Abstract:
A valve in a fluid treatment system adapted for controlling the flow of fluid between a source and a treatment media disposed in a treatment chamber. The valve includes a housing having a fluid passageway between an inlet and an outlet; a containment chamber; and a sealing member reciprocal between a first position in which the sealing member is retained in the containment chamber out of the flow of fluid in the passageway and a second position that seals the outlet. The containment chamber also includes a drain opening, which can be a venturi, for emptying the containment chamber of fluid.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to water treatment tanks of the type used to retain resin beads in a water softener system. More particularly, the present invention relates to an improved valve for controlling the flow of clean water and brine solution to and from a brine tank for the regeneration of resin beads. 
     Brine valves are an important part of almost all water softener systems. When used with a softener valve/controller and a brine tank, a brine valve controls the flow of brine solution from a brine tank when regenerating softener resin. It controls the flow of incoming fresh water into the tank to create fresh brine. If a brine valve does not shut off securely, flooding and property damage will result. 
     Reports have shown that brine valves are vulnerable to high velocity pressure spikes or surges. These pressure surges can cause the valve to shut off prematurely or “pre-seat” during refill, resulting in incomplete filling of the brine tank and resulting in subsequent incomplete resin regeneration. Most brine valves include a flow restrictor that absorbs most pressure spikes. In addition, most brine draw shut-off valves are check balls. These check ball valves are very sensitive to out-of-tolerance dimensions and brine tank contaminants, which makes it difficult to obtain a good seal. 
     Additionally, the conventional check ball design creates an obstacle to the flow of fluid in an out of the brine valve. This reduces the efficiency of the valves by decreasing the flow rate of fluid in and out of the valves and the subsequent time needed to create and draw brine. 
     Thus, a main object of the present invention is to provide an improved brine valve that makes a reliable watertight seal within the brine tank, replacing the unreliable ball check design. 
     Another object of the present invention is to provide an improved valve plug that prevents “pre-seating” and allows for the complete filling of the brine tank and subsequent complete resin regeneration. 
     Still another object of the present invention is to provide an improved valve check design that keeps the valve sealing member out of the flow of fluid entering and exiting the valve. 
     BRIEF SUMMARY OF THE INVENTION 
     The above-listed objects are met or exceeded by the present valve for a fluid treatment system, featuring a refill seat which is held out of the flow of fluid in a containment chamber by float weights as water enters the brine tank, thus preventing the “pre-seating” found in the prior brine valves. In addition, the plug is held securely in place by a float when the fluid level in the brine tank reaches the appropriate level, thus overcoming the unreliability of previous brine valves using ball checks to stop fluid flow. 
     More specifically, the invention provides a valve for use in a fluid treatment system for controlling the flow of fluid between a source and a treatment media disposed in a treatment chamber. The valve has a housing with an inlet, an outlet, and a passageway in communication between the inlet and the outlet. Further, the present invention also includes a refill seat configured to reciprocate in the housing between a first position and a second position, with the housing having a containment chamber for retaining the refill seat in the first position out of a flow of fluid in the passageway. 
     In another embodiment, the invention provides a valve for use in a fluid treatment system for controlling the flow of fluid between a source and a treatment media disposed in a treatment chamber. The valve has a housing with an inlet, an outlet and a passageway in communication between the inlet and the outlet. 
     Furthermore, a feature of the present invention also includes a refill seat configured to reciprocate within the housing between a first position and a second position and includes a containment chamber for retaining the refill seat in the first position out of the flow of fluid. The containment chamber also incorporates a Venturi in the floor of the containment chamber in communication with the passageway to allow for drainage of the containment chamber and the proper re-seating of the refill seat in the first position 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 is a fragmentary vertical section of the present valve at the termination of the brine tank refill; 
     FIG. 2 is a schematic vertical section of a brine tank suitable for use with the present valve at the termination of the brine tank refill; 
     FIG. 3 is a schematic vertical section of a brine tank suitable for use with the present valve during eduction of brine from the brine tank; 
     FIG. 4 is a fragmentary vertical section of the present valve shown during eduction of brine from the brine tank through the present valve; 
     FIG. 5 is schematic vertical section of a brine tank suitable for use with the present valve at the termination of eduction of brine from the brine tank; and 
     FIG. 6 is a fragmentary vertical section of the present valve at the termination of education of brine from the brine tank. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIG. 1, a valve for a water treatment system is generally designated  10  and includes a housing  12  having an upper portion  14 . The housing  12  is preferably cylindrical, although other configurations are also contemplated. 
     The housing  10  defines a passageway  16 , having an inlet  18  preferably parallel in orientation to an outlet  20  in the upper portion  14  of the housing, although other orientations are also contemplated. The inlet  18  is in fluid communication with an inlet pipe  19 . In the preferred embodiment the inlet  18  is threadably and sealingly engaged to the inlet pipe  19 , although other types of engagement and seals are also contemplated, including chemical adhesives and ultrasonic welding. 
     The passageway  16  has a first portion  22  in fluid communication with the inlet  18  and being perpendicularly oriented to a second portion  24  in fluid communication with the outlet  20 . In the preferred embodiment, the second portion  24  of the passageway  16  is cylindrical in structure when viewed in plan to reduce the size and use of materials in construction of the valve  10 , and yet retain an adequate volume for fluid communication between the outlet  20  and the inlet  18 . However, other shapes and configurations are also contemplated depending on the application. 
     The second portion  24  of the passageway  16  is in fluid communication with the outlet  20  via a passage chamber  26  situated between the outlet and a containment chamber  28 , the latter being defined by a cylindrical wall  30  and a floor  32 . While in the preferred embodiment the wall  30  of the containment chamber is cylindrical in shape, other shapes and configurations are also contemplated depending on the application. In the floor  32  of the containment chamber  28  is a drain opening  34  in fluid communication with the first portion  22  of the passageway  16  and having a relatively smaller diameter than the passageway. In the preferred embodiment the drain  34  forms a Venturi. 
     The containment chamber  28  is constructed and arranged to accommodate a sealing member  36  in a first position out of the flow of fluid passing through the passage chamber  26 . This allows for an increased flow rate of fluid through the outlet  20  by removing the obstruction of the sealing member  36  during a portion of the operation cycle of the valve. In the preferred embodiment, the sealing member  36  is a refill seat  38 , and is generally dome-shaped with a flat base  40 . 
     At least one seal  42  is disposed about a circumference of the sealing member  36  so that when the sealing member is in a second position adjacent the outlet  20 , it forms a seal with the outlet in the upper portion  14  of the housing  12 . While in the preferred embodiment, the seal  42  on the sealing member  36  is a lip seal or wiping-type seal, other seals as known in the art are also contemplated for establishing a seal of the outlet  20  including, but not limited to O-rings. In addition, the seal  42  on the sealing member  36  may be replaced by placing a seal about the circumference of the outlet  20  to form a seal with the sealing member when it is in the second position. 
     A chamber  44  is defined by the base  40  of the sealing member  36  that allows for the complete draining of the containment chamber  28  by the Venturi when the sealing member is in the first position. The Venturi also holds the sealing member  36  in the first position by a vacuum created by low pressure when fluid exits the valve  10 . 
     Referring now to FIGS. 1 and 2, the sealing member  36  is connected by a rod  46  to a refill float  48  (best seen in FIG. 2) that allows the sealing member to reciprocate between the first position (best seen in FIG. 4) and the second position (best seen in FIG. 1) with variations in the level of fluid  49  in a treatment tank  50 . 
     The refill float  48  also acts as a refill weight and holds the sealing member  36  in the first position to prevent “pre-seating” of the sealing member until the fluid level  49  in the treatment tank  50  reaches the refill float. As is known in the art, the volume of brine produced can be varied by the placement of the refill float  48  along the length of the rod  46 . 
     In the preferred embodiment, the treatment tank  50  is a brine tank configured to accommodate a supply of salt  52  upon a porous platform  54 . The present brine valve  10  is located within a generally vertically oriented, tubular brine well  56 . It is preferred that the brine well  56  is porous to water but not to salt particles to protect the valve  10  and related components. 
     Referring now to FIGS. 5 and 6, attached and slideable in relation to the rod  46  is an eductor float  58  having at least one seal  60  preferably attached to a base  62 . Attached to the rod  46  is a generally horizontally projecting stop  64  that prevents the eductor float  58  from rising beyond a designated level along the rod. In the preferred embodiment, the stop  64  is secured to the inlet pipe  19 , and prevents the rod  46  from horizontal movement. Further support to the rod  46  is preferably provided by a support bracket  65 . While in the preferred embodiment one additional support bracket  65  is present, additional support brackets are also contemplated depending upon the application. 
     Preferably provided in the shape of a donut which depends from the base  62 , the seal  60  is configured to create a secure seal between the upper portion  14  of the housing  12 , specifically the outlet  20 , and the treatment tank  50  at the end of brine draw. In the preferred embodiment, the eductor float  58  is generally cylindrical in shape, although other shapes are also contemplated. An eductor seat  66  is attached to the rod  46  and is configured to seal a space  68  between the rod and an inner bore (not shown) of the eductor float  58  when the eductor float has created a seal with the housing  12  at the end of brine draw. In the preferred embodiment, the eductor seat  66  has a conical lower portion  70  in shape to allow for a greater surface area to grip the rod  46 , to cut material costs in construction of the valve  10  and to reduce the volume of space the eductor seat occupies when fluid is entering or exiting the outlet  20 . While in the preferred embodiment, the eductor seat  66  is generally diamoned-shaped in cross section, other shapes are also contemplated depending on the application. 
     Referring now to FIGS. 1 and 2, in operation, the treatment tank  50  has been filled with fluid at a level  49  through the pipe  19  and the valve  10 . When the level of fluid  49  (typically water or a water/salt solution) in the treatment tank  50  reaches the appropriate level, the buoyant force of the refill float  48  overcomes the downward force of the weights and carries the refill seat  38  through the passage chamber  26  to a second position, in which the refill seat creates a seal of the outlet  20  at the upper portion  14  of the housing  12 , thus preventing the further flow of fluid into the treatment tank  50 . The eductor float  58  is held by the stop  64 , and is prevented from colliding with the refill float  48 . Brine is being made in the treatment tank  50  and the system is ready to regenerate the softener resin (not shown). 
     Referring now to FIGS. 3 and 4, when the control valve (not shown) is advanced to brine draw (eduction), low pressure develops in the inlet pipe  19 . A resulting pressure differential causes the refill seat  38  to fall away from the upper portion  14  of the housing  12  and brine is allowed to flow through the outlet  20 , the Venturi  34  and out through the passageway  16  and the inlet  18 . In this manner, the Venturi  34  drains the containment chamber  28 . The base  40  of the refill seat  38  is prevented from sealing the Venturi  34  by the upward buoyant force of the refill float  48  until the brine level drops to a low level above the inlet  18 . The refill seat  38  is held in a first position in the containment chamber  28  by the weight of the refill float  48  until eduction is complete. In this manner, the flow through the passage chamber  26  is not obstructed by the refill seat  38 . 
     Referring now to FIGS. 5 and 6, as the brine level within the treatment tank  50  falls, the eductor float  58  is carried down with the level of the fluid  49  until the seal  60  on the eductor float base  62  creates a seal with the outlet  20  in the upper portion  14  of the housing  12 . A seal is created by the eductor seat  66  in the space  68  between the eductor float and the rod  46 . The seal created by the eductor float  58  and the eductor seat  66 , and maintained by the low pressure within the inlet pipe  19 , prevents air from entering the inlet pipe at the end of the brine draw. 
     To refill the tank  50 , fresh water is introduced into the inlet pipe  19 , overcomes the force of the seal created by the eductor float  58 , and achieves the level  49  shown in FIG.  2 . At that point, the refill float  48  pulls the rod  46  upward to the second position of the refill seat  38  (best seen in FIG.  1 ). 
     Thus, it will be seen that the present valve provides a structure that facilitates obstruction-free flow through the interior fluid flow passageway. Accordingly, more efficient delivery of brine is obtained, without being subject to pressure spikes. Also, the Venturi  34  further ensures that the refill seat  38  will not obstruct flow during brine draw. 
     While particular embodiments of the valve for a fluid treatment system have been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.