Abstract:
Embodiments of the invention provide a diverter valve and a method of providing debris resistance in a diverter valve. The diverter valve can include a valve housing defining a valve chamber and at least an inlet port and an outlet port. The diverter valve can include a flow diverter extending into the valve chamber and pivotally coupled relative to the valve housing about a pivot axis defined through the valve chamber. The flow diverter can include a main portion extending into the valve chamber and a plunger portion disposed outside of the valve chamber. The main portion can have a diverting wall radially spaced apart from the pivot axis. The flow diverter can include a rib extending radially inwardly from the diverting wall toward the pivot axis. The diverter valve can also include at least one wing member positioned within the inlet port and secured relative to the valve housing.

Description:
BACKGROUND 
     Diverter valves are typically multi-port valves which close off or limit fluid flow from an inlet port to one or more outlet ports while allowing fluid flow to one or more other outlet ports. For example, a diverter valve can be used in a pool and spa system, where the diverter valve allows fluid flow into the spa and then can be switched to allow fluid flow into the pool. 
     A diverter valve operates to direct fluid flow between ports. However, typical operation of a diverter valve can result in turbulence and/or noise in the fluid flow, which can contribute to inefficient and/or undesirable performance of the diverter valve in the pool and spa system. Debris, such as sand, can accumulate in a diverter valve during normal operation. The accumulation of debris can inhibit the ability of the valve to rotate and, thus, can also contribute to inefficient and/or undesirable performance of the diverter valve in the pool and spa system. 
     SUMMARY 
     In some embodiments, the invention provides a diverter valve including a valve housing defining a valve chamber and a plurality of ports in fluid communication with the valve chamber. The plurality of ports can include at least an inlet port and an outlet port. The diverter valve can further include a flow diverter extending into the valve chamber. The flow diverter can be pivotally coupled relative to the valve housing about a pivot axis defined through the valve chamber. The flow diverter can include a main portion extending into the valve chamber and a plunger portion disposed outside of the valve chamber. The main portion can have a diverting wall radially spaced apart from the pivot axis. The diverter valve can also include a cap component disposed outside of the valve housing and coupled to the plunger portion of the flow diverter. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a diverter valve according to one embodiment of the invention; 
         FIG. 2  is a partially-sectioned perspective view of the diverter valve of  FIG. 1 ; 
         FIG. 3  is an exploded perspective view of the diverter valve of  FIG. 1 ; 
         FIG. 4  is a sectioned perspective view of a valve housing according to one embodiment of the invention; 
         FIG. 5  is a front view of a flow diverter according to one embodiment of the invention; 
         FIG. 6  is a perspective view of the flow diverter of  FIG. 5 ; 
         FIG. 7  is a perspective view of a diverter valve according to another embodiment of the invention; 
         FIG. 8  is a partially-sectioned perspective view of the diverter valve of  FIG. 7 ; and 
         FIG. 9  is an exploded perspective view of the diverter valve of  FIG. 7 . 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
       FIGS. 1-3  illustrate a diverter valve  20  according to one embodiment of the invention. The diverter valve  20  includes a valve housing  22 . The valve housing  22  defines a valve chamber  24 , an inlet port  26 , a first outlet port  28 , and a second outlet port  30 . The diverter valve  20  includes a flow diverter  40  and a cap  50 . The flow diverter  40  facilitates fluid communication between the inlet port  26  and one or more of a first outlet port  28  and a second outlet port  30 . A cap  50  is operable to manipulate fluid flow through the flow diverter  40 . 
     In some embodiments, the diverter valve  20  is configured for use with a pool and spa system. A user can manipulate the cap  50  in order to position the flow diverter  40  and, thus, control the flow of water from the inlet port  26  to the pool and another component (such as a spa or a heater) with the pool and the other component being in communication with the first outlet port  28  and the second outlet port  30 , respectively. 
       FIG. 4  illustrates that the valve housing  22  includes a main section  60  defining a valve chamber  24 . An inlet section  62  extends from the main section  60  and defines the inlet port  26 . A first outlet section  64  extends from the main section  60  and defines the first outlet port  28 , and a second outlet section  66  extends from the main section  60  and defines the second outlet port  30 . A support section  70  also extends from the main section  60 . An inside surface  72  extends throughout the valve housing  22  into each of the main section  60 , the inlet section  62 , the first outlet section  64 , the second outlet section  66 , and the support section  70 . 
     In some embodiments, the inlet section  62 , the first outlet section  64 , the second outlet sections  66 , and the support section  70  of the valve housing  22  each have a generally cylindrical shape. The term “axial” as used herein refers to a direction along the length of the generally cylindrical shape, and the term “radial” as used herein refers to a direction along a radius of the generally cylindrical shape. 
     The valve housing  22  is configured so that the inlet section  62  and the support section  70  oppose each other about the main section  60 . The inlet section  62  and the support section  70  are aligned and centered along a common axial direction. The first outlet section  64  and the second outlet section  66  are also configured to oppose each other about the main section  60  and are also aligned and centered along a common axial direction so as to be oriented substantially perpendicular to the inlet section  62  and the support section  70 . 
     As shown in  FIG. 4 , the valve housing  22  includes a diverter mounting feature  80 . The diverter mounting feature  80  is disposed within the inlet port  26  proximate the main section  60 , including a perimeter member  82  extending radially inwardly from the inside surface  72  around the inlet section  62 . A transverse member  84  extends between opposing portions of the perimeter member  82  along a radial direction of the inlet section  62 . A stop member  86  protrudes in an axial direction from the perimeter member  82  along the inside surface  72 , and an aperture  88  is disposed in a generally central portion of the transverse member  84 . The diverter mounting feature  80  engages and supports the flow diverter  40  when the diverter valve  20  is assembled. 
     As shown in  FIG. 4 , the valve housing  22  also includes a first wing member  90  and a second wing member  92 . The first wing member  90  and the second wing member  92  are secured relative to the valve housing  22  at the transverse member  84  of the diverter mounting feature  80 . The first wing member  90  and the second wing member  92  are generally elongate, rectangular, and thin in shape and are oriented to extend in an axial direction along the inlet section  62  away from the main section  60 . The first wing member  90  and the second wing member  92  are configured to have opposing positions along a radial direction of the inlet section  62 . The first wing member  90  and the second wing member  92  each define a length along the axial direction of the inlet section  62 , a width along the radial direction of the inlet section  62 , and a thickness in a direction perpendicular to both the axial and radial directions of the inlet section  62 . The lengths, widths, and thicknesses of the first wing member  90  and the second wing member  92  can be substantially similar or the same. During operation of the diverter valve  20 , the first wing member  90  and the second wing member  92  inhibit turbulence and noise from fluid flow through the inlet port  26  by encouraging a relatively laminar flow. 
     As shown in  FIGS. 5 and 6 , the flow diverter  40  includes a main portion  100  and a plunger portion  102 , each being generally cylindrically shaped portions. The main portion  100  includes an annular first end  110  proximate the plunger portion  102  and an annular second end  112  opposite the first end  110 . A sidewall  114  and an aperture  116  extend between the first end  110  and the second ends  112 . The main portion  100  includes an inclined wall  118  extending between the sidewall  114  and the first end  110 . 
     As shown in  FIG. 2 , when the diverter valve  20  is assembled, the main portion  100  is disposed within the valve chamber  24  and the plunger portion  102  is disposed within the support section  70 . During the operation of the diverter valve  20 , the flow diverter  40  facilitates fluid communication between the inlet port  26  and the first outlet port  28  and/or the second outlet port  30 . For example, the flow diverter  40  can be positioned with the sidewall  114  inhibiting fluid communication between the second outlet port  30  and the valve chamber  24 , while the inclined wall  118  is oriented toward the first outlet port  28  to facilitate fluid flow therethrough. 
     As shown in  FIGS. 5 and 6 , the flow diverter  40  includes a rib  130 . The rib  130  is a relatively thin, elongated member which extends radially inwardly from the sidewall  114  and the inclined wall  118 . The rib  130  is located at a central portion of the sidewall  114  and the inclined wall  118 . When the flow diverter  40  rotates, the rib  130  maintains its orientation relative to the sidewall  114  and, thus, maintains its orientation extending along the fluid flow directed by the flow diverter  40 . Accordingly, the rib  130  inhibits turbulence and noise as fluid flows through the diverter valve  20 . 
     As shown in  FIG. 6 , the flow diverter  40  includes a transverse member  132  proximate the second end  112 . The transverse member  132  extends between opposing portions of the second end  112  along a radial direction of the main portion  100 . In particular, the transverse member  132  is oriented to extend along and support the rib  130 . The transverse member  132  also supports an alignment pin  134 , as shown in  FIGS. 5 and 6 . The alignment pin  134  extends from the transverse member  132  in an axial direction away from the main portion  100  and is centered on the transverse member  132  along the radial direction. When the diverter valve  20  is assembled, the alignment pin  134  extends into the aperture  88  of the diverter mounting feature  80  and engages the transverse member  84 . Through this engagement, the flow diverter  40  maintains a desired alignment relative to the valve housing  22  while rotating. 
     As also shown in  FIGS. 5 and 6 , an axially outwardly facing surface  136  of the second end  112  has a two-tiered configuration including a recessed portion  138 , an outward portion  140 , and intermediate portions  142 ,  144  extending therebetween. When the diverter valve  20  is assembled, the outward portion  140  interfaces with the perimeter member  82 , and the intermediate portions  142 ,  144  engage the stop member  86  to limit the rotational range of the flow diverter  40  relative to the valve housing  22 . Accordingly, the recessed portion  138  and the stop member  86  are complementarily sized and configured. 
     As further shown in  FIGS. 5 and 6 , the main portion  100  of the flow diverter  40  can further define a debris pocket  150 . The debris pocket  150  is defined between the sidewall  114  and the inclined wall  118  opposite the rib  130 . During operation of the diverter valve  20 , the debris pocket  150  collects debris such as sand that accumulates in the diverter valve  20 . The debris pocket  150  contributes to the debris resistance of the diverter valve  20 , which provides for a decrease in friction and ease of rotation of valve components. 
     The flow diverter  40  also includes a groove  152  on the radially outer surface of the main portion  100  proximate the first end  110 . The groove  152  is configured to receive an o-ring  154 , as shown in  FIGS. 2 and 3 . The o-ring  154  sealingly engages the main portion  100  at the groove  152  and the inside surface  72  at the support section  70 . The o-ring  154  provides a seal between the valve chamber  24  and the debris pocket  150 . 
     As shown in  FIGS. 5 and 6 , the plunger portion  102  of the flow diverter  40  includes a cylindrical portion  160  and a coupling end  162 . The cylindrical portion  160  is secured to the main body  100  at the outer surface  151  of the inclined wall  118 . As shown in  FIG. 6 , an aperture  164  extends axially into the plunger portion  102  at the coupling end  162 . When the diverter valve  20  is assembled, the cap  50  engages the flow diverter  40  at the coupling end  162 . 
     As shown in  FIGS. 1-3 , the diverter valve  20  includes a plurality of components coupled outside of the valve housing  22  proximate the cap  50 . A housing connector  180  is threadingly engaged to a first threaded outer portion  181  of the support section  70 . An outer intake  182  is disposed on the housing connector  180 , a seal  184  is disposed on the outer intake  182 , and an inner intake  186  is disposed on the seal  184 . An intake diverter  188  extends over the inner intake  186  and the plunger portion  102 . Both the inner intake  186  and the intake diverter  188  threadingly engage a second threaded outer portion  189  of the support section  70 . An o-ring  190  is disposed between the intake diverter  188  and the plunger portion  102 , and an o-ring  192  is disposed between the intake diverter  188  and the support section  70 . The cap  50  is disposed over the intake diverter  188  and engaged with the flow diverter  40  at the coupling end  162  of the plunger portion  102 . 
     When assembled, the cap  50  engages the flow diverter  40  so that manipulation of the cap  50  positions the flow diverter  40  within the valve housing  22 . The positioning of the flow diverter  40  determines the fluid flow between the inlet port  26  and the first outlet port  28  and the second outlet port  30 . 
       FIGS. 7-9  illustrate a diverter valve  20 ′ according to another embodiment of the invention. Many of the components of diverter valve  20 ′ are substantially similar or the same as components described herein with respect to diverter valve  20 . Accordingly, the descriptions of such components will not be repeated herein. Such components are represented herein with similar reference numerals (e.g.  15  and  15 ′). 
     The diverter valve  20 ′ includes a housing extension  210 ′ between the support section  70 ′ and the cap  50 ′. A plunger extension  212 ′ is disposed within the housing extension  210 ′ and extends between the plunger portion  102 ′ and the cap  50 ′. A pin  214 ′ couples the plunger extension  212 ′ and the plunger portion  102 ′, and an o-ring  216 ′ is disposed between the support section  70 ′ and the housing extension  210 ′. The cap  50 ′ is disposed away from the flow diverter  40 ′ and the valve housing  22 ′ while maintaining an operable connection to the flow diverter  40 ′. 
     Various features and advantages of the invention are set forth in the following claims.