Method and structure for preventing freezing and cracking of water supply devices

Abstract

A method and structure are provided for preventing freezing and cracking of a water supply device. The device includes an inlet conduit, an outlet conduit, and a valve housing disposed between them. The inlet conduit includes an inlet port, and the valve housing comprises a valve seat and an inlet manifold connected to the inlet conduit. A resilient buffer layer is integrally formed with the inlet conduit and the inlet manifold by injection molding. The resilient buffer layer includes a divergent flow channel in the inlet conduit, defining a constricted terminus adjacent to the inlet manifold and a flared terminus adjacent to the inlet port. 20 25 20 38 84 26 M ay 2 02 5 A B S T R A C T 2 0 2 5 2 0 3 8 8 4 2 6 2 0 2 5 M a y

Description

FIELD OF INVENTION

[0001] The present invention relates to water supply devices and, more particularly, to a method and structure for preventing freezing and cracking of a water supply device installed in outdoor environments. BACKGROUND OF THE INVENTION

[0002] A conventional water supply device, such as a water spray gun, a sprinkler, or an electronic timer, is often installed in an outdoor environment for prolonged periods and typically comprises an internal water flow channel. When the water supply device ceases operation, water flow within the water flow channel stops, resulting in residual water accumulation therein. Under ambient temperature conditions, the presence of the residual water generally does not pose a problem. However, in environments where the temperature drops to freezing conditions (e.g., during winter), the residual water undergoes volumetric expansion of approximately 9% to 10% upon freezing. This expansion exerts internal pressure on the pipe walls of the water flow channel and may ultimately lead to pipe rupture, an outcome that is clearly undesirable to users.

[0003] In an effort to mitigate the risk of such damage, conventional approaches have attempted to incorporate an elastic material into the internal water flow channel of the sprinkler, wherein the elastic material is intended to absorb the volumetric expansion caused by the freezing of residual water, thereby alleviating direct pressure exerted on the internal walls of the water flow channel. 2025203884   26 May 2025

[0004] Despite these efforts, such conventional structures exhibit several limitations. For example, in addition to the water flow channel, a typical water supply device further includes a valve housing connected to the water flow channel. The internal configuration of the water flow channel and the valve housing is often non-linear, comprising bends, curved sections, and segments of varying diameter. Consequently, elastic material can only be partially deployed, typically in less than 50% of the internal regions, leaving substantial portions of the water flow channel and valve housing unprotected. These unprotected regions remain susceptible to freezing, induced expansion and the resulting pipe rupture. Therefore, conventional approaches fall short of providing comprehensive protection against freezing-related damage, thereby presenting a technical challenge that warrants continued attention and improvement within the industry. SUMMARY OF THE INVENTION

[0005] A primary objective of the present invention is to provide a method and structure for preventing freezing and cracking of a water supply device, thereby addressing the technical deficiencies of conventional designs. The water supply device comprises an inlet conduit, an outlet conduit, and a valve housing disposed between the inlet conduit and the outlet conduit. The inlet conduit has an inlet port, and the valve housing comprises a valve seat and an inlet manifold configured to be in fluid communication with the inlet conduit.

[0006] To achieve the foregoing objective, the present invention provides a technical solution that comprises the following steps: • defining a cryoprotective zone within the inlet conduit and the inlet manifold of the valve housing by a mold forming process; 2025203884   26 May 2025 • forming a resilient buffer layer within the cryoprotective zone by polymer injection molding, such that the resilient buffer layer is integrally bonded to the cryoprotective zone; and • forming a divergent flow channel within a region of the inlet conduit corresponding to the resilient buffer layer, wherein the divergent flow channel is configured to gradually increase in diameter toward the inlet port of the inlet conduit.

[0007] Another objective of the present invention is to provide a structural design for preventing freezing and cracking of the water supply device. The structural configuration includes the inlet conduit, the outlet conduit, and the valve housing disposed between the inlet conduit and the outlet conduit. The inlet conduit has the inlet port, and the valve housing comprises the valve seat and the inlet manifold, which is connected to the inlet conduit. The inlet conduit and the inlet manifold are integrally combined with the resilient buffer layer formed by injection molding. The resilient buffer layer includes the divergent flow channel, which is disposed within a region of the inlet conduit and defines a constricted terminus and a flared terminus. The flared terminus is positioned adjacent to the inlet port of the inlet conduit, and the constricted terminus is positioned adjacent to the inlet manifold of the valve housing.

[0008] The present invention provides several notable advantages. First, the resilient buffer layer, integrally formed by injection molding, enables comprehensive coverage of the cryoprotective zone and thereby addresses challenges associated with internal pipe geometries that are curved, tapered, or otherwise non-linear. Second, the divergent flow channel mitigates pressure surges caused by water hammer effects when a valve is rapidly closed, thereby extending the service life of the associated 2025203884   26 May 2025 piping system. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a perspective view of a preferred embodiment of the water supply device; FIG. 2 is a perspective view showing the inlet conduit and the outlet conduit of the preferred embodiment; FIG. 3 is a cross-sectional view of the inlet conduit and the outlet conduit of the preferred embodiment; FIG. 4 is an enlarged view of a portion labeled as 4 in FIG. 3; FIG. 5 is a schematic diagram illustrating a molding step of the anti-freezing method in the preferred embodiment; FIG. 6 is a schematic diagram illustrating another molding step of the anti-freezing method in the preferred embodiment; FIG. 7 is a functional diagram illustrating how the resilient buffer layer absorbs the volumetric expansion of freezing water; FIG. 8 is a view showing an embodiment in which the divergent flow channel has a straight-wall configuration between the constricted terminus and the flared terminus; FIG. 9 is a view showing an embodiment of the water supply device configured as a water spray gun; and FIG. 10 is a functional diagram illustrating how the divergent flow channel mitigates water hammer pressure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Referring to FIGS. 1 through 4, a preferred embodiment of a method and 2025203884   26 May 2025 structure for preventing freezing and cracking of a water supply device is illustrated. It is to be understood that the illustrated embodiment is provided solely for the purpose of explanation and is not intended to limit the scope of the present invention.

[0011] As shown in FIGS. 1 through 4, a water supply device 100 comprises an inlet conduit 10, an outlet conduit 20, and a valve housing 30 disposed between the inlet conduit 10 and the outlet conduit 20. The inlet conduit 10 includes an inlet port 11. The valve housing 30 comprises a valve seat 31 and an inlet manifold 32 configured to be in fluid communication with the inlet conduit 10.

[0012] A method for preventing freezing and cracking of the water supply device 100 comprises the following steps. As shown in FIGS. 5 and 6, a mold forming process 50 is performed to define a cryoprotective zone 60 that spans a portion of the inlet conduit 10 and the inlet manifold 32 of the valve housing 30. Thereafter, as illustrated in FIG. 5, a polymer injection molding 70 is employed to form a resilient buffer layer 40 within the cryoprotective zone 60, such that the resilient buffer layer 40 is integrally bonded to the cryoprotective zone 60. (It is noted that the cryoprotective zone 60 is coextensive with the coverage area of the resilient buffer layer 40.) Finally, the resilient buffer layer 40 is configured to include a divergent flow channel 41 formed within a corresponding region of the inlet conduit 10, wherein the divergent flow channel 41 is shaped to gradually increase in diameter in a direction extending toward the inlet port 11 of the inlet conduit 10.

[0013] The present invention further provides a structural configuration for preventing freezing and cracking of the water supply device 100. The water supply device 100 comprises the inlet conduit 10, the outlet conduit 20, and the valve housing 30 disposed between the inlet conduit 10 and the outlet conduit 20. The inlet conduit 2025203884   26 May 2025 10 includes the inlet port 11, and the valve housing 30 comprises the valve seat 31 and the inlet manifold 32 configured to be connected to the inlet conduit 10. In the present embodiment, the inlet conduit 10 and the inlet manifold 32 are integrally formed with the resilient buffer layer 40 by an injection molding process. The resilient buffer layer 40 includes the divergent flow channel 41 formed within a region of the inlet conduit 10, such that the divergent flow channel 41 defines a constricted terminus 42 and a flared terminus 43. The flared terminus 43 is disposed adjacent to the inlet port 11 of the inlet conduit 10, and the constricted terminus 42 is disposed adjacent to the inlet manifold 32 of the valve housing 30.

[0014] The resilient buffer layer 40 is composed of a microsphere foaming agent, such as EXPANCEL, in combination with a thermoplastic elastomer. The thermoplastic elastomer may be selected from a group consisting of thermoplastic rubber (TPR), thermoplastic elastomer (TPE), thermoplastic polyurethane (TPU), or thermoplastic polyamide (TPA).

[0015] As illustrated in FIG. 4, in a first embodiment of the water supply device 100, the divergent flow channel 41 of the resilient buffer layer 40 includes a stepped-wall configuration between the constricted terminus 42 and the flared terminus 43.

[0016] As illustrated in FIG. 8, in a second embodiment of the water supply device 100, a divergent flow channel 41B of a resilient buffer layer 40 includes a straight-wall configuration extending between a constricted terminus 42B and a flared terminus 43B.

[0017] As illustrated in FIG. 3, in one embodiment of the water supply device 100, the inlet manifold 32 of the valve housing 30 is connected to the inlet conduit 10 2025203884   26 May 2025 via a non-uniform diameter interface.

[0018] The resilient buffer layer 40 may be distributed over a portion of, or the entirety of, the inlet conduit 10. For example, as shown in FIG. 3, the resilient buffer layer 40 is disposed only within a partial region of the inlet conduit 10. A region near the inlet port 11 of the inlet conduit 10, which does not include the resilient buffer layer 40, is reserved for the assembly of additional components (e.g., connectors), and is therefore unsuitable for forming the resilient buffer layer 40.

[0019] As shown in FIG. 8, an inclination angle X defined by the divergent flow channel 41B between the constricted terminus 42B and the flared terminus 43B ranges from 5 degrees to 10 degrees. It should be noted that the specified angular range is illustrative, and the divergent flow channel 41B disclosed herein differs in geometry and function from conventional structures formed solely by draft angles.

[0020] As illustrated in FIG. 3, in another embodiment of the water supply device 100, the outlet conduit 20 is also integrally formed with the resilient buffer layer 40 through an injection molding process. This configuration demonstrates that the resilient buffer layer 40 may be further extended to cover at least a portion of the outlet conduit 20.

[0021] The water supply device 100 may be embodied in various forms, including but not limited to an electronic timer or a water spray gun. An embodiment of the water supply device 100 configured as an electronic timer is depicted in FIG. 1, and an embodiment configured as a water spray gun is illustrated in FIG. 9.

[0022] By virtue of the structural configurations and technical features described above, the method and structure for preventing freezing and cracking of the water supply device 100, as disclosed in the present invention, provide several practical 2025203884   26 May 2025 advantages, as illustrated in FIGS. 3 and 4. The resilient buffer layer 40, formed via the injection molding process and integrally bonded to both the inlet conduit 10 and the inlet manifold 32 of the valve housing 30, ensures a broader and more comprehensive distribution over the cryoprotective zone 60. This configuration effectively overcomes the structural limitations posed by the complex internal geometries of the water supply device 100, such as bends, varying cross-sectional diameters, and curved sections. When water contained within the inlet conduit 10 freezes and undergoes volumetric expansion, as indicated by the arrows L1 in FIG. 7, the resilient buffer layer 40 absorbs the resulting increase in volume, thereby preventing direct pressure from being exerted on the inner wall of the inlet conduit 10 and avoiding structural rupture. Additionally, the divergent flow channel 41 of the resilient buffer layer 40 serves to mitigate water hammer effects. As illustrated in FIG. 10, when a valve within the valve housing 30 is closed, as indicated by arrow L2, a transient pressure surge, or water hammer effect, is generated, as indicated by arrow L3. The tapered configuration of the divergent flow channel 41 guides and disperses the resulting pressure wave, as indicated by arrow L4, thereby alleviating the peak impact and prolonging the operational lifespan of the piping system. To clarify the functional mechanism: when fluid is flowing at high velocity within a conduit, the sudden closure of a valve generates a pressure wave, commonly referred to as water hammer, which can result in damage to the piping structure, as well as noise and vibration. The divergent flow channel 41, which comprises a narrow-to-wide channel geometry extending from the constricted terminus 42 to the flared terminus 43, provides a gradually increasing cross-sectional area that dissipates the energy of the pressure wave. This dissipation reduces the amplitude of the peak pressure, as well as 2025203884   26 May 2025 the velocity and intensity of wave transmission. Furthermore, in the embodiment illustrated in FIG. 4, the stepped-wall configuration of the divergent flow channel 41 enhances the mitigation of the water hammer effect by creating multiple surfaces that induce reflection and turbulence at each step, thereby further attenuating the magnitude of the transmitted pressure wave.

Claims

1. A method for preventing cracking of a water supply device due to water freezing, the water supply device comprising an inlet conduit, an outlet conduit, and a valve housing disposed between the inlet conduit and the outlet conduit, the inlet conduit having an inlet port, the valve housing comprising a valve seat and an inlet manifold configured to be connected to the inlet conduit, the method comprising:defining a cryoprotective zone in the inlet conduit and the inlet manifold of the valve housing by a mold forming process;forming a resilient buffer layer in the cryoprotective zone by polymer injection molding, wherein the resilient buffer layer is integrally bonded to the cryoprotective zone; andforming a divergent flow channel in a region of the inlet conduit corresponding to the resilient buffer layer, wherein the divergent flow channel is configured to gradually increase in diameter in a direction extending toward the inlet port.

2. A structure for preventing cracking of a water supply device due to water freezing, the water supply device comprising an inlet conduit, an outlet conduit, and a valve housing disposed between the inlet conduit and the outlet conduit, the inlet conduit having an inlet port, the valve housing comprising a valve seat and an inlet manifold configured to be connected to the inlet conduit, wherein the inlet conduit and the inlet manifold are integrally formed with a resilient buffer layer by injection molding, and wherein:the resilient buffer layer comprises a divergent flow channel formed in a region of the inlet conduit, the divergent flow channel defining a constricted terminus and a flared terminus;2025203884   29 Jun 2026the flared terminus is disposed adjacent to the inlet port of the inlet conduit; and the constricted terminus is disposed adjacent to the inlet manifold of the valve housing.

3. The structure according to Claim 2, wherein the resilient buffer layer is composed of a microsphere foaming agent and a thermoplastic elastomer, and wherein the thermoplastic elastomer is selected from the group consisting of thermoplastic rubber (TPR), thermoplastic elastomer (TPE), thermoplastic polyurethane (TPU), and thermoplastic polyamide (TPA).

4. The structure according to Claim 2, wherein the divergent flow channel has a stepped-wall configuration between the constricted terminus and the flared terminus.

5. The structure according to Claim 2, wherein the divergent flow channel has a straight-wall configuration between the constricted terminus and the flared terminus.

6. The structure according to Claim 2, wherein the inlet manifold of the valve housing and the inlet conduit are connected in a non-uniform diameter configuration.

7. The structure according to Claim 2, wherein the resilient buffer layer is distributed over a partial region or an entire region of the inlet conduit.

8. The structure according to Claim 2, wherein the divergent flow channel defines an inclination angle between 5 degrees and 10 degrees from the constricted terminus to the flared terminus.

9. The structure according to Claim 2, wherein the outlet conduit is also integrally formed with the resilient buffer layer by injection molding.

10. The structure according to Claim 2, wherein the water supply device is an2025203884   29 Jun 2026electronic timer or a water spray gun.

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