Pump header and implementation thereof

A header body for use in fluid circulation systems such as a hydronic heating system is provided in which the header body is configured to couple fluid flow to individual fluid circuits of the system. In one embodiment, the header body comprises a suction chamber with a fluid passage through which fluid flows as between one or more header bodies coupled together to form a manifold. A valve is disposed in the suction chamber, wherein in one example the valve comprises a valve body that is supported by portions of the suction chamber on opposite sides of the fluid passage. The valve body is configured with an aperture that is aligned with the fluid passage in a first and second operating state, one of which decouples the fluid circuit from the system.

TECHNICAL FIELD

The present disclosure relates to modular manifolds, and more particularly to a header body for use with a pump to distribute fluids to a fluid-circulation circuit that is part of a system of multiple fluid-circulation circuits.

BACKGROUND

Systems that circulate fluid through multiple fluid circuits, such as hydronic heating systems, typically utilize several pumps, one being dedicated to each of the fluid circuits of the system. The pump is connected to a manifold, the construction of which permits fluid from a single fluid source such as a water tank to be flowed to all of the fluid circuits. In many systems, the manifold is modularized such as by deploying a plurality of header bodies, which are coupled together and to the pumps and the fluid circuit. Often the header bodies are positioned adjacent one another so that the manifold can deliver fluid to all of the fluid circuits.

Because footprint of systems such as the hydronic heating systems is often critical, it is beneficial to reduce the space required for the manifold and, accordingly, the header bodies of the manifold. Moreover, these systems often require maintenance and repair. Pump failure and related defects can compel changes wherein it is necessary to disconnect one or more pumps from the manifold. Expansion of the system such as by installing or activating additional fluid circuits is also typically required as would occur in connection with upgrades to the system.

Therefore it would be advantageous to provide a header body and related modular manifold and system that is configured to avoid having to drain fluid from the entire system when one or more pumps is removed or taken off-line from the overall system. It would be likewise advantageous to permit construction of the system to include un-used fluid circuits in initial configurations, wherein such un-used fluid circuits permit expansion of the system as desired.

SUMMARY

There is described below a header body that is configured to attach to adjacent header bodies to form the modularized manifold. Embodiments of the header body are likewise adapted to decouple the corresponding fluid circuit from the manifold, while maintaining the other fluid circuits in fluid communication with the fluid source. Moreover, and to facilitate these features, configurations of the header body are disclosed that are constructed so as to economize the footprint of the manifold and the system overall, without sacrificing fluid flow properties such as flow rate, velocity, and pressure drop across the individual header body and the manifold as a whole.

These and other features are provided in one or more embodiments of the present disclosure, in which:

In one embodiment, a manifold header comprises a header body comprising a pair of opposing openings and an opening for receiving a pump. The manifold header also comprises a suction chamber coupled to the header body, the suction chamber comprising a fluid passage in communication with each of the pair of opposing openings. The manifold header further comprises a valve disposed in the fluid passage, the valve comprising a valve body having an aperture therethrough. In one example, the manifold header is defined wherein the valve body is operable in one or more operating states including a first state that couples the suction chamber and the opening of the header body and a second state that decouples the suction chamber and the opening of the header body, and wherein the aperture is aligned with the fluid passage in both the first state and the second state.

In another embodiment, a header body comprises a housing comprising a volute for receiving an impeller of a pump. The header body also comprises a suction chamber fluidly coupled to the volute, the suction chamber comprising a first opening, a second opening, and a fluid passage permitting a fluid to flow between the first opening and the second opening. The header body further comprises a valve disposed in the fluid passage. In one example, the header body is defined wherein the valve comprises a valve body that is supported along one or more peripheral walls of the fluid passage, and wherein the valve body rotates among one or more operating states that comprise a first state that permits the fluid to flow from the fluid passage to the volute and a second state that prohibits the fluid to flow to from the fluid passage to the volute.

In yet another embodiment, a circulation system for a fluid comprises a first header body and a second header body coupled adjacent the first header body. In one example, the circulation system is defined wherein one or more of the first header body and the second header body comprise a volute, a suction chamber in communication with the volute, and a valve disposed in the suction chamber and with a first state that permits the fluid to flow between the suction chamber and the volute. In another example, the circulation system is also defined wherein the valve comprises a valve body secured to peripheral walls of the suction chamber.

DETAILED DESCRIPTION

Illustrated in the appended drawings and broadly stated, a header body is provided below that is suitable for use in fluid circulation systems such as a hydronic heating system. Exemplary systems typically include several fluid circuits through which fluid is circulated via pumps, which are coupled to the header body. Pertinent to the discussion that follows, the header bodies of the present disclosure can form a manifold, wherein the header bodies are coupled to adjacent header bodies of the same or similar configuration. This manifold simplifies construction of the hydronic heating system, and in one construction fluid such as water flows from a single source into each of the fluid circuits via the header bodies that form the manifold.

Header bodies of the type disclosed herein are further configured to permit one or more of the pumps to be removed from the manifold without disrupting operation of the remaining fluid circuits of the hydronic system. Moreover, as a further improvement over conventional manifolds used in, e.g., hydronic heating systems, the header bodies incorporate a valve that is constructed to reduce the overall dimensions of the header body (and, accordingly the manifold), as well as to maintain flow rate and to reduce the velocity and pressure drop of the fluid as the fluid flows across the header body. These features maintain and/or enhance the efficiency of the pump, thus improving the operation of the fluid circuits coupled to the manifold and the overall hydronic system.

Discussion of these features is provided below in connection with the schematic cross-sectional diagram of an exemplary embodiment of a header body100that is illustrated inFIG. 1. In this example, the header body100comprises a housing102and a suction chamber104, through which fluid such as water can flow. The housing102comprises a volute106with an opening108configured to receive a pump110, and in one configuration the opening108can receive an impeller112of the pump110therein. The suction chamber104is coupled to the volute106to permit the fluid to flow between the suction chamber104and the volute106. The suction chamber104includes a chamber wall114with an inner peripheral wall116and an outer peripheral wall118. The chamber wall114forms a fluid passage120, which is configured to permit the fluid to flow to adjacent ones of the header body100that are coupled together to form, e.g., the manifold discussed above.

A valve122is disposed in the fluid passage120. The valve122is used to couple and decouple the volute106and the fluid passage120, thus permitting and/or preventing fluid from the suction chamber104from entering the volute106. The valve122comprises a valve body124that is configured to permit the fluid to flow through the valve122in at least three directions. In the present example, the valve body124has a pump opening126and an aperture128that is fluidly coupled to the pump opening126. The aperture128extends through the valve body124. The valve body124is positioned in the fluid passage120to form a flow area130, which in the present example is the effective area of the fluid passage120through which flows the fluid in the suction chamber104.

The valve body124includes one or more supported portions132, which are peripherally supported in the suction chamber104such as at or near portions of the chamber wall114that are peripheral to the fluid passage120. This configuration facilitates operation of the valve122, e.g., to couple and decouple the volute106and the fluid passage120such as by rotation134about an axis136. In one embodiment, the supported portions132include an inner supported portion138and an outer supported portion140. The supported portions132are engaged at or near the chamber wall114, with one configuration utilizing, respectively, one or more peripheral walls such as the inner peripheral wall116and the outer peripheral wall118. This engagement positions the valve body124in the fluid passage120and aligns the pump opening126so as to be fluidly coupled with the volute106. Exemplary mountings and configurations for such engagement can include bearings and bushings such as those that would fit the valve body124, as well as features that are incorporated unitarily with the construction of the suction chamber104, the chamber wall114, and/or the valve body124.

Construction of the valve122can vary, with configurations of the valve body124being selected in one example so that at least a portion of the valve body124is encapsulated in the fluid passage120. In one embodiment, the valve body124is positioned inside of the fluid passage120. Other constructions are likewise contemplated that are useful to reduce the overall dimensions of the header body100such as by minimizing the size and shape the suction chamber104. Suitable devices for use as the valve body124can include curvilinear devices (e.g., spheres, ellipses, and egg-shaped), wherein the device has an outer surface that is shaped to facilitate the flow of the fluid. Mechanical and electro-mechanical devices are also suitable such as, but not limited to, check valves, butterfly valves, choke valves, solenoid valves, and variations, derivations, and combinations thereof.

Actuation of the valve body124facilitates operation of the valve122as between one or more operating states. These operating states can include an open state, in which the volute106and the fluid passage120are fluidly coupled, such as through the pump opening126of the valve body124. The states can also include a closed state that prevents fluid from flowing between the volute106and the fluid passage120. In one embodiment, the aperture128is aligned with the fluid passage120in each of the operating states, thus maintaining the size of flow area130in both the open state and the closed state. When implemented as part of manifold, such as the manifold discussed above, the maintenance of the flow area130is beneficial because the flow properties of the fluid do not change even when one or more of the volute106in the manifold are closed to flow of the fluid. In one example, the configuration of the header body100is desirable because it minimizes pressure drop across the suction chamber104.

The housing102and the suction chamber104can be formed monolithically such as by casting, machining, or using other manufacturing techniques that are suited to form the various features of the header body100. Examples of this construction are provided in connection withFIGS. 2-5below. Likewise in other embodiments, the header body100can be formed as one or more separate pieces, which are assembled together using fastening mechanisms (e.g., welds and mechanical fasteners such as bolts and screws) of the type that can be used for the fluids and systems used in, e.g., hydronic heating systems.

Some of these features, broadly described in connection withFIG. 1, are further illustrated inFIGS. 2 and 3and described in detail below. InFIGS. 2 and 3, there is illustrated another exemplary embodiment of a header body200that is configured for use in the systems contemplated herein. Like numerals are used to identify like components as between the header body100and the header body200, but the numerals are increased by 100 (e.g.,100is now200inFIGS. 2 and 3). For example, the header body200includes a housing202, a suction chamber204, a volute206, and a pump210with an impeller212. The suction chamber204includes a chamber wall214, including an inner peripheral wall216and an outer peripheral wall218, and forming a fluid passage220. The header body200also includes a valve222with a valve body224, which is configured for rotation234about an axis236. The header body200further includes a discharge242, which is fluidly coupled to the volute206to permit fluid to flow under pressure from the impeller212of the pump210. Open ends244are located on opposite sides of the fluid passage220. The open ends244can comprise a fastening implement246such as a threaded surface248disposed thereto. In other examples, the fastening implement246can likewise incorporate additional components such as threaded nuts, clamps, as well as threaded surfaces that are located on or proximate the outside surfaces of the open ends244.

The valve body224comprises a ball250with a spherical shape252having a cylindrical bore254that extends through the ball250and terminates at bore ends256. A pump bore258is likewise incorporated into the spherical shape252, with one particular construction having the pump bore258located in generally perpendicular relation to the cylindrical bore254. As depicted inFIGS. 2 and 3, the header body200also includes a number of valve components260that are implemented to support the ball250in the fluid passage220. The valve components260include a pair of ball valve seats262, including an inner ball valve seat264and an outer ball valve seat266. The valve components260also include a ball compression plate268, which works in combination with the ball valve seats262to secure and/or position the ball250in the fluid passage220. The valve222also includes an actuator270for actuating the valve222amongst one or more of the operating states. In the present example, the actuator270includes a ball valve stem272on which is disposed a handle274for manipulating the valve body224, and more particular to the present example the handle274is coupled to the ball250to impart the rotation234about the axis236.

The ball valve seats262can be concave or otherwise constructed so that the spherical shape252is seated in, e.g., the inner ball valve seat264and the outer ball valve seat266. This seating supports the ball250within the fluid passage220, but also permits the rotation234of the ball250such as by actuation of the handle274. In one embodiment, one or more of the inner ball valve seat264and the outer ball valve seat266is secured to the chamber wall214such as by fastener (e.g., screws, adhesive, and weld). Portions of the chamber wall214such as the inner peripheral wall216and the outer peripheral wall218can also be constructed with features that engage the ball valve seats262such as by press and/or friction fit. This configuration can include bosses, bores, lips, and related material configurations that are arranged to engage and to retain the ball valve seats262. These features can be incorporated in the suction chamber204such as during the manufacturing (e.g., casting) of the suction chamber204and/or the housing202. Combinations of fasteners and features in the chamber wall214are likewise contemplated as suitable alternatives for securing the ball valve seats262in a position to receive at least a portion of the ball250therein.

Securing and positioning the ball250in this manner is advantageous because it permits the ball250to be secured without negatively affecting the flow of fluid through the fluid passage220. Peripheral support of the ball250exposes portions of the ball250to the fluid such as, for example, the cylindrical bore254and bore ends256. This configuration permits fluid to flow through the ball250in one or more of the operating state such as the open state and the closed state discussed above. This configuration likewise minimizes obstruction of the fluid as the fluid flows in the fluid passage220, and in one particular implementation the fluid continues to flow through the ball250when the pump210is absent from the header body200. In other examples, the suction chamber204is constructed in conjunction with these devices, wherein the design of the resulting header body200is configured to minimize pressure drop of the fluid through the suction chamber204and to minimize the size of the header body200.

Referring now toFIG. 4, yet another exemplary embodiment of a header body300is illustrated. Again like numerals are used to identify like components as betweenFIGS. 1-4, wherein in the present example the header body300includes a housing302, a suction chamber304, a volute306, a pump310with an impeller312, and a fluid passage320. The header body300also includes a valve322with a valve body324and a discharge342. The valve322includes a ball350with a spherical shape352. The ball350, like the ball250that is depicted inFIGS. 2 and 3, is configured to permit flow in three directions such as by having a cylindrical bore354and a pump bore358provided therein.

The header body300also includes a valve securing feature376with one or more valve receiving areas378. Each of the valve receiving areas378extend into the suction chamber304and are configured to receive and engage portions of the valve322. These portions include portions of the ball350as well as one or more valve components360. In the present example, the valve components360include an inner ball valve seat364, an outer ball valve seat366, and a ball compression plate368. The configuration of the valve components360and the valve receiving areas378are useful to permit rotation of the ball350such as by actuation of a handle374.

The valve securing feature376such as the valve receiving areas378can be formed integrally with portions of the housing302such as by way of machining and/or casting. In one embodiment, the valve securing feature376can be assembled as one or more separate pieces fastened to the housing302and/or the suction chamber304. Notably the valve receiving areas378are configured to permit fluid to flow into the cylindrical bore354from either side, thus effectuating both the three direction flow in the ball350and the overall operation of the header body300in the open and closed states as discussed herein. Depicted in its open state inFIG. 4, it is contemplated that rotation of the ball350about 180° from this initial position will implement the closed state, in which fluid will continue to flow through the ball350(e.g., through the cylindrical bore354), but will not flow to the volute306.

Various configurations of the valve receiving areas378and the valve components360can be used to engage and support the periphery of the ball350. Preferably these configurations position the ball350within the fluid passage320, but do not interfere with operation of the ball350as between the open state and the closed state. In the present example, the engagement of the ball350occurs on the outer supported portions of the ball350, and more particularly the inner ball valve seat364and the outer ball valve seat366are utilized to engage and support, respectively, the inner supported portion338and the outer supported portion340of the ball350. Other configurations are likewise contemplated to support and position the ball350in the suction chamber304. While some of these other configurations may utilize valve components (e.g., ball valve seats362), it is likewise suitable that the features of the ball valve seats362are integrated into the valve receiving areas378. In still other configurations, upper and lower portions of the ball350, such as an upper supported portion380and a lower supported portion382, are engaged to position the ball350in the suction chamber304.

Pertinent also to the header body100and200above, the construction of the header body300effectuates a minimized dimensional configuration, wherein in one example the suction chamber304is located more proximately to the pump310. Centrally locating the valve322in the suction chamber304is also beneficial because the valve322is relatively unnoticeable from the outside of the suction chamber304. This minimized dimension configuration allows the header body300to be installed in locations where limited space may be an issue.

Referring now toFIG. 5, there is shown still another exemplary embodiment of a header body400, in which like numerals are used to identify like components as betweenFIGS. 1-5. By way of example, the header body400includes a housing402, a suction chamber404, a volute406, and a pump410that is coupled to the volute406. Although not shown inFIG. 5, one or more of the concepts discussed above in connection with the header body100,200, and300, such as the concepts related to the valves (e.g., the valve122,222, and322), are applicable to the header body400.

Pertinent to the example depicted inFIG. 5, however, attention is focused on the exterior of the suction chamber404, which is configured to be mounted to a structure484such as a wall, utility panel, or other structure contemplated for use with the systems and manifolds of the present disclosure. In one embodiment, the housing402includes a mounting device486with one or more mounting feet488, each configured to work in conjunction with a fastener (not shown) to secure the header body400to the structure484. The mounting device486generally, and the mounting feet488in particular, can be constructed unitarily with the suction chamber404. In other constructions the mounting feet488are secured to the suction chamber404such as by screws, bolts, welds, and/or other fastening mechanism that are suitable for the loading and related physical construction and operation of the header body400. In other configurations, the mounting device486is mounted to the structure484, and is further constructed to engage the suction chamber404and/or the header body400, thus supporting and securing the header body400to the structure484.

For one implementation of embodiments of the header body100,200,300, and400of the present disclosure, reference is now directed to an exemplary embodiment of a fluid circulation system500inFIG. 6. There is shown that the fluid circulation system500includes a hydronic heating system502having a plurality of fluid circuits504with shut-off valves506. Fluid is forced through each of the fluid circuits504by a pump508. Each pump508is connected to a header body510(e.g., the header body100,200,300, and400). The header body510can be connected to form a manifold header512, and more particularly to the present example each header body510is configured to be adjoined to the header body510that is immediately adjacent. While a variety of means of connection are contemplated, in one example a quick-clamp fitting can be used such as is provided by Andron Stainless Corporation of Columbia, S.C. (e.g., part no. AC13HP). The manifold header512can be closed with a cap (not shown), which is secured to the header body510that is last or peripheral in the manifold header512.

In view of the foregoing, and discussing briefly the operation of the header bodies as implemented in the fluid circulation system500, by connecting a plurality of header bodies510as the manifold header512to form a common suction chamber (not shown), it is possible to isolate individual ones of the fluid circuits504without affecting the operation of the fluid circuits504other than the one selected for isolation. In one example, changing the valve of one of the header bodies510from its open state to its closed state, in combination with closing the corresponding shut-off valves506, isolates one of the fluid circuits504from the rest of the fluid circulation system500. This combination also stops the flow of fluid to the pump508in the fluid circuits504that are isolated and coupled to the closed valves. Ceasing the flow permits, for example, service and maintenance to be performed on a portion of the fluid circulation system500without negatively affecting the flow of fluid through the common suction chamber, which supplies fluid to the fluid circuits504via, e.g., the header bodies510with valves that are positioned in the open state.

Moreover, because the relationship along the suction chamber is not directional, it is possible to connect one or more of the header bodies510in a position that is inverted such as inverted with respect to the header bodies510coupled adjacent to the header bodies510, which is in a selectively inverted configuration. In one embodiment, as shown inFIG. 5, one of the header bodies510, in this case an inverted header body514may be positioned to discharge fluid in a direction that is different from the header bodies510of the manifold header512.

It is contemplated that numerical values, as well as other values that are recited herein are modified by the term “about”, whether expressly stated or inherently derived by the discussion of the present disclosure. As used herein, the term “about” defines the numerical boundaries of the modified values so as to include, but not be limited to, tolerances and values up to, and including the numerical value so modified. That is, numerical values can include the actual value that is expressly stated, as well as other values that are, or can be, the decimal, fractional, or other multiple of the actual value indicated, and/or described in the disclosure.

While the present disclosure has been particularly shown and described with reference to certain exemplary embodiments, it will be understood by one skilled in the art that various changes in detail may be effected therein without departing from the spirit and scope of the disclosure as defined by claims that can be supported by the written description and drawings. Further, where exemplary embodiments are described with reference to a certain number of elements it will be understood that the exemplary embodiments can be practiced utilizing either less than or more than the certain number of elements.