U.S. patent application number 13/774841 was filed with the patent office on 2013-09-19 for automated thermal exchange system.
This patent application is currently assigned to VISTA RESEARCH GROUP, LLC. The applicant listed for this patent is VISTA RESEARCH GROUP, LLC. Invention is credited to James W. Chandler.
Application Number | 20130240178 13/774841 |
Document ID | / |
Family ID | 49156576 |
Filed Date | 2013-09-19 |
United States Patent
Application |
20130240178 |
Kind Code |
A1 |
Chandler; James W. |
September 19, 2013 |
AUTOMATED THERMAL EXCHANGE SYSTEM
Abstract
A system for condensing steam is provided that includes a
cooling tank and a condensing coil extending into the cooling tank.
Coolant from a source of coolant flows into the tank to cool the
condensing coil when the temperature of the coolant in the cooling
tank exceeds a predetermined value. A drain is in fluid
communication with the cooling tank. An air gap assembly is located
between the tank and the source of coolant. The air gap assembly
includes an opening to atmospheric air and is constructed and
arranged to allow coolant to flow out of the opening air vent when
there is a predetermined amount of coolant back flowing into the
device.
Inventors: |
Chandler; James W.;
(Ashland, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VISTA RESEARCH GROUP, LLC |
Ashland |
OH |
US |
|
|
Assignee: |
VISTA RESEARCH GROUP, LLC
Ashland
OH
|
Family ID: |
49156576 |
Appl. No.: |
13/774841 |
Filed: |
February 22, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61611086 |
Mar 15, 2012 |
|
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|
Current U.S.
Class: |
165/104.19 |
Current CPC
Class: |
F28D 15/00 20130101;
F28B 1/02 20130101; A61L 2/07 20130101; F28D 1/0213 20130101; F28B
9/04 20130101; F28B 11/00 20130101 |
Class at
Publication: |
165/104.19 |
International
Class: |
F28D 15/00 20060101
F28D015/00 |
Claims
1. A system for condensing steam comprising: a cooling tank; a
condensing coil extending into the cooling tank; a source of
coolant in fluid communication with the cooling tank, wherein
coolant from the source of coolant flows into the tank to cool the
condensing coil when the temperature of the coolant in the cooling
tank exceeds a predetermined value; an air gap assembly located
between the tank and the source of coolant, wherein the air gap
assembly includes an opening to atmospheric air, wherein the air
gap assembly is constructed and arranged to allow coolant to flow
out of the opening when there is a predetermined amount of coolant
back flowing into the device.
2. The system of claim 1 including a thermal actuator operatively
connected to the cooling tank and a valve, wherein the valve is
located between the source of coolant and the cooling tank, wherein
the valve is operative to be in a closed position blocking the flow
of coolant from the source of coolant into the cooling tank and an
open position allowing the flow of coolant from the source of
coolant into the cooling tank, wherein the thermal actuator causes
the valve to be placed from the closed position to the open
position in response to the temperature of the coolant in the
cooling tank being above the predetermined value.
3. The system of claim 2 wherein the thermal actuator comprises an
expandable part, wherein the expandable part is in contact with the
coolant in the cooling tank and in operative connection with the
valve, wherein the expandable part is operative to expand in
response to the temperature of the coolant exceeding the
predetermined value and cause the valve to be placed in the open
position.
4. The system of claim 1 including a drain in fluid communication
with the cooling tank, a condensate line fluidly connected between
the drain and an outlet of the condensing coil, a coolant overflow
line fluidly connected between the cooling tank and the drain, a
steam line fluidly connected to an inlet of the condensing coil, a
thermal actuator operatively connected in-line in one of the
condensate line, the coolant overflow line, and the steam line,
wherein the valve is located between the source of coolant and the
cooling tank, wherein the valve is operative to be in a closed
position blocking the flow of coolant from the source of coolant
into the cooling tank and an open position allowing the flow of
coolant from the source of coolant into the cooling tank, wherein
the thermal actuator is operatively connected to the valve and
causes the valve to be placed from the closed position to the open
position in response to the temperature of a fluid in the one of
the condensate line, coolant overflow line, and steam line
exceeding a predetermined value.
5. The system of claim 2 wherein the thermal actuator includes an
actuating part that is movable between an actuating position that
causes the valve to be placed in the open position and a
nonactuating position that allows the valve to be placed in the
closed position, wherein the thermal actuator includes an opening
for viewing the position of the actuating part.
6. The system of claim 2 including a drain in fluid communication
with the cooling tank, a drain adaptor in operative connection with
the drain, wherein the drain adaptor includes a first input port in
fluid communication with condensate flowing from the condensing
coil and a second input port in fluid communication with coolant
flowing from the cooling tank.
7. The system of claim 6 wherein the drain adaptor is configured to
be received by a slip joint tee.
8. The system of claim 1 including a drain in fluid communication
with the cooling tank, wherein the drain is in fluid communication
with an outlet of the condensing coil, a thermal valve assembly
fluidly connected between the outlet of the condensing coil and the
drain, wherein the thermal valve assembly is operative to prevent
fluid from the condensing coil to flow into the drain in response
to the temperature of the fluid exceeding a predetermined
value.
9. The system of claim 8 including an indicator, wherein said
indicator is operative to indicate that the fluid flowing out of
the outlet of the condensing coil exceeds a predetermined
temperature.
10. The system of claim 1 wherein the air gap assembly includes at
least one barbed end, wherein the barbed end is securely received
by a tubular adapter, wherein the tubular adapter is configured to
be securely received by a fitting.
11. The system of claim 1 including a drain in fluid communication
with the cooling tank, a manifold fitting operatively mounted to
the tank, wherein the manifold includes first and second inlet
ports and first and second outlet ports, wherein the first inlet
port is in fluid communication with steam to be condensed and the
first outlet port is in fluid communication with the condensing
coil, wherein the second inlet port is in fluid communication with
the condensing coil and the second outlet port is in fluid
communication with the drain, wherein the manifold is configured
such that steam to be condensed enters the first inlet port into
the manifold and exits the manifold through the first outlet port
and into the condensing coil, wherein the manifold is configured
such that condensate from the condensing coil enters the second
inlet port into the manifold and exits the manifold through the
second outlet port to the drain.
12. The system of claim 1 including a drain in fluid communication
with the cooling tank, wherein the cooling tank includes a coolant
overflow outlet in fluid communication with the drain, wherein the
coolant overflow outlet allows coolant to flow out of the cooling
tank to the drain when the coolant in the cooling tank is at a
predetermined level.
13. The system of claim 2 including a drain in fluid communication
with the cooling tank, wherein the cooling tank is triangular in
shape and includes a coolant inlet port for receiving coolant from
the source of coolant, wherein the cooling tank includes a coolant
overflow outlet in fluid communication with the drain, wherein the
coolant overflow outlet allows coolant to flow out of the cooling
tank to the drain when the coolant in the cooling tank is at a
predetermined level, wherein the thermal actuator is positioned in
the cooling tank between the coolant inlet port and coolant
overflow outlet at a location in which temperature of the coolant
is substantially at the average coolant temperature of the cooling
tank.
14. The system of claim 2 including a drain in fluid communication
with the cooling tank, wherein the drain is in fluid communication
with an outlet of the condensing coil, a thermal valve assembly
fluidly connected between the outlet of the condensing coil and the
drain, wherein the thermal valve assembly is operative to prevent
fluid from the condensing coil to flow into the drain in response
to the temperature of the fluid exceeding a predetermined
value.
15. The system of claim 1 including a flow control device
operatively connected between the cooling tank and the source of
coolant, wherein the flow control device is operative to control
the flow of coolant into the tank at a predetermined rate.
16. The system of claim 2 wherein the thermal actuator includes a
wax portion and a piston, wherein the wax portion is operatively
connected to the piston, wherein the wax portion is operative to
expand and move the piston a predetermined distance that causes the
valve to be placed in the open position in response to the
temperature of the coolant in the cooling tank increasing above a
predetermined value.
17. The system of claim 6, including a drain in fluid communication
with the cooling tank, wherein the first input port includes a
first check valve and the second input port includes a second check
valve, wherein the first check valve is operative to prevent the
back flow of fluid from the drain to the condensing coil, wherein
the second check valve is operative to prevent the back flow of
fluid from the drain to the cooling tank.
18. The system of claim 17 wherein the check valve is a ball check
valve.
19. A system for changing the temperature of a fluid comprising: a
container; a thermal exchange device extending into the container;
a source of thermal exchange fluid in fluid communication with the
container, wherein the thermal exchange fluid from the source of
thermal exchange fluid flows into the container to change the
temperature of the thermal exchange device when the temperature of
the thermal exchange fluid in the container reaches a predetermined
value; a thermal actuator operatively connected to a valve, wherein
the valve is located between the source of thermal exchange fluid
and the container, wherein the valve is operative to be in a closed
position blocking the flow of thermal exchange fluid from the
source of thermal exchange fluid into the container and an open
position allowing the flow of thermal exchange fluid from the
source of thermal exchange fluid into the container, wherein the
thermal actuator causes the valve to be placed from the closed
position to the open position in response to the temperature of the
thermal exchange fluid reaching the predetermined value.
20. The system of claim 19 wherein the thermal exchange device
includes a condensing coil, wherein the container includes a
cooling tank, wherein the thermal exchange fluid includes coolant,
wherein the coolant from the source of thermal exchange fluid flows
into the cooling tank to cool the condensing coil when the
temperature of the coolant in the cooling tank exceeds the
predetermined value.
21. The system of claim 20 wherein the thermal actuator comprises
an expandable part, wherein the expandable part is in contact with
the coolant in the cooling tank and in operative connection with
the valve, wherein the expandable part is operative to expand in
response to the temperature of the coolant in the coolant tank
exceeding the predetermined value and cause the valve to be placed
in the open position.
22. A system for condensing steam comprising: a cooling tank; a
condensing coil extending into the cooling tank; a drain in fluid
communication with the cooling tank; a condensate line fluidly
connected between the drain and an outlet of the condensing coil; a
coolant overflow line fluidly connected between the cooling tank
and the drain; a steam line fluidly connected to an inlet of the
condensing coil; a source of coolant in fluid communication with
the cooling tank; a thermal actuator operatively connected to a
valve, wherein the valve is located between the source of coolant
and the cooling tank, wherein the valve is operative to be in a
closed position blocking the flow of coolant from the source of
coolant into the cooling tank and an open position allowing the
flow of coolant from the source of coolant into the cooling tank,
wherein the thermal actuator is operatively connected to one of the
condensate line, coolant overflow line, and steam line, wherein the
thermal actuator causes the valve to be placed from the closed
position to the open position in response to the temperature of a
fluid in the one of the condensate line, coolant overflow line, and
steam line exceeding a predetermined value.
23. The system of claim 19 wherein the thermal actuator includes an
actuating part that is movable between an actuating position that
causes the valve to be placed in the open position and a
nonactuating position that allows the valve to be placed in the
closed position, wherein the thermal actuator includes an opening
for viewing the position of the actuating part.
24. A system for changing the temperature of a fluid comprising: a
container; a thermal exchange device extending into the container;
a source of thermal exchange fluid in fluid communication with the
container, wherein the thermal exchange fluid from the source of
thermal exchange fluid flows into the container to change the
temperature of the thermal exchange device when the temperature of
the thermal exchange fluid in the container reaches a predetermined
value; an air gap assembly located between the container and the
source of thermal exchange fluid, wherein the air gap assembly
includes an opening to atmospheric air, wherein the air gap
assembly is constructed and arranged to allow thermal exchange
fluid to flow out of the opening when there is a predetermined
amount of thermal exchange fluid back flowing into the device.
25. The system of claim 24 wherein the thermal exchange fluid
includes coolant, wherein the coolant from the source of thermal
exchange fluid flows into the container to lower the temperature of
the thermal exchange device when the temperature of the thermal
exchange fluid in the container reaches a predetermined value.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit under 35 U.S.C. .sctn.119(e)
of Provisional Application No. 61/611,086 filed Mar. 15, 2012. The
disclosure of which is incorporated herein by reference in its
entirety.
TECHNICAL FIELD
[0002] This invention relates generally to the cooling of fluids,
more particularly, to systems and methods for reducing the
temperature of effluents and coolants for devices like autoclaves,
steam sterilizers, computers, etc. for delivery of such effluents
and/or coolants to a drain or waste vessel while also avoiding
cross connections of source coolants to drain or waste
connections.
BACKGROUND
[0003] Steam sterilizers (also called autoclaves) are used in the
medical, dental, veterinarian, spa, ear-piercing and tattoo
industries to sterilized instruments used for the patients or
clients in order to prevent transfer of disease organisms one to
another. Systems for condensing the steam after it is used to
sterilize theses instruments may benefit from improvements.
SUMMARY
[0004] The following is a brief summary of subject matter that is
described in greater detail herein. This summary is not intended to
be limiting as to the scope of the claims.
[0005] A system for condensing steam is provided that includes a
cooling tank and a condensing coil extending into the cooling tank.
Coolant from a source of coolant flows into the tank to cool the
condensing coil when the temperature of the coolant in the cooling
tank exceeds a predetermined value. A drain is fluid communication
with the cooling tank. An air gap assembly is located between the
tank and the source of coolant. The air gap assembly includes an
opening to atmospheric air and is constructed and arranged to allow
coolant to flow out of the opening air vent when there is a
predetermined amount of coolant back flowing into the device.
[0006] In another aspect of the invention, a system for changing
the temperature of a fluid is provided that includes a container
and a thermal exchange device extending into the container. A
source of thermal exchange fluid is in fluid communication with the
container. The thermal exchange fluid from the source of thermal
exchange fluid flows into the container to change the temperature
of the thermal exchange device when the temperature of the thermal
exchange fluid in the container reaches a predetermined value. A
thermal actuator is operatively connected to a valve. The valve is
located between the source of thermal exchange fluid and the
container. The valve is operative to be in a closed position
blocking the flow of thermal exchange fluid from the source of
thermal exchange fluid into the container and an open position
allowing the flow of thermal exchange fluid from the source of
thermal exchange fluid into the container. The thermal actuator
causes the valve to be placed from the closed position to the open
position in response to the temperature of the thermal exchange
fluid reaching the predetermined value.
[0007] In another aspect of the invention, a system for condensing
steam is provided. The system includes a cooling tank, a condensing
coil extending into the cooling tank, a drain in fluid
communication with the cooling tank, a condensate line fluidly
connected between the drain and an outlet of the condensing coil, a
coolant overflow line fluidly connected between the cooling tank
and the drain, a steam line fluidly connected to an inlet of the
condensing coil, a source of coolant in fluid communication with
the cooling tank, and a thermal actuator operatively connected to a
valve. The valve is located between the source of coolant and the
cooling tank. The valve is operative to be in a closed position
blocking the flow of coolant from the source of coolant into the
cooling tank and an open position allowing the flow of coolant from
the source of coolant into the cooling tank. The thermal actuator
is operatively connected to one of the condensate line, coolant
overflow line, and steam line. The thermal actuator causes the
valve to be placed from the closed position to the open position in
response to the temperature of a fluid in the one of the condensate
line, coolant overflow line, and steam line exceeding a
predetermined value.
[0008] In another aspect of the invention, a system for changing
the temperature of a fluid is provided that includes a container, a
thermal exchange device extending into the container, and a source
of thermal exchange fluid in fluid communication with the
container. The thermal exchange fluid from the source of thermal
exchange fluid flows into the container to change the temperature
of the thermal exchange device when the temperature of the thermal
exchange fluid in the container reaches a predetermined value. An
air gap assembly located between the container and the source of
thermal exchange fluid. The air gap assembly includes an opening to
atmospheric air. The air gap assembly is constructed and arranged
to allow thermal exchange fluid to flow out of the opening when
there is a predetermined amount of thermal exchange fluid back
flowing into the device.
[0009] Other aspects will be appreciated upon reading and
understanding the attached figures and description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic view of a typical steam condensing
system for a cassette style autoclave.
[0011] FIG. 2 is a schematic view of a typical steam condensing
system for a chamber style autoclave.
[0012] FIG. 3 is a schematic view of a steam condensing system for
a cassette style autoclave according to an exemplary embodiment of
the present invention.
[0013] FIG. 4 is a partial front sectional view of portion of the
steam condensing system of FIG. 3 showing the manifold assembled to
the condensing coil and their related elements.
[0014] FIG. 5 is a front and top perspective view of the cooling
tank of the steam condensing system of FIG. 3.
[0015] FIG. 6 is a front side view of the thermal valve assembly of
the steam condensing system of FIG. 3 in the closed position with
portions removed away for purposes of illustration.
[0016] FIG. 7 is a view similar to FIG. 6 but with the thermal
valve assembly in the open position.
[0017] FIG. 8 is a front side view of the thermal valve assembly
with the adapter of the steam condensing system of FIGS. 20-22 in
the closed position with portions removed away for purposes of
illustration.
[0018] FIG. 9 is an end view taken along lines 9-9 of FIG. 8.
[0019] FIG. 10 is a sectional side view of the flow control device
of the steam condensing system of FIG. 3 taken along the
longitudinal axis of the flow control device.
[0020] FIG. 11 is a front side view of the air gap assembly of the
steam condensing system of FIG. 3.
[0021] FIG. 12 is a rear side view of the top end of the air gap
assembly of the steam condensing system of FIG. 3 with the cover
cap removed for illustrative purposes.
[0022] FIG. 13 is a top view of the top end of the air gap assembly
of the steam condensing system of FIG. 3 with the cover cap removed
for illustrative purposes.
[0023] FIG. 14 is a side view of a portion of the steam condensing
system of FIG. 3 showing the drain adapter and related elements
connected to the slip joint tee, condensate line, and coolant
line.
[0024] FIG. 15 is a side view of a portion of the steam condensing
system of FIG. 3 showing the drain adapter and related elements
connected to the slip joint tee and with portions removed for
illustrative purposes.
[0025] FIG. 16 is a front side sectional view of a drain adapter
for the steam condensing system of FIG. 3 that has straight outlet
ports.
[0026] FIG. 17 is a front side sectional view of another drain
adapter for the steam condensing system of FIG. 3.
[0027] FIG. 18a is a side view of the in-line thermal valve
assembly in an open position of the system of FIG. 3 with portions
removed for illustrative purposes.
[0028] FIG. 18b is a view similar to FIG. 18a but with the in-line
thermal valve assembly in a closed position.
[0029] FIG. 19 is a schematic view of a steam condensing system for
a chamber style autoclave according to another exemplary embodiment
of the present invention.
[0030] FIG. 20 is a schematic view of a steam condensing system for
an autoclave according to another exemplary embodiment of the
present invention.
[0031] FIG. 21 is a schematic view of a steam condensing system for
an autoclave according to another exemplary embodiment of the
present invention.
[0032] FIG. 22 is a schematic view of a steam condensing system for
an autoclave according to another exemplary embodiment of the
present invention.
[0033] FIG. 23 is a schematic view of a system for liquid cooling a
computer according to another exemplary embodiment of the present
invention.
[0034] FIG. 24 is a schematic view of a steam condensing system for
an autoclave according to another exemplary embodiment of the
present invention.
DETAILED DESCRIPTION
[0035] Various technologies pertaining to steam condensing systems
will now be described with reference to the drawings, where like
reference numerals represent like elements throughout. In addition,
several functional block diagrams of example systems are
illustrated and described herein for purposes of explanation;
however, it is to be understood that functionality that is
described as being carried out by certain system components and
devices may be performed by multiple components and devices.
Similarly, for instance, a component/device may be configured to
perform functionality that is described as being carried out by
multiple components/devices.
[0036] There are generally two types of autoclaves (cassette and
chamber). FIG. 1 shows a typical cassette style autoclave 20.
Cassette style autoclaves are designed for rapid processing of
small volumes of instruments. These designs typically utilize a
narrow, elongated, clamshell slide-in cassette constructed of
stainless steel that holds the instruments to be sterilized.
Cassette style autoclaves have a sterilization or heating chamber
and a separate small reservoir for distilled-quality water. When a
cycle is started, water is delivered to the sterilization cassette
and heated to create steam. Once steam is created, the system is
pressurized for a specific period of time to kill organisms. When a
cycle is complete, steam and very hot water is discharged from the
cassette via a drain port while filtered air at ambient temperature
is used to begin to cool the cassette and instruments. The steam
and condensate flows via a line 22 to a waste bottle 24. The bottle
24 has a cap 26 with an inlet fitting and an internal copper
condensing coil 28. A small amount of cool water is to be manually
added to the bottle by the user periodically to cover the lower
section of the condensing coil 28 to help begin condensation of the
steam and cooling of the condensate or water. As the steam is
converted to water, the water rises in the condensing coil 28 and
drops out of the end directly into the self-contained bottle 24
adding to the water in the bottle 24.
[0037] After a few cycles, an attendant or other person has to
remove the cap 26 and condensing coil 28 from the bottle 24 to
empty the hot water into a sink or other suitable drain. If the
attendant forgets, the excess water will escape via a small
pressure relief port located in the cap 26. This overflow creates
rotting, warping, delamination and mold in the cabinetry in which
it's stored. Additionally, if the number of cycles occurs too
quickly in succession, the steam may not have time to condense and
thus, the steam and water vapor escapes via the relief port hole in
cap 26 also creating moisture damage to the property. Further, the
effluent waste or condensate from the system may be too hot to
discharge directly to plumbing drains. Moreover, it would be a
violation of the plumbing codes to discharge steam and/or water too
hot for the plumbing system to drain. Also, this type of waste
design also endangers the attendant who must handle extremely hot
equipment.
[0038] FIG. 2 shows a typical chamber style autoclave 30. Chamber
style autoclaves 30 are designed for processing large volumes of
instruments and have much longer cycle times. These designs
typically resemble a large countertop microwave and have a round or
square access door on the front of the autoclave 30. They usually
have an internal, cylindrical sterilization chamber 32 constructed
of stainless steel with multiple shelves that hold trays or wrapped
instruments to be sterilized. Chamber style autoclaves 30 also have
a heating chamber and a separate larger reservoir such as a water
tank 34 for storing distilled-quality water. When a cycle is
started, water is delivered via a line 31 to the sterilization
chamber 32 from the water tank by the opening of a solenoid valve
33. The water is heated in the sterilization chamber 32 to create
steam. Once steam is created, the sterilization chamber 32 is
pressurized for a specific period of time to kill organisms.
[0039] When a cycle is complete, a solenoid valve 35 in a line 36
between the water tank 34 and sterilizing chamber 32 is opened and
the steam and very hot water is discharged from the sterilization
chamber 32 and sent to the water tank 34 while at the same time
filtered ambient temperature enters the chamber 32 to begin cooling
the cassette and instruments. The water tank 34 contains a copper
condensing coil 38 that is immersed in the stored water supply and
serves to help condense the steam. The opening and closing of the
solenoids is operated by a controller 37. The chamber style
autoclave 30 re-uses water for many cycles and does not use a waste
bottle. Periodically the attendant must physically drain the entire
water tank 34 by use of a drain fitting and clean the water tank 34
and sterilization chamber. Fresh distilled-quality water is added
back to the reservoir and the process may continue. This type of
system does not present the same problems as the cassette style
autoclaves create with use of a waste bottle but does require a
great deal of labor to clean the water tank.
[0040] Referring to the drawings and initially to FIG. 3, an
exemplary embodiment of a steam condensing system 40 is provided to
overcome the above mentioned problems of the steam condensing
systems for the autoclaves shown in FIGS. 1 and 2. This steam
condensing system 40 is used for a cassette type autoclave 42. The
condensing system comprises a condensing coil 44, a source of
coolant 46, a cooling tank 48, and a drain 50. The cassette type
autoclave 42 contains the instruments or other objects that are
sterilized by steam. The autoclave 42 includes a heating element
52, sterilization chamber 54 and a separate reservoir 56 for
distilled-quality water. This water is heated by the heating
element 52 to create the steam that is provided in the
sterilization chamber 54 used to sterilize the instruments. The
sterilization chamber 54 is provided with the steam and is
pressurized for a predetermined time to kill organisms.
[0041] A high temperature resistant steam line 58 is fluidly
connected between the autoclave 42 and a manifold 60. The manifold
60 is fluidly connected to the condensing coil 44 and mounted on a
top wall 62 of the cooling tank 48. As seen in FIG. 4, the manifold
60 includes a head 63 and connecting body 64. When the manifold 60
is mounted to the cooling tank 48, the connecting body 64 extends
through a threaded opening 66 (FIG. 5) into the tank 48 and the
head 63 abuts the top wall 62. The connecting body 64 may have
threads that engage threads 72 in the threaded opening 66 to secure
the manifold 60 to the top wall 62 of the tank 48. The lower end of
the head includes a groove 68 that receives An O-ring that abuts or
pushes against a flange 70 (FIG. 5), which is attach to the top
wall 62 and extends around the opening 66, to seal the manifold 60
to the top wall 62 of the tank 48. The threads 72 may be blow
molded, rotocasted, machined, molded or otherwise formed in the
tank 48 at the opening 66 to engage the threads of the connecting
body 64 to secure the manifold 60 to the top wall of the tank.
Alternatively, the manifold 60 may be mounted to the tank 48 by
other ways. For example, the manifold 60 may be bolted to the tank
using a bolt down method. The manifold 60 may be made of
polyethylene, polypropylene or other suitable material.
[0042] The manifold 60 includes a first inlet port 74 provided on
top of the head 63 and is in fluid communication with the steam
line 58 (FIG. 3). A high temperature resistant Kynar.RTM. fitting
76 is fluidly connected to the steam line 58 and is threadibly
mounted in the first inlet port 74 to provide thermal protection
from the steam or hot fluid. The high temperature resistant
material may be Kynar.RTM., brass or other suitable material that
resists high temperatures. The first inlet port 74 fluidly
communicates with a first outlet port 78 provided on the bottom of
the connecting body 64. The first outlet port 78 is fluidly
connected to the condensing coil 44 by a first brass compression
fitting adapter 80. The first fitting adapter 80 is secure to the
inlet 81 of the condensing coil 44 and threadibly mounted in the
first outlet port 78.
[0043] The condensing coil 44 is generally comprised of copper or
other suitable thermal transfer material and extends downwardly
near bottom wall 79 of the cooling tank 48 as seen in FIG. 3. The
number of turns 82 on the coil 44 helps the steam to condense as it
flows through the coil 44. The number of coils may vary depending
on the system. The outlet 83 of the condensing coil 44 is fluidly
connected to a second brass compression fitting adapter 84. The
second fitting adapter 84 is threadibly mounted in a second input
port 86 provided on the bottom of the connecting body 64. The
second input port 86 fluidly communicates with a second outlet port
88 provided on the top of the head 63 of the manifold 60. A
standard temperature fitting 90 is threadibly mounted in the second
outlet port 88 and fluidly connected to an elbow fitting 92. The
elbow fitting is fluidly connected to a condensate line 96 (FIG.
3), which is connected to the drain 50.
[0044] Referring to FIG. 5, the cooling tank 48 is generally
comprised of plastic such as polyethyene and is shaped in the form
of a right triangle. This shape allows for efficient or space
saving placement of the tank in a corner of the cabinet or along a
flat surface of a side wall of the cabinet. For mounting the tank
to the side wall of the cabinet, the mounting structure may
include, for example, threaded inserts in the sides of the tank to
receive machine screws, which are hung on a hanger tab mounted on
the side wall of the cabinet. The triangular shape design also
allows for maximum efficiency for packaging and shipping
considerations, since little space is wasted. The cooling tank 48
may be in the form of other shapes to fit into suitable structures.
For example, the cooling tank may be rectangular in shape and
mounted on the side wall. The cooling tank 48 includes the top and
bottom walls 62, 79 and right, left, and rear side walls 98, 100,
102 (as viewed in FIGS. 1 and 5). The right and left side walls 98,
100 are generally at a right angle with respect to each other. The
side walls may include removable plates 104 for additional
protection.
[0045] The cooling tank 48 contains coolant such as water that
substantially surrounds the condensing coil 44 in a coolant bath to
cool the condensing coil 44 heated by the steam flowing through the
condensing coil 44. The coolant source 46 may be a cold water line
from a sink 105 as shown in FIG. 1. A separate coolant line 106 is
fluidly connected to the cold water line 46. A manually operated
in-line shut off valve 108 is provided in the coolant line 106 to
selectively allow the flow of water through the coolant line 106
from the cold water line 46. The coolant line 106 is fluidly
connected to a barbed inlet 120 (FIG. 6) of a water valve 114
(FIGS. 6 and 7)) of a thermal valve assembly 112.
[0046] Referring to FIGS. 6 and 7, the thermal valve assembly 112
includes the water valve 114 and a thermal actuator 116. The water
valve 114 includes a valve body 118, the barbed inlet 120 and a
barbed outlet 122. A valve poppet 110 is slidingly received in a
bore 124 of the valve body 118. The bore 124 axially extends from
the inlet 120 to past the outlet 122. A return spring 125 is
provided between the head 128 of the valve 114 and an end portion
of the valve body 118 at the inlet 120. The bore 124 is in fluid
communication with the inlet 120 and outlet 122. The head 128 of
the valve poppet 110 has a larger diameter than that of the bore
124. The valve poppet 110 axially moves within the bore 124 to
place the valve 114 between a closed position (FIG. 6) and an open
position (FIG. 7). In the valve's closed position as seen in FIG.
6, the head 128 of the valve poppet 110 engages the funnel shaped
seat 130 of the bore 124 to block the inlet of the bore 124 and
prevent water from the coolant line 106 from flowing through the
bore 124 and the outlet 122 of the valve 114. In the open position
as seen in FIG. 7, the head 128 of the valve poppet 110 moves
upstream off of the seat 130 to allow water to flow from the
coolant line 106 into the inlet 120 and the bore 124 and through
the outlet 122 of the valve 114. The valve poppet 110 extends
through a threaded cylindrical end 132 of the valve body 118.
[0047] The valve 114 is secured to the thermal actuator 116. In
particular, the threaded end 132 of the valve 114 extends into a
stem 134 of the thermal actuator 116 and threadibly engages threads
in the inner side 136 (FIG. 7) of an end of the stem 134.
Alternatively, the stem 134 and the valve body 118 may be attached
by other suitable ways or may be formed in one piece. The thermal
actuator 116 includes a movable piston 138 located in the stem 134
and engages wax 140 in a wax cup 142 at the lower end of the piston
138. The wax 140 may be a paraffin wax of an oil base or any other
type of wax that expands when heated. Other suitable types of
material that expand when heated may be used instead of the wax.
The piston 138 extends through a return coil spring 144 and is
secured to the spring 144. The lower end of the spring 144 is
secured to a base or wax cup 142 of the thermal actuator 116. A
diaphragm 141 is secured to the wax cup 142 and provided inside the
wax cup 142 between the wax 140 and the lower end of the piston
138. The diaphragm 141 may be made of rubber or other suitable
flexible material. The wax 140 expands as it is heated and pushes
the diaphragm upwardly which in turn flexes and pushes the piston
138 upwardly. When the temperature in the expanded wax decreases,
the wax 140 contracts and the diaphragm retracts back down to allow
the return spring 144 to urge the piston 138 downwardly.
[0048] The stem 134 includes a lateral sight opening 146 at the
upper end of the piston 138 for viewing the position (actuating or
non-actuating) of the piston 138. The thermal valve assembly 112 is
configured such that the valve 114 is placed in the open position
when the water in the tank is heated to the predetermined
temperature that is too high to help condense the steam. In
particular, the water, which is heated at the predetermined
temperature, causes the wax 140 to expand at a sufficient amount to
overcome the biasing force of the spring 144 and move the piston
138 upwardly until it engages the poppet 110 and moves the head 128
of the poppet off of the seat 130 to allow water to flow from the
coolant line 106 into the inlet 120 and the bore 124 and through
the outlet 122 of the valve 114. When the water is below the
predetermine value, the valve 114 is in the closed position in
which the head 128 engages the seat 130 to block the water from
flowing into the bore 124 and through the outlet 122.
[0049] The thermal actuator 116 includes a threaded base 148 that
is threadibly secured into a threaded opening 150 (FIG. 5) in the
top wall 62 of the cooling tank 48 such that the wax cup 142 is
inserted into the water of the cooling tank 48. Referring to FIGS.
8 and 9, a cylindrical adapter 152 may be removably connected to
the thermal valve assembly 112 so that the thermal actuator 116 may
be used to monitor the temperature of the water in a line. In
particular, the adapter 152 includes a lateral bore 154 extending
radially through the adapter 152. The bore 154 has threaded inlet
and outlet ports 158, 160 that are configured to threadibly engage
respective male fittings connected to the line. The adapter 152
also includes a threaded axial bore 156 that is perpendicular to
the lateral bore 154 and is in fluid communication with the lateral
bore 154. The base 148 of the thermal actuator is threadibly
secured to the axial bore such that the wax cup 142 extends into
the lateral bore 154 to monitor the temperature of the water
flowing through the line and the lateral bore 154. The adapter 152
may be made of brass or other suitable material.
[0050] A coolant line 162 (FIG. 3) is fluidly connected between the
outlet 122 of the valve 114 and an inlet 164 of a flow control
device 166, which controls the flow of water to a predetermined
value such as 200 or 300 ml/minute. Specifically, as seen in FIG.
10, the flow control device 166 may include a cylindrical housing
168 with an axial bore 170 having the inlet 164 and an outlet 172.
A rubber flow control button 174 is provided in the bore 170 and is
sufficiently ported and sized to control the flow of water at a
specific flow rate for a wide range of fluid pressures. The
controlled flow of water into the cooling tank 48 is set to ensure
optimal thermal reduction of the condensate and overflow water to
the drain and protects plumbing components while also optimizing
and minimizing the use of water.
[0051] Coolant line 176 is fluidly connected between the outlet 172
of the flow control device and an inlet 177 of an air gap assembly
or air gap assembly 180. Referring to FIG. 11, the air gap assembly
180 includes a generally Y-shaped tubular housing 182. The housing
182 may be made of a thermoplastic material such as
Ultra-high-molecular-weight polyethylene or other suitable
material. The housing 182 includes a riser tube 184, an inlet
branch 186, and an outlet branch 188. The inlet and outlet branches
186, 188 merged into the riser tube 184. The outlet branch 188 has
a larger diameter or cross section than that of the inlet branch
186. The riser tube 184 includes a top end 189 that has an oval
shaped lateral pressure relief openings 190, 192 (FIGS. 11 and 12)
on opposite sides of the top end 189. As seen in FIG. 13, an inner
cap 194 is inserted into the top opening of the riser tube 184 and
snap fitted to the riser tube 184 by tabs 196 that engage the upper
ends of the lateral openings 190, 192. The tabs 196 may be
integrally molded on the inner cap 194. The inner cap 194 is spaced
radially inward from opposite sides of the riser to define arcuate
air gaps 197, 199. The inner cap 194 deflects water flowing up the
riser to the lateral openings 190, 192.
[0052] Referring to FIG. 11, a decorative cover cap 198 press fits
or friction fits on the top end 189 to cover the top end 189. The
cover cap 198 includes a generally rectangular shaped opening 200
that may be aligned over one of the relief openings 190, 192. The
cover cap 198 is generally cylindrical and may be metallic or
chrome like in appearance for aesthetics. The lower end of the
cover cap 198 abuts a plastic upper flange nut 202 that threadibly
engages a threaded portion 204 on the riser 184. A plastic lower
flange nut 206 threadibly engages the threaded portion 204
downwardly opposite the upper flange nut 202. The flange nuts 202,
206 clamp upon a support surface 208 (FIG. 3) such as the lip of a
sink or a countertop to secure the air gap assembly 180 to the
support surface 208. The air gap assembly 180 may be configured to
fit in the sprayer hole of a standard sink. A rubber washer 210 may
be inserted between the upper flange nut 202 and support surface
208.
[0053] The inlet branch 186 includes a barbed end 212 that is
attached to one end of a tubular adapter 214. The tubular adapter
214 may be made of a flexible clear plastic material such as
polyvinyl chloride. A barbed adapter 216 is attached to the other
end of tubular adapter 214. The tubular adapter 214 may be attached
to the barbed end 212 and the barbed adapter 216 by thermal fusion.
For example, the tubular adapter 214 may be heated near its melting
point. The melting point of the tubular adapter 214 is lower than
that of the barbed end 212 and barbed adapter 216. The barbed end
212 and the barbed adapter 216 are then inserted into their
respective ends of the tubular adapter 214. The barbed adapter 216
is inserted such that the barbs 218, 220 in them dig into the inner
surface of the tubular adapter 214 so that the melted material of
the tubular adapter 214 surrounds the barbs 218, 220. Upon cooling,
the melted material hardens to fuse and secure the barbed end 212
and the barbed adapter 216 to the tubular adapter 214.
Alternatively, the barbed end 212 and the barbed adapter 216 could
be first inserted into the tubular adapter 214 and then have heat
applied to the tubular adapter 214 to melt and fuse the plastic
material from the tubular adapter 214 to the barbed end 212 and
barbed adapter 216.
[0054] Alternatively, the barbed end 212 and the barbed adapter 216
may be heated to a temperature near the melting point of the
tubular adapter 214. The barbed end 212 and the barbed adapter 216
are then inserted into their respective ends of the tubular adapter
214. The plastic material in the tubular adapter 214 is melted as
the barbed end 212 and the barbed adapter 216 are inserted such
that the barbs 218, 220 in them dig into the inner surface of the
tube so that the melted material surrounds the barbs 218, 220. Upon
cooling, the melted material hardens to fuse and secure the barbed
end 212 and the barbed adapter 216 to the tubular adapter 214. A
tubular fitting 222 is threadibly secured into the barbed adapter
216 and serves as the inlet 177 of the air gap assembly 180. The
coolant line 176 is fluidly connected to the fitting 222.
[0055] The outlet branch 188 also includes a barbed end 224 that is
attached to one end of a tubular adapter 226. The tubular adapter
226 may be made of a flexible clear plastic material such as
polyvinyl chloride. A barbed adapter 228 is attached to the other
end of tubular adapter 226. The tubular adapter 226 may be attached
to the barbed end 224 and the barbed adapter 228 by thermal fusion.
For example, the tubular adapter 226 may be heated near its melting
point. The melting point of the tubular adapter 226 is lower than
that of the barbed end 224 and barbed adapter 228. The barbed end
224 and the barbed adapter 228 are then inserted into their
respective ends of the tubular adapter 226. The barbed adapter 228
is inserted such that the barbs 230, 232 in them dig into the inner
surface of the tubular adapter 226 so that the melted material of
the tubular adapter 226 surrounds the barbs 230, 232. Upon cooling,
the melted material hardens to fuse and secure the barbed end 224
and the barbed adapter 228 to the tubular adapter 226.
Alternatively, the barbed end 224 and the barbed adapter 228 could
be first inserted into the tubular adapter 226 and then have heat
applied to the tubular adapter 226 to melt and fuse the plastic
material from the tubular adapter 226 to the barbed end 224 and
barbed adapter 228.
[0056] Alternatively, the barbed end 224 and the barbed adapter 228
may be heated to a temperature near the melting point of the
tubular adapter 226. The barbed end 224 and barbed adapter 228 are
then inserted into their respective ends of the tubular adapter
226. The plastic material in the tubular adapter 226 is melted as
the barbed end 224 and barbed adapter 228 are inserted such that
the barbs 230, 232 in them dig into the inner surface of the tube
so that the melted material surrounds the barbs 230, 232. Upon
cooling, the melted material hardens to fuse and secure the barbed
end 224 and the barbed adapter 228 to the tubular adapter 226.
Alternatively, the barbed end 224 and the barbed adapter 228 could
be first inserted into the tubular adapter 226 and then have heat
applied to the tubular adapter 226 to melt and fuse the plastic
material from the tubular adapter 226 to the barbed end 224 and
barbed adapter 228. Alternatively, the tubular adapter 226 may be
heated instead of the barbed end 224 and the barbed adapter 228. A
tubular fitting 234 is threadibly secured into the barbed adapter
228 and serves as the outlet 236 of the air gap assembly 180. A
coolant line 238 (FIG. 3) is fluidly connected to the fitting 234.
The tubular adapters 214, 226 allow for the use of standard male
and female plumbing fittings and standard tubing sizes.
[0057] The air gap assembly 180 allows water to flow out of the
lateral openings 190, 192 and air gaps 197, 199 at the top end 189
of the riser 184 and opening 200 of the cover cap 198, when there
is a predetermined amount of water back flowing through the device.
This prevents the water from backing up into the water line 46 and
causing cross contamination and code violations. The openings and
air gaps and their location thereof also allow operation of the
cooling system at atmospheric pressure.
[0058] To install the air gap assembly 180, the cover cap 198 and
the upper flange nut 202 are removed and from beneath the sink 105,
the riser 184 is inserted into and up through a hole in the support
surface 208 until the lower flange nut 206 abuts the underside of
the support surface 208. The rubber washer 210 may then be inserted
around the riser 184 positioned on top of the support surface 208.
The upper flange nut 202 is then threadibly inserted over and down
the threaded portion 204 until the upper flange nut 202 rests upon
the rubber washer 210. The cover cap 198 is then friction fitted on
the riser 184.
[0059] Referring to FIG. 3, the coolant line 238 is fluidly
connected between the outlet 236 of the air gap assembly 180 and a
male connector 240 that is threadibly secured in a threaded coolant
inlet opening 242 (FIG. 5) in the top wall 62 of the cooling tank
48. A coolant riser 244 is fluidly connected to the male connector
240 and extends downwardly near the bottom wall 79 of the cooling
tank 48. The coolant riser 244 may be made of polypropylene or
other suitable material. The coolant inlet opening 242 is located
near the left and rear corner of the cooling tank 48.
[0060] As depicted in FIGS. 3 and 5, a threaded coolant overflow
opening 246 is provided in the top wall 62 of the cooling tank 48
and is located near the right and rear corner of the cooling tank
48. A male connector 248 is threadibly secured in the overflow
opening 246 and is fluidly connected to an elbow 249. The coolant
overflow opening 246, the coolant inlet opening 242, and threaded
opening 150 for the thermal valve assembly 112 are positioned with
respect to each other such that the average water temperature in
the cooling tank 48 is monitored by the thermal actuator 116 for a
more accurate temperature control of the system. Cool and hot areas
in the water of the tank are not monitored. In particular, as seen
in FIG. 5, the opening 150 is located at the midpoint between the
coolant overflow opening 246 and the coolant inlet opening 242 near
the rear or hypotenuse side of the cooling tank 48. The opening 150
for the thermal actuator valve assembly is also located rearwardly
opposite the opening 66 for the manifold 60, which is located at
the front corner of the cooling tank 48 at the junction of the
right and left side walls 98, 100.
[0061] A coolant overflow or drain line 250 (FIG. 3) is fluidly
connected to the elbow 249 and a first threaded inlet port 254 of a
dual drain adapter 256. The drain adapter 256 may be made of a
thermoplastic material such as ultra-high-molecular-weight
polyethylene or other suitable material. Referring to FIG. 17, the
drain adapter includes first and second threaded inlet ports 254,
258 and first and second outlet ports 260, 262. The inlet ports
254, 258 have a larger diameter than that of their respective
outlet ports 260, 262. The first inlet port 254 is in fluid
communication with the first outlet port 260. The first outlet port
260 tapers toward the first inlet port 254. A floating hollow ball
264 is provided in the first outlet port 260 and acts as a check
valve to prevent back flow of the water. Specifically, during the
normal flow of water the ball 264 is located away from the seat 266
of the first outlet port 260 to allow water to flow to the drain 50
through the space between the first outlet port 260 and the ball
264. If a back flow of water occurs, the water moves the ball 264
toward the seat 266 until it engages the seat 266 to block the
water from flowing back to the cooling tank 48.
[0062] The second inlet port 258 is in fluid communication with a
second outlet port 262. The second outlet port 262 tapers toward
the second inlet port 258. A floating hollow ball 268 is provided
in the second outlet port 262 and acts as a check valve to prevent
the back flow of the water. Specifically, during the normal flow of
water, the ball 268 is located away from the seat 270 of the second
outlet port 262 to allow water to flow to drain 50 through the
space between the second outlet port 262 and the ball 268. If a
back flow of water occurs, the water moves the ball 268 toward the
seat 270 until it engages the seat 270 to block the water from
flowing to the cooling tank 48. Both of the balls 264, 268 are
retained in their respective outlet ports 260, 262 by a stainless
steel drive pin 272. Other types of check valves may be used
instead of the ball such as spring loaded poppets. Alternatively,
the drain adapter may have straight outlet ports as shown in FIG.
16.
[0063] Referring to FIGS. 14 and 15, the drain adapter 256 is
inserted into an inlet 273 of a slip joint tee 274 that is fluidly
connected in the drain line 50 of the sink 105. The drain adapter
256 flares outwardly at its inlet 275 to define a shoulder 279. The
shoulder 279 engages a compression nut 276 secured to the inlet 273
of the slip joint tee 274 to prevent further insertion of the drain
adapter 256 into the inlet 273. The compression nut 276 is inserted
around the inlet 273 and drain adapter 256 and secures the drain
adapter 256 to the inlet 273 of the slip joint tee 274. A
compression seal washer 278 is provided between the outer surface
of the drain adapter 256 and inner surface of the inlet to seal the
drain adapter 256 to the inlet 273.
[0064] As seen in FIGS. 14 and 17, the first input port threadibly
receives a male fitting 280 secured to the overflow line 250 to
fluidly connect the overflow line 250 to the drain adapter 256. The
second input port 258 threadibly receives a male fitting 282
secured to the overflow line 250 to fluidly connect the condensate
line 96 to the drain adapter 256. The system 40 also includes an
in-line thermal valve assembly 284 (FIG. 3) located in the
condensate line 96 that monitors and blocks condensate flow to the
drain 50 if the temperature of the condensate in the condensate
line 96 exceeds a predetermined value. Specifically, as seen in
FIGS. 18a and 18b, the inline thermal valve assembly 284 includes a
cap 286 and a body 288. The body 288 includes a threaded inlet
opening 290 that threadibly receives a male fitting 292, which is
fluidly connected to the condensate line 96. The inlet opening 290
is in fluid communication with a chamber 294. The chamber 294
houses a thermal actuator 296. The thermal actuator 296 includes a
movable piston 298 that engages wax 300 in a wax cup 302 at the
upstream end of the piston 298. The wax 300 may be a paraffin wax
of an oil base or any other type of wax that expands when heated.
Other suitable types of material that expand when heated may be
used instead of the wax. The piston 298 extends through a return
coil spring 304 and is secured to spring 304. The upstream end of
the spring 304 is secured to a base 306 or the wax cup of the
thermal actuator 296.
[0065] The wax cup 302 is exposed to the condensate in the chamber
294. A diaphragm 301 is secured to the wax cup 302 and provided
inside the wax cup 302 between the wax 300 and upstream end of the
piston 298. The diaphragm 301 may be made of rubber or other
suitable flexible material. The wax 300 expands as it is heated and
pushes the diaphragm 301 which in turn flexes and pushes the piston
298 downstream. When the temperature in the expanded wax decreases,
the wax 300 contracts and the diaphragm 301 retracts back down to
allow the return spring 304 to urge the piston 298 in the upstream
direction. When the temperature in the expanded wax decreases, the
wax contracts to allow the return spring 304 to urge the piston 298
in the upstream direction. The body 288 may be constructed of clear
polyvinyl chloride or other clear material for viewing the position
of the piston 298. A cylindrical retainer 308 extends around the
wax cup and radially extends outwardly to the inner surface of the
chamber 294. The retainer 308 holds the thermal actuator 296 in
place so that the piston 298 is aligned with an outlet port 310 of
the chamber 294. Four bypass holes 312 extend axially through the
retainer and are spaced circumferentially equally from each other.
The number and size of the bypass holes may vary according to the
system.
[0066] The cylindrical cap 286 includes an inlet opening 314 in
fluid communication with a threaded outlet opening 316. The outlet
opening 316 threadibly receives a hollow male fitting 318, which is
fluidly connected to the condensate line 96. The cap 286 of the
in-line thermal valve assembly 284 is threadibly secured to the
body 288. An O-ring seal 321 is provided between the cap 286 and
the body 288 to seal them from the water. When the cap 286 and the
body 288 are threadibly connected to each other, the outlet port
310 of the chamber is in fluid communication with the inlet opening
314 of the cap 286. During normal operation as seen in FIG. 18a,
the piston 298 is spaced from the outlet port 310 to place the
in-line thermal valve assembly 284 in the open position. In the
open position, the condensate from the condensate line 96 flows
through the fitting 292 in the inlet opening 258 and into the
chamber 294. The condensate then flows through the bypass holes and
outlet port of chamber. The condensate then flows out of the
fitting 318 in the outlet opening 316 of the cap 286 and into the
condensate line 96 and to the drain 50.
[0067] The thermal actuator 296 is constructed such that when
condensate in the chamber 294 is at a predetermined temperature
that could cause damage to the elements of the drain, the wax
expands and causes the piston 298 to move in the downstream
direction and block the outlet port 310 as seen in FIG. 18b. This
places the in-line thermal valve assembly 284 in the closed
position and prevents the condensate from flowing to the drain 50.
A sensor 320 may also be operatively connected to the in-line
thermal valve assembly 284 or condensate line 96 or 396 to detect
that the condensate is at or above the predetermined temperature or
that the outlet port 310 is blocked by the piston 298. The sensor
320 may be operatively connected to a display 322 and cause the
display 322 to display an error message in response to this
condition. The sensor 320 may also be operatively connected to the
autoclave and cause the autoclave to stop its current cycle in
response to this condition. The sensor 320 may, for example, be a
pressure sensor operatively connected to the condensate line 96
that detects back pressure in the condensate line 96 created by the
blocking of the outlet port 310 by the piston 298. Alternatively or
in addition, the sensor may be operatively connected to a warning
light, audible device, or other suitable indicator to indicate that
the condensate is at the temperature in which the steam and/or
heated water vapor in the condensate line 96 could cause elements
of the drainage system to melt or be damage.
[0068] The retraction and resetting of the piston 298 may be
accomplished by allowing time for the fluid in the chamber to cool
or manually by opening the body 288, cooling the wax by use of cold
water (which will retract the piston in seconds), placing the wax
back into the chamber 294, closing the body 288, and then
re-installing the in-line thermal valve assembly 284 in the
condensate line 96. The in-line thermal valve assembly size, inlet
and outlet connection size, flow rate capacity, and thermal
activation set point of the wax motor may all be adjusted as
required by specific application.
[0069] Referring to FIG. 3, the system operates as follows. The
cooling tank 48 initially contains cold water before sterilization
begins. Also, the shut off valve 108 is turned on to allow water to
flow to the valve 114 of the thermal valve assembly 112. During
sterilization of the instruments in the autoclave, water in the
reservoir 56 is heated by the heating element 52 to create the
steam that is used to sterilize the instruments. The sterilization
chamber 54 containing the instruments is provided with the steam
and is pressurized for a predetermined time to kill organisms. The
steam is directed through the steam line 58 and through the first
inlet and outlet ports 74, 78 of the manifold 60 and into the
condensing coil 44. The cold water surrounding the condensing coil
44 helps condensation of the steam traveling through the condensing
coil 44. This water is heated by the coil 44 as the steam travels
through the coil 44. The steam condenses into condensate which
flows through the second inlet and outlet ports 86, 88 to the
manifold 60 and into the condensate line 96. The condensate then
flows through the in-line thermal valve assembly 284 and drain
adapter 256 and then to the drain 50.
[0070] When the water is heated to the predetermined temperature
that is too high to help condense the steam and/or that may cause
damage to the system from the condensate, the thermal actuator 116
operates to place the valve 114 in the open position as previously
mentioned. Cool water from the cold water line 46 then flows out of
the valve and through the flow control device 166 and the air gap
assembly 180. The water then flows down from the air gap assembly
180 by gravity and through the riser tube 244 and into the cooling
tank 48. As the cool water flows into the cooling tank 48, the cool
water displaces the warmer water which flows out of the overflow
opening 246. The warmer water flows through the overflow line 250,
the drain adapter 256 and to the drain 50. This lowers the
temperature of the water in the cooling tank 48 to further help
condense the steam and lowers the temperature of the condensate to
a value that prevents damage to the components of the drain. When
the temperature of the water in the cooling tank 48 lowers below
the predetermined temperature, the wax 140 contracts to place the
valve 114 in the closed position to block the cool water from the
cold water line from entering the cooling tank 48.
[0071] If the water in the cooling tank 48 back flows through the
riser 244 and the line 238, the water will flow through the lateral
openings 190, 192 and air gaps 197, 199 and out of the opening 200
of the air gap assembly 180. This will also visually alert a user
of this condition. The air gap assembly 180 is designed so that the
cooling system operates completely at atmospheric pressure. Since
the air gaps and openings in the air gap assembly are at the inlet
side of the system (before the cool water flows into the tank),
nothing can cross connect and no additional back flow prevention
device is needed.
[0072] FIG. 19 shows another exemplary system 401 that is used with
a chamber style autoclave. The chamber style autoclave is similar
to FIG. 2, except that the outlet 323 of the coil 38 is fluidly
connected to the line 324 that is fluidly connected to the inlet
port 74 of the manifold 60. This condensing coil 38 serves to
further condensate the steam and cool the condensate prior to its
entry in to the cooling tank 48. In this way, less coolant water is
used and the entire system stays cooler. Alternatively, the coil 38
may be removed and the line 36 may instead be fluidly connected
directly to the inlet port 74 of the manifold 60. In all other
aspects, the exemplary system is similar in structure and function
to that shown and described in FIG. 3.
[0073] FIG. 20 shows an exemplary steam condensing system 400 in
which the thermal valve assembly 112 with the cylindrical adapter
152 is fluidly connected in the steam line 58 for monitoring the
temperature of the fluid and/or gas from the autoclave. In
operation, when the temperature of the water and/or gas in the
steam line 58 is at or above a predetermined temperature, the
thermal actuator 116 operates to place the valve 114 in the open
position as previously mentioned. Cool water from the cold water
line 46 then flows out of the valve 114 and through the flow
control device 166 and the air gap assembly 180. The water then
flows down from the air gap assembly 180 by gravity and through the
riser tube 244 and into the cooling tank 48. As the cool water
flows into the cooling tank 48, the cool water displaces the warmer
water which flows out of the overflow opening 246. The warmer water
flows through the overflow line 250, the drain adapter 256 and to
the drain 50. This lowers the temperature of the water in the
cooling tank 48 to further help condense the steam and lowers the
temperature of the condensate to a value that prevents damage to
the components of the drain 50. When the temperature of the water
and/or gas in the steam line 58 lowers below the predetermined
temperature, the wax 140 contracts to place the valve 114 in the
closed position to block the cool water from the cold water line 46
from entering the cooling tank 48. In all other aspects, the
exemplary steam condensing system 400 is similar in structure and
function to that shown and described in FIG. 3.
[0074] FIG. 21 shows an exemplary steam condensing system 410 in
which the thermal valve assembly 112 with the cylindrical adapter
152 is fluidly connected in the overflow line 250 for monitoring
the temperature of the water in the line 250. In operation, when
the temperature of the water in the overflow line 250 is at or
above a predetermined temperature, the thermal actuator 116
operates to place the valve 114 in the open position as previously
mentioned. Cool water from the cold water line 46 then flows out of
the valve 114 and through the flow control device 166 and the air
gap assembly 180. The water then flows down from the air gap
assembly 180 by gravity and through the riser tube 244 and into the
cooling tank 48. As the cool water flows into the cooling tank 48,
the cool water displaces the warmer water which flows out of the
overflow opening 246. The wanner water flows through the overflow
line 250, the drain adapter 256 and to the drain 50. This lowers
the temperature of the water in the cooling tank 48 to further help
condense the steam and lowers the temperature of the condensate to
a value that prevents damage to the components of the drain. When
the temperature of the water in the overflow line 250 lowers below
the predetermined temperature, the wax 140 contracts to place the
valve 114 in the closed position to block the cool water from the
cold water line 46 from entering the cooling tank 48. In all other
aspects, the exemplary steam condensing system 410 is similar in
structure and function to that shown and described in FIG. 3.
[0075] FIG. 22 shows an exemplary steam condensing system 420 in
which the thermal valve assembly 112 with the cylindrical adapter
152 is fluidly connected in the condensate line 96 for monitoring
the temperature of the condensate in the line 96. In operation,
when the temperature of the condensate in the condensate line 96 is
at or above a predetermined temperature, the thermal actuator 116
operates to place the valve 114 in the open position as previously
mentioned. Cool water from the cold water line 46 then flows out of
the valve 114 and through the flow control device 166 and the air
gap assembly 180. The water then flows down from the air gap
assembly 180 by gravity and through the riser tube 244 and into the
cooling tank 48. As the cool water flows into the cooling tank 48,
the cool water displaces the warmer water which flows out of the
overflow opening 246. The warmer water flows through the overflow
line 250, the drain adapter 256 and to the drain 50. This lowers
the temperature of the water in the cooling tank 48 to further help
condense the steam and lowers the temperature of the condensate to
a value that prevents damage to the components of the drain. When
the temperature of the condensate in the condensate line 96 lowers
below the predetermined temperature, the wax 140 contracts to place
the valve 114 in the closed position to block the cool water from
the cold water line 46 from entering the cooling tank 48. In all
other aspects, the exemplary steam condensing system 420 is similar
in structure and function to that shown and described in FIG.
3.
[0076] FIG. 23 shows an exemplary system 430 that is used to liquid
cool a computer 340. In this system, liquid used to cool the
computer flows through the line 358 and through the first inlet and
outlet ports 74, 78 of the manifold 60 and into the condensing coil
44. The cold water surrounding the condensing coil 44 helps cool
the liquid traveling through the condensing coil 44. This water is
heated by the coil 44 as the liquid travels through the coil 44.
The liquid flows through the second inlet and outlet ports 86, 88
of the manifold 60 and into the line 396, which is routed through
the computer 340 and is in fluid communication with the line 358. A
pump 360 in the line 396 draws the cooled liquid into a reservoir
362 in the line 396 and pumps the liquid through the line 396 to
the computer 340 to cool the computer 340. A check valve 364 may be
provided in the line 396 upstream of the pump 360 and reservoir 362
to prevent back flow of the liquid. In all other aspects, the
exemplary system 430 is similar in structure and function to that
shown and described in FIG. 3.
[0077] FIG. 24 shows another exemplary steam condensing system 440
in which the air gap assembly 180 is removed such that the outlet
172 of the flow control device 166 is directly fluidly connected
via a line to the male connector 240, which is fluidly connected to
the coolant riser 240. In all other aspects, the exemplary system
is similar in structure and function to that shown and described in
FIG. 3. The air gap assembly 180 may also be removed in each of the
exemplary embodiments of FIGS. 19-23 such that the outlet 172 of
the flow control device 166 is directly fluidly connected via a
line to the male connector 240, which is fluidly connected to the
coolant riser 240 for each embodiment. In all other aspects, this
exemplary system is similar in structure and function to the
associated embodiment shown and described in FIGS. 19-23.
[0078] The steam condensing system 40 is installed as follows.
First, the cooling tank 48 is filled with cold tap water. The
threaded base 148 of the thermal actuator is then threadably
inserted into the threaded opening 150 (FIG. 5) in the top wall 62
of the cooling tank 48 and tightened with a wrench such that the
wax cup 142 is inserted into the water of the cooling tank 48. The
manifold 60 is attached to the condensing coil 44 and the coil 44
is lowered through the threaded opening 66. The manifold 60 is
threaded firmly around the threaded flange 70 of the opening 66
such that the lower edge of the manifold 60 is secured tight
against the flange 70. The cooling tank 48 is then moved into the
cabinet and positioned against a corner or back wall of the cabinet
or other structure.
[0079] The air gap assembly 180 is installed on the lip of the sink
105 or countertop 208 depending on the sink configuration or other
support surface. The air gap assembly 180 is designed to fit in the
sprayer hole of standard sinks. If there is no sprayer hole or
there is one but the user wishes to keep the sprayer, a hole may be
drilled in the lip of the sink or countertop to accommodate the air
gap assembly 180. The air gap assembly 180 is installed by first
removing the decorative (friction-fit) chrome cover cap 198 by
pulling straight upward.
[0080] The upper flange nut 202 and washer 210 is then removed from
the riser 184 and while the lower flange nut 206 is left intact.
From beneath the sink, the riser 184 is inserted into and up
through the hole until the lower flange nut 206 abuts the underside
of the sink deck or countertop. The rubber washer 210 is pushed
down over the riser 184 while pulling up on the riser 184. The
upper flange nut 202 is then threaded over and down the riser until
the nut 202 has pushed the washer 210 into contact with the sink
deck or countertop. The chrome cover cap 198 is fitted over the
riser 184 until it locks into place to ensure that it fits
properly. The chrome cover cap 198 is then removed. Then, while
holding the riser still, tighten the lower flange nut 206 up
against the underside of the sink deck or countertop to secure the
assembly. Fit the chrome cover cap 198 over the riser 184 and lock
into place again.
[0081] The drain adapter 256 may then be installed in a vertical or
horizontal orientation in the sink drain piping as needed and at a
position that is below the air gap assembly 180 and such that the
water will not flow out of the lateral openings during normal the
flow of water (no back flow). Preferably, the drain adapter 256 is
installed at the lowest possible level in the system 40. To install
the drain adapter 256, mark the center point of the area desired
for installation, then cut a section of the existing drain tubing
out to allow room for the slip joint tee 274. A slip joint
compression nut 330 (FIG. 15) over each end of the tubing followed
by one beveled washer 277. The beveled edge of the washer is facing
the fitting as, for example, depicted in FIG. 15. The slip joint
tee 274 is fitted into the open section and the nuts and washers
are tightened securely to the threaded ends of the Tee. With the
beveled washer 277 and compression nut 276 already in place and not
yet tightened, the dual port drain adapter 256 is inserted into the
inlet 273 of the slip joint tee 274 and pushed until its shoulder
279 is in contact with the nut 276. While tightening the
compression nut 276, the drain adapter 256 is pushed towards the
slip joint tee 274 until tight. The drain adapter 256 is then
rotated so that the second inlet port 258 for the condensate line
96 is below the first inlet port 254 of the coolant overflow line
250. If the slip joint tee 274 is installed horizontally in the
plumbing piping, the dual port adapter 256 should always be rotated
to the 12:00 O'clock position so the first and second inlet ports
254, 258 are at the top and discharge downward into the slip joint
tee 274. The lines are then connected to their respective elements
(e.g. air gap assembly 180, in-line thermal valve assembly 284,
flow control device 166, thermal valve assembly 112, manifold 60,
coolant riser 244, cooling tank 48, and drain adapter 256) via
their respective fittings.
[0082] To put the condensing system 40 in its operation mode, the
shut off valve 108 is turned on. To test the condensing system 40,
a small-bladed, standard screw drive or similar tool is inserted
through the sight opening 146 in the side of the thermal actuator
stem 134 and moved directly upward upon the poppet 110 to move the
poppet upwardly to place the valve in the open position. Held in
that position, water should begin flowing from the outlet 122 of
the water valve 114, up through the line 162, 176, through the flow
control device 166 and into the inlet 177 of the air gap assembly
180. Temporarily remove the chrome decorative cover cap 198 from
the air gap assembly 180 by pulling upward. Water should be seen
(via the gaps and openings) flowing very slowly into the air gap
assembly 180. After a few moments, the water will have filled the
chamber in the air gap assembly 180 and begin flowing from the
outlet 236, downward to the coolant riser 244 in the cooling tank
48. Temporarily pull the coolant overflow line 250 out of the
fitting 280 at the drain adapter 256 by pushing and holding in a
collet around the perimeter while pulling outwardly on the overflow
line 250. When a slow, intermittent flow of water is observed
flowing from the coolant overflow line 250, push the line 250 back
into the coolant overflow fitting and reassemble the decorative
chromed cover cap 198 to the top of the air gap assembly 180.
Remove the tool used to manually actuate the water coolant valve
114.
[0083] It should be noted that the system in any of the exemplary
embodiments may be configured to be used for any type of thermal
transfer of heat between a fluid in a heat exchange device and a
fluid surrounding the heat exchange device. For example, the system
may be set up to have a container filled with warm water to heat
fluid in a heat exchange device. Also, instead of a condensing
coil, other types of heat exchange devices that help to cool,
condense, or heat up fluids may be used such as a heat sink. Also,
a pressure relief device may be used instead of an air gap
assembly. The pressure relief device may be an open pressure relief
device. Also, various tubing sizes can be used for the coolant and
other lines (e.g. 1/4'', 3/8'', 1/2'', 3/4'' outer diameter
tubing).
[0084] It is noted that several examples have been provided for
purposes of explanation. These examples are not to be construed as
limiting the hereto-appended claims. Additionally, it may be
recognized that the examples provided herein may be permutated
while still falling under the scope of the claims.
* * * * *