Bypass valve for a water system

Abstract

A valve for a water supply system including a water supply pipe has a valve body (14) defining a valve inlet (18) and a valve outlet (20). The valve inlet is connected to the water supply pipe, and at least one piston (32) is disposed within the valve body and configured to guide flow within the valve. A motor (44) associated with the valve body (14) is operatively attached to the piston and further configured to drive the piston between a service position, a bypass position, and a closed position. The valve further includes at least one sensor (62, 64, 66, 68, 70) associated with the valve inlet or the valve outlet for monitoring water conditions. A control system (60) receives data from at least one sensor and is configured to actuate the motor between the service position, the bypass position, and the closed position in response to the data.

Description

[Technical Field]

[0001] The present invention relates to a household water system, and more specifically, such a system includes a valve, preferably a bypass valve, which can automatically adjust according to water flow conditions to prevent damage caused by indoor water leakage. [Previous Technology]

[0002] In the technical field to which this invention pertains, bypass valves are known to be used in water treatment systems, such as water softeners and water filters. Typically, when the water treatment system requires maintenance or when treated water is unavailable (e.g., when the water softener is in regeneration cycle), the bypass valve can be manually operated from a service position to a bypass position to supply untreated water.

[0003] A known problem with domestic water systems is that they may periodically leak, usually due to burst pipes or defective appliances (e.g., water heaters, toilets, faucets, or similar items). These leaks are difficult to detect and often cause significant damage to personal property and, in some cases, to the building structure before they are detected. Such leaks occur regardless of whether the known bypass valve is in service or bypass position.

[0004] One problem with the above-mentioned technology is that known devices and valves cannot easily and efficiently monitor indoor water conditions and cut off the water supply to the household water system when necessary. In view of this, a better method is needed to detect leaks in the household water system before causing significant damage. [Summary of the Invention]

[0005] The valve of the present invention for a domestic water system meets or exceeds the above-mentioned requirements. Although the valve of the present invention is preferably a bypass valve, other water system valves may also be considered. One feature of the bypass valve of the present invention is that a motor is operably attached to an internal piston and communicates with a valve control system. The piston is movable between a service position, a bypass position, and a shut-off position. At least one sensor communicates with the control system and is configured to collect patterns of normal water use in the residence. In response to the stored sensor data, the control system actuates the piston. Thus, the bypass valve can automatically move the piston between the service position, the bypass position, and the shut-off position in response to water flow conditions. A noteworthy feature is that abnormal water usage or a decrease in water flow or pressure (indicating leakage) will cause the control system to actuate the motor to move the piston to the shut-off position. In this case, water damage due to leakage is reduced. Another advantage of the bypass valve of the present invention is that it can be easily connected to conventional water softeners.

[0006] More specifically, a valve is provided for a water supply system including a water supply pipe. The valve includes a valve housing defining a valve inlet and a valve outlet connected to the water supply pipe. In a preferred embodiment, at least one piston is disposed within the valve housing to guide flow within the valve. Furthermore, the valve includes a motor associated with the valve housing and operatively attached to the piston. Preferably, the motor drives the piston between a service position, a bypass position, and a closed position. Additionally, at least one sensor associated with at least one of the valve inlet and valve outlet is provided for monitoring water conditions. Preferably, a control system receives data from the at least one sensor and actuates the motor between the service position, bypass position, and closed position in response to the data.

[0007] In a preferred embodiment, the valve housing further defines a softener inlet and a softener outlet. The softener inlet is opposite to and aligned with the valve inlet. Similarly, the softener outlet is opposite to and aligned with the valve outlet. Preferably, the water system further includes a water treatment system, and the softener inlet and softener outlet are fluidly connected to the water treatment system.

[0008] In one embodiment, the valve housing further defines a bypass chamber having a bypass chamber inlet and a bypass chamber outlet. When the piston is in the bypass position, the bypass chamber allows flow through the bypass valve.

[0009] In a preferred embodiment, the piston further includes an inlet passage associated with a valve inlet and an outlet passage associated with a valve outlet. The inlet and outlet passages allow water to flow through the piston. The piston further includes an inlet blocking portion and an outlet blocking portion. Preferably, the inlet blocking portion blocks and prevents flow in the valve inlet in a closed position, blocks and prevents flow in the softener inlet in a bypass position, and blocks and prevents flow in the bypass chamber inlet in a service position. Similarly, the outlet blocking portion blocks and prevents flow in the valve outlet in a closed position, blocks and prevents flow in the softener outlet in a bypass position, and blocks and prevents flow in the bypass chamber outlet in a service position.

[0010] A control housing is mounted to the valve housing, and the control system is disposed within the control housing. Preferably, the at least one sensor is selected from the group consisting of a flow meter, a pressure sensor, a temperature sensor, and a total dissolved solids (TDS) sensor.

[0011] Preferably, the at least one sensor includes a flow meter. In one embodiment, the control system alerts a user or actuates the piston to a closed position when the flow meter detects a predetermined flow rate. Alternatively, the flow meter is configured to measure a predetermined flow rate for a predetermined time. An ultrasonic flow meter may be considered.

[0012] In one embodiment, the at least one sensor further includes a temperature sensor. The control system alerts a user or actuates a piston to a closed position when the temperature sensor detects a predetermined temperature.

[0013] In another embodiment, the at least one sensor includes a total dissolved solids sensor. According to this embodiment, the control system alerts a user or actuates a piston to a closed position when the total dissolved solids sensor detects a predetermined dissolved solids concentration.

[0014] In a preferred embodiment, the sensor is a total dissolved solids sensor or a conductivity sensor—one located at or near the valve inlet, and one located at or near the valve outlet. Changes in conductivity are used to assess the effectiveness of the softener or filter. For example, the inflow (high ferric) water entering an iron reduction filter typically has a different conductivity than the outflow water. Such readings indicate whether the filter is functioning properly or whether the filter media needs replacement. Similarly, the difference in conductivity between the inflow and outflow water of a water softener is also evaluated to determine whether the water softener is functioning properly.

[0015] In another embodiment, the at least one sensor further includes an inlet pressure sensor associated with the valve inlet and an outlet pressure sensor fixed in the valve outlet. Here, the control system uses data from the inlet pressure sensor or the outlet pressure sensor to detect leaks in the water system and alerts a user or actuates a piston when a leak is detected.

[0016] In a preferred embodiment, the inlet pressure sensor and the outlet pressure sensor are used together to measure the differential pressure. This process is particularly useful for multi-media filters, as it signals when media is loaded (differential pressure increases) and when the filter needs backwashing.

[0017] In a preferred embodiment, the control system further sends signals to and receives signals from the cloud. A user communicates with the cloud through a user device. Using the user device, the user actuates the piston of the bypass valve between a service position, a bypass position, and a closed position.

[0018] Preferably, the bypass valve includes a handle attached to one of the valve housings. The handle allows manual movement of the piston between a service position, a bypass position, and a closed position.

[0019] In another embodiment, the valve of the present invention is connected to a control system and includes remote sensors for monitoring temperature, leakage, water flow, etc. These remote sensors are installed in other areas of the house and configured to communicate with the main control system and the valve.

[0020] In another embodiment, a remote valve or / and other isolation valves (e.g., shut-off valves located in other areas of the house (e.g., adjacent to the equipment)) are connected to the valve of the present invention and communicate with the control system. The aforementioned remote sensor for use in conjunction with the remote valve is capable of isolating parts of the household water system such as tracking, locating, and identifying leaks or flow problems, and isolating various parts of the household water system.

[0021] In one embodiment, the main valve is connected to an inlet pressure sensor and a control system, such that the pressure sensor is configured to sense increased pressure above the rated operating pressure of the water softener, filter or other equipment, and the control system closes the valve to protect the equipment from excessive pressure.

[0022] In another embodiment, the valve housing is provided with a connection port for adding parts, including a pressure gauge, a water sample tap, and accessories for directing treated water to other systems, including, but not limited to, point-of-use reverse osmosis (RO) units or similar accessories.

Implementation Method

[0029] Referring now to Figures 1 through 3, a valve is typically designated 10 and shown connected to a water treatment system (typically designated 12). In a preferred embodiment, the water treatment system 12 is a water softener, but it is conceivable that the system may comprise other types of water treatment devices or filtration devices comprising multiple treatment units. The water treatment system 12 includes a system controller and interface 12a, as well as a system control valve 12b, which differs from the bypass valve 10 of this invention.

[0030] Referring now to Figures 1 through 6, a preferred bypass valve 10 includes a valve housing 14 and a control housing 16 mounted to the valve housing. Preferably, the valve housing 14 has a generally cylindrical shape and also defines a valve inlet 18 receiving water from a water supply pipe 19 and a valve outlet 20 horizontally aligned with and adjacent to the valve inlet 18. A bypass chamber 22 is also defined by the valve housing 14 and includes a bypass chamber inlet 24 adjacent to and opposite to the valve inlet 18 and a bypass chamber outlet 26 adjacent to and opposite to the valve outlet 20. It is conceivable that the valve 10 of the present invention can be configured for retrofitting into an existing water treatment system 12 designed for use with conventional bypass valves that do not include the features set forth herein.

[0031] Furthermore, the valve housing 14 defines a softener inlet 28 aligned with and opposite to the valve inlet 18, and a softener outlet 30 aligned with and opposite to the valve outlet 20. The softener inlet 28 and softener outlet 30 are clearly visible in Figure 3 and guide fluid into and out of the water treatment system 12. Moreover, the design and dimensions of the softener inlet 28 and softener outlet 30 are configured to be compatible with various water treatment and filtration devices and systems.

[0032] Referring to Figures 5 and 6, within the valve housing 14, at least one valve piston 32 is rotatably fixed within a valve chamber 34 and operable by rotation between a service position, a bypass position, and a closed position. It should be understood that in this application, "piston" refers to any valve control element or flow guiding element, including but not limited to a ball. More specifically, the piston 32 is generally cylindrical and includes a flow-blocking portion 36 with a "D"-shaped cross-section (Figure 5). The flow-blocking portion 36 is configured to rotate within the valve chamber 34 and selectively block the bypass chamber inlet 24 in the service position, the softener inlet 28 in the bypass position (as shown in Figure 5), and the valve inlet 18 in the closed position. Since the valve 10 controls the outflow from two ports (i.e., valve inlet 18 and valve outlet 20), the piston 32 is symmetrical and has two flow-blocking portions 36, one for each port. Each flow-blocking portion 36 is provided with a resilient sealing element or O-ring 38 to prevent leakage. As can be clearly seen in Figure 5, the piston 32 further includes a flow-through service passage 40 and a bypass passage 42 for controlling the flow through the valve 10 according to the rotational position of the piston.

[0033] To actuate the piston 32 between these positions, a motor 44 is fixed within the valve housing 14 and drives the rotation of the piston 32. In a preferred embodiment, the motor 44 is speed-regulated and selected relative to the size of the bypass chamber 22 and the flow rate specifications of the water treatment system 12. Furthermore, the motor 44 drives the piston 32 via a hexagonal or other polygonal or non-circular connector fitting 46 that matingly engages with one of the sockets 48 within the piston 32.

[0034] In the service position, water flows into the service passage 40 via valve inlet 18, into the water treatment system 12 via softener inlet 28, out of the water treatment system 12 via softener outlet 30, and finally out of the bypass valve 10 via valve outlet 20. In the bypass position, piston 32 is positioned to allow water to flow into valve inlet 18, through bypass chamber 22, and out of valve outlet 20. In the bypass position, water does not flow through the water treatment system 12. Finally, in the closed position, piston 32 is rotated to a position that prevents water from entering valve inlet 18 due to flow blocking portion 36. Therefore, when piston 32 is in the closed position, no water flows through bypass valve 10, and water is prevented from flowing into the domestic water management system downstream of bypass valve 10.

[0035] Another feature of the bypass valve 10 is a manual handle 50 operably engaged with a motor clutch system 52, which allows the motor 44 to be overridden. The handle 50 is used to manually move the piston 32 between a service position, a bypass position, and a closed position, for example, when the motor is not operating or when there is a power outage. The motor clutch system 52 is speed-adjusted to allow the user to operate the handle 50 with lower torque.

[0036] In a preferred embodiment, a control system 60 is housed within a control housing 16 and includes a programmable chip and suitable programming, such that the control system 60 is configured to monitor, record, and compare data provided by a plurality of sensors that monitor the properties and characteristics of water and fluids in the bypass valve 10 and throughout the domestic water system. The control system 60 uses lookup tables to establish patterns of water flow and usage data. To protect the control system 60, the control housing 16 is sealed to prevent moisture from entering the control housing 16 and to allow for outdoor installation. The control system 60 communicates with the motor 44 and sends signals to the motor to move the piston 32 in the bypass valve 10 between a service position, a bypass position, and a closed position. The control system 60 also sends signals to and receives signals from the cloud.

[0037] As clearly seen in Figure 5, at least one flow meter 62 is included in the bypass valve 10, preferably in at least one of the valve inlet 18, valve outlet 20, bypass chamber inlet 24, or bypass chamber outlet 26. Alternatively, multiple flow meters 62 may be included in the bypass valve 10 to measure and compare water flow rates in different parts of the domestic water management system 12. It is conceivable that the flow meter may be a mechanical flow meter (e.g., a turbine flow meter), an ultrasonic flow meter, or any other type of flow meter known in the art to which this invention pertains. The flow meter 62 is used to measure and track flow rates in the home and can be used to detect leaks and unwanted water flow in the domestic water management system. Furthermore, the flow meter 62 is used to track the total cumulative flow entering the domestic water management system over a predetermined time interval. Alternatively, the flow meter is configured to measure a predetermined flow rate for a predetermined time period.

[0038] Pressure sensor 64 (Figure 5) is further configured to operate in conjunction with both valve inlet 18 and valve outlet 20. Preferably, pressure sensor 64 is used to detect leaks, particularly small leaks, in both the water treatment system 12 and the bypass valve 10, as well as in the entire water system (e.g., a household water system). To detect leaks in the water treatment system 12, control system 60 measures the pressure drop between valve inlet 18 and valve outlet 20 of bypass valve 10. To detect leaks in the entire water system, flow to valve inlet 18 is cut off, and control system 60 measures the pressure decay of pressure sensor 64 over a period of time. Control system 60 also uses the same process to detect leaks in the water treatment system 12 by comparing data from pressure sensor 64 at valve inlet 18 with data from pressure sensor 64 at valve outlet 20. In one embodiment, the inlet pressure sensor 64 and the outlet pressure sensor 64 are used together and connected to the control system 60 to measure the pressure difference between them in order to maintain an appropriate equipment pressure value.

[0039] The bypass valve 10 is also provided with a temperature sensor 66 to detect the water temperature. If the water temperature is close to the freezing point, the control system 60 warns the user and moves the bypass valve 10 to the closed position. Alternatively, the control system 60 can be optionally configured to warn the user that the water temperature is low. In this case, the user chooses whether to instruct the control system 60 to move the bypass valve 10 to the closed position.

[0040] Referring again to Figure 6, a position sensor 68 is included in the control housing 16, connected to the control system 60 like all sensors, and positioned near the piston 32 so that the position sensor 68 monitors the position of the piston 32. The position sensor 68 is preferably a magnetic sensor or an optical sensor, but may also be any other position sensor known in the art to which this invention pertains. The control system 60 uses the position sensor 68 to detect whether the bypass valve 10 is in the service position, bypass position, or closed position.

[0041] Referring now to Figure 3, the bypass valve 10 further includes a total dissolved solids (TDS) sensor 70 located at either the softener outlet 30 or the valve outlet 20, for measuring the concentration of dissolved solids in the water. The TDS sensor 70 is used to estimate water hardness and evaluate the performance of the water softener. For example, if the TDS sensor 70 detects a high mineral concentration level, the control system 60 warns the user that the water treatment system 12 needs maintenance. The user can then choose whether to instruct the control system 60 to move the bypass valve 10 to the bypass position or the closed position as needed.

[0042] In one embodiment, a pair of TDS sensors, alternatively selected as conductivity sensors 70, are provided, one located at or near the valve inlet 18 of valve 10, and the other located at or near the valve outlet 20 of valve 10. Changes in conductivity are used to assess the effectiveness of a softener or filter. For example, the inflow (high-iron) water entering an iron reduction filter typically has a different conductivity than the outflow water. Such readings indicate whether the filter is functioning properly or whether the filter media needs replacement. Similarly, the difference in conductivity between the inflow and outflow water of a water softener is evaluated to determine whether the water softener is functioning properly.

[0043] In another embodiment, the valve 10 of the present invention is connected to the control system 60 and includes a remote sensor similar to the remote sensors designated 64, 66, and 68 for monitoring temperature, leakage, water flow, and similar information. These remote sensors are installed in other areas of the house and are configured to communicate with the main control system 60 and the valve 10.

[0044] In one embodiment, a remote valve or / and other isolation valves (e.g., shut-off valves located in other areas of the house (e.g., adjacent to the equipment)) are connected to the valve 10 of the present invention and communicate with the control system 60. The remote sensor and remote valve used in combination can isolate parts of the household water system such as tracking, locating, and identifying leaks or flow problems, and isolate various parts of the household water system.

[0045] In one embodiment, the main valve 10 is connected to the inlet pressure sensor 64 and the control system 60 such that the pressure sensor is configured to sense an increase in pressure above the rated operating pressure of the water softener, filter or other equipment, and the control system 60 closes the valve 10 to protect the equipment from excessive pressure.

[0046] In another embodiment, the valve housing 14 is provided with a connection port (not shown) for adding parts, such parts including a pressure gauge, a water sample tap, and accessories for directing treated water to other systems, including but not limited to point of use reverse osmosis (RO) units or similar accessories.

[0047] Furthermore, the control system 60 receives instructions from a user or remote device and executes commands. For example, if a leak is detected, or if the water temperature is close to freezing, the control system 60 selectively and automatically moves the bypass valve 10 to the closed position. Alternatively, the control system 60 selectively warns the user of abnormal flow patterns, leaks, low water temperature, total dissolved solids (TDS) values, or any other programmed conditions or properties of the water or management system. Accordingly, the user selectively instructs the control system 60 to execute a command. For example, if a small leak is detected in the water softener, the control system 60 warns the user. The user then instructs the control system 60 to move the bypass valve 10 to the bypass position. Referring now to Figure 4, the control system 60 is preferably equipped with a data connector or a data port 72 for connecting the control system to a user's computer (not shown) or ultimately to the Internet via a communication cable. Wireless connectivity may also be considered. Alternatively, the data connector or data port 72 could be adapted to a "multi-tank" system, in which multiple valves can be connected to each other and communicate with one another or to other devices and communicate with each other.

[0048] When the control system 60 collects data from the system, the bypass valve 10 also includes the option to track and obtain household water usage trends. For example, the bypass valve 10 detects the total water consumption of different household appliances. In addition, the control system 60 identifies differences between various water flow curves, appliance usage, water flow into and out of bathtubs, showers, sinks, irrigation systems, or leaks in the household water system.

[0049] This application claims priority to U.S. Provisional Application No. 63 / 262,670, the contents of which are incorporated herein by reference.

[0050] Although a particular embodiment of the bypass valve of the present invention has been described herein, those skilled in the art will understand that various changes and modifications may be made without departing from the broader features of the invention as described in the following claims. [Simplified Explanation of the Diagram]

[0023] Figure 1 is a partial top perspective view of the water system of the present invention, including the bypass valve of the present invention.

[0024] Figure 2 is a partial side view of the water system of the present invention, including the bypass valve of the present invention.

[0025] Figure 3 is a top view of the water system of the present invention including the bypass valve in Figure 1.

[0026] Figure 4 is a top perspective view of the bypass valve of the present invention.

[0027] Figure 5 is a cross-sectional view taken along line 5-5 of Figure 4 and in the generally indicated direction.

[0028] Figure 6 is a cross-sectional view taken along line 6-6 of Figure 4 and in the generally indicated direction. [Biomaterial Storage]

[0052] None

Claims

1. A bypass valve for a water system including a water supply pipe and a system control valve, the bypass valve comprising: a bypass valve housing separated from the system control valve and defining a bypass valve inlet and a bypass valve outlet, the bypass valve inlet being connected to the water supply pipe located upstream of the system control valve; at least one piston disposed within the bypass valve housing and configured to guide flow within the bypass valve; a motor associated with the bypass valve housing and operatively attached to the piston, the motor being further configured to drive the piston only between a service position, a bypass position, and a closed position; and at least one sensor associated with one of the bypass valve inlet and the bypass valve outlet for monitoring a water condition; A control system receives data from the at least one sensor, the control system being configured to actuate the motor only between the service position, the bypass position, and the closed position in response to the data; and a handle, external to the bypass valve housing and attached to the bypass valve housing via a connection between the handle and the motor, and configured such that the handle is connected to a motor clutch system and then to the piston for manually moving the piston between the service position, the bypass position, and the closed position via the handle.

2. The bypass valve as claimed in claim 1, wherein the bypass valve housing defines a softener inlet and a softener outlet, the softener inlet being opposite and aligned with the bypass valve inlet, and the softener outlet being opposite and aligned with the bypass valve outlet; wherein the water system includes a water treatment system; and wherein the softener inlet and the softener outlet are configured for fluid connection with the water treatment system.

3. The bypass valve as claimed in claim 2, wherein the bypass valve housing defines a bypass chamber having a bypass chamber inlet and a bypass chamber outlet; when the piston is in the bypass position, the bypass chamber allows flow through the bypass valve.

4. The bypass valve as claimed in claim 3, wherein the piston further comprises: an inlet passage associated with the bypass valve inlet and an outlet passage associated with the bypass valve outlet, the inlet passage and the outlet passage being configured to allow flow through the piston; and an inlet blocking portion and an outlet blocking portion, the inlet blocking portion being configured to block flow from the bypass valve inlet in a closed position, to block flow from the softener inlet in a bypass position, and to block flow from the bypass chamber inlet in a service position, and the outlet blocking portion being configured to block one of: blocking flow from the bypass valve outlet in a closed position, blocking flow from the softener outlet in a bypass position, and blocking flow from the bypass chamber outlet in a service position.

5. The bypass valve as described in claim 1 further includes a control housing mounted to the bypass valve housing, the control system being disposed within the control housing.

6. The bypass valve as claimed in claim 1, wherein the at least one sensor is selected from the group consisting of a flow meter, a pressure sensor, a temperature sensor and a total dissolved solids sensor.

7. The bypass valve as claimed in claim 1, wherein the at least one sensor is a flow meter, and the control system is configured to warn a user or actuate the piston to the closed position when the flow meter detects a predetermined flow rate for a predetermined time.

8. The bypass valve as claimed in claim 1, wherein the at least one sensor is a temperature sensor, and the control system is configured to alert a user or actuate the piston to the closed position when the temperature sensor detects a predetermined temperature.

9. The bypass valve as claimed in claim 1, wherein the at least one sensor is a total dissolved solids sensor, and the control system is configured to warn a user or actuate the piston to the closed position when the total dissolved solids sensor detects a predetermined dissolved solids concentration.

10. The bypass valve as claimed in claim 1, wherein the at least one sensor is an inlet pressure sensor associated with the inlet of the bypass valve and an outlet pressure sensor fixed in the outlet of the bypass valve, and the control system is configured to use data from the inlet pressure sensor or the outlet pressure sensor to detect a leak in the water system, wherein when the leak is detected, the control system warns a user or actuates the piston.

11. The bypass valve as described in claim 1, wherein the control system sends signals to and receives signals from a cloud.

12. A bypass valve for a water system including a water supply pipe and a system control valve, the bypass valve comprising: a bypass valve housing separated from the system control valve and defining a bypass valve inlet and a bypass valve outlet, the bypass valve inlet being connected to the water supply pipe located upstream of the system control valve; a piston disposed within the bypass valve housing and configured to guide flow within the bypass valve; a motor associated with the bypass valve housing and operatively attached to the piston, the motor being further configured to drive the piston only between a service position, a bypass position, and a closed position; and at least one total dissolved solids sensor associated with one of the bypass valve inlet and the bypass valve outlet for monitoring a water condition; A control system receives data from the at least one total dissolved solids sensor, the control system being configured to actuate the motor between the service position, the bypass position, and the closed position in response to the data; and a handle, external to the bypass valve housing and attached to the bypass valve housing via a connection between the handle and the motor, and configured such that the handle is connected to a motor clutch system and then to the piston for manually moving the piston by moving the handle between the service position, the bypass position, and the closed position.

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