The present invention relates to damping a shock wave that sometimes appears in fluids flowing through pipes. More particularly, the present invention relates to a water hammer arrester used to damp the shock wave that sometimes appears in water flowing inside residential and commercial plumbing.
Water hammer is a specific plumbing noise that most everyone is familiar with. It occurs when someone shuts off a tap and water flow is stopped suddenly so that the fast-moving water in the plumbing is blocked by a closed valve. Similarly, a residential dishwasher or washing machine in operation feeds water to the wash tank at a high volume and flow rate, and when the washer detects a sufficient water level in the tank, a valve is shut off suddenly blocking the water flow. Due to the momentum in the flowing water, the sudden blockage of water flow creates a shock wave that travels at the speed of sound along the pipe until it impacts an elbow or bend in the pipe which causes a pinging or hammering noise. The shock wave may get reflected back along the same section of pipe multiple times until its energy is dissipated, but making more pinging noises along the way. These sorts of shock waves traveling through the plumbing is detrimental and damaging to the plumbing as well as being a noisy irritation for the resident in the home or apartment.
There have been efforts to reduce or eliminate the water hammer effect. One such device is a water hammer arrester, which is a device added to the pipeline. Typically, the water hammer arrester has a gas pocket trapped on one side of a piston sliding inside a tubular housing, and the opposite side of the piston receives the water flowing through the pipe. As a shock wave propagates through the pipe, enters the arrester, and impacts the piston, the piston is displaced against the gas pocket compressing it and thereby absorbing some of the energy of the shock wave. The energy from the water hammer is thus diminished or dampened.
Some examples of such water hammers include: U.S. Pat. No. 3,422,853 (J. H. Schmid); U.S. Pat. No. 4,819,698 (Ismert); 5,385,172 (Perrott et al.); U.S. Pat. No. 6,095,195 (Park et al.); U.S. Pat. No. 6,154,961 (Park et al.); U.S. Pat. No. 6,539,976 (Whiteside); and U.S. Patent Application Publication No. 2011/0036437 (McCoy et al.).
The present invention in various preferred embodiments is directed to a process for making a water hammer arrester, and an apparatus for arresting water hammer effects in piping. The present invention includes processes for making a water hammer arrester for damping a shock wave propagating inside a liquid medium within a pipe, a preferred process comprising: providing a carrier slidable on a frame; providing a pressure chamber having first and second ends at one end of the frame; providing a hollow cylinder with a gas end and a liquid end, a piston, and a cap having tabs; assembling the hollow cylinder, piston, and cap together to create an arrester assembly outside of the pressure chamber, wherein the piston is slidable inside the cylinder and the cap is disposed over the gas end of the cylinder with a slight gap supported by the tabs, wherein a plenum chamber is formed between the cap and the piston; providing an ultrasonic welding horn disposed at the first end of the pressure chamber; wherein the carrier receives the arrester assembly therein; moving the carrier with the arrester assembly toward the second end of the pressure chamber such that the gas end and only a portion of the arrester assembly and the cap are inserted into the pressure chamber; increasing the pressure inside the pressure chamber to a pressure higher than outside the pressure chamber wherein the pressure inside the plenum chamber is increased concurrently; advancing the ultrasonic welding horn to engage at least one of the cap and the arrester cylinder, and forcing the cap to abut the gas end of the cylinder and closing the gap therebetween; ultrasonically welding the cap to the cylinder of the arrester sealing the plenum chamber closed at the pressure of the pressure chamber; and withdrawing the carrier to retract the arrester assembly out of the pressure chamber.
The present invention process optionally includes snap fitting a pipe fitting to the liquid end of the cylinder for connecting the arrester to the pipe, and mounting at least one O-ring to the piston outside of the pressure chamber. The ambient pressure inside the plenum chamber is preferably the same as the ambient pressure inside the pressure chamber when the gas end, the portion of the arrester assembly, and the cap are inserted into the pressure chamber. Furthermore, the ambient pressure inside the plenum chamber is the same as the ambient pressure inside the pressure chamber, and is ≧about 60 psi.
The present invention also contemplates a water hammer arrester for damping a shock wave in a liquid-carrying pipe, comprising a hollow cylinder having a gas end and a liquid end; a piston slidable within the hollow cylinder dividing the interior of the cylinder to a gas section in communication with the gas end and a liquid section; an O-ring disposed on the piston to seal leakage of gas and liquid from the gas section and the liquid section; a plug shaped cap covering the gas end, wherein the piston, cap, and cylinder wall form a sealed plenum chamber at the gas section; an ultrasonic weld joining the cap to the gas end of the cylinder and sealing closed the gas end to any gas leak; at least one of nitrogen, air, or carbon dioxide, contained inside the plenum chamber at a pressure of ≧about 60 psi; and a fitting extending from the liquid end having a passage therein in communication with the liquid section, and connected to the pipe.
The water hammer arrester may have a fitting that is made from a thermoplastic polymer and is adapted for standard ½ inch copper tubing size pipes. The fitting and arrester cylinder may be made from different polymer-based materials so that the polymer fitting can be chemically bonded to existing polymer or CPVC-type valves, fittings, joints, etc. The 60 psi or higher gas pressure inside the arrester dampens the water hammer effect more quickly and effectively.
The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as modifications and variations thereof which would occur to a person of ordinary skill in the art upon reading the following description and which are not in the prior art.
The preferred embodiment arrester 10 has a tubular shaped, cylindrical housing 22 with an open, gas end to be covered by a plug-shaped cap 12. Sliding through the gas end and into the hollow interior of the housing 12 is an optional pipe fitting 20, and an O-ring 18 that pass through the opposite, liquid end of the housing 12, where the lip of the port at the liquid end seats against a barbed connection or detent 24 of the pipe fitting 20. The pipe fitting 20 preferably extends out the gas end of the housing 22 through this optional port. A piston 16 also slides into the interior of the housing 22 where one or more optional O-rings 14 seat into respective detents 26.
Pipe fitting 20 has a further optional detent 28. As seen in
The fitting 20 has an internal passage or conduit 32 (seen in
The present preferred embodiment fitting 20 is a separate, discrete part from the cylindrical housing 22, and assembled to it after the cylindrical housing is formed, typically by injection molding. As such, the fitting 20 can be and is preferably made from a different material than the housing 22. The fitting 20 as mentioned above is made from CPVC to allow for bonding to a standard CTS socket, while the housing and other components of the arrester 10 is preferably made from acetal for their engineering characteristics. The present invention arrester 10 and its pipe fitting 20 can thus be made from two different resins, polymers, or materials. As a result, the selection of the pipe fitting 20 material, size, and shape can be chosen for its intended use in connecting to a plumbing socket, joint, fitting, etc., while the material for the housing and components may be chosen for its engineering characteristics.
The arrangement in
Furthermore, through empirical observations, the gas contained inside the plenum chamber 34 in the static, unconnected (from the plumbing) state of the arrester 10 is preferably at about 60 psi at room temperature, or greater than 60 psi. The gas used in the plenum chamber 34 is preferably ambient air, carbon-dioxide, but more preferably nitrogen.
The 60 psi gas pressure is preferred because it is a common line pressure for the plumbing in residential homes. If the gas pressure inside the water hammer arrestor 10 is less than the line pressure, the piston 16 moves up and compresses the gas until the gas and line pressures are equal. By choosing a gas pressure closer to the line pressure, the arrester 10 insures that the piston 16 is using more of the full length of the arrestor for the shock absorber effect. In contrast, if, say, 40 psi were used for the fill pressure inside gas chamber 34, the piston 16 would move up approximately 0.557″ to allow it to come to equilibrium with a 60 psi line. This is approximately half the total available stroke of the piston 16 inside the cylinder housing 22 (based on the dimensions shown in
Because of the higher gas plenum chamber pressures in the present invention arrester 10, the piston 16 is displaced more due to the governing equations of the gas-liquid system. A higher initial pressure means more “pre-shock” volume inside the housing cylinder. Because the quantity (Pressure)×(Volume) is approximately a constant in the gas side of this system, a higher “pre-shock” volume results in a “softer” gas spring encountered by the water hammer. In other words, the system pressure changes less for a given displacement of the piston 16 if the initial plenum chamber 34 charge is 60 psi (for a 60+ psi line pressure). Use of the water hammer arrester 10 in a common residential plumbing system therefore keeps the water pressure below 150 psi during pressure surges caused by the water hammer.
Furthermore, the greater displacement of the piston 16 and softer “gas spring” in the present invention arrester result in more energy of the water hammer being absorbed or dissipated. By the same token, a softer gas spring (as compared to a rigid gas spring) further minimizes the possibility of reflecting the shock wave back through the pipe, which would prolong the water hammer effect. So as a result of the longer piston travel and the softer gas spring, the water hammer effect is very quickly damped and eliminated, avoiding damage to the plumbing system.
Dual actuation pneumatic or hydraulic cylinders 48 move the carrier 40 up and down along the frame 42. The entire ultrasonic welding tool using actuators, motors, pumps, etc., can be controlled by a programmable pc or microprocessor (not shown).
Notably, the entire ultrasonic welding tool is located at standard ambient temperature and pressure on the shop floor. Before welding, the water hammer arrester assembly 38 is hand or machine assembled under these standard atmospheric conditions, and when assembled, the assembly 38 appears as depicted in
In
Pressure chamber 44 is pressurized and the plenum chamber 34 inside the arrester assembly 38 is simultaneously pressurized. This occurs because the cap 12 is supported and spaced apart from the housing 22 (as in
Thus, the gas charging process takes place inside the relatively small and easily environmentally-controlled pressure chamber 44 of the machine tool. It is not necessary to place the machine tool in a climate-controlled room at an elevated pressure in order to charge the plenum chamber 34 of the arrester assembly 38 up to a high pressure. It is also not necessary to fill that climate controlled room with nitrogen or other gasses specifically to charge the gas chamber 34. Accordingly, the present invention process and apparatus for making an arrester save much by way of material costs and manufacturing environment costs. And because the basic assembly process for the arrester takes place outside of the pressure chamber 44, there is no need for the production workers and technicians to be exposed to the higher pressures and charging gasses. Worker safety is maintained while labor costs are minimized. Finally, because the present invention machine tool does not require a pressurized, gas filled, climate-controlled room to function, it can be located on the shop floor. As a result, there is no need for workers, raw materials, and finished parts to enter or exit such a sealed room through an interfering barrier. Production throughput for the present invention machine tool and process and manufacturing efficiency are thus maximized.
From the foregoing detailed description, it should be evident that there are a number of changes, adaptations and modifications of the present invention that come within the province of those skilled in the art. Features or structures of one embodiment may be combined with features or structures in another embodiment. However, it is intended that all such variations not departing from the spirit of the invention be considered as within the scope thereof except as limited solely by the following claims.