U.S. patent application number 09/853308 was filed with the patent office on 2001-12-20 for bypass valve.
This patent application is currently assigned to United States Filter Corporation. Invention is credited to Wichmann, Mark E..
Application Number | 20010052367 09/853308 |
Document ID | / |
Family ID | 24382042 |
Filed Date | 2001-12-20 |
United States Patent
Application |
20010052367 |
Kind Code |
A1 |
Wichmann, Mark E. |
December 20, 2001 |
Bypass valve
Abstract
A bypass valve for directing fluid flow, where the bypass valve
includes a valve body with a notch in at least one end thereof and
a spool seated within the valve body. The spool is rotatable within
the valve body. One preferred embodiment of the present invention
also includes at least one endcap attached to an axial end portion
of the spool, where the endcap includes a protrusion extending
thereon for preventing relative rotation between the spool and the
valve body when the protrusion is positioned within the notch. A
further aspect of the present invention relates to a bypass valve
with a valve body including a plurality of ports and a generally
cylindrical inner periphery, as well as a spool seated within the
valve body, where the spool is rotatable and axially translatable
within the valve body. The spool further preferably includes a top
seal seated upon a seal seating surface, where the top seal acts in
one mode to block a service inlet port, without blocking the other
ports, or, in another mode, blocks the service inlet port and the
service outlet port, without blocking the other ports.
Inventors: |
Wichmann, Mark E.; (Chicago,
IL) |
Correspondence
Address: |
GREER, BURNS & CRAIN
300 S WACKER DR
25TH FLOOR
CHICAGO
IL
60606
US
|
Assignee: |
United States Filter
Corporation
|
Family ID: |
24382042 |
Appl. No.: |
09/853308 |
Filed: |
May 11, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09853308 |
May 11, 2001 |
|
|
|
09595171 |
Jun 16, 2000 |
|
|
|
Current U.S.
Class: |
137/625.29 |
Current CPC
Class: |
F16K 11/078 20130101;
Y10T 137/86549 20150401; Y10T 137/86726 20150401; F16K 11/076
20130101 |
Class at
Publication: |
137/625.29 |
International
Class: |
F16K 011/07 |
Claims
1. A bypass valve for directing fluid flow, said bypass valve
comprising: a valve body with a notch in at least one end thereof;
a spool seated within said valve body, said spool being rotatable
within said valve body; and at least one endcap attached to an
axial end portion of said spool, said endcap including a protrusion
extending therefrom for preventing relative rotation between said
spool and said valve body when said protrusion is positioned within
said notch.
2. The bypass valve according to claim 1, further comprising: a
second endcap attached to a second axial end portion of said spool;
a second protrusion extending from said second endcap; a second
notch in said valve body, said second notch being configured and
arranged to cooperate with said second protrusion for preventing
relative rotation between said spool and said valve body when said
second protrusion is seated within said second notch.
3. The bypass valve according to claim 1, wherein: said valve body
includes a plurality of ports extending therethrough; said spool is
divided by a partition into at least two chambers; said partition
includes a seal on an outer periphery thereof for sealing against
an interior wall of said valve body; and said plurality of ports in
said valve body each include a plurality of bars positioned near
said interior wall of said valve body, said bars being configured
and arranged to help maintain said seal in position upon said
partition.
4. The bypass valve according to claim 3, wherein: said bars on
said ports extend in a generally axial direction; and said seal is
an o-ring that is seated in a notch in said outer periphery of said
partition.
5. The bypass valve according to claim 1, wherein: said valve body
includes a plurality of ports extending therethrough; said spool
includes three partitions that cooperate with an interior wall of
said valve body to define two chambers; said three partitions are
designated as first, second and third partitions; a first set of
two axially extending supporting ribs that are positioned
approximately 180.degree. apart from each other extend between said
first and second partitions; and a second set of two axially
extending supporting ribs that are positioned approximately
180.degree. apart from each other extend between said second and
third partitions.
6. The bypass valve according to claim 5, wherein when said
protrusion of said spool is seated within said notch of said valve
body, neither said first set of supporting ribs nor said second set
of supporting ribs is positioned in front of any of said ports of
said valve body.
7. A bypass valve for directing fluid flow, said bypass valve
comprising: a valve body with an underside; a spool seated within
said valve body, said spool being axially translatable within said
valve body; at least one endcap attached to an axial end portion of
said spool, said endcap including a locking snap positioned on an
outer periphery thereof, said locking snap being configured and
arranged to maintain said spool in a first axial position with
respect to said valve body, wherein when said locking snap is
unlocked, said spool may be moved to a second axial position; and
alignment means for maintaining said locking snap in engagement
with an underside of said valve body.
8. The bypass valve according to claim 7, wherein said locking snap
consists of a finger that extends generally axially along said
endcap, with a proximal end connected to said endcap and a distal
end extending outwardly from said outer periphery of said spool,
said alignment means extending from said distal end.
9. The bypass valve according to claim 8, wherein: said endcap
includes an inner end and an outer end, whereby said inner end is
closer to said spool than said outer end; and said proximal end of
said finger is located closer to said outer end of said endcap and
said distal end of said finger is located closer to said inner end
of said endcap, whereby said distal end of said finger prevents
axial movement of said spool within said valve body in a first
direction by abutting against an edge of said valve body unless
said finger is pressed inwardly, and where said first direction is
defined as the direction extending from said endcap toward said
valve body.
10. A bypass valve for directing fluid flow, said bypass valve
comprising: a valve body including a service inlet port, a service
outlet port, a valve inlet port, and a valve outlet port; and a
spool seated within said valve body, said spool being rotatable and
axially translatable within said valve body, whereby particular
combinations of rotation and axial translation of said spool result
in the following modes of operation: a first mode in which the
fluid flow is directed from said service inlet port, through a
first portion of the bypass valve, then to said valve outlet port,
then to said valve inlet port, through a second portion of the
bypass valve, and finally out said service outlet port; a second
mode in which the fluid flow is blocked from passing through said
service inlet port, but the fluid flow is unhindered from passing
through said service outlet port; a third mode in which the fluid
flow is directed from said service inlet port, through the bypass
valve, and then to said service outlet port; and a fourth mode in
which the fluid flow is blocked from passing through said service
inlet port as well as being blocked from passing through said
service outlet port.
11. The bypass valve according to claim 10, wherein: in said first
mode, said spool is positioned within said valve body in a first
axial position and a first radial position; in said second mode,
said spool is positioned within said valve body in said first axial
position and a second radial position, where said second radial
position is different from said first radial position; in said
third mode, said spool is positioned within said valve body in a
second axial position and said first radial position, where said
second axial position is different from said first axial position;
and in said fourth mode, said spool is positioned within said valve
body in said second axial position and said second radial
position.
12. The bypass valve according to claim 11, wherein: when in said
first axial position, said spool is pushed toward a first end of
said valve body; and when in said second axial position, said spool
is pushed toward a second end of said valve body.
13. The bypass valve according to claim 11, wherein said second
radial position is approximately 90.degree. offset from said first
radial position.
14. A bypass valve for directing fluid flow, said bypass valve
comprising: a valve body including a notch near each axial end
thereof; a spool seated within said valve body, said spool being
both rotatable and axially translatable within said valve body; and
an endcap attached to each axial end of said spool, each endcap
including a protrusion extending outwardly therefrom for preventing
relative rotation between said spool and said valve body when said
protrusion is positioned within said notch.
15. The bypass valve according to claim 14, further comprising a
locking snap positioned on an outer periphery of each of said
endcaps, each of said locking snaps being configured and arranged
to maintain said spool in a different axial position with respect
to said valve body.
16. The bypass valve according to claim 15, wherein each of said
locking snaps consists of a finger extending radially outwardly at
an angle in a generally axial direction along said associated
endcap, and at least one of said fingers being provided with
alignment means for maintaining a sliding relationship between said
finger and an underside of said valve body.
17. A bypass valve comprising: a valve body including a plurality
of ports and a generally cylindrical inner periphery; a spool
seated within said valve body, said spool being rotatable within
said valve body and including a relatively flat wall defining a
seal seating surface; and a top seal seated upon said seal seating
surface, said top seal including a relatively flat bottom surface
configured to match said seal seating surface, and a curved top
surface configured to match said inner periphery of said valve
body.
18. The bypass valve according to claim 17, wherein said top seal
is made from an elastomeric material.
19. The bypass valve according to claim 17, wherein said top seal
includes three sealing lips protruding from said curved top
surface, each of said three sealing lips defining a closed shape
when viewed from above.
20. The bypass valve according to claim 19, wherein: said plurality
of ports on said valve body include a service inlet port, a service
outlet port, a valve inlet port, and a valve outlet port; and said
three sealing lips are configured and arranged such that: when said
spool is located in a first position with respect to said valve
body, fluids are blocked from passing through said service inlet
port; and when said spool is located in a second position with
respect to said valve body, fluids are blocked from passing through
both said service inlet port and said service outlet port, as well
from passing from said service inlet port to said service outlet
port.
21. A bypass valve for directing fluid flow, said bypass valve
comprising: a valve body with an underside; a spool seated within
said valve body, said spool being axially translatable within said
valve body; at least one endcap attached to an axial end portion of
said spool, said endcap including a locking snap positioned on an
outer periphery thereof, said locking snap being configured and
arranged to maintain said spool in a first axial position with
respect to said valve body, wherein when said locking snap is
unlocked, said spool may be moved to a second axial position; and
said locking snap being integrally formed from said wall to have an
inherent spring force.
22. The bypass valve according to claim 21 further including an
alignment formation provided to said locking snap locking snap in
engagement with an underside of said valve body.
23. The bypass valve according to claim 22 wherein said alignment
formation is a pin formation extending from a distal end of said
locking snap.
Description
RELATED APPLICATION
[0001] This application is a Continuation-In-Part of U.S. Ser. No.
09/595,171 filed Jun. 16, 2000 and entitled "Bypass Valve".
BACKGROUND
[0002] The present invention relates generally to a bypass valve,
and more particularly to a bypass valve, such as a valve of the
type used with a water softener, that includes a set of service
ports (inlet and outlet) on one side thereof and a set of valve
ports (inlet and outlet) on the opposite side thereof. One
important feature of the present invention is that it includes
structures for maintaining the valve in the selected mode of
operation. An addition important feature is that the present bypass
valve includes means for sealing off the service inlet port, while
keeping the other three ports open, and means for sealing off both
the service inlet port and the service outlet port, while keeping
the other two ports open.
[0003] By pass valves are known, and are used for connecting a
water source to a water softener, or other water processing device,
and for connecting the water softener to plumbing fixtures for use
of the treated water. The known bypass valves generally have a
service side facing the source of untreated water and a valve side
facing the water softener. Service ports, located on the service
side, include a service inlet port for connecting the water source
to the bypass valve, and a service outlet port for connecting the
bypass valve to the plumbing fixture for use throughout the
dwelling. Similarly, on the valve side, there is a valve outlet
port for carrying untreated water out of the bypass valve and to
the water softener, and a valve inlet port for carrying treated
water from the softener to the bypass valve.
[0004] In addition, conventional bypass valves also generally
include a bypass passage that is configured so that water entering
the valve through the service inlet port can exit the valve through
the service outlet port, thus skipping treatment by the softener.
One example of such a bypass valve is disclosed in U.S. Pat. No.
5,152,321 to Drager et al. The use of such a bypass valve, which is
normally manually actuated, prolongs the supply of treated softener
water when the use of harder water is adequate, such as for
watering the lawn or for washing a car.
[0005] Known bypass valves, such as those of the type described in
the Drager et al. patent, normally include a spool that is
rotatably seated within a valve body. Rotation of the spool within
the valve body is normally used to switch modes from a normal
operation mode, in which the water passes through the water
softener, to a bypass mode, in which the water bypasses the water
softener and is simply directed from the service inlet, through the
bypass valve, and then through the service outlet to be used in the
dwelling. In some bypass valves, the spool can be accidentally
rotated (such as by being accidentally bumped), resulting in an
unintentional switch from one mode to the other.
[0006] Another problem with many of the current bypass valves is
that there is no simple way to close the service inlet port.
Instead, in these bypass valves, the service inlet port is always
open, whether it is in communication with the service outlet port
or in communication with the valve outlet port. The present
inventor has determined that closing the service inlet port,
without closing the other ports, is desirable because it allows
pressure to be removed, and for the water to be drained, from the
portion of the plumbing system positioned after the bypass
valve.
[0007] Thus, in light of the above, one object of the present
invention is to provide an improved bypass valve that can be more
securely retained in a particular mode.
[0008] Another object of the present invention is to provide an
improved bypass valve where the service inlet port can be blocked,
without blocking the remainder of the ports.
[0009] A third object of the present invention is to provide an
improved bypass valve in which both the service inlet port and the
service outlet port can be blocked, without blocking the other
ports.
[0010] An additional object of the present invention is to provide
an improved bypass valve in which the fluid flow during the normal
operation mode is essentially unhindered by the spool since the
supporting ribs of the spool are all positioned very close to the
inner periphery of the valve body.
[0011] These and other objects of the present invention are
discussed or ill be apparent from the following detailed
description of the present invention.
BRIEF SUMMARY OF THE INVENTION
[0012] The above-listed objects are met or exceeded by the present
bypass valve, which includes a valve body and a spool that is
seated for rotation within the valve body, and preferably further
includes structure for selectively preventing relative rotation
between the valve body and the spool after the desired mode of
operation is selected. Preferably, the spool of the present bypass
valve is also configured for axial translation within the valve
body, in which case there is also preferably structure for
maintaining the spool at the desired axial location. Accordingly,
with one or both of these two structures, the bypass valve of the
present invention can be securely maintained in the selected mode
of operation.
[0013] One optional preferred feature of the present invention is
the ability to prevent fluid from passing through the service inlet
port, while still allowing fluid to flow through the other ports.
With the service inlet port closed, the fluid in the system can be
drained back to the bypass valve. A related optional feature of the
present invention is the ability of certain embodiments to prevent
fluid from passing through both the service inlet port and the
service outlet port. With this feature, the water softener, or
other processing device, can be isolated. Additionally, additional
fluid flow into the system downstream from the water softener can
also be prevented.
[0014] The present invention may also optionally include a spool in
which the supporting ribs are positioned near the inner periphery
of the valve body. With such a configuration, the fluid that flows
through the bypass valve during the normal operating mode is
essentially unhindered by the spool, resulting in a reduction in
undesirable pressure drops common in other bypass valves in which
the supporting ribs extend axially through the center of the spool,
partially obstructing the fluid flow through the valve.
[0015] More specifically, the present invention provides a bypass
valve for directing fluid flow, where the bypass valve includes a
valve body with a notch in at least one end thereof and a spool
seated within the valve body. The spool is rotatable within the
valve body. One preferred embodiment of the present invention also
includes at least one endcap attached to an axial end portion of
the spool, where the endcap includes a protrusion extending thereon
for preventing relative rotation between the spool and the valve
body when the protrusion is positioned within the notch. In the
preferred embodiment, the protrusion is provided with an alignment
formation for preventing unwanted obstruction of the protrusion to
the desired axial movement of the spool.
[0016] Another aspect of the present invention relates to a bypass
valve for directing fluid flow, where the bypass valve includes a
valve body with a notch in at least one end thereof, a spool seated
within the valve body, and where the spool is axially translatable
within the valve body. This embodiment preferably also includes at
least one endcap attached to an axial end portion of the spool. The
endcap further includes a locking snap positioned on an outer
periphery thereof, with the locking snap being configured and
arranged to maintain the spool in a first axial position with
respect to the valve body, and wherein when the locking snap is
unlocked, the spool may be moved to a second axial position.
[0017] Additionally, the present invention also relates to a bypass
valve for directing fluid flow, where the bypass valve includes a
valve body with a service inlet port, a service outlet port, a
valve inlet port, and a valve outlet port, as well as a spool
seated within the valve body. The spool is preferably rotatable and
axially translatable within the valve body, whereby particular
combinations of rotation and axial translation of said spool result
in the following modes of operation: (1) a first mode in which the
fluid flow is directed from the service inlet port, through a first
portion of the bypass valve, then to the valve outlet port, then to
the valve inlet port, through a second portion of the bypass valve,
and finally out the service outlet port; (2) a second mode in which
the fluid flow is blocked from passing through the service inlet
port, but the fluid flow is unhindered from passing through the
service outlet port; (3) a third mode in which the fluid flow is
directed from the service inlet port, through the bypass valve, and
then to the service outlet port; and (4) a fourth mode in which the
fluid flow is blocked from passing through the service inlet port
as well as being blocked from passing through the service outlet
port.
[0018] An additional aspect of the present invention relates to a
bypass valve for directing fluid flow, where the bypass valve
includes a valve body with a notch near each axial end thereof and
a spool seated within the valve body, where the spool is both
rotatable and axially translatable within the valve body.
Preferably, there is also an endcap attached to each axial end of
the spool, and each endcap preferably includes a protrusion
extending outwardly therefrom for preventing relative rotation
between the spool and the valve body when the protrusion is
positioned within the notch. Additionally, as stated above, in the
preferred embodiment, the protrusion is provided with an alignment
formation for preventing unwanted obstruction of the protrusion to
the desired axial movement of the spool.
[0019] A further aspect of the present invention relates to a
bypass valve with a valve body including a plurality of ports and a
generally cylindrical inner periphery, as well as a spool seated
within the valve body, where the spool is rotatable within the
valve body. The spool further preferably includes a relatively flat
wall defining a seal seating surface. In addition, there is also
preferably a top seal seated upon the seal seating surface, where
the top seal includes a relatively flat bottom surface configured
to match the seal seating surface, as well as a curved top surface
configured to match the inner periphery of the valve body.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] Preferred embodiments of the present invention are described
herein with reference to the drawings wherein:
[0021] FIG. 1 is an exploded view of a first embodiment of the
present bypass valve;
[0022] FIG. 2 is an enlarged top view of a preferred embodiment of
the top seal, which is one of the components shown in the FIG. 1
embodiment;
[0023] FIG. 3 is an enlarged bottom view of the top seal of FIG.
2;
[0024] FIG. 4 is a side view of the top seal of FIG. 2;
[0025] FIG. 5 is a cross-sectional view of the top seal of FIG. 2,
taken along line V-V of FIG. 4;
[0026] FIG. 6A is a cross-sectional view of the bypass valve of
FIG. 1, showing a first mode of operation;
[0027] FIG. 6B shows a side view of the bypass valve of FIG. 1
positioned in the first mode of operation, as in FIG. 6A;
[0028] FIG. 7A is a cross-sectional view of the bypass valve of
FIG. 1, showing a second mode of operation;
[0029] FIG. 7B shows a side view of the bypass valve of FIG. 1
positioned in the second mode of operation, as in FIG. 7A;
[0030] FIG. 8A is a cross-sectional view of the bypass valve of
FIG. 1, showing a third mode of operation;
[0031] FIG. 8B shows a side view of the bypass valve of FIG. 1
positioned in the third mode of operation, as in FIG. 8A;
[0032] FIG. 9A is a cross-sectional view of the bypass valve of
FIG. 1, showing a fourth mode of operation;
[0033] FIG. 9B shows a side view of the bypass valve of FIG. 1
positioned in the fourth mode of operation, as in FIG. 9A;
[0034] FIG. 10 is an exploded view of a second embodiment of the
present bypass valve;
[0035] FIG. 11 is an assembled view of the bypass valve of FIG.
10;
[0036] FIG. 12 is a cross-sectional view of the bypass valve of
FIG. 10, taken along line XII-XII of FIG. 11;
[0037] FIG. 13 is an enlarged view of the endcap of FIG. 11, taken
within circle A;
[0038] FIG. 14 is a side elevational view of an alternate
embodiment of an endcap of the present valve; and
[0039] FIG. 15 is a perspective elevational view of the endcap of
FIG. 14.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Referring now to FIG. 1, a first preferred embodiment of the
present bypass valve 10 will be explained. Briefly, FIG. 1 shows,
in an exploded view, a valve body 12, a stem or spool 14, and a
pair of endcaps 16A and 16B. As can be seen from FIG. 1, the spool
14 is configured to be seated within the valve body 12, and the
endcaps 16A/16B each have a wall 17 and are each positioned upon
the axial ends 18A/18B of the spool 14 (such as shown in FIGS. 6A
and 6B).
[0041] The valve body 12 includes two threaded service ports
(service inlet port 20 and service outlet port 22) and two valve
ports (valve inlet port 24 and valve outlet port 26). As known to
those skilled in the art, service inlet port 20 is normally
connected to the water supply at or near the point that the water
first enters the dwelling, valve outlet port 26 is normally
connected to the input pipe of a water softener (not shown) or
other water treatment device, valve inlet port 24 is normally
connected to the water softener output pipe for receiving softened
water, and service outlet port 22 is normally connected to the main
plumbing input pipe of the dwelling. Thus, when the bypass valve 10
is in its normal operating mode (other modes will be described
hereinbelow), untreated water enters the bypass valve 12 through
service inlet port 20, exits the valve through valve outlet port
26, at which point it enters the water softener (or other water
treatment device). Inside the water softener, the water is treated
and it is once again directed into the valve, this time via valve
input port 24. Next, the water flows through the valve and to
service output port 22, where the treated water is directed to the
main plumbing of the house for use in the dwelling.
[0042] In addition to ports 20, 22, 24 and 26, the valve body 12
(which is preferably configured as a generally cylindrical hollow
tube) may also include mounting means, such as ears 28, for
mounting the valve body 12 upon the water softener (or other
treatment device). One of the important aspects of the present
valve body 12 are notches 30A, 30B, 32A, and 32B (notch 32A is not
shown, but is positioned in a similar location as 32B, except it is
on the same edge as notch 30A). The purpose of the notches 30A,
30B, 32A and 32B, which are basically used to prevent unwanted
rotation of the spool 14, will be more fully described below when
describing endcaps 16A and 16B.
[0043] Turning now to spool 14, this component includes a series of
partitions, such as first partition 34, second partition 36, third
partition 38, and fourth partition 40. The first partition 34 and
the second partition 36 define a first chamber 42 between them, in
cooperation with the interior periphery 43 of the valve body 12. In
a similar manner, the second partition 36 and the third partition
38 define a second chamber 44 between them and the interior
periphery 43. Preferably, the second partition 36 performs the dual
functions of acting as a wall for both the first chamber 42 and the
second chamber 44. However, if desired, the second partition may
take the form of two separate partitions, where one partition
cooperates with the first partition 34 and the other cooperates
with the fourth partition 38.
[0044] A third chamber 46 is defined between the third partition 38
and the fourth partition 40 in a similar manner as the first and
second chambers 42, 44. If desired, the third partition 38, which
serves as parts of both the second chamber 44 and the third chamber
46, may be modified into two separate partitions, similar to that
described above for the second partition 36.
[0045] The outer periphery of each of the partitions 34, 36, 38,
and 40 includes a groove, which is each designated, respectively,
as groove 48, 50, 52 and 54. When the bypass valve 10 is assembled,
an o-ring is seated in each of the grooves 48, 50, 52 and 54. These
o-rings are shown in the exploded view of FIG. 1, and are
designated, respectively, as o-rings 56, 58, 60 and 62. When the
bypass valve 10 is assembled, the o-rings 56, 58, 60 and 62 abut
against the interior periphery 43 of the valve body 12, and prevent
fluid from passing across the partitions 34, 36, 38, and 40.
[0046] The partitions 34, 36, 38, and 40 are connected to each
other by a plurality of supporting ribs. In particular, supporting
ribs 64 and 66 connect partitions 34 and 36; supporting ribs 68 and
70 connect partitions 36 and 38, and a single supporting rib 72,
which is preferably cross-shaped in cross-section, connects
partitions 38 and 40.
[0047] One important feature of the present invention is that the
supporting ribs 64 and 66, which surround the first chamber 42, and
the supporting ribs 68 and 70, which surround the second chamber
44, are preferably set to be at or near the outer periphery of
their associated partitions. As will become more apparent from the
description below, placing the supporting ribs 64, 66, 68, and 70
at or near the outer periphery of the partitions allows the first
and second chambers 42 and 44 to provide essentially unobstructed
fluid flow through the valve when the valve is set to the normal
service operating mode. Such a configuration of the supporting ribs
eliminates the pressure drops caused by the centered supporting
ribs of prior art devices. It should be noted that cross-shaped rib
72, which passes through the third chamber 46, need not be
configured in the same manner as ribs 64, 66, 68 and 70 because
fluids are not intended to flow completely through the third
chamber 46, so pressure drops at this chamber are not a
concern.
[0048] Another important feature of this first embodiment of the
present invention is the inclusion of a top seal 74, which is
configured to be seated upon a seal seating surface 76, which is
the upper surface of the supporting rib 68. The seal seating
surface 76 is preferably a generally flat surface, and preferably
includes a projection 78 that is configured to mate with recess 80
(shown in FIGS. 3 and 5) for positioning the seal 74 upon the seal
seating surface 76. Preferably, an adhesive is used to firmly affix
the top seal 76 to the seal seating surface 76. Although only one
configuration for securing the top seal 74 and the supporting rib
68 together has been shown, other configurations, such as the use
of mechanical locking means (with or without adhesive) are also
contemplated as being within the scope of the invention.
[0049] The top seal 74 is preferably made of an elastomeric
material so that a tight seal can be made with the interior
periphery 43 of the valve body 12. Referring now to FIGS. 2-5,
enlarged views of the top seal 74 are shown. More specifically,
FIG. 2 shows a top view of top seal 74; FIG. 3 shows a bottom view;
FIG. 4 shows a side view; and FIG. 5 shows a cross-sectional view
taken along line V-V of FIG. 4.
[0050] As shown in FIGS. 1, 2, and 5, the top surface 82 of the top
seal 74 is preferably curved with a curve that generally coincides
with the curve of the interior periphery 43 of the valve body 12.
There are a plurality of raised sealing lips 86A, 86B, and 86C
located upon the top surface 82. As best shown in FIG. 2, these
lips each define a separate closed shape so that fluid within the
closed shape defined by one of the lips 86A, 86B or 86C is not
passed outside of the closed shape. As best shown in FIG. 5, the
bottom surface 84 of the top seal 74 is a generally flat surface
(except for recess 80), so that it can be seated upon the
relatively flat seal seating surface 76 of the spool 14. However,
if the seal seating surface 76 includes a profile other than flat,
the bottom surface 84 may also be made of a complementary
profile.
[0051] Referring back to FIG. 1, it can be seen that the axial ends
18A and 18B of the spool 14 are configured for retaining,
respectively, the endcaps 16A and 16B. Preferably, ends 18A and 18B
each include a generally T-shaped leg (90A and 90B) and a generally
flat leg (92A and 92B) that is inclined slightly upwardly. The
generally flat legs 92A and 92B each preferably include a thickened
portion (94A and 94B). The interior surfaces of the endcaps 16A and
16B are configured to receive the legs 90A, 90B, 92A and 92B. In
particular, the T-shaped legs 90A and 90B serve to position the
axial ends 18A and 18B within the curved interior surfaces 96A and
96B, and the flat legs 92A and 92B seat against the flat interior
surfaces 98A and 98B. The thickened portions 94A and 94B mate with
slots 100A and 100B in the endcaps 16A and 16B to secure the
endcaps in place upon the axial ends 18A and 18B of the spool 14.
The slight upward incline of the flat legs 92A and 92B provides a
slight upward bias for directing the thickened portions 94A and 94B
into the slots 100A and 100B.
[0052] Another important feature of the present invention relates
to the interaction between endcap protrusions 102A/102B and notches
30A/30B and 32A/32B. As mentioned above, the spool 14 is rotatably
seated within the valve body 12, whereby rotating the spool 14
changes the operating mode of the bypass valve 10. In order to
prevent the spool 14 from being unintentionally rotated within the
valve body 12 (which may change the operational mode of the valve
10), the projection 102A or 102B is seated within one of the
notches (i.e., either notch 30A or notch 30B for projection 102A or
notch 32A or notch 32B for projection 102B). Thus, even if the
present bypass valve 10 is unintentionally bumped or otherwise
jarred, the projection/notch combination maintains the valve in the
selected mode of operation.
[0053] The basic operating modes of the first embodiment of the
present bypass valve 10 will now be described while referring to
FIGS. 6A through 9B. Each operational mode is arrived at by
rotating and/or axially translating the spool 14 within the valve
body 12 so that different valve configurations are achieved. In
this discussion, FIGS. 6A, 7A, 8A and 9A each show a
cross-sectional view (taken through a plane that is slightly offset
from the axial center of the device) of a different operational
mode. FIGS. 6B, 7B, 8B, and 9B are top views that coincide with the
operation mode of the "A" figures of the same number. For example,
FIGS. 6A and 6B both depict the same operation mode, which, in this
case, is the service mode with normal operation, FIGS. 7A and 7B
both depict the second operation mode, etc.
[0054] Referring now to FIGS. 6A and 6B, the first operational mode
is depicted. In this mode, which is the normal service mode, water
flows into the service inlet port 20 via opening 20', through the
second chamber 44 and then out of the valve through the valve
outlet port 26 (via opening 26'), whereby the fluid flows into the
water softener (or other treatment device) since port 26 is
connected to an input port of a water softener (not shown). The
water is then treated, and is directed back into the valve 10 via
valve inlet port 24 (through opening 24'). The fluid then passes
through first chamber 42, and finally out of the valve through
service outlet port 22 (via opening 22'), which is connected to the
main plumbing of the dwelling, whereby the treated water can be
used throughout the dwelling.
[0055] Referring primarily to FIG. 6B, in this first operational
mode, the spool 14 is positioned axially within the valve body 12
such that it is located as far to the right (as shown in FIGS. 6A
and 6B) as possible. Thus, since the spool 14 is axially longer
than the valve body 12, a portion of the endcap 16B (the right hand
endcap, as shown in FIG. 6B) sticks out from the valve body 12.
Accordingly, only one of the endcap protrusions (protrusion 102A)
mates with one of the notches (in this case, notch 30A), while the
other protrusion (protrusion 102B) is un-mated with any notch.
[0056] As can be seen from the cross-sectional view of FIG. 6A, in
this operational mode the first partition 34 (along with its
associated o-ring) prevents the fluid from flowing out of the
bypass valve in the leftward direction, since this partition is
positioned to the left of openings 22' and 24'. The second
partition 36 (along with its associated o-ring) separates the
treated water flowing between openings 24' and 22' from the
untreated water flowing between openings 20' and 26' (since this
partition is located between openings 22' and 20' as well as
between openings 24' and 26'). In addition, the third partition 38
(and the associated o-ring) prevents fluid from flowing out of
chamber 44 in the rightward direction since it is positioned to the
right of openings 20' and 26'.
[0057] In order to maintain the spool 14 in the axial position of
FIGS. 6A and 6B, a locking snap, such as locking snap 104B, may be
included. As the locking snap is an important feature of the
invention, a full description of this feature will be provided when
describing the second embodiment and while referring to FIGS. 10,
11, and 13. It should be noted that although described in more
detail in the second embodiment, the locking tab is preferably also
provided with this first embodiment. Briefly, locking tab 104B is a
finger that is inclined radially outwardly. The end of the finger
of the locking tab 104B abuts against the axial end surface of the
valve body 12, thereby preventing the spool 14 from moving to the
left. When such leftward movement is desired, the finger is simply
depressed radially inwardly, whereby it no longer abuts against the
end surface.
[0058] As can be seen from reviewing FIG. 1 in connection with FIG.
6A, the supporting ribs 64, 66, 68, and 70 do not hinder the flow
of the fluid passing through chambers 42 and 44 because these ribs
are positioned very near the interior periphery 43 of the valve
body 12. Thus, in the cross-sectional view of FIG. 6A, supporting
ribs 66 and 70 are positioned very near to the rear of the interior
periphery 43, and supporting ribs 64 and 68 are not shown in this
view because they are positioned very near to the front of the
interior periphery 43, which has been cut away to show the
cross-sectional view of FIG. 6A.
[0059] Referring now to FIGS. 7A and 7B, a second operational mode
is depicted. Briefly, in this operational mode, the spool 14 has
been rotated approximately 90.degree. from that of the first mode
so that the top seal 72 seals the opening 20' of the service inlet
port 20. In this mode, the protrusion 102A is seated within a
different slot from that of FIG. 6B. In this mode, the protrusion
102A is seated in slot 32A, while slot 30A remains open. It should
be noted that although the spool 14 has been rotated, the axial
location of the spool within the valve body 12 has not been changed
from that of the first operational mode.
[0060] The primary purpose of this second operational mode is to
allow the user to stop the incoming water flow through service
inlet port 20 and its associated opening 20'. Although not clearly
shown in FIG. 7A, the lip 86B of FIGS. 2 and 4 prevents fluid from
passing from opening 20' and into chamber 44. In this mode, the
entire system downstream of the service inlet port 20 can be
drained since ports 22, 24, and 26 remain open.
[0061] FIGS. 8A and 8B show the third operational mode, which is
the bypass mode whereby the water softener is bypassed, whereby
untreated water is directed to the dwelling. To achieve this mode,
the spool 14 is moved axially to the left, and is rotated back to
the position of FIGS. 6A and 6B. In this mode, untreated water
enters service inlet port 20, goes through opening 20', travels
through chamber 44, and exits the bypass valve through opening 22'.
This untreated water is directed to the dwelling via service outlet
port 22. As can be seen in FIG. 8A, chamber 42 (which is sealed
between partitions 48 and 50) keeps any residual water from opening
24' from leaking out of the bypass valve 10, and chamber 46 (which
is sealed between partitions 52 and 54) keeps any residual water
from opening 26' from leaking out of the valve. In this mode, as in
the first mode of FIGS. 6A and 6B, the supporting rib 70 does not
hinder the flow of water through chamber 44 because rib 70 is
located very near to the rear wall of the interior periphery 43 of
the spool 14.
[0062] As can be seen in FIG. 8B, the spool 14 is axially shifted
to the left-hand side of the figure with respect to the valve body
12. In this mode, locking snap 104A, which operates in the
identical manner to locking snap 104B of FIG. 6B, retains the spool
14 in its axial position. To prevent relative rotation between the
spool 14 and the valve body 12, the endcap protrusion 102B is
seated within the notch 30B.
[0063] FIGS. 9A and 9B show the fourth operational mode of the
present bypass valve 10. In this mode, both the service inlet port
20 (and opening 20') and the service outlet port 22 (and opening
22') are closed by the top seal 74, and openings 24' and 26' remain
open. To arrive at this mode, the spool 14 is moved axially to the
far left, as in the third mode shown in FIGS. 8A and 8B. However,
the position of the spool 14 in this mode is rotated approximately
90.degree. from its position in the third mode of FIGS. 8A and
8B.
[0064] To maintain the spool in its rotated position, endcap
protrusion 102B engages notch 32B. To maintain its axial position,
locking snap 104A is activated, as in the mode of FIG. 8B. With
regard to the locking snaps 104A and 104B, care must be taken to
make sure that the notches 30A, 30B, 32A and 32B do not interfere
with the operation of the locking snaps. One simple method of
preventing such interference is to make the locking snaps 104A and
105B wider than the notches 30A, 30B, 32A, and 32B. If the locking
snaps are wider than the notches, the snaps cannot enter the
notches.
[0065] Referring now to FIGS. 10-13, a second preferred embodiment
of the present bypass valve will be described. Wherever possible,
components of the second embodiment that are similar to components
of the first embodiment will be numbered with the same reference
numbers. Components that are different will be designated with the
suffix "X", such as supporting rib 68X of FIG. 10, which is
different from supporting rib 68 of FIG. 1.
[0066] One of the main differences between the first embodiment and
the second embodiment is that the supporting rib 68X of the second
embodiment does not include the top seal 74 of the first
embodiment. Instead, supporting rib 68X of the second embodiment is
essentially identical to supporting rib 70. Accordingly, since the
second embodiment lacks the top seal, it cannot operate in the
second mode (in which the service inlet port 20 is closed), nor can
it operate in the fourth mode (in which both the service inlet port
20 and the service outlet port 22 are closed). Instead, the second
embodiment bypass valve only operates in two modes--a normal
service mode, in which the water flows through the water softener
(the first mode of the first embodiment), and a bypass mode, in
which water bypasses the water softener and goes directly into the
dwelling (the third mode of the first embodiment).
[0067] Turning now to FIG. 11, the second embodiment bypass valve
is shown in bypass mode, which is similar to the bypass mode of the
first embodiment shown in FIGS. 8A and 8B. As in the first
embodiment, the bypass mode of the second embodiment is realized by
axially moving the spool 14 to the far left, and by rotating the
spool so that endcap protrusion 102B is seated within notch
30B.
[0068] The axial position of the spool 14 is maintained by the
locking snap 104A. Referring now to FIG. 13, which is an enlarged
version of the portion of FIG. 11 enclosed by circle A, the locking
snap 104A (which is preferably found in both embodiments) will be
described in detail. As shown in FIG. 13, the locking snap 104A is
basically a finger 99 that includes a proximal end 101 and a distal
or free end 103. In the preferred embodiment, the finger 99 is an
integral portion of the wall 17 of the endcap 16A, 16B, and is
formed from a segment of the wall. The wall 17 defines a generally
cylindrical shape dimensioned to be slidably engaged within an
interior of the valve body 12. The finger 99 is inclined radially
outwardly in the direction from its proximal end 101 to its distal
end 103. In this manner, the finger 99 can abut against axial
endwall 105 of the valve body 12 in order to prevent the spool 14
from moving axially in the rightward direction. When such rightward
movement is desired, the finger 99 is simply pressed radially
inwardly, at which point it can slide under the axial endwall
105.
[0069] Referring now to FIGS. 13-15, in some cases it has been
found that, when the endcap 16A is pressed axially in the rightward
direction to adjust the position of the spool 14, in some cases the
finger 99 becomes disengaged with the desired underside of the
endwall 105, and hyperextends above the exterior of the valve body
12, thus obstructing the axial movement of the spool. More
specifically, when the endcap 16A is in the pulled open position
(best seen in FIG. 13), the finger 99 has sufficient inherent
spring force to ride up over the edge of the endwall 105. Thus, as
the endcap 16A is pressed toward the valve body 12, in some cases
the finger 99 continues to slide upward over the endwall 105 and
the valve body, and eventually prevents further axial movement of
the spool 14.
[0070] To address this problem, the finger 99 has been modified to
be provided with an alignment formation, designated 110, which is
configured for maintaining a sliding engagement with the inner
surface of the valve body 12. In the preferred embodiment, the
finger 99 is provided with an alignment formation taking the form
of an extended pin-like lug or other protrusion. The lug 110 is
preferably integrally formed with the finger 99, however separate
formation and attachment to the finger 99 by adhesive, ultrasonic
welding or other techniques known in the art are contemplated. As
an alternate construction, the finger 99 could be provided with a
depressed, blade-like extension, or other configuration performing
the function of preventing the finger from becoming disengaged from
the underside or interior wall 112 (best seen in FIG. 1) of the
valve body 12. When the formation 110 is provided, the user can
more confidently radially depress the finger 99 once the position
of the valve spool needs to be changed.
[0071] If desired, a lead-in or groove (not shown) may be provided
in the axial endwall located on the opposite side of axial endwall
105. Such a lead-in provides a space for the finger 99 to move
axially into, and effectively disables the axial locking function
on this side of the device. Such a lead-in may be provided on one
side of the device where no axial lock is desired for preventing
the valve from switching modes from the service mode to the bypass
mode, but the axial lock is still desired for preventing a switch
from the bypass mode to the service mode. More specifically, if
such a one-sided axial lock is desired in the embodiment as shown
in FIGS. 11 and 12, the locking snap 104A on the left side will
operate normally (preventing axial movement to the right), but the
locking snap on the left side will include a lead-in or groove in
the right axial endwall, so axial movement to the left is
permitted.
[0072] Referring back to FIG. 12, this figure is a cross-sectional
view of FIG. 11 taken along line XII-XII. FIG. 12, like FIG. 11,
depicts the bypass mode. Accordingly, in this operational mode,
fluid enters the service inlet port 20 (and the opening 20'),
passes through the chamber 44, and then exits the valve through the
opening 22' and the service outlet port 22, without being treated
by a water softener or other treatment device. One important
feature depicted in FIG. 12 is the axially extending bars 106 that
are shown crossing the openings 22' and 20'. Although not shown,
similar bars also cross openings 24' and 26'. These bars prevent
the o-rings 56, 58, 60, and 62 from expanding into the openings
20', 22', 24' and 26'. Although the o-rings are best shown in the
FIG. 1 embodiment, these same o-rings are utilized in both
embodiments, and the bars are preferably also included in both
embodiments. Without the use of such bars, the o-rings may become
dislodged from their grooves (48, 50, 52, and 54, shown in FIG. 1)
when they are moved past the openings.
[0073] Referring to FIG. 10 in combination with FIG. 12, another
difference between the first embodiment and the second embodiment
will be discussed. In the second embodiment of FIGS. 10 and 12,
legs 90AX and 90BX are shown as being generally cross-shaped in
cross-section. In contrast, legs 90A and 90B of FIG. 1 were
generally T-shaped. The cross-shaped legs of the second embodiment
provide better support, while the T-shaped legs of the first
embodiment save on material costs. Legs of either shape may be used
in either embodiment, depending upon the desired results (cost
savings vs. additional strength).
[0074] One final difference between the second embodiment and the
first embodiment lies in the positioning of the notches. In the
second embodiment, notches 30A and 32AX, as well as notches 30B and
32BX, are positioned approximately 180.degree. apart from each
other, as best seen in FIG. 10. In contrast, in the first
embodiment, notches 30A and 32A, as well as notches 30B and 32B,
are positioned approximately 90.degree. apart from each other, as
best seen in FIG. 1. This is the case because in the second
embodiment the notches (and the protrusions) help to maintain the
spool in positions where the supporting ribs 64, 66, 68X, and 70 do
not block the openings 20', 22', 24' and 26'. In contrast, in the
first embodiment, the openings are intended to not be blocked in
only two of the four modes (the first or normal service mode and
the third or bypass mode), and the openings are intended to be
blocked by the supporting rib 68 (and the top seal 74) in the other
two modes (the second and fourth modes). The 90.degree. notch
spacing of the first embodiment allows for such blockage.
[0075] In general, the second embodiment is more economical to
produce than the first embodiment because it includes less parts
since the top seal is missing in the second embodiment. However,
many of the benefits of the first embodiment are also realized by
the second embodiment. For example, the rotary and axial locking
features of the first embodiment are also found on the second
embodiment, as well as the feature in which fluid flow through the
chambers is essentially uninterrupted by the supporting ribs since
the supporting ribs are positioned near the interior periphery of
the valve body.
[0076] While particular embodiments of the present bypass valve
have been shown and described, it will be appreciated by those
skilled in the art that changes and modifications may be made
thereto without departing from the invention in its broader aspects
and as set forth in the following claims.
* * * * *