Ceramic disc valve cartridge

Abstract

A valve cartridge (120) includes a valve body (102) that defines a hot water port (198) that has a first end and a second end. The valve body includes a cold water port (199) that has a first end and a second end. The valve cartridge includes a rotatable control stem (134) that is disposed at least partially within the valve body. The valve body includes a main flow control disc (154) that is coupled to the control stem. The main flow control disc has a cold water opening (184) and a hot water opening (182). The valve cartridge includes a first auxiliary disc (156a) positioned between the first end of the hot water port and the main flow control disc and a second auxiliary disc (156b) positioned between the first end of the cold water port and the main flow control disc.

Description

<DP=1>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²CERAMIC DISC VALVE CARTRIDGE²Cross Reference to Related Application ²This application is being filed on 30 October 2018, as a PCT International²patent application, and claims priority to U.S. Provisional Patent Application ²Serial²No. 62 / 580,330, filed November 1, 2017, which application is hereby ²incorporated²by reference in its entirety.²Background ²Valve cartridges are used to control the mixing of hot and cold fluid (e.g.,²water) from input lines before the fluid is sent to output structures, such as ²²showerheads and bathtub spigots. Often these valve cartridges are connected ²to, and ²controlled by, a single rotatable handle. As the handle is rotated, the water ²that is ²output from the output structures gets colder or hotter (i.e., the proportion ²of cold ²and hot water is changed) via the valve cartridge. To ensure proper sealing ²and to²increase the longevity of the valve cartridges, valve cartridges often include ²²components that limit how easily the handle, and thereby valve cartridge, can ²be ²rotated. Therefore, there is a need for a valve cartridge that has adequate ²longevity ²and that can be easily rotated for operation.²Summary ² The present disclosure relates generally to mixing valves. In one possible²configuration, and by non-limiting example, the mixing valve disclosed herein ²includes a plurality of ceramic discs.²In one example of the present disclosure, a valve cartridge is disclosed. The ²valve cartridge includes a valve body that defines a hot water port that has a ²first end²and a second end. The valve body includes a cold water port that has a first ²end and ²a second end. The valve cartridge includes a rotatable control stem that is ²disposed ²at least partially within the valve body. The valve body includes a main flow ²control ²disc that is coupled to the control stem. The main flow control disc has a ²cold water ²opening and a hot water opening. The valve cartridge includes a first ²auxiliary disc²positioned between the first end of the hot water port and the main flow ²control disc ²and a second auxiliary disc positioned between the first end of the cold water ²port ²and the main flow control disc.²1²<DP=2>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²In another example of the present disclosure, a valve cartridge is disclosed. ²The valve cartridge includes a valve body that includes a hot water port that ²has a ²first end and a second end. The valve body also includes a cold water port ²that has a ²first end and a second end. The valve cartridge includes a rotatable control ²stem that²is disposed at least partially within the valve body. The valve cartridge ²includes a ²main flow control disc that is coupled to the control stem. The main flow ²control ²disc includes a cold water opening and a hot water opening. The cold water ²opening ²and the hot water opening selectively correspond with the hot water port and ²cold ²water port, respectively. The valve cartridge includes at least one auxiliary ²disc²positioned adjacent to, and in contact with, the main flow control disc. The ²at least ²one auxiliary disc is positioned around a first end of only a single hot or ²cold water ²port.²In another example of the present disclosure, a valve cartridge is disclosed. ²The valve cartridge includes a rotatable control stem that is disposed at ²least²partially within a valve body. The valve cartridge includes a main flow ²control disc ²that is coupled to the control stem. The main flow control disc has a cold ²water ²opening and a hot water opening. The valve cartridge includes a first ²auxiliary disc ²that has a first face positioned adjacent to, and in contact with, the main ²flow control ²disc. The first auxiliary disc has a central aperture. The valve cartridge ²includes a²second auxiliary disc having a first face positioned adjacent to, and in ²contact with, ²the main flow control disc. The second auxiliary disc has a central aperture. ²The ²valve cartridge includes a first seal positioned adjacent to, and in contact ²with, a ²second, opposite face of the first auxiliary disc. The valve cartridge ²includes a ²second seal positioned adjacent to, and in contact with, a second, opposite ²face of²the second auxiliary disc. The hot water opening of the main control disc ²selectively ²corresponds with the central aperture of the first auxiliary disc, and the ²cold water ²opening of the main control disc selectively corresponds with the central ²aperture of ²the second auxiliary disc. The main flow control disc, first auxiliary disc, ²and second ²auxiliary disc are constructed of a ceramic material.² A variety of additional aspects will be set forth in the description that ²follows. The aspects can relate to individual features and to combinations of ²features. It is to be understood that both the foregoing general description ²and the ²following detailed description are exemplary and explanatory only and are not²2²<DP=3>²CA 03081417 2020-04-29²WO 2019 / 089605 ²PCT / US2018 / 058224²restrictive of the broad inventive concepts upon which the embodiments ²disclosed ²herein are based.²Brief Description of the Drawings ²The following drawings are illustrative of particular embodiments of the²present disclosure and therefore do not limit the scope of the present ²disclosure. The ²drawings are not to scale and are intended for use in conjunction with the ²explanations in the following detailed description. Embodiments of the present ²²disclosure will hereinafter be described in conjunction with the appended ²drawings, ²wherein like numerals denote like elements.² FIG. 1 illustrates a schematic view of a water delivery system, according to ²one embodiment of the present disclosure.²FIG. 2 illustrates a perspective view of a valve cartridge, according to one ²embodiment of the present disclosure.²FIG. 3 illustrates another perspective view of the valve cartridge of FIG. 2.² FIG. 4 illustrates a top view of the valve cartridge of FIG. 2.²FIG. 5 illustrates an exploded view of the valve cartridge of FIG. 2.²FIG. 6 illustrates a cross-sectional view of the valve cartridge along line 6-²6²in FIG. 4.²FIG. 7 illustrates a cross-sectional view of the valve cartridge along line 7-²7² in FIG. 4.²FIG. 8 illustrates a perspective cross-sectional view of a portion of the ²valve²cartridge of FIG. 2.²FIG. 9 illustrates a perspective view of a flow control disc and a pair of²auxiliary discs of the valve cartridge of FIG. 2 in an OFF position.² FIG. 10 illustrates a bottom view of the flow control disc and the pair of²auxiliary discs of FIG. 9 in the OFF position.²FIG. 11 illustrates a top view of the flow control disc and the pair of²auxiliary discs of FIG. 9 in the OFF position.²FIG. 12 illustrates a top view of the flow control disc and the pair of² auxiliary discs of FIG. 9 in an ON position.²FIG. 13 illustrates a top view of the flow control disc and the pair of²auxiliary discs of FIG. 9 in another ON position.²3²<DP=4>²CA 03081417 2020-04-29²WO 2019 / 089605 ²PCT / US2018 / 058224²FIG. 14 illustrates a top view of the flow control disc and the pair of ²auxiliary discs of FIG. 9 in another ON position.²Detailed Description ²Various embodiments will be described in detail with reference to the²drawings, wherein like reference numerals represent like parts and assemblies ²throughout the several views. Reference to various embodiments does not limit ²the ²scope of the claims attached hereto. Additionally, any examples set forth in ²this ²specification are not intended to be limiting and merely set forth some of the ²many ²possible embodiments for the appended claims.² The valve cartridge disclosed herein has several advantages. In some ²examples, the valve cartridge includes ceramic flow control discs to increase ²the ²longevity of the valve cartridge and to reduce the torque required to rotate a ²control ²stem of valve cartridge.²FIG. 1 shows a schematic view of a water delivery system 100. In the²depicted example. The water delivery system 100 includes a valve body 102 that ²²includes a hot water source arm 104 that is in communication with a hot water ²source 106, a cold water source arm 108 that is in communication with a cold ²water ²source 110, a first fluid delivery arm 112 that is in communication with a ²first fluid ²delivery device 114, and a second fluid delivery arm 116 that is in ²communication²with a second fluid delivery device 118. In some examples, the valve body 102 ²includes only a single fluid delivery arm 112, 116. In other examples still, ²the water ²delivery system 100 includes only a single fluid delivery device 114, 118. In ²other ²examples still, the water delivery system 100 includes a plurality of fluid ²delivery ²devices 114, 118.² The valve body 102 includes a valve cartridge 120 removably disposed ²therein near an intersection of the hot water source arm 104, the cold water ²source ²arm 108, the first fluid delivery arm 112, and the second fluid delivery arm ²116. As ²shown, the water delivery system 100 includes a handle 122 in communication ²with ²the valve cartridge 120. As the handle 122 is rotated, the handle 122 operates ²the²valve cartridge 120 so that the valve cartridge 120 selectively delivers a ²stream of ²water 124 (i.e., either hot, cold, or a mixture of hot and cold) to the first ²and / or ²second fluid delivery device 114, 118. In some examples, the valve cartridge ²120, ²handle 122, and other associated components may be referred to as a mixing ²valve.²4²<DP=5>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²The valve body 102 can be a standard behind the wall valve body 102 that is ²commonly used in showers. In other examples, the valve body 102 can be a valve ²²body commonly utilized in a sink faucet.²The fluid delivery devices 114, 118 can be spouts, spigots, heads, or the like²that are configured to deliver the stream of water 124 to the user operating ²the valve ²cartridge 120. In some examples, the fluid delivery devices 114, 118 can be a ²showerhead and a bathtub spigot.²FIGS. 2 and 3 show a perspective view of the valve cartridge 120. FIG. 4 ²shows a top view of the valve cartridge 120.² The valve cartridge 120 includes a main body 125, a first end 126, a second ²end 128, and a mixing assembly 130 mated with a pressure balance assembly 132. ²²At the first end 126, the valve cartridge 120 includes a stem 134 protruding ²from the ²mixing assembly 130. At the second end 128, the valve cartridge 120 includes a ²hot ²water inlet 136 and a cold water inlet 138. The hot water inlet 136 is ²configured to²receive hot water from the hot water source 106 via the hot water source arm ²104 of ²the valve body 102, and the cold water inlet 138 is configured to receive cold ²water ²from the cold water source 110 via the cold water source arm 108 of the valve ²body ²102. The valve cartridge 120 also includes a flange 139 for mounting the valve ²²cartridge 120 to the valve body 102.² The mixing assembly 130, as will be discussed in more detail here, is ²configured to selectively mix hot water received at the hot water inlet 136 ²with cold ²water received at the cold water inlet 138 and supply the water stream 124 via ²a ²plurality of outlets 140 disposed around the main body 125. The water stream ²124 is ²then delivered to the first and / or second fluid delivery device 114, 118 via ²the valve²body 102, as noted above. In some examples, after the water stream 124 leaves ²the ²outlets 140, the water stream 124 flows between an inner surface of a ²cylindrical ²port (not shown) of the valve body 102 and the pressure balance assembly 132 ²of the ²valve cartridge 120, which is positioned within the cylindrical port. In some ²examples, the mixing assembly 130 is positioned outside of the valve body 102² The pressure balance assembly 132 is configured to balance the pressure of ²the hot and cold water received at the hot and cold water inlets 136, 138. In ²some ²examples, the pressure balance assembly 132 can be a spool-type pressure ²balancing ²valve of the type known in the art. One example of a pressure balance assembly ²is ²disclosed in U.S. Patent No. 7,100,630, the disclosure of which is hereby²5²<DP=6>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²incorporated by reference in its entirety. In some examples, the pressure ²balance ²assembly 132 is positioned inside of the valve body 102.²The stem 134 is rotatable about a central axis 142 relative to the main body ²125 of the valve cartridge 120. The stem 134 is configured to be attached the ²handle²122. In some examples, the handle 122 can be a knob, a dial, or other like ²structure.²FIG. 5 shows an exploded view of the valve cartridge 120. The mixing²assembly 130 and the pressure balance assembly 132 are shown separated by a ²dashed line.²The mixing assembly 130 is shown to include a hot water limiter 144, a²housing 146, an outer seal 148, the stem 134 which includes a shaft 150 and a ²head ²152, and a main flow control disc 154. The pressure balance assembly 132 is ²shown ²to include a pair auxiliary discs 156a, 156b, a pair of auxiliary disc seals ²158a, 158b, ²a housing 160, and a pair of screens 162a, 162b.²The hot water limiter 144 is used to limit the amount of hot water that is²mixed with cold water received in the water stream 124 that is provided at the ²²outlets 140. In some examples, the hot water limiter 144 limits the rotation ²of the ²stem 134 when positioned within the housing 146. In some examples, the hot ²water ²limiter 144 can be a hot water limiter of the type known in the art.²The housing 146 of the mixing assembly 130 is part of the main body 125 of²the valve cartridge 120. In the depicted embodiment, the housing 146 can ²include ²exterior threads 147 to receive other components of the water delivery system ²100 ²(not shown) and the flange 139.²The outer seal 148 is configured to be positioned around the housing 146 to ²form a seal with the valve body 102 and the housing 146. Specifically, the ²outer seal²148 is positioned around the housing 146 at a location between the flange 139 ²and ²an end 141 that interfaces with the pressure balance assembly 132. In some ²examples, the outer seal 148 is a rubber 0-ring.²The shaft 150 of the stem 134 is configured to interface with the handle 122 ²and the stem head 152 so that rotation of the handle 122 about the central ²axis 142 of²the stem 134 rotates the shaft 150 and the stem head 152. In some examples, ²the ²shaft 150 is at least partially positioned within the housing 146. The stem ²134 also ²includes a seal 164 positioned around the shaft 150 to form a seal between the ²shaft ²150 and the housing 146. The shaft 150 is connected to the head 152 at a ²mating²6²<DP=7>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²interface 166. In some examples, the mating interface 166 is a splined ²interface. In ²some examples, the shaft 150 is secured to the head 152 by way of a fastener ²168. ²The head 152 of the stem 134 is configured to be attached to the shaft 150 at ²a first end 170 and configured to interface with the flow control disc 154 at ²a second²end 172. The stem head 152 includes a plurality of projections 180 at the ²second end ²172 that are sized and shaped to interface within the flow control disc 154 to ²transfer ²torque between the stem 134 and the main flow control disc 154. When mated ²with ²the flow control disc 154, rotation of the stem head 152 about the central ²axis 142 of ²the stem 134 causes rotation of the flow control disc 154 about the about the ²central² axis 142.²The flow control disc 154 includes a hot water opening 182, a cold water ²opening 184, and a plurality of periphery recesses 186. As the flow control ²disc 154 ²is rotated by the stem 134, the hot water opening 182 and the cold water ²opening ²184 selectively align with hot and cold water ports 198, 199 (shown in FIG. 6)²defined by housing 160 of the pressure balance assembly 132. The hot and cold ²water ports 198, 199 are in fluid communication with the hot and cold water ²inlets ²136, 138, respectively. As the hot and cold water openings 182, 184 of the ²flow ²control disc 154 selectively align with the hot and cold water ports 198, 199, ²water is ²proportionally mixed to create the water stream 124.² The periphery recesses 186 of the flow control disc 154 are sized and shaped ²to receive the projections 180 of the stem head 152 to facilitate simultaneous ²²rotation, and torque transfer, of the stem head 152 and the flow control disc ²154.²The flow control disc 154 can be constructed from a wide range of materials ²such as plastic or metal. In one example, the flow control disc 154 is ²constructed² from a ceramic material such as aluminum oxide.²The flow control disc 154 is configured to mate with, and be in contact with, ²the first and second auxiliary discs 156a, 156a at a bearing face 155 (i.e. an ²interface ²surface). The flow control disc 154 is rotatable relative to the first and ²second ²auxiliary discs 156a, 156a.² The first and second auxiliary discs 156a, 156a have a first side 190a, 190b ²that is configured to mate and be in contact with the flow control disc 154. ²In some ²examples, at the first side 190, the first and / or second auxiliary disc 156a, ²156b ²includes raised ridges / rings that are configured to be in contact with the ²bearing face ²155 of flow control disc 154, thereby reducing the contact patch between the ²flow²7²<DP=8>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²control disc 154 and the first and second auxiliary discs 156a, 156b. At a ²second side ²192a, 192b, the first and second auxiliary discs 156a, 156a are configured to ²be in ²contact with the auxiliary disc seals 158a, 158b. Further, the first and ²second ²auxiliary discs 156a, 156a are configured to be non-rotatably positioned ²within the² housing 160 of the pressure balance assembly 132.²In the depicted embodiment, the first and second auxiliary discs 156a, 156a ²each include a central aperture 194a, 194b. The central apertures 194a, 194b ²are ²configured to align with the hot and cold water ports 198, 199 of the pressure ²²balance assembly 132.² The first and second auxiliary discs 156a, 156b can be constructed from a ²wide range of materials such as plastic or metal. In one example, the first ²and second ²auxiliary discs 156a, 156a are constructed from a ceramic material such as ²aluminum oxide.²The first and second auxiliary disc seals 158a, 158b are configured to be²positioned between the first and second auxiliary discs 156a, 156b and the ²housing²160. In some examples, the seals 158a, 158b are flexible and configured to be ²compressed. In some examples, the seals 158a, 158b are rubber seals.²The housing 160 of the pressure balance assembly 132 is part of the main ²body 125 of the valve cartridge 120. The housing 160 houses a pressure ²balancing²valve 197 (shown in FIG. 6) and defines the hot and cold water ports 198, 199 ²(shown in FIG. 6)²The screens 162a, 162b are sized and shaped to positioned over the hot and ²cold inlets 136, 138 to aid in filtering the water from the hot and cold ²sources 106, ²110 before the water enters the valve cartridge 120.²FIG. 6 shows a cross sectional view of the valve cartridge 120 along line 6-6 ²in FIG. 4. As shown, the pressure balance assembly 132 includes the pressure ²balance valve 197. Further, the housing 160 defines the hot water port 198 and ²the ²cold water port 199. The hot water port 198 and the cold water port 199 each ²include ²first ends 191a, 191b and second ends 193a, 193b. The first ends 191a, 191b of ²the²hot and cold water ports 198, 199 are adjacent the control disc 154 while the ²second ²ends 193a, 193b are adjacent the hot and cold water inlets 136, 138. Each hot ²and ²cold water port 198, 199 corresponds with, and is in fluid communication with, ²the ²hot and cold water inlets 136, 138 respectively. In the depicted example, the ²hot and²8²<DP=9>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²cold water ports 198, 199 each travel through the pressure balance valve 197 ²between the first ends 191a, 191b and second ends 193a, 193b.²The stem 134 is shown to be positioned within a cavity 200 defined by the ²housing 146 of the mixing assembly 130. Specifically, the stem head 152 is ²shown²to be positioned between a stop shoulder 202 ( which can include a bushing) at ²the ²second end 172 of the head 152 and the main control disc 154 at the first side ²170 of ²the head 152. In some examples, when assembled, the stem 134, via the head ²152, ²exerts a force toward the first and second auxiliary discs 156a, 156b to ²partially ²compress the first and second auxiliary disc seals 158a, 158b between the ²housing²160, specifically within recesses 203a, 203b defined by the housing 160, and ²the ²first and second auxiliary discs 156a, 156b.²The first and second auxiliary discs 156a, 156b are spaced apart from one ²another within the recesses 203a, and 203b. Each auxiliary disc 156a, 156b ²extends ²a common distance from the hot and cold water openings 182, 184 of the control²disc 154. The first and second auxiliary discs 156a, 156b concurrently ²interface to²different portions of the bearing face 155 of main flow control disc 154 ²during ²operation.²The flow control disc 154 is positioned within an outlet cavity 204 that is ²defined between the housing 146 of the mixing assembly 130 and the housing 160 ²of²the pressure balance assembly 132. The outlet cavity 204 is in communication ²with ²the plurality of outlets 140, as shown in FIGS. 7 and 8. The hot and cold ²water ²openings 182, 184 of the flow control disc 154 are configured to selectively ²place ²the central apertures 194a, 194b of the first and second auxiliary discs 156a, ²156b in ²fluid communication with the outlet cavity 204 and thereby the outlets 140. In ²some²examples, water flows into the hot and cold water ports 198, 199 after passing ²²through the pressure balance valve 197.²During operation of the valve cartridge 120, as the flow control disc 154 is ²rotated by the stem 134, the bearing face 155 of the flow control disc 154 ²contacts ²the first sides 190a, 190b of first and second auxiliary discs 156a, 156b. ²Such²contact between the bearing face 155 and the first and second auxiliary discs ²156a, ²156a effects the amount of torque required to rotate the stem 134. In some ²examples, ²the required torque to rotate the stem 134 is less than about 12.5 in-lbs of ²torque. In ²some examples, the required torque to rotate the stem 134 is between about 5 ²in-lbs ²and 8 in-lbs of torque. In some examples, the torque required to rotate the ²stem 134²9²<DP=10>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²from an OFF positioned (i.e., no water flowing out of the outlets 140) is ²higher than ²the torque required to the rotate the stem 134 when the stem 134 is in the ON ²position (i.e., water flowing from the outlets 140).²FIG. 7. shows a cross section along line 7-7 in FIG. 4. As shown, the outlet²cavity 204 is in communication with the outlets 140 to allow fluid within the ²outlet ²cavity 204 to exit the valve cartridge 120 via the outlet 140.²FIG. 8 shows a cross section that illustrates the fluid communication between²the hot water port 198 and the outlet 140. Specifically, fluid communication ²is ²illustrated by a dashed line F and fluid flows between the hot water port 198, ²central²aperture 194a of the first auxiliary disc 156a, hot water opening 182 of the ²flow ²control disc 154, outlet cavity 204, and the outlet 140. Substantially similar ²fluid ²communication selectively exists between the cold water port 199, the central ²aperture 194b of the second auxiliary disc 156b, cold water opening 184 of the ²flow ²control disc 154, outlet cavity 204, and the outlet 140.²As shown in FIG. 8, the first auxiliary disc seal 158a is positioned within ²the ²recess 203a. Specifically, the first auxiliary disc seal 158a is positioned ²between a ²shoulder 205a of the recess 203a and the second side 192a of the first ²auxiliary disc ²156a. The first auxiliary disc seal 158a aids in preventing water from ²traveling ²around the first auxiliary disc 156a, between the first auxiliary disc 156a ²and the² recess 203a.²As noted above, because the flow control disc 154 is rotatable relative to the ²²first and second auxiliary discs 156a, 156b, and thereby the hot and cold ²ports 198, ²199, the alignment of the hot and cold water openings 182, 184 of the flow ²control ²disc 154 can be altered to meter the amount of water that passes from the hot ²and²cold water ports 198, 199 and into the outlet cavity 204. When the hot water ²opening ²182 and the central aperture 194a are at least partially aligned, fluid then ²flows from ²the central aperture 194a, through the hot water opening 182 and into the ²outlet ²cavity 204. When the hot water opening 182 and the central aperture 194a are ²not ²aligned, fluid is prevented from traveling out of the central aperture 194a by ²way of²the bearing face 155 of the control disc 154. Such is the case with the cold ²water ²opening 184 and the central aperture 194b as well.²FIGS. 9-14 show the main flow control disc 154 and the first and second ²auxiliary discs 156a, 156b in the same mated relationship that the main flow ²control²<DP=11>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²disc 154 and the first and second auxiliary discs 156a, 156b exist in within ²the ²assembled valve cartridge 120.²FIG. 9 shows a perspective view of the main flow control disc 154 and the ²first and second auxiliary discs 156a, 156b when the main flow control disc ²154 is in²an OFF position. As shown, the central apertures 194a, 194b of the first and ²second ²auxiliary discs 156a, 156b are misaligned with the hot and cold openings 182, ²184 of ²the control disc 154.²In some examples, a maximum contact surface area between the bearing face ²155 of the flow control disc 154 and the first sides 190a, 190b of first and ²second²auxiliary discs 156a, 156b is about 35 % of the surface of area of the bearing ²face ²155 of the control disc 154. In some examples, less than the entire bearing ²face 155 ²contacts the first sides 190a, 190b of first and second auxiliary discs 156a, ²156b. In ²some examples, the control disc 154 and first and second auxiliary discs 156a, ²156b ²are constructed of the same material. In some examples, the control disc 154 ²and²first and second auxiliary discs 156a, 156b are both constructed of a ceramic ²material. In other examples, the control disc 154 and first and second ²auxiliary discs ²156a, 156b are constructed of the different materials. In other examples ²still, at least ²one of the bearing face 155 of the control disc 154 and the first sides 190a, ²190b of ²the first and second auxiliary discs 156a, 156b include a low friction ²coating.² FIG. 10 shows a bottom view of the main flow control disc 154 and the first ²and second auxiliary discs 156a, 156b when the flow control disc 154 is in an ²OFF ²position.²FIG. 11 shows a top view of the main flow control disc 154 and the first and²second auxiliary discs 156a, 156b when the flow control disc 154 is in an OFF² position.²FIG. 12 shows a top view of the flow control disc 154 and the first and ²second auxiliary discs 156a, 156b when the flow control disc 154 in an ON ²position. ²The control disc 154 is considered to have an ON position when at least one of ²the ²hot and cold openings 182, 184 are at least partially aligned with at least ²one of the²central apertures 196a, 196b of the first and second auxiliary discs 156a, ²156b. In ²some examples, the control disc 154 has a plurality of ON positions. As shown ²in ²FIG. 12, the central aperture 194b of the second auxiliary disc 156b is ²aligned with ²the cold opening 184 of the control disc 154 to deliver only cold water to the ²²outlets 140.²11²<DP=12>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²As shown, both the hot and cold openings 182, 184 of the control disc 154 ²have a teardrop shape, resulting in a tapered width of the openings 182, 184 ²along ²the length of the openings 182, 184. The control disc 154 is shown rotated in ²a ²clockwise direction from the OFF position. Due to the tapered shape of the ²cold²water opening 184, as the control disc 154 is further rotated in a clockwise ²direction, ²the amount of cold water allowed through the cold water opening 184 is ²reduced. ²FIG. 13 shows a top view of the main flow control disc 154 and the first and ²second auxiliary discs 156a, 156b when the main flow control disc 154 is in ²another²ON position. As shown, the central apertures 194a, 194b of the first and ²second²auxiliary discs 156a, 156b are aligned with the hot and cold openings 182, 184 ²of the ²control disc 154 so as to a mixed stream of hot and cold water 124 to the ²outlets 140. ²FIG. 14 shows a top view of the main flow control disc 154 and the first and ²second auxiliary discs 156a, 156b when the main flow control disc 154 is in ²another ²ON position. As shown, the central aperture 194a of the first auxiliary disc ²156a is²aligned with the hot water opening 182 of the control disc 154 to deliver only ²hot ²water to the outlets 140. Due to the tapered shape of the hot water opening ²182, as ²the control disc 154 is rotated in a clockwise direction, the amount of hot ²water ²allowed through the hot water opening 182 is increased. In some examples, the ²hot ²water limiter 144 can limit the rotation of the stem 134, and thereby the ²control disc²154, to limit the fluid communication of the hot water opening 182 and the ²central ²aperture 194a of the first auxiliary disc 156a.²Examples ²Illustrative examples of the valve cartridge disclosed herein are provided²below. An embodiment of the valve cartridge may include any one or more, and ²any ²combination of, the examples described below.²Example 1 is a valve cartridge that includes a valve body that defines a hot²water port that has a first end and a second end. The valve body includes a ²cold ²water port that has a first end and a second end. The valve cartridge includes ²a²rotatable control stem that is disposed at least partially within the valve ²body. The ²valve body includes a main flow control disc that is coupled to the control ²stem. The ²main flow control disc has a cold water opening and a hot water opening. The ²valve ²cartridge includes a first auxiliary disc positioned between the first end of ²the hot²12²<DP=13>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²water port and the main flow control disc and a second auxiliary disc ²positioned ²between the first end of the cold water port and the main flow control disc.²In Example 2, the subject matter of Example 1 is further configured such that ²the first auxiliary disc includes an aperture aligned with the hot water port ²and the² second auxiliary disc includes an aperture aligned with the cold water port.²In Example 3, the subject matter of Example 1 is further configured such that ²rotation of the control stem alters both the alignment of the cold water ²opening of ²the main flow control disc and the cold water port of the valve body and the ²alignment of the hot water opening of the main flow control disc and the hot ²water²port of the valve body.²In Example 4, the subject matter of Example 1 is further configured such that ²the valve body includes a hot water recess and a cold water recess. The first²auxiliary disc is positioned at least partially within the hot water recess. ²The second ²auxiliary disc is positioned at least partially within the cold water recess.² In Example 5, the subject matter of Example 4 is further configured to ²include a first and a second seal, the first seal being positioned between a ²seal ²shoulder of the hot water recess and the first auxiliary disc and the second ²seal being ²positioned between a seal shoulder of the cold water recess and the second ²auxiliary ²disc.²In Example 6, the subject matter of Example 1 is further configured such that ²the valve body includes a first valve body and a second valve body, the hot ²and cold ²water ports being defined by the second valve body, and the control stem being ²at ²least partially positioned within an aperture defined by the first valve body.²In Example 7, the subject matter of Example 1 is further configured such that²the main flow control disc includes at least one recess at the periphery of ²the main ²flow control disc. The recess is configured to receive at least one projection ²of the ²control stem to facilitate simultaneous rotation of the control stem and the ²main flow ²control disc.²In Example 8, the subject matter of Example 1 is further configured such that²the control stem includes a control head, the control head being positioned ²between ²the first and second auxiliary discs at a first side and the main flow control ²disc at a ²second side.²13²<DP=14>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²In Example 9, the subject matter of Example 1 is further configured such that ²the main flow control disc, first auxiliary disc, and second auxiliary disc ²are ²constructed of a ceramic material.²In Example 10, the subject matter of Example 1 is further configured such²that the main flow control disc has an interface surface facing the first ²auxiliary disc ²and the second auxiliary disc. Less than the entire interface surface contacts ²the first ²auxiliary disc and the second auxiliary disc.²In Example 11, the subject matter of Example 1 is further configured such²that the valve cartridge is installed in at least one of a shower system, a ²faucet² system, and a bathtub system.²Example 12 is a valve cartridge that includes a valve body. The valve body ²includes a hot water port that has a first end and a second end. The valve ²body ²includes a cold water port that has a first end and a second end. The valve ²cartridge ²includes a rotatable control stem disposed at least partially within the valve ²body and²a main flow control disc coupled to the control stem. The main flow control ²disc has ²a cold water opening and a hot water opening. The cold water opening and the ²hot ²water opening selectively correspond with the hot water port and cold water ²port, ²respectively. The valve cartridge includes at least one auxiliary disc ²positioned ²adjacent to, and in contact with, the main flow control disc. The at least one²auxiliary disc is positioned around a first end of only a single hot or cold ²water port. ²In Example 13, the subject matter of Example 12 is further configured such ²that rotation of the control stem alters both the alignment of the cold water ²opening²of the main flow control disc and the cold water port of the valve body and ²the ²alignment of the hot water opening of the main flow control disc and the hot ²water² port of the valve body.²In Example 14, the subject matter of Example 12 is further configured to²include a seal, the seal being positioned between a seal shoulder defined by ²the valve²body and the at least one auxiliary disc.²In Example 15, the subject matter of Example 12 is further configured such²that the valve body includes a first valve body and a second valve body, the ²hot and ²cold water ports being defined by the second valve body, and the control stem ²being ²at least partially positioned with an aperture defined by the first valve ²body.²In Example 16, the subject matter of Example 12 is further configured such ²that the main flow control disc includes at least one recess at the periphery ²of the²14²<DP=15>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²main flow control disc. The recess is configured to receive at least one ²projection of ²the control stem to facilitate simultaneous rotation of the control stem and ²the main ²flow control disc.²In Example 17, the subject matter of Example 12 is further configured such²that the main flow control disc, first auxiliary disc, and second auxiliary ²disc are ²constructed of a ceramic material.²In Example 18, the subject matter of Example 12 is further configured such ²that valve cartridge is installed in at least one of a shower system, a faucet ²system, ²and a bathtub system.²Example 19 is a valve cartridge that includes a rotatable control stem that is ²²disposed at least partially within a valve body. The valve cartridge includes ²a main ²flow control disc that is coupled to the control stem. The main flow control ²disc has ²a cold water opening and a hot water opening. The valve cartridge includes a ²first ²auxiliary disc that has a first face positioned adjacent to, and in contact ²with, the²main flow control disc. The first auxiliary disc has a central aperture. The ²valve ²cartridge includes a second auxiliary disc having a first face positioned ²adjacent to, ²and in contact with, the main flow control disc. The second auxiliary disc has ²a ²central aperture. The valve cartridge includes a first seal positioned ²adjacent to, and ²in contact with, a second, opposite face of the first auxiliary disc. The ²valve²cartridge includes a second seal positioned adjacent to, and in contact with, ²a ²second, opposite face of the second auxiliary disc. The hot water opening of ²the ²main control disc selectively corresponds with the central aperture of the ²first ²auxiliary disc, and the cold water opening of the main control disc ²selectively ²corresponds with the central aperture of the second auxiliary disc. The main ²flow²control disc, first auxiliary disc, and second auxiliary disc are constructed ²of a ²ceramic material.²In Example 20, the subject matter of Example 19 is further configured such ²that the valve cartridge is installed in at least one of a shower system, a ²faucet ²system, and a bathtub system.² The various embodiments described above are provided by way of ²illustration only and should not be construed to limit the claims attached ²hereto. ²Those skilled in the art will readily recognize various modifications and ²changes that ²may be made without following the example embodiments and applications²<DP=16>²CA 03081417 2020-04-29²WO 2019 / 089605 PCT / US2018 / 058224²illustrated and described herein, and without departing from the true spirit ²and scope ²of the following claims.²16²

Claims

<DP=1>²²WE CLAIM:²²1. A valve cartridge comprising:²a valve body defining:²a hot water port having a first end and a second end; and²a cold water port having a first end and a second end;²a rotatable control stem disposed at least partially within the valve body;²a main flow control disc coupled to the control stem, the main flow control²disc having a cold water opening and a hot water opening;²a first auxiliary disc positioned between the first end of the hot water port²and the main flow control disc; and²a second auxiliary disc positioned between the first end of the cold water ²port²and the main flow control disc.²2. The valve cartridge of any of the preceding claims, wherein the first ²auxiliary ²disc includes an aperture aligned with the hot water port and the second ²auxiliary ²disc includes an aperture aligned with the cold water port.²3. The valve cartridge of any of the preceding claims, wherein rotation of ²the ²control stem alters both the alignment of the cold water opening of the main ²flow ²control disc and the cold water port of the valve body and the alignment of ²the hot ²water opening of the main flow control disc and the hot water port of the ²valve body.²4. The valve cartridge of any of the preceding claims, wherein the valve ²body ²includes a hot water recess and a cold water recess, wherein the first ²auxiliary disc is ²positioned at least partially within the hot water recess, and wherein the ²second ²auxiliary disc is positioned at least partially within the cold water recess.²5. The valve cartridge of any of the preceding claims, further comprising a ²first ²and a second seal, the first seal being positioned between a seal shoulder of ²the hot ²water recess and the first auxiliary disc and the second seal being positioned ²²between a seal shoulder of the cold water recess and the second auxiliary ²disc.²6. The valve cartridge of any of the preceding claims, wherein the valve ²body ²includes a first valve body and a second valve body, the hot and cold water ²ports²² 17²<DP=2>²²being defined by the second valve body, and the control stem being at least ²partially ²positioned within an aperture defined by the first valve body.²7. The valve cartridge of any of the preceding claims, wherein the main ²flow ²control disc includes at least one recess at the periphery of the main flow ²control ²disc, wherein the recess is configured to receive at least one projection of ²the control ²stem to facilitate simultaneous rotation of the control stem and the main flow ²control ²disc.²8. The valve cartridge of any of the preceding claims, wherein the control ²stem ²includes a control head, the control head being positioned between the first ²and ²second auxiliary discs at a first side and the main flow control disc at a ²second side.²9. The valve cartridge of any of the preceding claims, wherein the main ²flow ²control disc, first auxiliary disc, and second auxiliary disc are constructed ²of a ²ceramic material.²10. The valve cartridge of any of the preceding claims, wherein the main ²flow ²control disc has an interface surface facing the first auxiliary disc and the ²second ²auxiliary disc, and wherein less than the entire interface surface contacts ²the first ²auxiliary disc and the second auxiliary disc.²11. The valve cartridge of any of the preceding claims installed in at ²least one of ²a shower system, a faucet system, and a bathtub system.²12. A valve cartridge comprising:²a valve body including:²a hot water port having a first end and a second end; and²a cold water port having a first end and a second end;²a rotatable control stem disposed at least partially within the valve body;²a main flow control disc coupled to the control stem, the main flow control²disc having a cold water opening and a hot water opening, wherein the cold ²water²opening and the hot water opening selectively correspond with the hot water ²port²and cold water port, respectively; and²²18²<DP=3>²²at least one auxiliary disc positioned adjacent to, and in contact with, the ²main flow control disc, the at least one auxiliary disc being positioned ²around a first ²end of only a single hot or cold water port.²13. The valve cartridge of any of the preceding claims, wherein rotation of ²the ²control stem alters both the alignment of the cold water opening of the main ²flow ²control disc and the cold water port of the valve body and the alignment of ²the hot ²water opening of the main flow control disc and the hot water port of the ²valve body.²14. The valve cartridge of any of the preceding claims, further comprising ²a seal, ²the seal being positioned between a seal shoulder defined by the valve body ²and the ²at least one auxiliary disc.²15. The valve cartridge of any of the preceding claims, wherein the valve ²body ²includes a first valve body and a second valve body, the hot and cold water ²ports ²being defined by the second valve body, and the control stem being at least ²partially ²positioned within an aperture defined by the first valve body.²16. The valve cartridge of any of the preceding claims, wherein the main ²flow ²control disc includes at least one recess at the periphery of the main flow ²control ²disc, and wherein the recess is configured to receive at least one projection ²of the ²control stem to facilitate simultaneous rotation of the control stem and the ²main flow ²control disc.²17. The valve cartridge of any of the preceding claims, wherein the main ²flow ²control disc, first auxiliary disc, and second auxiliary disc are constructed ²of a ²ceramic material.²18. The valve cartridge of any of the preceding claims installed in at ²least one of ²a shower system, a faucet system, and a bathtub system.²19. A valve cartridge comprising:²a rotatable control stem disposed at least partially within a valve body;²²19²<DP=4>²²a main flow control disc coupled to the control stem, the main flow control ²disc having a cold water opening and a hot water opening;²a first auxiliary disc having a first face positioned adjacent to, and in ²contact ²with, the main flow control disc, the first auxiliary disc having a central ²aperture;²a second auxiliary disc having a first face positioned adjacent to, and in ²contact with, the main flow control disc, the second auxiliary disc having a ²central ²aperture;²a first seal positioned adjacent to, and in contact with, a second, opposite ²face of the first auxiliary disc; and²a second seal positioned adjacent to, and in contact with, a second, opposite ²face of the second auxiliary disc,²wherein the hot water opening of the main control disc selectively ²corresponds with the central aperture of the first auxiliary disc, and wherein ²the cold ²water opening of the main control disc selectively corresponds with the ²central ²aperture of the second auxiliary disc, and²wherein the main flow control disc, first auxiliary disc, and second auxiliary ²²disc are constructed of a ceramic material.²20. The valve ²cartridge of any of the preceding claims installed in at least one of²a shower system, a faucet system, and a bathtub system.²²