Patent Application
20080314466
The present invention relates to valves for use with tankless water heaters.
Tankless water heaters are well known in the art and generally comprise a device which heats water “on demand” rather than in a predetermined quantity such as in a hot water tank. Accordingly, such devices are known in the art as “tankless” water heaters. Such tankless water heaters may use, for example, electricity to provide the source of heat (i.e., through resistance coils) or they may use the combustion of gas or any other suitable material as the source of heat. In addition, it is possible that the tankless water heater may also use some other source of heat for the device. In order to operate and periodically service such a tankless water heater, various valve arrangements are typically provided at both a cold water inlet and a hot water outlet for the tankless hot water heater.
In the prior art, such valve arrangements for use with tankless water heaters have been undesirable because of the significant number of different fittings that were generally assembled in the field (i.e., at the location of the tankless water heater). In the prior art devices roughly 10 separate fittings would be assembled for each valve arrangement for a tankless water heater. Such prior art valve arrangements were generally inefficient and inconvenient to install and did not provide for easy maintenance, repair and replacement. In addition, such prior art valve arrangements oftentimes would not provide ready access to the individual valves with the requirement that sometimes the valves were unusable with particular tankless water heater installations or the use of an adapter kit or other accommodation was required.
Various prior art valve arrangements, including some valve arrangements that are disclosed for use with tankless water heaters, are disclosed in U.S. Pat. Nos. 4,177,832; 4,479,459; 4,655,078; 6,148,845; 6,186,169; 6,302,146; 6,655,412; 6,779,561; WO 03/001092; and WO 2005/031200. Various valve arrangements are also known in the art such as the Model PB-56 Purge and Balancing Valve of Watts Regulator Co., (IS-PB-56, Copyright 2000); the Isolator EXP of Webstone Company, Inc., (40653EXP Sep. 9, 2005); the Series RPV Residential Purge, Drain and Balancing Valves of Watts Regulator Co. (ES-RPV, Copyright 2004). Also, the use of a filter in the cold water inlet is generally known, for example, from the instructions provided by various tankless water heater manufacturers. For example, the Rinnai tankless water heater installation instructions show a conical filter which is to be inserted at the connection of the cold water supply pipe to the cold water inlet of the tankless water heater.
Accordingly, the need remains for an arrangement for connecting a valve to piping or other fittings which overcomes the difficulties in the prior art.
Various arrangements for connecting non-threaded pipe ends and pipe fittings are known in the art, such as are shown in U.S. Pat. No. 5,409,066 of McHugh and U.S. Pat. No. 5,609,212 of McHugh. Similarly, various embodiments of push-fit connectors have long been known for joining pipe ends and tubing ends together, such as are shown in, for example, U.S. Pat. No. 3,312,484 of Davenport, U.S. Pat. No. 3,365,219 of Nicolaus, U.S. Pat. No. 3,924,882 of Ellis, U.S. Pat. No. 5,188,401 of Staniforth, U.S. Pat. No. 5,593,186 of Harris, U.S. Patent Application Publication No. 2004/0090067 of Pridham, U.S. Patent Application Publication No. 2005/0084327 of Chelchowski et al., U.S. Patent Application Publication No. 2005/0104369 of Webb et al., UK Patent Application Publication No. GB 2 280 006 of THD Manufacturing Limited, and UK Patent Application Publication No. GB 2 266 569 of F W Talbot & Company Limited. These patent publications are primarily concerned with connecting pipe ends together in a push-fit or quick connect arrangement.
Other push-fit connections for pipe ends are available from Cash Acme at the website: http://www.cashacme.com/sharkbite.html, under the trademark SharkBite Connection System. The SharkBite connections spin around the pipe and are removable with a specially designed tool which releases a teeth ring. Other push-fit connections which spin around the pipe are available from I-TAP under the trademark Itap-Fit at the website: http://www.itap.it. N-Vent sells push-fit connectors for pipe ends and valves with push-fit connectors which make a permanent, unmovable & non removable connection under the trademark PermaLynx at the website http://www.nventsolutions.com.
In various preferred embodiments of the present invention, a valve arrangement for use with a tankless water heater, comprises an integral valve housing which comprises an interior passageway in communication with a first port, a second port, and a third port. A first valve member is provided within the valve housing at the first port with the first valve member being selectively positioned to control communication with the interior passageway of the valve housing at the first port. A second valve member is provided within the valve housing at the second port with the second valve member being selectively positioned to control communication with the interior passageway of the valve housing at the second port.
In a preferred embodiment, the first port of the valve housing further comprises an integrally formed push-fit connection arrangement which comprises a teeth ring having a plurality of teeth directed generally radially inwardly and generally toward the interior passageway of the valve housing. The valve arrangement may further comprise an annular sealing member which is provided axially between the teeth ring and the valve housing. A first shoulder limits movement of the teeth ring toward the valve member and an annular ring is provided between the teeth ring and the first shoulder.
The valve housing may further comprise a second shoulder which is provided between the first shoulder and the valve member with the second shoulder having a smaller diameter than the first shoulder. The annular sealing member may be provided between the second shoulder and the annular ring with the valve housing further comprising a third shoulder provided between the second shoulder and the valve member. The third shoulder has a smaller diameter than the second shoulder with the third shoulder having a diameter corresponding to the outside diameter of a pipe to be received within the teeth ring. The sealing member, when not compressed, has an inside diameter which is smaller than the outside diameter of the pipe to be received within the teeth ring.
The valve arrangement may further comprise a teeth ring retainer which maintains the teeth ring positioned between the first shoulder and the teeth ring retainer and wherein rotation of the teeth ring relative to the valve housing is prevented. Preferably, the first port forms a cold water inlet for the tankless water heater or forms a hot water outlet for the tankless water heater. The valve housing may further comprise a fourth port with a pressure relief valve being provided at the fourth port.
In another preferred embodiment, a valve arrangement for use with a tankless water heater comprises an integral valve housing which comprises an interior passageway in communication with a first port, a second port, and a third port. A first valve member is provided within the valve housing at the first port with the first valve member being selectively positioned to control communication with the interior passageway of the valve housing at the first port. The first port forms a cold water inlet for the tankless water heater. A second valve member is provided at the second port with the second valve member being selectively positioned to control communication with the interior passageway of the valve housing at the second port. A strainer may be provided within the interior passageway of the valve housing adjacent the second port.
Preferably, the strainer comprises wire mesh which is provided within the interior passageway of the valve housing between the inlet and the third port. Preferably, the second valve member may be disconnected to the second port and the strainer may be removed from the interior passageway of the valve housing when the second valve is disconnected from the second port.
The valve housing may be adapted so as to provide a cylindrical chamber with the strainer being provided within the cylindrical chamber. The strainer may be generally cylindrical in shape. The strainer preferably has an opening in a sidewall of the strainer corresponding to a cross sectional configuration of the interior passageway at the first port, with the opening in the sidewall of the strainer being aligned with the first port of the valve housing when the strainer is provided within the valve housing. A guide member may be provided at a first end of the strainer with the guide member having at least one radially extending tab which is selectively received within a corresponding slot provided at the second port to align the opening of the strainer with the first port of the valve housing.
The first port of the valve housing preferably further comprises an integrally formed push-fit connection arrangement comprising a teeth ring having a plurality of teeth directed generally radially inwardly and generally toward the interior passageway of the valve housing. Preferably the valve arrangement further comprises an annular sealing member which is provided axially between the teeth ring and the valve housing. A first shoulder limits movement of the teeth ring toward the valve member, with an annular ring being provided between the teeth ring and the first shoulder. Preferably, the valve housing further comprises a second shoulder which is provided between the first shoulder and the valve member with the second shoulder having a smaller diameter than the first shoulder. An annular sealing member may be provided between the second shoulder and the annular ring, with the valve housing further comprising a third shoulder provided between the second shoulder and the valve member with the third shoulder having a smaller diameter than the second shoulder. The third shoulder has a diameter corresponding to the outside diameter of a pipe to be received within the teeth ring with the sealing member, when not compressed, having an inside diameter which is smaller than the outside diameter of the pipe to be received within the teeth ring. Preferably, the valve arrangement further comprises a teeth ring retainer which maintains the teeth ring positioned between the first shoulder and the teeth ring retainer and wherein rotation of the teeth ring relative to the valve housing is prevented.
Preferably, the valve arrangement further comprises a check valve which is provided generally at the first outlet. Preferably, the check valve is provided upstream of the valve member of the first outlet of the valve housing.
The present invention will appear more clearly from the following detailed description of several embodiments illustrated in the enclosed figures in which:
With reference to
Typically, the tankless water heater 100 is provided within a rectangular housing 101. The tankless water heater is provided with water to be heated through a cold water supply pipe 108. A cold water valve arrangement 104 according to the present invention is provided between the tankless water heater and the cold water supply pipe 108. A hot water supply valve arrangement 106 according to the present invention is provided between the tankless water heater and the hot water supply pipe 110.
With reference now to
With reference now to
In both the hot water valve arrangement 106 and the cold water valve arrangement 104, the first port may be provided with a threaded connection (FIPT), with a copper sweat connection, with a push or push-fit connection (especially with the CimPUSH technology and as described in ASSE 1061) or with a CimPRESS connection which uses a cold copper crimp connection. The valve arrangements 104, 106 are preferably made of heavy-duty forged brass and the valve arrangements have color coded handles (blue for the cold water valve arrangement and red for the hot water valve arrangement) in order to facilitate correct installation.
With reference now to
Similarly, the second port 124 has a valve member 162 which is selectively positioned by a handle actuator which rotates a valve stem that is sealed by packing or O-rings. The valve stem of the valve member 162 is likewise keyed into the valve member 162 in order to selectively rotate the valve member 162 (as the handle is rotated) in order to control communication with the interior passageway of the valve housing at the second port. The valve member 162 may be selectively moved between a first position in which the second port 124 is open and a second position in which the first port 124 is closed.
If the first port 132 of the hot water valve arrangement 106 is provided with an integrally formed push-fit connection, a teeth ring is provided (see
With reference now to
Similarly, the second port 147 has a valve member 164 which is selectively positioned by a handle actuator which rotates a valve stem that is sealed by packing or O-rings. The valve stem of the valve member 164 is likewise keyed into the valve member 164 in order to selectively rotate the valve member 164 (as the handle is rotated) in order to control communication with the interior passageway of the valve housing at the second port. The valve member 164 may be selectively moved between a first position in which the second port 147 is open and a second position in which the first port 147 is closed. The first port 152 of the cold water valve arrangement 104 may be provided with an integrally formed push-fit connection such as described above in connection with
Although in the embodiment of
With reference now to
The housing 204 differs significantly from the housing 140 (of the embodiment of
With reference now to
An O-ring 224 is provided on the threaded coupling 230 and then a collar 222 is threaded onto the coupling 230. Before the collar 222 is threaded onto the coupling 230, the cylindrical strainer 226 is inserted into the second port and received within the additional tubular portion 236 of the valve housing. An annular member is provided in the strainer at the outermost end in order to maintain the cylindrical shape of the strainer and also to facilitate alignment of the strainer opening 234 with the first port. The annular member includes one or more tabs 228 that extend radially outwardly and are received within the corresponding recess in the coupling 230.
The valve 212 comprises a suitable conventional valve which is then attached to the collar 222 such as by a threaded coupling to enable selective removal of the valve 212 as desired. In this way, the strainer may be periodically removed from the valve housing and cleaned of debris and particles. The valve 212 may be provided with a cap 214 that is connected to the valve by a strap 220 as discussed above.
As discussed in connection with the valves of
With reference now to
Preferably, a teeth ring retainer maintains the teeth ring positioned between the first shoulder and the teeth ring retainer and rotation of the teeth ring relative to the valve housing is prevented such as by one or more tabs which extend radially outwardly from the teeth ring and which engage a corresponding slot in the first port 238. An annular retainer member 246 maintains the teeth ring 244 and the annular ring 242 and the sealing member 240 in proper orientation in the first port 238. The teeth ring retainer member 246 has an inner diameter which is slightly larger than the outside diameter of the pipe or fitting to be received. The teeth ring retainer 246 has a radial ring portion which abuts the teeth ring. An axial portion of the teeth ring retainer extends toward the valve member and directs the teeth radially inwardly and generally toward the ball valve member. The axially extending innermost portion of the teeth ring retainer also prevents the teeth from bending away from the ball valve member, i.e., if the pipe or fitting is being pulled out of the ball valve retainer.
The ring may have a radial slit and be slightly compressed during assembly so as to be positioned beneath the shoulder of the ball valve member retainer. The ring is then released so as to increase its outside diameter and thereby maintain its position beneath the shoulder.
The teeth ring 244 preferably includes an annular ring and a plurality of teeth directed radially inwardly of the ring. The annular ring has a plurality of tabs provided about the outer perimeter of the annular ring. In the preferred embodiment of the teeth ring, there are four tabs spaced apart by 90°. Each of the tabs projects only slightly beyond the outer circumference of the annular ring.
In the preferred embodiment of the teeth ring, the individual teeth have generally parallel sides rather than the tapered sides as shown in earlier figures. However, whether the sides are tapered or parallel is generally a matter of design choice and a result of the manufacturing process. It is generally understood that making a teeth ring in which the individual teeth have parallel sides is easier and perhaps less expensive that making teeth with tapered sides. In addition, there is some indication that teeth with parallel sides may have better grip performance when the teeth ring is under tension due to a relatively stronger surface where the tension stress is distributed over the teeth ring.
In the preferred embodiment, the teeth ring 244 is produced by stamping a metal sheet but other methods of production that result is a suitable teeth ring are within the scope of the present invention. The annular ring of the teeth ring provides a correct or desired alignment of the gripping teeth initially about the pipe. The annular ring also permits the provision of the tabs about the perimeter of the teeth ring.
During assembly of a valve with the teeth ring, the flat tabs provided about the outer perimeter of the teeth ring are pushed against the valve sidewall. The flat tabs are configured to engage the valve sidewall so as to eliminate or significantly reduce the possibility of valve rotation relative to the pipe end being gripped by the teeth ring. The flat tabs are preferably pushed into the sidewall of the valve during assembly of the teeth ring in the valve housing and the tabs preferably engage the sidewall of the valve before the pipe end is inserted.
The piping that is received by the push or push-fit connectors (if provided) at the first port of the hot water valve arrangements or the cold water valve arrangements are preferably copper, but may also be CTS, PVC or CPVC depending upon the applicable local codes. The valve arrangements according to the present invention may also be used with pipe or tubing of polybutylene or PeX (cross-linked polyethylene) but the use of PeX tubing may require the use of an adapter which is provided within the PeX tubing to stiffen the end of the PeX tubing received by the inlet or the outlet. The adapter (not shown) comprises an annular ring which has an outside diameter corresponding to the inside diameter of the uncompressed PeX tubing. The adapter prevents the PeX tubing from being unduly compressed by the teeth ring of the press-fit connection arrangement.
With reference now to
In use, cold water valve arrangement 104 is provided between the cold water supply pipe 108 and the cold water inlet of the tankless water heater. The valve at the first port is open in order to supply cold water to the tankless water heater through the third port. The second port is normally closed by the second valve member. Similarly, the hot water valve arrangement 106 is connected between the hot water outlet of the tankless water heater and the hot water supply pipe 110. The valve at the first port is open in order to allow hot water to flow through the valve arrangement as desired. The valve at the second port is normally closed. When it is desired to flush or drain the tankless water heater, the valve members at the first ports of the cold water valve arrangement and the hot water valve arrangement are closed and the valves at the respective second ports are opened. The water in the tankless water heater may be drained (by removing the threaded caps) and opening the valves at the second ports). The second valve of the cold water valve arrangement may then be connected to a hose or other source of water to flush the tankless water heater. When the tankless water heater has been sufficiently flushed, the valves at the second ports may be closed and the valves at the first ports opened to allow normal operation of the tankless water heater. If a strainer is provided and if the strainer needs to be cleaned, the valve at the second port of the cold water valve arrangement may be removed from the second port and the strainer then removed and cleaned or flushed. The strainer is then replaced and the tab or tabs of the strainer assembly are aligned with the coupling member of the second port to align the strainer hole with the first port. The second valve is then replaced or reconnected to the second port. Finally, the threaded caps which had been removed from the second valves during draining and flushing are reattached to the outlets of the second valve arrangements.
The principles, preferred embodiments and mode of operation of the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. The embodiments are therefore to be regarded as illustrative rather than as restrictive. Variations and changes may be made without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such equivalents, variations and changes which fall within the spirit and scope of the present invention as defined in the claims be embraced thereby.
