Abstract:
Disclosed herein are water control devices having a normally closed valve preventing water flow upon breakage of an outer mechanism having a float weight, that float weight overcoming the resistance of the valve under conditions of non-contact with water, that submerged float weight reducing in apparent weight as seen by the valve actuator. A float weight may be made from a material with about the same density as water, or with heavier materials with voids or pockets having an overall density of water or a substantial density greater than that of air. A control mechanism may be provided that moves independently of the valve, providing for decoupling of the float weight from the valve if the float weight is forced out of position. Detailed information on various example embodiments of the inventions are provided in the Detailed Description below, and the inventions are defined by the appended claims.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 61/027,035 filed Feb. 7, 2008, which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    The claimed systems and methods relate generally to automatic water level control valves, and more particularly to those valves that include a normally-closed valve and a float weight that diminishes its apparent weight when submersed in water. 
         [0003]    Depicted in  FIG. 1A  are the elements of an ordinary float valve used to control the level of water inside a tank, such as a toilet tank. That valve includes a stopper  7  riding in a mounting  6  between an open and closed position, the open position shown in  FIG. 1A . In the open position, a gap is maintained between stopper  7  and inlet pipe  8  through which gap water is allowed to flow as indicated by the arrows. Inlet pipe  8  contains a continuous pressurized stream of water. 
         [0004]    The end of stopper  7  extends beyond the confines of mounting  6  whereby contact may be made to adjustment screw  1 , which screw is mounted in a control arm  2  mounted to pivot on pin  3 . A float  5  is mounted to a lever arm  4  which is in turn connected to control arm  2 . In the state shown in  FIG. 1A  the level of water in the surrounding tank is sufficiently low that float  5  does not make contact. In that state, neither adjustment screw  1  nor control arm  2  makes contact with stopper  6 . 
         [0005]    As water continues to flow through inlet pipe  8  and into the surrounding tank, the level of water rises also raising float  5 . Eventually, assuming that no water escapes the tank, the level of water will rise to the steady-state shown in  FIG. 1B . In that state, float  5  applies an upward pressure on control arm  2  through lever arm  4 , causing a downward force to be exerted on stopper six against the pressure of water in inlet pipe  8 . Because there is no gap between stopper  7  and inlet pipe  8 , in theory no further water flows provided that there is an effective seal. 
         [0006]    The ordinary float valve control systems are well adapted for mild and temperate environments such as might be experienced in a house. However, when these systems are brought into outdoor or livestock environments a number of problems may be experienced. In one of these problems, a tank may be exposed to rain or other precipitation, thereby causing the water level to exceed the steady-state level. An ordinary float valve system may be designed to accommodate that, particularly by designing a control arm  2  to withstand the force imposed by the buoyancy of the float valve  5  even though it may become submerged. Now referring to  FIG. 1C , if water  9  is subjected to freezing temperatures, it may be that a layer of ice  10  will form on the surface of water  9 . If the ice  10  is sufficiently thick, it may prevent float  5  from breaking through. If the level of water  9  is raised, through precipitation for example, the level of ice  10  will also be raised and will cause float  5  to exert pressure on control arm  2 . As control arm has reached the limit of its movement due to contact between screw  1 , stopper  7  and inlet pipe  8 , it will become stressed and will eventually break. If control arm  2  breaks, the pressure on stopper  7  is released and water will flow uncontrolled, potentially leading to an overflow of the surrounding tank and further damage. 
       BRIEF SUMMARY 
       [0007]    Disclosed herein are water control devices having a normally closed valve preventing water flow upon breakage of an outer mechanism having a float weight, that float weight overcoming the resistance of the valve under conditions of non-contact with water, that submerged float weight reducing in apparent weight as seen by the valve actuator. A float weight may be made from a material with about the same density as water, or with heavier materials with voids or pockets having an overall density of water or a substantial density greater than that of air. A control mechanism may be provided that moves independently of the valve, providing for decoupling of the float weight from the valve if the float weight is forced out of position. Detailed information on various example embodiments of the inventions are provided in the Detailed Description below, and the inventions are defined by the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1A  shows a conventional float valve in a filling state. 
           [0009]      FIG. 1B  shows a conventional float valve in a full state. 
           [0010]      FIG. 1C  shows a conventional float valve in a stressed or broken state. 
           [0011]      FIG. 2A  presents a cross-sectional view of a first exemplary float-weight water control valve. 
           [0012]      FIG. 2B  depicts the first exemplary float-weight water control valve in perspective. 
           [0013]      FIG. 3A  shows in cross-section an exemplary normally-closed water valve in a closed state. 
           [0014]      FIG. 3B  shows in cross-section an exemplary normally-closed water valve in an open state. 
           [0015]      FIG. 4  depicts a second exemplary normally-closed valve in its open and closed states. 
           [0016]      FIG. 5A  shows in perspective a second exemplary and compact water level controller having a lower-mounted float. 
           [0017]      FIG. 5B  depicts the second exemplary water level controller having a lower-mounted float. 
           [0018]      FIG. 5C  shows from the side a third exemplary water level controller having a lower-mounted float. 
           [0019]      FIG. 5D  shows in cross-section the third exemplary water level controller having a lower-mounted float. 
           [0020]      FIG. 6A  shows in perspective a fourth exemplary water level controller having a laterally-mounted float. 
           [0021]      FIG. 6B  shows in cross-section the fourth exemplary water level controller having a laterally-mounted float. 
           [0022]      FIG. 6C  shows in close cross-section the valve portion of the fourth exemplary water level controller. 
           [0023]      FIG. 7  shows in cross-section a fifth exemplary water level controller having a post-chamber, transfer rod and exit tubes. 
           [0024]      FIG. 8  depicts a sixth exemplary water level controller with a lower-mounted float weight suspended from a flexible chain link. 
           [0025]      FIG. 9A  shows in cross-section a seventh exemplary water level controller having a post-chamber, a transfer rod and exit tubes. 
           [0026]      FIG. 9B  shows in perspective and cross-section the seventh exemplary water level controller. 
           [0027]      FIG. 9C  shows in perspective the seventh exemplary water level controller from the side. 
           [0028]      FIG. 9D  shows in perspective the seventh exemplary water level controller in an offset front view. 
           [0029]      FIG. 10  shows an exemplary arrangement of a horizontally mounted valve linked through two arms. 
           [0030]      FIG. 11  shows an exemplary arrangement of a vertically mounted valve linked through a pivoted arm. 
           [0031]      FIG. 12  shows an exemplary arrangement of a horizontally mounted valve linked through a pivoted arm. 
           [0032]      FIG. 13A  shows in cross-section an exemplary one-piece valve body in an open state. 
           [0033]      FIG. 13B  shows in cross-section the exemplary one-piece valve body in a closed state. 
           [0034]      FIG. 14  depicts a water level controller having a ball-shaped float weight with a flexible linkage. 
           [0035]      FIG. 15  depicts a water level controller having a ball-shaped float weight with a flexible linkage and an upwardly-directed arm. 
           [0036]      FIG. 16  depicts a water level controller having downwardly-directed a fixed float weight. 
           [0037]      FIG. 17  depicts a water level controller having upwardly-directed a fixed float weight. 
       
    
    
       [0038]    Reference will now be made in detail to particular implementations of the various inventions described herein in their various aspects, examples of which are illustrated in the accompanying drawings and in the detailed description below. 
       DETAILED DESCRIPTION 
       [0039]    An exemplary water level control system is displayed in  FIG. 2B  and in cross-section in  FIG. 2A . The system includes a valve body  20 , an inlet pipe  23  and an arm  21  to which is attached a buoyant weight  22 . Valve body  20 , in this example, is formed of machined cast iron having a first and second bore. In the first bore is mounted a valve  24  and a plug  30  sealing the opposite end of the first bore. Valve  24  and plug  30  are formed of plastic in the example, and mount into the first bore by way of threads formed in each of body  20 , valve  24  and plug  30 . In this and other examples a valve body, a valve or a plug may be formed of other materials such as brass, aluminum, plastics, composites, etc., and may be coupled together through many methods such as welding, glues, etc., so long as these materials and coupling methods withstand the internal water pressure provided. A second bore is formed perpendicular to the first allowing for the attachment of inlet pipe  23 , forming a channel between the inlet pipe  23  and the valve  24  through which water may flow where valve  24  is in an open state. 
         [0040]    Now referring to  FIG. 3A , the components of exemplary valve  24  are more easily seen. A valve housing body  28  includes a bore into which is inserted an articulating portion  26 . A return spring  27  provides a return force for articulating portion  26  to the position shown in  FIG. 3A . A rubber stop  29  seals against the end of housing  28  thereby providing a blockage against fluids through its inner passages. A contact surface  25  provides a surface upon which a pressure may be applied against return spring  27 , whereupon under such force articulating portion  26  moves inwardly. In doing so, stop  29  is moved away from housing  28  providing a gap in allowing for the passage of fluids through the inner bore as shown in  FIG. 3B . The valve shown in  FIGS. 3A and 3B  is merely one exemplary valve that can be used; other valves having an actuator and configured to be normally-closed may provide usable substitutes. In the example and as shown in  FIG. 4 , housing  24  may be formed of molded plastic and actuator  26  is formed of machined brass, however other materials can be used selected for cost, ease of manufacturing, resistance to liquids controlled, service life, and other factors as desired. 
         [0041]    Now returning to  FIGS. 2A and 2B , in the exemplary float valve arm  21  angularly moves about a pivot  30  whereby a screw  31 , mounted to arm  21 , may be brought into contact with surface  25 . At the far end of arm  21  is mounted a buoyant weight  22 , in this example through a bolt-and-thread arrangement. A downward force of weight  22  produces a force applied by screw  31  to contact surface  25 , thus causing spring  27  to be compressed and valve  24  to open. As shown in  FIG. 2A , weight  22  may be partially submerged in water  9  or another liquid. This produces a buoyancy of weight  22 , reducing the force applied by screw  31  on surface  25  allowing valve  24  to return to its normally closed position as shown. The effective fill level depends on the buoyancy of weight  22  and the force applied by spring  27 ; less buoyant materials in weight  22  and stronger springs  27  will cause the fill water level to rise. 
         [0042]    In the example arm  21  and screw  31  are formed of steel, and weight  22  is formed of a high-density polyethylene (HDPE) with a specific gravity of about 0.955. However, other materials and configurations may be used. For example, arm  21  may be replaced by a rod or other extensional member, or by another structure whereby a force may be applied to a valve under conditions of float buoyancy. In another example, an arm is not attached by a pivot, but rather a flexible hinge attached to an arm. In yet another example, the arm itself is flexible and forms an effective hinge. Likewise other substitutions may be made in keeping with the principles and operation disclosed herein. Shown in  FIG. 16  is an alternate construction, wherein arm  21  includes a guard surrounding the area around actuator  26 , providing further protection. 
         [0043]    Hereinafter other examples will be described that include a float that has a density of about that of water. Thus, when the float is not immersed it has a substantial weight of about that at the same volume of water. This weight may be used to overcome the bias in a normally-closed valve by way of arms, linkages and control mechanisms as described herein in the first example and otherwise. When the float is introduced to water, its weight is reduced as seen by the arm or other control mechanism and, because the density is about that of water, the weight of the float is supported by the buoyancy of the float and not substantially by the linkage. Other floats may not have a density the same as water, but differ from its hollow counterparts in common use in that it has a substantial weight sufficient to overcome the bias in a normally-closed valve. This kind of weight having a density producing a substantial weight that may optionally be near that of a fluid of application is herein referred to as a float weight because when not immersed in the fluid it appears to be a weight to connecting linkages, while at the same time acting as a level sensing device that would otherwise be identified as a float by an ordinary person on merely a visual inspection. Herein when speaking of buoyancy with respect to a float weight, that term means a reduction in weight of the float weight when immersed and does not mean that it would necessarily float in water or another liquid. 
         [0044]    In a second example depicted in  FIGS. 5A and 5B  and a third example depicted in  FIGS. 5C and 5D , a float valve mechanism need not include an arm that imposes an angular force produced by a float weight. These examples include an inlet pipe  43  on which is fastened a manifold  50 , inside which manifold is a normally-closed valve  46 . Also provided is a buoyant weight  42  guided by inlet pipe  43 , to which is attached a pull rod  47 . To manifold  50  is attached a solid arm  45  including a pivot. A lever arm  41  is attached on one end to the pivot, and on the other end a hole is provided through which rod  47  may pass. A cap  49  is attached to the upper end of rod  47  thus limiting the travel of rod  47  within the whole of arm  41 . As weight  42  and rod  47  move down cap  49  contacts arm  41 , and the weight of buoyant weight  42  is applied to valve  46 . As shown in  FIG. 5A , an adjustment screw  48  may be provided between lever arm  41  and valve  46 . Furthermore, as water rises in a surrounding tank, the buoyancy of weight  42  increases, applying less force to lever arm  41  and correspondingly to valve  46 , thus permitting valve  46  to return to its normally-closed state. 
         [0045]    Now in the previous examples the relative position of the valve is higher than the float weight. This may be desirable for some applications, particularly where a culinary water source is used as a water supply. Thus, a design that requires that incoming water fall into a tank prevents backflow of water and correspondingly contamination. In one particular example, a fill valve as described herein is used to supply a cattle trough of water, that valve being connected to either a culinary water source or cistern that supplies multiple applications. Many domestic animals behave in a manner that does not protect the cleanliness of their water, and thus a reservoir may become contaminated with disease-causing microorganisms. 
         [0046]    A design may be used that places a buoyant float weight and a corresponding full water level at or above a valve exhaust port, potentially discharging water without a fall. For these designs, it may be desirable to incorporate an anti-backflow valve to avoid contamination issues. Referring now to  FIGS. 6A ,  6 B and  6 C, a water filling device is shown that incorporates an inlet pipe  43 , a manifold  50 , a valve housing  44 , a valve actuator  46 , and extension arm  45  upon which a straight lever arm  51  is pivotably attached. Float weight  52  is attached to lever arm  51  opposite its pivot, here beneath lever arm  51  although another configurations weight  52  may be mounted above, to the side, etc. of lever arm  51 . The float weight valve of  FIGS. 6A ,  6 B and  6 C positions a valve close to the fill level, i.e. the fill level might be set in the upper half or near the top of float weight  52 . For this arrangement an anti-backflow valve would be appropriate when connected to a culinary water system. 
         [0047]    Now turning to  FIG. 7 , an alternate design includes an inlet pipe  63  on which is mounted a valve actuator  66  controlling the flow of water through a valve housing formed in larger housing  69 . A hinged portion  65  built into housing  69  fixes one end of a lever arm  61  in position, whereupon a float weight  62  is mounted to the other end of the lever arm  61 . The movement of float weight  62  download applies pressure to a transfer shaft  68 , held in place by housing  69 , which pressure is transferred to actuator  66  and thereby controlling the flow of water. In this example, housing  69  forms a chamber  64  having exit ports to which are attached outflow tubing members  67 , the valve  66  venting water into this post-chamber. Tubing members  67  may be arranged so that water is streamed to a higher location than float weight  62 , thus avoiding the problem of backflow contamination. In another arrangement, tubes  67  may be positioned for use in an ordinary toilet tank, i.e. with one tube directed into an overflow pipe and another tube positioned in the tank for filling. If two or more exit tubes are provided, they may be fashioned in different sizes to accommodate differing flow needs in the areas to which the tubes are directed. In another example, a post-chamber may be used to create pressure in one tube and a tubeless exit port may direct water to the area and immediate vicinity of the chamber. 
         [0048]    Now turning to  FIGS. 9A ,  9 B,  9 C and  9 D, a valve assembly may be constructed with an outer wall containing a post-chamber that also acts as the outer wall the valve itself. Such constructions may simplify the assembly of a level controlling device and reduce the number of component parts. The level controlling assembly and coupled to an inlet pipe  83  by way of manifold section  80  that also couples to outer wall portion  89 . Valve actuator  86  rides in formations constructed within outer wall  89 , including seats for this spring and seal of this example. A post-chamber  84  is formed within the outer wall  89  with outflows  87  connected thereto. An arm  81  pivots about a pin mounted within protrusion  85 , which arm also contacts and presses transfer shaft  88  by which a force an arm  81  is transferred through to valve actuator  86 . Float weight  82  is attached to the end of arm  81  and, when the weight is not in contact with water, supplies a force to the end of arm  81  supplying a force download to transfer shaft  88  and actuator  86 . 
         [0049]    In the examples above, an arm or extensional member is used with a direct attachment to a float weight, which is the simplest arrangement. Other control mechanisms may be used. In the example of  FIG. 10 , two arms  102 a and  102 b are used to depress a valve  24 . A change of direction of the force of weight  100  is accomplished through a bend at one of pivots  101 , thereby permitting the valve  24  to be mounted with a side-discharge. In another example depicted in  FIG. 11 , a straight arm  103  is mounted to a pivot and a float weight  100 , pressing on a valve in a discharge-down orientation. In yet another example depicted in  FIG. 12 , a valve is mounted in a side-discharge orientation with a bent arm  104  providing for change of direction of force and a float weight  100  that is potentially at a higher level than valve  24 . This mounting or the mounting of  FIG. 10  is suitable for the upward-arm mountings shown in  FIGS. 15 and 17 . 
         [0050]    However, solid linkages are not needed with a float weight; flexible linkages may also be used. For example, the float weights of  FIGS. 14 and 15  are mounted to an arm through a flexible chain linkage, permitting the weight to swing freely on an arm. By using a flexible linkage it is possible to avoid damage to a water leveling system by interference with solid objects and bumps through animals or other causes. For example, referring to the installation of  FIG. 8 , a cow bumping its nose against the hanging float weight from the side will not cause undue pressure to be exerted on the arm or the valve. 
         [0051]    Now turning to  FIGS. 13A and 13B , a one-piece valve body may be fashioned from a block of stock material now described. A housing body  120  is constructed from a sufficiently large block, which may be a plastic material such as PTFE or the like. A horizontal first bore is drilled the long way through the block having a diameter of ½ inch. On the valve end the bore is enlarged to ¾ inch diameter and on the other side the bore is enlarged for an ante-chamber  121 , a center portion being left at ½ inch diameter. Threads  122  may be formed for a direct attachment for a water supply pipe, and the bore therein may be about one inch diameter. A second vertical ¾ inch bore  123  forms an exhaust port, that bore intersecting with the ¾ inch bore enlargement. A valve piston  124  is formed of a rod having a diameter slightly less than the ¾ inch diameter, which is shouldered for the receipt of a spring  125 . The inner center of piston  124  is drilled and threaded for receipt of a rod  126 , which rod is threaded on both ends. On rod  126  is mounted a seal  127 , formed of rubber or other pliable material, secured by a washer  128  and nut  129 . 
         [0052]    In the examples above and other examples that will be apparent to the reader, some general comments apply. First, the length of an arm on which a float weight is mounted and the distance between a valve actuator and its pivot determines the lever arm of the float weight on the valve. Thus, a valve may be used having a heavy spring that requires more force to open. In that case, a longer lever arm or a heavier float weight may be used. 
         [0053]    Float weights may be composed of many materials in many arrangements, so long as a float weight maintains a substantial opening weight for a normally-closed valve. Generally speaking, the shell-type air-filled floats available for toilet applications are not suitable because they have insufficient weight to open a valve when a water level is low. However, many other configurations and materials may be used. In the examples above a float weight is made of a solid plastic material; solid high-density polyethylene is appropriate for many applications. Although examples are described above having a density close to that of water, a less-dense material can be used if a lighter valve spring and/or a longer arm is used. Likewise, a material denser than water can be used if an appropriate spring is used that discriminates between the full, open-air weight and the lesser apparent weight of the float weight somewhat buoyed up by surrounding water. Similarly, a float weight could be constructed of a container filled with water, which may be by a shell formed of plastic, metal or other generally impermeable material. This kind of float weight might be fully enclosed or might be partially enclosed allowing for filling on submersion in a tank, such as the tank where the float will be used. If a partially enclosed float is used, a means of limiting evaporation may be employed such as a stopper or even the use of small fill-holes preventing substantial air circulation through the interior. Also, materials that are substantially heavier than water may be used, keeping in mind that voids or pockets within a float weight may reduce the density as a whole to an appropriate value. 
         [0054]    The shape of a float weight may be selected for its application of use. For example, where ice buildup is likely the sides of a float weight may be substantially vertical at the water line under full conditions. This may mitigate the condition shown in  FIG. 1C , i.e. a negative slope on the bottom of the ball-like float that pushes up. A float-weight positive slope may also be used, such as that shown in  FIG. 11 , that presents a slope at the waterline that pushes down. 
         [0055]    Now although certain exemplary embodiments have been described above particularly to water level control devices, one of ordinary skill in the art will recognize that the functions, principles and methods presented herein may be generalized to the control of other liquids and fluids, including alcohols, oils, gasoline, kerosene, cryo-fluids, compressed gasses, and many others. Additionally, the exact configurations described herein need not be adhered to, but rather these may be varied according to the skill of one of ordinary skill in the art. The invention, as defined by the appended claims, is to be fully embraced within its scope.