U.S. patent number RE35,252 [Application Number 08/168,472] was granted by the patent office on 1996-05-28 for fluid flow control device for water treatment systems.
This patent grant is currently assigned to Clack Corporation. Invention is credited to Richard E. Clack, Robert A. Clack, Melvin R. Hemp.
United States Patent |
RE35,252 |
Clack , et al. |
* May 28, 1996 |
Fluid flow control device for water treatment systems
Abstract
New and improved filtration purification or water treatment
systems for providing improved purified drinking water at a point
of use are provided in a substantially leak-free fluid flow control
device to which the other filtration purification system elements
may be matedly engaged. Other system elements may include various
filters or filter modules, as well as.[.,.]. system leads for
conveying incoming tap water in, outgoing waste water out to drain
and purified water from the filter section to a storage tank until
desired for use. The fluid flow control device is preferably a
unitary thermoplastic body having a number of discrete fluid flow
passages extending therein. In a preferred embodiment, the fluid
flow control device includes integrally formed input/output
connector features, filter-receiving socket portions and an
automatic shut off valve disposed in fluid flow communication with
certain ones of the passages.
Inventors: |
Clack; Robert A. (Sun Prairie,
WI), Clack; Richard E. (Windsor, WI), Hemp; Melvin R.
(Lodi, WI) |
Assignee: |
Clack Corporation (Windsor,
WI)
|
[*] Notice: |
The portion of the term of this patent
subsequent to March 26, 2008 has been disclaimed. |
Family
ID: |
27051321 |
Appl.
No.: |
08/168,472 |
Filed: |
December 16, 1993 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
494155 |
Mar 15, 1990 |
5002664 |
|
|
Reissue of: |
653040 |
Feb 8, 1991 |
05128035 |
Jul 7, 1992 |
|
|
Current U.S.
Class: |
210/251;
210/432 |
Current CPC
Class: |
B01D
61/022 (20130101); B01D 61/08 (20130101); B01D
61/10 (20130101); B01D 61/12 (20130101); B01D
65/00 (20130101) |
Current International
Class: |
B01D
61/10 (20060101); B01D 61/08 (20060101); B01D
61/12 (20060101); B01D 61/02 (20060101); B01D
65/00 (20060101); B01D 061/08 () |
Field of
Search: |
;210/652,195.2,251,257.2,321.6,321.72,418-424,428-432,321.65 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Spear; Frank
Attorney, Agent or Firm: Nilles & Nilles
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of prior application
Ser. No. 494,155, filed Mar. 15, 1990 now U.S. Pat. No. 5,002,664.
Claims
We claim:
1. A fluid flow control device for use in a water treating system
for making fluid connections between a series of water treatment
modules and other system elements, said fluid flow control device
comprising:
an elongate unitary thermoplastic body .Iadd.formed from a pair of
interconnected housing halves and .Iaddend.including a plurality of
treatment module-receiving sockets for mutably engaging a like
plurality of treatment modules, input/output connector means
defined in said body for matably engaging complimentary
input/output connector means adapted to convey impure tap water
.[.from the system.]. to said fluid flow control device and treated
product water and waste water away from the fluid flow control
device to provide communication with other elements of said system,
a plurality of fluid flow passages .[.being defined.]..Iadd.,
formed .Iaddend.in said body .Iadd.from mating grooves in said
housing halves, .Iaddend.for conveying fluids therein and to and
from said sockets and said body further including channel means for
conveying fluids .[.extending.]. between selected ones of said
passages and said input/output connector means.
2. A fluid flow control device as defined in claim 1, wherein said
.[.unitary thermoplastic body comprises a pair of fusion bonded.].
housing halves .Iadd.are fusion bonded.Iaddend..
3. A fluid flow control device as defined in claim 2, wherein said
device is capable of withstanding elevated pressures above tap
water line pressure without rupturing or leaking.
4. A fluid flow control device as defined in claim 3, wherein said
passages and said channels within said body are each individually
capable of withstanding elevated pressures of up to about 1100 psi
without rupturing or leaking.
5. A fluid flow control device as defined in claim 1, further
including locking means for releasably locking the input/output
means of said device and said complimentary input/output connector
in sealed and mated engagement with each other.
6. A fluid flow control device as defined in claim 1, further
including automatic shutoff valve means defined in said body in
fluid flow communication with certain ones of said passages.
7. A fluid flow control device as defined in claim 1, wherein said
thermoplastic body comprises an alloyed blend of nylon and an ABS
resin.
8. A modular multi-filter subassembly for use in water filtration
purification system, said filtration-purification system including
a source of impure tap water at line pressure, means for dispensing
purified water from a storage tank to a point of use, means for
introducing purified water into the storage tank; and means for
conveying waste water to drain, said subassembly comprising: a
fluid flow control device including an elongate unitary
thermoplastic body .Iadd.formed from a pair of interconnected
housing halves and .Iaddend.having a plurality of filter
module-receiving sockets defined therein at spaced apart locations
along the length thereof, a plurality of discrete fluid flow
passages .[.defined.]..Iadd., formed .Iaddend.in said body
.Iadd.from mating grooves in said housing halves, .Iaddend.for
making various fluid flow connections to and from each of said
sockets in said device, input/output connector means defined in
said body, said connector means including a plurality of channel
means for connecting selected ones of said passages to said system
tap water source, said introducing means said conveying means, and
a plurality of filter modules matedly and sealingly engaged in said
sockets, each filter module having chemical or mechanical removal
media therein, said .[.device.]. body further having aperture means
defined in each socket for providing inflow and outflow of fluids
as required for each of said filter modules, said subassembly
further including means for maintaining each of said filter modules
in sealed, pressure tight engagement with said sockets, and means
for connecting said subassembly to the remainder of said filtration
purification system.
9. A modular subassembly as defined in claim 8 including at least
three sockets and three filter modules sealingly engaged
therein.
10. A modular subassembly as defined in claim 9 wherein at least
one of said filter modules comprises a reverse osmosis type filter
module.
11. A modular subassembly as defined in claim 8 wherein said filter
modules are the same or different and each filter module includes
physical or chemical removal media for selectively removing certain
suspended or dissolved solids from a flow of water traveling
through said filter module.
12. A modular subassembly as defined in claim 11 wherein each of
said filter modules .[.are.]. .Iadd.is .Iaddend.different.
13. A modular subassembly as defined in claim 12 including a
sediment filter, a granular activated carbon filter and a reverse
osmosis filter.
14. A modular subassembly as defined in claim 8 wherein said means
for maintaining said filter modules in sealed fluid tight
engagement with said sockets comprises cooperating threaded
coupling means on each said socket and filter module.
15. A reverse osmosis filtration water purification system
comprising:
a source of impure tap water at line pressure, a pure water storage
tank, means for dispensing purified water from said storage tank to
a point of use, means for introducing purified water into the
storage tank, means for conveying waste water to drain, and a
modular filter subassembly including a fluid flow control device
and a plurality of filter modules operatively connected to said
fluid flow control device, said fluid flow control device including
an elongate unitary thermoplastic body .Iadd.formed from
interconnected housing halves and .Iaddend.having a plurality of
filter-module receiving socket means defined therein for matably
engaging a like plurality of filter modules, a plurality of fluid
flow passages.Iadd., .Iaddend.defined in said body .Iadd.and formed
from mating grooves formed in said housing halves, .Iaddend.for
conveying fluids therein to and from said sockets, and
.Iadd.channel .Iaddend.means for connecting selected ones of said
passages to said system tap water source, said introducing means
and said conveying means, respectively, said subassembly including
means for maintaining each said filter module in sealed, pressure
tight engagement within said sockets, whereby a system
characterized by having a minimum number of potential sites for
leakage is provided.
16. A water filtration purification apparatus for use in a reverse
osmosis (R.O.) system, said R.O. system including: a source of
impure tap water at line pressure, means for dispensing purified
water from a storage tank to a point of use, means for introducing
purified water into the storage tank, and means for conveying waste
water to drain, said water filtration purification apparatus
comprising: a fluid flow control device including an elongate
unitary thermoplastic body .Iadd.formed from interconnected housing
halves and .Iaddend.having spaced and opposed upper and lower major
surfaces, a plurality of filter module-receiving socket means
projecting downwardly from said lower surface at spaced apart
locations along the length thereof, each socket means including a
pair of spaced apart apertures defined therein in the lower major
surface of said body, a plurality discrete fluid flow passages
defined in said body .Iadd.and formed from mating grooves formed in
said housing halves.Iaddend., some of said passages connecting
certain ones of said socket apertures, input/output connector means
disposed at one end of said body including a plurality of channel
means for connecting selected ones of said passages to said system
tap water source, said introducing means and said conveying means,
respectively, a like plurality of filter modules matingly and
sealingly engaged in said socket means .[.and means designed for
communicating with said R.O. system.].. .Iadd.
17. A fluid flow control device for use in a water treating system
for making fluid connections between a series of water treatment
modules and other system elements, said fluid flow control device
comprising:
an elongate unitary thermoplastic body formed from interconnected
housing halves and including a plurality of treatment
module-receiving sockets for engaging a like plurality of treatment
modules, input/output connector means defined in said body for
engaging complimentary input/output connector means adapted to
convey impure tap water to said fluid flow control device and
treated water away from the fluid flow control device to provide
communication with the other elements of the system, a plurality of
fluid flow passages being defined in said body and formed from
mating grooves formed in said housing halves, for conveying fluids
therein and to and from said sockets, and said body further
including channel means for conveying fluids between selected ones
of said passages and said input/output connector means. .Iaddend.
.Iadd.18. A fluid flow control device as defined in claim 17,
wherein said complimentary input/output connector means are further
adapted to convey waste water
away from said fluid flow control device. .Iaddend. .Iadd.19. A
fluid flow control device comprising:
A. a unitary plastic body formed from interconnected housing halves
and including
(1) a plurality of treatment module-receiving sockets which are
capable of engaging a like plurality of treatment modules,
(2) input and output port means for supplying impure water to and
for conveying treated water from said body,
(3) a plurality of flow apertures which are defined therein and
which are capable of conveying fluids to and from said sockets,
and
(4) a plurality of fluid flow passages which are formed from mating
grooves formed in said housing halves and which convey fluids
between selected
ones of said flow apertures and said ports. .Iaddend. .Iadd.20. A
fluid flow control device as defined in claim 19, wherein said body
further includes another output port which is provided therein and
which is
capable of conveying waste water from said body. .Iaddend.
.Iadd.21. A fluid flow control device as defined in claim 19,
wherein said body is an elongate thermoplastic structure. .Iaddend.
.Iadd.22. A fluid flow control device as defined in claim 21,
wherein said housing halves are fusion bonded. .Iaddend. .Iadd.23.
A modular multi-filter subassembly for use in a water purification
system, said subassembly comprising:
A. first and second filter modules having filtration media therein;
and
B. a thermoplastic plastic body formed from interconnected housing
halves and including
(1) first and second module-receiving sockets which engage said
first and second filter modules, respectively,
(2) input and output ports which are provided therein and which are
capable of supplying impure water to and conveying treated water
from said body,
(3) a plurality of flow apertures which are defined therein and
which are capable of conveying fluids to and from said sockets,
and
(4) a plurality of fluid flow passages which are formed from mating
grooves formed in said housing halves and which convey fluids
between selected
ones of said flow apertures and said ports. .Iaddend. .Iadd.24. A
subassembly as defined in claim 23, wherein said body further
includes another output port which is provided therein and which is
capable of conveying waste water from said body. .Iaddend.
.Iadd.25. A subassembly as defined in claim 23, further comprising
a third filter module having a filtration medium therein, and
wherein said body further includes a third module-receiving socket
which engages said third filter module. .Iaddend.
.Iadd.26. A filtration water purification system comprising:
A. a pure water storage tank; and
B. a modular multi-filter subassembly including
(1) first and second filter modules having filtration media
therein; and
(2) a unitary plastic body formed from first and second bonded
housing halves having mating surfaces, said body including
(A) first and second module-receiving sockets which are formed in
said first housing half and which engage said first and second
filter modules, respectively,
(B) input and output ports which are formed in said second housing
half and which are connectable to a source of impure water and to
said storage tank, respectively,
(C) a plurality of flow apertures which are formed in said first
housing half and which are capable of conveying fluids to and from
said sockets, and
(D) a plurality of fluid flow passages which are formed from mating
grooves formed in the mating surfaces of said first and second
housing halves and which convey fluids between selected ones of
said flow apertures and said
ports. .Iaddend. .Iadd.27. A system as defined in claim 26, wherein
said body further includes another output port which is formed in
said second housing half and which is capable of conveying waste
water from said body
to a drain. .Iaddend. .Iadd.28. A system as defined in claim 26,
further comprising a third filter module having a filtration medium
therein, and wherein said body further includes a third
module-receiving socket which
engages said third filter module. .Iaddend. .Iadd.29. A system as
defined in claim 28, wherein each of said first, second, and third
filter modules contains one of a sediment filter, a granular
activated carbon filter, and
a reverse osmosis filter. .Iaddend. .Iadd.30. A system as defined
in claim 23, further comprising an automatic shutoff valve housing
molded
into said body. .Iaddend. .Iadd.31. A system as defined in claim
30, further comprising an automatic shutoff valve disposed in said
shutoff valve housing. .Iaddend. .Iadd.32. A system as defined in
claim 30, further comprising a device which is disposed in said
shutoff valve housing and which includes at least one of a flow
meter, a reed switch, and an alarm assembly. .Iaddend.
Description
BACKGROUND OF THE INVENTION
The present invention generally relates to reverse osmosis
filtration purification systems including a plurality of filter
cartridges connected together in series for selectively and
sequentially removing specific kinds of impurities from a tap water
supply, for disinfecting incoming water and/or for adding nutrients
or other additives to the tap water supply. More particularly, it
relates to a fluid flow control apparatus which mountingly receives
each of the filter or additive cartridges to be used, directs fluid
flow internally between the filters within the filter section and
connects the filter section to other elements of the overall R.O.
purification system.
Reverse osmosis (hereinafter, "R.O.") filtration purification
systems are increasingly being employed to purify municipal and
well water supplies to provide improved drinking water for the
home, for use in ice makers, vending machines, humidifiers, for
watering indoor plants and the like. Many applications require that
more than one filter be employed in series to selectively remove
different impurities. Another reason a series of filters may be
needed is that some R.O. membrane filters and other specialty
filters require pre-removal of chlorine and/or sediment in order to
operate efficiently and properly. In this situation, chlorine may
be first removed from the feed water by passing it through an
upstream pre-filter before it is fed into the chlorine-sensitive
filter positioned downstream.
Various filter cartridges have been developed for use in commercial
and residential point of use water purifier systems. Examples
include sediment filters, granular activated carbon (GAC) filters;
reverse osmosis (R.O.) membrane filters including thin film
composite, cellulose acetate, cellulose triacetate and hollow-fiber
types; specialty filters for removing lead, iron, phosphates,
sulfates, nitrates, as well as, bacteria-removal filters such as
ceramic filters, microfilters and ultrafilters. Filter cartridges
containing both mechanical and/or chemical removal media generally
have a standardized cylindrical configuration including entry and
outlet structures for attaching the filters to other system
elements. Filter cartridges for adding desired nutrients such as
vitamins, calcium, fluoride or the like are also known.
The filter cartridges are placed in standardized pressure vessels
and incoming feed water passes into the vessel and through the
filter under pressure. Flow through the filter module including the
filter cartridge and pressure vessel may vary depending on the type
of filter cartridge employed. Some filters work by directing
incoming fluid along the periphery of the filter and vessel. Water
is forced radially inwardly through the removal media to enter a
centrally disposed tube or passage defined in the filter. Product
water within the central tube may flow concurrently or counter
currently with respect to the feed water flow entering the vessel.
R.O. filters typically have three ports to the module including an
impure water inlet, a product water outlet and a concentrate or
waste water outlet.
Different combinations of these filters in series will require
different specific fluid flow connections between the filters, due
to variations in flow requirements for each filter in the series.
Conventionally, the various flow connections within the filter
section from one filter to another and between the filter section
and the remainder of the R.O. system are made using plastic or
flexible thermoplastic tubing provided with coupling adapters. A
major disadvantage associated with these tubing linked networks is
leakage. The systems operate under pressure and each and every
coupling provides a potential site for leakage.
Another disadvantage of these systems is that changeover of filters
within the system is burdensome. Some tubing connections must be
detached before a pressure vessel can be removed from the filter
series and the filter cartridge replaced. Every time the tubing
sections are disconnected and reconnected, the risk of leakage in
the system increases. Moreover, some systems present such a
complicated network of criss-crossing tubes, that a skilled
technician is needed to make repair calls. Lastly, tubing
connection systems are undesirably expensive.
In order to overcome the disadvantages of the prior art systems, it
is an object of the present invention to provide a filter section
fluid flow control apparatus which significantly reduces or
eliminates the need for tubing connections between filter
modules.
It is another object of the invention to provide a self-contained
filter section having a simple connectorized input/output
connection to other system elements.
It is a further object of this invention to provide a substantially
tubeless fluid flow control device for a filter section including
quick disconnect features for the filter modules to facilitate
changeover, maintenance and repair.
It is still another object of the present invention to provide a
new and improved filter section for use in R.O. systems having a
pop-in pop-out feature enabling the entire filter section to be
disconnected and removed as a unit from the remainder of the system
for repair or substitution by a new filter section unit which may
contain the same or different filter cartridges.
SUMMARY OF THE INVENTION
In accordance with these and other objects, the present invention
provides a new and improved fluid flow control device for use in a
filtration purification apparatus and system to provide improved
water quality. The fluid flow control device serves as a substrate
for treating the entire filter section as a module or unit. The
fluid flow control device includes socketing features for receiving
and mounting standard filter modules and other non-standard but
commercially available water treatment modules and provides a
single connectorized input/output connection to the remainder of
the purification system components.
More particularly, in accordance with the invention, the new and
improved fluid flow control device comprises a unitary
thermoplastic body portion, preferably having a generally
rectangular configuration including spaced apart, opposed upper and
lower major surfaces. An input/output (I/O) connector is defined at
one end of the body portion for connecting the fluid flow control
device to a matable I/O connector which is attached to an impure
water inlet, a purified water outlet and a waste water outlet
associated with the overall system. A plurality of socket
formations project outwardly at spaced apart locations from the
lower major surface of the body. Each socket formation preferably
includes inner and outer tubular projections which define inner and
outer recesses. Each recess is provided with a fluid flow aperture
defined in the lower major surface of the body portion. Preferably,
external threads are provided on the outer surfaces of the outer
tubular projection in each socket formation to provide for threaded
engagement of a pressure vessel and its associated filter cartridge
to the fluid flow control device. A check valve to prevent pure
water back flow from the storage tank back to the system may
advantageously be of a type configured to be received in the inner
recess of the R.O. receiving socket formation.
The fluid flow control device further includes a plurality of fluid
flow control passages defined therein for connecting various ones
of the socket apertures to specific other socket apertures for
directing water flow to and from each filter element, as well as,
fluid flow control channels for connecting one or more flow control
passages to the integral I/O connector portion. A drain restrictor
may be installed in the I/O connector port or along a waste line
before drain.
The new and improved fluid flow control device of the present
invention may be prepared by hot plate fusion bonding of a pair of
individually molded housing halves. The resulting fusion bonded
body is a unitary, one piece body whose defined inner fluid flow
control passages and channels may be capable of withstanding
elevated pressures of up to above about 1100 psi. The fluid flow
control passages are defined in the mating faces of each housing
half and are bounded by moat regions which provide enhanced fusion
bonding of the passage-forming regions and ensures that crossover
contamination does not occur.
The fluid flow control passages are specifically designed to
include various dams or flow gates for defining a particular flow
path through the device which may easily be added or removed from
the molds for making the housing halves. This provides a distinct
manufacturing advantage in that, by selective removal of mold
inserts generally in the form of mold plugs and pins, the flow
pattern through the device may be programmed for any combination of
filters used with the device, arranged in any order. As a result, a
large number of different flow control bodies can be made from the
same mold which dramatically reduces manufacturing costs by
eliminating the need for several individual molds. Moreover, this
feature provides improved flexibility in terms of production and
inventory control.
In a preferred embodiment, the fluid flow control device also
includes an integral automatic shut off valve formation adapted to
receive valve diaphragm inserts, or not, as the particular filter
section requires.
In accordance with the invention, the new and improved modular
filter section unit may be detached from the system and a new unit
put in its place by an unskilled service person. The removed filter
section may be returned to a central location for replacement or
reconditioning of the filter cartridges within the unit.
Other objects and advantages of the invention will become apparent
from the following Detailed Description of the Invention taken in
conjunction with the Drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a conventional prior art reverse
osmosis filtration purification system including an R.O. purified
water dispensing faucet, a pressure resistant storage tank and
showing a top plan view of a filter section assembly board with
tubing connections shown between filter section elements;
FIG. 2 is a front elevation view of the filter section of the prior
art reverse osmosis water purification system shown in FIG. 1;
FIG. 3 is a front elevation view of the new and improved filter
section of the present invention illustrating one embodiment of the
new and improved fluid flow control device with three filter
modules attached thereto;
FIG. 4 is a left hand end elevation view of the new and improved
filter section in accordance with the present invention taken along
lines 4--4 in FIG. 3;
FIG. 5 is a right hand end elevation view of the new and improved
filter section taken along view lines 5--5 in FIG. 3:
FIG. 6 is a top plan view of the new and improved fluid flow
control device of the present invention; FIG. 7 is a front
elevation view partly in section of the bottom housing half of the
new and improved fluid flow control device of the invention; FIG. 8
is a bottom plan view of the bottom housing half of the new and
improved fluid flow control device of this invention; FIG. 9 is a
top plan view of the bottom housing half of the new and improved
fluid flow control device of the present invention;
FIG. 10 is an elevated cross sectional view of the bottom housing
half taken along view lines 10--10 in FIG. 8;
FIG. 11 is a front elevation view of the top housing half of the
new and improved fluid flow control device of the present
invention;
FIG. 12 is a top plan view of the upper housing half of the fluid
flow control device;
FIG. 13 is a bottom plan view of the upper housing half of the
fluid flow control device;
FIG. 14 is an elevated cross sectional view of the upper housing
half taken along view lines 14--14 in FIG. 13;
FIG. 15 is an elevated cross sectional view of the upper housing
half taken along view lines 15--15 in FIG. 13:
FIG. 16 is a left hand end elevation view of the upper housing half
taken along view lines 16--16 in FIG. 12;
FIG. 17 is a cross sectional view of the female I/O connector in
the upper housing half taken along view lines 17--17 in FIG.
12;
FIG. 18 is a cross sectional view of the female input/output
connector on the upper housing half taken along view lines 18--18
in FIG. 12;
FIG. 19 is an elevated cross sectional view of the automatic
shutoff valve for use with the fluid flow control device of this
invention; and
FIG. 20 is an elevated cross sectional view of the automatic
shutoff housing which has been converted so that no automatic
shutoff function is provided;
FIG. 21 is a top plan view of the male and female I/O connector
halves shown in mated, sealingly engaged relationship;
FIG. 22 is a top plan view, partly in section, showing the male
connector half of the I/O connector of this invention;
FIG. 23 is a front elevational view of the mating face of the male
connector half;
FIG. 24 is an elevated side view of the male connector half, taken
along view lines 24--24 in FIG. 22;
FIG. 25 is a top plan view of the locking bracket for use with the
I/O connector of the invention;
FIG. 26 is a front elevation view of the locking bracket; and
FIG. 27 is a side elevation view of the locking bracket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-2, a conventional prior art system 1 of a
filtration purification reverse osmosis type is shown. As shown in
FIG. 1, prior art R.O. system 1 includes a dispensing faucet 2 for
dispensing purified R.O. water from a storage tank 3 which is
provided to temporarily store water made from the reverse osmosis
filter section 4 until withdrawn from the faucet 2 as desired. As
shown in FIGS. 1 and 2, the filter section 4 of the prior art
reverse osmosis filtration purification system 1 includes a
generally L-shaped mounting flange 5 to which components and
elements of the filter section are mounted.
Referring now to FIG. 2, a series of three different filter modules
including a sediment pre-filter 6, an intermediate granular
activated carbon (GAC) filter 7 and a right hand reverse osmosis
(R.O.) membrane filter 8 are shown extending downwardly from the
mounting flange 5. A plurality of tube connections are provided
above the filter modules on the mounting flange to connect the
various filters together in series and to connect the output from
the various filter elements to other system elements. As shown in
FIG. 2, the conventional system 1 includes a drain restrictor 9
which is connected to the waste water outlet 10 from a reverse
osmosis filter 8 which continues on to drain. An automatic shutoff
valve assembly 11 is shown connected to the pure water outlet 12 of
the reverse osmosis filter 8 and with a continuing connection to
the storage tank 3 shown at the left hand portion of the drawings.
The automatic shutoff valve 11 is also connected at its lower
portion in between the sediment filter output 14 and the granular
activated carbon (GAC) filter input 15.
With respect to the conventional filter section 4 depicted in FIG.
2, incoming tap water at line pressure enters the filter section 4
at the left hand portion as shown in FIG. 2 to enter the sediment
pre-filter 6. Pre-filtered water exits the sediment filter module 6
through a central tube 14 and enters the lower left hand portion of
the automatic shutoff valve 11. If the shutoff valve 11 is in an
open condition, the pre-filtered water exits at the right hand side
at the automatic shutoff valve 11 and is directed to the input 15
of the granulated activated carbon (GAC) filter 7. The pre-filtered
water is directed downwardly along the length of the pressure
vessel containing the granular activated carbon filter 7 and then
at the base of module 6 is redirected upwardly through a central
filter product tube 16. The sediment pre-filtered and GAC
pre-filtered water exits from a central location above the
granulated activated carbon filter and is directed by a tubing
connection 17 to the base of the reverse osmosis pressure vessel 8.
The water enters the bottom of the R.O. vessel 8 and fills the
pressure vessel. An upper right hand outlet 10 directs waste water
to drain restrictor 9 to drain 10. Pressurized water to be purified
migrates through the revere osmosis membrane and thereafter,
radially inwardly to a conduit which spirals toward a central pure
water return tube 12 which exits upwardly from a central portion of
the reverse osmosis filter module 8 to enter the automatic shutoff
valve 11 at the upper right hand connection as shown. Thereafter,
the R.O. purified water is directed into the storage tank 3 for
temporary storage prior to consumption.
As is clearly shown in FIGS. 1 and 2, the conventional filter
section 4 of a prior art multi-filter reverse osmosis system 1
includes a large number of tubing connections between various
elements within the system 1 and filter section 4. Each of these
connection points provides a potential site for system leakage
which is clearly undesirable. Moreover, each of the specific tubing
connections are of a given length and changes in the types and
patterns of flow for the filters positioned within the filter
module arrangement generally cannot be made without preparing a
brand new mounting bracket with new dedicated tubing connections
between the differing filter elements.
Referring now to FIGS. 3-6, the new and improved modular
multi-filter subassembly or filter section 20 of the present
invention is illustrated. As shown in FIG. 3, modular subassembly
20 includes a fluid flow control device 22 to which three separate
filter modules 24 are mountedly engaged. A mounting bracket 26
including clamping means (not shown) may be employed for removably
mounting subassembly 20 to a door, wall or panel in a well known
manner, by means of mounting screws 28 and screw head-engaging
mounting slots 30. A double ended tubing connector 32 is shown
connecting an elbow fitting 34 and a male coupling adaptor 36
extending from fluid flow control device 22.
Fluid flow control device 22 also includes an input/output
connector portion 38 shown to include three mating ports 40, 42 and
44, for connecting device 22 to other elements of an R.O.
purification system, such as system 1 shown in FIGS. 1-2. A
connector locking member 46, for locking a complimentary mating I/O
connector 70 (FIG. 22) in mated and sealed relation with connector
portion 38 of device 22 may be removably secured to the device 22
by means of phillips head screws 48 as shown in FIG. 6. An
integrally formed automatic shut-off valve assembly 50 (FIGS. 15
and 19-20) projects upwardly from fluid flow control device 22.
Filter modules 24 depending from fluid flow control device 22 are
all substantially the same and each includes an outer hollow,
generally cylindrical pressure vessel 52 having an open top end
portion 54 and an opposing closed bottom or free end 56. The top
end portion 54 is provided with an internally threaded, rotatably
mounted coupling nut 58 for securely mounting each filter module 24
to fluid flow control device 22 in a manner to be more particularly
described hereinafter. Each of the pressure vessels 52 includes a
filter receiving cavity 60 for receiving a standardized water
treatment element or insert, indicated generally at 62, which
includes chemical and/or mechanical removal media for selective
removal of suspended and/or dissolved solids from water flowing
through filter element 62 and module 24 or may include a mechanical
or chemical disinfectant element or a nutrient or water additive
element or cartridge.
In the preferred embodiment depicted in FIG. 3, the modular
multi-filter subassembly 20 is provided with a sequence of filter
modules 24 having a sediment pre-filter insert 64, a granular
activated carbon (GAC) filter insert 66 and a thin film cellulose
(TFC) reverse osmosis (R.O.) filter insert 68. In accordance with
the present invention, substantially all of the fluid flow
connections between the various filters and elements in the filter
section are made internally within fluid flow control device 22.
The filter section arrangement shown in FIG. 3, has a similar
filtering sequence and flow path as the prior art system 1 shown in
FIGS. 1 and 2.
Accordingly, for this illustrated embodiment, impure tap water at
line pressure is introduced into subassembly 20 through mating port
40 in the I/O connector portion 38 of fluid flow control device 22.
The incoming tap water is directed by device 22 into pressure
vessel 24 containing sediment pre-filter 64 at the opposed end of
device 22, wherein suspended solids are removed. The pre-filtered
water is directed upwardly into fluid flow control device 22,
through the automatic shut off valve assembly 50 and into the
second filter module 24 containing the GAC filter 66. Undesired
organics, trihalomethanes (THMs) and chlorine, are removed from the
flowing stream by the GAC filter 66 and the GAC-filtered water is
again directed upwardly into fluid flow control device 22. The GAC
filtered water emerges again travelling downwardly through tubing
connector 32 to enter elbow fitting 34 in the bottom end 56 of left
hand filter module 24 containing the TFC R.O. filter 68. A waste
water drain outlet and a central R.O. purified water outlet are
provided in device 22 to receive and direct waste water and pure
water, respectively, up into different regions fluid flow control
device 22. R.O. purified product water leaves the fluid flow
control device 22 through input/output connector 38 at mating port
44. A check valve 45 may be provided in the R.O. purified product
water outflow line in a socket 90 or in the appropriate mating port
44 in I/O connector 38. Concentrate or waste water exits device 22
through mating port 42 in I/O connector 38. A waste water drain
restrictor 43 is preferably provided in mating port 42 of the I/O
connector 38.
In accordance with the present invention, means designed to
communicate with the remaining elements of the R.O. system are
provided to connect the modular multifilter subassembly 20 into the
system 1. In accordance with the preferred embodiment, an incoming
tap water tubing line 72, an outflowing waste water tubing line 74
to system drain and an outflowing filter-purified product water
tubing line 76 to a pure water storage tank, such as tank 3 in FIG.
1, are all co-terminated in a complimentary mating I/O connector 70
shown in FIG. 22 and discussed in detail below.
As a result of its improved features and construction, the modular
multifilter subassembly 20 may be placed into operation in an
overall filtration purification circuit or system and the
possibilities for leakage within the connections of the system are
thereby reduced. For example, and by way of illustration, a total
of only five poly-tubing connections to and from the device 22 and
within the filter section 20 are presented in the preferred
embodiment shown in FIGS. 3-5, including two connections at the
opposite ends of the double ended tubing connector 32 and three
connections for the tubes 72, 74 and 76 terminated in the
complimentary I/O connector 70. The prior art system shown in FIGS.
1-2, included sixteen separate tubing connections. By comparison,
the new and improved filter section 20 in accordance with this
invention significantly reduces the number of tubing connections,
thereby reducing the risk of system or section leakage and provides
these advantages at reduced cost.
In greater detail and referring again to FIGS. 3-6, the new and
improved fluid flow control device 22 of this invention comprises a
unitary or one-piece thermoplastic body 80. In the preferred
embodiment depicted therein, device body portion 80 has an elongate
generally rectangular configuration and includes spaced and
opposing upper and lower major surfaces 82 and 84, respectively. In
accordance with the preferred embodiment, body 80 is formed from a
pair of hot-plate fusion-bonded housing halves, including upper
housing half 86 and lower housing half 88. The preferred features
for upper housing half 86 are shown in FIGS. 11-16, whereas, the
preferred features for lower housing half 88 are depicted in FIGS.
7-10. Although hot plate fusion bonding methods are preferred,
other modern plastics bonding methods such as vibration welding,
friction welding and sonic welding may also be used.
Referring now to FIGS. 7-10, lower housing half 88 is seen to
include three spaced-apart filter-module receiving sockets 90
projecting normally downwardly from the lower surface 84 of housing
half 88. The socket formations 90 have generally the same
configuration and as shown in FIG. 7, each socket 90 is defined by
coaxially-aligned radially inner and radially outer spaced apart
tubular or cylindrical projections 92 and 94, respectively. Inner
tubular projection 92 extends from lower surface 84 to a free end
96 provided with an inwardly flared or tapered lead-in section 98.
Inner tubular projection 92 defines an inner recess 100 having a
generally cylindrical configuration which is adapted to
telescopically receive and, preferably sealingly engage, a top
centralized mating port provided on a standard filter module insert
62. In accordance with standard filter design, the mating port of a
filter insert is defined by a projecting cylindrical member which
is provided with a peripheral or circumferential groove adjacent
the free end which receives an O-ring seal. The O-ring on the side
of the cylindrical central mating port of the filter insert is
compressed as the filter is engaged in the inner recess 100 in
socket 90 so that the O-ring forms a fluid tight seal between the
groove on the mating port and the inner cylindrical sidewall
surface 102 defining recess 100 on projection 92. A fluid flow
aperture 104 is defined in lower surface 84 within inner recess
100. A disk-shaped in-line check valve may be inserted into an
inner recess 100 intermediate the mating port of the filter insert
and the fluid flow aperture, as desired, to prevent back flow from
a storage tank into an R.O. cartridge and vessel, for example.
Socket portions 90 also include a second coaxial and radially outer
tubular projection 94, extending from lower surface 84 to a free
end 106. A wide bearing surface 108 is defined at free end 106. The
outer surface of tubular projection 94 includes an array of
external threads 110 adapted to threadingly engage the internal
threads provided on coupling nuts 58 carried on pressure vessels
52. The upper open top ends 54 of pressure vessels 52 typically
include a wide end lip surface (not shown) provided with a groove
and O-ring seal which sealingly engages and abuts against bearing
surface 108 on outer projection 94. Accordingly, a liquid tight and
pressure tight seal is formed when the coupling nut 58 is rotated
to move the vessel .Iadd.to .Iaddend.a locked position so that the
O-ring is compressed to fully engage the pressure vessels 52 and
filter elements 62 in the sockets 90. Socket 90 additionally
includes an outer annular recess 112 defined between inner
projection 92 and outer projection 94. An inner surface portion 114
extending between inner projection 92 and outer projection 94 may
be provided in socket 90. A second fluid flow aperture 116 is
provided in the outer annular recess 112.
Referring to FIGS. 7, 8 and 10, lower housing half 88 is preferably
molded in a modularized mold incorporating a number of quick change
tooling elements such as mold plugs and mold pins, so that the
basic mold may be quickly and easily modified to produce any one of
a number of predetermined bottom housing half configurations. More
particularly, as shown in the bottom view in FIG. 8, lower housing
half 88, has a generally symmetrical configuration. A central
elongate mold groove 118 is shown extending the length of bottom
half 88 which intersects each of the socket portions 90. Branching
mold groove formations 120-126 are shown projecting laterally from
central groove 118 on either side of the middle socket 90. In mold
groove branches 120 and 126, a moldable port site 128 is defined at
formations 130.
As shown in FIG. 10, formation 130 in branch 120 has been cored out
in the mold to define a port site 128 in lower housing half 88
including a threaded receptacle portion 132 and a fluid flow
communication opening or aperture 134. Port site 128 may be
provided in any one or more of the branch lobe locations 120-126 as
desired for a particular filter section combination. The threaded
receptacle portion 132 is adapted to matedly engage or receive a
threaded poly tube coupling adaptor 36, known to those skilled in
this art and indicated in FIG. 3. Symmetrically positioned circular
mold indentations 136 shown in each annular recess area 112 of each
socket 90 opposite their respective apertures 116 also indicate
that the apertures 116 may be located on either side of the socket
90 as needed by simply moving the quick change tooling in the
modular mold.
Turning now to FIGS. 7, 9 and 10, lower housing half 88 has an
upper mating contact surface 140 disposed opposite lower surface
84. Upper contact surface 140 on lower housing half 88 has an
uneven surface configuration. As is best indicated in FIGS. 7 and
10, upper contact surface 140 is characterized by raised upwardly
projecting wall portions 142, which define fluid grooves 144
therebetween. Moreover, adjacent each upwardly projecting wall 142
extending on outer sides thereof, opposite the fluid grooves 144,
are recessed moat or trough areas 146. The free upper ends 148 of
each wall portion 142 define raised fusion bonding surfaces 150
adapted to mate and fuse with complimentary bonding surface
structures 152 provided in a lower contact surface 154 of upper
housing half 86. As is best shown by rectangular zones in FIG. 9, a
number of flow gates or dam partitions 340 may be imparted or
removed from fluid grooves 144 to alter the fluid flow paths
defined by each groove 144 also by means of quick change tooling
designed into the convertible modular housing molds.
Referring now to FIGS. 11-15, the structured details of upper
molded housing half 86 are shown. Upper housing half is similar in
many important respects to its complimentary lower housing half 88
in that it includes the upper surface 82 and an opposing lower
contact surface 154. Lower contact surface 154 is also
characterized by raised projecting walls 156 whose upper surfaces
define bonding surfaces 152 for the upper half 86. Wall projections
156 also define inner fluid flow grooves 158 between adjacent walls
156. Moat or recess areas 160 are likewise provided adjacent the
outside edges of wall projections 156. Flow gate or dam areas 340
are also indicated in upper housing 86 at complimentary locations
to those shown in lower part 88. In the preferred embodiment
depicted in the drawings, top housing half 86 is additionally
molded to include an integrally molded automatic shut off valve
housing 300 for receiving the automatic shut off valve assembly 50.
Top housing half 86 is also molded to include an integrally molded
input/output connector portion 38. The automatic shut off valve
assembly 50 and I/O connector portion 38 will be described in
particular detail hereinafter.
In accordance with the preferred embodiment of the present
invention, fluid flow control device 22 is preferably made by hot
plate fusion bonding the upper and lower housing halves 86 and 88
together to define a unitary body 80 with fluid flow-control
passages extending within said thermoplastic body 80 for directing
the flow of fluids in a leak-free manner from one filter module 24
to the next in subassembly 20. Hot plate fusion bonding methods for
joining thermoplastic parts are generally known. Hot plate melt
fusion methods of bonding basically involve contacting edge
surfaces 152 and 150 to be joined with a heated plate to plasticize
the thermoplastic edge surfaces. A molten plastic bead is formed by
applying pressure so as to push the molded parts against the heated
plate. The depth of the molten material or bead can be determined
by the design of the grip tooling which holds the parts during
melting and fusion bonding, as well as, by employing a pressure
regulating system. After contacting the parts or the surfaces of
the parts to be joined against the heated plate for a time and at a
pressure designed to impart a desired amount of bead, the parts are
rapidly separated from the plate surfaces and the plate is
withdrawn. Thereafter, the holding fixtures for housing halves 86
and 88 are moved together to contact the molten plastic surfaces
150 and 152 under applied pressure. The molten beads at 150 and 152
of a properly selected thermoplastic material flow together and
fuse as the plastic cools forming a unitary thermoplastic body
80.
The hot plate fusion bonding method provides parts which after
fusion bonding can withstand very high internal pressures within
the fluid flow passageways formed by grooves 144 and 158 defined
therein of up to 1100 psi. Air gaps and flashes and incomplete
bonding are eliminated by controlling the depth of molten plastic
bead that is formed and by providing flash tracks or moat areas 146
and 160 adjacent the upstanding walls 142 and 156. In accordance
with the present invention, each of the housing halves 86, 88 for
forming the fluid flow control device 22 is preferably molded of a
thermoplastic material and, especially preferably each is molded
from an alloyed thermoplastic composition comprising ABS and
nylon.
The temperatures to which the heat plate must be heated to provide
hot plate fusion bonding may vary depending on the thermoplastic
material selected. Generally, temperatures on the order of
375.degree. to 520.degree. F. are suitable.
Referring now to FIGS. 3, 9 and 13, the new and improved fluid flow
control device 22 is prepared by aligning housing halves 86 and 88
together so that their respective mating contact surfaces 154 and
140 are brought into opposing face to face contact and so that side
edge 170 on lower half 88 is aligned with side edge 172 on upper
half 86. When disposed in this relationship, the wall projections
142 and 156 are disposed in registration with each other and fuse
to form fluid flow passages having a generally rectangular
cross-sectional configuration by uniting the U-shaped,
semi-rectangular fluid flow grooves 144 and 158. These discrete
fluid flow passages direct all fluid flow within device 22 between
the filter modules 24.
More particularly and referring now to FIGS. 9 and 13 in the
preferred subassembly 20 shown in FIG. 3, impure tap water enters
fluid flow device 22 from tubing 72 attached to complimentary male
I/O connector 70. Tap water enters into integral female I/O
connector section 38 through port 40. A fluid flow channel 180
extends downwardly in upper half 86 between port 40 and a fluid
flow passage 182 defined by complimentary grooves 182a and 182b
(FIG. 9). Tap water enters passage 182 adjacent channel orifice 184
and flows along passage 182 substantially the entire length of the
device body 80 until it reaches a downflow orifice 186 in lower
half 88 (FIG. 9) which communicates with annular recess aperture
116 in the right hand socket 90. Impure tap water fills filter
module 24 including sediment pre-filter insert 64 and is forced
under line pressure to flow radially inwardly through filter 64 to
an axial discharge tube sealingly engaged in inner recess 100. The
sediment filtered tap water flows upwardly from filter 64 through
fluid flow aperture 104 into a passage 188 in device 22 defined by
grooves 188a and 188b. An upflow orifice 190 feeds the sediment
pre-filtered tap water up through automatic shutoff valve assembly
50 (FIGS. 15 and 19-20). If the valve assembly 50 is in an open
condition, the pre-filtered tap water flows downwardly out of valve
assembly 50 and through orifice 192 into passage 194.
Passage 194 extends between the valve 50 and a second, center
filter module 24 containing the GAC filter 66. The flowing water
enters the GAC filter module 24 through annular recess aperture 196
and after downward flow around the central carbon filter media, the
filtered water is directed upwardly through the axial GAC filter
66, through central socket aperture 198 and into passage 200 in
device 22 formed by grooves 200a and 200b. In place of the GAC
filter an extruded, radial-flow carbon block filter module may also
be used.
The sediment pre-filtered and GAC-filtered tap water flows along
passage 200 and through port aperture 134 to flow through coupling
adapter 36, double ended tubing 32 and elbow fitting 34 into the
bottom end 56 of left hand filter module 24 containing a TFC upflow
R.O. filter insert 68. R.O. purified and filtered water is forced
upwardly through central socket aperture 202 into curving passage
204. The R.O.-purified product water leaves passage 204 through a
channel orifice which communicates with pure water channel 206.
Pure water channel 206 fluidly connects with pure water outlet port
44 in female I/O connector section 38. Pure water is also directed
along passage 204 to another orifice 208 which leads to an upper
pressurizable chamber 210 in automatic shutoff valve assembly
50.
Waste water or concentrate from R.O. filter module 68 travels
upwardly through the associated socket annular recess aperture 212
into a waste water outflow passage 214 which is in turn disposed in
fluid flow communication with waste water channel 216 associated
with mating port 42 of the female I/O connector portion 38 as has
been mentioned above, a small cylindrical in-line drain restrictor
insert 43 may be provided in mating port 42.
Having described the formation of the discrete fluid flow passages
and the flow circuit there-through for one set up of the preferred
filter section 20, a description of other preferred features of
fluid flow control device 22 may now be made. As has been mentioned
above, fluid connections between the system generally and the fluid
flow control device 22, in accordance with the preferred
embodiment, are made in a connectorized manner by means of a two
piece input/output connector assembly. The two piece I/O connector
includes a male plug connector 70 and a matable female receptacle
connector 38. In accordance with the invention, it is preferred
that one part of the I/O connector be integrally molded with
thermoplastic device body 80. In the preferred embodiment shown in
FIGS. 4, 12, 16-18 and 21, the female receptacle I/O connector
portion 38 is integrally molded into the upper housing half 86 of
device body 80.
Referring now to FIG. 12, at the left hand portion of the figure,
the female input/output connector housing 38 is shown to include
connector locking bracket screw receiving flange members 220, 222,
as well as positioning pin receiving apertures 224, 226. The
pin-receiving apertures 224 and 226 are adapted to receive
positioning pins 228, 230 on the connector locking bracket member
46 (FIG. 26) to keep the male and female input/output connectors 70
and 38 in their fully mated and sealed condition (shown in FIG.
21).
Referring now to FIGS. 16, 17, 18 and FIGS. 21-27, further details
of connectors 38 and 70 are shown. More particularly, as shown in
FIG. 16, the mating face 232 of the female connector half 38
includes three spaced-apart circular openings 234, 236 and 238 and
a pair of intermediate rectangular openings 240 and 242. As shown
in FIGS. 17 and 18, each of circular openings 234-238 extends
rearwardly from mating face 232 to define stepped sockets 280, 282,
284 for receiving fluid conveying projections 246, 248, 250
extending forwardly from the complimentary face 252 of the male
plug connector 70. The stepped configuration of each socket 280-284
includes a tapered transition portion 254 best shown in FIGS. 17
and 18, which provides a bearing surface 256 which cooperates with
a similarly angled bearing surface 258 on the male projections
246-250 to axially and/or radially compress an O-ring seal 260
(FIG. 21) therebetween to form a fluid tight, sealed connection
between each fluid conveying projection 246, 248, 250 defined in
the male plug 70 and the respective receptacle sockets 280-284
defined in the female connector 38. As shown in FIGS. 17-18, each
of the female receptacle sockets 280-284 includes a fluid flow
channel 180, 206 and 216, respectively, connecting the fluid
circuits 72, 74, 76 in the male plug member 70 to the aligned
passageways 182, 204 and 214 within the fluid control device
22.
Each of the rectangular openings 240, 242 also extends rearwardly
from the mating face 232 of the female connector 38 to provide
mating alignment guideways for guiding the male alignment
projections 262, 264 on the face of plug member 70 into mated
engagement within the female connector 38. Also as shown in FIG. 16
and 18, the female connector 38 includes a pair of pin receiving
vertical passageways 224, 226 which intersect the alignment guide
openings or guideways 240, 242. Pin members 228, 230 extending from
the locking member 46 shown more particularly in FIGS. 25 through
27 are positioned through these pin receiving holes 266, 268
defined in the projecting male mating guide members 262, 264 to
urge and maintain the front end portions of fluid conveying
projections 246-250 on the mating face 252 of the male connector 70
into locked and sealing engagement with sockets 280-284 of the
female connector 38, respectively. In addition, as shown in FIG.
16, adjacent the lower left and right hand sides of the mating face
232 of the female connector 38 are undercut notches 270, 272 which
are adapted to receive lateral locking flange members 274, 276
projecting from opposed sides of the mating face 252 of the male
connector 70. These notches 270, 272 further serve to polarize the
mating of the male plug 70 with the female connector 38 and further
assist in guiding the male connector 70 into fully mated position
within the female connector 38.
Referring now to FIG. 21, the input/output connector 38 and 70 is
shown in its mated, locked and sealed position with the locking
bracket member 46 in place. Each of the O-ring seals 260 carried on
the mating face 252 of the male member 70 are compressed radially
and/or axially between the angled surfaces 258 of the male member
70 and the angled surfaces 256 socket members 280-284 to provide a
fluid tight seal for the fluid conducting projections 246-250. Each
of the guiding projections 262, 264 have been received within the
guiding apertures 240, 242 defined in the mating face 232 until the
pin hole openings 266, 268 in the guiding projections 262, 264 are
disposed in registration with the pin receiving openings 224, 226
of the female connector 38. This ensures that the male connector 70
has been urged forwardly into a mated and sealed engagement within
the female connector 38 so that the O-ring seals are axially and/or
radially compressed. The locking bracket 46 may be affixed into
position by inserting the pins 228, 230 into the aligned openings
224. 266 and 226, 268 respectively. Locking member 46 may be
secured by passing threaded screws 48 through the lateral mounting
flanges 274, 276 of the male connector 70 to secure it in locked
and mated condition to flanges 220, 222 of the female connector 38
as shown.
Referring now to FIG. 19, the automatic shutoff assembly 50
comprises a housing 300 molded into the upper surface 82 of the
upper body half 86. Valve housing 300 is adapted to receive
automatic shutoff valving elements as shown. The valving elements
include a positioning ring 302, a movable piston 304 secured
between upper and lower diaphragm members 306, 308, and sealingly
engaged in to the valve housing structure by a valve cap structure
310. In assembled condition, as shown in FIG. 19, a lower valve
chamber 312 is defined adjacent the valve seat 314 and an upper
valve chamber 316 is defined within the secured cap member 310. The
area of the upper piston surface 318 is considerably larger than
the area of the lower piston surface 320.
In accordance with this arrangement, incoming sediment prefiltered
tap water at line pressure passes upwardly through upflow opening
190 into the lower valve chamber 312, thereby exerting an upward
pressure on the lower piston surface 320. This causes the movable
piston 304 to be lifted off of valve seat 314, permitting the
pre-filtered water to flow into the valve outlet 192 for
transmission along passage 194 to the granular activated carbon
inlet aperture 196. The upper valve chamber 316 is connected by
means of a vertical channel 322 to the R.O. purified water passage
204 and channel 206 which are in turn connected to the pure water
line 76 to the storage tank, such as tank 3 in FIG. 1.
As purified R.O. water fills the storage tank 3 to capacity,
pressure in the pure water line 76, 206, 204 and 322 increases
causing pressure to develop or increase in the upper valving
chamber 316. Pressure in the upper valving chamber 316 exerts a
downward pushing force against upper piston surface 318 causing
downward movement of the piston 304 against the valve seat 314 to
shut off incoming water flow from opening 190 when the tank 3 is
substantially filled. By adjusting the relative area of the upper
piston surface 318 to the lower piston surface 320, the valve 50
can be adjusted to shut off incoming water flow when a relatively
moderate amount of pressure increase is experienced in the storage
tank 3 and pure water line 74. For example, valve 50 may be
actuated to its closed or shutoff position at approximately 2/3
line pressure or less. After being moved to its closed, shutoff
position, the relative area of lower piston surface is reduced even
further to that circumscribed by valve seat 314. In order to reopen
the automatic shut-off (ASO) valve assembly 50, the storage tank
pressure is permitted to drip 1/2 of line pressure or less,
preferably 1/3 of line pressure or less, before the incoming tap
water exerts sufficient upward pressure on the piston to reopen the
ASO. Thereafter, the R.O. filter section may run continuously for a
time until storage tank pressure again rises sufficiently to shut
off the ASO valve assembly. Improved R.O. product water quality is
expected from this continuous cycling.
Referring now to FIG. 20, in some embodiments the filter section 20
in accordance with the present invention may not require there to
be an automatic shutoff valve provided. In accordance with these
arrangements, the shutoff valve housing 300 may be effectively
closed off by means of a conversion plug member 324 which
cooperates with the valve housing cap 310 to permit incoming fluid
to flow through the lower valve chamber 312 and out through the
exit opening 192 without any other valve activity. The ASO valve
housing 300 may also be used to receive paddle wheel flow meters,
reed switches, LED and alarm assemblies to indicate total flow and
alert when a changeover and/or service of treatment modules should
be performed.
The ability to hot plate fusion bond thermoplastics enables the
fluid flow control device to be molded from independent
complimentary housing halves. This provides improved flexibility in
channel and passageway design by injection molding of the housing
parts, rather than trying to core out or machine similar
passageways in a solid molded block of thermoplastic resin.
Moreover, the ability to mold the housing parts enables the various
other structures to be incorporated into the mold such as lo the
valve 50 and the tube connector for the R.O. filter tubing 32.
These additional features may be molded in without having to
provide separate leakable structures for connecting them to the
housing of the fluid flow control device. As is shown by the
rectangular areas in FIGS. 9 and 13, optional pins and holes, dams
or flow gates 340 are preferably designed into molds for upper and
lower housing halves 86 and 88 to either open up or close off
portions of fluid flow passages in the device 22. The dams 340 are
also added or removed easily by means of quick change pins and
plugs designed into the mold tooling. In this manner, fluid flow
device 22 maybe programmed to provide appropriate fluid flow for
other filter sequence combinations, by making minor mold changes
built into the molds.
In accordance with this invention, the fluid flow control device
permits the filter section of an R.O. system to have pop-in/pop-out
easy access feature.
Although the present invention has been described with reference to
a modular filter subassembly including a sediment pre-filter 64, a
granulated activated carbon filter 66 and a reverse osmosis
membrane filter 68, other filter or water treatment cartridges 62
could be affixed to the fluid flow control device 22 by means of a
socketing portions 50, as desired. The socket number may be
increased or decreased as desired to meet the requirements for
additional treatment modules and vessels required for any end use
application, while retaining the advantages provided by the present
fluid flow control device. Additional fluid flow circuits may be
added as additional ports in the I/O connector section in
accordance with the principles of the invention. For example, it
may be desired to store purified water in a storage tank and to
pass the water from the tank through a GAC filter to remove any
residual tank taste before the purified water leaves the dispenser
faucet. In accordance with this arrangement, the post storage GAC
filter may be added as a fourth socket module assembly and circuit
path defined in the fluid flow control device. In this case one or
more additional I/O ports may be required to be added to I/O
connector including a return pure water line in from tank and a new
post filter line out to dispenser faucet.
Regardless of the number of sockets, ports, channels and
passageways that may be needed, they may be readily accommodated in
multiple duty molds for the housing halves to provide for a variety
of programmable flow possibilities. As indicated in the drawings,
quick change tooling in the mold can convert the mold from one
arrangement to another. Only one basic mold is therefore needed to
produce a variety of fluid flow control devices for use with a
number of filter module arrangements.
The fluid flow control device dramatically cuts down on the number
of potential leakage problems caused by connections of tubing. More
particularly, a comparison of the FIG. 2 prior art assembly with
the assembly of this invention shown in FIG. 3, indicates that the
prior art system 1 included 16 separate polytube connectors
susceptible of leaking in the pressure environment, whereas the
FIG. 3 device, in accordance with the present invention, has a
total number of five possible leaking connections to tubing, which
may be reduced even further for filter subassembly which do not
include a TFC R.O. filter 68. In this case, the double ended tubing
connector 32 could be avoided, thereby reducing the total potential
leakage sites to three or less.
Although the present invention has been described with reference to
certain preferred embodiments, modifications or changes may be made
therein by those skilled in this art. For example, other filters
and filter modules may be employed in substitution for those
disclosed. Ceramic filters or other specialty filters may be used.
Lead removal or nitrate removal filter modules may be employed.
Various other water treatment modules might be used such as
iodinated resin disinfectant modules, as well as calcium or vitamin
nutrient additive modules. Moreover, instead of providing a three
socket device adapted to matingly and sealingly receive three
filter modules, a device having any number of module-receiving
sockets provided in an extended length fluid flow control device
may be molded and prepared in accordance with the teachings of the
present invention. All such obvious modifications or changes may be
made herein by those skilled in this art without departing from the
scope and spirit of this invention as defined by the appended
claims.
* * * * *