic, or a combination thereof. The illustrated embodiment of seal plate 50 is plastic. Referring to FIGs. 8 and 9, seal plate 50 further includes a first seal plate surface 57 and a second seal plate surface 58 according to an exemplary embodiment. First seal plate surface 57 faces generally away from cavity 42, while second seal plate surface 58 faces generally toward cavity 42. As will be discussed in more detail below, one or more sealing elements are positioned at or proximate to the seal plate surfaces 57, 58 to help prevent undesirable fluid flow or leakage when the valve assembly 20 is utilized. A gasket channel 54 is shown recessed relative to first seal plate surface 57 and substantially corresponding to the fluid ports 52 according to an exemplary embodiment. That is, gasket channel 54 extends substantially about the perimeters of fluid ports 52. Gasket channel 54 at least partially receives and helps retain (e.g., maintain, hold, confine, etc.) one or more gaskets, shown as a first gasket 56 (see, e.g., FIG. 7), in a desired position. The gasket 56 is configured to seal the interface between fluid ports 52 and the fluid inlet and outlet sources. According to some exemplary embodiments, other gasket configurations may be utilized (e.g., each fluid port of seal plate 50 may have an individual gasket). According to other exemplary embodiments, fluid sealing elements other than a gasket may be used (e.g., such as adhesives and/or 11 putties). According to still other exemplary embodiments, a combination of gaskets and other fluid sealing elements may be used. One or more gaskets, shown as second gaskets 59 are also disclosed at or proximate to second seal plate surface 58 according to an exemplary embodiment. Similar to gasket 56, gaskets 59 are disposed substantially about the perimeters of fluid ports 52. Unlike gasket 56, gaskets 59 are retained in the desired position by one or more retaining features shown as walls 68 (e.g., raised contours, lips, projections, etc.) that extend generally outward from second seal plate surface 58. As shown, gaskets 59 are placed in tension about walls 68. Alternatively, fluid ports 52 at second seal plate surface 58 could have a single second gasket 59 disposed about multiple fluid ports 52, or other types of fluid sealing elements, such as adhesive or putty for example. Referring to FIG. 10, first disc 60 includes a plurality of openings 62 that help define fluid flow paths within the valve assembly 20 according to an exemplary embodiment. First disc 60 includes three openings - fluid inlets 61A,B and fluid outlet 63 that are generally aligned with the fluid inlet ports 51A,B and fluid outlet 53 of the seal plate when the valve assembly 20 is assembled. Accordingly, in exemplary embodiment shown, one fluid inlet 61 (e.g. 61A) has cold water flow therethrough, the other fluid inlet 61 (e.g. 61 B) has hot water flow therethrough, and the fluid outlet 63 has a mixture of the cold water and the hot water flow therethrough. Generally, the openings 62 can be sized and shaped as desired to affect fluid flow through valve assembly 20. Further, the alignment of the openings 62 of first disc 60 and the openings 51 of seal plate 50 can be 12 adjusted to affect the fluid flow through valve assembly 20. First disc 60 can be formed from any industry standard material such as metal, ceramic or plastic, for example. The illustrated embodiment of first disc 60 is ceramic. First disc 60 is coupled to seal plate 50 according to an exemplary embodiment. In the exemplary embodiment shown, first disc 60 is fixedly engaged with seal plate 50 and stationary with respect to seal plate 50, as seen in FIG. 13. Any number of elements suitable for coupling first disc 60 and seal plate 50 may be used. For example, tabs, slots, hooks or adhesives. In the illustrated embodiment, seal plate 50 includes securing members 55 that engage with securing grooves 65 of first disc 60. As shown in FIG. 1 1A, second disc 70 may include at least one fluid opening 72, at least one blocking surface 74 and is fixedly engaged with a coupling member 38. Coupling member 38 is adapted to fixedly engage with fluid adjustment member 92 such that second disc 70 is movable relative to first disc 60 (and, accordingly, seal plate 50 as shown) to adjust the flow of fluid into and out of the valve assembly according to an exemplary embodiment. Second disc 70 is rotatable about an axis relative to first disc 60 (and, therefore, also relative to seal plate 50 in the exemplary embodiment shown). Second disc 70 is disposed substantially adjacent to first disc 60. Because of the differences in the size, shape, and number of openings in first disc 60 and second disc 70, the movement of the second disc 70 changes the alignment of openings 62, 72 and, accordingly, the ability of fluid to flow in through fluid inlets 61 (and, accordingly, fluid inlet ports 51), mix together in cavity 42, and flow out through fluid outlets 63 13 (and, accordingly, fluid outlet port 53). As shown, as second disc 70 rotates, an opening 62 of first disc 60 can be partially or wholly blocked (e.g. occluded, obstructed, closed off, etc.) by a portion, blocking surface 74, of second disc 70, thereby affecting the flow of fluid through that fluid pathway 62, as seen in FIG. 16. For example, when inlet 61 B is blocked off, fluid can enter the valve assembly through only inlet 61A. Accordingly, only cold water will be entering the valve assembly. Second disc 70 can be formed from any industry standard material such as metal, ceramic or plastic, for example. The illustrated embodiment of second disc 70 is ceramic. Alternatively, as shown in FIG. 11 B, second disc 70 may have a mixing cavity 76 instead of fluid opening 72. Mixing cavity 76 prevents fluid from flowing through second disc 70 and instead causes the incoming fluids to intermingle and flow out fluid outlets 63 (and, accordingly, fluid outlet port 53). FIGs. 13-15 illustrate an embodiment of flow control member 80 according to an exemplary embodiment. Flow control member 80 changes the opening profile of the valve assembly 20 in two primary ways. First, the inlet port area for a fluid source is reduced to prevent the flow of high pressure fluid from overtaking or dominating the flow of low pressure fluid. For example, cold water may be fed by a municipal water system at a pressure of 3 to 5 bars and hot water may be gravity fed from a tank in the building at a pressure as low as 0.1 bar. Therefore, flow control member 80 can reduce the inlet port opening profile for the cold water inlet, thereby reducing the flow of cold water into mixing chamber 32. 14 Second, the inlet port opening profile is changed such that the open area increases much more gradually as that port of the valve assembly 20 is opened, as seen in FIG. 17. This profile change from flow control member 80 allows valve assembly 20 to have a more gradual temperature adjustment, thereby giving the user better control of the outlet temperature. Flow control member 80 includes a first end 82 and a second end 86 according to an exemolarv embodiment. First end 82 can be sized and shaped as desired. For example, in the illustrated embodiment first end 82 is sized and shaped such that the outer perimeter 83 of first end 82 fits just inside the inner perimeter 49 of fluid inlet 51 as seen in FIG. 4. A restricted fluid opening 84 is defined in the flow control member 80 at a first end 82. As shown in FIG. 13, fluid opening 84 extends substantially through first end 82, redefining the opening profile 47 of the inlet (e.g., fluid inlet 51) in which it is disposed to be smaller, thereby restricting fluid flow through the inlet. Fluid opening 84 can be sized and shaped to achieve a desired affect on fluid flow through fluid inlet 51. For example, as the size of fluid opening 84 affects how much fluid can flow in a time period into cartridge assembly 30 from a fluid source, it is generally the case that increasing the size of opening 84 will provide for a greater fluid flow rate and decreasing the size of opening 84 will provide for a lesser fluid flow rate. While the illustrated embodiment shows a restricted fluid opening 84 having an arcuate shaped slot with a central circular opening, the fluid opening 84 may be of any size and shape that can be accommodated in an inlet into 15 which the flow control member is disposed and that restricts the flow of fluid into that inlet (e.g., the fluid opening at the first end of the flow control member is smaller than the inlet opening). For example, restricted fluid opening 84 can be a circular opening, a square opening, a squared off slot, or multiple openings. These different sizes and shapes may be used to vary both the fluid flow rate, the turbulence of the fluid flow, and other flow factors as discussed in more detail below. Flow control member 80 can be formed from any industry standard material such as metal, ceramic or plastic, for example. The illustrated embodiment of flow control member 80 is plastic. The shape of fluid opening 84 also affects the manner (e.g. turbulence) in which the fluid flows into cartridge assembly 30. For example, the arcuate shaped fluid opening 84 shown in FIG. 13 mimics the shape of the second end 86, thereby smoothing the flow of fluid into cartridge assembly 30 and reducing the turbulence of the passing fluid. Second end 86 is disposed generally opposite first end 84 and partially or wholly secures flow control member 80 within cartridge assembly 30, as well as helps position flow control member 80 such that restricted fluid opening 84 is properly oriented with respect to fluid inlet 51. Second end 86 is sized and shaped so that, when flow control member 80 is at least partially within the valve 20, the second end cannot be inserted beyond fluid inlet 51 or and/or fluid inlet pathway 61. In the illustrated embodiment, flow control member 80 is shown inserted into cartridge assembly 30 such that second end 86 fits through fluid inlet 51 and within fluid inlet pathway 61, while first end 82 fits within inner 16 perimeter 49 of the opening profile 47 of fluid inlet 51, as can be seen in FIGs. 4 and 12. Opening profile 47 can be sized and shaped as desired, such as circular, square or oval, for example. The opening profile 47 of the illustrated embodiment is circular. Second end 86 can also be sized and shaped to affect fluid flow and/or turbulence through fluid inlet 51 and fluid inlet pathway 61as desired, by the manner discussed previously regarding restricted fluid opening 84. For example, second end 86 can be rectangular, square, circular or arcuate in shape. In the illustrated embodiment, second end 86 is sized and shaped in an arcuate manner to leave a gap 88 between at least a portion of the outer surface 87 of second end 86 and at least a portion of an inner fluid port surface 48 and an inner fluid pathway surface 66. Accordingly, after entering the valve assembly through restricted fluid opening 84, fluid will pass through gap 88 (e.g., in order to reach the second disk 70). Also in the illustrated embodiment, second end 86 is sized to terminate before entering fluid opening 72 of second disc 70, thereby allowing disc 70 to move freely in relation to first disc 60. FIG. 12 illustrates that second end 86 can terminate very close to the nearest surface of second disc 70, such as within .020 inch for example. Flow control member 80 allows a fluid flow to be modified through the fluid port 52 and fluid pathway 62 in which flow control member 80 is positioned. For example, a cold water source may be provided at a disparate pressure from a hot water source, making it difficult to accurately mix the hot and cold water and to effectively control the temperature of the mixed water. Positioning flow control 17 member 80 within the inlet 51 of cartridge assembly 30 that receives the higher pressured fluid source reduces the pressure of the fluid flow exiting that inlet 51 into a mixing chamber 32 of the cartridge assembly 30. The amount of pressure reduction and the turbulence of the fluid flow can be modified by the size and shape of both restricted fluid pathway 84 and second end 86. For example, the inlet port opening area can be reduced significantly to prevent the flow of the high pressure water from overtaking and dominating the flow of the low pressure water. A flow control member 80 can be positioned in just one fluid port 52 and its corresponding fluid pathway 62, or multiple numbers of fluid ports 52 and their corresponding fluid pathways 62. Flow control member 80 can be a separate part that is inserted into cartridge assembly 30 or it can be integrally formed with any of seal plate 50, first disc 60 and second disc 70. For example, the illustrated embodiment of flow control member 80 is a separate part that can be easily inserted into cartridge assembly 30 during manufacturing or during installation of valve assembly 20 into a shower or faucet. Having a separate flow control member 80 allows for easy removal for servicing or for easy replacement of a differently sized and shaped flow control member 80 as desired. For example, if the pressure of the fluid supply is changed, such as the cold water pressure provided by the municipal water utility, then a new or different flow control member 80 can be easily installed in cartridge assembly 30 to compensate for the change. Therefore, fluid flow parameters of a fluid delivery system 90 can be changed by adding a flow control member 80 to an open fluid inlet of a cartridge assembly 18 30, for example. Alternatively or in addition, fluid flow parameters of a fluid delivery system 90 can be changed by changing out an existing flow control member 80 for a different flow control member 80 having a different sized and shaped restricted fluid opening 84 and/or second end 86, for example. Valve assembly 20 may be assembled in any desired manner. For example, first gasket 56 may be inserted into gasket channel 54 of seal plate 50 and second gaskets 59 may be positioned around walls 68 of seal plate 50. First disc 60 may be fixedly attached to second seal plate surface 58 by engaging securing members 55 with securing grooves 65. Coupling member 38 may be attached to housing 40 and second disc 70 may be fixedly attached within cavity 42 to coupling member 38. The seal plate 50 and first disc 60 assembly may be inserted into cavity 42 to form cartridge assembly 30. At least one flow control member 80 may be inserted into a fluid port 52 and corresponding opening 62 to form valve assembly 20. Valve assembly 20 may then be installed within fluid delivery system 90. Operation of valve assembly 20 can be accomplished by the user manipulating a fluid adjustment member 92 of a fluid delivery system 90 as seen in FIG. 1. Fluid delivery system 90 can be a shower, a bathroom sink or a kitchen sink for example. Fluid adjustment member 92 can be a lever, a knob or a handle, for example. When fluid adjustment member 92 is manipulated, second disc 70 is moved in relation to first disc 60. For example, a faucet handle can be coupled to second disc 70 such that when the faucet handle is turned the second disc 70 rotates about an axis in relation to the first disc 60, first disc 60 19 being fixedly coupled to seal plate 50. In the illustrated embodiment, various positions of second disc 70 in relation to first disc 60 cause varying levels of occlusion of fluid pathways 62. FIG. 16 shows a graphical view of various levels of occlusion of fluid pathway 62 without flow control member 80 installed. Fluid port 52 of seal plate 50 and opening 62 of first disc 60 are fixedly aligned, allowing a consistent fluid pathway for fluid to flow through. As second disc 70 rotates, an opening 62 of first disc 60 can be partially or wholly inhibited by blocking surface 74 of second disc 70, thereby affecting the flow of fluid through the fluid pathway consisting of fluid port 52, opening 62 and fluid opening 72. FIG. 17 shows a graphical view of various levels of occlusion of fluid opening 62 with flow control member 80 installed. Flow control member 80 restricts the opening profile of fluid port 52 and opening 62, forcing fluid to flow through restricted fluid opening 84 in first end 82, and then through an altered fluid pathway formed by second end 86 and opening 62. As second disc 70 rotates, the altered fluid pathway is partially or wholly inhibited by blocking surface 74 of second disc 70, thereby further affecting the flow of fluid through the fluid pathway consisting of fluid port 52, opening 62, flow control member 80 and fluid opening 72. For example, because the flow control member blocks a portion of fluid pathway, the inlet port opening can be changed such that as the port of the valve is opened, the open area increases much more gradually than it would without the presence of the flow control member 80, as shown in FIG. 17. 20 A preferred embodiment of the present disclosure is a valve assembly 20, including a cartridge assembly 30 including a housing 40, a seal plate 50 having a fluid port 52, a first disc 60 having an opening 62, and a second disc 70 having at least one of a fluid opening 72 and a mixing cavity 76, and a flow control member 80, wherein the flow control member 80 is positioned within at least one of the fluid port and the opening of the first disc, and wherein the flow control member modifies the onenina profile of at least one of the fluid port 52 and the opening of the first disc 62, thereby altering the flow of fluid through at least one of the fluid port 52 and the opening of the first disc 62. An optional embodiment of the present disclosure is a valve assembly 20 in which the flow control member 80 is a removable insert. Another optional embodiment of the present disclosure is a valve assembly 20 in which the removable insert 80 extends through portions of the fluid port 52 of the seal plate 50 and the fluid opening 62 of the first disc 60. A further optional embodiment of the present disclosure is a valve assembly 20 in which the removable insert 80 extends through substantially all of the opening 62 of the first disc and terminates just before the closest surface of the second disc 70. Another optional embodiment of the present disclosure is a valve assembly 20 in which the removable insert 80 has a first end 82 sized and shaped to substantially correspond to a portion of an opening profile 47 of the fluid port 52. 21 A further optional embodiment of the present disclosure is a valve assembly 20 in which the first end 82 is sized and shaped such that a portion of the outer surface of the first end 82 of the removable insert 80 defines a perimeter 83 that is substantially flush with a perimeter 49 defined by a portion of an inner surface of the fluid port 52. Yet another optional embodiment of the present disclosure is a valve assembly 20 in which the first end 82 fiirther comprises a restricted fluid opening 84. Another optional embodiment of the present disclosure is a valve assembly 20 in which the restricted fluid opening 84 has an arcuate shape. A further optional embodiment of the present disclosure is a valve assembly 20 in which the removable insert 80 has a second end 86 sized and shaped to be positioned within the fluid opening 62 of the first disc 60. Yet another optional embodiment of the present disclosure is a valve assembly 20 in which the second end 86 is sized and shaped such that a portion of the outer surface of the second end 86 defines a perimeter 87 that is substantially flush with a perimeter 66 defined by a portion of an inner surface of the opening of the first disc 60, wherein there is a gap 88 between a portion of the outer perimeter 87 of the second end 86 and a portion of the inner perimeter 66 of the opening 62 of the first disc 60, the gap allowing fluid to flow therethrough. Another optional embodiment of the present disclosure is a valve assembly 20 in which the second end 86 has an arcuate shape. 22 A further optional embodiment of the present disclosure is a valve assembly 20 in which the first and second discs 60, 70 are ceramic. Yet another optional embodiment of the present disclosure is a valve assembly 20 in which the first disc 60 is stationary and the second disc 70 is moveable. Another optional embodiment of the present disclosure is a valve assembly 20 in which the flow control member 80 is an integral portion of the seal plate 50. A further optional embodiment of the present disclosure is a fluid delivery system 90 including a fluid inlet 94, a fluid outlet 96, a fluid adjustment member 92, and a valve assembly 20, including a cartridge assembly 30 including a housing 40, a seal plate 50 having a fluid port 52, a first disc 60 having an opening 62, and a second disc 70 having at least one of a fluid opening 72 and a mixing cavity 76, and a flow control member 80, wherein the flow control member 80 is positioned within at least one of the fluid port 52 and the opening 62 of the first disc 60, and wherein the flow control member 80 modifies the opening profile 47 of at least one of the fluid port 52 and the fluid opening 62 of the first disc 60, thereby altering the flow of fluid through at least one of the fluid port 52 and the opening of the first disc 62. Another optional embodiment of the present disclosure is a fluid delivery system 90 in which the fluid delivery system 90 is one of a shower, a bathroom faucet and a kitchen faucet. 23 A further optional embodiment of the present disclosure is a flow control member 80 including a first end 82 sized and shaped to substantially correspond to an opening profile 47 of a fluid port 52, wherein a portion of the outer surface of the first end 82 of the removable insert 80 defines a perimeter 83 that is substantially flush with a perimeter 49 defined by a portion of an inner surface 48 of the fluid port 52, and wherein the first end 82 further comprises a restricted fluid opening 84, and a second end 86 generally opposite with the first end 82. Yet another optional embodiment of the present disclosure is a flow control member 80 in which the second end 86 is sized and shaped such that a portion of the outer surface of the second end defines a perimeter 87 that is substantially flush with a perimeter 66 defined by a portion of an inner surface of the opening 62 of the first disc 60, wherein there is a gap 88 between a portion of the outer perimeter 87 of the second end 86 and a portion of the inner perimeter 66 of the fluid opening 62 of the first disc, the gap 88 allowing fluid to flow therethrough. Another optional embodiment of the present disclosure is a flow control member 80 in which at least one of the restricted fluid opening 84 and the second end 86 have an arcuate shape. Exemplary embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for 24 the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriate manner. It will be understood that there are numerous modifications of the illustrated embodiments described above which will be readily apparent to one skilled in the art, such as variations and modifications of the valve assembly and/or its components, including combinations of features disclosed herein that are individually disclosed or claimed herein, explicitly including additional combinations of such features, or alternatively other types of valve assemblies. For example, valve assemblies can have both removable and integral flow control members or one flow control member can extend into multiple fluid ports and/or pathways. Also, there are many possible variations in the materials and configurations. For example, the surfaces of the elements could be textured, smooth or grooved. These modifications and/or combinations fall within the art to which this disclosure relates and are intended to be within the scope of the claims, which follow. As utilized herein, the terms "approximately," "about," "substantially," and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential 25 modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims. It should be noted that the term "exemplary" as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intenrid to connote that such embodiments are necessarily extraordinary or superlative examples). The terms "coupled," "connected," and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. It is also important to note that the construction and arrangement of the valve assembly as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments of the present disclosures have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., 26 variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter disclosed herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosures. It is to be understood that a reference herein to a prior art document does not constitute an admission that the document forms part of the common general knowledge in the art in Australia or in any other country. In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or comprising is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. 27 Industrial Applicability The present invention provides a valve assembly with a fluid flow control member to provide effective mixing of fluid sources having different pressures. 28

Claims (20)

1. A valve assembly, comprising: a cartridge assembly, comprising; a housing; a seal plate having a fluid port; a first disc having an opening; a second disc having at least one of a fluid opening and a mixing cavity; and a flow control member, wherein the flow control member is positioned within at least one of the fluid port and the opening of the first disc, and wherein the flow control member modifies the opening profile of at least one of the fluid port and the opening of the first disc, thereby altering the flow of fluid through at least one of the fluid port and the opening of the first disc.

2. The valve assembly of Claim 1, wherein the flow control member is a removable insert.

3. The valve assembly of Claim 2, wherein the removable insert extends through portions of the fluid port of the seal plate and the opening of the first disc. 29

4. The valve assembly of Claim 3, wherein the removable insert extends through substantially all of the opening of the first disc and terminates just before the closest surface of the second disc.

5. The valve assembly of Claim 2, wherein the removable insert has a first end sized and shaped to substantially correspond to a portion of an opening profile of the fluid port.

6. The valve assembly of Claim 5, wherein a portion of the outer surface of the first end of the removable insert defines a perimeter that is substantially flush with a perimeter defined by a portion of an inner surface of the fluid port.

7. The valve assembly of Claim 6, wherein the first end further comprises a restricted fluid opening.

8. The valve assembly of Claim 7, wherein the restricted fluid opening is sized and shaped to be smaller than an opening profile defined by the fluid port.

9. The valve assembly of Claim 2, wherein the removable insert has a second end sized and shaped to be positioned within the opening of the first disc. 30

10. The valve assembly of Claim 9, wherein there is a gap between a portion of an outer perimeter of the second end and a portion of an inner perimeter of the opening of the first disc, the gap allowing fluid to flow therethrough.

11. The valve assembly of any of Claims 7 through 10, wherein at least one of a restricted fluid opening and a second end has a substantially arcuate shape.

12. The valve assembly of Claim 2, wherein at least one of the first and second discs is ceramic.

13. The valve assembly of Claim 2, wherein the second disc is moveable relative to the first disc.

14. The valve assembly of Claim 13, wherein the first disc is stationary.

15. The valve assembly of Claim 1, wherein the flow control member is an integral portion of the seal plate.

16. A fluid delivery system, comprising: a fluid inlet; a fluid outlet; a fluid adjustment member; and a valve assembly, comprising: 31 a cartridge assembly having at least one fluid port; and a flow control member, wherein the flow control member is disposed at least partially within the at least one fluid port of the cartridge, and wherein the flow control member modifies the opening profile of at least one of the fluid port, thereby altering the flow of fluid into the cartridge assembly.

17. The fluid delivery system of Claim 16, wherein the fluid delivery system is one of a shower, a bathroom faucet and a kitchen faucet.

18. A flow control member, comprising: a first end sized and shaped to substantially correspond to an opening profile of a fluid port, wherein a portion of the outer surface of the first end of the removable insert defines a perimeter that is substantially flush with a perimeter defined by a portion of an inner surface of the fluid port, and wherein the first end further comprises a restricted fluid opening; and a second end generally opposite with the first end.

19. The flow control member of Claim 18, wherein the second end is sized and shaped such that a portion of the outer surface of the second end defines a perimeter that is substantially flush with a perimeter defined by a portion of an inner surface of an opening of a first disc, wherein there is a gap between a portion of the outer perimeter of the second end and a portion of the inner 32 perimeter of the opening of the first disc, the gap allowing fluid to flow therethrough.

20. The flow control member of Claim 19, wherein at least one of the restricted fluid opening and the second end has a substantially arcuate shape. 33