CA2009541A1 - Bypass valve - Google Patents

Abstract

Abstract A bypass/diverter valve for controlling the flow of fluid from a source to a fluid treatment device such as a water softener. The valve includes a valve housing defining a circular chamber having a cylindrical wall into which three spaced ports open into. Two of the ports form inlet/outlet ports communicating with connecting conduits. The third port forms an intermediate port that communicates with the input to the water softener. The valve housing also defines a second intermediate port communicating with the output of the water softener and which communicates with the valve chamber though a passage arrangement. A plug-like valving member is rotatable within the chamber and includes a recess which together with the chamber wall defines a passage for selectively communicating one of said inlet/outlet ports with said first intermediate port while concurrently communicating said other inlet/outlet port with the second intermediate port or alternately for communicating said first inlet/outlet port with said second intermediate port while concur-rently communicating the second inlet/outlet port with said first intermediate port. The valving member is also positionable to block flow out of either of said inlet/outlet ports. The plug member includes a recess for communicating fluid from the passage to one of the inlet/outlet ports when the valving member is rotated to a predetermined position. A movement control disc delimits the extremes of movement in the valving member and is positionable in two different positions to change the extremes of movement.

Description

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11-059 Bvpa~s Valve Technical Field The present invenkion relates gensrally to fluid control valves and in particular to a by pass or diverter valve.
BackqrQund Art ~ y-pass valves also termed diverter valves are often used in plumbing systems to control the communication of fluid to a plumbing fixture or fluid processing device. For example, in the case of a water softener, it has been known to use a valving assembly to control the communicat~on of source water to tha w ter softener as well as provide a diversion path for the incoming water so that the water supply to the household is not interrupted during service of the water softener.
Known prior devices have been complex and/or expensiva. Some have ineluded ~ultiplQ valve~, manifolds and complex conduits in order to achieve the desired ~ontrol.
Another problem asso~iated with the installation of a plumbing ~ixtura or fluid treatment device tha~
includes an inlet and an outlet, such as a water softener or hot water tank, is a mismatch that often occ-~rs between the inlet and outlet of the device and the source and the watsr supply pipe~ form~ng part o~
the plumbing system. In instances where household plumbing connections do not match the plumbing fixture conneotions, installers are requ~red to devise awkward, cross-over connectlons in order to couple the household plumbing to the fixture. In instances where the fixture is being installed in a limited space, the installation can be extremely difficult and expensive.

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The present invention provides a new and improved by-pass or diverter valve that not only controls the communication o~ fluid to a plumbing fixture or other fluid treatment device also provides conduit structure for providing connections to the fluid or plumbing system that are adaptable to the position and location of the source and supply conduits of the system.
The present invention will be described in connection with a water treatment system and in particular, a water softener system which is normally serially connected in a fluid stream so that under normal operating conditions source water to be treated enters an inlet to the water softener and is discharged through an outlet of the water softener for delivery to a water supply. It should be understood that the present invention is adaptable to fluid systems in general in which a fluid device must occasionally be isolated from an inlet fluid stream.
In the preferred and illustrated entbodiment, the valve includes a housing defining four ports and a valving member for selectively communicating the ports in predetermined configurations~. The housing defines a fluid chamber into which all of the ports communicate.
The valving member ls moveable within the chamber, to several predetermined positions and dafines a flow passage segment. When the valving member is moved to predetermined positions the passags cross communicates certain of the four ports in predetermined configura~ions depending on the selected position.
According to a preferred embodiment of the invention, the valving chamber is circular in configuration and includes a circular wall having a predetermined axial extent. In accordance with this 2~09~

embodiment, the valving member includes a plug-like portion that is rotatably supported in the ~alving chamber.
In the preferred and illustrated embodiment, three of the four ports communicate directly into valving chamber and are spaced apart. Preferably these chamber ports are located equidistant apart, i.e., substantially 120 apart~ In accordance with this embodiment, two of the three chamber port~ function as inlet/outlet ports for the valve and are connected to a source line through which *luid to be treated is delivered to the control valve and a supply line to which treated fluid leaving the control valve is discharged. The third port is connected to the inlet to the fluid treatment device.
When the disclosed valve is used to control the communication of water to a water softener, one of the inlet/outlet ports is connected to the source of hard water while the other inlet/outlet port is connected to the household plumbing system. The third pcrt would be connected to the inlet of the water softener.
The plug portion of the valving member defines the passage segment which is sized to span the distance between adjacent ports so that at predetermined rotative positions of the valving member two adjacent ports of the three chamber ports can be directly intercom-municated by the passage segment. The passage is also sized such that when the valving member is rotated to either one of two intermediate positions the passage communiaates with only one of the two inlet/outlet ports and in effect surrounds the inlet/port and blocks fluid flow out of the port covered or enclosed by the passa~e.
According to the preferred embodiment of the invention, the fourth port opens into a secondary 2 ~ 4 ~

chamber which in turn communica~es with the valving chamber. In the disclosed construction, the ~ourth port communicates with the outlet of the fluid treatment device, i.e. water softener. The plug portion of the valving member preferably d~fine~ two segments. One segment forms the cross communicating passage for communicating two adjacent ports of the three chamber ports. The other se~ment provides a flow path from the secondary chamber to either one of the ~wo inlet/ou~let ports depending on the rokative posi~ion of the valving member.
With the disclosed invention, the two inlet/outlet ports define changeable inlet and outlet ports either of which can serve as an inlet and be connected to the source line. Preferably, the combination inlet/outlet ports are located in an adjacent relationship and are intercommunicated by the passage segment defined by the valving member when the valving member is placed in a "bypass" position.
When the valving member is rotated ~o a "service"
position, the passage seyment communicates the in-let/outlet port connected to the source line with the water softener inlet port. At the same time, the device outlet port (which communicates with the secondary chamber) is communicated with the other inlet/outlet port via the second plug segment.
According to a feature of the invention the valving member is positionable, during valve installation in one of two operational configurations. According to this feature, the installed position of the valving member determlnes which of the inlet/outlet ports will function as the actual inlet (and be connected to the source) and which will function as the outlet (and be connected to the house supply). With the present invention, the valve can be adapted to the existing plumbing so that complex and/o;r contorted connections are not necessary to connect the household plumbing to the control valva. In the preferred construction, conduits associated with the inlet/outlet ports extend from the valve housing and are connectable to the household plumbing, pre~erably using removable threaded connections or compression fittings.
In the preferred arrangement, ~tructure formed on the housing cooperates with a movement controller and determines the extent of movement of the valving member and in particular establishes:
1) the "bypass" position o~ the valving member at which the inlet is communicated directly to the outlet and flow to the water softener is bypassed.:
and, 2) the "service" position of the valving member at which fluid from the source is allowad to proceed to the water softener and flow from the water softener is communicated to the household supply.
An "off position, at which flow out of the inlet port (which is connected to the source) is blocked, is located intermediate the "bypass" and "service"
positions. In the disalosed embodiment, the valve housing includes a removable cap by which access to the valve chamber is achieved. The cap is installed after the valving member is positioned in the chamber. The valving member includes an operating stem that extends from the plug portion and through an aperture in the cap. The stem is adapted to receive an operating handle by which the valving member is rotated to one of the threa operating positions: "bypass", 'Iservice'' or "off".
According to this embodiment, the movement 2 ~

controller is mounted on the valving member stem intermediate the cap and handle. The cap includes stops which cooperate with the movement controller and restrict movement in the valving member to predetermine limits.
According to a feature of this embodiment, the valving member is placed in one of two operating positions during installation and once the controller and handle hava been attached, the valve operating configuration is establish. In particular, the initial position of the valving member determines which of the inlet/outlet ports will function as the inlet and which will function as the outlet. The configuration is easily changed by repositioning the valving member and reinstalling the movement controller and the handle.
The controller preferably includes indicia for indicating which position the valving member is in.
According to another feature of the invention, the passage segment includes a peripheral seal which seals the passage to the wall of the chamber. As a result, when the passage is positioned over a single port, that port is isolated from the rest of the chamber and hence the other ports. In this position, the valve member blocks flow to and out of the port it overlaps. With this feature, the valve member can be placed in ~he "off" position to completely isolate the household supply from the source line. In other words, the disclosed valve can also serve as a water "shut-off'!
valve when service to the plumbing system, downstream from the water treatment device, is needed.
Additional features of the inve~tion will become apparent and a full understanding obtained by reading the following detailed description made in connection with the accompanying drawings.

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Brief Description of D_awlnqs Figure 1 is a top plan view of a by-pass/diverter valve constructed in accordance with the preferred embodiment of the invention;
Figura 2 is a partial sectional view of the valve shown in Figure l;
Figure 3 is a perspective view of a portion of a valve housing forming part of the valve shown in Figure l;
Figure 4 is a perspective view o~ a valving member forming part of the valve shown in Figure ~;
Figure 5 is an elevational view of the housing shown in Figure 3;
Figures 6A-6C schematically illustrate the fluid flow paths thxough the valve for various rotatiYe positions of the valving member when the valve is in one operating mode;
Figures 7A-7C schematically illustrate the fluid flow paths through the valve for various rotative positions of the valving member when the valve is in another operating mode;
Figure 8 is a top plan view of a chamber cap forming part of the by-pass valve; and, Figures 9A and 9B are elevational views of opposite sides of a movement control disc forming part of the by-pass valve.
Best Mode for_Carryina Out ~he Invention Referring to Figures 1 and 2, the overall construction of a by-pass/diverter valve aonstructed in accordance with the preferred embodiment of the invention is illustrated. As seen best in Figure 1, the valve includes a valve housing indicated yenerally by the reference character 10. Four short conduits 12, 14, 16, 18 extend from a valve chamber sPction 20 of the _ . .

housing 10. In the preferred and illustrated embodiment, th~ conduits and valve chamber section, as seen best in Figure 3, are integrally molded as a unitary member. One or more of the conduits may include threaded or compression fittings 12a, 14a for removably connecting the conduits to fluid supply/receiving lines (not shown).
Each of the conduits communicate directly or indirectly with an internal valve chamber (shown best in Figure 3) through an associated port. The valve chamber 22 is de~ined at least partially by a uniform circular wall 22a having a predetermined~axial extent and a base or end wall 22b that closes of~ one radial side o~ the axial wall. The other radial side of the chamber 22 is closed o~f by a removable chamber cap 30. The cap 30 is held in position by a plurality of threaded fasteners 25. In Figure 3, ports 24, 26 are illustrated which communicate the conduits 12, 14, respectively with the chamber 22. The conduit 16 also communicates directly with the valve chamber 22 through an associated port 27 (shown partially in Figure 2). As seen ln ~he Figures, the ports 24, 26, 27 extend through the circular wall 22a.
The conduit 18, however, as seen best in Figures 3 and 5, communicates with a passage-like transfer chamber 29. The tran~fer chamber 29 commun~cates with the main valve chamber 22 by way of a clearance gap 31a formed in a wall segment 31 forming part of the chamber wall 22a.
The wall segment is preferably integrally molded with the housing 10. The gap defines a clearance space between the wall segment 31 and ~he chamber cap 30 when the valve is assembled. Re~erring to Figures 2 and 4, a valving member 40 for controlling the fluid communication between the various ports, and the 2~09~3 associated conduits is rotatably supported within the valve chamber 22.
The valving member 40 ~as seen best in Figure 4) includes a stem 42 that extends upwardly (as viewed in Figure 2) through a bore 44 formad in the cap 30. An o-ring seal 45 inhibits fluid leakage between the stem 42 and the cap 30. The axial position of the valving member 40 within the housing is maintained by a tubular, downwardly depending standoff 3Oa formed in the cap 30.
A handle 46 is operatively connected to the stem by a fastener 47 which is threaded into an axial bore 43 formed at the top of the stem 42. A rotation controller in the form of a disc 4B is located between the handle 46 and the chamber cap 30 and as will be explained later, controls the extent of rotation of the valving member 40.
Referring again to Figure 4, the valving memher 40 includes a plug-like lower portion 50 including an annular base surface 55 which rides atop at least a portion of the end wall 22b forming the bottom of the valve chamber 22. Ext~nding upwardly (as viewed in Figure 4) from the base surface 55 is a cylindrical segment 49a that at least partially support~ the plug portion 50 for rotation in the valve chamber 22 and in particular confronts the cylindrical wall 22a of the chamber 22. A semi-circular, cylindrical rotation support surface 49b is defined near the top of the plug portion 50. The plug portion 50 includes a passage section 50a and a relieved section 50b. The axial extent of the passage section 50a is substantially e~ual to the axial extent of the wall segment 31. With this construction, fluid leaving the transfer chamber 29 can flow over the plug portion 50.
The passage section 50a of the plug porkion 50 2 ~

~defines a recess which in radial cross section is semi-circular in shape. In particular the recess is defined by a pair of spaced apart, substantially planar walls 53a/ 53b interconnected by an arcuate wall 53c.
Preferably, the midpoint D of the arc of the wall 53c lies substantially on a dlametral line of the plug portion 50 (shown in Figure 6A). An arcuate, oval shaped groove 54 which is adapted to receive an 0-ring 56 (shown in Figure 2) surrounds the recess. ~he lo transvexse portions of the groove 54 (as viewed in Figure 4) are formed in the cylindrical support segments 49a, 49b. The 0-ring 56 sealingly engages the cylindrical wall 22a of the main valve chamber 22. When the valving member 40 is positioned in the chamber 22, a passage 60 is defined between the recess in the plug member and the portion of the main chamber wall 22a engaged by the 0-ring 56. In operation, the passage 60 is isolated from the remainder of the main valve chamber by the o~ring 56.
~ predetermined rotative positions of the valve member 40, the passage 60 cross communicates certain ports associated with the conduits 12, 14, 16, 18. By rotating the valving member 40, the cross communication can be changed.
Referring in particular Figures 6A-6C, the communication achieved by various positions of the valving member are illustrated for one mode of operation. In Figure 6A, the valving member 40 is rotated to the "service" position where the passage 60 defined by the valving member overlaps the ports 24, 27.
With the valving member in this position, the conduits 12, ~6 are intercommunicated and fluid flows from ~he inlet conduit 12 to the water softener conduit 16.
Concurrently, the conduit 18 communicates with the 2 0 ~

conduit 14 via the transfer chamber 29, clearance gap 31a, and the main chamber portion exposed by the relieved section 50b of the plug portion 50. The main chamber portion exposed in this position includes the section of the cylindrical wall 22a that defines the port 27. In this configuration, the conduit 12 would be connected to the ineoming water supply. The household supply would be connected to the conduit 14 which as seen in Figure 6A communicates with tha conduit 18 that is connected to the outlet of the water softener (not shown).
If the wat~r softener requires repair, cleaning, maintenance, etc., the valving member 40 is rotated clockwise to the "bypass" position shown in Figure 6B.
In this position, the passage 60 defined by the plug member communicates the inlet/outlet port 24 (associated with the inlet/outlet conduit 12) with the inlet/outlet port 26 (associated with the outlet conduit 14) thereby directly conveying the incoming water to the port 26.
In this configuration, the incoming water is piped directly from the conduit 12 to the conduit 14. In this position, the water softener or other water treatment device is totally isolated from the fluid supply.
According to the invention, movement of the plug member to an intermediate or "o~f" position lshown in Figure 6C) serves to totally disconnect the incoming source fluid (communicated through the conduit 12) from both the fluid treatment device and the housPhold supply. In other words, the disclosed by-pass valve will also function as a shut-off valve for the water supply ln a residential environment.
Referring to Figures 7A-~C, the disclosed control valve includes a feature by which it can be adapted to alternately positioned supply lines. When the valve is confiyu~ed as shown in Figures 6A-6C, the incoming source line would be on the left (as viewed in Figures 6A-6~) whereas the connection to the household supply would be on the right. By repositioning the valving member 40, the disclosed control valve can be configured to connect to a source line located on the right and a household supply line located on the left. In particular, the valve can be configured such that the inlet/outlet conduit 14 can be connec~ed to the source and the inlet/outlet conduit 12 can be connected to the supply.
When the valving member 40 is rotated to the alternate "service" po~ition shown in Figure 7A, the passage 60 defined by the plug portion 50 cross communicates the port 26 associated with the inlet/oùtlet conduit 14 with the port 27 associated with the device inlet conduit 16. Fluid communication is established between the device outlet conduit 18 and the inlet/outlet conduit 12 by way of the transfer chamber 29 and clearance gap 31a in the wall segment 31 (which together communicate ~luid from the conduit 18 to the valve chamber 22). The fluid flows over a top surface of the plug member 50 and enters the port 24 associated with the inlet/outlet conduit 12 which is exposed by the relieved section 50b of the valving member 40. When the water softener is to be isolated from the source and supply lines without interrupting flow between the conduits 12 and 14, the valvlng member 40 is rotated counterclockwise to the "bypass" position shown in 7B
which causes the passage 60 in the plug member 50 cross communicate the ports 24, 26, and henca the conduits 12, 14. When flow is to be terminated, the valving member 40 is rotated to the altarnate intermediate "off"
position shown in Figure 7C which blocks ~low out of .

the port 26 and hence from the conduit 14.
The rotation limits o~ the plug member in either mode of operation are established by the movement control disc 48 located between the operating handle 46 and the cap 30. In the preferred and illustrated embodiment, the control disc 48 is rotatably coupled to the stem 42 by a keyed arrangement which allows the disc to be installed on~o ~he stem 42 in either of $wo ways. The keyed arrangement comprises a slot 42a formed lo in the stem 42 which is adapted to receive a key 82 forming part of the disc ~8. Referring to Figure 2I the disc 48 can be installed with either a surface 48a (designated "A" in Figures 6A-6C) or a surface 48b (designated "Bl' in Figures 7A-7C) facing upwardly. In position "A", (shown in Figures 6A-6B) a raised wall-like segment 90 formed on the surfac~ 48a of the disc 48 is aligned with a raised lug or stop 92 forming part of the cap 30 (shown best in Figure ~). End surfaces 9oa of the wall segment 90 (shown best in Figure 9A) form abutments for the stop 92. The arcuate extent o~ the wall segment 90 determines the limits of rotation for the valving member 40.
Referring to Figures 6A, 6B the "service" and "by-pass" positions are established at the opposite extremes of movement of the valving member 40. When the fluid flow from source line is to be terminated, the valving member is rotated to the intermediate position i.e., to the position where the indicia llof~l' is located at the 12 o'clock position as viewed in Figure 6C. With the control disc 48 positioned as shown in Figurss 6A
6B, the condui;t 12 serves as the inlet conduit whereas the conduit 14 serves as the outlet conduit. It should be noted that in either valve configuration, the conduits 16, 18 remain as the inlet and outlet to the ~9~

fluid device. As a result, the disclosed valve can be permanently attached to the device without compromising the ability to switch the functions of the inlet/outlet conduits 12, 14.
To switch the functions of the conduits 12, 14, the movement control disc 48 is removed from the stem 42 (by first removing the handle 46) to enable the valving member 40 to be rotated to either of the alternate positions shown in Figures 7A, 7B or any intermediate position between these two positions. The control disc 48 is then reversed to position the "B" surface 48b upwa~dly and reinstalled so that a second raised lug 34 (shown best in Figure 8) formed on the cap 30 is aligned with an associated raised wall-like segment 96 forming part o~ the control disc 48. The alternate segment 96 is for~ed on the disc surface 48a and includes end surfaces 96a that ~orm abutments for the lug 94 After installation, rotation of the valving member is limited by the arcuate extsnt of the segment 96. As indicated above, when in this position, the conduit 14 serves as the inlet conduit whereas the conduit 12 serves as the outlet conduit.
In the disclosed and preferred embodiment, the "bypass" position of the valving member 40 is the same in both modes of operation. This feature ~urther facilitates the ability to switch the functions of the conduits 1~, 14. According to this embodiment, the by-pass valve is switched between its operating modes by first rotating the valving member 40 to the "by-pass"
position. With the valving member 40 in this position, the handle 46 and movement controller disc 48 are removed. The disc 48 is then flipped and the handle 46 reinstalled. Using this method of ~witching valve functions does not require that the valving m~mber 40 be 2~9~

repositioned priox to installing the controller disc 48.
With the disclosed invention, a very useful but inexpensive by~pass/diverter valve is provided which enables fluid flow to a fluid treatment device such as a water softener, to ba diverted directly to an outlet conduit when service on the water softener is needed.
In addition, the by-pass valve includes a shut-off position at which ~luid ~low from the inlet is totally isolated from both the fluid device and the rest of the household supply. Moreover, by repositioning the valving memb~r 40 within the valve chamber 22, the function o~ the inlet/outlet conduits can be changed to facilitate installation of the water softener.
Although the invention has been described with a certain degree of particularity, it should be understood that those skilled in the art can make various changes to it without departing from the spirit or scope of the invention as hereinafter claimed.

Claims (16)

1. A control valve, comprising:
a) a housing defining a valve chamber;
b) a valving member disposed within said chamber and mounted for movement between predetermined positions;
c) a pair of inlet/outlet ports opening into said chamber and at least one intermediate port opening into said chamber;
d) means communicating a second intermediate port with said chamber;
e) said valving member defining a passage portion having an extent such that in one position it cross communicates said pair of inlet/outlet ports, in another position it communicates one of said inlet/outlet porks with said first intermediate port and in third and fourth positions it blocks flow out of said inlet/outlet ports;
f) movement control means for limiting movement in said valving member between predetermined positions.

2. The control valve of claim 1 wherein said means for communicating said second intermediate port comprises an auxiliary passage that communicates with said valve chamber and said valving member includes a relieved portion for exposing one of said inlet/outlet ports in order to fluidly communicate said passage with said exposed port.

3. The control valve of claim 1 wherein said movement control means comprises a control disc located outside of said housing and operatively connected with a stem member forming part of said valving member.

4. The control valve of claim 1 wherein said valve chamber is defined in part be a cylindrical wall and said inlet/outlet ports and said first intermediate port extend through said cylindrical wall.

5. The apparatus of claim 4 wherein said valving member confrontingly engages said cylindrical wall such that said passage portion is defined between said chamber wall and a semicircular shaped recess defined by said valving member.

6. The apparatus of claim 1 wherein said valving member includes a plug-like portion that is rotatable within said chamber.

7. A by-pass/diverter valve for controlling the communication of a fluid supply to and from a fluid treatment device, comprising:
a) a valve housing including a pair of inlet/outlet connection means for connecting said valve to a fluid source and to an outlet for receiving treated fluid;
b) structure defining inlet/outlet ports associated with said pair of inlet/outlet connection means;
c) structure defining a fluid treatment device input port and a fluid treatment device output port;
d) means for fluid communicating either one of said inlet/outlet ports with said fluid treatment device input port while concurrently communicating the other of said inlet/outlet ports with said fluid treatment device output port.

8. The bypass valve of Claim 7 wherein said means for communicating includes a plug-like valving member rotatable within a control chamber forming part of said valve housing.

9. The apparatus of Claim 8 wherein said valving member is installable in said valve housing in either of two positions and said apparatus further comprises a movement control means for delimiting the extremes of movement of said valving member.

10. The valve of Claim 9 wherein said movement control means is positionable in one of two positions, the position of said movement control means establishing a mode of operation for said bypass/diverter valve.

11. The apparatus of Claim 10 wherein said movement control means comprises a disk installable on a valving member portion and cooperating with structure formed on said valve housing to delimit a range of rotation of said valving member.

12. The apparatus of Claim 11 wherein said movement controlled disk includes at least two control surfaces each including structure engagable by a stop means formed on said valve housing.

13. A control valve, comprising:
a) a valve housing defining a circular chamber having a cylindrical wall having a predetermined axial extent;
b) at least three, spaced apart fluid ports opening into said chamber through said cylindrical wall;

c) a valving member including a plug-like portion sized to fit within said chamber and rotatable therein;
d) said plug portion defining a recess which forms an isolated flow passage that extends across a portion of said valving chamber and having an extent such that any two adjacent ports of said three ports can be cross-communicated at predetermined positions of said valving member;
e) structure defining a fourth port com-municating with a region of said valving chamber through a passage means;
f) said plug member including means for communicating said passage means with selected ports when said valving member is moved to predetermined positions.

14. The apparatus of claim 13 wherein said three ports are spaced substantially 120° apart.

15. The apparatus of claim 13 wherein two of said three spaced apart fluid ports form inlet/outlet ports, one of said inlet/outlet ports communicating with a fluid source, the other of said inlet/outlet ports communicating with a fluid receiving means.

16. The apparatus of Claim 15 wherein said means for communicating said passage means comprises a recess formed in said plug-like portion which is arranged to selectively communicate one of said inlet/outlet ports with said fourth port when said valving member is moved to a predetermined position.