GB2549422A

GB2549422A - An extruded shower valve

Info

Publication number: GB2549422A
Application number: GB1710234.4A
Authority: GB
Inventors: Singh Kanth Kuldip
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-10-03
Filing date: 2017-06-26
Publication date: 2017-10-18
Anticipated expiration: 2037-06-26
Also published as: GB201616831D0; GB2549422B; GB201710234D0

Abstract

A shower valve 2 which has been made by extrusion comprises a body 4 which is made of an extruded metal such as brass or aluminium, and has straight sides 6, 8, 10, 12. The body also has a longitudinally extending extruded bore 14, a hot water inlet 16, a cold water inlet 18, a thermostat 20 for controlling mixing of hot and cold water in order to achieve a desired water temperature, and an outlet (22, Fig. 2) for the mixed hot and cold water. A plurality of machined bores 24, 26, 28, 30, 32 in the body have been formed by machining the body after the formation of the body and the extruded bore. The machined bores connect to the extruded bore, the hot water inlet, the cold water inlet and the thermostat.

Description

AN EXTRUDED SHOWER VALVE i

This invention relates to a shower valve and, more especially, this invention relates to a shower valve which has been made by extrusion and which has straight sides.

Straight-sided shower valves are known. They suffer from three problems. The first problem is that of a build-up of lime scale during use of the valves. The lime scale builds up and closes bores throughout the valve, which in turn causes the valve to fail. The second problem is that of flow rate, with there often not being enough volume of water achievable through use of the valve. The third problem is that of temperature fluctuations during use of the valve.

The known shower valves are traditionally made by casting. More specifically, approximately 98% of shower valves on the market are cast. The shower valve production is driven by volume sales and the need to minimise on costs. It is known that shower valves made by casting have pitted surfaces. The pits in the surfaces provide anchor points for lime scale, and thus encourage the formation of the lime scale which in turn closes bores and causes the valves to fail.

It is also known that the inadequate flow rate is due at least in part to the fact that bores in the valves are not of a sufficiently large diameter. However, there is a limit on the size of bores that can be used when the valves are made by casting. If the bores are too large, then the casting collapses during the casting process. Thus the cast valves have bores which are known to be small but which are nevertheless retained because larger bores would tend to cause the valve to collapse during the casting process.

In spite of the known deficiencies with cast straight-sided shower valves, the valves continue to be made by casting because, as mentioned above, commercial production is driven by volume sales and the need to keep costs to the minimum. In view of this commercial need for high volume sales and minimum production costs, attempts to look at alternative ways of producing straight-sided shower valves have been limited.

One alternative to casting is machining. However, machining a straightsided shower valve would normally be substantially instantly discounted due to the fact that a machined straight-sided shower valve would cost very considerably more to produce than a cast straight-sided shower valve. The machining process would be longer than the cast process, which would result in an unacceptable high cost of manufacture. Thus although a machined straight-side shower valve would have smoother surfaces than the surfaces in a cast shower valve, and whilst the smoother surfaces might help to avoid the formation of lime scale, straight-sided shower valves made by machining have not been adopted by the plumbing industry.

Similarly, the commercial needs of the plumbing industry for high volume sales and minimum production costs have caused the production of straightsided shower valves by machining to be discounted even although bores in the shower valves could be machined to have a larger diameter than those possible in cast shower valves.

Another alternative to casting is extrusion. However, extruding a straight-sided shower valve would normally be discounted as bores in the shower valve have to be at angles to an extruded axis of the shower valve. Since extrusion can only produce bores that are aligned with the extrusion axis of the shower valve, the production of shower valves by extrusion would normally be discounted.

It is an aim of the present invention to provide a shower valve which reduces the above mentioned problems.

Accordingly, in one non-limiting embodiment of the present invention there is provided a shower valve which has been made by extrusion and which comprises: (i) a body which is made of an extruded metal material, and which has straight sides; (ii) a longitudinally extending extruded bore; (iii) a hot water inlet; (iv) a cold water inlet; (v) a thermostat for controlling mixing of hot and cold water in order to achieve a desired water temperature; (vi) an outlet for the mixed hot and cold water; (vii) a plurality of machined bores in the body, with the machined bores being such that: (viii) the machined bores have been formed by machining the body after the formation of the body and the extruded bore; (ix) the machined bores connect to the extruded bore, the hot water inlet, the cold water inlet, and the thermostat; and (x) the machined bores constitute all the bores in the body apart from the extruded bore.

The valve of the present invention is not as cost-effective to produce as a comparable straight-sided shower valve made by casting. Nevertheless, the shower valve of the present invention is able to be produced at costs which are not so much more expensive than producing a comparable shower valve by casting, and thus the shower valve of the present invention is still able to compete commercially. More specifically, whilst the combined extruding and subsequent machining required to produce the shower valve of the present invention give the increased manufacturing cost which is a commercial disadvantage, the valve of the present invention has the advantage that the extruding and the machining both produce smooth surfaces which are able to discourage the build-up of lime scale. This enables the shower valve of the present invention to be offered with a guarantee of a considerably longer life than a comparable cast valve of the same size. An increased life guarantee is commercially significant and this, together with the fact that the shower valve of the present invention is able to be produced at a cost which is not too substantially more than the cost of producing a comparable shower valve by casting, enables the valve of the present invention to become commercially viable. By way of example only, the valve of the present invention may be produced with production costs being only 25% greater than the cost of producing a comparable sized shower valve by casting.

In addition, the shower valve of the present invention enables the extruded bore and the machined bores in the shower valve body to be larger than comparable bores in a comparable shower valve made by casting. This enables the known problems of flow rate and temperature fluctuation in cast valves to be obviated.

In addition, the shower valve of the present invention enables the mass of material in the valve to be greater than in a comparable shower valve made by casting. This enables the known problem of temperature fluctuation in cast shower valves to be obviated.

In total, the ability to produce the shower valve of the present invention by extruding and subsequent machining at a cost which is not too substantially more than the cost of producing a comparable shower valve by casting, and the commercial advantages of the reduction of lime scale build-up, poor flow rate, and temperature water fluctuation, all combine together to enable the valve of the present invention to be a viable commercial alternative to a comparable cast valve, and with end users being able to have a valve which does not have the usual problems of lime scale build-up and early failure, inadequate flow rates, and temperature fluctuations.

The shower valve may be one in which the straight sides of the body are first, second, third and fourth sides; and in which the first side is a flat side, the second and third sides are flat sides which are opposite one another, and the fourth side is a stepped top side. The stepped top side by virtue of its steps is able to use less material than a flat topped side. This enables savings in material, which further helps to minimise on production costs.

The shower valve may be one in which one of the second and third sides contains the hot water inlet and the cold water inlet, and in which the fourth side contains the thermostat.

The valve may be one in which the extruded bore and/or the machined bores are larger than in standard straight-sided shower valves.

The valve may be one in which the extruded bore has at least one plug in the extruded bore to cause the water to flow as required through the shower valve. The plug may be a friction fit, a brazed fit, or a glued fit in position in the extruded bore. Other ways of retaining the plug in position may be employed.

The extruded body may be heat treated. The heat treatment may include quenching. Quenching may enable the extruded body to be brought to a required temperature without the body going soft in the middle. Alternatively, the extruded body may be left to cool to the required temperature, but this takes longer than quenching.

The metal material is preferably a brass material. The brass material may be an alloy of copper and lead. The brass material helps to prevent the build-up of the lime scale. This is in contrast to materials such as stainless steel which encourage the build-up of lime scale. Other metal materials may be used if desired. Thus, for example, the metal may be an aluminium material. The aluminium material may allow the build-up of the lime scale but the build-up will be minimised by the machining give a smooth surface which will not encourage the formation of the lime scale.

The body of the shower valve may be 2 inches by 3 inches in cross section. The shower valve may have other cross-sectional sizes if desired.

The shower valve may be constructed such that it is able to provide a plurality of different lengths to give a plurality of choices of shower valve. For example, the shower valve may be produced in three different lengths to give three choices of the type of shower valve, i.e. a shower valve with one outlet, two outlets, or three outlets. The ability of the shower valve of the present invention to be produced in the different lengths does not require many different types of tooling as would be required to produce cast valves of different lengths. Also, the avoidance of many different types of tooling facilitates the production of the shower valve in small batches. These are yet further commercial advantages of the shower valve of the present invention, and also its process of production.

An embodiment of the invention will now be described solely by way of example and with reference to the accompanying drawings in which:

Figure 1 is a perspective view of a valve produced by the process of the present invention;

Figure 2 is a cross-section through the valve shown in Figure 1, and with the thermostatic control valve and on/off valves indicated in Figure 1 removed;

Figure 3 is a perspective view of an extruded valve body for use in producing the valve shown in Figure 1;

Figure 4 is an section through the extruded valve body shown in Figure 3; and

Figure 5 is an end view of the extruded valve body shown in Figure 1.

Referring to the drawings, there is shown a shower valve 2 which has been made by extrusion and which comprises a body 4 which is made of an extruded brass material, and which has straight sides 6, 8, 10, 12. The shower valve 2 also comprises a longitudinally extending extruded bore 14 in the body 4.

The body 4 has a hot water inlet 16 and a cold water inlet 18. A thermostat 20 is provided for controlling mixing of the hot and cold water in order to achieve a desired water temperature.

The body 4 has a plurality of machined bores 22, 24, 26, 28, 30, 32, 34. The machined bores 22 - 34 are such that they have been formed by machining in the body 4 after the formation of the body 4 and the extruded bore 14. The machined bores 22 - 34 are also such that they connect to the extruded bore 14, the hot water inlet 16, the cold water inlet 18, and the thermostat 20. The machined bores 22 - 34 still further constitute all the bores in the body 4 apart from the extruded bore 14.

The straight sides 6, 8, 10, 12 of the body 4 are first, second, third and fourth sides. The first side is a flat side 6. The second and third sides are flat sides 8,10 and these sides 8, 10 are opposite one another. The fourth side is a stepped top side 12. As can best be appreciated from Figures 3 and 5, the stepped top side 12 uses less material than would be the case if the top side 12 were to be formed such that the uppermost part 34 of the top side 12 were extended horizontally left and right as viewed in Figures 3 and 5 until it met the second and third sides 8,10. This saving in material is indicated by broken lines 36, 38 in Figure 5.

As shown in Figure 1, the second side 8 contains the hot water inlet 16 and the cold water inlet 18. In an alternative embodiment of the invention, the third side 10 could contain the hot water inlet 16 and the cold water inlet 18. The fourth side 12 contains the thermostat 20. Screw threads 9, 11 are able to receive blanking caps (not shown).

The extruded bore 12 and the machined bores 22 - 34 are larger than they would be in a standard comparable straight-sided shower valve made by casting.

The extruded bore 14 has two plugs 40, 42. There is one of these plugs 40, 42 at each end of two end portions of the extruded bore 14. The plugs 40, 42 ensure that the water is appropriately directed through the body 4 of the shower valve 2. The plugs 40, 42 may be secured in position by friction. The plugs 40, 42 may alternatively be secured in position by other fixing means such for example as brazing or gluing.

The body 4 may optionally be heat treated after the extrusion. The heat treatment may include quenching.

The body 4 is preferably of approximately 2 inches by 3 inches in cross-section. The body 4 may be extruded to be of other cross-sectional shapes.

The body 4 may be extruded such that it is able to be cut in a plurality of different lengths to give a plurality of choices of types of valve. Thus, for example, the body 4 may be extruded such that it is able to be cut into three different lengths to give three different choices of types of valve. The body 4 shown in Figure 1 is of such a length that it is able to be used a double valve providing a first outlet 45 to a first shower such for example as a fixed shower, and a second outlet 47 at a second and opposite end of the body 4 and leading to another shower such for example as hand held shower.

Referring to Figures 1 and 2, the various bores in the shower and the mode of operation of the shower valve 2 are as follows.

The bore 24 leads to the water inlet 16. The bore 26 leads to the water inlet 18. The water inlet 16 is for hot water, and the water inlet 18 is for cold water. Either inlet 16, 18 can be for cold water, with the other inlet 16, 18 being for hot water. The bore 24 leads via the bores 32 and 27 to the bore 22. The bore 26 leads via the bores 30 and 29 to the bore 22. In the bore 22, the hot and cold water from the bores 24, 26 are mixed together until a required temperature is reached as determined by a thermostat control valve 20 which is positioned in the top of the bore 22. As viewed in Figure 2, the mixed water at the required temperature then passes to the right along the bore 14 to the bore 28. The bore 28 terminates in the non-return check valve 49. When the non-return check valve 49 is opened, water from the bore 28 flows via a bore 51 into a bore 53 and out through the first outlet 45 to the first shower. The bore 14 is blocked by a plug 40 as shown in Figure 2. Similarly, water at the required temperature from the bore 22 is able to pass to the left along bore 14 into bore 34. The upper end of the bore 34 receives another non-return check valve 38. When the non-return check valve 38 is opened, then water is able to pass from the bore 34 via a bore 40 and into the bore 55. The water at the required temperature is then able to pass through the second outlet 47 to a second shower. The bore 14 is also blocked by a plug 42. The plugs 40, 42 ensure that the water flow to the first and second outlets 45, 47 is always via the nonreturn check valves 49, 38.

The body 4 has brass material at the areas 50, 52. These areas 50, 52 would normally be hollow if the body 4 were to be made as a casting. The extra material in the areas 50, 52 acts to help avoid temperature fluctuations during operation of the valve 2.

Measurements given above have been given in imperial units. This is because plumbing requirements in the United Kingdom are often used in imperial units. Corresponding metric sizes for 2 inches by 3 inches are 76.2 x 50.80mm.

It is to be appreciated that the embodiment of the invention described above with reference to the accompanying drawings has been given by way of example only and that modifications may be effected. Thus, for example, the metal material may be another metal material, for example an aluminium material. Individual components shown in the drawings are not limited to use in their drawings and they may be used in other drawings and in all aspects of the invention.

Claims

1. A shower valve which has been made by extrusion and which comprises: (i) a body which is made of an extruded metal material, and which has straight sides; (ii) a longitudinally extending extruded bore; (iii) a hot water inlet; (iv) a cold water inlet; (v) a thermostat for controlling mixing of hot and cold water in order to achieve a desired water temperature; (vi) an outlet for the mixed hot and cold water; (vii) a plurality of machined bores in the body, with the machined bores being such that: (viii) the machined bores have been formed by machining the body after the formation of the body and the extruded bore; (ix) the machined bores connect to the extruded bore, the hot water inlet, the cold water inlet, and the thermostat; and (x) the machined bores constitute all the bores in the body apart from the extruded bore.

2. A shower valve according to claim 1 in which the straight sides of the body are first, second, third and fourth sides; and in which the first side is a flat side, the second and third sides are flat sides which are opposite one another, and the fourth side is a stepped top side.

3. A shower valve according to claim 2 in which one of the second and third sides contain the hot water inlet and the cold water inlet, and in which the fourth side contains the thermostat.

4. A shower valve according to any one of the preceding claims in which the extruded bore and/or the machined bores are larger than in standard straight-sided plumbing valves.

5. A shower valve according to any one of the preceding claims in which the extruded bore has at least one plug in the extruded bore to cause the water to flow as required through the shower valve.

6. A shower valve according to claim 5 in which the plug is a friction fit, a brazed fit, or a glued fit in position in the extruded bore.

7. A shower valve according to any one of the preceding claims in which the extruded metal material is an extruded brass material.

8. A shower valve according to any one of the preceding claims in which the body is heat treated.

9. A shower valve according to claim 8 in which the heat treatment includes quenching.

10. A shower valve according to any one of the preceding claims in which the body is 2 inches by 3 inches in cross-section.

11. A shower valve according to any one of the preceding claims and which is constructed such that it is able to be provided in a plurality of different lengths to give a plurality of different choices of types of valve.

12. A shower valve according to claim 11 in which the shower valve is constructed such that it is able to be cut to give three choices of type of valve.