HK1237330B - Control valve for fluid treatment apparatus - Google Patents

Description

Control valves for fluid handling devices

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 USC §119 to U.S. Provisional Application Serial No. 62/245,751, filed on October 23, 2015.

Technical Field

The present invention relates generally to fluid flow control systems and, more particularly, to water softener control valves.

Background Art

Water softener control valves typically use a piston fitted with a radial ring seal to control flow within the valve's cylinder. This control is used to periodically close some flow paths and open others, controlled by the timer portion of the control valve. As is known in the art, the softener is periodically cycled between service, backwash, brine flush, slow flush, fast flush, brine refill, and other operations known to the designers of the device. The operation of this valve is described in U.S. Patents Nos. 8,302,631; 6,644,349; and 6,176,258, all of which are incorporated by reference.

A need exists for an improved fluid handling device control valve that is easier to manufacture and assemble.

Summary of the Invention

This need is met by the water treatment control valve of the present invention, particularly suitable for use in commercial water softeners. Features incorporated into this control valve include an improved piston valve and cylinder assembly that enhances fluid closure without generating cavitation forces that could potentially compromise a properly sealed flow seal. This structure comprises upper and lower piston valve sections that sandwich a resilient seal and have a toothed periphery to allow pressure to escape when the piston valve is closed. The cylinder is also preferably provided with structure for guiding the piston valve into position and for mitigating sudden pressure changes.

Another feature is a lower tank adapter portion that is secured to the lower end of the control valve by an easily removable clamp and seals the fluid connection between the two portions by a plurality of radial seals. The control valve of the present invention is also characterized by a vacuum circuit breaker that is integrally formed with the tank adapter portion and is in direct communication with the process tank. Similarly, a pressure relief valve is also integrally formed into the tank adapter portion of the valve. Selected ports of the valve body are provided with clamps that are configured to facilitate connection and disconnection of associated nozzle accessories. In addition, at the upper end of the valve body, opposite the tank adapter portion, a spindle controller is integrally connected to the cover for wiring control water and thereby controlling the movement of the piston valve. In addition, the tank adapter portion is provided with an easily convertible upflow/downflow adapter accessory to change the direction of fluid flow during the operating cycle.

More specifically, a control valve is provided for use in a fluid handling device and includes a housing having at least one cylinder defining a fluid flow path within the device, each cylinder having an associated reciprocating piston valve. The valve includes a first piston valve half; a second piston valve half complementary to the first piston valve half; and a resilient seal configured and arranged to be sandwiched between the first and second piston valve halves. The first piston valve half is configured and arranged to engage the cylinder before the second piston valve half, and the first piston valve half has an outer circumferential edge defined by a plurality of circumferentially spaced teeth to form flow spaces between the teeth.

In another embodiment, a control valve for a fluid treatment device is provided, the control valve including a valve body having a control portion and a treatment portion, the control portion and the treatment portion being separate from each other so that fluid in the control portion is isolated from fluid in the treatment portion. The treatment portion includes a plurality of piston valves that reciprocate in corresponding cylinders to control water to be treated in the device, with an end of each piston valve disposed in the control portion. A tank adapter is engageable on the end of the valve body opposite the control portion, the tank adapter defining a plurality of seats corresponding to the cylinders, each seat being sized to accommodate a corresponding one of the cylinders. An elastic annular seal is sealingly disposed in the seat to prevent fluid from passing between the cylinders and the tank adapter. A clamping member couples the tank adapter to the valve body.

In another embodiment, a control valve is provided for use with a fluid treatment device and includes a valve body having a control portion and a treatment portion, the control portion and treatment portion being separable from each other so as to separate fluid in the control portion from fluid in the treatment portion. The treatment portion includes a plurality of piston valves that reciprocate within respective cylinders to control water to be treated in the device, with an end of each piston valve disposed within the control portion. A tank adapter is engageable on the end of the valve body opposite the control portion. The tank adapter defines a plurality of seats corresponding to the cylinders, each seat being sized to accommodate a respective one of the cylinders. The valve body is connected to the tank adapter at least at the connection of the flow passages using an elastomeric seal to prevent leakage, thereby achieving a gasketless connection between the valve body and the adapter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a top perspective view of the control valve mounted on a processing box;

FIG2 is a top plan view of the control valve of FIG1 ;

FIG3 is an exploded top perspective view of the pilot valve of the control valve;

FIG3A is an exploded perspective view of a spindle controller of the present invention for use with the valve of the present invention shown in FIG3 ;

FIG4 is a fragmentary vertical cross-sectional view of the control valve of the present invention with the piston in the closed position;

FIG5 is a fragmentary vertical cross-sectional view of the control valve of the present invention with the piston in the open position;

FIG6 is a top perspective view of a partial vertical cross-section of the valve of the present invention;

FIG7 is an enlarged, incomplete, top perspective view of the valve of FIG6;

FIG8 is an enlarged, incomplete top perspective view of the cylinder portion of the valve of FIG6;

FIG9 is a side view and a partial vertical cross-sectional view of the control valve of the present invention;

FIG10 is an enlarged fragmentary side view of the piston and cylinder engaged in the control valve of the present invention;

FIG11 is a bottom view of the piston valve of the present invention;

FIG12 is a partially enlarged bottom view of the piston of FIG11;

FIG13 is an exploded bottom perspective view of the piston of the present invention;

FIG14 is a bottom perspective view of the control valve of the present invention;

FIG15 is an exploded bottom perspective view of the control valve of the present invention;

16 is a fragmentary top perspective view of a tank adapter of the control valve of the present invention;

FIG17 is an exploded top perspective view of the tank adapter shown in FIG16;

FIG18 is a front view of a clamp used in the control valve of the present invention;

FIG19 is a top perspective view of the clamp of FIG18;

20 is an exploded side perspective view of the control valve of the present invention illustrating the engagement of the clamps of FIG. 18 and FIG. 19 .

FIG21 is an enlarged incomplete perspective view of the clamp shown in FIG20;

FIG22 is a top plan view of a brine redirection cover in a control valve of the present invention;

FIG23 is a top perspective view of the cover of FIG22;

24 is an exploded top perspective view of the control valve of the present invention illustrating the positioning of the cover of FIGS. 22 and 23 .

DETAILED DESCRIPTION

Referring now to Figures 1, 2, and 4, a control valve, generally designated 10, is provided for controlling the flow of fluid in a fluid treatment device, generally designated 12. In a preferred embodiment, the treatment device is a water softener, and tank 12 is a resin tank, however, other types of water filtration or fluid treatment equipment are contemplated. Furthermore, in this description, "fluid" is intended to mean any type of flowing liquid, but preferably means water.

The control valve 10 includes a valve body 14 having a valve body cover 16 mounted to its upper end 18 and a tank adapter 20 mounted to its lower end 22. Furthermore, the valve body 14 includes an upper portion or control portion 24 positioned closer to the cover 16 than to the tank adapter 20, and a process portion 26 positioned closer to the tank adapter than to the cover. In a normal operating position, the control portion 24 is positioned above the process portion 26, and there is no fluid communication between the control portion and the process portion, thereby isolating and maintaining the control fluid separate from the process fluid. As is well known in the water softening art, the control valve 10 includes an inlet port 28, an outlet port 30, a discharge outlet port 32, and a brine inlet port 33.

Referring now to Figures 3, 3A, and 4, the cap 16 is provided with a spindle controller 34 comprising a housing 35 surrounding a spindle body 36, which encloses a rotating spindle 37 and is retained by a bracket 38. Preferably, a lower portion 39 of the bracket 38 is integrally secured to the cap 16, such as by ultrasonic welding, heat staking, chemical adhesive, or the like. The spindle 36 has a plurality of flow ports 40 for controlling fluid flow received from a pilot line 42, which draws a portion of the fluid flow from the inlet port 28 and directs this flow into the spindle controller 34. Preferably, the hexagonal vertical cross-sectional shape of the spindle body 36 complements corresponding portions of the spindle bracket 38 and lower portion 39. This configuration allows a single sealing member, preferably an O-ring 38a, to provide a leak-proof connection between the spindle body 36, the bracket, and the lower portion 39. This configuration offers the advantage of avoiding multiple individual tube and fitting connections and the ability to use leak-prone gaskets. In other words, the housing portions 38 and 39 are arranged to be in fluid communication with the spindle body 36 without the use of gaskets, with the components held together by mechanical fasteners, and with leakage protection provided by the elastomeric seal (O-ring) 38a.

A clock or timing mechanism 44 rotates the spindle 36 and thereby directs the flow of pilot fluid to a designated one of a plurality of piston valves 46, each of which reciprocates in a designated cylinder 48. In a preferred embodiment, there are eight piston valves 46, however, the number of valves can be varied to suit the application. In addition, an indicator wheel 47, fixed to the end of the spindle 37 for co-rotation, has perforations or slots 49 arranged in various arrangements on its circumferential edge to cooperate with an optical sensor 49a or the like connected to a main control valve printed circuit board (PCB) (not shown) and to coordinate with the various operating stages of the valve 10. In addition, the position of the perforations 49 on the wheel 47 and an optional digital indicator 49b ( FIG. 3 a ) are visible to the operator through a window 49c in the housing 35, allowing the operator to monitor the operating status of the valve 10.

In a preferred embodiment, the lower portion 39 of the bracket 38 has an internal flow passage 39a ( FIG. 3 ) that is in fluid communication with a corresponding passage 39b in the cover 16 . The pilot flow is directed through an engaging fitting, such as a flow passage or port 50 ( FIG. 4 ), positioned in the cover 16 , and each flow passage is associated with a specific cylinder 48 . Movement of the piston valve 46 in the corresponding cylinder 48 by the action of the pilot flow from the spindle controller 34 causes the control valve 10 to cycle through various known water softener operating positions well known in the art. This cycling operation includes service, backwash, brine flush, slow flush, fast flush, brine fill, etc., as described in more detail in the patents referenced above.

It should be noted that only the pilot flow of fluid is utilized to control movement of the piston valve 46 via the spindle controller 34. Furthermore, the pilot flow of fluid remains in the control portion 24 and, as described above, does not mix with the fluid in the process portion 26 of the valve body.

Referring now to Figures 4-13, an important feature of the present control valve 10 is that the piston valve 46 and associated cylinder 48 are constructed and arranged to suppress sudden pressure changes that sometimes occur when process fluid flow is redirected within the valve during changes in operating cycles.

Each piston valve 46 includes a spindle 52 having an upper flange 54 positioned in the control portion 24 and configured to periodically receive a pilot flow from the spindle controller 34. At least one radial seal 56, such as an "O" ring, seals the area of the cylinder 48 below the flange to prevent access to the control portion 24 and any control fluid. In a preferred embodiment, a plurality of "O" rings 56b are also provided to separate the control portion 24 from the process or flow portion 26. Opposite the upper flange 54, the piston valve 46 is provided with a first piston valve half 58, a second piston valve half 60 complementary to the first piston valve half, and an elastomeric seal 62 configured and arranged to be sandwiched between the first piston valve half and the second piston valve half. Each of the first valve half and the second valve half has a common diameter and is combined to define a recess 64 for accommodating the elastomeric seal 62.

7-13 , in a preferred embodiment, the resilient seal 62 has a generally "T"-shaped vertical cross-section including a main body 66 and a pair of outwardly extending arms 68. The arms 68 are secured in recesses 64 formed by respective portions of the first and second valve halves 58, 60. Furthermore, the main body 66 extends radially from a peripheral edge 70 to form a wiping seal with a cylinder wall 72 ( FIG. 8 ), thereby preventing fluid from flowing into the cylinder 48 when the piston approaches and engages the cylinder ( FIG. 10 ).

Another feature of the piston valve 46 is that the first piston valve half 58 is constructed and arranged to engage the cylinder 48 before the second piston valve half, and the outer circumferential edge 70 includes a plurality of circumferentially spaced teeth 74 to form flow spaces 76 between the teeth (Figures 11 and 12). In a preferred embodiment, the teeth 74 are regularly spaced and include approximately half of the circumferential edge of the first valve half 58. It has been found that this construction suppresses the typically sudden pressure changes experienced in the valve 10 when the piston valve 46 seals the cylinder 48 during operation. Such pressure changes are known to form destructive cavitation to the extent that they damage the proper seal of the cylinder 48. Suitable fasteners 78, such as screws, secure the first half 58 to the second half 60 and indirectly the elastomeric seal 62 to the end of the piston shaft 52 (Figure 13).

Referring now to Figures 7 and 8, another feature of the valve 10 of the present invention is that each cylinder 48 includes a complementary opening 80 sized to accommodate the piston valve 46 and having a plurality of circumferentially spaced guide ribs 82, each of which has an inclined inner edge 84. The guide ribs protrude axially above the opening 80, facilitating engagement of the piston valve 46 with the opening and further reducing undesirable cavitation. It is further preferred that the inclined edges 84 define an angle α, and that the first piston valve half 58 define a complementary angled edge 86 (Figures 10 and 13) to facilitate introduction of the piston into the cylinder 48.

Referring now to Figures 14-17 and 24, tank adapter 20 defines a plurality of generally cylindrical seats 88 that open to an upper surface 90 secured to lower end 22 of valve body 14. Seats 88 are portions of a plate 91 (Figure 24) of tank adapter 20 joined by ultrasonic welding, hot plate welding, chemical adhesives, or fasteners as known in the art. In Figures 16 and 17, seats 88 are shown unattached to tank adapter 20. Each seat 88 corresponds to and is integral with an associated cylinder 48. A central outlet aperture 92 allows for the flow of processed fluid between control valve 10 and process tank 12. Furthermore, a resilient annular seal 94 (Figure 15), such as an "O" ring, is sealingly disposed in each seat 88 and circumscribes cylinder 48 to prevent fluid from passing between cylinder 48 and tank adapter 20 once tank adapter 20 is attached to valve body 14. Furthermore, without the need for a gasket, the tank adapter 20 is more simply and easily connected to the lower valve body end 22 by using the seal 94. Thus, the same type of elastomeric seal around the flow passage and the gasketless attachment system described above with respect to the spindle controller 34 is used to attach the valve body 14 to the tank adapter 20.

Referring now to Figures 4, 5, and 15, the aforementioned attachment between tank adapter 20 and valve body 14 is further simplified by a single clamping member 96 that engages the tank adapter to the valve body. The valve 10 of the present invention is characterized in that tank adapter 20 is secured to valve body 14 solely by clamping member 96. As seen in Figure 15, clamping member 96 is disposed within two "C"-shaped portions 98 that engage at opposing free ends 100 using fasteners 102, such as screws (Figure 4). Furthermore, as seen in Figure 15, the clamping engagement of tank adapter 20 with valve body 14 is preferably achieved by clamping member 96 that fixedly engages and axially compresses corresponding radially extending flanges 104, 106 of valve body 14 and process portion 26 of tank adapter 20. With this arrangement, since this connection is not exposed to water pressure, control valve 10 can be manufactured from lighter materials to save costs while still maintaining a strong connection to valve adapter 20. Furthermore, the single clamp 96 is easily removable and still securely holds the valve body 14 to the tank adapter 20 .

Referring again to Figures 16 and 17, another feature of the control valve 10 of the present invention is that a vacuum interrupter 108 is associated with the tank adapter 20, preferably integrally formed therewith and in fluid communication with the tank 12. This communication is through the intermediate outlet perforation 92. In conventional control valves, vacuum interrupters are provided to protect the valve and processing equipment from damage caused by the vacuum that forms when the fluid supply is shut off. In some cases, the height of the installation above sea level is a factor in the risk of vacuum damage. Typically, a vacuum interrupter is provided upstream and/or downstream of the valve to prevent the tank from collapsing during valve operation. By directly communicating with the tank, as in the present valve 10, only one vacuum interrupter 108 is required. The vacuum interrupter 108 is held in place by a plug 110 that engages a designated port 112 and is held in place by a clamp as described below with reference to Figures 18-21.

A pressure relief valve (PRV) 114 is also mounted to the tank adapter 20. The PRV 114 is provided to prevent damage to the valve 10 caused by pressure spikes created by rapidly opening or closing a fluid passage under pressure. As seen in Figures 16 and 17, the valve 114 is enclosed within a valve housing 116 having a plug 118 at an open end. Opposite the plug 118, the valve housing 116 is secured to the tank adapter 20 using a clamp 120, described in greater detail below. In a preferred embodiment, the PRV 114 is positioned on the valve adapter 20 diametrically opposite the vacuum interrupter 108, although other locations are contemplated. When assembled, the valve 10 with the tank adapter 20 is secured to the process tank 12 by threaded engagement with a mounted tank fitting 122.

Referring now to Figures 18-21 and 24, another feature of the control valve 10 is the quick, secure connection of input and/or output conduits or other accessories with attached nozzle fittings 124, achieved by releasable retaining clamps 120. Each clamp 120 is used to connect the nozzle fitting 124 to an associated port 126 on the valve body 14 or tank adapter 20 and is movable between a released position (Figures 20 and 21) and an engaged position (Figure 24). When viewed from the front or rear (Figure 18), the clamp 120 is generally "U"-shaped and has a pair of deflection arms 128, each having a free end 130 with a "T" lever structure 132. Associated hook protrusions 134 on the port 126 receive and retain the "T" lever structure 132 to prevent the clamp 120 from being removed from the port 126 during upward vertical movement. Furthermore, the clamp 120 includes at least one overhanging guide structure 136 for engaging with a corresponding slot 138 in the port 126 and with an associated recess 140 in the nozzle fitting 124 ( FIG. 20 ). Preferably, there are a pair of overhanging guide structures 136, each associated with an associated recess 140 on each side of the nozzle fitting 124. A tab 142 on the upper end 144 of the clamp facilitates gripping by an operator to release the clamp 120 when necessary. If desired, the tab 142 is grippable using pliers. The clamp 120 is used to secure the vacuum interrupter 108, the PRV 114, the vent line 146, and other desired connections. In the case of the vent line 146, the clamp 120 is used to allow easy access to the flow control disk (not shown). In other cases, the clamp 120 is used to allow the valve body 14 to accommodate nozzle fittings 124 having a variety of thread styles.

Referring now to Figures 22-24, as is well known in the art, another feature of the control valve 10 of the present invention is a brine redirecting cap or flow guide 148 for alternating the flow direction of brine in the process tank 12 during regeneration, alternating between upward flow and downward flow. The cap 148 is sized for easy installation and removal from a designated recess 150 in the tank adapter 20. A pair of through-holes (not shown) are included in the recess 150, each of which is connected to a respective end of the process tank 12.

Included in the cap 148 is a cover portion 152 defining an internal chamber 154. A nozzle plug 156 depends from the cover portion 152 and is configured to engage a selected one of the through-holes in the recess 150. The cover portion 152 also has a flow through-hole 158 sized to align with the other of the two through-holes in the recess 150. At least one gripping tab 160 protrudes vertically in the chamber 154 for grasping by an operator. In use, the operator grasps the tab and pulls the cap 148 upward, inserting the appropriate one of the two through-holes into the recess 150, leaving the other through-hole open for flow. In this way, the flow direction can be easily changed by pulling the cap 148 and rotating it axially to selectively insert one of the through-holes into the recess 150, without requiring major modifications to the valve 10 or rewiring of the process water.

While particular embodiments of the present control valve for a fluid handling device have been shown and described, it will be understood by those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects and as set forth in the following claims.

Claims (7)

1. A control valve for a fluid handling apparatus, comprising a housing having at least one cylinder defining a fluid flow path in the fluid handling apparatus, each cylinder having an associated reciprocating piston valve, the piston valve comprising: First piston valve half; The second piston valve half is complementary to the first piston valve half, wherein the first piston valve half and the second piston valve half have a common diameter. An elastic seal is constructed and arranged to be sandwiched between the first piston valve half and the second piston valve half; The first piston valve half is constructed and arranged to engage the cylinder body ahead of the second piston valve half, and the first piston valve half has an outer circumferential edge defined by a plurality of circumferentially spaced teeth to form a flow space between the teeth. 2. The control valve of claim 1, wherein the teeth form approximately half of the outer circumferential edge of the first piston valve half. 3. The control valve according to claim 1, wherein the teeth are regularly spaced around the outer peripheral edge of the first piston valve half. 4. The control valve of claim 1, wherein the resilient seal has a generally "T"-shaped vertical cross-section comprising a body and a pair of outwardly extending arms, wherein the arms are secured to designated recesses in each half by corresponding portions of the first and second piston valve halves, and the body extends radially from the outer periphery toward the edge to seal fluid flow when the piston valve engages with the cylinder. 5. The control valve of claim 1, wherein the cylinder body includes complementary openings sized to accommodate the piston valve, and includes a plurality of circumferentially spaced guide ribs, each guide rib having an inclined inner edge. 6. The control valve of claim 5, wherein the inclined inner edge defines an angle, and the first piston valve half defines a complementary angled edge to facilitate guiding the piston valve into the cylinder. 7. The control valve according to claim 1, wherein flow control is achieved once the resilient seal engages with the inner surface of the cylinder.