A wearless water distribution valve directs a flow of water through a swimming pool cleaning system and includes a housing having an inlet, outlets, and an inner surface bounding and defining an interior coupled in fluid communication with the inlet and the outlets. The valve further includes a disc having a port, and being mounted for rotation in the housing for movement among a plurality of positions, each position of the disc characterized by the port being aligned with a respective one of the outlets. The valve further includes a drive assembly carried by the housing and operably coupled to impart rotation to the disc. In response to application of the flow of water into the housing, actuation of the drive assembly imparts rotation to the disc through the plurality of positions. The disc is disposed in spaced relation away from the inner surface of the housing.

FIELD OF THE INVENTION

The present invention relates generally to swimming pools, and more particularly to valves for use with pool pump assemblies in swimming pools having in-floor cleaning systems.

BACKGROUND OF THE INVENTION

There are many ways to clean a pool, and pool owners are continually looking for easier ways to do so. Pools can be cleaned by hand, such as by brushing the pool surface with a brush fit on the end of a long pole. This causes debris and material collected on the pool surface to be lifted off the surface; when the pool pump and filter assembly is operated in conjunction with this practice, water and debris together are drawn through the pool pump into a filter which filters and collects much of the debris, thereby removing it from the pool and rendering the pool cleaner. Brushing can be laborious and time-consuming, however.

Automatic pool vacuums were developed to reduce the work of pool owners. Pool vacuums operate in a number of different ways, but most creep along the pool surface and suck, or disturb and then suck, debris and material collected on the pool surface up a hose into the operating pump and filter assembly. Vacuums can be difficult to operate, however. They must be calibrated to provide sufficient suction, they must be maintained, they are vulnerable to jamming from large debris, and they can provide a random cleaning pattern that may be inadequate.

In-floor cleaning heads were developed as an automated, low-oversight way to keep a pool surface clean. In-floor cleaning heads are outlets that are permanently installed in the swimming pool structure. The heads recede into the pool structure when not in use, and pop up when operating. Although there are a great number of kinds of pop-up heads, most operate with the basic functionality of directing a stream of water across a portion of the pool surface to clean that portion of the pool surface. Some heads rotate to direct that stream across different portions of the pool surface. Typically, the heads are installed in a number of locations across a pool surface, and often clusters of heads are grouped together in “lines,” with each line including heads that receive water independently of the heads in other lines. This independent operation of lines requires a way to provide a flow of water to each line independently, and so swimming pool distribution valves were developed.

Swimming pool distribution valves generally have an inlet, a plurality of outlets, and some internal mechanism for directing the flow of water from the inlet to each of the outlets independently. However, many swimming pool distribution valves are susceptible to wear, which requires laborious maintenance or difficult replacement. An improved water distribution valve is needed.

SUMMARY OF THE INVENTION

A wearless water distribution valve directs a flow of water through a swimming pool cleaning system and includes a housing having an inlet, outlets, and an inner surface bounding and defining an interior coupled in fluid communication with the inlet and the outlets. The valve further includes a disc having a port, and being mounted for rotation in the housing for movement among a plurality of positions, each position of the disc characterized by the port being aligned with a respective one of the outlets. The valve further includes a drive assembly carried by the housing and operably coupled to impart rotation to the disc. In response to application of the flow of water into the housing, actuation of the drive assembly imparts rotation to the disc through the plurality of positions. The disc is disposed in spaced relation away from the inner surface of the housing.

DETAILED DESCRIPTION

Reference now is made to the drawings, in which the same reference characters are used throughout the different figures to designate the same elements.FIGS. 1A and 1Bare top and bottom perspectives of a wearless multi-port water distribution valve10for directing a flow of water from a pump in a swimming pool cleaning assembly among several conduits of a piping assembly, each of which leads to a line of in-floor cleaning heads installed in the swimming pool. The valve10is useful for sequentially communicating water to each in-floor cleaning head to clean the pool surface of dirt, debris, growth, and other material without succumbing to internal wear, and without causing wear to any parts which permanently fixed to the pool structure or the pump assembly. In this way, maintenance of the valve10does not eventually require laborious replacement of the valve, which typically involves cutting the conduits to remove a worn valve, obtaining a new valve, and plumbing the new valve into the cut conduits.

The valve10includes a generally symmetric housing11having a sidewall12extending between a bottom13and a lip defining a top14of the housing11. The housing11bounds and defines an interior15, shown inFIG. 2, and a lid20covers and encloses the interior15at the top14. The lid20is releasably secured on the housing11with a clamp ring21.

Referring still toFIGS. 1A and 1B, a lateral inlet22is formed in the sidewall12in fluid communication with the interior15, and six downwardly extending outlets23are formed in the bottom13of the housing11, also in fluid communication with the interior15. Each of the inlet22and outlets23are cylindrical ports sized to interface and engage easily with conventional swimming pool plumbing conduits, which are typically arranged in a circumferentially-spaced apart, radial arrangement. The pump of the swimming pool cleaning assembly pumps water through the inlet22into the interior15and then sequentially out each of the outlets23to each of the in-floor cleaning heads installed in the swimming pool.

Referring now toFIG. 2, the housing11and the lid20cooperate with a distribution assembly16carried in the interior15to sequentially and cyclically communicate water from the inlet22to each of the outlets23so that the surface of the swimming pool is cleaned. The housing11, which in operation is plumbed to the conduits leading to the cleaning heads, carries a cartridge24which separates moving parts of the valve10from interaction with the housing11so as to prevent wear to the housing11. The distribution assembly16sequentially and cyclically communicates water from the inlet to the outlets23include the cartridge24, but also includes an impeller25, a table30, and a reduction cassette31, each mounted around a central axle32. The cartridge24, also mounted around the central axle32, carries a disc33which is mounted for rotation, and does rotate entirely within the cartridge24so as not to engage the sidewall12of the housing11or rub against the sidewall12of the housing11. The disc33includes a single port34which extends entirely through the disc33to selectively allow water to pass through the disc33from the inlet22to the outlets23, as will be explained in detail herein. As the disc33rotates within the cartridge24, the port34sequentially moves into alignment with each of the outlets23, so as to allow water from the interior15out the respective outlet23. The cartridge24and the disc33define an operational assembly17within the distribution assembly to render the valve10operable to distribute water.

Turning now toFIG. 3, which is a section view of the valve10taken along the line3-3inFIG. 1A, the arrangement of the distribution assembly16of the valve10is shown. The lid20has been removed for clarity of the illustration. The impeller25is proximate to the top14, generally parallel with respect to the inlet22. The impeller25includes a plurality of canted blades35formed integrally to and extending radially outward from a hub40fixed on a drive fitting41. The drive fitting41is mounted for free rotation on the axle32, so that the impeller25is mounted for free rotation on the axle32. The drive fitting41is more clearly shown inFIG. 2, where it can be seen that the drive fitting41includes an enlarged top portion, to which the hub40of the impeller25is secured, and a lower, monolithically-formed drive gear42. The drive gear42is coupled in meshing engagement with the reduction cassette31. The impeller25thus rotates on the axle32to drive the reduction cassette31.

Returning toFIG. 3, application of water through the inlet22along line W causes the impeller25to rotate in a counter-clockwise manner, as indicated with rotational arrows inFIG. 3, thereby imparting rotation to each gear of the reduction cassette31. The axle32is aligned along an axis A, and for purposes of orientation, various terms used herein will be used in reference to the axis A, such as “horizontal,” which means extending generally perpendicular to the axis A, “vertical,” which means extending generally parallel to the axis A, “radial,” which means extending horizontally outward from or inward to the axis A, and “circumferential,” which means extending in a horizontal arc defined by the axis A.

In the preferred embodiment shown throughout the drawings, the impeller25includes eight blades35, but one having ordinary skill in the art will readily appreciate that a fewer or greater number of blades35may be used so long as performance of the valve10is comparable. The blades35each have a length in the radial direction which is shorter than the shortest radial distance between the axis A and the sidewall12, such that the blades35can rotate without impact, wear, rubbing, or other interference with an inner surface43of the sidewall12, thereby ensuring the continuous, uninterrupted rotation or the impeller25as well as the prevention of wear to the inner surface43of the sidewall12. The inner surface43of the sidewall12is generally hexagonal.

Still referring toFIG. 3, the impeller25is disposed above the table30. The table30has a diameter less than the diameter of the impeller25; the table30is approximately one-half as wide as the impeller25and approximately one-third as wide as the housing11. The table30prevents the impeller25from moving downward on the axle32and also contains the reduction cassette31in vertical movement. The table30is formed with a coaxial bore44(seen inFIG. 2) through which the drive fitting41extends on the axle32to engage with the reduction cassette31. The table30also includes four posts45which are supported by the cartridge24below and space the table30above the cartridge24. Within the space between the table30and the cartridge24, the reduction cassette31operates to convert the relatively fast rotation of the impeller25into relatively slow rotation of the disc33within the cartridge24.

The reduction cassette31includes a vertically-stacked set of central gears50meshingly engaged with two vertically-stacked sets of offset gears51. Each of the central and offset gears50and51includes an upper large gear integrally formed to a lower small gear, such that the large gears of the central gears50engage with the small gears of the offset gears51, and the small gears of the central gears50engage with the large gears of the offset gears51. The central gears50are mounted for free rotation on the axle32, and the offset gears51are mounted for free rotation on shafts (seen inFIG. 2) which are fit into and contained from vertical movement by the table30and the cartridge24. The impeller25, the drive fitting41, and the reduction cassette31are thus elements of a drive assembly carried by the housing11and operably coupled to the disc33in the cartridge24so as to impart rotation to the disc33within the cartridge24in response to application of water through the valve10and consequential actuation of the drive assembly. The central gears50and the offset gears54are mounted just above the cartridge24on the axle32and the shafts52, respectively, which are secured in place. The reduction cassette31is thereby contained vertically between the table30and the cartridge24.

Turning toFIGS. 4, 5A, and 5B, the cartridge24is shown in detail. InFIG. 4, the cartridge24is shown together with the reduction cassette31mounted atop the cartridge24. The cartridge24, and the reduction cassette31, are removable from the housing11and may be replaced if either wears out. Neither wears against nor engages with the housing11in a manner in which the housing11itself is worn, so that the housing11need not be replaced. The cartridge24and the reduction cassette31are applicable to the housing11to render the valve10operable.

The cartridge24includes a top plate53, an opposed bottom plate54, and the disc33interposed therebetween. The reduction cassette31is mounted on top of the top plate53. Turning toFIGS. 5A and 5B, the top plate53includes an upper surface60, an opposed lower surface61, a perimeter edge62, and a large central bore55. The top plate53is generally hexagonal prismatic, such that the perimeter edge62includes six sides which correspond in dimension to the hexagonal inner surface43of the sidewall12of the housing11into which the top plate53is snug fit as part of the cartridge24. The snug fit between the top plate53and the inner surface43of the sidewall12prevents water from flowing from the inlet22to the outlets23around the cartridge24. The top plate53has a relatively thin profile. The top plate53includes six apertures63. The apertures63are identical in every way other than location, and so only one aperture63will be described and referenced herein specifically, with the understanding that the description is equally applicable to the other apertures63unless otherwise noted. Additionally, not every aperture63will be marked with reference characters, for the sake of clarity of the drawings.

The aperture63is generally rectangular and extends vertically entirely through the top plate53. The aperture63is disposed between the perimeter edge62and the central bore55. The aperture63has an inner edge64, an opposed outer edge65, and opposed parallel sides66and67. The inner edge64and the outer edge65are each curved such that the inner edge64forms a convex edge of the aperture63and the outer edge65forms a concave edge of the aperture63. The sides66and67are parallel and arranged nearly radially with respect to the axis A. The sides66and67are tangential to the central bore55of the top plate53and are generally transverse to the inner and outer edges64and65.

As stated above, each of the apertures63is identical in structure. In location, the apertures63are spaced apart circumferentially about the central bore55, each separated by a solid wedge70. Each wedge70is formed integrally and monolithically as part of the top plate53. The wedges70are identical in every way other than location, and so only one wedge70will be described and referenced herein specifically, with the understanding that the description is equally applicable to the other wedges70unless otherwise noted. Additionally, not every wedge70will be marked with reference characters for the sake of clarity of the drawings. The wedge70has an inner end71and an outer end72. The inner end71is proximate to the central bore55and is defined between the inner edges64of two adjacent apertures63. The outer end72is proximate to the perimeter edge62and is defined between the outer edges65of the same two adjacent apertures63. The inner end71is narrower than the outer end72, such that the wedge70expands in width from the inner end71to the outer end72. The inner end71is approximately one-sixth the circumferential width of the inner edge64of one of the apertures63. The outer end72is approximately two-thirds the circumferential width of the outer edge65of one of the apertures63. Thus, the horizontal area of the wedge70is approximately one-third the horizontal area of one of the apertures63.

The top plate53includes four posts73which snap into and engage with the four posts45on the underside of the table30via fasteners74, as seen inFIGS. 2 and 3. The top plate53is also formed with two sockets75into which the shafts52are seated. The top plate53further includes a circumferential lip76depending from the lower surface61. The lip76contains the disc33at the top plate53.

Referring primarily toFIGS. 5A and 5Bstill, the bottom plate54includes an upper surface80, an opposed lower surface81, and a perimeter edge82extending around the bottom plate54between the upper and lower surfaces80and81. The bottom plate54is generally hexagonal prismatic, such that the perimeter edge82includes six sides which correspond in dimension to the hexagonal inner surface43of the sidewall12of the housing11into which the bottom plate54is snug fit as part of the cartridge24. The snug fit between the bottom plate54and the inner surface43of the sidewall12prevents water from flowing from the inlet22to the outlets23around the cartridge24. The bottom plate54includes a depending lip83formed on the lower surface81thereof, which lip83fits into a groove in the bottom13of the housing11to further lock the cartridge24in place and prevent water from flowing around the underside of the cartridge24. The bottom plate54has a relatively thin profile.

The bottom plate54includes six apertures83. The apertures83are identical in every way other than location, and so only one aperture83will be described and referenced herein specifically, with the understanding that the description is equally applicable to the other apertures83unless otherwise noted. Additionally, not every aperture83will be marked with reference characters, for the sake of clarity of the drawings. The aperture83is generally rectangular and extends vertically entirely through the bottom plate54. The aperture83has an inner edge84, an opposed outer edge85, and opposed parallel sides86and87. The inner edge84and the outer edge85are each curved such that the inner edge84forms a convex edge of the aperture83and the outer edge85forms a concave edge of the aperture83. The sides86and87are parallel and arranged nearly radially with respect to the axis A. The sides86and87are generally transverse to the inner and outer edges84and85.

As stated above, each of the apertures83is identical in structure. In location, the apertures83are spaced apart circumferentially about bottom plate54, each separated by a solid wedge90. Each wedge90is formed integrally and monolithically as part of the bottom plate54. The wedges90are identical in every way other than location, and so only one wedge90will be described and referenced herein specifically, with the understanding that the description is equally applicable to the other wedges90unless otherwise noted. Additionally, not every wedge90will be marked with reference characters for the sake of clarity of the drawings. The wedge90has an inner end91and an outer end92. The inner end91is proximate to the geometric center of the bottom plate54and is defined between the inner edges84of two adjacent apertures83. The outer end92is proximate to the perimeter edge62and is defined between the outer edges85of the same two adjacent apertures83. The inner end91is narrower than the outer end92, such that the wedge90expands in width from the inner end91to the outer end92. The inner end91is approximately one-sixth the circumferential width of the inner edge84of one of the apertures83. The outer end92is approximately two-thirds the circumferential width of the outer edge85of one of the apertures83. Thus, the horizontal area of the wedge90is approximately one third the horizontal area of one of the apertures83.

The bottom plate54includes several posts through which fasteners are applied so as couple the bottom plate54to the top plate53. The bottom plate54also includes a socket93located centrally on the upper surface80of the bottom plate54which extends into the bottom plate54from the upper surface80and is sized to receive the axle32. Opposed from the socket93, the bottom plate54has a post94extending downwardly from center of the lower surface81, which fits into and is seated in the bottom13of the housing11. When applied to the bottom13of the housing11, each of the apertures83is aligned with one of outlets23in the housing11. The bottom plate54includes an upstanding guide lip95extending upwardly from the upper face80proximate to the socket93; the guide lip95maintains rotational alignment of the disc33, as will be explained. The bottom plate54also includes an upstanding circumferential lip96which contains the disc33, in cooperation with the lip76formed on the lower surface61of the top plate53.

Disposed between the top and bottom plates53and54in the cartridge24is the disc33. The disc33is mounted in the cartridge24for rotation about the axle32in response to actuation of the drive assembly. As described above, relatively fast rotation of the impeller25imparts rotation to the central and offset gears50and51of the reduction cassette31, which imparts reduced and relatively slow rotation to the disc33, which moves the port34sequentially into and out of alignment with each of the apertures63and in the top and bottom plates53and54, so as to sequentially open and close each of the outlets23. In this manner, the disc33controls the opening and closing of the outlets23, thereby directing the flow of water through the valve10from the inlet22to each of the outlets23.

The disc33includes an upper surface100, a lower surface101, and a peripheral edge102extending continuously around the disc33between the upper and lower surfaces100and101. The disc33is circular and has a thin profile. The peripheral edge102of the disc33corresponds to the lip76on the lower surface61of the top plate53and the outer lip96on the upper surface81of the bottom plate54. The disc33includes the port34, and in the preferred embodiment shown throughout the drawings, there is only one port34. The port34is formed entirely through the disc33from the upper surface100through to the lower surface101. The port34corresponds in shape to the apertures63and83and is generally rectangular. The port34has an inner edge104, an opposed outer edge105, and opposed parallel sides106and107. The inner edge104and the outer edge105are each curved such that the inner edge104forms a convex edge of the port34and the outer edge105forms a concave edge of the port34. The sides106and107are parallel and arranged nearly radially with respect to the axis A. The sides106and107are generally transverse to the inner and outer edges104and105.

The disc33has an elevated gear110coaxial to the axis A and preferably formed integrally to the disc33. The gear110has a bore formed centrally therethrough to receive the axle32when the valve10is assembled. The gear110extends through the central bore55formed in the top plate53above the upper surface61of the top plate53and meshingly engages with the offset gears51of the reduction cassette31so that rotation of the offset gears51imparts rotation to the gear110and the disc33.

The disc33further includes a circular track103formed into the lower surface101of the disc33. The track103receives the circular, upstanding guide lip95when the disc33is carried on the bottom plate54. Cooperation of the track103and the guide lip95guides rotation of the disc33and limits lateral movement of the disc33within the cartridge24.

As seen inFIGS. 3, 4, 5A, and 5B, when the cartridge24is assembled, each of the apertures63in the top plate53is aligned with a corresponding one of the apertures83in the bottom plate54, thus forming a “set of apertures63and83.” As described above, the apertures83in the bottom plate54are aligned with the outlets23in the valve10, such that each set of apertures63and83is also aligned with the outlets23in the valve10. As the disc33rotates, it passes over the sets of apertures63and83to open and close the sets of apertures63and83. Referring now toFIG. 3, as water enters the valve10from the inlet22along arrowed line W, the impeller25rotates in a counter-clockwise rotation, causing the central and offset gears50and51in the reduction cassette31to rotate. The reduction cassette31, engaged with the gear110of the disc33, causes the disc33to rotate, albeit much more slowly than the impeller25. The rotating disc33sequentially moves the port34past each of the sets of apertures63and83. The disc33thus moves among a plurality of positions; when the port34is aligned with a first set of apertures63and83, the port34corresponds to the set of apertures63and83, and couples the interior15of the valve10in fluid communication with the outlet23with which the set of apertures63and83is aligned. Water may thus flow uninterrupted from the interior15through the aperture63in the top plate53, through the port34in the disc33, through the aperture83in the bottom plate54, and then exit out the outlet23, as shown by the line X inFIG. 3. The outlet23is thereby fully opened.

Rotation of the disc33slowly moves the port34out of position and out of alignment with the set of apertures63and83and thus slowly closes the outlet23aligned with that set of apertures63and83. To distinguish from the set of apertures63and83and the outlet23which is being closed, the port34moves toward an “adjacent” set of apertures63and83which are aligned with an “adjacent” outlet23. As the port34is rotated out of alignment, the side106of the port34moves away from the sides66and86of the apertures63and83, respectively, and over the wedges70and90in the top and bottom plates53and54, respectively. Likewise, the opposed side107moves away from the sides67and87of the apertures63and83, respectively, and over the apertures63and83themselves. The approximately one-third surface area of the wedges70and90, compared with that of the apertures63and93, together with the wide inner ends71and91of the wedges70and90, provides the valve10with a unique timing feature. In other valves, water is nearly always simultaneously passed through one valve and an adjacent valve, or “shared” between adjacent valves. However, the valve10delays sharing between valves for a considerable amount of time. The port34is able to move approximately one third of the way out of one of the sets of apertures63and83before any water is passed through the adjacent set of apertures63and93. This provides a more dedicated flow of water out of each outlet23to each in-floor cleaning head for a longer amount of time than has been conventionally available.

The disc33continues rotation to place the port34over the adjacent set of apertures63and83to open the adjacent outlet23aligned with that adjacent set of apertures63and83. When the port34is aligned over the adjacent set of apertures63and83, water may flow uninterrupted from the interior15through the adjacent aperture63in the top plate53, through the port34in the disc33, through the adjacent aperture83in the bottom plate54, and then exit out the adjacent outlet23. The adjacent outlet23is thereby fully open. Rotation of the disc33continues, thereby slowly and sequentially opening and closing all of the outlets23to communicate water to the in-floor cleaning heads installed throughout the pool.

A preferred embodiment is fully and clearly described above so as to enable one having skill in the art to understand, make, and use the same. Those skilled in the art will recognize that modifications may be made to the described embodiment without departing from the spirit of the invention. To the extent that such modifications do not depart from the spirit of the invention, they are intended to be included within the scope thereof.