Patent Application
20170175368
This invention relates to a system for committing hot water bypass from a hot water line to the cold water line in order to inter alia provide instant hot water from any given hot water tap.
Many systems have been devised for providing instantaneous hot water from a hot water tap in order to avoid unnecessary wasting of water while waiting for hot water to reach a particular tap after an extended period of non use. Especially during a cold winter season, hot water lines between a hot water heater and a particular tap, especially one several floors above the hot water heater, are likely to contain a substantial quantity of cold water that must be exhausted before the water coming from the tap is hot. There are many parts of the world, including many portions of the United States, where wasting of water has become a serious issue, threatening the very ability to maintain a civilized existence in specific areas. There are systems that are electronically operated that provide a useful and credible way of continuing to flow hot water through a hot water line so that hot water is substantially immediately available upon opening any hot water line due to the fact that the hot water line interconnects to a cold water line that flows back into the heater, and that way instantaneous hot water can be provided without wasting water down a drain and efficiently providing the hot water.
The prior art included two types of systems to accomplish this. One includes thermostatically controlled pumps and thermostatically controlled valves, using thermistors in the hot water line that turn on electric motor drives to permit water from a hot water line to flow into a cold water line, so as to bring hot water to the pump. The pumps and valves are powered by electric motors. However, it becomes awkward in many jurisdictions to have a live electric outlet in a bathroom, adjacent water, especially when located under a flowing water sink.
A second system includes automatic mechanical valves that respond to temperature differences between the hot and cold water lines, which change as a result of the cooling of the hot water line, when there is no flow. The changing temperature differential causes flexing of a valve operator to open or close a line. Such a valve is used combined with a pressure maintenance operation, such as a small pump, which maintains a small pressure drop between the hot water line and the cold water line beneath a sink. Such valves include a wax motor-driven valve that does not utilize a thermostatically responsive, flexing, disc. Another type of wholly mechanical valves uses a thermostatically responsive flexing bi-flexive disc, serving as the valve disc, which flexes towards and away from the valve seat so as to open the valve when the temperature differential is below a defined value, as shown in U.S. Pat. Nos. 6,024,174 and 6,536,676, among others.
One such prior art disc valve is sold by the Armstrong Pumps Inc. company of North Tonawanda, N.Y., under the name Armstrong Astro Express Hot Water Recirculation System. This product utilized a bi-metal disc having a central hole through the disc.
In accordance with the present invention, an improved, wholly mechanical valve unit is provided to allow for flow between a high temperature liquid line and a cooler temperature liquid line in order to maintain the immediate availability of hot liquid immediately upstream of the valve, the valve being placed upstream of a hot liquid outlet and cooler liquid pipe bringing cool liquid to a heater for the hot liquid. Most commonly this invention will be used for hot water in a building. In such a system, the cold water line returns, at least in part, to the hot water source, whether it be a heated water tank or an immediate flow heater, and no water is wasted by being passed down a drain to a sewer or septic tank.
The present invention improves on the prior art types of mechanical valves, based upon a thermally-activated, bi-metal, or more broadly bi-flexive, disc, by optimizing the flow path of the liquid from the higher temperature, higher pressure, line to the lower temperature line, based upon the support provided to the disc, both when in a closed position and in an open position. By providing two-sided, circumferential support of the bi-flexive disc and substantially equalizing the pressure against both sides of the disc, even when in the closed valve position, the durability and accuracy of the disc valve is improved, while maintaining required flow potential. There is also provided additional central support in the closed position, that the bimetal disc is less likely to be damaged by any excessive pressure differential or unusually high temperatures that may occur either accidentally or as part of the normal operation of the overall system. One use for this type of bimetal disc valve is for an undersink connection between the hot and cold water lines to ensure that there is always hot water close to the hot water tap so as to avoid having to run the hot water tap for extended periods of time, thus wasting water before a suitable temperature is reached.
The operational heart of the thermostatic valve of this invention is a known bi-flexive, usually bi-metal, thermostatic disc formed of two different materials, usually two metal alloys, having different thermal expansion properties. Generally, the alloy having the greater thermal expansion value is placed in contact with the higher temperature fluid stream and the face having the lower thermal expansion property is in contact with the cooler fluid stream. Generally these discs vary in size from approximately 0.3 inch to 1.5 inches in diameter and a total thickness in the range of less than 0.5 inch, and preferably not greater than 0.03 inch, in thickness. These discs are readily available on the open market and have the general property that at the higher temperature the surface of the disc is cupped spherically in one direction and at a lower temperature the surface curvature is quickly reversed, i.e., by a ‘snap’.
The exact temperature at which the curvature snap occurs is dependent upon the property of the bi-flexive construction, including its size and, most significantly, the material forming the two sandwiched discs. Suitable discs are generally characterized by their ASTM designation and it has been found that useful discs include those formed of ASTM designation TM1 and TM2. There are also a range of industry designations in addition to the ASTM designations, for example, Truflex standards; these industry standards are available from EMS (Engineered Material Solutions).
Examples of suitable thermostatic discs include one where the high temperature side is primarily a nickel-chromium-iron alloy on one side, and a nickel-iron alloy on the opposite side to form the TM1 bi-metal disc. The TM2 disc, on the other hand, contains primarily a manganese alloy with nickel and copper, on the high temperature side, and a nickel-iron alloy on the low temperature side. The selection of a suitable disc, either TM1 or TM2, or any of the many other ASTM or Truflex bi-flexive discs available, depends upon the requirements for a particular valve, such as the need for corrosion resistance of the materials, the ability to use a corrosion protective coating, and the degree of movement necessary from the snap action. Although the lack of manganese can be considered a durability enhancement, the addition of manganese does result in a higher flexivity value and thus greater range of movement. The presence of manganese does usually require a coating in order to enhance corrosion resistance.
In the present environmental situations in many part of the U.S. as well as in other countries of the world, water has become an increasing valuable commodity and one which users cannot and should not afford to waste. The following drawings, and the ensuing verbal descriptions, show and describe a preferred embodiment or embodiments of this invention by way of illustration of one of the modes best suited to carry out and use the present invention. As it will be realized, the invention is capable of other different embodiments and uses and its several details are capable of modification to various obvious aspects, all without department from the scope of the invention. The following drawings and descriptions should be regarded as illustrative in nature and not as restrictive.
The accompanying drawings incorporate and form a part of this description and illustrate aspects of the present invention which, together with the verbal text, explains the principles of the invention, while providing a specific example thereof. Referring to the drawings:
The outer valve body, generally designated by the numeral 1, includes the hot and cold water connections, specifically the inlet from the cold water source 11 and the outlet 12 to the cold water tap in the sink above, and the inlet from the hot water source 21, whether it is a hot water heater or a hot water tank 30 as shown in
The interior of the bi-flexive disc cartridge subassembly 2, as shown in
The bimetallic disc 24 is structurally supported around its external circumference within the cartridge body 26 during both the open flow and closed conditions by two annular washers 23,25; these washers 23,25 are preferably made of a material softer than the material forming the bi-flexive disc, and include other metals or polymers such as polytetra fluoroethylese polymer, e.g., sold as Teflon, by DuPont. The subassembly of the bimetal disc valve is threadedly secured into the valve body 1 by valve stem 3. Leakage of liquid is prevented during the closed position of the bimetal disc valve by external O rings 31 and 28, which prevent fluid leakage external of the device.
The bimetal disc 24 is supported within the cartridge body by the washers 23,25 and, in the closed condition, the central washer 22, and the internal walls of the cartridge body 26. Flow channels are formed in the cartridge body 26 and the cartridge tailpiece 21, to allow fluid flow around the bimetal disc 24 and its two supporting washers 23,25, when the disc is in the closed position (see
This system is especially useful for situations where only relatively low flow past the open valve is required. For example, if the primary purpose for a valve is to provide for an on demand hot water system, permitting a small flow of hot water past a tap that is not regularly used in order to maintain suitably high temperature water readily available for use, only a small flow is usually required. Thus, a disc having a diameter in the range of 0.5 to 1.5 inches and a thickness in the range of 0.01 to 0.03 inch has been found to be useful; the amount of fluid flow obtainable is dependent upon the degree of flexivity of the two sandwiched alloys, that is the distance moved by the central part of the disc, as the disc snaps back and forth with changes in temperature in the hot water line. It has been found that sufficient flow for this purpose can be achieved with an area of flow in the range of 0.0005 to 1.77 square inches, with a flow gap for net outward flow between the center of the valve disc 24 and the central o-ring valve seat 22, of from 0.002 inch to 0.2 inch.
The flow around the outer circumference of the disc is made possible by the scalloped, i.e., interrupted, edge surfaces, supporting both sides of the outer circumference of the biflexive disc, as shown in greatest details in
In one example, when utilizing a disc having a one-inch diameter and a thickness of 0.016 inch, the supporting flat surfaces 125,225 occupy approximately 34% of the circumference of the disc and the open spaces between the supporting shelves 1256,225 66% of the circumference of the disc. The specific parameters are to be determined based upon the circumference of the individual disc, the materials from which it is made, the required flow capacity and the pressure drop between the hot water line and the cold water line. Generally, the supporting flat surfaces of the shelves comprise at least 10% of the circumference, and extend radially inwardly from the outer circumference a distance of at least 10% of the radius. Regardless of the proportions, it is preferred that the supporting shelf portions 125,225 be opposite each other so as to support the disc equally on both major surfaces.
When the disc is caused to move by snapping into the open position by virtue of a reduced temperature on the hot water side of the disc (as hot water is cooled by the surrounding ambient air), the disc moves upwardly, away from the central O ring 22, allowing flow to pass outwardly through the exhaust channel 211, which in this embodiment is centrally located within the cartridge tailpiece 62. Fluid is caused to flow through the device by virtue of a relatively small pressure differential between the hot and cold water sides of the valve. This pressure differential is generated, as shown in the overall flow system drawing of
Under ambient conditions, i.e., room temperature, the bimetal disc is in a neutral, open position, as shown in
Based upon the pressure differential created by the pump 55, between the hot water line and the cold water line, the cartridge inlet and outlets 261 and 211, are critically sized to restrict fluid passing through the device to a maximum allowable flow rate. This ensures a minimal pressure differential between the two sides of the bimetal disc 24. The forces on the bimetal disc 24 resulting from flow conditions are limited to a negligible magnitude as the sum of each of the cross-sectional flow hole areas 261 and 211 are minimized in relation to the cross-sectional area between the bimetal disc 24 and the face sealing O ring 22.
The inlet to the valve cartridge 26 may be in line with the bimetal disc 24 or, preferably, as shown in the accompanying drawings, is perpendicular to the bimetal disc passing through the screen filter 27. The flow then circumferentially flows around the bimetal disc and then out the central opening of the valve cartridge 211.
By structurally supporting the bimetal disc evenly around its outer circumference from both sides of the primary surfaces, undue stress is avoided on the material of the disc, thereby extending its operating life. By sealing the disc along its central portion and opening that to allow flow, the disc maintains its circumferential supports, while opening and closing to permit flow, as the upstream temperature fluctuates. The circumferential supports however, are scalloped, so as to allow the higher temperature hot water to contact most of the area of the downstream side of the bimetal disc, even when no flow out of the valve body is permitted through the central hole 211.
The bimetal disc is preferably formed of two different alloys, having different thermal expansion coefficients, sandwiched together between the top and bottom major surfaces. The side contacting the central O ring 22 can be formed, for example, as is shown in the following table of three of the most commonly available bimetal disc materials. Each of these various formulations has advantages as well as disadvantages. The TM1, for example, because it is substantially free of manganese, is less susceptible to cracking and does not require a coating to protect it against corrosion when using the system between a hot water and cold water line. TM2 has a greater flexivity value and is lowest in cost, but requires a parylene polymer coating in order to protect it from corrosion and is also susceptible to cracking after extended use. Truflex standard discs utilize an industry standard that is also generally accepted, and can be used for this purpose. For residential hot water systems, corrosion resistance is important, but range of movement less so because of the low flow rates required, and temperature range tolerances are less critical in such systems, and low flexivity can be compensated for in the particular mechanical design forming the present invention.
When the thermostatically operated by-pass valve of the present invention is used for providing continuous on demand hot water to a sink tap, e.g., in a residence, the valve is provided together with a circulator that is connected in the hot water line, preferably adjacent the hot water source; a return line is provided by the cold water line back to cold water inlet to the hot water source, e.g., the hot water tank. A special line is not required as, by returning into the cold water line, this cold water line always has a connection to the hot water tank; as long as the cold water taps are closed, all of the water from the hot water line, passing through the by-pass valve of this invention, and entering the cold water line, will be returned to the, e.g., hot water tank, and thus not be wasted down the drain.
It has been found that a circulator pump that provides as low as a 5 psi differential is sufficient to allow this system to operate effectively in a residential situation. It is believed that the optimal size for the bimetal disc is in the range of 0.75 inch to 1.5 inches for the usual residential single family home in the U.S. In other situations, a smaller or larger bimetal disc could be preferable, depending upon the quantity of flow required, and the temperature differential that would be utilized to cause the bimetal disc to flex. Preferably, the bimetal disc is formed of two different alloys in accordance with ASTM specs referred to as TM1 and TM2, or another industry standard, the Truflex standard. Generally, these discs are formed of alloys containing nickel, chromium, manganese, copper, iron, aluminum, carbon nickel iron, cobalt, chromium and manganese on the two different sides. By eliminating aluminum, carbon and copper from one side and including or excluding cobalt from the second side, a variety of effects can be achieved.
Two discs formed of different metal alloys with different coefficients of thermal expansion are co-bonded together to form the bimetallic disc. There also are trimetal discs having three discs sandwiched together, but these are less commonly used and present greater difficulty in determining the coefficients of thermal expansion among the three sandwiched discs. They do have special uses, but would generally not be used in the present situation. The biflex metal discs each generally contain nickel in substantial percentages, as well as iron, cobalt, chromium, manganese and, in some cases, copper. Some of the bimetal or trimetal discs can include a percentage of aluminum as well on one or more of the discs. The proportions of metal in each alloy are significant in that, for example on the hot water side, manganese is a problematic component as manganese may even dissolve in water. On the other hand, the other materials are important in order to get the necessary flexure as a result of the temperature drop across the bimetal disc, as well as the ability to avoid any type of deterioration from, for example, corrosion or such items as dissolution of any of the metal components.
Except as needed to meet the critical properties of the discs, the composition of the two discs is not critical and does not form a part of this invention. Many different combinations of compositions can be selected within the scope of this invention. It is for this reason that although ‘bi-metal’ discs are most commonly used for this purpose, there is no reason why two polymer discs having sufficiently different coefficients of thermal expansion could not be used, or alternatively one polymer disc layer bonded to one metal disc layer. Accordingly, the term “bi-flexive disc” should be considered a shorthand for any thermostatically flexive snap disc that can snap into a new position depending upon the temperature to which the bi-flexive disc is in contact.
The system, preferably, is constructed so as to minimize stress on the disc caused by the pressure differential between the hot and cold water lines when the device is in the closed, no flow condition, by permitting the higher pressure hot water to almost surround the bimetal disc, except for the relatively small portion contacting the central O-ring. This is achieved by providing the circumferential flow openings, which allow the higher pressure water to exist on both sides around a large annular space, but not permit the hot water to flow outwardly into the cold water line.
The other parts of the system, the overall cartridge body and tailpiece, are preferably made of a corrosion resistant material, such as stainless steel, brass, copper or plastic. The valve body and retaining stem are also of similar material, but are even subject to greater chemical stresses and, therefore, include not only brass, but also bronze. A suitably structurally strong polymer plastic material can also be used. The sealing washers and supporting washers are preferably a resilient plastic material such as Teflon, which is generally inert to all of these materials that may be in the fluid flow, but may also be relatively hard materials such as stainless steel or brass. Such materials of the harder variety have to be more carefully positioned and absolute dimensions become more critical. The symmetrical placement of the washers formed of relatively soft polymer materials, such as Teflon around the circumferences of the bimetal discs protect the discs from abrasive surfaces.
Although the entire surface of the disc on the downstream side is not open to the upstream hot water pressure when the disc is in the non-flow sealing position, the proportion of the surface that is blocked by the central O ring is not sufficient to create physical stress problems that would otherwise cause structural failure of the disc. This allows the disc to be less thick than might otherwise be necessary if structural strengths became a significant issue. Note that the stop valve or check valve in the cold water line prevents any backflow of cold water into the hot water line, thereby avoiding temperature problems when the hot water tap is opened and the pressure in the hot water line may drop.
The present design can be considered a “free floating” disc design, different from the center post support used by the prior art. It is this free floating disc design, where the disc is constantly supported around its outer circumference from either side of the disc, that enables this disc to perform in a superior and more effective, durable way.
The overall system of the present invention in one embodiment is shown in
The valve of the present invention is connected between the hot and cold water lines to a sink or other water outlet, preferably including the tap farthest from the hot water tank, upstream of the two water taps in the sink. When there is hot water usage in the system, the temperature of the hot water upstream of the valves in line 252 remains high. However, after an extended period of non-use, for example, during the day when most people are not in their residences, the temperature of the water in line 252, especially during a cold winter season, would fall below the desired hot water temperature by a significant amount. When the temperature of the water in line 252 immediately adjacent the sink 230 falls below a certain value, the disc 24 snaps to the open position as shown in
It is noted that the pump 51 is independently operated and can either operate constantly as it is only achieving a very low pressurization, i.e., generally not more than 5 psi differential, or can be caused to operate only at specified time, depending upon the control system for that pump. Its only purpose is to provide the necessary pressure increase so that when the disc 24 snaps into the open position, water will flow from the hot water line into the cold water line, which would be at a lower pressure. In the event of a pressure failure, the check valve 4 in the cold water line prevents backward flow from the cold water line into the hot water line. Generally, it has been found that a hot water temperature from the tap of at 110° F. is considered comfortable, whereas if that hot water line temperature cools to below 80° F., it is too cool for the intended use. In that case, the valve 24 will snap into the open position when the hot water is at 80° F. and re-snap back to the closed position when the temperature reaches 110° F.
Different grades of materials can be used for bi-flexive discs; there are bi-metal discs that are prepared in accordance with ASTM grades as well as so-called industry grades which are also readily available and have known characteristics. The user must determine, based upon the parameters of use to which a particular valve is to be put, exactly what materials should be used and what size disc would be most suitable. Of course, the surrounding valve body supporting and containing the bi-flexive disc valve must be designed accordingly with respect to size and open space. A standard source of the bi-flexive composite material or trimetal composite material is made by Engineered Material Solutions and sold under the Trueflex trademark.
The space between the support shelves 125,225 and the bi-flexive disc permits a greater flow area, i.e., the distances between the supporting points, than would otherwise be effective without the washers. It is for that reason that the material forming the washers 23,25 is important in determining whether sufficient stress-free support is achieved when there is sufficient flow openings to ensure pressure equalization between the upstream and downstream sides of the major surfaces of the bi-flexive disc. Accordingly, materials such as Teflon or metals have sufficient rigidity that they will not collapse into the open spaces and thus reduce flow area. As designed, the washers 23,25 should remain substantially on the same level, whether it is on the support points or extending across the channel flow areas. Materials having sufficient rigidity include, for example, polymers such as Teflon and other halogenated hydrocarbon polymers as well as certain polyalkanes such polypropylene, as well as many metals. Preferably, if a metal is used to manufacture the washers, it is preferably softer than the metal of the bi-metal disc surface.
In operation, when the by-pass valve 1 of the present invention is in place between the hot water and cold water taps, e.g., beneath a sink 250, as in the embodiment of the example shown in
When the hot water auxiliary pump 51 is not turned on, the pressure between the two lines will be substantially identical and there will be substantially no flow between the hot and cold water line, whether or not the disc is in the open or closed position, relative to the central O-ring 22. Thus, programming of the auxiliary pump in effect dictates whether the continuous hot water system will be operational or whether it will operate only at certain designated times, for example, early in the morning or in the evening, and will not operate in the middle of the day, thus saving fuel for the hot water system during the day.
The design of the present invention allows for straight forward manufacturing and avoids the difficult balancing required for a central opening through the bimetal disc. The foregoing description of a preferred embodiment of this invention is illustrative of the advantages therein. It is not exhaustive or limiting of the invention to the specific form disclosed herein. Obvious modifications or variations accessible to persons skilled in this art are within the scope of this invention and the present embodiment was selected and is described herein to provide a clear illustration of the principles of the present invention and its practical application to plumbing systems, but is not limited to that. Modifications and variations accessible to persons skilled in the art should be considered to be within the scope of this invention and the scope is to be determined solely by the following claims. The following claims define the scope of this invention.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US15/49757 | 9/11/2015 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62049709 | Sep 2014 | US |
