Mixing Valve With Segmented Discs For Noise Reduction
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Solution Overview
Problem
Existing single-handle water faucet control valves face challenges in efficiently controlling water temperature and flow rate while minimizing noise and leakage, particularly in mixing hot and cold water effectively.
Innovation Solution
A valve assembly with a lower disc and upper disc configuration, featuring a closed flow channel with varying width and depth to selectively communicate between hot and cold water inlets and the outlet, and a stem assembly for pivotal movement to adjust flow rates and temperatures, reducing noise and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single-handle control valve is used to control water temperature and flow rate, then ease of operation is improved, but noise and leakage increase
Solution Approach 1:
The valve is divided into two separate discs: a upper disc for controlling flow rate and a lower disc for controlling temperature. This segmentation allows independent optimization of each control function, reducing interference between temperature and flow control, thereby minimizing noise and leakage while maintaining ease of operation.
Solution Approach 2:
A stem assembly with ball and stem mechanism acts as an intermediary between the user's handle operation and the two discs. The ball rotates about orthogonal axes to independently actuate the upper and lower discs, mediating the control inputs to achieve precise temperature and flow regulation without direct mechanical coupling that would cause noise and leakage.
2Device complexity
If hot and cold water are mixed in a simple channel, then device complexity is reduced, but mixing efficiency and temperature control deteriorate
Solution Approach 1:
The lower disc features a non-uniform seal profile with varying depth and width along its circumference. This local variation in seal geometry creates different flow resistance characteristics at different angular positions, enabling precise control of hot and cold water mixing ratios. The localized quality changes in the seal structure achieve superior temperature control without requiring complex external mixing mechanisms.
3Manufacturing precision
If the flow channel has constant width and depth, then manufacturing precision is improved, but flow control and noise reduction deteriorate
Solution Approach 1:
The upper disc seal profile is designed with dynamically varying width and depth characteristics that change along the flow direction. This dynamic geometry allows the seal to adapt to different flow rates and pressure conditions, optimizing flow control and noise reduction across a wide operating range while maintaining manufacturability through standardized molding processes.
Solution Approach 2:
The flow channel dimensions (width and depth) are varied as design parameters along the flow path rather than being constant. By changing these geometric parameters strategically, the patent achieves superior flow control characteristics and noise reduction while the variations are within manufacturing tolerances that can be achieved through standard injection molding or machining processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The valve assembly effectively controls water temperature and flow rate, reduces noise, and minimizes leakage by ensuring efficient mixing and flow regulation, enhancing user control and faucet performance.
Implementation Method 1
The closed channel is configured to mix hot water from the first port and cold water from the second port before reaching the third port
Implementation Method 2
The closed channel extends around a center portion of the lower surface and is configured to mix hot water from the first port and cold water from the second port
Data Source
AI summary
The present invention relates generally to fluid control valves and, more particularly, to a mixing valve for use within a faucet.