Patent Application
20250019942
This environmentally friendly invention refers to a control process for reducing water waste in hot water installations, carried out by a recirculation valve and/or a control device, through the control of water flow and its direction according to temperature, with application at any point of consumption with hot water available, with the purpose of avoiding waste by recirculating cold or unheated water at the desired temperature existing in the water pipe between the consumption and heating points, with the advantage of being completely mechanical, without requiring any electrical installation or dedicated hydraulic installation.
As it is known from technical resources in the field of water heating systems used to supply hot water to showers and taps, specifically those where the heating point is far from the point of consumption, there is a waiting time for the water to reach the desired temperature and this water, while not properly heated, is completely wasted. This is repeated every time enough time passes between closing the tap and opening it again for the water in the hot water pipe to cool down.
Making conservative estimates based on the population in colder Brazilian regions, around 80 million people, the number of residences is approximately 20 million and, of these, considering that only 20% use a system where the heating point is far from the heating point. of use (e.g. gas or solar), there are approximately 4 million homes. If there are 2 purges per day in each one and, on average, 5 liters of water are wasted each time the water is expected to reach the desired temperature, then approximately 40,000 m3 of potable water per day are wasted in the country, due to the purge of the water from the hot water pipes of homes. This value may be higher for Brazil, as the estimates are conservative, and will certainly be much higher if we consider other countries.
To overcome this problem, there are currently two methods used to reduce the waste of unheated water at the unwanted temperature:
Such processes have the disadvantage of using electronic systems for sensing and/or controlling the hydraulic pump, requiring at least one electrical power point, which may be close to the point of consumption, as well as requiring the installation of additional piping, which implies in additional costs, and/or reservoirs that, in addition to costs, also require space to be positioned.
Brazilian patent BR1020150153210, entitled “Hydraulic set with reservoir installed in a gas heating shower, for water reuse system”, revealed a system developed to prevent cold water, initially accumulated in the bathroom pipes, from being discarded by the user after opening of the shower through a pump working with a mixing tube connected to the piping of a shower with heater, in which the cold water in the piping is collected and released into the water tank, simultaneously with the introduction of hot water into the mixing tube. This revealed set presents the inconvenience of using an electrical system with timer and hydraulic pump to control the supply of hot water at the point of consumption and the disadvantage of using two auxiliary reservoirs and float switches to control the operation of the hydraulic pump and safety against overflows in the event of an electrical failure of the hydraulic pump.
Brazilian patent BR1020160296730 entitled “Improvements introduced in a diverter register for water reuse integrated into a hydraulic shower installation or related” revealed a diverter register for water reuse integrated into a hydraulic shower installation or related with an electric, gas or solar water heating system, with the diverter valve being mounted on the shower hydraulic installation piping, specifically between the mixer set and the heated water outlet shower piping, in order to divert the cold drinking water contained in the hydraulic installation to another hydraulic installation, such as hydraulic plumbs for buildings or similar, with the body of the diverter valve being integrally embedded in the masonry of bathrooms or similar. This diverter valve has the disadvantage that the user must empirically determine the necessary time for hot water with the desired temperature to be available in the pipes, and then activate the diverter valve handle, so that this properly heated water is delivered to the shower. It also has the disadvantage of requiring skilled labor to install the diverter valve on the bathroom wall and its connection with the existing shower supply pipe and the building's plumb line, in addition to the fact that, on its own, the invention does not guarantee that the pressure of hot water will be greater than that of cold water, which is mandatory for it to work.
Brazilian patent BR1020130339911 entitled “Passive valve for reducing water waste from a heating system through recirculation” revealed a passive valve for circulating water from a heating system, with passive automatic closing by thermal actuation, with the main objective to eliminate cold water contained in the hot water pipe, directing it to the cold water reservoir. The release of the water flow passage is carried out manually by the user, and the flow is closed automatically through a thermal system. The arrival of hot water at the valve heats a thermal fluid that expands and displaces a piston, releasing an internal assembly to return the valve to the closed position, ceasing the flow of water. The water that was contained in the hot water piping is directed to the cold water reservoir, taking advantage of the existing piping and the difference in level between the reservoirs.
This revealed valve has the drawbacks of needing to have its parts designed and sized specifically for the flow and pressure conditions of each application where it is used, and also needing the user to remember to activate it before using the consumption point, as it is installed in a different location.
Patent US2015075631 entitled “Temperature-activated cold water diversion valve” revealed a valve that directs cold or unheated water at the desired temperature to a user-defined reservoir, which can be installed, for example, on a sink counter basin, and uses a single water flow stream through an internal pipe around a thermally sensitive coil that transmits rotation for automatic closing of a valve upon arrival of heated water to the valve and after closing, the valve resets itself to the next activation and use. The disclosed system has the disadvantage of requiring an additional reservoir chosen by the user to divert cold water or water at a temperature below the desired temperature and, like other patents already mentioned, it is a valve installed in addition to the one already existing at the point of use, making water savings dependent on user action.
The control process for reducing water waste in water heating systems, corresponding control device and recirculation valve, object of the present invention, was developed to overcome the disadvantages, limitations and inconveniences encountered in systems for reducing waste of unheated water at the desired temperature currently used in water heating systems, through the use of a control device which can be inside a recirculation valve or in the user's tap, with commands to open and close the water flow, whether hot, cold or at an intermediate temperature, and to activate the recirculation system, with the advantage of being completely mechanical, without requiring any electrical installation or dedicated hydraulic installation.
The following technical problems that currently exist and the way the present invention resolved are:
The control process for reducing water waste in water heating systems, corresponding control device and recirculation valve, objects of the present invention, represent the final result of the inventor's development, after his unsuccessful search for a product that was capable of avoiding the waste of water purged from the hot water pipe that was easy to use and install, and that was capable of recirculating water as long as necessary, automatically serving the user only the water that was already heated. For application in sinks with two taps, one for hot water and the other for cold water, the inventor then modified a commercial thermostatic valve, which is designed as an anti-scalding safety device mixing very hot water with cold water to obtain water at the desired temperature according to a setting, so that it works in reverse, now to separate hot water from cold water, using this valve adapted under a sink. The inventor was already aware that the commercial valve contained, among other components, check valves, which, due to previous studies, were known to be necessary, but in the modified valve they were used in the opposite direction, allowing the water to only leave the valve, when in the original commercial version the retentions only allow water to enter the connections for hot and cold water. The modified valve had its inlet port (previously, it was the mixed water outlet) connected to the outlet of the sink's hot water tap, the cold water port was connected to the cold water pipe, and the hot water port was connected to the hot water inlet of the sink mixer, which was previously connected to the hot water tap outlet. The idea was that, when opening the tap, the water would be directed to the cold water pipe while it was not yet heated, and would only come out of the sink spout when it was hot. After installation and, when trying to use it for the first time, the inventor proved the theory that the pressure of the hot water pipe needs to be greater than that of the cold water pipe, due to the fact that recirculation did not start spontaneously after opening the faucet. It was necessary for the inventor to manually activate the pressurizer of his property's heating system so that the water began to recirculate. Once this was done, the rest of the process happened as expected, so that the water came out of the sink spout only when it was heated. Also as expected, it was proven that, once recirculation was carried out and the water in the pipe was still hot, the tap worked normally, without the need to start recirculation again, so that only hot water always came out of the tap spout. As the sink was very close to the shower, the inventor realized that he could use his installation made in the bathroom sink to recirculate the water from the hot water pipes throughout the bathroom, including the shower, as, by doing so, the water from the shower also came out hot, with no waste. There was still one problem to be resolved: the presence of two valves, one for opening and closing the hot water flow and another, a modified thermostatic one, with retainers, for directing it according to the water temperature. That was when the inventor developed a unique valve, with the ability to control the flow of water and, at the same time, initiate recirculation, directing the water that had not yet been heated through the cold water pipe and the hot water to the hot water inlet of the mixer. As it was observed that shower water could be recirculated through the sink, in the initial inventive process a valve was developed with the appropriate shape and dimensions so that it could be installed to replace the sink's original hot water tap, as it is a much easier assembly to be installed, so that the greatest number of parts from the original installation could be reused, including all the finishing parts of the tap, so that, once installed, the valve would not cause any aesthetic changes to the sink. In a second inventive process, however, even knowing the greater difficulty in installation, the inventor also developed a version to be installed in showers or bathtubs, which could be embedded in the masonry, in the case of a new construction or bathroom renovation planned by other reasons. The development of a second base option for the installation was necessary due to the great difference in the positions of the tap axis and hydraulic connections between the installation under a sink and the one built into the wall, however the concept of a modular product line was defined, because the set of components that controls the flow and direction of water, the control device, can be used in both applications, in shower and sink bases. The thread system with pin locks between the control device shaft and the shaft adapters and was designed so that the same control device can be used on any base, adapting to different heights of tap handles. The slots at the ends of the shaft adapters were designed to enable the assembly of the handle that the user will have from its original installation. The base lids and the bases are designed to jointly hold the control device and shaft adapters in the correct position, direct water flow correctly, and enable assembly of both the entire assembly in place and other components from the original installation. In a third inventive process, a control device was created for application in types of taps known as single-lever taps, in which only one handle can be raised and lowered to open and close the water flow, and also rotated to regulate the proportion of taps. hot and cold water available. In this type of faucet, the commercially established construction concept is a piece known as a “cartridge”, which has market standard dimensions, functioning within a normally metallic part that makes up the body of the faucet. The cartridge is a part with plastic components, with a very low cost when compared to the complete faucet and is commercially available as a replacement part among faucet manufacturers. Therefore, the control device for single-lever faucets was designed so that it can be installed to replace the original cartridge, at a much reduced cost, to maintain the user's original faucet.
As an alternative, new lid and housing models were developed, without threads, which fit together by interference, facilitating assembly.
For a better understanding of the control device and recirculation valve of the present invention, the following figures are attached:
In the control process for reducing the waste of unheated water at the desired temperature, in water heating systems, object of the present invention, the function of the hot water inlet valve is incorporated in the recirculation valve (VR), as shown in
The recirculation valve (VR), whose diagram is shown in
The control process for reducing water waste in water heating systems, carried out by the recirculation valve (VR), object of the present invention patent, as shown in
The present invention is not limited to the constructive details and assemblies described and illustrated in this document, as it can be adapted to different formats and be applied in various ways within the scope of the claims. Some terms, such as “horizontal” and “vertical” are used only to help understand the applicability of the invention. The terminology presented is used to describe the invention, not to be used as a limitation.
The recirculation valve (VR) can incorporate the function of the mixer (MX) and also a single-lever type valve, where the mixer (MX) and the hot water valve with the cold water valve (RAF) form a single piece.
According to
The lid (T), hollow, cylindrical in shape, equipped with a lid hole (OTE), circular in shape, through and aligned with the central segment of the shaft (ECC) of the shaft (E), and being the lower part of the lid (TI) with a smaller diameter than the top part of the lid (TS), with internal vertical channels for fitting the upper part of the seat (ASS), and with an internal channel for fitting the locking ring (AT), in a U shape.
The shaft (E), with the upper shaft segment (ES), cylindrical in shape, threaded and with the shaft through hole (OPE), with the central shaft segment (ECC), cylindrical, hollow and with a slightly larger diameter than the diameter of the upper shaft segment (ES), with the ringed shaft segment (EA), hollow, ring-shaped, around the central shaft segment (ECC), with a lateral channel (CLE), for fixation of the shaft sealing ring (OE), of the o-ring type, and aligned with the guide hole (OGE), and with the lower segment of the shaft (EI), hollow and of prismatic shape with a hexagonal section to fit the guide (G).
The guide (G), hollow, cylindrical in shape, staggered into an upper guide part (GS) and a lower guide part (GI), with the upper guide part (GS) having an outer circular channel (ROG), for fixing the guide sealing ring (OG), of the o-ring type, and a guide hole (OGE), through, cylindrical in shape and aligned with the ring segment of the shaft (EA), and with the part lower part of the guide (GI) with a smaller diameter than that of the upper part (GS), externally threaded on the left, for threaded fitting with the upper part of the seat (ASS) and equipped with internal longitudinal channels for fitting the shaft (E).
The seat (AS), hollow, stepped into a seat upper part (ASS) and a seat lower part (ASI), the seat upper part (ASS) externally of prismatic shape of hexagonal section, fitted into the lower part of the lid (TI), internally circular in shape, internally threaded on the left to thread the lower part of the guide (GI), and the lower part of the seat (ASI) in a cylindrical shape of small thickness.
The temperature sensing device (EC) with the force pin (P), metallic, cylindrical in shape, aligned with the piston hole (OEB) and internally fitted to the lower segment of the shaft (EI).
The plunger (EB), with the outer part (PEB), made of rubber or similar, in the shape of a ring and with sealing protrusions (SEB) around the center of the outer face, and with the inner part (IEB), metallic, of small thickness cylindrical shape, with the piston hole (OEB), through, circular in shape and aligned with the temperature sensing device (EC) and with the through holes (OPEB), circular, of small diameter and distributed radially.
The suitable elastic means (M) is fitted to the bottom of the housing (CI) and the bottom of the piston (EB).
The housing (C), hollow and of small thickness, with the upper part of the housing (CS), cylindrical in shape, with internal thread for fixing the lower part of the lid (TI), with the upper external side channel (RC-1), for fitting the upper housing sealing ring (OC-1), of the o-ring type, with the lower external side channel (RC-2), for fitting the lower housing sealing ring (OC-2), o-ring type, with lower water flow holes (OIC) and upper water flow holes (OSC), through, circular, radially arranged and distributed on the lateral surface, and with the lower part of the housing (CI), hollow, prismatic in shape with a hexagonal section on the outside and circular on the inside.
In this configuration, the control device (DC) is inserted into a sink base (BP), the shaft (E) has its reach increased with the use of the shaft adapter (AE), which is threaded onto the shaft (E) and secured with locking pin (PT) and a sink base lid (TBP) completes the recirculation valve (VR) assembly.
The sink base lid (TBP) is hollow, cylindrical in shape, stepped into an externally threaded top sink lid (TBPS) and a bottom sink lid (TBPI), internally threaded and flush with the nozzle (BB) from the base to the sink (BP).
The shaft adapter (AE), with the upper segment (AES) in a cylindrical shape with grooves distributed radially on the external side, with the central segment (AEC) in a cylindrical shape and with the lower segment (AEI), with a diameter slightly larger than that of the central segment, threaded from the inside to fit the shaft (E) and with two lateral oblong holes (REI) for the locking pin (PT) to pass through.
The locking pin (PT), cylindrical in shape.
The sink base (BP), with a base body (CB), cylindrical in shape, hollow, of small thickness, which serves as a housing for mounting the control device (DC), with a nozzle (BB), threaded externally, and with three externally threaded connections and diameters compatible with standard commercial fittings, with the connections being a water inlet (RA), a hot water outlet (SQ) and a cold water outlet (SF), the hot water (SQ) and the cold water outlet (SF) positioned on opposite sides of the base body (CB) and at different levels in relation to the base of the base body (CB), the hot water outlet (SQ) in superior position in relation to the cold water outlet (SF), the hot water outlet (SQ), aligned with the upper water flow holes (OSC) of the housing (C), with a centralized hot water outlet hole (OQ) and the cold water outlet (SF), aligned with the lower water flow holes (OIC) of the housing (C), with a centralized cold water outlet hole (OF) and equipped with a pressure check cold water valve (VAF) of the snap type, or similar.
In this assembly, the sink base lid (TBP) allows the entire recirculation valve assembly (VR) to be fixed to the sink top (TMP) at the same height as the hot water valve and/or at the same height as the tap base and cold water (RAF), and the upper internal part of the sink base lid (TBP) also accepts the assembly of the castle nut (CT), which, in turn, is responsible for securing the tap canopy finishing with the canopy fastener, these last 3 components coming from the user's previous installation. The shaft adapter (AE) is screwed onto the shaft (E) of the control device (DC) until its end reaches the necessary height so that the hot water handle is at the same height as the cold water handle. The shaft adapter (AE) is held in position with the locking pin (PT). The hot water outlet (SQ) of the sink base (BP) is connected to the mixer (MX) and the cold water outlet (SF) of the sink base (BP) is connected to the cold water pipe (TAF). The water inlet (RA) of the sink base (BP) is connected to the hot water pipe (TAQ).
The base of the cold water tap (RAF) has the inlet connected to the cold water pipe (TAF), and the cold water outlet (SF) from the base to the sink (BP) through the recirculation connection (LRA).
The mixer output (MX) is connected to the consumption point (PC).
The hot water knob controls the flow of water to the mixer (MX) and allows rapid flow of cold or undesired water from the hot water piping (TAQ) to the point of consumption (PC), which may be required to connect the pressurization pump of the hot water hydraulic installation, according to items (6c) and (6d) above.
In this configuration, the control device (DC) is inserted into a shower base (BC) with a shower tray lid (TBC) and the shaft (E) has its reach increased by using the shower shaft adapter (ACE), which is threaded onto the shaft (E) and secured with the locking pin (PT).
The hollow shower base lid (TBC), with the hole of the shower base lid (OTBC) and staggered in a cylindrical shaped and externally threaded upper part of the shower base lid (TBCS) in a central part of the shower tray lid (TBCC), of prismatic shape, and in a lower part of the shower tray lid (TBCI), cylindrical in shape, externally threaded and aligned with the main body of the shower tray (CBC).
The shower shaft adapter (ACE), with the upper part (PAS) in a cylindrical shape with grooves distributed radially on the external side, with the central segment (PAC) in a cylindrical shape and with the lower segment (PAI), threaded from the inside and with side cavities (PAL) for the passage of the locking pin (PT).
The shower base (BC), with a cylindrical, hollow, internally threaded main body of the shower base (CBC), which serves as a housing for mounting the control device (DC), with a central body of the base (CCBC) with three connections for water pipes of diameters compatible with standard commercial fittings and arranged in a “T” shaped structure, one being a connection for the shower's hot water inlet (CEQ), internally threaded and with a hot water inlet through hole (OCEQ), a shower hot water outlet connection (CSQ), externally threaded and with a hot water outlet through hole (OCSQ), and a recirculating cold water outlet (SFB), with a through hole for the hot water outlet (OSFB), with a shower cold water check valve, snap type or similar, inserted into the recirculation cold water outlet (SFB).
As an alternative, a new housing model (CA) was developed, which does not have an internal thread, which makes assembly easier, and a new lid (TA) was developed, which is simpler and fits more easily to the housing (CA).
According to
According to
The alternative housing (CA) and alternative lid (TA) can replace the housing (C) and lid (T) during the installation process without necessary changes, and the operating process remains the same.
In order to also serve the different types of single-lever taps, a control device (DCM) was developed to reduce water waste for single-lever taps, which is equipped with a housing (CM), a lever support (SA), with two pins (PI-1) and (PI-2), a lever (AL), a guide wire (AG), a limit switch (FC), a clip washer (ARP), a guide (DIR), a temperature sensing device (EC) with a force pin (P), a spacer washer (ARE), a divider (DIV), a divider sealing ring (OVD), a sealing (VED), a suitable elastic medium (MO) and a base (BA).
The housing (CM) has a stepped cylindrical shape and has an upper part (CMS), cylindrical with a circular through hole, a lower part (CMI), cylindrical, hollow and with a diameter larger than the upper part (CMS), with an internal threaded section (CMR) and two locking holes (OTL), rectangular and with guide relief.
The lever support (SA) has a cylindrical upper part (SAS), with a cross-shaped hole (OSA) and four circular pin holes (OPI), two on each face concentric with each other, one part bottom (SAI), hexagonal in shape, with four oblong holes (OI) through, with an entrance (ESA), shaped like two staggered concentric circles and a rectangular passing hole on its lower face.
The lever (AL), with a stepped prismatic shape, has a hole (OSAL) on its upper face and has two flaps (AAL) on its lower part, each flap (AAL) contains a lower hole (OIAL) that positions and retains the wire guide (AG).
The limit switch (FC), shaped like an oblong section with a hexagonal central hole, has a thread (RFC) on its rounded external sides, has an inlet in both parallel straight sections of the upper face and has a circular inlet (ECFC) partial on its lower face.
The director (DIR), with a hollow cylindrical shape, has an oblong hole (ODIR) through it, has two semicircular tabs (ADIR) that allow the limit switch (FC) to be fitted, and has a smooth upper face (FSDIR) that sits the clip washer (ARP) connected to the temperature sensing device (EC).
The clip washer (ARP), has a stepped cylindrical shape with a central hole (OARP), circular passing hole and a central inlet (EARP) of larger diameter, on its lower face.
The divider (DIV), cylindrical in shape, has an upper face (FSDIV) that contains an oblong arched entrance (EADIV), contains a central hole (OCDIV) through and contains two sectioned holes (OSDIV), passing, in circular segment format; has a lower face (FIDIV) that contains three cylindrical elongations (EDIV) with a hole (OEDIV) inside that meets the arched entrance (EADIV) of the upper face (FSDIV); having a channel (CDIV) on its side for seating the divider sealing ring (OVD).
The base (BA), cylindrical in shape, has two extrusions (EOBA) with an “eye” shaped section, has an extrusion (ECBA), with a section shaped like two tangent circles with a semicircle in its lower part, which contains a through circular hole (OLBA) and contains a through hole (OSBA) in the shape of a “half-moon”, has two locks (TR) opposite each other and has a channel (CBA) on its side; in its inner part, it has three through holes (OIBA), partially obstructed by the extrusions (EOBA) and (ECBA), which accommodate the cylindrical elongations (EDIV) of the divider (DIV), it has a central circular inlet (EBA), which accommodates the appropriate elastic medium (MO), and has a housing (ALB) that accommodates the seal (VED).
The process of assembling the control device for single-lever faucets follows the following sequence of operations:
The operation of the control device for single-lever taps follows the following steps:
| Number | Date | Country | Kind |
|---|---|---|---|
| BR 1020210227885 | Nov 2021 | BR | national |
| BR 1020220226466 | Nov 2022 | BR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/BR2022/050430 | 11/9/2022 | WO |
