U.S. patent application number 11/104748 was filed with the patent office on 2005-08-11 for one-piece manifold for a reverse osmosis system.
This patent application is currently assigned to Watts Regulator Co., a Massachusetts corporation. Invention is credited to Schmitt, Craig A..
Application Number | 20050173317 11/104748 |
Document ID | / |
Family ID | 43706228 |
Filed Date | 2005-08-11 |
United States Patent
Application |
20050173317 |
Kind Code |
A1 |
Schmitt, Craig A. |
August 11, 2005 |
One-piece manifold for a reverse osmosis system
Abstract
A one-piece manifold for a reverse osmosis system includes a
filter configured to receive water from a water port and a membrane
configured to receive filtered water via a first conduit. The
membrane is also configured to send permeate water to a reverse
osmosis tank. The manifold also includes a flow restrictor
configured to receive concentrate water from the membrane via a
second conduit and to pass concentrate water to a drain port.
Inventors: |
Schmitt, Craig A.; (Phoenix,
AZ) |
Correspondence
Address: |
FISH & RICHARDSON PC
225 FRANKLIN ST
BOSTON
MA
02110
US
|
Assignee: |
Watts Regulator Co., a
Massachusetts corporation
|
Family ID: |
43706228 |
Appl. No.: |
11/104748 |
Filed: |
April 13, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11104748 |
Apr 13, 2005 |
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10771621 |
Feb 4, 2004 |
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60444864 |
Feb 4, 2003 |
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60456153 |
Mar 20, 2003 |
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60519364 |
Nov 12, 2003 |
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60537363 |
Jan 20, 2004 |
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Current U.S.
Class: |
210/109 ;
210/321.65; 210/323.1; 210/443; 210/450 |
Current CPC
Class: |
B01D 2313/10 20130101;
B01D 61/025 20130101; B01D 2313/105 20130101; B01D 61/04 20130101;
B01D 2313/125 20130101; B01D 61/10 20130101; B01D 2311/04
20130101 |
Class at
Publication: |
210/109 ;
210/321.65; 210/443; 210/450; 210/323.1 |
International
Class: |
B01D 065/00 |
Claims
What is claimed is:
1. A one-piece manifold for a reverse osmosis system, comprising: a
filter configured to receive water from a water port; a membrane
configured to receive filtered water via a first conduit, the
membrane configured to send permeate water to a reverse osmosis
tank; and a flow restrictor configured to receive concentrate water
from the membrane via a second conduit and to pass concentrate
water to a drain port.
2. The manifold of claim 1, further comprising a shut-off
valve.
3. The manifold of claim 1 wherein the manifold comprises
polypropylene material.
4. The manifold of claim 1, wherein the filter is a sediment
filter.
5. The manifold of claim 4, further comprising a carbon filter
6. The manifold of claim 5, further comprising end caps defining
grooves that control the path of water flow to the filters.
7. The manifold of claim 6, wherein the end caps control the path
of water flow from each of the filters and the membrane.
8. The manifold of claim 1, wherein the flow restrictor defines
threads that restrict flow of water.
9. A one-piece manifold for a zero-waste reverse osmosis system,
comprising: a filter configured to receive water from a water port;
a membrane configured to receive filtered water via a first
conduit, the membrane configured to send permeate water to a
reverse osmosis tank; and a flow restrictor configured to receive
concentrate water from the membrane via a second conduit and to
pass concentrate water to a water source port.
10. The manifold of claim 9, further comprising a shut-off valve
modified for zero-waste.
11. The manifold of claim 9 wherein the manifold comprises
polypropylene material.
12. The manifold of claim 9, wherein the filter is a sediment
filter.
13. The manifold of claim 12, further comprising a carbon
filter
14. The manifold of claim 13, further comprising end caps defining
grooves that control the path of water flow to the filters.
15. The manifold of claim 14, wherein the end caps control the path
of water flow from each of the filters and the membrane.
16. The manifold of claim 9, wherein the flow restrictor defines
threads that restrict flow of water.
Description
[0001] This application is a division of U.S. patent application
Ser. No. 10/771,621, filed Feb. 4, 2004, now pending, which claims
benefit from U.S. Provisional Application No. 60/444,864, filed
Feb. 4, 2003, now expired, U.S. Provisional Application No.
60/456,153, filed Mar. 20, 2003, now expired, U.S. Provisional
Application No. 60/519,364, filed Nov. 12, 2003, now expired, and
U.S. Provisional Application No. 60/537,363, filed Jan. 20, 2004,
now expired. This application is also related to U.S. patent
application Ser. No. 10/692,398, filed Oct. 23, 2003, now pending.
The entire disclosures of all of these applications are
incorporated herein by reference. This disclosure relates to
reverse osmosis systems.
TECHNICAL FIELD
BACKGROUND
[0002] A typical reverse osmosis water filtering system used in
purifying water includes a semi-permeable membrane. Typically,
pressure is applied to incoming water that forces the incoming
water through the membrane. The membrane filters impurities from
the incoming water leaving purified water on the other side of the
membrane called "permeate" water. The impurities left on the
membrane are washed away by a portion of the incoming water that
does not pass through the membrane. The impurities and the water
used to wash them away from the membrane are called "concentrate"
water.
SUMMARY
[0003] In one aspect, a one-piece manifold for a reverse osmosis
system includes a filter configured to receive water from a water
port and a membrane configured to receive filtered water via a
first conduit. The membrane is also configured to send permeate
water to a reverse osmosis tank. The manifold also includes a flow
restrictor configured to receive concentrate water from the
membrane via a second conduit and to pass the concentrate water to
a drain port.
[0004] In another aspect, the one piece manifold is adapted for use
in a zero waste reverse osmosis system by passing the concentrate
water to a water source port. This aspect may include a feature of
having a shut-off valve modified for zero-waste.
[0005] In still another aspect, a flow restrictor defines a
restricted flow path for liquid. The flow restrictor includes a
housing defining an elongated conduit having a tapering conical
wall defining a first screw thread and a water-channel thread
extending along the tapering conical wall. The housing includes a
first opening into a distal region of the conduit for receiving a
flow of liquid and a second opening into a proximal region of the
conduit. The flow restrictor also includes an axially elongated
plug received into the conduit. A surface of the plug is opposed to
the tapering conical wall defining a second screw thread and a
tapering surface. The second screw thread is disposed in threaded
engagement with the first screw thread defined by the conical wall
of the housing. The opposed surface of the water-channel thread and
the tapering surface of the plug are disposed in sealing engagement
within the conduit and opposite to define a region for liquid flow.
The housing with the water-channel thread and the tapering surface
of the plug thereby cooperatively define a generally spiral liquid
flow path along the water-channel screw thread and the tapering
surface, for flow of liquid generally between the first opening and
the second port for delivery of liquid from the conduit.
[0006] In still another aspect, the flow restrictor is modified for
flow of liquid generally between the first opening and a port
defined by the flow restrictor for delivery of liquid from the
conduit.
[0007] The aspects above may have one or more of the following
advantages. A one-piece manifold combines many components of a
standard reverse osmosis system into a single unit. Thus, tubular
connections between these components are eliminated, thereby
providing a system that reduces the number leaks caused by these
tubular connections. In addition, a one-piece manifold can be
installed relatively faster than the standard reverse osmosis
system because there are less overall components.
[0008] A tapered plug within the flow restrictor can be
manufactured using injection molding techniques compared to
standard tubular flow restrictor designs. In addition,
modifications can further be made in flow restrictor flow rate at
little cost. For example, the flow rate of the restrictor can be
controlled by maintaining the same insert length while adjusting
the length of the plug.
[0009] The details of one or more implementations are set forth in
the accompanying drawings and the description below. Other
features, objects, and advantages will be apparent from the
description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a is a diagrammatic plan view of a reverse osmosis
water filtering system (prior art).
[0011] FIGS. 2-5 are views of a one-piece manifold.
[0012] FIG. 6 is an exploded view of the one-piece manifold.
[0013] FIG. 7 is a cross-sectional view of the one-piece
manifold.
[0014] FIG. 8A is a view of one end cap.
[0015] FIG. 8B is a view of another end cap.
[0016] FIG. 9 is a view of a filter bowl.
[0017] FIG. 10 is a view of a membrane housing.
[0018] FIG. 11 is a top view of the housing of the one-piece
manifold.
[0019] FIG. 12 is a side view of a flow restrictor plug.
[0020] FIG. 13 is an end view of the flow restrictor plug of FIG.
12 looking from the tip end, with a section taken along the line
A-A.
[0021] FIG. 14 is a view of a restrictor housing.
[0022] FIG. 15 is a side view, partially in section, of a flow
restrictor housing with a cross-sectional view of threads within
the housing.
[0023] FIG. 16 is an enlarged cross-sectional view of an interface
between the housing and the plug.
[0024] FIG. 17A is a side view of the flow restrictor housing with
a view of the threads within the housing.
[0025] FIG. 17B is an enlarged view of threads taken along line B
in FIG. 17A.
[0026] FIG. 17C is an enlarged view of threads taken along line C
in FIG. 17A.
[0027] FIG. 17D is an enlarged view of threads taken along line D
in FIG. 17C.
[0028] FIG. 18 is a cross-sectional exploded view of a shut-off
valve in FIG. 11 taken along the line E-E.
[0029] FIG. 19 is a cross-sectional view of an implementation of
the shut-off valve for use in a zero-waste reverse osmosis
system.
[0030] FIG. 20 is a cross-sectional view of a second implementation
of the shut-off valve for use in a zero-waste reverse osmosis
system.
[0031] FIG. 21 is a one-piece manifold for zero-waste reverse
osmosis having the shut-off valve of FIG. 20.
[0032] FIG. 22A is a flow restrictor
[0033] FIG. 22B is a plug of the flow restrictor of FIG. 22A.
[0034] FIG. 22C is a housing of the flow restrictor of FIG.
22A.
[0035] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0036] Referring to FIG. 1, a typical prior art reverse osmosis
water filtering system 10 may be modified by combining components
of system 10 into a single housing, a one-piece manifold 110 (FIG.
2), to minimize leaks that result from standard tubular connections
between the components. System 10 includes a filter system 14, a
reverse osmosis membrane 18, a reverse osmosis storage tank 22, a
flow restrictor 26, a shut-off valve 28, a carbon filter 70 and an
air gap faucet 72. Filter system 14 includes a sediment filter 30
and carbon filters (e.g., carbon filter 34a and carbon filter 34b).
Intake water enters system 10 from a cold water angle stop valve
36, which is connected to a cold water source 84, and is routed
through an intake tube 38 to filter system 14. Cold water angle
stop valve 36 is also connected to a standard faucet 62 through a
cold water faucet line 64 providing cold water to the standard
faucet.
[0037] Sediment filter 30 removes sediment such as sand, dirt and
the like from the intake water. Carbon filters 34a and 34b remove
chlorine and other contaminants that cause bad color, odor and
taste. The filtered water is routed to membrane 18 through a water
tube 40.
[0038] Membrane 18 includes three ports: an intake port 42, a
permeate outlet port 46 and a concentrate outlet port 50. Intake
port 42 receives filtered intake water from filter system 14
through water tube 40. Permeate water is routed from outlet port 46
through permeate tubes 52a and 52b and shut-off valve 28 to tank 22
to be stored under pressure. Shut-off valve 28 is automatic and
stops the flow of water to membrane 18 and to tank 22. When air gap
faucet 72 is opened by a user, permeate water is forced from tank
22 and through a carbon filter 70 though the faucet 72 for use by a
user. Concentrate water is routed from outlet port 50 through a
waste water tube 78, having a flow restrictor 26, through a drain
tube 74 for subsequent disposal down drain 68.
[0039] Referring to FIGS. 2-11, a one-piece manifold 110 combines a
sediment filter, carbon filters, a membrane, a flow restrictor and
a shut-off valve into a single unit within a reverse osmosis water
filtering system.
[0040] One-piece manifold 110 includes a sediment filter 112, two
carbon filters 114a and 114b, a membrane 116, a check valve 115, a
flow restrictor 117, and a shut-off valve 119, all encased in a
housing or manifold 118 made of a light but solid material (e.g.,
polypropylene, plastic, glass, talc). Each filter 112, 114a and
114b is located within its own separate filter bowl 121a, 121b and
121c, respectively. The one-piece manifold 110 is injected molded.
Thus, instead of having tubes interconnecting the components of the
reverse osmosis system like traditional systems, the one-piece
manifold system 110 uses grooves and conduits (e.g., conduit 171a
and conduit 171b) molded in the housing 118, thereby reducing the
potential for leaks to occur, e.g. as compared to standard tubing
connections.
[0041] Water enters system 110 via an intake port 154 and through
shutoff valve 119. The water can pass through sediment filter 112
and/or through each of the carbon filters 114a and 114b, depending
on the mold configuration. End caps 120a and 120b located on each
end of the manifold define grooves (not shown) that can be
manufactured in different desired configurations to control the
flow of the water between membrane 116 and each of the filters 112,
114a and 114b. Thus, the reconfigurable end caps alter the order of
filtration through the filters 112, 114a and 114b and membrane 116.
For example, water can flow through sediment filter 112 and one
carbon filter and then to membrane 116. Other implementations
include routing the water from one of the carbon filters, carbon
filter 114a, for example, to membrane 116 and then to the other
carbon filter, carbon filter 114b. The end cap 120a and membrane
vessel cap 123 are plate welded to housing 118 and an end cap 120b,
respectively.
[0042] Membrane 116 is positioned within a membrane housing 126
defining threads that screw onto the membrane vessel cap 123. A
clip 153 over the membrane housing supports the membrane housing if
the membrane housing 126 is used as a handle e.g., to lift the
entire unit when the housing is full of water.
[0043] The water exits the membrane via one of three paths. The
first path carries the permeate water through the check valve 115
through to a tank port 156. The tank port 156 includes a 3/8-inch
fitting for connection to a 1/4-inch inside diameter tube that
allows the water to flow faster from the tank to the faucet. The
second path carries water from the tank to a faucet port 152.
Faucet port 152 includes a 3/8-inch fitting. The third path carries
the concentrate water to the flow restrictor 117.
[0044] Referring next to FIGS. 12-17D, flow restrictor 117
consisting of a plug 124 and a hollow housing or insert 125
constructed to receive plug 124. Plug 124 includes a tapered shaft
226 having a length, L1, e.g. about 1.5 inches, a screw thread
section 227, and an O-ring 128 at a proximal end 262. Tapered shaft
226 has a taper angle of approximately 1.5.degree.. Screw thread
section 227 includes screw threads 23 la and 23 lb separated from
one another by a first gap 232a and a second gap 232b. Without gaps
232a and 232b, screw threads 231 a and 231 b would form one
continuous thread around the circumference of plug 124. Each gap
231a and 232b extends 90.degree. about the circumference of plug
124. Plug 124 is made of a suitable material such as polyethylene
and the like so it is softer than the housing material.
[0045] Housing 125, having a length, L2, e.g., about 3 inches,
includes screw thread 241 and water-channel thread 242.
Water-channel thread 242 includes a pointed end 244, with a gap 246
between the thread that is a part of a water-flow path. Housing 125
is made of a suitable material such as ABS plastic and the like so
it is harder than the plug material.
[0046] Plug 124 and housing 125 are interengaged by screw threads
231a and 231b with screw thread 241 initially and then interengaged
by screw thread 244 with plug material as the plug is screwed in
further, which provide a water tight seal. Tapered shaft 226
extends into housing 125 about one-half its length, L2. Flow
restrictor 117 is constructed so that the water-channel thread 242
seals around tapered shaft 226 to provide a sealed gap 246 forming
a spiral flow path for water along and around the tapered shaft. In
particular, point 244 of water-channel thread 242 slightly
penetrates into the opposed surface of the tapered shaft 226 to
ensure the tight seal.
[0047] The flow path of the water through flow restrictor 117
starts by passing through an aperture 258 at distal end 260 of the
housing 125 and continues into housing 125 until the water comes in
contact with the tip region 229 of the tapered plug 124. The volume
occupied by tapered shaft 226 within housing 125 directs the water
into sealed gap 246. The water continues to spiral around and along
the tapered shaft following the water-channel thread until the
water reaches threads 23 la, 232b and 241. The water is forced
through gaps 232a and 232b and into the end cap 120a and through a
drain port 158. However, in other implementations, the flow can be
restricted in the opposite direction.
[0048] The flow path cross section is designed to restrict water
flow using capillary characteristics of water, while at the same
time providing a large enough flow cross section to prevent small
particles from clogging the flow path.
[0049] The tapering of plug 125 from the proximal end 262 to the
distal end region 229, and the use of water-channel thread 242,
allows the flow restrictor to be injected molded very easily and
inexpensively. For example, after plug 124 has been injected
molded, it can be easily released from a mold by rotating the plug
a few turns and then drawing the plug from the mold. The tooling
also allows the flow restrictor to be configured for "stand alone"
use as a flow restrictor for other common reverse osmosis water
filtration systems.
[0050] Water-channel thread 242 within flow restrictor 117 controls
the flow of the water by generating a capillary action around
tapered shaft 226 to restrict the flow of water. Thus, the flow
restrictor restricts the water, unlike the traditional winding tube
design. The length, i.e., pitch, of the thread can be altered to
change the degree of flow restriction.
[0051] In other implementations, the length, L1, of tapered shaft
226 can also be modified to control flow rate. For example, housing
125 can have the same dimensions, thus saving on manufacturing
costs, and the length of plug 125 can be modified to be shorter,
thereby to increase the flow rate through the flow restrictor, or
longer, thereby to reduce the flow rate through the flow
restrictor.
[0052] The one-piece manifold is mountable by screws (not shown)
lodged through each of the screw openings 182a and 182b.
[0053] The advantages of the one-piece manifold are not limited to
the following. The one-piece manifold has an easy-to-change
membrane accessible by simply unscrewing the membrane housing 126.
The one-piece manifold integrates the check valve for permeate
water. The one-piece manifold includes high flow water paths from
the tank inlet to the faucet outlet. The filter bowls 121 have two
"slip" type o-rings 106, each of which the top o-ring will also
seal in compression, and an end stop (not shown) for the threads,
so that the bowls cannot be over tightened and will maintain a good
seal.
[0054] Referring to FIGS. 18A, 18B, and 19 to 21, the one-piece
manifold 110 is modified from a standard configuration (a reverse
osmosis system that empties concentrate water into a drain) to a
zero-waste reverse osmosis system that empties concentrate water
into a water source by modifying the shut-off valve 119. Details of
converting a standard reverse osmosis system to a zero-waste
reverse osmosis system are described in U.S. patent application
Ser. No. 10/692,398, filed Oct. 23, 2003, the entire disclosure of
which is incorporated herein by reference.
[0055] Without modification, shut-off valve 119 stops the flow of
intake water based on the pressure in the reverse osmosis tank.
Shut-off valve 119 is a barrier between an intake water flow path
700 and a permeate water flow path 702. The shut-off valve includes
a piston 720 and a spacer 721. Intake water flow path 700 is opened
or closed by the piston 720 depending on the water pressure in the
tank. When the piston 720 is closed, the flow of intake water from
the filter 112 is prevented from flowing to the filter 114a.
[0056] In one implementation of a zero-waste reverse osmosis
system, a modified shut-off valve 619 includes a piston 730 having
a shorter length than piston 720 and replaces piston 720. The
intake water path 700 will continuously flow from filter 112a to
filter 114a independent of the pressure in the reverse osmosis tank
due to the piston 730 stopping before it can close the water path
700 to the next filter 114a. An external pump of a zero-waste
reverse osmosis system (not shown) pumps into the normal inlet port
154.
[0057] In another implementation, a shut-off valve 719 is modified
to include a spacer 740, in place of piston 720 and spacer 721,
that is long enough to restrict flow of incoming water from filter
112 from flowing to filter 114a, regardless of the pressure within
the reverse osmosis tank. Instead, the water flows out through a
zero-waste port 671 and in through a zero-waste port 672 and
continues on to filter 114a.
[0058] Referring to FIGS. 22A to 22C, in other implementations, the
flow restrictor may be modified for systems that do not include a
one-piece manifold. For example, a flow restrictor 917 may be used
in system 10 or in zero-waste reverse osmosis systems such as those
described in U.S. patent application Ser. No. 10/692,398, filed
Oct. 23, 2003, the entire disclosure of which is incorporated
herein by reference. The flow restrictor 917 includes a plug 924
and a housing 925.
[0059] Plug 924 includes a tapered shaft 226 having a length, L3,
e.g., about 1.5 inches, a screw thread section 927, an o-ring 928
and an aperture 930 that leads into a proximal end 962 forming a
port 964. Screw thread section 927 includes screw threads 931 a and
931b separated from one another by a first gap 932a and a second
gap (not shown). Plug 924 and housing 925 are interengaged by screw
threads 931a and 931b with screw thread 941, which along with
o-ring 928 provide a water tight seal. Water flow is similar to
flow restrictor 117 except after water passes through the first and
second gaps, the water is forced through aperture 930 and out port
964.
[0060] There have been described novel apparatus and techniques for
reverse osmosis systems. It is evident that those skilled in the
art may now make numerous modifications and uses of and departures
from specific apparatus and techniques herein disclosed without
departing from the inventive concepts. Consequently, this
disclosure is to be construed as embracing each and every novel
feature and novel combination of features present in or possessed
by the apparatus and techniques herein disclosed and limited solely
by the spirit and scope of the appended claims. It will thus be
understood that various modifications may be made without departing
from the spirit and scope of this disclosure. Accordingly, other
implementations are within the scope of the following claims.
* * * * *