HK1136859B

HK1136859B - Valve cartridge with low point of contact for installation

Info

Publication number: HK1136859B
Application number: HK10103509.6A
Authority: HK
Inventors: M‧S‧凯西克; W‧R‧塔克
Original assignee: 莫恩股份有限公司
Priority date: 2007-01-31
Filing date: 2008-01-31
Publication date: 2012-03-23

Description

Valve cartridge with low contact point for installation

RELATED APPLICATIONS

This application is filed as a non-provisional patent application claiming priority and any other benefit of U.S. provisional patent application No.60/898,542 filed on 31/1/2007 according to 35u.s.c. § 119(e), the entire contents of which are incorporated herein by reference.

Technical Field

The present invention relates generally to valve spools and, more particularly, to valve spools having low contact points for mounting the valve spool in a valve body.

Background

Typically, for plumbing fixtures (e.g., faucets, tub spouts, shower heads), the valve body carries water flowing from a mains water source to a desired destination (e.g., sink, tub, washbasin). The valve body typically has two water inlet passages through which cold and hot water from the mains water supply can flow, respectively. The valve body also has an outlet passage through which cold water, hot water, or a mixture of cold water and hot water can be discharged to an outlet portion (e.g., spout) of the plumbing fixture. In the single-handle version of the valve body, the valve body has a cavity for receiving a valve cartridge that allows a user to control the flow and temperature of water flowing through the inlet water passageway to the outlet water passageway using a single valve actuation mechanism.

One type of (conventional) valve cartridge is a structural assembly that includes a housing in which two or more disks, plates, etc. are disposed. The disc is typically made of a hard material (e.g., ceramic or metal). At least one of the disks (i.e., the stationary disk) is fixed relative to the housing. The other of the disks (i.e., the movable disk) is disposed above the fixed disk and is movable relative to the fixed disk. The valve spool includes an actuation mechanism that is directly or indirectly connected at one end to the movable disk. The other end of the actuation mechanism extends through an opening in the housing for manipulation by a user. The end of the actuation mechanism that extends through the opening in the housing may be connected to a handle, knob, or the like to assist the user in operating the valve cartridge.

In the single-handle version of this type of cartridge, which is used in the valve body of the single-handle version, the fixed disk includes two water inlets (i.e., a cold water inlet and a hot water inlet) that are substantially aligned with the water inlet passages of the valve body when the cartridge is installed in the valve body. In addition, the stationary disk includes a water outlet that is substantially aligned with the water outlet passage of the valve body when the valve cartridge is installed in the valve body. The actuating mechanism is connected to the movable disc via a coupling. The actuating mechanism may be pivoted to cause translational movement of the movable disc. The actuating mechanism may be rotated to cause angular movement of the movable disc.

In this way, the movable tray can assume different positions relative to the fixed tray. Specifically, pivoting of the actuation mechanism changes the flow rate of the water from zero to a maximum flow rate, while rotation of the actuation mechanism changes the temperature of the water. Thus, a single-handle actuation mechanism can control both the flow rate and the temperature of the water flowing through the cartridge.

The cartridge also includes one or more seals for preventing water from leaking from the cartridge. The seals may be located, for example, below, between, and/or above the disks in the valve cartridge. When the valve cartridge is installed in the valve body, the retaining nut is used to secure the valve cartridge in the valve body. The retaining nut engages a mounting lug of the housing of the cartridge to cause the seal in the cartridge to be compressed and thereby apply a loading force to the components (including the disk) in the cartridge. Thus, the fixed disk and the movable disk are kept in watertight contact after the valve cartridge is mounted in the valve body.

Generally, a conventional valve cartridge has a mounting lug formed at a higher position on a housing of the valve cartridge, for example, near an upper opening of the valve cartridge. The higher mounting lugs form contact points between the retaining nut and the valve cartridge when the valve cartridge is installed in the valve body.

As one example, a conventional valve cartridge 100 is shown in fig. 1A to 1C and is also described in U.S. patent No.7,063,106. As shown in fig. 1A-1B, a conventional valve cartridge 100 has several separate components, including a housing 102, a lower seal 104, a bottom member 106, an upper seal 108, a fixed plate 110, a movable plate 112, a carrier 114, a rotatable support member 116, an operating lever 118, and a cover 120. The housing 102 has a tubular shape for receiving the remaining components of the valve cartridge 100.

The lever 118 is part of the actuation mechanism of the valve cartridge 100. The operating lever 118 is connected to the rotatable support member 116 via a pin 122. The lower surface of the rotatable support member 116 rests on the upper surface of the carrier 114. The rotatable support member 116 may rotate relative to the housing 102. A portion of the lever 118 extends into the housing 102 below the rotatable support member 116, which helps to connect the lever 118 to the movable plate 112, as will be described below. A portion of the lever 118 extends out of the housing 102 above the rotatable support member 116, which facilitates connection of the lever 118 to an operating member (not shown), such as a handle, knob, or the like.

Housing 102 has an internal shoulder 124 formed near the lower opening of housing 102, wherein internal shoulder 124 is shaped to receive a correspondingly shaped portion of base member 106. The cover 120 has teeth 126, the teeth 126 snap-fitting into openings 128 formed near the upper opening of the housing 102. Thus, the lower opening of the housing 102 is closed by the bottom member 106, and the upper opening of the housing 102 is closed by the cover 120, thereby fixing these components in the valve cartridge 200.

The fixing plate 110 has a water outlet passage 132 and a pair of water inlet passages 130. The fixing plate 110 is disposed above the base member 106. The movable plate 112 is supported on top of the fixed plate 110 and can slide on top of the fixed plate 110. The movable plate 112 includes a mixing chamber 134 for mixing the cold water and the hot water flowing into the cartridge 100 through the respective water inlet passages 130 in the fixed plate 110. The mixed water then flows out of the valve cartridge 100 through the water outlet passage 132 in the fixed plate 110.

The function of the carrier 114 and the rotatable support member 116 is to translate the movement of the operating rod 118 into the movement of the movable plate 112. The lower portion of the carrier 114 engages the upper portion of the movable plate 112. The upper portion of the carrier 114 has a recess 136 for receiving a lower end 138 of the operating rod 118, thereby connecting the operating rod 118 (said operating rod 118 being connected to the rotatable support member 116 via the pin 122) to the carrier 114 and the movable plate 112.

Lower seal 104 fits in a recess on the lower surface of base member 106, and upper seal 108 fits in a recess on the upper surface of base member 106. The lower seal 104 forms a water-tight seal between the valve body 140 in which the valve cartridge 100 is installed and the bottom member 106 (see fig. 1C). The upper seal 108 forms a water-tight seal between the base member 106 and the fixing plate 110 (see fig. 1B). The lower seal 104 and the upper seal 108 prevent water from leaking from the valve cartridge 100.

As shown in fig. 1C, when the valve cartridge 100 is installed in the valve body 140 of a plumbing fixture 142 (e.g., a faucet), the retaining nut 144 serves to secure the valve cartridge 100 in the valve body 140. The retaining nut 144 engages a mounting lug 146 formed on the cap 120 of the housing 102 of the valve cartridge 100 to cause the seals 104 and 108 in the valve cartridge 100 to be compressed and, in turn, to apply a loading force to the components in the valve cartridge 100, including the fixed plate 110 and the movable plate 112. Thus, the fixed plate 110 and the movable plate 112 remain in watertight contact after the valve cartridge 100 is installed in the valve body 140.

The position and orientation of the movable plate 112 relative to the fixed plate 110 is controlled by an operating lever 118 protruding from the housing 202. Specifically, the operating lever 118 may pivot about the pin 122 inside the rotatable support member 116, and the rotatable support member 116 may be caused to rotate by rotation of the operating lever 118. An operating member (not shown) may be connected to the lever 118 to assist a user in manipulating the lever 118. Thus, after the valve cartridge 100 is installed in the valve body 140, a user may manipulate the operating member, which moves the operating lever 118 to change the position and/or direction of the movable plate 112 relative to the fixed plate 110, thereby controlling the flow rate and/or temperature of water exiting the plumbing fixture 142 through the valve cartridge 100, such as through the spout 148 (see fig. 1C).

The mounting lug 146 is formed on the cap 120 so as to be disposed at a higher position on the valve cartridge 100. As described above, the retaining nut 144 engages the mounting lug 146 to secure the valve cartridge 100 in the valve body 140. In this manner, the seals 104 and 108 are compressed, and the loading force due to the compression of the seals 104 and 108 is transmitted upward to the components in the valve cartridge 100.

However, the taller mounting lugs 146 have several disadvantages. For example, a higher mounting lug 146 results in less freedom in the design of the plumbing fixture for receiving the valve cartridge 200. In addition, a taller mounting lug 146 results in increased cost because the height of the sidewall 150 of the valve body 140 is typically at least as high as the height of the mounting lug 140.

Accordingly, there is a need in the art for a valve cartridge having low contact points for mounting the valve cartridge in a valve body.

Disclosure of Invention

In view of the foregoing, it is an exemplary aspect of the present invention to provide a valve cartridge having a housing with a low contact point formed thereon for mounting the valve cartridge in a valve body.

Another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one installation ledge formed thereon, wherein a ratio of a height of a highest installation ledge of the housing to a maximum outer diameter of the housing is less than or equal to 0.53.

Yet another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one installation ledge formed thereon, wherein a ratio of a height of a highest installation ledge of the housing to a maximum outer diameter of the housing is less than or equal to 0.50.

Yet another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one mounting lug formed thereon, wherein a ratio of a height of a highest mounting lug of the housing to a maximum outer diameter of the housing is less than or equal to 0.41.

Another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one mounting lug formed thereon, wherein a ratio of a height of a highest mounting lug of the housing to a height of the housing is less than or equal to 0.49.

It is a further exemplary aspect of the present invention to provide a valve cartridge having a housing with at least one mounting lug formed thereon, wherein the ratio of the height of the highest mounting lug of the housing to the height of the housing is less than or equal to 0.39.

Yet another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one installation ledge formed thereon, wherein a ratio of a height of a highest installation ledge of the housing to a height of a pin of the valve cartridge is less than or equal to 0.67.

Another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one installation lug formed thereon, wherein a ratio of a height of a highest installation lug of the housing to a height of a pin of the valve cartridge is less than or equal to 0.55.

It is a further exemplary aspect of the present invention to provide a valve cartridge having a housing with at least one mounting lug formed thereon, wherein the highest mounting lug of the housing is located below an actuating mechanism of the valve cartridge.

It is a further exemplary aspect of the present invention to provide a cartridge having a housing with at least one mounting lug formed thereon, wherein the highest mounting lug of the housing is located below the actuation mechanism of the cartridge and above the mixing chamber of the cartridge.

Yet another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one mounting lug formed thereon, wherein the highest mounting lug of the housing is located below an actuating mechanism of the valve cartridge and above a fixed disk of the valve cartridge. The uppermost mounting lug of the housing may extend beyond a portion of the mounting plate.

Yet another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one installation ledge formed thereon, wherein the highest installation ledge of the housing has a height of between 0.641 and 0.651 inches.

Yet another exemplary aspect of the present invention is to provide a valve cartridge having a housing with at least one mounting lug formed thereon, wherein the highest mounting lug of the housing has a height of between 0.486 and 0.494 inches.

Drawings

The foregoing and further aspects, features and advantages will become more readily apparent by describing in detail exemplary embodiments of the present invention with reference to the attached drawings, wherein like reference numerals designate like elements, and in which:

FIGS. 1A to 1C illustrate a conventional valve cartridge wherein the contact point between the valve cartridge and a retaining nut for securing the valve cartridge in a valve body is high, FIG. 1A illustrates a cross-sectional view of the valve cartridge in unassembled form, FIG. 1B illustrates a cross-sectional view of the valve cartridge of FIG. 1A in assembled form, and FIG. 1C illustrates a cross-sectional view of the valve cartridge of FIG. 1B after installation in a plumbing fixture;

FIG. 2 is an exploded perspective view of a valve cartridge according to an exemplary embodiment;

fig. 3A to 3E illustrate an example housing used in the example valve cartridge of fig. 2, fig. 3A being a perspective view of the housing, fig. 3B being a side view of the housing, fig. 3C being a cross-sectional view of the housing taken along line a-a in fig. 10A, fig. 3D being a cross-sectional view of the housing taken along line B-B in fig. 10A, and fig. 3E being a cross-sectional view of the housing taken along line C-C in fig. 3C.

FIG. 4 is a perspective view of an example bulb of the example valve cartridge of FIG. 2;

FIGS. 5A-5C illustrate an example spring used in the example valve cartridge of FIG. 2, with FIG. 5A being a perspective view of the spring, FIG. 5B being a plan view of the spring, and FIG. 5C being a side view of the spring;

6A-6D illustrate an example bushing for use in the example valve cartridge of FIG. 2, FIG. 6A being a perspective view of the bushing, FIG. 6B being a side view of the bushing, FIG. 6C being a bottom view of the bushing, and FIG. 6D being a cross-sectional view of the bushing taken along line A-A of FIG. 6C;

fig. 7A through 7D illustrate an example flow plate for use in the example valve cartridge of fig. 2, fig. 7A being a perspective view of the flow plate, fig. 7B being a plan view of the flow plate, fig. 7C being a cross-sectional view of the flow plate taken along line a-a of fig. 7B, and fig. 7D being a cross-sectional view of the flow plate taken along line B-B of fig. 7B;

FIG. 8 is a perspective view of an example manifold of the example valve cartridge of FIG. 2;

9A-9B illustrate an example base seal for use in the example valve cartridge of FIG. 2, FIG. 9A being a top perspective view of the base seal, and FIG. 9B being a bottom perspective view of the base seal;

10A-10C illustrate the example valve cartridge of FIG. 2 in an assembled form, with FIG. 10A being a plan view of the valve cartridge in an assembled form, FIG. 10B being a cross-sectional view of the valve cartridge taken along line A-A of FIG. 10A, and FIG. 10C being a cross-sectional view of the valve cartridge taken along line B-B of FIG. 10A;

FIG. 11 is a mirror image of a cross-sectional view of the example valve cartridge of FIG. 2 (taken along line B-B of FIG. 10A) after installation in a plumbing fixture;

FIG. 12 is an exploded perspective view of a valve cartridge according to another exemplary embodiment;

13A-13C illustrate an example upper housing for use in the example valve cartridge of FIG. 12, with FIG. 13A being a perspective view of the upper housing, FIG. 13B being a side view of the upper housing, and FIG. 13C being a cross-sectional view of the upper housing taken along line A-A of FIG. 13B;

FIG. 14 illustrates a perspective view of an example bulb of the example valve cartridge of FIG. 12;

15A-15C illustrate an example spring used in the example valve cartridge of FIG. 12, FIG. 15A being a perspective view of the spring, FIG. 15B being a plan view of the spring, and FIG. 15C being a cross-sectional view of the spring taken along line A-A of FIG. 15B;

FIGS. 16A-16C illustrate an example bushing for use in the example valve cartridge of FIG. 12, with FIG. 16A being a side view of the bushing, FIG. 16B being a cross-sectional view of the bushing taken along line A-A of FIG. 16A, and FIG. 16C being a plan view of the bushing;

fig. 17A to 17D illustrate an example carrier for use in the example valve cartridge of fig. 12, fig. 17A being a perspective view of the carrier, fig. 17B being a plan view of the carrier, fig. 17C being a bottom view of the carrier, and fig. 17D being a side view of the carrier;

18A-18C illustrate an example movable disk for use in the example valve cartridge of FIG. 12, FIG. 18A being a plan view of the movable disk, FIG. 18B being a cross-sectional view of the movable disk taken along line A-A of FIG. 18A, and FIG. 18C being a bottom view of the movable disk;

fig. 19A to 19D illustrate an exemplary fixed disk used in the exemplary valve cartridge of fig. 12, fig. 19A being a top perspective view of the fixed disk, fig. 19B being a bottom perspective view of the fixed disk, fig. 19C being a plan view of the fixed disk, and fig. 19D being a bottom view of the fixed disk;

20A-20B illustrate an example base seal for use in the example valve cartridge of FIG. 12, FIG. 20A being a top perspective view of the base seal and FIG. 20B being a plan view of the base seal;

fig. 21A to 21D illustrate an example lower housing used in the example valve cartridge of fig. 12, fig. 21A being a top perspective view of the lower housing, fig. 21B being a bottom perspective view of the lower housing, fig. 21C being a plan view of the lower housing, and fig. 21D being a bottom view of the lower housing;

fig. 22A-22C illustrate the example valve cartridge of fig. 12 in an assembled form, with fig. 22A being a plan view of the valve cartridge in an assembled form, fig. 22B being a cross-sectional view of the valve cartridge taken along line a-a of fig. 22A, and fig. 22C being a cross-sectional view of the valve cartridge taken along line B-B of fig. 22A.

Detailed Description

While the general inventive concept is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the general inventive concept. Accordingly, the general concepts of the invention are not limited by the specific embodiments described herein.

The single handle valve cartridge 200 according to the exemplary embodiment has a low contact point for securing the valve cartridge 200 in the valve body 240. Accordingly, the valve cartridge 200 may overcome the disadvantages of the conventional valve cage having a high contact point.

As shown in fig. 2 and 10A-10C, the example valve cartridge 200 has several separate components, including a housing 202, a bulb 204, a pin 206, a spring 208, a bushing 210, a flow plate 212, a manifold 214, and a base seal 216. The flow plate 212 and/or the manifold 214 may be made of a hard material. For example, the flow plate 212 and/or the manifold 214 may be made of stainless steel. The housing 202 may be made of plastic or metal, for example.

As shown in fig. 3A to 3E, the housing 202 has a dome portion 218 and a cylindrical portion 220. A cavity 222 is formed in the housing 202 for receiving the remaining components of the valve cartridge 200. The cavity 222 extends within the dome portion 218 and the cylindrical portion 220 of the housing 202. The cylindrical portion 220 of the housing 202 includes a lower opening 224 through which components may be inserted into the housing 202. The dome portion 218 of the housing 202 includes an upper opening 226, and a stem portion 228 of the bulb 204 extends through the upper opening 226. The cavity 222 in the housing 202 is wider near the lower opening 224 than near the upper opening 226. The portion of the cavity 222 proximate the upper opening 226 of the housing 202 receives the ball portion 230 of the bulb 204. Thus, the shape of the first inner surface 232 of the portion of the cavity 222 proximate the upper opening 226 substantially conforms to the shape of the bulb portion 230 of the bulb 204 (see fig. 10B-10C and 11).

The portion of the cavity 222 proximate the lower opening 224 of the housing 202 receives the liner 210, flow plate 212, manifold 214, and base seal 216. The diameter of the cavity 222 near the lower opening 224 is substantially the same as the diameter of the base seal 216, the manifold 214, and the flat annular portion 234 of the bushing 210 so that when these components are received in the housing 202, there is only a small clearance between these components and the housing 202.

The portion of the housing 202 where the dome portion 218 meets the cylindrical portion 220 forms a mounting lug 236 on the outer surface of the housing 202. The mounting ears 236 are located substantially below the upper opening 226 of the housing 202. A retaining nut 238 engages the mounting lug 236 to secure the valve cartridge 200 in a valve body 240 (see fig. 11). In addition, the housing 202 has one or more keys 242, each of which engages a complementary shaped recess (not shown) in the valve body 240 to prevent rotation of the housing 202 relative to the valve body 240 after installation of the valve cartridge 200. One or more keys 242 may have the shape of a small blade. The housing 202 also includes a pair of slots 244 formed on opposite sides of the housing 202, the pair of slots 244 interfacing with the distal ends of the pins 206 to function as temperature limiters, as will be described below.

As shown in fig. 4, the bulb 204 is the actuating mechanism for the valve cartridge 200. The bulb 204 includes a bulb portion 230 and a stem portion 228. The ball portion 230 and the stem portion 228 may be separate components or may be integrally formed. Ball portion 230 includes a projection 246 extending from one side of ball portion 230 and stem portion 228 extends from an opposite side of ball portion 230. The protrusions 246 serve as coupling means for connecting the bulbs 204 to the flow plate 212, as will be described below. Ball portion 230 and protrusion 246 may be separate components or may be integrally formed.

A hole 248 is formed through the center of the bulb portion 230 of the bulb 204. The bore 248 is orthogonal to the stem portion 228 of the bulb 204. After the bulb 204 is inserted into the cavity 222 of the housing 202, the pin 206 may be inserted through a slot 244 in the housing 202 into a hole 248 of the bulb 204. In this way, the pin 206 retains the bulb 204 in the housing 202.

As shown in fig. 5A-5C, the spring 208 is annular in shape with a central opening 250. The spring 208 is in the housing 202 and is disposed below the ball portion 230 of the bulb 204 (see fig. 10B-10C). The spring 208 is coupled to the second inner surface 252 of the housing 202 (e.g., via a threaded connection, a friction fit, a snap fit, a weld) such that the spring 208 also retains the bulb 204 within the housing 202. The spring 208 has a plurality of grooves 254, the plurality of grooves 254 being formed on an outer periphery 256 of the spring 208. These grooves 254 engage corresponding protrusions 258 (see fig. 3C) formed on the second inner surface 252 of the housing 202, thereby securing the spring 208 beneath the bulb 204 within the housing 202.

The projection 246 of the bulb 204 extends through a central opening 250 in the spring 208. Some of the ball portion 230 of the bulb 204 may also extend through a central opening 250 in the spring 208. The spring includes a plurality of resilient flanges 260 surrounding the central opening 250. The resilient flange 260 of the spring 208 contacts the ball portion 230 of the bulb 204 and urges the ball portion 230 of the bulb 204 against the complementary shaped first inner surface 232 of the housing 202.

As shown in fig. 6A to 6D, the bushing 210 includes a flat annular portion 234 and a convex annular portion 262. The diameter of the flat annular portion 234 is greater than the diameter of the convex annular portion 262. The bushing 210 is disposed below and spaced apart from the spring 208 in the cavity 222 of the housing 202 (see fig. 10B-10C). An upper surface 264 of the flat annular portion 234 of the bushing 210 contacts a third inner surface 266 of the housing 202, the third inner surface 266 being located below the mounting lugs 236 (see fig. 3C-3D and 10B-10C). The lower surface 268 of the flat annular portion 234 of the liner 210 rests on the upper surface 270 of the flat portion 272 of the flow plate 212. In addition, the male annular portion 262 of the bushing 210 extends into the portion of the cavity 222 of the housing 202 directly above the mounting lugs 236. The male annular portion 262 of the bushing 210 is sized to fit snugly within the portion of the cavity 222 of the housing 202 that receives the male annular portion 262 of the bushing 210. Accordingly, the liner 210 provides a support surface between the housing 202 and the flow plate 212.

The bushing 210 has an opening 274, the opening 274 extending through the flat annular portion 234 and the convex annular portion 262 of the bushing 210. The male portion 276 of flow plate 212 extends into the opening 274 of the liner 210. The convex portion 276 of flow plate 212 forms a mixing chamber 278. The shape of the inner surface of a portion of the opening 274 of the liner 210 conforms to the shape of the convex portion 276 of the flow plate 212 (see fig. 6C-6D). In addition, a coupling recess 280 is formed on the convex portion 276 of the flow plate 212 (see fig. 7A to 7D). After the flow plate 212 is installed in the valve spool 200, the coupling recess 280 is positioned within the opening 274 of the liner 210 and surrounded by the convex annular portion 262 of the liner 210 (see fig. 10B-10C).

Coupling recess 280 of flow plate 212 receives protrusion 246 of bulb 204, thereby connecting the actuation mechanism (i.e., bulb 204) and flow plate 212. The projection 246 of the bulb 204 may have four sides that respectively contact corresponding sides of the coupling recess 280. The protrusion 246 of the bulb 204 does not contact the bottom surface of the coupling recess 280. It should be appreciated that although exemplary embodiments are described herein, the bulbs 204 may be connected to the flow plate 212 in any suitable manner that allows the bulbs 204 to move the flow plate 212 in translation and in angular motion.

As shown in fig. 7A-7D, the flow plate 212 is a valve member formed as a plate, disc, or the like that is movable relative to the housing 202. Flow plate 212 includes a flat portion 272 and a convex portion 276. The flat portion 272 of the flow plate 212 forms a sealing surface that can cover and open the water inlet apertures 282 and 284 in the manifold 214 to allow only cold water, only hot water, or both cold and hot water to flow through the manifold 214. Water flowing into the manifold 214 through the water inlet apertures 282 and 284 enters a mixing chamber 278 (i.e., a cavity formed below the convex portion 276 of the flow plate 212), where the cold and hot water are mixed at the mixing chamber 278 before being discharged through the water outlet apertures 286 in the manifold 214. In addition, as described above, the flow plate 212 also includes a coupling recess 280, the coupling recess 280 being formed on the convex portion 276 of the flow plate 212.

As shown in fig. 8, the manifold 214 is a valve member formed as a plate, disc, or the like that is fixed relative to the housing 202. The manifold 214 includes one or more protrusions 288 formed on a perimeter 290 of the manifold 214, wherein each protrusion 288 fits within an interior cavity 292 of one of the plurality of keys 242 of the housing 202 (see fig. 3A and 3E). The protrusion 288 secures the manifold 214 relative to the housing 202, thereby preventing the manifold 214 from rotating within the housing 202.

The manifold 214 includes water inlet apertures 282 and 284, the water inlet apertures 282 and 284 corresponding to the cold water inlet aperture and the hot water inlet aperture, respectively. The manifold 214 also includes a water outlet aperture 286 through which cold water flowing through the cold water inlet aperture 282, hot water flowing through the hot water inlet aperture 284, or a mixture of cold and hot water may flow to an outlet passage (not shown) of the valve body 240.

As shown in fig. 9A to 9B, the base seal 216 is a seal member formed of an elastic material (e.g., rubber). The base seal 216 includes one or more protrusions 294, the one or more protrusions 294 being formed on the perimeter 296 of the base seal 216, wherein each protrusion 294 fits within the interior cavity 292 of one of the plurality of keys 242 of the housing 202. The protrusion 294 secures the base seal 216 relative to the housing 202, thereby preventing the base seal 216 from rotating within the housing 202. The base seal 216 also includes one or more protrusions 298, the one or more protrusions 298 formed on the perimeter 296 of the base seal 216, wherein the one or more protrusions 298 deformably fit within and extend through corresponding one or more openings 300 to secure the base seal 216 within the housing 202, wherein the one or more openings 300 are formed in the housing 202. The one or more projections 298 may be of different sizes.

As with the manifold 214, the base seal 216 has a cold water inlet aperture 302, a hot water inlet aperture 304, and an outlet aperture 306. The cold water inlet aperture 302 and the hot water inlet aperture 304 of the base seal 216 each have a wall 308 that slopes from near a lower surface 310 of the base seal 216 to near an upper surface 312 of the base seal 216 to enhance the flow of water through the base seal 216 and into the valve cartridge 200. The water outlet aperture 306 of the base seal 216 has a wall 314 that slopes from near the upper surface 312 of the base seal 216 to near the lower surface 310 of the base seal 216 to enhance the flow of water through the base seal 216 and out of the valve cartridge 200. Importantly, when the valve cartridge 200 is assembled, the apertures 282, 284, and 286 in the manifold 214 are aligned with the apertures 302, 304, and 306 in the base seal 216. Thus, the protrusion 288 on the manifold 214 and the protrusion 294 on the base seal 216 ensure that the manifold 214 and the base seal 216 fit into the housing 202 in only one direction in which the apertures 282, 284, and 286 in the manifold 214 are aligned with the apertures 302, 304, and 306 in the base seal 216.

Surrounding the apertures 302, 304, and 306 in the base seal 216 on the upper surface 312 of the base seal 216 is a ridge 316 (see fig. 9A). Similarly, on the lower surface 310 of the base seal 216 surrounding the apertures 302, 304, and 306 in the base seal 216 is a ridge 318 (see fig. 9B). When the valve cartridge 200 is installed in the valve body 240, the ridges 316 and 318 of the base seal 216 are compressed (see fig. 10B-10C and 11, which show the ridges 316 and 318 overlapping the compression structure for illustrative purposes). Specifically, when the retaining nut 238 is tightened down on the mounting ledge 236 of the housing 202, the ridge 316 is compressed between the manifold 214 of the valve cartridge 200 and the base seal 216, while the ridge 318 is compressed between the base seal 216 and the seating surface 320 of the valve body 240 (see fig. 11). It should be noted that while the protrusion 288 of the manifold 214 prevents the manifold 214 from rotating within the housing 202, the protrusion 288 allows the manifold 214 to move axially within the housing 202. As such, compression of the ridges 316 and 318 of the base seal 216 exerts a loading force on the flow plate 212 and the manifold 214. Thus, the flow plate 212 and manifold 214 remain in water-tight engagement with one another after the valve cartridge 200 is installed.

The retaining nut 238 is a hollow nut that engages the sidewall 322 of the valve body 240 to secure the valve cartridge 200 in the valve body 240 (see fig. 11). For example, the retaining nut 238 may have external threads for engaging complementary threads on the sidewall 322. The inner surface of the retaining nut 238 is shaped to substantially conform to the shape of the domed portion 218 of the housing 202. However, the mounting lugs 236 are the only portion of the housing 202 that contacts the retaining nut 238 during installation of the valve cartridge 200 in the valve body 240.

Additionally, the retaining nut 238 and/or the valve body 240 may have structural features that prevent excessive torque from being transmitted to the valve spool 200. For example, the retention nut 238 includes an annular flange 326 that bottoms out on a surface 328 of the valve body 240 to prevent over-tightening of the retention nut 238 (see fig. 11). Thus, the annular flange 326 functions to limit the maximum amount of torque transferred from the retaining nut 238 to the valve spool 200.

The position and orientation of the flow plate 212 relative to the manifold 214 is controlled by a stem portion 228 of the bulb 204, which stem portion 228 protrudes from the housing 202 through the upper opening 226. For example, pivoting the stem portion 228 of the bulb 204 about the pin 206 may change the position of the flow plate 212 relative to the manifold 214, which changes the flow rate of the water. Rotating the stem portion 228 of the bulb 204 may change the orientation of the flow plate 212 relative to the manifold 214, which changes the temperature of the water.

An operating member 330 (see fig. 11), such as a handle, knob, or the like, may be connected to the stem portion 228 of the bulb 204 to assist a user in manipulating the stem portion 228. Thus, after the valve cartridge 200 is installed in the valve body 240, a user may manipulate the operating member 330, which operating member 330 actuates the stem portion 228 of the bulb 204 to change the position and/or orientation of the flow plate 212 relative to the manifold 214, thereby controlling the flow rate and temperature of water through the valve cartridge 200 and out of the plumbing fixture 332, such as out of the plumbing fixture 332 through a spout (not shown) of the plumbing fixture 332 (see fig. 11).

Pivoting of the stem portion 228 of the bulb 204 about the pin 206 may be limited by the stem portion 228 contacting an opposing surface of the upper opening 226 of the housing 202. Thus, when the valve cartridge 200 is in the fully closed position corresponding to zero flow, the stem portion 228 of the bulb 204 contacts the first surface 334 of the upper opening 226 of the housing 202 (see fig. 10C). When the valve cartridge 200 is in the fully open position corresponding to maximum flow, the stem portion 228 of the bulb 204 contacts the second surface 336 of the upper opening 226 of the housing 202.

Rotation of the stem portion 228 of the bulb 204 may be limited by the distal end of the pin 206 contacting an end portion 338 of the slot 244 (see fig. 2, 3A-3B, and 10A). Thus, the length of the slot 244 defines the range of temperatures of water that the valve cartridge 200 may deliver, the slot 244 acting as a temperature limiter.

The valve cartridge 200 has a low contact point (i.e., a mounting lug 236 formed on the housing 202) against which a retaining nut 238 presses. The mounting lug 236 is a circular lug extending around the housing 202 where the dome portion 218 of the housing 202 meets the cylindrical portion 220 of the housing 202. The mounting lugs 236 are the highest points on the housing 202 that are in contact with the retaining nut 238.

In the exemplary embodiment of the exemplary valve cartridge 200, one or more mounting lugs (e.g., mounting lug 236) are formed on the housing 202 of the valve cartridge 200. The highest of the mounting lugs is a low contact point on the housing 202 for mounting the valve cartridge 200 in the valve body 240.

Height h of the highest mounting lug on housing 202₁Ratio R to the maximum outer diameter d of the housing 202₁Less than or equal to 0.50 (see FIG. 10B), which can be expressed as h₁D is less than or equal to 0.50. In another exemplary embodiment of the exemplary valve cartridge 200, the height h₁Ratio R to maximum outer diameter d₁Less than or equal to 0.41 (see fig. 10B). In yet another exemplary embodiment of the exemplary valve cartridge 200, the height h₁Ratio R to maximum outer diameter d₁Approximately equal to 0.40.

According to yet another exemplary embodiment of the exemplary valve cartridge 200, the height h₁Height h from the housing 202₂Ratio R of₂Less than or equal to 0.39 (see FIG. 10B), which can be expressed as h₁/h₂Less than or equal to 0.39. In another exemplary embodiment, the height h₁Specific height h₂Ratio R of₂Approximately equal to 0.38. In yet another exemplary embodiment, the height h₁Specific height h₂Ratio R of₂Approximately equal to 0.36.

According to yet another exemplary embodiment of the exemplary valve cartridge 200, the height h₁Height h from pin 206₃(e.g., from the bottom of the housing 202 to the centerline of the pin 206) ratio R₃Less than or equal to 0.55 (see FIG. 10B), which can be expressed as h₁/h₃Less than or equal to 0.55. In another exemplary embodiment, the height h₁Specific height h₃Ratio R of₃Approximately equal to 0.54. In yet another exemplary embodiment, the height h₁Specific height h₃Ratio R of₃Approximately equal to 0.50.

According to another exemplary embodiment of the exemplary valve cartridge 200, the highest mounting lug on the housing 202 is below the actuating mechanism (e.g., the bulb 204) of the valve cartridge 200 (see fig. 10B). In yet another exemplary embodiment of the exemplary valve cartridge 200, the highest mounting lug on the housing 202 is below the actuation mechanism of the valve cartridge 200 and above the mixing chamber (e.g., mixing chamber 278). In yet another exemplary embodiment of the exemplary valve cartridge 200, the highest mounting lug on the housing 202 is below the actuation mechanism of the valve cartridge 200 and above the fixed disk (e.g., manifold 214).

According to an exemplary embodiment of the exemplary valve cartridge 200, the height h of the highest mounting lug on the housing 202₁Is between 0.486 and 0.494 inch. In an exemplary embodiment, the height h of the highest mounting lug on the housing 202₁Equal to approximately 0.490 inches.

According to another exemplary embodiment of exemplary valve cartridge 200, the height h of housing 202₂Is between 1.377 and 1.385 inches. In another exemplary embodimentExample, height h of the housing 202₂Is between 1.277 and 1.285 inches. In another exemplary embodiment, the height h of the housing 202₂Approximately equal to 1.381 inches. In another exemplary embodiment, the height h of the housing 202₂Approximately equal to 1.281 inches.

According to yet another exemplary embodiment of the exemplary valve cartridge 200, the height h of the pin 206₃Is between 0.977 and 0.994 inches. In another exemplary embodiment, the height h of the pin 206₃Is between 0.902 and 0.919 inches. In an exemplary embodiment, the height h of the pin 206₃Approximately equal to 0.986 inches. In another exemplary embodiment, the height h of the pin 206₃Approximately equal to 0.911 inches.

According to yet another exemplary embodiment of the exemplary valve cartridge 200, the outer diameter d of the housing 202 is between 1.216 and 1.224 inches. In an exemplary embodiment, the outer diameter d of the housing 202 is approximately equal to 1.220 inches.

As illustrated by the exemplary embodiments described herein, the mounting lug 236 (which is the highest mounting lug on the housing 202) is a low contact point on the housing 202 against which the retaining nut 238 may press during installation of the valve cartridge 200 in the valve body 240. Thus, the valve cartridge 200 has a compact configuration that provides increased flexibility in the design of a plumbing fixture that houses the valve cartridge 200 (e.g., the plumbing fixture 332 shown in fig. 11). Further, because the sidewall 322 of the valve body 240 may be made shorter (see FIG. 11), the lower mounting lugs 236 allow less material to be used to form the valve body 240. As a result, lower mounting lug 236 may be cost effective.

A single handle valve cartridge 400 according to another exemplary embodiment has a low contact point for securing the valve cartridge 400 in a valve body (e.g., the exemplary valve body 240 shown in fig. 11). Accordingly, the valve cartridge 400 may overcome the disadvantages of conventional valve cartridges having high contact points.

As shown in fig. 12 and 22B-22C, the example valve cartridge 400 has several separate components including an upper housing 402, a bulb 404, a pin 406, a spring 408, a bushing 410, a carrier 412, a movable disk 414, a fixed disk 416, a base seal 418, and a lower housing 420. The movable disk 414 and/or the fixed disk 416 may be made of a hard material. For example, the movable disk 414 and/or the fixed disk 416 may be made of ceramic. The upper housing 402 may be made of plastic or metal, for example.

As shown in fig. 13A to 13C, the upper housing 402 has a dome portion 422 and a cylindrical portion 424. A cavity 426 is formed in the upper housing 402 for receiving the remaining components of the valve cartridge 400. The cavity 426 extends inside the dome portion 422 and the cylinder portion 424 of the upper housing 402. The cylindrical portion 424 of the upper housing 402 includes a lower opening 428 through which the component may be inserted into the upper housing 402. The dome portion 422 of the upper housing 402 includes an upper opening 430, and a stem portion 432 of the bulb 404 extends through the upper opening 430. The cavity 426 in the upper housing 402 is wider near the lower opening 428 than near the upper opening 430. The portion of the cavity 426 proximate the upper opening 430 of the upper housing 402 receives the bulb portion 434 of the bulb 404. Thus, the shape of the first inner surface 436 of the portion of the cavity 426 proximate the upper opening 430 substantially conforms to the shape of the bulbous portion 434 of the bulb 404 (see fig. 13C and 22B).

The portion of the cavity 426 proximate the lower opening 428 of the upper housing 402 receives the bushing 410, the carrier 412, the movable disc 414, the fixed disc 416, and the base seal 418 (see fig. 22B-22C). Further, as will be explained below, the lower housing 420 is coupled to the upper housing 402 to form a housing assembly 438 that holds these components within the cavity 426 of the upper housing 402 (see fig. 22B-22C).

The portion of the upper housing 402 where the dome portion 422 meets the cylinder portion 424 forms a mounting lug 440 on the outer surface of the upper housing 402 (see fig. 13A-13C and 22A-22C). The mounting lugs 440 are substantially below the upper opening 430 of the upper housing 402. In one exemplary embodiment, a retaining nut (e.g., the retaining nut 234 shown in fig. 11) engages the mounting lugs 440 to secure the valve cartridge 400 in a valve body (e.g., the valve body 240 shown in fig. 11). In addition, the upper housing 402 has one or more keys 442 that each engage a complementary shaped recess in the valve body to prevent rotation of the upper housing 402 relative to the valve body after installation of the valve cartridge 400. One or more of the keys 442 may have the shape of a small blade. The upper housing 402 also includes a pair of slots 444 formed on opposite sides of the upper housing 402, the pair of slots 444 being connected to the distal ends of the pins 406 to function as temperature limiters, as will be described below.

As shown in fig. 14, the bulb 404 is the actuating mechanism for the valve cartridge 400. The bulb 404 includes a bulb portion 434 and a stem portion 432. The ball portion 434 and the stem portion 432 may be separate components or may be integrally formed. The ball portion 434 includes a projection 446 extending from one side of the ball portion 434 and the stem portion 432 extends from an opposite side of the ball portion 434. The projection 446 serves as a coupling means for connecting the bulb 404 to the carrier 412, as will be described below. The ball portion 434 and the projection 446 may be separate components or may be integrally formed.

A hole 448 is formed through the center of the bulb portion 434 of the bulb 404. The hole 448 is orthogonal to the stem portion 432 of the bulb 404. After the bulb 404 is inserted into the cavity 426 of the upper housing 402, the pin 406 may be inserted through one of the slots 444 in the upper housing 402 into the hole 448 of the bulb 404. In this manner, the pin 406 retains the bulb 404 in the upper housing 402.

As shown in fig. 15A to 15C, the spring 408 has an annular shape with a central opening 450. The spring 408 is disposed in the upper housing 402 below the ball portion 434 of the bulb 404 (see fig. 22B-22C). The spring 408 is attached (e.g., by threaded connection, friction fit, snap fit, welding) to a second inner surface 452 of the upper housing 402 such that the spring 408 also retains the bulb 404 in the upper housing 402 (see fig. 13C and 22C). In an exemplary embodiment, at least a portion of the outer perimeter 454 of the spring 408 is welded to the second inner surface 452 of the upper housing 402.

The projection 446 of the bulb 404 extends through a central opening 450 in the spring 408. Some of the ball portion 434 of the bulb 404 may also extend through a central opening 450 in the spring 408. The spring 408 includes a plurality of resilient flanges 456 surrounding the central opening 450. The resilient flanges 456 are spaced apart from each other so as to create a gap 458 between the resilient flanges 456. The resilient flange 456 of the spring 408 contacts the bulb portion 434 of the bulb 404 and urges the bulb portion 434 of the bulb 404 against the complementary shaped first inner surface 436 of the upper housing 402. The gap 458 functions, for example, to reduce the stress exerted on the spring 408 by the engaging bulb 404.

As shown in fig. 16A to 16C, the bushing 410 includes a flat annular portion 460 and a convex annular portion 462. The diameter of the flat annular portion 460 is greater than the diameter of the convex annular portion 462. The bushing 410 is disposed below and spaced apart from the spring 408 in the cavity 426 of the upper housing 402 (see fig. 22B-22C). The upper surface 464 of the flat annular portion 460 of the bushing 410 contacts a third inner surface 466 of the upper housing 402, the third inner surface 466 being located below the mounting lugs 440 (see fig. 13C and 22B). The lower surface 468 of the flat annular portion 460 of the bushing 410 rests on the upper surface 470 of the flat portion 472 of the carrier 412 (see fig. 17A-17B, 17D, and 22B-22C). In addition, the male annular portion 462 of the bushing 410 extends into a portion of the cavity 426 of the upper housing 402 directly above the mounting lugs 440 (and adjacent to the mounting lugs 440). The male annular portion 462 of the bushing 410 is sized to fit snugly within the portion of the cavity 426 of the upper housing 402 that receives the male annular portion 462 of the bushing 410. Thus, the bushing 410 provides a support surface between the upper housing 402 and the carrier 412.

The bushing 410 has an opening 474 that extends through the flat annular portion 460 and the convex annular portion 462 of the bushing 410. The male annular portion 462 may include a first male annular portion 476 and a second male annular portion 478 with a rib 480 disposed between the first male annular portion 476 and the second male annular portion 478 (see fig. 16C). The male portion 482 of the carrier 412 extends into the opening 474 of the bushing 410 (see fig. 17A-17B and 17D). In addition, a coupling recess 484 is formed in the male portion 482 of the carrier 412. After the carrier 412 is installed in the valve cartridge 400, the male portion 482 including the coupling recess 484 is positioned within the opening 474 of the bushing 410 and surrounded by the bushing 410 (see fig. 22B to 22C).

The coupling recess 484 of the carrier 412 receives the protrusion 446 of the bulb 404, thereby connecting the actuation mechanism (i.e., the bulb 404) and the carrier 412 (see fig. 22B-22C). The projection 446 of the bulb 404 may have four sides that respectively contact corresponding sides of the coupling recess 484. The protrusion 446 of the bulb 404 does not contact the bottom surface of the coupling recess 484. It will be appreciated that although exemplary embodiments are described herein, the bulbs 404 may be connected to the carrier 412 in any suitable manner that allows the bulbs 404 to impart translational and angular motion to the carrier 412.

As shown in fig. 17A-17D, the carrier 412 includes a flat portion 472 and a convex portion 482. The lower surface 486 of the flat portion 472 of the carrier 412 includes structure for coupling with the upper surface 488 of the movable disc 414 in order to couple the carrier 412 and the movable disc 414 to one another without moving relative to one another. In an exemplary embodiment, the lower surface 486 of the carrier 412 includes three U-shaped projections 490, the three U-shaped projections 490 being friction fit into corresponding U-shaped recesses 492, the U-shaped recesses 492 being formed in the upper surface 488 of the movable disc 414. The spacing between adjacent U-shaped projections 490 (and thus also between corresponding U-shaped recesses 492) may be varied so that the carrier 412 will only be connected to the movable disc 414 in one direction. Further, as described above, the carrier 412 also includes a coupling recess 484, which coupling recess 484 is formed in the male portion 482 of the carrier 412. As such, the carrier 412 functions to interconnect the actuation mechanism (e.g., the bulb 404) and the dynamic sealing element (e.g., the movable disc 414) within the valve cartridge 400.

As shown in fig. 18A to 18C, the movable disc 414 is a valve member formed as a plate, disc, or the like that is movable relative to the upper housing 402. As described above, the upper surface 488 of the movable plate 414 includes the U-shaped recess 492. The upper surface 488 is substantially flat. The lower surface 494 of the movable disc 414 includes a mixing chamber 496 (i.e., a cavity formed in the movable disc 414). In an alternative exemplary embodiment, mixing chamber 496 extends through movable disk 414 (i.e., from lower surface 494 to upper surface 488). The lower surface 494 is substantially flat. Lower surface 494 of movable disk 414 forms a sealing surface that may cover and open water inlet apertures 498 and 500 in fixed disk 416 to allow cold water only, hot water only, or both cold and hot water to flow through fixed disk 416. Water flowing through water inlet apertures 498 and 500 in fixed disk 416 enters mixing chamber 496 where cold and hot water are mixed before being discharged through water outlet apertures 502 in fixed disk 416.

As shown in fig. 19A to 19D, the fixed disk 416 is a valve member formed as a plate, disk, or the like fixed with respect to the upper housing 402. Mounting plate 416 has an upper surface 504 and a lower surface 506. The fixed disk 416 includes structure for coupling with the lower housing 420 to fix the fixed disk 416 relative to the housing assembly 438 (i.e., prevent rotation of the fixed disk 416 relative to the housing assembly 438) once the valve cartridge 400 is assembled. For example, four grooves 508 are formed along the perimeter 510 of mounting plate 416. One or more grooves 508 engage corresponding protrusions 512 formed on lower housing 420, thereby preventing rotation of fixed disk 416 relative to lower housing 420. In an exemplary embodiment, two of the grooves 508 engage corresponding protrusions 512. By varying the size of grooves 508 and/or the spacing between grooves 508 (and thus the size of corresponding protrusions 512 and/or the spacing between protrusions 512), it can be ensured that fixed disk 416 is connected to lower housing 420 in only one direction. Thus, because fixed disk 416 is prevented from rotating relative to lower housing 420 and lower housing 420 is fixed to upper housing 402, as described below, fixed disk 416 does not rotate within housing assembly 438.

Fixed disk 416 includes water inlet apertures 498 and 500, which correspond to cold water inlet apertures and hot water inlet apertures 498 and 500, respectively. Fixed disk 416 also includes outlet apertures 502 through which cold water flowing through cold water inlet apertures 498, hot water flowing through hot water inlet apertures 500, or a mixture of cold and hot water may flow to the outlet passage of the valve body through outlet apertures 502. Cold water inlet apertures 498 and hot water inlet apertures 500 of fixed disk 416 each have a wall 514 that slopes from near lower surface 506 of fixed disk 416 to near upper surface 504 of fixed disk 416 to enhance the flow of water through fixed disk 416 into valve cartridge 400. The water outlet port 502 of the fixed disk 416 has a wall 516 that is sloped from near the upper surface 504 of the fixed disk 416 to near the lower surface 506 of the fixed disk 416 to improve the flow of water through the fixed disk 416 and out of the valve cartridge 400.

As shown in fig. 20A to 20B, the base seal 418 is a seal member formed of an elastic material (e.g., rubber). Base seal 418 forms a watertight seal around cold water inlet aperture 498, hot water inlet aperture 500, and outlet aperture 502 of fixed disk 416. Like fixed disk 416, base seal 418 has a cold water inlet aperture 518, a hot water inlet aperture 520, and an outlet aperture 522. In an exemplary embodiment, the water outlet aperture 522 of the base seal 418 is formed by inserting a member 524 (e.g., an elastomeric insert) having the water outlet aperture 522 therein into an opening in the base seal 418. In another exemplary embodiment, the base seal 418 is integrally formed with the lower housing 420.

The cold water inlet aperture 518, the hot water inlet aperture 520, and the outlet aperture 522 are all connected by a hub 526 near the center of the base seal 418. Further, the cold water inlet aperture 518 is connected to the outlet aperture 522 by a first connection 528; the hot water inlet aperture 520 is connected to the water outlet aperture 522 by a second connection 530; the cold water inlet aperture 518 is connected to the hot water inlet aperture 520 by a third connection 532. The junction between the cold water inlet aperture 518 and the water outlet aperture 522 achieved by the first connection 528 forms a first space 534; the junction between the hot water inlet aperture 520 and the water outlet aperture 522 by the second connection 530 forms a second space 536; also, the junction between the cold water inlet aperture 518 and the hot water inlet aperture 520 by the third connection 532 forms a third space 538.

Importantly, when the valve cartridge 400 is assembled, the apertures 498, 500, and 502 in the fixed disk 416 are aligned with the apertures 518, 520, and 522 in the base seal 418. Thus, as will be explained below, the hub 526, the first connection 528, the second connection 530, the third connection 532, the first space 534, the second space 536, and the third space 538 all serve to align the base seal 418 in the lower housing 420, and thus the fixed disk 416.

As shown in fig. 21A-21D and 22B-22C, the lower housing 420 interfaces with the upper housing 402 to form a housing assembly 438 for retaining components (e.g., the bushing 410, the carrier 412, the movable disk 414, the fixed disk 416, and the base seal 418) within the housing assembly 438 (e.g., within the cavity 426 of the upper housing 402) after assembly of the valve cartridge 400. The lower housing 420 may be made of plastic or metal, for example. The lower housing 420 may be formed of the same material as the upper housing 402.

In addition, the lower housing 420 serves as a support member to orient and retain the fixed disk 416 and base seal 418 prior to assembly of the valve cartridge 400. Similar to fixed disk 416 and base seal 418, lower housing 420 includes cold water inlet aperture 540, hot water inlet aperture 542, and outlet aperture 544 (see fig. 21A-21D). As described above, the lower housing 420 also includes the protrusion 512. The one or more protrusions 512 extend beyond the side wall 546 of the lower housing 420. In one exemplary embodiment, the two protrusions 512 extend beyond the side wall 546. The height of the one or more protrusions 512 may be substantially the same as the height of the side walls 546. In an exemplary embodiment, the height of the two protrusions 512 is substantially the same as the height of the side walls 546.

One or more protrusions 512 may fit into corresponding openings 548 formed in the upper housing 402 below the keys 442 (see fig. 13A-13C). In one exemplary embodiment, three protrusions 512 fit into three openings 548. The protrusions 512 are substantially the same shape as the keys 442, e.g., each is in the shape of a leaflet. The protrusion 512 also serves as a component of the key 442 by fitting into an opening 548 below the key 442, for example, by engaging a complementary shaped recess in the valve body.

The size and/or shape of the protrusions 512 may be varied such that the lower housing 420 will interface with the fixed disk 416 and the upper housing 402 in only one direction, thereby ensuring that the fixed disk 416 will be properly oriented with respect to the upper housing 402 and the lower housing 420 when the valve cartridge 400 is assembled. By engaging groove 508 in fixed disk 416, protrusions 512 also prevent fixed disk 416 from rotating relative to lower housing 420 (and thus also prevent fixed disk 416 from rotating relative to upper housing 402).

The lower housing 420 includes a first recess 550, a second recess 552, a third recess 554, and a fourth recess 556. The lower housing 420 further includes a first protrusion 558, a second protrusion 560, and a third protrusion 562. The hub 526, the first connection 528, the second connection 530, and the third connection 532 of the base seal 418 are fitted into the first recess 550, the second recess 552, the third recess 554, and the fourth recess 556 of the lower housing 420, respectively. Further, the first, second, and third protrusions 558, 560, and 562 of the lower housing 420 are fitted into the first, second, and third spaces 534, 536, and 538 of the base seal 418, respectively. Thus, the lower housing 420 orients, secures, and retains the base seal 418 within the lower housing 420.

The lower shell 420 also includes a pair of resilient flanges 564, each resilient flange 564 having an angled upper portion 566. The groove 508 in the retention disk 416 allows the resilient flange 564 to be pressed inward (i.e., toward the central vertical axis of the poppet 400) so that the angled upper portion 566 may enter the cavity 426 in the upper housing 402. When the ramped upper portion 566 is aligned with a corresponding opening 568 (see fig. 13A-13C) formed in the upper housing 402, the resilient flange 564 is pressed outwardly and the ramped upper portion 566 is received in the opening 568. In this way, the lower housing 420 (including the retention disk 416 and base seal 418 interfacing therewith) may be secured to the upper housing 402 (see fig. 22B-22C).

It should be noted that while groove 508 of fixed disk 416 interfaces with protrusion 512 of lower housing 420 to prevent fixed disk 416 from rotating within lower housing 420 (and thus prevent fixed disk 416 from rotating within upper housing 402), fixed disk 416 is allowed to move axially within housing assembly 438 (i.e., upper housing 402 and lower housing 420). Thus, compression of the base seal 418 exerts a loading force on the movable disk 414 and the fixed disk 416. Thus, the movable disk 414 and the fixed disk 416 remain in watertight engagement with each other after assembly of the valve cartridge 400.

The position and orientation of the movable plate 414 relative to the fixed plate 416 is controlled by a stem portion 432 of the bulb 404 that protrudes from the upper housing 402 through the upper opening 430. For example, pivoting of the stem portion 432 of the bulb 404 about a pivot (e.g., pin 406) changes the position of the movable disk 414 relative to the fixed disk 416, which changes the flow rate of the water. Rotation of the stem portion 432 of the bulb 404 changes the orientation of the movable disk 414 relative to the fixed disk 416, which changes the temperature of the water.

An operating member (e.g., operating member 330 shown in fig. 11) such as a handle, knob, or the like may be connected to the stem portion 432 of the bulb 404 to assist a user in manipulating the stem portion 432. Thus, after the valve cartridge 400 is installed in the valve body, a user may manipulate an operating member that moves the stem portion 432 of the bulb 404 to change the position and/or orientation of the movable disk 414 relative to the fixed disk 416, thereby controlling the flow rate and temperature of water flowing out of a plumbing fixture (e.g., the plumbing fixture 332 shown in fig. 11) through the valve cartridge 400.

Pivoting of the stem portion 432 of the bulb 404 about the pin 406 may be limited by the stem portion 432 contacting an opposing surface of the upper opening 430 of the upper housing 402. Thus, when the valve spool 400 is in the fully closed position corresponding to zero flow, the stem portion 432 of the bulb 404 contacts the first surface 570 of the upper opening 430 of the upper housing 402 (see fig. 22C). When the valve spool 400 is in the fully open position corresponding to maximum flow, the stem portion 432 of the bulb 404 contacts the second face 572 of the upper opening 430 of the upper housing 402.

Rotation of stem portion 432 of bulb 404 may be limited by distal end of pin 406 contacting end portion 574 of slot 444 (see fig. 22A). Thus, the length of the slot 444 defines the temperature range of water that the valve cartridge 400 can deliver, the slot 444 serving as a temperature limiter.

The valve cartridge 400 has a low contact point (i.e., a mounting lug 440 formed on the upper housing 402) against which the retaining nut presses. The mounting lugs 440 are circular lugs extending around the upper housing 402 where the dome portion 422 of the upper housing 402 meets the cylindrical portion 424 of the upper housing 402. Mounting lugs 440 are the highest point on housing assembly 438 that contacts the retaining nut.

In an exemplary embodiment of the example valve cartridge 400, one or more mounting lugs (e.g., the mounting lug 440) are formed on the housing assembly 438 of the valve cartridge 400. The highest point of the mounting lugs is a low contact point on the housing assembly 438 for mounting the valve cartridge 400 in the valve body.

Height h of highest mounting lug on housing assembly 438₁Ratio R to maximum outer diameter d of housing assembly 438₁Less than or equal to 0.53 (see fig. 22C), which can be expressed as h₁D is less than or equal to 0.53. In another exemplary embodiment of the exemplary valve cartridge 400, the height h₁Ratio R to maximum outer diameter d₁Less than or equal to 0.52. In yet another exemplary embodiment of the exemplary valve cartridge 400, the height h₁Ratio R to maximum outer diameter d₁Approximately equal to 0.53.

According to yet another exemplary embodiment of the exemplary valve cartridge 400, the height h₁Height h from housing assembly 438₂Ratio R of₂Less than or equal to 0.49 (see FIG. 22C), which can be expressed as h₁/h₂Less than or equal to 0.49. In another exemplary embodiment, the height h₁And a height h₂Ratio R of₂Less than or equal to 0.47. In yet another exemplary embodiment, the height h₁And a height h₂Ratio R of₂Approximately equal to 0.48.

According to yet another exemplary embodiment of the exemplary valve cartridge 400, the height h₁Height h from pin 406₃Ratio R (height from bottom of housing assembly 438 to centerline of pin 406)₃Less than or equal to 0.67 (see FIG. 22C), which can be expressed as h₁/h₃Less than or equal to 0.67. In another exemplary embodiment, the height h₁And a height h₃Ratio R of₃Less than or equal to 0.65. In yet another exemplary embodimentIn the examples, the height h₁And a height h₃Ratio R of₃Approximately equal to 0.66.

According to another exemplary embodiment of the exemplary valve cartridge 400, the highest mounting lug on the housing assembly 438 is located below the actuating mechanism (e.g., the bulb 404) of the valve cartridge 400. In yet another exemplary embodiment of the exemplary valve cartridge 400, the highest mounting lug on the housing assembly 438 is located below the actuation mechanism of the valve cartridge 400 and above the mixing chamber (e.g., mixing chamber 496). In yet another example embodiment of the example valve cartridge 400, the highest mounting lug on the housing assembly 438 is located below the actuation mechanism of the valve cartridge 400 and above a fixed disk (e.g., fixed disk 416).

According to an exemplary embodiment of the exemplary valve cartridge 400, the height h of the highest mounting lug on the housing assembly 438₁Is between 0.641 and 0.651 inches. In an exemplary embodiment, height h of the highest mounting lug on housing assembly 438₁Approximately equal to 0.646 inches.

According to another exemplary embodiment of the exemplary valve cartridge 400, the height h of the housing assembly 438₂Is between 1.339 and 1.369 inches. In an exemplary embodiment, height h of housing assembly 438₂Approximately equal to 1.354 inches.

According to yet another exemplary embodiment of the exemplary valve cartridge 400, the height h of the pin 406₃Is between 0.973 and 0.993 inches. In an exemplary embodiment, the height h of the pin 406₃Approximately equal to 0.983 inches.

According to yet another exemplary embodiment of the exemplary valve cartridge 400, the outer diameter d of the housing assembly 438 is between 1.220 and 1.228 inches. In an exemplary embodiment, outer diameter d of housing assembly 438 is approximately equal to 1.224 inches.

As illustrated by the exemplary embodiments described herein, the mounting lugs 440 (as the highest mounting lug on the housing assembly 438) are low contact points on the housing assembly 438 against which the retaining nut may press during installation of the valve cartridge 400 in a valve body. Thus, the valve cartridge 400 has a compact configuration that provides increased flexibility in the design of a plumbing fixture that houses the valve cartridge 400 (e.g., the plumbing fixture 332 shown in fig. 11). Further, because the side walls of the valve body can be made shorter (see FIG. 11), the lower mounting lugs 440 allow less material to be used to form the valve body. As a result, the lower mounting lug 440 may be cost effective.

The foregoing description of specific embodiments has been presented by way of example only. From the description given, those skilled in the art will not only understand the general concepts of the invention and the attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. It is therefore intended in the appended claims to cover all such changes and modifications and equivalent arrangements as fall within the true spirit and scope of the general inventive concept as defined herein.

Claims

1. A valve cartridge for controlling a flow rate of a fluid and operatively secured in a valve body by a retaining member, the valve cartridge comprising:

a housing;

an actuation mechanism; and

the fluid control member is a member of the type described,

wherein the fluid control member is disposed in the housing,

wherein a portion of the actuation mechanism extends through an upper opening in the housing,

wherein movement of the actuation mechanism moves the fluid control member to change the flow rate of the fluid,

wherein the highest point on the housing for contacting the retaining member forms a mounting lug, an

Wherein the mounting lug is located substantially below the upper opening in the housing.

2. The valve cartridge of claim 1, wherein a ratio of a height of the installation ledge on the housing to a maximum outer diameter of the housing is less than or equal to 0.50.

3. The valve cartridge of claim 2, wherein the height of the installation ledge is between 0.486 inches and 0.494 inches.

4. The valve cartridge of claim 1, wherein a ratio of a height of the installation ledge on the housing to a height of the housing is less than or equal to 0.39.

5. The valve cartridge of claim 4, wherein the height of the installation ledge is between 0.486 inches and 0.494 inches.

6. The valve cartridge of claim 1, wherein a pin secures the actuation mechanism in the housing such that the actuation mechanism is operable to pivot about the pin, and

wherein a ratio of a height of the mounting lug on the housing to a height of a center of the pin is less than or equal to 0.55.

7. The valve cartridge of claim 6, wherein the height of the installation ledge is between 0.486 inches and 0.494 inches.

8. The valve cartridge of claim 1, wherein a ratio of a height of the installation ledge on the housing to a maximum outer diameter of the housing is less than or equal to 0.53.

9. The valve cartridge of claim 8, wherein the height of the installation ledge is between 0.641 inches and 0.651 inches.

10. The valve cartridge of claim 1, wherein a ratio of a height of the installation ledge on the housing to a height of the housing is less than or equal to 0.49.

11. The valve cartridge of claim 10, wherein the height of the installation ledge is between 0.641 inches and 0.651 inches.

12. The valve cartridge of claim 1, wherein a pin secures the actuation mechanism in the housing such that the actuation mechanism is operable to pivot about the pin, and

wherein a ratio of a height of the mounting lug on the housing to a height of a center of the pin is less than or equal to 0.67.

13. The valve cartridge of claim 12, wherein the height of the installation ledge is between 0.641 inches and 0.651 inches.

14. The valve cartridge of claim 1, wherein the installation ledge is located below the actuation mechanism.

15. The valve cartridge of claim 14, wherein the installation ledge is located above the fluid control member.

16. The valve cartridge of claim 1, wherein the installation ledge extends around an outer circumference of the housing.

17. A valve cartridge for controlling a flow rate and a mixing ratio of cold water and hot water, and operatively fixed in a valve body by a holding member, the valve cartridge comprising:

a housing;

an actuation mechanism;

a movable control member; and

the control member is fixed to the frame body,

wherein the movable control member and the stationary control member are both disposed in the housing,

wherein movement of the actuating mechanism about a first axis is operable to move the movable control member relative to the fixed control member to vary the flow rate of at least one of the cold water and the hot water,

wherein movement of the actuating mechanism about a second axis is operable to move the movable control member relative to the fixed control member to change the mixing ratio of the cold water and the hot water,

18. The valve cartridge of claim 17, wherein the installation ledge is located below the actuation mechanism.

19. The valve cartridge of claim 18, wherein the installation ledge is located above the stationary control member.

20. The valve cartridge of claim 18, further comprising a mixing chamber within the housing for mixing cold and hot water, an

Wherein the mounting lugs are located above the mixing chamber.

21. The valve cartridge of claim 17, wherein the installation ledge extends around an outer circumference of the housing.