Abstract:
A system for removably connecting plumbing to a device includes a flange, one end of which is configured to bond to the plumbing. An insertion area at a distal end of the flange is sized and shaped to fit within a port of the device. An o-ring seat is cut/formed across a perimeter (e.g. outer circumference) of the insertion area of the flange. An o-ring is positioned around/in the o-ring seat such that, after insertion of the insertion area of the flange into the port, the o-ring provides a seal between the insertion area and an inner surface of the port. A retention device such as a retention nut holds the insertion area within the port.

Description:
[0001]    This application is also related to U.S. patent application Ser. No. titled Spa Jet Interface, attorney docket number 2699.10, filed evendate herewithin. 
     
    
     FIELD 
       [0002]    This invention relates to the field of spa/hot-tub plumbing and more particularly to a system and method for interfacing plumbing to a device such as a pump. 
       BACKGROUND 
       [0003]    Spas, hot tubs and pools have pumps for circulating water from the spa/hot-tub/pool through a filter, and back out through various orifices or jets. For many Spas, hot tubs and pools, the water is circulated through a series of pipes, typically polyvinylchloride tubing (PVC). It is well known how to plumb with such tubing, using couplings, PCV cleaner, and PVC cement to join such tubing. Good PVC joints are relatively easy to make, very cost effective, have very low chances of leakage, and are structurally sound. Proper PCV joints are often so good that it is physically impossible to separate the joined PCV sections without damaging the PVC tubing and/or coupling (as opposed to, for example, copper sweat fittings that are easily separated by heating the fitting). 
         [0004]    Unfortunately, there are components in the circulation system that may, at times, require replacement. Examples of such components are pumps and heaters. If the above mentioned method of coupling is used to join a PVC tube/pipe directly to a Spa, hot tub, or pool device (e.g. pump or heater), it would be extremely difficult to later break this coupling when the pump needs replacement (e.g. when the pump seal fails as often is the case). Instead, the PCV tube/pipe is coupled to a flange that has a threaded retaining nut. The retaining nut is placed onto the PVC tube/pipe, and then the PCV tube/pipe is coupled to the flange (e.g. using the cleaner/adhesive method). After the adhesive sets, a washer or o-ring is placed between the flange and the pump inlet/outlet and the retaining nut is threaded onto the pump inlet/outlet, applying pressure between the pump inlet/outlet and the flange, thereby removably sealing the flange and PVC pipe/tube to the pump inlet/outlet. 
         [0005]    This method of connecting the spa, hot tub, and pool plumbing to repairable/replaceable devices (e.g. pumps or heaters) has been used to some extent for many years. The method requires substantial torque on the retaining nut in order to apply proper pressure on the washer or o-ring to prevent leaks. It is often difficult to apply the needed torque due to the location and/or orientation of the device (e.g. pump or heater) within cabinetry, etc. Over torqueing is also a problem, resulting in stripping of the threads on either the device (e.g. pump or heater) or the retaining nut or both. Over torqueing also leads to difficulties in removing the retaining nut and potential breakage/stripping of the retaining nut during removal. Under and over tightening also lead to leakage problems that sometimes occur months or years after installation. Although an under tightened retaining nut is often easy to tighten, when deployed within a home, the leak often goes unnoticed until serious structural issues or mold occurs. Additionally, placement of the washer/o-ring is a problem, in that, a skewed washer/o-ring will result in one area that is properly sealed and another area that has insufficient pressure to result in a proper seal, again leading to eventual leaking. Once the retaining nut is in place, there is no way to see how the washer/o-ring is situated. 
         [0006]    The sealing systems of the prior art rely upon the torque of the retaining nut to maintain a proper seal. Many applications include periodic heat/cool cycles such as weather related or when a pool/spa heater cycles on and off. Such heat/cool cycles often lead to reduction of torque and/or reduction of proper pressure on the washer/o-ring. 
         [0007]    What is needed is a coupling system that will couple a removable device to fixed plumbing with little or no leaking. 
       SUMMARY 
       [0008]    In one embodiment, a system for removably connecting plumbing to a device is disclosed. The device has a port. The system includes a flange, one end of which is configured to bond to the plumbing. An insertion area at a distal end of the flange is sized and shaped to fit within the port of the device. An o-ring seat is cut or formed across a perimeter (e.g. outer circumference) of the insertion area of the flange. An o-ring is placed around the o-ring seat such that, after insertion of the insertion area of the flange into the port, the o-ring provides a seal between the insertion area and an inner surface of the port. A retention device such as a retention nut holds the insertion area within the port. 
         [0009]    In another embodiment, a system for removably connecting plumbing to a pool/spa pump is disclosed. The pool/spa pump has an inlet port. The system includes a flange, one end of which is configured to bond to the plumbing. An insertion area at a distal end of the flange is sized and shaped to fit within the inlet port of the pool/spa pump. An o-ring seat is cut or formed across a perimeter of the insertion area of the flange and an o-ring is positioned within the o-ring seat such that, after insertion of the insertion area of the flange into the inlet port, the o-ring provides a seal between the insertion area and an inner surface of the inlet port. A retention device such as a retention nut holds the insertion area within the port. 
         [0010]    In another embodiment, a method of removably attaching and sealing PCV plumbing to a pool/spa pump is disclosed. The pool/spa pump has a port. The method includes placing the retaining nut as above over the plumbing then applying PCV cleaning fluid to an inside surface of the one end of the flange and to an outside surface of an end of the PVC plumbing. Next, PCV adhesive to both the inside surface of the one end of the flange and the outside surface of the end of the PCV plumbing and the end of the PVC plumbing is inserted into the one end of the flange and the adhesive is allowed to set. The o-ring is installed onto the o-ring seat of the flange and the insertion area of the flange is pushed into the port, thereby sealing between the flange and the inside area of the port. The retaining nut is tightened around an outside threaded area of the port, thereby holding the insertion area within the port. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
           [0012]      FIG. 1  illustrates a perspective view of an exemplary pump coupling system of the prior art. 
           [0013]      FIG. 2  illustrates a second perspective view of an exemplary pump coupling system of the prior art. 
           [0014]      FIG. 3  illustrates a perspective view of a pump coupling having an improved sealing system. 
           [0015]      FIG. 4  illustrates a cross sectional view of a pump coupling having an improved sealing system. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
         [0017]    In the following description, examples of coupling plumbing to a pump are used to best illustrate the method of coupling plumbing to a removable and/or replaceable device. Even though the described system is very effective for interfacing plumbing (e.g. PCV pipes) to a pump, as shown, there are no limitations as to the target system (e.g. a spa system, hot-tub system, pool system, etc.) and there are no limitations as to the device being connected (e.g. solenoid valves, pumps, heating elements, heating units, etc.). There are many applications of the disclosed system for coupling and the examples used are just that, examples. 
         [0018]    In the following description, examples of coupling plumbing to a pump to PVC plumbing are used to best illustrate the method of coupling to such plumbing. PCV plumbing is widely used for spa, hot-tub, and pool systems, but the present invention is not limited to spa, hot-tub, and pool systems as any plumbing system is anticipated. Likewise, although PVC plumbing is used to best illustrate the method of coupling, any type and/or composition of tubing/pipe is anticipated including, but not limited to, plastic tubing, metal tubing, copper tubing, electrical conduit, hose, rubber hose, etc. 
         [0019]    The examples of the system, method, and apparatus for coupling plumbing to a device in this description use a tubular inlet/outlet on the device mating with a tubular flange. Although a tubular inlet/outlet is typical mating with flange having a circular cross section, there is no shape/geometric limitation. For example, in some embodiments, the inlet/outlet has an oval cross-section and the flange conforms to the oval shape of the portion of the inlet/outlet in which it interfaces. Any geometric cross-sectional shape is anticipated, and specialized o-rings are also anticipated for use with cross-sectional shapes that have sharp edges (e.g. a triangular or square cross-sectional shape will work better using a triangular or square shaped o-ring). 
         [0020]    The disclosed sealing system takes advantage of the substantially smooth (e.g. regular) inner surface of device connections. A flange fits within the device connection and has one or more o-rings (e.g., a gasket in the shape of a torus made of an elastomer) interfaced between the flange and the device connection, thereby sealing from leaks, particularly, though not limited, from leaks of a liquid/gas. The o-rings enable a good seal without the requirement of torqueing a retaining nut to provide this seal. Although o-rings are typically circular in cross-section, for some applications, any closed-loop elastomer is anticipated with cross-sectional shapes that match the device connection and flange, including, but not limited to, oval, triangular, square, hexagonal, octagonal and irregular shapes. 
         [0021]    Referring to  FIGS. 1 and 2 , perspective views of an exemplary pump coupling system of the prior art are shown. A typical pump  514  is shown with mounting standoffs  506 , connecting the pump  514  to a motor  502 . A shaft of the motor  502  typically interfaces with an impeller (not visible) within the pump  514 . Although shown as a typical impeller-type pump  514 , the disclosed system is anticipated for use with any existing pump. 
         [0022]    In operation, a liquid (e.g. water) is sucked in through an inlet  508  of the pump  514  and is discharged through an outlet  504  of the pump  514 . The inlet  508  and outlet  504  are coupled to plumbing (not shown) to connect the pump  514  to the spa, hot-tub, or pool water through various orifices, for example, jets, drains, filter arrangements, weirs, etc. 
         [0023]    In the prior art, the pump is connected to plumbing (one section of plumbing  550  is shown) through a flange  510 . In typical pools, spas and hot-tubs, the plumbing  550  is a section of PVC pipe/tube and the end of the PCV pipe/tube  550  is bonded to the flange  510  using PCV pipe cleaner and PVC pipe adhesive (not shown) to provide a substantially permanent bond between the flange  510  and the plumbing  550 . Note that the retaining nut  512  needs to be over the plumbing  550  before the plumbing  550  is bonded to the flanged  510  or there needs to be access to slide the flange  510  over the plumbing  550  after the plumbing  550  is bonded to the flange  510 . 
         [0024]    After the plumbing  550  is bonded to the flanged  510 , a washer or o-ring  516  is situated between the flange  510  and the pump inlet  508  and the retaining nut  512  is threaded onto threads  509  of the inlet  508  (the retaining nut  512  has mating threads  513 ) and tightened to seat the washer/o-ring  516  between the flange  510  and the pump inlet  508 . In order to prevent leaks, the washer/o-ring  516  must be properly positioned and the retaining nut  512  must be torqued sufficiently to apply appropriate pressure to the washer/o-ring  516 . In the prior art, it is often difficult to properly position washer/o-ring  516  and to apply proper torque to the retaining nut  512  due to interfering structures, plumbing, electronics, etc. Furthermore, many pools, spas, and hot-tubs are heated. Such heating and/or weather cycles result in heating and cooling cycles of the connection between the pump inlet  508  and the flange  510 , thereby affecting the performance of the washer/o-ring  516 , leading to leaks. 
         [0025]    Referring to  FIG. 3 , a perspective view of a pump coupling having an improved sealing system is shown. As in the description of the prior art, a typical pump  514  is shown with mounting standoffs  506 , connecting the pump  514  to a motor  502 . A shaft of the motor  502  typically interfaces with an impeller (not visible) within the pump  514 . Although shown as a typical impeller-type pump  514 , the disclosed system is anticipated for use with any type of pump. 
         [0026]    In operation, a liquid (e.g. water) is sucked in through an inlet  508  (suction side) of the pump  514  and is discharged through an outlet  504  (discharge side) of the pump  514 . The inlet  508  and outlet  504  are coupled to plumbing (only one section of plumbing  550  is shown for clarity reasons) to connect the pump  514  to the spa, hot-tub, or pool water through various orifices, for example, jets, drains, filter arrangements, weirs, etc. Again, note that a spa, hot-tub, pool situation is used as an example for connecting plumbing  550  to a device such as a pump  514  and any other plumbing/system such as PCV pipe/tubes, plastic pipes/tubes, copper pipes/tubes, electrical conduit, etc.; and/or devices such as heaters, heating elements, solenoid valves, filter units, etc., are anticipated. 
         [0027]    The inlet  508  of the pump  514  is connected to plumbing (one section of plumbing  550  is shown) through a flange  610 . Likewise, it is anticipated that the outlet  504  be connected in a similar way. In typical pools, spas and hot-tubs, the plumbing  550  is a section of PVC pipe/tube and the end of the PCV pipe/tube  550  is bonded to the flange  610  using PCV pipe cleaner and PVC pipe adhesive (not shown) to provide a substantially permanent bond between the flange  610  and the plumbing  550 . This substantially permanent bond is extremely difficult to break, often requiring destruction of either the flange  610  and/or the plumbing  550  and often requires sawing the flange  610  off of the plumbing  550 . 
         [0028]    Note that the retaining nut  512  needs to be placed over the plumbing  550  before the plumbing  550  is bonded to the flanged  610  or there needs to be access to slide the flange  610  over the plumbing  550  after the plumbing  550  is bonded to the flange  610 . 
         [0029]    O-rings  620  form very good seals and are used in many water sealing systems in device such as faucets and drains. As discussed above, in the past, a washer or o-ring  516  was placed between a flange  510  and the device  514  and pressure was applied between the flange  510  and the device  514  by a retaining nut  512 . As discussed above, such seals have known issues. 
         [0030]    The interface/seal shown has a superior seal and requires no pressure between the flange  610  and the device  514  to retain this seal because the o-ring(s)  620  seal between o-ring grooves  616  and an inner wall of the, for example, inlet port  508  (or the outlet port  504 ). Although not required, it is preferred that there is a retainment mechanism (e.g. a snap, wedge, press-fit, screw, snap, etc.) that retains the flange  610  within the, for example, inlet  508 , in this example, the original retaining nut  512  is used to keep an interface area  614  of the flange  610  within the inlet  508 . The interface area  614  of the flange  610  has an outer cross-sectional shape that is substantially the same as an inner cross-sectional shape of the inlet  508  (circular cross-sectional shape in this example) and the interface area  614  has a cross-sectional outer dimensions that is substantially the same as a cross-sectional inner dimension of the inlet  508 , thereby the interface area  614  of the flange  610  fits into the inlet  508 . This fit ranges from a relatively tight fit, perhaps requiring some amount of force to insert the interface area  614  into the inlet  508  or a loose fit which requires very little force to insert the interface area  614  into the inlet  508  until at least one o-ring or closed-loop elastomer seal  620  is installed in the at least one o-ring seat  616  (or closed-loop elastomer seal seat  616 ). A snug fit is preferred so that the o-ring or closed-loop elastomer seal  620  properly seals. In this way, no modifications need be made to existing devices  514  to interface using the disclosed improved sealing system. 
         [0031]    Although the device  514  is shown as a typical spa, hot-tub, or pool pump  516 , any device is anticipated, including, but not limited to, pumps, heating elements, heaters, filter systems, solenoid valves, etc. 
         [0032]    Although most anticipated devices  516  have tubular connections such as the inlet  508 , the disclosed system is anticipated for use with any shaped connection. In this example, the inlet  508  has a substantially tubular inner cross-section area. The outer shape and dimension of the insertion area  614  of the flange  610  is substantially similar to this inner cross-sectional area and is therefore substantially tubular as well. The inner diameter of the insertion area  614  is close to, but preferably less than, the inner diameter of the inlet  508 , allowing free insertion of the insertion area  614  into the inlet  508  (before addition of o-ring(s)  620 ). The insertion area  614  as shown in this example has a ledge  612  that, as the insertion area  614  is inserted into the inlet  508 , the ledge  612  abuts a lip of the inlet  508  and prevents over insertion, keeping an end of the insertion area  614  from extending too far into the inlet  508 . 
         [0033]    After the o-ring(s)  620  are seated into the at least one o-ring seats  616 , the insertion area  614  is pushed into the pump inlet  508 , compressing the o-ring(s)  620  between the o-ring seats  616  and the inner wall of the pump inlet  508 . The o-ring seat(s)  616  hold the o-ring(s)  620  in place while the insertion area  614  is pushed into the pump inlet  508  so the o-ring(s)  620  don&#39;t get pushed off of the insertion area  616 . 
         [0034]    In this example, one o-ring  620  and one o-ring groove  616  are shown, though on other embodiments, any number of o-rings  620  and o-ring grooves are anticipated. The o-ring(s)  620  is/are placed into respective o-ring groove(s)  616  and the insertion area  614  is pushed into the device connection (e.g. pump inlet  508  in this example). 
         [0035]    In this example, the retaining nut  512  is threaded onto threads  509  of the inlet  508  (the retaining nut  512  has mating threads  513 ) and tightened to hold the flange insertion area  614  within the pump inlet  508 . As opposed to the prior art, the retaining nut  512  does not need to be tightened or torqued to apply pressure to the seal. Therefore, the retaining nut  512  need only be tightened sufficiently as to prevent the retaining nut from coming loose due to, for example, vibration, etc. Although shown as a threaded retaining nut  512 , any retaining mechanism is anticipated to hold the flange insertion area  614  within the pump inlet  508  since there is no requirement for a certain amount of torque In embodiments in which the plumbing  550  has sufficient resiliency, it is anticipated that the plumbing  550  holds the flange insertion area  614  within the pump inlet  508 . 
         [0036]    Again, the described seal is anticipated for use in many situations and is not limited to any particular plumbing  550  or any particular device  516 . 
         [0037]    Referring to  FIG. 4 , a cross sectional view of a pump coupling having an improved sealing system is shown connected to an inlet  508  of a pump  516 . A portion of a cross section of an inlet  509  and a portion of a typical pump  514  is shown for clarity reasons. Again, the disclosed system is anticipated for use with any device such as a pump  516 , etc. 
         [0038]    In operation, a liquid (e.g. water) is sucked in through an inlet  508  of the pump  514 . The inlet  508  is coupled to plumbing (only one section of plumbing  550  is shown for clarity reasons) to connect the pump  514  to the spa, hot-tub, or pool water through various orifices, for example, jets, drains, filter arrangements, weirs, etc. Again, note that a spa, hot-tub, pool situation is used as an example for connecting any plumbing  550  to any device such as a pump  514  and any other plumbing/system such as PCV pipe/tubes, plastic pipes/tubes, copper pipes/tubes, electrical conduit, etc; and/or devices such as heaters, heating elements, solenoid valves, filter units, etc., are anticipated. 
         [0039]    The inlet  508  is connected to plumbing (one section of plumbing  550  is shown) through a flange  610 . In typical pools, spas and hot-tubs, the plumbing  550  is a section of PVC pipe/tube and the end of the PCV pipe/tube  550  is bonded to the flange  610  using PCV pipe cleaner and PVC pipe adhesive (not shown) to provide a substantially permanent bond between the flange  610  and the plumbing  550 . This substantially permanent bond is extremely difficult to break, often requiring destruction of either the flange  610  and/or the plumbing  550  and often requires sawing the flange  610  off of the plumbing  550 . 
         [0040]    In this example, only one o-ring  620  and o-ring seat  616  is shown, though in other embodiments, multiple o-rings  620  and o-ring seats  616  are employed. The o-ring(s)  620  seal between o-ring grooves  616  and an inner wall of the, for example, inlet  508 . Although not required, it is preferred that there is a retainment mechanism (e.g. a snap, wedge, press-fit, screw, snap, etc.) that retains the flange  610  within the, for example, inlet  508 , in this example, the original retaining nut  512  is used to keep an interface area  614  of the flange  610  within the inlet  508 . The interface area  614  of the flange  610  has an outer cross-sectional shape that is substantially the same as an inner cross-sectional shape of the inlet  508  (circular cross-sectional shape in this example) and the interface area  614  has a cross-sectional outer dimensions that is substantially the same as a cross-sectional inner dimension of the inlet  508 , thereby the interface area  614  of the flange  610  fits into the inlet  508 . This fit ranges from a relatively tight fit, perhaps requiring some amount of force to insert the interface area  614  into the inlet  508  or a loose fit which requires very little force to insert the interface area  614  into the inlet  508  until the o-ring or closed-loop elastomer seal  620  is installed in the o-ring seat  616  (or closed-loop elastomer seal seat  616 ). A snug fit is preferred so that the o-ring or closed-loop elastomer seal  620  properly seals. This sealing system does not require modifications need be made to existing devices  514  to interface using the disclosed improved sealing system. 
         [0041]    After the o-ring(s)  620  are seated into the at least one o-ring seats  616 , the insertion area  614  is pushed into the pump inlet  508 , compressing the o-ring(s)  620  between the o-ring seats  616  and the inner wall of the pump inlet  508 . The o-ring seat(s)  616  hold the o-ring(s)  620  in place while the insertion area  614  is pushed into the pump inlet  508  so the o-ring(s)  620  don&#39;t get pushed off of the insertion area  616 . 
         [0042]    In this example, the retaining nut  512  is threaded onto threads  509  of the inlet  508  (the retaining nut  512  has mating threads  513 ) and tightened to hold the flange insertion area  614  within the pump inlet  508 . As opposed to the prior art, the retaining nut  512  does not need to be tightened or torqued to apply pressure to the seal. Therefore, the retaining nut  512  need only be tightened sufficiently as to prevent the retaining nut from coming loose due to vibration, etc. Although shown as a threaded retaining nut  512 , any retaining mechanism is anticipated to hold the flange insertion area  614  within the pump inlet  508  since there is no requirement for a certain amount of torque. In embodiments in which the plumbing  550  has sufficient resiliency, it is anticipated that the plumbing  550  holds the flange insertion area  614  within the pump inlet  508 . 
         [0043]    Again, the described seal is anticipated for use in many situations and is not limited to any particular plumbing  550  or any particular device  516 . 
         [0044]    Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
         [0045]    It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.