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U.S. Patent Jul. 1, 1997 Sheet 1 of 4 Re. 35,545
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CERAMC WALWE U.S. Pat. No. 4,821,765 to Iqbal et al. and U.S. Pat. No.
4,651,770 to Denham et al. show valve cartridges including
Matter enclosed in heavy brackets appears in the ceramic discs and having gaskets which secure the discs in
original patent but forms no part of this reissue specifi the cartridge body. The gaskets also provide a sealing
cation; matter printed in italics indicates the additions surface adjacent the inlet of the valve cartridge. However, a
made by reissue. force exerted on the gaskets is transferred to the ceramic
This is a continuation of application Ser: No. 08/090,884, discs which makes it difficult to predict and control the force
filed Jul. 12, 1993, now abandoned, which is a reissue exerted on the discs when the cartridge is inserted into a
application of application Ser. No. 08/643,796, issued as faucet casting. Additionally, the gaskets may expand under
U.S. Pat, No. 5, 174,324. O certain conditions which would increase the force exerted on
the ceramic discs. Further, the gaskets may harden and crack
BACKGROUND OF THE INVENTION which may lead leaking and loss of the gasket's resilience.
The present invention relates to a ceramic disc valve When the gasket looses resilience it will not adequately
cartridge for faucets, spigots, taps, or the like, and more secure the ceramic discs within the valve body,
15
particularly to such a valve cartridge including a force-fit SUMMARY OF THE INVENTION
retainer which holds the ceramic discs in said valve.
Valve cartridges are known which use a rotating ceramic The present invention avoids the problems of prior valve
cartridges by including a retainer having a complementary
disc and a fixed ceramic disc adjacent one another to control shape to a cartridge valve body and force-fit on an end of the
the flow of fluids through the cartridge. The rotating and valve cartridge body to secure the ceramic discs therein. The
fixed ceramic discs have apertures therethrough such that the retainer includes a portion which contacts the end of the
rotating disc moves between a fully closed position wherein valve body to positively locate the retainer relative to the
the rotating disc completely blocks the apertures in the fixed valve body. Because a force-fit is relied on to secure the
disc and a fully open position wherein apertures in both discs retainer, there is no need to weld the retainer in place, which
are fully aligned. Additionally, the rotating disc may assume 25 would vary the dimension between the retainer and the disc
any position between the fully blocking and fully aligned stack, thereby eliminating positive location of the retainer
positions which allows the user to adjust fluid flow through relative to the valve body.
the cartridge. The contacting surfaces of the fixed and By providing such a positively located retainer, the pres
ceramic discs are manufactured to a tolerance that prevents sure exerted on the contacting surfaces of the ceramic discs
water passing therebetween. An advantage of the ceramic 30 is controlled and the life of the ceramic discs carried within
discs is that they do not require a large number of turns in the valve body is increased. Additionally, the valve body
order to move between the completely open and the com
pletely closed positions. Additionally, such ceramic disc may be easily manufactured. Furthermore, the coupling of
valves do not drip and last substantially longer than con the valve cartridge to the casting with which the valve
ventional gasket valves. 35
assembly is used is facilitated by the ring seal retainer, as the
Valve cartridges are also known which include two retainer may be shaped to interface with any casting. Thus,
ceramic discs secured within the valve body by a retainer. a standard valve body may be used in different faucets by
One such retainer is illustrated in U.S. Pat. No. 3,807.455 to providing different retainers each of which is adapted to
Farrell which shows a valve body and retainer which are interconnect the standard body with a respective faucet
made from plastic. The valve body and retainer are held casting. These and other objects, advantages and features
together by ultrasonic welding. However, plastic parts do not will become apparent upon review of the following speci
have sufficiently stable properties for long term durability. fication in conjunction with the drawings.
Additionally, ultrasonic welding increases the steps required BRIEF DESCRIPTION OF THE DRAWINGS
to assemble the valve and may alter the body or retainer FIG. 1 is a bottom elevational view of a valve assembly
shape during welding. 45
Other prior art retainers are illustrated in U.S. Pat. No. according to the invention;
3,881,570 to Ziebach et al. and U.S. Pat No. 3,831,621 to FIG. 2 is a side sectional view of the valve assembly
Anthony et al. Both of these retainers are received on the end according to the invention taken along the plane I-II of
of the valve body and held in a channel circumscribing the FIG. 1;
inside of the valve body. However, providing a circumscrib 50 FIG. 3a is a top elevational view of the valve assembly
ing channel on the inside of the valve body makes manu body according to the invention;
facturing of the valve body difficult. Further, the retainers of FIG. 3b is a side elevational view of the valve assembly
Ziebach et al. and Anthony et al. only support two sides of body according to the invention;
a sealing gasket adjacent the inlet end of the valve cartridge FIG. 3c is a bottom elevational view of the valve assem
and thus do not provide sufficient support for an O-ring. 55 bly body according the the invention;
U.S. Pat. No. 4331, 176 to Parkinson shows a valve FIG. 3d is a side sectional view of the valve assembly
cartridge including ceramic discs and a tail piece which is body taken along the plane III-III in FIG. 3a;
received within the valve assembly body. However, the tail FIG. 4a is a top elevational view of the actuator shaft
piece includes a projection received within the fixed ceramic according to the invention;
disc, and the tail piece exerts a force on the ceramic discs FIG. 4b is a side sectional view of the actuator stem taken
which varies. Thus, the tail piece may exert too much force along the line IV-TV in FIG. 4a;
on the ceramic disc which substantially reduces the life of FIG. 4c is a bottom elevational view of the actuator stem:
the valve discs or increase the force required to rotate the
ceramic discs. On the other hand, the tail piece may not exert FIG. 5a is a bottom elevational view of the plastic disc
sufficient force on an O-ring positioned between the tail 65 according to the invention;
piece and the fixed ceramic disc for the O-ring to provide a FIG. 5b is a side elevational view of the plastic disc
fluid seal. according to the invention;
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FIG. 5c is a top elevational view of the plastic disc Plastic disc 32 further includes three projections 90,92 and
according to the invention; 94. Slot 98 is parallel to projections 90,92 and 94, and thus
FIG. 6a is a top elevational view of the rotating ceramic is illustrated for left-hand control, whereas right-hand con
disc according to the invention; trol would be implemented by slot 86 being orthogonal to
FIG. 6b is a side elevational view of the rotating ceramic 5 projections 90,92 and 94. Rotating ceramic disc 34 includes
disc according to the invention; a central slot 98 and flat sides 104 and 106 parallel thereto.
The rotating ceramic disc also includes a first passage 100
FIG. 6c is a side sectional view of the rotating ceramic and a second passage 102 which provide passages for fluid.
disc taken along the plane VI-VI in FIG. 6a; Fixed ceramic disc 36 includes passages 110 and 112,
FIG. 7a is a top elevational view of the fixed ceramic disc through which fluid flows when passages 100 and 102 are
according to the invention; aligned therewith. The fixed disc further includes projec
FIG.7b is a side elevational view of the fixed ceramic disc tions 114 and 116 which are received within slots 64 and 66
according to the invention; of valve body 60 (FIG.2b) which hold the fixed disc against
FIG. 7c is a bottom elevational view of the fixed ceramic rotation. Apertures 110 and 112 include increasing area
disc according to the invention; 15 portions 118 and 120, respectively, which channel fluids
FIG. 8a is a top elevational view of the force fit retainer from the aperture in the force-fit retainer 40 to passages 100
according to the invention; and 102 of rotating ceramic disc 34.
FIG. 8b is a side sectional view taken along the line A brass force-fit retainer 40 (FIGS. 8a and 8b) is comple
VII-VIII in FIG. 8a; and mentary to the end 60 (FIG. 3d) of valve body 22. Thus,
20 retainer 40 is force-fit on the valve body and the friction
FIG. 9 illustrates a retainer clip of the invention. therebetween secures discs 32, 34 and 36 as well as O-ring
DESCRIPTION OF THE PREFERRED 38 within body 22. Retainer 40 includes a first annular
EMBODIMENT surface 124 which circumscribes retainer 40 for positioning
adjacent end 61 of body 22. A second circumscribing surface
A valve cartridge 20 according to an embodiment of the 25 126 projects orthogonally to surface 124 for positioning
invention is illustrated in FIGS. 1 and 2 and includes a valve adjacent circumscribing surface 63 in body 22. By position
assembly body 22 which receives actuating stem 24 carrying ing surface 124 against end 61, and by using a force-fit rather
a first O-ring 26 and a second O-ring 28, said actuating shaft than a welded construction, retainer 40 is positively located
being held in valve assembly body 22 by a retaining ring 30. relative to valve body 22. The distance between retainer 40
Additionally, valve cartridge 20 includes a disc stack com 30 and fixed disc 36 is thus positively established and the
prising a plastic disc 32 which is keyed to the actuating stem pressure on disc 36 and disc 34 is consistent from valve to
24, a rotating ceramic disc 34 which is also keyed to plastic valve. By "positively located" it is meant that the position of
disc 32, and a fixed ceramic disc 36 positioned adjacent retainer 40 relative to valve body 22 is constant and repeat
rotating ceramic disc34. An O-ring 38 is positioned between able from valve to valve. That would not be true if annular
force-fit retainer 40 and fixed disc 36. Retainer 40 holds 35 portion 124 did not engage end 61 of valve body 22, or if
O-ring 38 as well as discs 32.34 and 36 in body 22 and retainer 40 were welded in place, which operation could
carries an O-ring 42. Retainer 40 is shown with an aperture change the effective length of valve body 22.
43 comprising varying diameter portion 44 and a constant Annular surfaces 128 and 130 project orthogonally to one
diameter portion 46, although the diameter of the internal another and provide two of the four surfaces which contact
opening 43 may be uniform throughout retainer 40. O-ring 38 (FIG. 2) when it is sealed within valve body 22.
Valve assembly body 22 (FIGS. 3a-3d) is preferably An annular channel 132 has three orthogonal sides 136, 138
brass, and includes an upper portion 50 having flat sides 52 and 140, sides 136 and 138 being parallel to one another and
and 54 which provide surfaces by which a tool grips the substantially orthogonal to side surface 140. The three sides
cartridge body for rotating it or holding it against rotation. 136, 138 and 140 provide three of four sides for an O-ring
Upper portion 50 may also be advantageously provided with 45 42 (FIG. 2) which provides a seal between the end of valve
more than two flat surfaces. Body 22 further includes fluid cartridge 20 and the casting of a faucet (not shown) which
outlet apertures 56 and 58 through which fluid exits the receives the cartridge. An increasing diameter portion 143 of
cartridge. Additionally, a circumscribing counterbore 62 is retainer 40 channels fluid between smaller opening 144 and
positioned adjacent opening 60 for receiving O-ring 38 and larger opening 146 of the retainer. The larger diameter
retainer 40. A pair of slots 64 and 66 receive tabs of fixed 50 opening 146 is adjacent fixed disc 36. Thus, diameter 146 is
disc 36, as described below. Additionally, slots 68 and 70 large enough that the retainer does not interfere with passage
receive the blade of actuator shaft 24 (FIG. 4c) to limit the of water through passages 110 and 112 in disc 36. However,
rotation of actuating shaft 24, plastic disc 32, and rotating increasing diameter portion 143 would not be necessary
disc 34. where the opening 144 is large enough that it would not
Actuating shaft 24 (FIGS. 4a–4c) includes a serrated head 55 interfere with apertures 110 and 112. Although side 150 is
72 which receives a handle (not shown), the handle includ illustrated generally flat, side 150 may be shaped to connect
ing a screw (not shown) which is received within a threaded with any faucet casting. Thus, the cartridge may be used in
central aperture 74. A channel 80 receives retainer 30 to hold any faucet by providing a retainer which complements the
shaft 24 in the valve body. Channels 76 and 78 circumscribe casting in which it is used.
shaft 24 and receive O-rings 26 and 28. Actuating shaft 24 A retainer clip 30 is illustrated in FIG. 9. The shape of the
further includes a substantially rectangular projection 82 retainer clip is only illustrative, as the clip need only secure
having a blade 84 thereon. Projection 82 rotates within slots actuator shaft 24 in valve assembly body 22. Accordingly,
68 and 70 (FIG. 3c) and blade 84 is received in a slot in the clip need only be configured to resiliently engage the
plastic disc 32 (FIG. 5c) as described below. channel 80 and provide a large enough surface to prevent the
A disc stack includes plastic disc 32 (FIG. 2), rotating disc 65 clip from moving into opening 53 in body 22,
34 and fixed disc 36. Plastic disc 32 (FIGS. 4ia-4c) includes To assemble cartridge 20, actuator shaft 24 carrying
a slot 86 which receives blade 84 of actuating shaft 24. O-rings 26 and 28 is inserted through opening 60 in valve
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body 22 until the channel 80 projects past the opening 53. a sealing means adapted to be positioned adjacent said
O-rings 26 and 28 provide a seal which prevents fluid from fixed ceramic disc; and
flowing between actuating shaft 24 and body 22. The a force-fit retainer positioned on the second end of said
O-rings may either be self-lubricating or may have a lubri valve assembly body, an outside diameter of said
cant applied to the surface thereof. Channel 80 will be retainer at least equal to the outside diameter of said
properly positioned to receive the clip 30 when projection 82 valve body, said retainer having a stepped annular
is positioned within slots 68 and 70 of the valve body. Clip recess adapted to befrictionally secured on said second
30 is then inserted into channel 80 which secures the end of said body, whereby a portion of said retainer
position of shaft 24. Plastic disc 32 is then inserted into the contacts the inside surface of said valve body and a
valve body and blade 84 received within slot 86. Rotating 10 portion of said retainer contacts said second end of said
ceramic disc 3 is then inserted such that projection 90 is valve boy to positively locate said retainer relative to
received within slot 98, and projections 92 and 94 are said body, said retainer frictionally securing said seal
positioned between flat sides 104 and 106 of ceramic disc34 ing means and said disc stack within said body.
and body 22. The fixed ceramic disc is inserted by sliding 2. A valve cartridge including a fixed ceramic disc and a
projections 114 and 116 into grooves 64 and 66. The retainer 15 rotating ceramic disc, said discs for controlling fluid flow
with O-ring 38 carried thereon is then force-fit onto end 61 between an inlet and at least one outlet of said cartridge, said
of valve body 22. Surface 124 is thus positioned against cartridge comprising:
surface 61 on body 22, and surface 126 is positioned against a body having said outlet therein, said body comprising an
surface 63 to frictionally secure retainer 40 on body 20. opening at one end; and
Thus, cartridge 20 provides a one-piece unit which may be 20 a retainer comprising first and second orthogonal surfaces
inserted into a faucet. which are complementary to said body, said retainer
In operation, rotation of actuator shaft 24 causes rotation being positioned in said opening against first and
of plastic disc 32 and rotating ceramic disc 34 which are second orthogonal surfaces of said body, said first
keyed thereto. Fixed disc 36 will not rotate with rotating disc surface of said body being said one end of said body
34 as the projections 114 and 116 hold it in a fixed position. whereby said retainer is positively located on said body
Thus, openings 100 and 102 will be adjusted with respect to by said first surface of said retainer engaging said first
openings 110 and 112 whereby the flow of fluid through the surface of said body to positively locate said retainer
valve body between inlet 144 and outlets 56 and 58 will be relative to said body and thereby control the force
controlled. O-rings 26 and 28 prevent water from flowing applied by said retainer to said discs and said second
between valve stem 34 and valve body 22. O-ring 38 30 surface of said retainer frictionally engaging said sec
prevents water from flowing past retainer 40 and between ond surface of said body to frictionally secure said
disc 36 and valve body 22, as well as preventing water from retainer on said one end of said cartridge whereby said
flowing between retainer 40 and valve body. discs are secured with said valve cartridge body with a
positively controlled force pressing said discs into
It can thus be seen that a valve is shown which is easy to 35 engagement with one another.
manufacture and provides a secure assembly. Additionally, 3. A valve cartridge including a fixed ceramic disc and a
the retainer which is used to secure the components of the rotating ceramic disc, said discs for controlling fluid flow
valve cartridge within the valve body secures an O-ring between an inlet and at least one outlet of said cartridge, said
against the ceramic cartridges in a predetermined position cartridge comprising:
which exerts a predetermined amount of force against the a body having said outlet therein, said body comprising on
ceramic plates. The valve assembly thus avoids the problem opening at one end; and
of the prior art wherein the valve assembly bodies were aretainer comprising first and second orthogonal surfaces
difficult to manufacture and the retainers and sealing gaskets which are complementary to said body said retainer
exerted an indeterminate amount of force on the ceramic being positioned in said opening against two orthogo
discs and thus could cause premature wearing of the con 45 nal surfaces of said body, one of said orthogonal
tacting surface. The above description is considered that of surfaces of said body being said one end of said body,
the preferred embodiment only, and modifications of the whereby said retainer is positively located in and is
invention will occur to those who make or use the invention.
Therefore, it is to be understood that the embodiments frictionally secured to said body and secures said discs
shown in the drawings and described above are merely for within the valve cartridge body, and wherein said
illustrative purposes and are not intended to limit the scope 50 retainer is stepped whereby said first surface of said
of the invention, which is defined by the following claims as retainer is at a diameter of said body, and said second
surface of said retainer is at a diameter which is
interpreted according to the principles of patent law. substantially equal to an inside diameter of said body.
The embodiments of the invention in which an exclusive
property or privilege is claimed are defined as follows. 4. The valve cartridge as defined in claim 1, wherein said
1. A ceramic, valve cartridge comprising: 55 retainer is ring-like and includes a central opening through
a generally cylindrical valve body including an opening which fluid enters said valve body.
5. The valve cartridge as defined in claim 1, wherein said
on first and second opposite ends of said body, and at retainer has a first side which contacts said second end of
least one opening intermediate said ends of said body; said valve body and a second side which includes an annular
an actuator stem carried by said housing, a portion of said channel for receiving an O-ring therein.
actuator stem projecting through the opening on said 6. The valve cartridge as defined in claim 2 wherein said
first end of said body, and rotating within said body; retainer carries a first resilient ring which is positioned
a disc stack carried within said body comprising a rotating between said retainer and said fixed ceramic disc to provide
ceramic disc, and a fixed ceramic disc, said stem and a fluid seal, said retainer having third and fourth orthogonal
said rotating ceramic disc being operably connected, 65 surfaces which contact said resilient ring.
and said fixed ceramic disc being positioned adjacent 7. The valve cartridge as defined in claim 6 wherein said
said rotating ceramic disc; ring seal retainer includes a channel which receives a second
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7 8
resilient ring for providing a seal between said valve car 16. A valve cartridge including a fixed ceramic disc and
tridge and a casting with which said valve assembly is used. a rotating ceramic disc, said discs controlling fluid flow
8. The valve cartridge as defined in claim3, wherein said between an inlet and at least one outlet of said cartridge,
second surface of said retainer is adapted to be parallel to the said cartridge comprising:
inside surface of said body when said retainer is inserted in 5
a body having said at least one outlet therein and includ
said body, whereby said inside surface of said body fric ing an opening at one end and further including first
tionally contacts said second surface of said retainer. and second orthogonal surfaces, and
9. The valve cartridge as defined in claim 2, wherein said a retainer comprising first and second orthogonal sur
retainer and said body are brass. faces which are complementary to said first and second
10. The ceramic valve cartridge as defined in claim 1, 10
orthogonal surfaces of said body, said retainer being
wherein said valve body and said retainer are metal. positioned proximate said opening against first and
11. The ceramic valve cartridge as defined in claim 10, second orthogonal surfaces of said body, said first
wherein said valve body and said retainer are brass. surface of said body being accessible from said one end
12. The ceramic valve cartridge as defined in claim 1, of said body by said retainer whereby said retainer is
wherein said stepped annular recess includes a first annular 15
positively located on said body by said first surface of
surface for contacting said second end of said valve body, a said retainer engaging said first surface of said body
second surface orthogonal to said first surface for contacting
said inside surface of said valve body, a third surface which thus positively locates said retainer relative to
orthogonal to said second surface for contacting a resilient said body and thereby controls the force applied by said
ring, and a fourth surface orthogonal to said third surface for retainer to said discs, and said second surface of said
contacting said resilient ring. retainer frictionally engaging said second surface of
13. The ceramic valve as defined in claim 2 wherein said said body to frictionally secure said retainer on said
retainer includes a channel circumscribing said central open one end of said cartridge whereby said discs are
ing for receiving a resilient ring, said circumscribing channel secured with said valve cartridge body with a positively
having three surfaces for contacting said resilient ring. 25 controlled force pressing said discs into engagement
with one another:
14. The valve cartridge as defined in claim 6 wherein said 17. A valve cartridge including a fixed ceramic disc and
second surface is orthogonal to said third surface. a rotating ceramic disc, said discs controlling fluid flow
15. A ceramic valve cartridge comprising:
a generally cylindrical rigid valve body including an between an inlet and at least one outlet of said cartridge,
said cartridge comprising:
opening on first and second opposite ends of said body; a body having said outlet therein, said body including an
an actuator stem carried by said body, a portion of said opening at one end and a step defining first and second
actuator stem projecting through the opening on said orthogonal surfaces; and
first end of said body, and rotating within said body; a retainer comprising third and fourth orthogonal sur
a disc stack carried within said body comprising a 35 faces which are complementary to said first and second
rotating ceramic disc and a fixed ceramic disc, said orthogonal surfaces of said body, said retainer being
stem and said rotating ceramic disc being operably positioned proximate said opening against said first
connected, and said fixed ceramic disc being positioned and second orthogonal surfaces of said body, said
adjacent said rotating ceramic disc, orthogonal surfaces of said body being accessible from
a sealing means positioned adjacent said fied ceramic said one end of said body and engageable by said
disc; and retainer, whereby said retainer is positively located
an inflexible retainer force fit onto the second end of said relative to said body by engagement of said first and
valve body, said retainer having a stepped annular third orthogonal surfaces and is frictionally secured to
recess frictionally secured proximate said second end said body by engagement of said second and fourth
of said body with a portion of said stepped annular 45 orthogonal surfaces and thus secures said discs within
recess of said retainer frictionally engaging said valve the valve cartridge body, and wherein said fourth
body and an adjacent portion of said stepped annular orthogonal surface of said retainer has a diameter
recess of said retainer abutting said valve body to which is adapted to be frictionally force-fit into secure
positively locate said retainer relative to said valve engagement with said second orthogonal surface of
body, said retainer securing said sealing means and 50 said body.
said disc stack within said valve body whereby to
assure a predetermined force on the disc stack.