Tap valve assembly with a pair of oppositely extending valve stem portions and associated annular washer seals

Field of the Invention.

The present invention relates to tap valves and assemblies and in particular to tap valve assembly with greater flexibility in metering the flow through the tap and increased useable life..

Background Art.

Many taps, regardless of their type, possess a what is called a jumper valve which is the element that opens and closes to allow water to flow through the tap, controls the rate at which the water flows through the tap, and when adjacent the valve seat in the tap, prevents the flow of water. An exploded view of a typical tap assembly is illustrated in Figure 1.

The jumper valve is normally fitted with washer or "O" ring washer manufactured of plastic or nitrate, polyurethane or other composite material that meets standards for the country it is to be used in, which is slightly resilient and is located between the jumper valve and the valve seat. The slight resilience of the washer is valuable as it accounts for any small gaps in the jumper valve and the valve seat which are both normally metal, and thereby increases the sealing properties of the tap.

Normally, however, the plastic and other washers degrade over time, abraded by the flow of water and suspended particles in the water or by a combination of heat and cold, being over-tightened and therefore consistently deformed and the tap begins to leak. When this occurs, the tap washer or jumper valve would need to be changed. Many home handyman or do-it-yourself types of users attempt to change their own tap washers or the whole jumper valve. One of the main problems of changing a tap washer or jumper valve comes with the inconvenience. Normally, when tap washers or jumper valves are purchased, they are usually sold in a pack of more than the number required. This means that each time a washer or jumper valve needs to be changed, the user must purchase new washers or jumper valves as the washers or jumper valves they had left over from the last time that they needed them were probably misplaced. The process of changing a tap washer 10 is explained as follows and in figures 2 to 4: Traditional taps 1 On traditional taps 50, replacement of the tap washer 10 begins by unscrewing the

cover or shield 11 as illustrated in Figure 2. If the shield 11 sticks, a spanner 12 is normally used, protecting the shield 11 with a cloth.

2 The headgear nut 13 is then loosened, just above the body 14 of the tap 50, with a spanner. The headgear assembly 15 can then be lifted out. In most cases, the jumper valve 16 and washer 10 will come out with the headgear assembly 15 but sometimes they will be left lying in the tap body 14. This can be seen in Figure 3.

3 The washer 10 can then be prised off the jumper valve 16 body, or undo the fixing nut if there is one (penetrating oil may be required). This is illustrated in Figure 4.

4 Fit a new washer 10, refit the nut, and reassemble the tap 50. Restore water supply. If the tap drips it probably means the seat is worn, allowing water to leak past the washer. One cure is to fit a nylon seat insert, sold with a matching jumper and washer. A more permanent solution is to re-cut the old seat flat with a DIY tap reseating tool. Water byelaws All plumbing in a home or other building must conform to local water authority regulations. One of the main regulations relates to flow ratings for taps under which all ¹ A" taps must have a flow rating of either 6, 9 or 12 litres per minute and should be identified as such. It may be the case that a user of a tap may wish to use a tap with a 6 litres per minute rating at a higher output. This may particularly be the case when a home is purchased by a new owner who may wish to use the taps of the previous owners in a completely different configuration around the home. Without the present invention, this could be an expensive and time consuming chore.

It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

Summary of the Invention.

The present invention is directed to an improved tap valve assembly, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice. In one form, the invention resides in a tap valve assembly including a double ended tap valve, the valve having an annular body portion with a pair of annular surfaces, and a pair of valve stem portions, one valve stem portion extending from each annular surface.

The valve has an annular body portion with, a pair of annular body surfaces. Typically, when the valve is properly located in the tap assembly, the annular surfaces will generally be an upper annular surface and a lower annular surface. Adjacent each annular surface will normally be a tap washer. As discussed above, each tap washer will typically be a plastic or other washer that is slightly resilient and is located between the tap valve and a valve seat which is located in the tap body. The tap washers are normally at least slightly resilient to assist with the sealing of any small gaps between the tap valve and the valve seat which are both normally metal, thereby increasing the sealing properties of the tap. The annular body portion will generally be substantially similar in diameter to the tap washer provided. The tap valve will normally be provided with a rebated portion to receive a washer therein to assist with the location and security of the washer on the tap valve. The rebated portion will typically be located adjacent each annular surface. The valve also includes a pair of valve stem portions, one valve stem portion extending from each annular surface. The stem portions will generally be approximately centrally located on the valve. According to a particularly preferred embodiment, the valve will be circular in cross section with a longitudinal axis about which all components of the valve are based. The annular body portion and both stem portions will typically be co-axial.

One or both of the stem portions may be removeably attached to the annular body portion as an alternative to the whole valve being moulded or machined in one piece. This may be through the means of a threaded association with the annular body portion, preferably with a male thread on one end of the stem portion engageable with a female threaded receiver opening on the annular body portion. One or both of the stem portions may alternatively be a press type friction fit.

Either or both of the stem portions may be at least partially threaded to facilitate attachment to the spindle of the tap to which the valve is attached. If threaded, the stem can be screwed into the spindle and if not threaded, the stem can be simply pushed into the spindle.

Each stem portion will generally be at least partially either frustoconical or cylindrical. A valve may have stem portions which are both

frustoconical, both cylindrical or one stem may be frustoconical and one may be cylindrical.

According to an alternative environment, at least one of the stem portions may have a stepped profile with frustoconical or cylindrical parts. Each stepped stem may have at least two portions, and each portion may be either frustoconical or cylindrical.

Where frustoconical portions are provided, the angle of the frustum wall may be important in providing an appropriate flowrate through the tap. For example, a more steeply angled frustum wall, may result in less variation in flow when the tap is turned on and off, whereas the more shallow the angle of the frustum wall may provide greater variation in flow between the open and closed tap conditions.

The valve will typically be manufactured of metal, usually aluminium or brass. It is to be appreciated that as prior art valves are made of plastic, so may the valve of the present invention.

There will typically be at least one washer associated with each stem portion. The washers of the valve will normally be associated with the valve stem portions and may be mounted on the valve about the valve stem portions.

According to a preferred embodiment, the valve will include a plurality of washers associated with at least one of the stem portions. By using multiple washers, generally stacked one on top of the other, the valve of the invention can be included in a tap assembly and the flow rate through the tap can be adjusted according to the number of washers used. For example, for a higher flow rate, a single washer may be used, for a medium flow rate, a pair of washers may be used and for a low flow rate, three or more may be used. By adding more washers, the tap is prevented from opening as far as it would with only a single washer, thus regulating the flow rate through the tap. According to this embodiment, the washers may be of the same or differing thicknesses. Spacing members may alternatively be used instead of some or all of the washers. The washers may be attached relative to the valve by locating a preferably resilient, washer between a centrally located valve body and a spaced apart washer retaining portion. In addition to the washer retaining portion assisting to retain the washer in position on the valve, the portion may also act as an anti-water hammer

portion. The diameter of the portion is preferably slightly smaller than the diameter of the opening through which the water flows through the tap, thereby "slowly" shutting off the water flow.

In a second form, the invention resides in a tap valve assembly with a tap valve and a tap valve seat with a opening sized to engage with the tap valve to provide a metered flow through the opening.

The valve used in this aspect of the invention may be a double ended tap valve as described herein.

The valve has an annular body portion with a pair of annular body surfaces. Typically, when the valve is properly located in the tap assembly, the annular surfaces will generally be an upper annular surface and a loser annular surface. Adjacent each annular surface will normally be a tap washer. As discussed above, each tap washer will typically be a plastic washer which is slightly resilient and is located between the tap valve and a valve seat which is located in the tap body. The tap washers are normally at least slightly resilient to assist with the sealing of any small gaps between the tap valve and the valve seat which are both normally metal, thereby increasing the sealing properties of the tap.

The annular body portion will generally be substantially similar in diameter to the tap washer provided. The tap valve will normally be provided with a rebated portion to receive a washer therein to assist with the location and security of the washer on the tap valve. The rebated portion will typically be located adjacent each annular surface.

The valve also includes a pair of valve stem portions, one valve stem portion extending from each annular surface. The stem portions will generally be approximately centrally located on the valve. According to a particularly preferred embodiment, the valve will be circular in cross section with a longitudinal axis about which all components of the valve are based. The annular body portion and both stem portions will typically be co-axial.

Each stem portion will generally be at least partially either frustoconical or cylindrical. A valve may have stem portions which are both frustoconical, both cylindrical or one stem may be frustoconical and one may be cylindrical. Generally both stem portions will be cylindrical. There may be one or more annular plate members spaced from the annular surface(s) of the annular body

portion to assist with the location and security of the washers relative to the stem portion. Typically a washer will be located between an annular surface of the annular body portion and an annular plate member.

According to an alternative environment, at least one of the stem portions may have a stepped profile with frustoconical or cylindrical parts. Each stepped stem may have at least two portions, and each portion may be either frustoconical or cylindrical.

Where frustoconical portions are provided, the angle of the frustum wall may be important in providing an appropriate flowrate through the tap. For example, a more steeply angled frustum wall, may result in less variation in flow when the tap is turned on and off, whereas the more shallow the angle of the frustum wall may provide greater variation in flow between the open and closed tap conditions.

The valve will typically be manufactured of metal, usually stainless steel, brass or a form of plastic. It is to be appreciated that as prior art valves are made of plastic, so may the valve of the present invention.

The washers of the valve will normally be associated with the valve stem portions and may be mounted on the valve about the valve stem portions.

Alternatively, the tap valve used may be of a more conventional type, provided that the tap valve used includes a portion or the ability to engage with the tap valve seat to provide a metered flow through the opening in the seat.

The valve seat is normally manufactured of metal, usually brass. However, similarly to the double ended tap valve, it is appreciated that the valve seat may be manufactured from other materials such as plastics materials. The valve seat will generally be annular. The valve seat will generally include an annular outer portion and a hollow, frustoconical inner portion. The valve seat will normally have an opening therein and normally the opening will be a substantially central opening through the frustoconical portion. The opening may be sized to closely receive the valve stem but typically, there will be radial clearance between the valve stem and the opening, even when the valve stem is located in the opening. The radial clearance between the valve stem and the opening may determine the flow rate through the tap vale assembly. There may be predetermined clearances such as those that correlate to a 6, 9 and 12 litres for a ¹ A" tap or other rates as required

per minute flow rate. The valve may be sealed by the washer associated with the annular body portion abutting the annular outer portion of the valve seat.

In use, the stem of the tap valve engages with the opening in the valve seat to control or limit the flow rate of fluid through the tap in line with the local water authority regulations. One of the main regulations relates to flow ratings for taps, under which all Vi" taps must have a flow rating of either 6, 9 or 12 litres per minute (Other flow-rates may be applicable for different sized taps). The provision of a tap valve assembly according to the present invention allows not only rigorous control of the flow rate, but by providing a removable valve seat which can be swapped, a user may be able to simply and easily adjust the flow rate of the tap as required.

As stated above, the annular outer portion of the valve seat typically abuts the washer on the tap valve in order to close the valve assembly and prevent flow. Normally, the valve seat will be located in the tap body and associated with the flow pathway through the tap. The valve seat may be fixed in location or it may merely be maintained in position by the tap valve or any other means allowing easy replacement, for example threaded, glued or press friction fitted.

Normally, the underside of the annular outer portion and/or the frustoconical portion of the valve seat abuts the tap body to correctly locate the valve seat. Normally, the valve seat will be positioned so that the frustoconical portion of the valve seat is downstream of the annular outer portion of the valve seat. This will typically locate the frustoconical portion in an opening of the tap body.

Brief Description of the Drawings. Various embodiments of the invention will be described with reference to the following drawings, in which:

Figure 1 is a schematic view of a conventional tap assembly. Figure 2 is an illustration of a typical first step in replacing a tap washer in a conventional tap assembly. Figure 3 is an illustration of a typical second step in replacing a tap washer in a conventional tap assembly.

Figure 4 is an illustration of a typical third step in replacing a tap washer in a conventional tap assembly.

Figure 5 is a side view of a pair of double ended tap valves with associated tap washers according to a first aspect of the present invention.

Figure 6 is an end view of the tap valves illustrated in Figure 5. Figure 7 is a side view of a pair of double ended tap valves with associated tap washers and stems according to a second aspect of the present invention.

Figure 8 is an end view of the tap valves illustrated in Figure 7. Figure 9 is a side view of a double ended tap valve with associated tap washers and stems according to a third aspect of the present invention. Figure 10 is a bottom view of a tap valve seat used in conjunction with the double ended tap valve illustrated in Figure 9.

Figure 11 is a view of the components illustrated in Figures 9 and 10 in approximate positions.

Figure 12 is a side view of the components illustrated in Figures 9 and 10 in engagement.

Detailed Description of the Preferred Embodiment. According to a first preferred aspect of the invention, a double ended tap valve 51 is provided.

Alternative embodiments of the double ended tap valve 51 are illustrated in Figures 5 to 9. Each of the valves illustrated in Figures 5 to 9 include an annular body portion having a pair of annular surfaces 17 (obscured), and a pair of valve stem portions 18, one valve stem portion 18 extending from each annular surface.

Each valve 51 has an annular body portion 17 with a pair of annular body surfaces, which, when the valve 51 is properly located in the tap assembly, the annular surfaces are an upper annular surface and a lower annular surface. Adjacent each annular surface is a tap washer 10. As discussed above, each tap washer 10 is a plastic washer which is slightly resilient and is located between the tap valve 51 and a valve seat which is located in the tap body 14. The tap washers are at least slightly resilient to assist with the sealing of any small gaps between the tap valve 51 and the valve seat which are both normally metal, thereby increasing the sealing properties of the tap.

The annular body portion 17 is substantially similar in diameter to the tap washer 10 provided. The tap valve 51 is further provided with a rebated portion to receive a washer 10 therein to assist with the location and security of the washer on the tap valve. The valve 51 also includes a pair of valve stem portions 18, one valve stem portion 18 extending from each annular surface. The stem portions 18 are approximately centrally located on the valve 51. Each valve is circular in cross section with a longitudinal axis about which all components of the valve are based. The annular body portion and both stem portions are co-axial. Each stem portion 18 is either frustoconical or cylindrical. For example, the left valve stem in Figure 5 (upper) is frustoconical and the right is cylindrical and in Figure 5 (lower), both valve stems are cylindrical.

According to an alternative environment illustrated in Figures 7 and 8, the stem portions may have a stepped profile with frustoconical or cylindrical parts. Each stepped stem portion illustrated in Figures 7 and 8 has at least two portions, and each portion in these Figures is cylindrical.

The valves 51 are manufactured of metal, usually brass. The washers 10 of the valve are associated with the valve stem portions 18 and are mounted on the valve about the valve stem portions 18. According to a second preferred aspect as illustrated in Figures 10 to

12, the invention resides in a tap valve assembly with a tap valve 51 and a tap valve seat 52 with a opening 19 sized to engage with the tap valve 51 to provide a metered flow through the opening.

The valve used in this aspect of the invention is a double ended tap valve as described above having an annular body portion with a pair of annular body surfaces, a washer located adjacent each annular surface and a pair of valve stem portions, one valve stem portion extending from each annular surface.

There is an annular plate member 20 spaced from the annular surface of the annular body portion 18 to assist with the location and security of the washers 10 relative to the stem portion 18.

The valve seat 52 illustrated in Figure 10 in particular is manufactured of metal, usually aluminium or brass.

The valve seat 52 is annular and includes an annular outer portion 21 and a hollow, frustoconical inner portion 22. The valve seat 52 has an opening 19 therein and the opening 19 is a substantially central opening through the frustoconical portion 23. The opening 19 is sized to closely receive the valve stem 18 but, there is radial clearance between the valve stem 18 and the opening 19, even when the valve stem 18 is located in the opening 19. The radial clearance between the valve stem 18 and the opening 19 determines the flow rate through the tap valve assembly. There will be predetermined clearances that correlate to a 6, 9 and 12 litres per minute flow rate for a ¹ A" tap. In use, the stem 18 of the tap valve 51 engages with the opening 19 in the valve seat 52 to control or limit the flow rate of fluid through the tap in line with the local water authority regulations. The provision of a tap valve assembly according to the present invention allows not only rigorous control of the flow rate, but by providing a removable valve seat which can be swapped, a user may be able to simply and easily adjust the flow rate of the tap as required.

The annular outer portion 21 of the valve seat 52 will abut the washer 10 on the tap valve 51 as seen in Figure 12 in order to close the valve assembly and prevent flow.

Normally, the valve seat 52 is located in the tap body 14 and associated with the flow pathway through the tap. Normally, the underside of the annular outer portion 21 and/or the frustoconical portion 22 of the valve seat 52 abuts the tap body to correctly locate the valve seat 52. Normally, the valve seat 52 will be positioned so that the frustoconical portion 22 of the valve seat 52 is downstream of the annular outer portion 21 of the valve seat 52. In the present specification and claims (if any), the word "comprising" and its derivatives including "comprises" and "comprise" include each of the stated integers but does not exclude the inclusion of one or more further integers.

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or

characteristics may be combined in any suitable manner in one or more combinations.