Abstract:
Embodiments of the present invention provide systems and methods for disposal of liquid and food into a sink basin. The disclosed system cooperates with and delivers the received waste material to the main waste system on-board the vehicle. This is typically an aircraft waste tank. The system does not require a manual flush, but includes a sensor system that activates drainage of the holding line when the liquid and/or other waste material reaches a certain level therein. The disclosed system combines the functionalities of a common galley sink and a galley waste disposal unit, but occupies only the space envelope of an existing galley sink. The use of an existing galley sink means that no additional space on the countertop is required.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application Ser. No. 62/189,576, filed Jul. 7, 2015, titled “Amalgamated Compact Water and Food Disposal Unit for Managing Waste Products on Board Aircraft,” U.S. Provisional Application Ser. No. 62/192,853, filed Jul. 15, 2015, titled “Amalgamated Compact Water and Food Disposal Unit for Managing Waste Products on Board Aircraft Part II,” and U.S. Provisional Application Ser. No. 62/290,141, filed Feb. 2, 2016, titled “GEMini Description Single Stage,” the entire contents of each of which are hereby incorporated by reference. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    Embodiments of the present disclosure relate generally to systems and methods for draining solid, liquid, and slurry food waste into a galley sink and its delivery to a waste system, rather than to a drain mast. The disclosed embodiments may be used to retrofit existing sink units, such that an entire disposal system or new sink footprint is not required. 
       BACKGROUND 
       [0003]    In passenger transportation environments, it is often necessary to dispose of unwanted fluids and slurries/small solids. Most commercial aircraft and other passenger transportation vehicles are equipped with galley and lavatory sinks, however, these sinks are primarily intended for the disposal of liquid waste only. It is often the case that these sinks terminate at the drain mast of the aircraft (or other vehicle) for exhaustion of the liquids to the atmosphere. This presents multiple challenges. First, when the liquids to be disposed of are dark and potentially staining, such as wine, coffee, and so forth, expelling the liquids to the outside of the aircraft can cause the liquids to “paint” the aircraft sides. This can result in an unsightly streak, staining the aircraft and potentially damaging a “clean aircraft” image and leading to increased maintenance/cleaning cost on the ground. Another problem is that disposing of many liquids to the atmosphere is not environmentally friendly. A further problem is that the lines leading between the sink drain and the drain mast are often small in diameter and if any food particles or slurry material is poured into the sink, it can lead to clogging of the drain line. (Most solids are disposed of in a trash compactor or other waste compartment, but there may be instances where small solids, particles, or granules are combined with liquids to be disposed, and it is desirable to pour unseparated slurry or viscous-like liquids into a sink.) However, traditional sink systems are limited in their ability to dispose of more viscous liquid or particulate waste products. 
         [0004]    Some attempted solutions include providing a vacuum galley waste disposal system. These disposal systems function much like an aircraft vacuum toilet. Not only can they dispose of liquid, but they can also flush solid waste. Current systems, however, require an entire disposal system to be installed. They do not use the existing sink space in the galley. Instead, they occupy valuable countertop space inside the galleys. Galley disposal systems also generally include a lid to help reduce sound generated by the vacuum flush. They are manually activated by the user depressing a flush switch or button located near the sink. They also create a somewhat loud flushing sound, which can be a nuisance to passengers seated near the galley. These systems are also similar to toilets in that they typically have a rinse valve/rinse ring incorporated into the basin and require additional fresh water to operate properly. 
         [0005]    Improvements to liquid and food disposal in passenger transportation vehicles, such as aircraft, are desired. 
       BRIEF SUMMARY 
       [0006]    The present inventors have designed a system that allows for disposal of liquid and food into a sink basin. For example, the liquid may be mixed with food particles, granules, or other small solid materials. If desired, a sink strainer may be provided to prevent large solid pieces from entering the disposal system disclosed, but is not required. The disclosed system cooperates with and delivers the received waste material to the waste system on-board the vehicle. This is typically an aircraft waste tank. The system does not require a manual flush, but includes a sensor system that activates drainage of the holding line when the liquid and/or other waste material reaches a certain level therein. The disclosed system combines the functionalities of a common galley sink and a galley waste disposal unit, but occupies only the space envelope of an existing galley sink. The use of an existing galley sink means that no additional space on the countertop is required. The open sink can be also used for draining of dripping equipment, such as the galley spigot. 
         [0007]    In some examples, there is provided an integrated sink system, comprising: a standard sink basin; a vent/holding line having a generally constant diameter along its length; a conduit between the standard sink basin and the vent/holding line, wherein the conduit joins with the vent/holding line at a joint; at least one level sensor; and a flush valve positioned below the joint. The level sensor can be positioned above the joint. When installed on an aircraft, the vent/holding line, the at least one level sensor, and the flush valve are mounted behind the aircraft galley monument. It is also possible for the components to be mounted within the galley monument or a combination of behind and within. 
         [0008]    In other examples, there is provided a vent/holding line, comprising: a generally constant diameter along a tube length; a connection joint where the vent/holding line cooperates with a conduit from a sink basin; at least one level sensor positioned above the connection joint; and a flush valve positioned below the joint. 
         [0009]    A further example provides an integrated sink system for an aircraft galley, comprising: a standard sink basin; a transition pipe connecting the standard skin basin with a reservoir, the transition pipe routed along a rear wall of the aircraft galley; the reservoir comprising a vent line, a level sensor, and first and second flush valves, the first flush valve positioned at an upper portion of the reservoir, the second flush valve positioned at a lower portion of the reservoir. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  shows a side plan view of one example of an integrated sink/disposal unit. 
           [0011]      FIG. 2A  shows the unit of  FIG. 1  with material in the vent/holding line. 
           [0012]      FIG. 2B  shows an alternate unit having a Y-shaped connection joint. 
           [0013]      FIG. 3  shows a perspective view of one example of a vent/holding line feature. 
           [0014]      FIG. 4  shows the vent/holding line of  FIG. 3  installed on a rear surface of the galley. 
           [0015]      FIG. 5  shows a side view of one example of an integrated sink/disposal unit having a manual bypass valve. 
           [0016]      FIG. 6  shows a side view of one example of an integrated sink./disposal unit h having a bypass to the drain mast. 
           [0017]      FIG. 7  shows a side plan view of an alternate embodiment disposal unit. 
           [0018]      FIG. 7A  shows the unit of  FIG. 7 , with the first flush valve open and the second flush valve closed, in a liquid receiving configuration. 
           [0019]      FIG. 7B  shows the unit of  FIG. 7 , with the first flush valve closed and the second flush valve open, in a flushing configuration. 
           [0020]      FIG. 8  shows a rear view of a galley having a disposal unit tubing installed. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]      FIG. 1  illustrates one embodiment of an integrated sink system  10 . This system  10  amalgamates traditional galley sink functions (receiving liquid) with disposal functions (receiving food and other types of slurry or waste). One advantage of the systems described herein is that they may be used to retrofit an existing galley sink without removing the galley sink itself. These systems do not require a specialized disposal sink, such as those having rinse valves and/or air inlet ports. Instead, a standard sink basin  12  is all that is required. Such a sink basin  12  may be the basin already installed (or scheduled for installation) in a galley. Although the system described herein finds particular use in galley sink configurations, it should be understood that they may find use in other sink configurations, such as lavatory sinks. 
         [0022]    The term “standard sink basin” as used herein means a sink basin that has not been modified to have rinse valves, rinse ports, or air inlet ports. A standard sink basin may be a metallic and/or composite bowl having a drain port  16 . A standard sink basin may have an angled lower surface  13  that guides waste contents poured therein toward the drain port  16 . A standard sink basin may be any basin that is currently installed in the galley, and/or a sink basin that was originally designed only to receive liquid waste. 
         [0023]    Extending from the standard sink basin  12  is a conduit  14 . In some examples, the conduit  14  may be a standard sink drain line. In other examples, the conduit  14  may be a flexible drain line. If made of a flexible material, the conduit may be silicone. The conduit  14  may have any appropriate dimensions, depending upon aircraft specifications. 
         [0024]    In one example, the conduit may be ¾ inches in diameter. In another example, the conduit may be 1 inch in diameter. And further examples, the conduit may be 1.5 inches in diameter. Of course, other diameter options are possible and considered within the scope of this disclosure. 
         [0025]    The conduit  14  is in fluid communication with the sink drain  16  and with a vent/holding line  18 . In use, material leaving the sink basin  12  drains via gravity through the conduit  14  into the vent/holding line  18 .  FIG. 1  illustrates vent/holding line  18 . FIG.  2  illustrates vent/holding line  18  with material “M” therein, after having been poured into the sink basin. In the illustrations shown, the vent/holding line  18  has a constant diameter “D” throughout the length of the line. For example, the diameter D at an upper portion  20  of the line is the same diameter as a mid portion  22  and a lower  24  portion of the line. For example, the constant diameter D may be about ¾ inches up to 3 inches. 
         [0026]    In one specific example, the constant diameter D may be about 2 inches. In other examples, the constant diameter D may be about ¾ inches, 1 inch, 1.5 inches, 2 ¼ inches, 2.5 inches, or 3 inches. Of course, other diameter options are possible and considered within the scope of this disclosure, and depend primarily upon aircraft specifications and requirements. 
         [0027]    The vent/holding line  18  may be made of a titanium material, a composite material, combinations thereof, or any other appropriate material. The vent/holding line  18  may be coated internally with antimicrobial coating or other treatment in order to reduce microbial growth and/or to prevent odors. 
         [0028]    The conduit  14  joins the vent/holding line  18  at joint  26 . Joint  26  is illustrated as being a right angle between the conduit  14  and the line  18  in  FIG. 2A . Joint  26  is illustrated as being a Y-shaped, V-shaped, or as otherwise having an acute angle between the conduit  14  and the line  18  in  FIG. 2B . It should be understood that other joining angles are possible and considered within the scope of this disclosure. 
         [0029]    In use, the vent/holding line  18  functions as a temporary reservoir, but is not shaped differently than a vent line. The vent/holding line  18  features a level sensor  28  positioned above the joint  26 . The level sensor  28  may be an intrusive level sensor, such that it contacts the liquid or other material to be sensed. Alternatively, the level sensor  28  may be a non-intrusive sensor. The level sensor  28  may be an optical sensor. The level sensor  28  may be a conductive sensor. The level sensor  28  may be a capacitive sensor. The level sensor  28  may be a float sensor. The level sensor  28  may be an ultrasonic sensor. The level sensor  28  may be a pressure sensor. Other types of sensors are possible and considered within the scope of this disclosure. The general goal of the sensor  28  is to alert a controller when liquid, slurry, or other material reaches the height of the level sensor  28  in order to trigger a flush. Providing the level sensor  28  positioned above the joint  26  helps prevent the level sensor  28  from being in constant contact with liquid and other waste material M. 
         [0030]    The vent/holding line  18  also features an air silencer  30  or muffler at its upper end. This allows intake of air into the vent line, but also prevents a loud rush of air during the intake process. It is generally desirable for the air silencer  30  to be lightweight and to take up only a small envelope of space, if possible. 
         [0031]    Below the joint  26  and along the vent/holding line  18  is a flush valve  32 . Flush valve  32  may be a standard flush valve or a specialized flush valve, many of which are described in the current assignee&#39;s co-pending applications. Because specific features of the flush valve  32  are not critical to this disclosure, they will not be described further. In some examples, the flush valve  32  is a vacuum toilet flush valve. In some examples, the flush valve  32  uses leading-edge technology that minimizes buildup inside the flush valve. One of ordinary skill in the art would understand features of various types of flush valves  32  that may be used in accordance with this disclosure. 
         [0032]    In use, material poured into the sink basin  12  flows into the conduit  14  and down into the vent/holding line  18 . The flush valve  32  is in a normally closed position. This causes the material M to accumulate in the vent/holding line  18  on the sink side  34  of the line  18 , as shown by  FIG. 2A . The angle of joint  26  and gravity may cause the material M to migrate slightly up the conduit  14  as well, as illustrated by  FIG. 2B . In one example, the distance and diameter of the line  18  between the flush valve  32  and the level sensor  28  allows the line to hold approximately 1.5 liters of liquid and/or other waste material. Once the material M reaches the level sensor  28 , the level sensor  28  indicates to a controller that sufficient material has accumulated in the line  18  such that a flush is necessary. (Although a manual flush valve may be provided, the general intent is that the system function like a standard sink, without requiring any action on the part of the user.) A controller checks to confirm that sufficient vacuum is available. For example, a vacuum sensor  50  may be present on the vacuum side  58  of the vent/holding line  18 . If sufficient vacuum is not present, a vacuum generator may be started. (For example, if the aircraft is not in flight such that a pressure differential is not available, a vacuum generator may be used to create the vacuum for the flush process. Similarly, a vacuum generator may be used if the system is mounted on a land or water-based vehicle, rather than an aircraft.) Otherwise, the pressure differential between cabin pressure and outside pressure may be used to create vacuum. 
         [0033]    Once the controller ensures that sufficient differential pressure/vacuum is available, the controller opens the flush valve  32 , allowing the liquid/material to be transported to the vacuum waste tank  36 . When the flush valve  32  opens, vacuum from the aircraft main waste tank  36  is applied to the vent/holding line  18 . Exposure of the vent/holding line  18  to vacuum pulls the material M out of the vent/holding line  18  and into the waste tank  36 . Once the flush is complete, the flush valve  32  is re-closed. 
         [0034]    The fact that the level sensor  28  is positioned above the joint  26  helps quiet the flush process. The presence of a column of liquid/material helps reduce noise. Additionally, the presence of the venting air silencer  30  means that as the flush process begins, a small amount of air is drawn into the vent/holding line  18  to help reduce noise by preventing air from being drawn in through the sink basin  12 . The time for the entire flush process to take place is barely noticeable to the user. As an example, the flush valve  32  may be open for approximately 1 to 4 seconds, then closed. In other examples, the flush valve  32  may be open for approximately 1 to 2 seconds. In further examples, the flush valve may be open for only a few seconds or less. 
         [0035]      FIG. 3  illustrates the vent/holding line  18  external from the galley and the sink.  FIG. 4  illustrates the vent/holding line  18  positioned along a rear surface  38  of a galley  40 . One benefit of the disclosed system is that the flush valve  32  and other portions of the system need not be positioned directly in the galley itself or directly beneath the sink. Use of the conduit  14  may allow a standard sink basin  12  to be connected to the vent/holding line  18 , when the line  18  is positioned a distance from the sink basin  12 .  FIGS. 3 and 4  illustrate securement features  42  which may be used to secure the vent/holding line  18  to the galley (or other structure) rear surface  38 . 
         [0036]      FIG. 3  illustrates the conduit  14  extending from the line  18  at joint  26 . The conduit  14  may be any appropriate length. For example, it may be 1 to 2 feet. In other examples, its length may be even shorter. However, in other examples, conduit  14  may be many feet long in order to connect a standard sink basin  12  with a remote vent/holding line  18 . The figures also illustrate the presence of the level sensor  28  above the joint  26 . Although level sensor  28  is shown as positioned a few inches (or less than about a foot) above the joint  26 , it should be understood that level sensor  28  may be positioned anywhere along the vent/holding line  18 . It is generally preferred that the level sensor  28  be positioned above joint  26  in order to prevent the level sensor from being in contact with the material to be flushed for an extended period of time. 
         [0037]      FIG. 5  illustrates an embodiment having a manual bypass valve  44 . The manual bypass valve  44  may be a spring-loaded valve, or any other appropriate valve. The manual bypass valve  44  has a first connection point  46  to the line  18  at a position above the flush valve  32 . The manual bypass valve  44  has a second connection point  48  to the line  18  at a position below the flush valve  32 . A vacuum sensor  50  is positioned between the flush valve  32  and the second connection point  48 . In the unlikely event of failure of the flush valve  32  and/or loss of vacuum (as detected by the vacuum sensor  50 ), the manual bypass valve  44  may be activated in order to cause a manual flush. In this instance, material in the vent/holding line  18  is rerouted away from the flush valve  32  through the first connection  46 , through the conduit  47 , and back into the vent/holding line  18  via the second connection  48 . Vacuum suction then pulls the material to the main waste tank. The manual bypass valve  44  may be activated by maintenance personnel or flight crew. It may be keyed or otherwise provided with a safety feature preventing tampering. As shown by  FIG. 4 , an access door  56  may be provided on a rear surface  38  of galley in order to allow access to portions of the system  10  (for either maintenance personnel or crew.) In the example shown, the manual bypass valve  44  and conduit  47  are positioned around an elbow  76  in the line  18 . 
         [0038]    In the event that the flush valve  32  fails in its open position and/or if the bypass valve  44  becomes stuck open, it is possible to provide an emergency shut-off valve  78 . One example is illustrated by  FIG. 5 . As illustrated, the emergency shut-off valve  78  will generally be positioned downstream of the flush valve  32  and past the joint between conduit  47  and the line  18 . The emergency shut-off valve  78  may work via a handle or other structure that can manually block application of vacuum from the waste tank  36  up through vent/holding line  18 . 
         [0039]      FIG. 5  also illustrates a controller  52 , which is in communication with the level sensor  28 , with an override flush switch  54 , with the flush valve  32 , and with the vacuum sensor  50 . (Although shown on the embodiment with the manual bypass valve  44 , it is possible for these features to be present on other embodiments disclosed herein.) If a user pours a great deal of material into the sink and wishes to activate a flush manually, the override flush switch  54  may be activated. Activation of the override flush switch  54  communicates to the controller  52  to open the flush valve  32 , even if the level sensor  28  does not detect material. The override flush switch  54  may also be used in the event that the level sensor  28  fails. The user may simply activate a flush at will. A final “end of flight” flush may also be activated by the override flush switch  54 . This can purge the lines and ensure that any liquid that may be present in the vent/holding line  18  that does not quite reach the height of the level sensor  28  is flushed prior to the aircraft being parked/stored. This can help prevent freezing of water in the line and/or prevent bacterial growth. 
         [0040]    It is also possible to provide a waste tank override  80 , which will direct the material in the vent/holding line  18  to the drain mast. As illustrated by  FIG. 6 , the waste tank override  80  may be positioned on or near the manual bypass valve  44 . For example, it may be positioned along the same line. It is generally positioned before the flush valve  32 , on the sink side of the line  18 . However, in another example, it may be positioned after the flush valve, on the vacuum side of the line  18 . In use, liquids passing through the system can be routed into tubing that directs fluid to the drain mast “DM.” 
         [0041]      FIG. 7  illustrates an alternative embodiment of a sink system  60 . In this example, a standard sink basin  12  may be used. The conduit  14  may be attached as described above. This example, however provides first and second reservoirs  62 ,  64 . The first reservoir  62  incorporates a level sensor  28 . This example is illustrated by  FIG. 7 . In the alternate embodiment illustrated by  FIG. 7A and 7B , the level sensor  28  may be positioned in the second reservoir  64 . In one example, the first reservoir  62  has a widened diameter, as illustrated. In other examples, the first reservoir  62  may function much like the vent/holding line described above, having a constant diameter. The second reservoir  64  is illustrated as having a diameter that is wider than a water line, but this is not required. Below the first reservoir  62  is a first flush valve  66 . System  60  also has an air vent  68 . In one example, air vent  68  extends from an upper portion of the second reservoir  64 . At a lower portion of the second reservoir  64  is a second flush valve  70 . 
         [0042]    In initial use, flush valve  66  may be open and the flush valve  70  may be closed. One example is illustrated by  FIG. 7A . A user pours liquid or other material into the standard sink basin  12 . The liquid or other material travels past the first pipe portion  62 , past the open flush valve  66 , and rests in the second reservoir  64 , on the sink side of the flush valve  70 . Once the liquid reaches the height of the level sensor  28 , a flush may be triggered. Triggering of the flush causes the first flush valve  66  to close and the second flush valve  70  to open. One example of this configuration is illustrated by  FIG. 7B . External air is also pulled into the second reservoir  64  via the vent line  68 . Once all liquid or other material has been evacuated from the second reservoir  64  by application of vacuum through the second flush valve  70 , the second flush valve  70  closes and the first flush valve  66  is allowed to re-open. 
         [0043]    Although  FIG. 7  illustrates the first and second reservoirs  62 ,  64  as being widened portions of the tubing, it is possible for these reservoirs to have a constant diameter as described above. The holding ability of the reservoirs is determined based on a combination of the length and diameter of the tubing, which may be altered depending upon space and other requirements. 
         [0044]      FIG. 8  illustrates one example of sink system  60  positioned along a rear surface  38  of a galley monument  40 . Installation along the rear surface generally means that the system is installed behind the galley monument, and not underneath the sink or cabinet area. In other examples, however, it is possible for the components described herein to be installed within the galley monument. In this example, the transport pipe  72  functions as the first reservoir. The air vent  68  is shown extending from the second reservoir  64 . The second reservoir  64  is shown as having a slightly larger diameter than the first reservoir/transfer pipe  72 , but this is not required. First flush valve  66  and second flush valve  70  are shown positioned with respect to the second reservoir  64 . A connection  74  to the aircraft vacuum system is also illustrated. 
         [0045]    The specific components used of any of the disclosed embodiments may be determined based on aircraft specifications. For example, the vacuum sensor used may be a current robust differential pressure switch used on other aircraft applications. The level sensing technology may be assured to provide reliable sensing under all possible conditions (including build-up on the reservoir walls). The controller may be a unit that controls the opening and closing of the flush valve based upon signals from the level sensor and vacuum switch. The vent/holding line may be manufactured from a lightweight high impact material. Non-limiting examples include composites and/or titanium. The conduit drain line  14  from the galley sink may be helical wound silicone hoses connected to the system with stainless steel hose clamps. 
         [0046]    Changes and modifications, additions and deletions may be made to the structures and methods recited above and shown in the drawings without departing from the scope or spirit of the disclosure or the following claims.