Brining system

A brining system including a brine reservoir containing a supply of salt and a brine valve assembly disposed in the reservoir below the level of the salt and including a vessel for accumulating a predetermined quantity of fluid to be discharged into the reservoir to form a regeneration solution. A control valve forming part of the brine valve assembly includes a spool member shiftable between two positions. In one position a fluid supply line is communicated with the accumulating vessel and in a second position the vessel is communicated with the brine reservoir. The spool includes effective pressure areas for monitoring pressures in the supply line and the vessel. When a predetermined level in the accumulating vessel is reached, a flow of fluid into the vessel is terminated and the resulting change in pressure sensed by the spool causes it to shift to a position at which fluid in the vessel is discharged into the brine reservoir while fluid flow from the supply line is concurrently terminated. During a regeneration cycle, "suction" pressures generated in the supply line cause the spool to return to its first position. In one embodiment, the vessel includes a check ball controlled vent port whereas in an alternate embodiment an adjustable float mechanism controls the final fluid level in the vessel.

TECHNICAL FIELD 
This invention relates generally to valves, and in particular, to a brining 
system used in a water softening apparatus. 
BACKGROUND ART 
A household water softener system typically includes a resin tank through 
which hard water passes to exchange its "hard" ions of calcium and 
magnesium for "soft" sodium ions or other regenerant ions. Regeneration of 
the resin bed is required periodically to replenish the supply of "soft" 
ions and to remove the accumulation of "hard" ions from the bed. The 
regeneration is effected by flushing a brine solution through the resin 
tank. A water softener of this type is more fully described in U.S. Pat. 
No. 3,891,552, issued June 24, 1975 to William C. Prior and James W. 
Kewley, entitled CONTROL VALVE FOR WATER SOFTENERS, the disclosure of 
which is incorporated herein by reference. 
Modern water softeners of the type disclosed in U.S. Pat. No. 3,891,552 
typically employ a brine tank which includes a reservoir and a supply of 
salt disposed at a level above the bottom of the reservoir. A tube 
connected to a source of water provides a path for supplying water to the 
reservoir. Upon the attainment of a predetermined level in the reservoir, 
the water begins dissolving some of the salt supply and creates a source 
of brine for regeneration of the resin bed. When regeneration is required, 
the brine is aspirated through the same tube that supplied water to the 
reservoir. The amount of water introduced to the brine reservoir after a 
regeneration cycle and the amount of brine aspirated from the reservoir 
during a regeneration cycle is controlled by a brine valve mechanism. 
Many prior art brine valves utilize float arrangements to directly control 
the level of brine in the brine tank as well as the quantity of brine 
solution discharged from the brine tank during a regneration cycle. The 
floats in these prior brine valves are usually exposed to the brine 
solution. An example of such a brine valve is illustrated in Pat. No. 
4,336,134 which is owned by the assignee of the present application. The 
trend today in water softening equipment is to minimize the quantity of 
salt and hence brine solution that is used during regeneration and as a 
consequence, and it therefore is desireable to reduce the volume of brine 
solution stored in the brine tank. In order for the system to function 
properly, the volume of fresh water added to the brine tank as well as the 
quantity of brine solution withdrawn from the tank during regeneration 
must be precisely controlled. Although the brine valve illustrated in U.S. 
Pat. No. 4,336,135 operates satisfactorily and has been commercially 
successful, it has been found that under some conditions, the volume of 
water added to the reservoir after regeneration varies and as a result the 
brine solution quantity also varies. These types of brine valves are also 
sensitive to orientation and if the brine tank is not absolutely level, 
variations in liquid level will occur that will vary the amount of salt 
consumed for a given regeneration cycle. 
DISCLOSURE OF THE INVENTION 
The present invention provides a new and improved brining system and in 
particular provides a new and improved brine valve assembly that is 
capable of precisely controlling the amount of brine solution created and 
used in water treatment system such as a water softener. Unlike most prior 
art brine valves, the valve assembly of the present invention meters a 
predetermined volume of fluid (i.e., fresh water) into a brine reservoir 
in order to provide a precise quantity of brine solution. 
In the preferred embodiment, the brine valve assembly for use with a water 
softening system includes a storage tank or vessel that is used to measure 
and accumulate a precise, predetermined quantity of fluid such as water 
that is added or discharged into the brine reservoir to form the brine 
solution. A valve member, responsive to pressurization and 
depressurization of a brine supply conduit controls the filling of the 
vessel and the discharge of the accumulated fluid from the vessel into the 
brine reservoir. 
According to the preferred and illustrated embodiment, the brine valve 
assembly defines an inlet port through which brine solution is drawn 
during a regeneration cycle and at least one outlet port through which 
fluid from the vessel is discharged into the brine reservoir. According to 
the exemplary embodiment, the valve member for controlling the 
communication of the storage vessel with the fluid supply line and with 
the brine reservoir comprises a spool valve that is shiftable between two 
positions. In one position, the fluid supply line is communicated with the 
vessel; in the second position the vessel is communicated with the 
regeneration solution reservoir. 
The spool is preferably operated by sensed pressures in the supply line. In 
the preferred embodiment, the flow path of fluid from the supply line to 
the vessel includes a check valve which prevents fluid flow from the tank 
into the supply line when the supply line is depressurized. Regeneration 
solution is drawn from the brine reservoir through the inlet port whenever 
the supply line is depressurized below ambient pressure. The check valve 
in the flow path between the inlet port and the supply line inhibits or 
prevents fluid flow into the regeneration reservoir from the inlet port 
when the supply line is pressurized. 
According to a feature of the invention, the inlet port includes a valving 
member which seals off the inlet when the solution level in the brine 
reservoir is drawn down to a predetermined level. In this way, a precise 
quantity of brine solution is always drawn from the reservoir during a 
regeneration cycle. Once the predetermined quantity is drawn, the inlet 
port is sealed by the valving member to prevent further solution draw. 
According to the preferred method of operating, the brining system is 
started with the valve member in the first position at which the fluid 
supply line is communicated with the vessel. The brine supply line is 
normally pressurized when not in the regeneration cycle and as a result, 
if the vessel is empty it will fill with fluid, i.e., water from the 
supply line. After the vessel is filled, the valve member shifts to its 
second position at which the supply line is sealed from the vessel and at 
which the outlet port is communicated with the vessel so that fluid in the 
vessel is discharged into the brine reservoir thereby generating a precise 
quantity of brine solution. 
When a regeneration cycle is initiated, the fluid supply line will 
depressurize and cause brine solution to be drawn from the brine solution 
reservoir through the inlet port. When the brine solution in the reservoir 
is lowered to a predetermined level, the valving member seals off the 
inlet and causes the pressure in the supply line to decrease further. The 
negative pressure (with respect to ambient) developed in the supply line 
once the inlet port is sealed, is sensed by the valve member causing it to 
move to its first position at which the supply line is communicated with 
the vessel. The check valve, however, in the flow path between the supply 
line and the vessel prevents air or other fluid from being drawn from the 
vessel. At the conclusion of the regeneration cycle, the supply line is 
again pressurized. The check valve allows fluid under pressure from the 
supply line to flow into the tank until the tank is again filled whereupon 
the spool valve shifts to the second position. With the spool in the 
second position, the fluid is discharged from the vessel into the brine 
reservoir. 
In one embodiment of the invention, the vessel comprises a fixed volume 
tank having a discharge passage at its lower end so that fluid is 
discharged from the tank under the influence of gravity, when permitted. A 
check valve controlled vent is located at an uppermost portion of the tank 
through which air within the tank is discharged as the tank fills with 
fluid. When the tank is substantially completely filled, the check valve 
seals the vent thus causing the tank pressure to rise towards the pressure 
of the supply line. This pressurization is sensed by the valve member and 
upon sensing a predetermined rise in pressure causes it to shift to its 
second position at which the outlet port is communicated with the tank to 
enable the fluid in the tank, under the influence of gravity, to be 
discharged into the brine reservoir. 
In an alternate embodiment, the vessel comprises a tank assembly including 
a float mechanism that is operatively connected to a valve element for 
controlling the communication of the fluid supply conduit with the tank. 
In the alternate embodiment, the valve element is located in a passage 
located between the tank and the supply conduit. The pressure in the 
passage is sensed by the spool. When a predetermined quantity of fluid has 
entered the tank (as determined by the float setting) the float causes the 
valve element to terminate the communication of the supply conduit with 
the tank and causes the passage to pressurize. This pressurization is 
sensed by the valve member and drives it to its second position at which 
the outlet port is communicated with the tank and causes fluid in the tank 
to be discharged into the brine reservoir under the influence of gravity. 
In the alternate embodiment, the tank includes an overflow conduit which, 
in the event of failure in the valve member, directs the excess fluid 
communicated to the tank, to a remote location to inhibit or prevent over 
filling of the brine reservoir. 
Additional features of the invention will become apparent and a fuller 
understanding obtained by reading the following detailed description made 
in connection with the accompanying drawings.

BEST MODE FOR CARRYING OUT THE INVENTION 
FIG. 1 illustrates, somewhat schematically, the overall construction of a 
water softening apparatus embodying the present invention. The illustrated 
apparatus would be termed a "twin tank" system and includes a pair of 
resin tanks 10, 12 interconnected by a control valve 14. The control valve 
may, for example, be of the type disclosed and claimed in U.S. Pat. Nos. 
3,891,552 and 4,298,025, which are both owned by the assignee of the 
present application and which are both hereby incorporated by reference. 
Among other functions, the control valve 14 controls which of the two 
tanks is "on-line" and actively treating water and controls the 
regeneration of an exhausted tank. After a regeneration cycle, the 
regenerated tank is maintained off-line by the control valve 14 until the 
on-line tank is exhausted and requires regeneration. 
Regeneration of an exhausted tank requires that a regeneration solution be 
passed through the resin bed in order to displace the ions that were 
captured during the treating process. The source of regeneration solution 
is provided by a regeneration reservoir 16. In a water softening system, 
this unit is usually termed a brine unit. The brine unit 16 includes a 
tank 20 which normally contains a supply of salt 18 or other source of 
regenerant ions. A quantity of water is usually added to the tank to form 
a brine solution near the bottom of the tank. During a regeneration cycle, 
a quantity of this solution is drawn into the control valve 14 and is 
passed through the resin bed of an exhausted tank. The flow of water into 
the regeneration vessel and the flow of brine solution out of the 
reservoir is controlled by a brine valve assembly 30 constructed in 
accordance with the preferred embodiment of the invention. Fluids are 
conveyed between the reservoir 16 and the control valve 14 by a supply 
line 32, one end of which is connected to the control valve 14, the other 
end of which is attached to a fitting 34 on the brine valve assembly 30. 
The brine valve 30 is disposed near the bottom of the regeneration 
reservoir 16. The supply of salt may be supported above the brine valve by 
a support grid (not shown) or alternately, the salt supply completely 
surrounds the brine valve assembly 30 as shown in FIG. 1. 
In the preferred embodiment, the brine valve 30 is located in a brine well 
36 (shown in FIG. 2) which in turn is surrounded by the salt supply. The 
brine well 36 physically protects the valve assembly and also facilitates 
access to the valve for service or maintenance. The brine well may include 
one or more openings 38 (shown only in FIG. 2) through which the brine 
solution enters the well and/or through which water enters the reservoir. 
The brine valve assembly 30 includes a valve unit 40 and a vessel or tank 
42 defining a predetermined volume. According to one embodiment of the 
invention, the volume of the tank 42 determines the quantity of 
regeneration solution generated in the reservoir and hence the amount of 
solution drawn into the control valve 14 during a regeneration cycle. For 
this reason, the quantity of solution and the amount of salt consumed 
during a regeneration cycle can be carefully controlled since precise 
amounts of fluid as measured and/or determined by the tank 42 are used in 
creating the regeneration solution. 
The valve assembly 40 includes a valve housing 50 that slidably supports a 
control spool 52. The spool 52 which, as seen in FIG. 1, is vertically 
oriented is slidable between two positions. The valve unit 40 defines a 
passage 54 which is connected to the supply line 32. The spool housing 
includes a cap-like structure 70 that is internally threaded and is 
adapted to threadedly receive a neck-like portion 42a of the vessel 42. An 
O-ring 72 seals the connection between the tank and the cap. A narrow 
segment 50a of the valve housing 50 extends into the interior of the 
vessel 42 and defines a plurality of radially directed bores 74 that 
communicate the interior of the spool housing 50 with the inside of the 
vessesl 42. A plurality of bores 76 are also defined in a lower segment 
50b of the spool housing 50 just below the cap and communicate the 
interior of the housing with the brine tank. 
As seen in FIG. 1, the spool 52 includes a central passage 77 terminating 
in a blind end wall 77a. A cross bore is machined at the upper end of the 
spool and defines two radial bores 78. The bores 78 communicate the 
internal passage 77 with the outside of the spool in an isolated region 79 
defined between upper and lower O-rings 80, 82, respectively. A check 
valve 84 which may be of the "duckbill" variety is mounted near or at the 
bottom of the spool 52 (as viewed in FIG. 1) and allows fluid to enter the 
internal passage 77 from the supply passage 54 (via branch bore 54a) while 
preventing reverse flow. With the spool 52 in the lower position, as shown 
in FIG. 1, fluid from the supply passage flows past the check valve 84 
into the internal passage 77 and out the cross bores 78 and into the 
interior of the vessel via the housing bores 74. A port 88 is formed at 
the top of the housing segment 50a and vents fluid above the spool 52 into 
the tank 42. 
An air check mounted at or near the top of the vessel 42 includes a buoyant 
ball check 90, engageable with a seat 92 which communicates with 
atmosphere through a vent 96. The ball check is captured by a cage 98 
including a screen 98a. As the vessel fills with fluid the displaced air 
is discharged through the passage 96. When the tank fills, the buoyant 
check valve engages the seat and prevents further discharge of air and/or 
fluid from the interior of the tank. 
When the passage 96 seals, the vessel begins to pressurize and as a result 
fluid pressure in the supply passage exerts an upwardly directed force on 
the spool, the magnitude of which is determined by the diameter or 
effective pressure area 102 of a lower region 52a of the spool 52. In the 
disclosed embodiment, the effective pressure area 102 to which supply 
pressure is applied is larger than an upper effective pressure area 104 to 
which vessel pressure is applied. When sufficient force is developed on 
the area 102, the spool 52 is shifted to its upper position shown in FIG. 
2. In this position, a flow path is established, as indicated by the arrow 
100 in FIG. 2 between the vessel outlets 74 formed in the upper segment 
50a of the spool housing 50 and the discharge outlets 76 formed in the 
lower segment 50b via an internal passage 106 defined between the housing 
50 and the spool 52. In the disclosed configuration, gravity causes the 
fluid in a vessel to drain through the ports 74, 76 and the interior 
passage 106 of the housing 50 into the brine reservoir 20. With the spool 
52 in the upper position, (shown in FIG. 2) fluid from the supply passage 
54 is prevented from entering the vessel 42. The check valve 84 prevents 
fluid (or air) from the tank from being drawn into the supply passage when 
it is depressurized (as occurs during the regeneration cycle). 
The supply passage 54 communicates with a port 110 by a short, upwardly 
directed (as viewed in FIG. 1) passage 112 that connects the port 110 with 
the supply line 32. The 110 port defines a valve seat for a buoyant valve 
check 122. The ball check is captured by a cylindrical filter screen 124 
that also surrounds the discharge port 110 and valve seat so that fluid 
entering the port from the brine tank 20 is filtered. A check valve 126 
which may be of the "duckbill" variety is mounted near the valve seat 110 
and allows fluid flow from the port into the short connecting passage 112 
but prevents reverse flow. In the preferred and disclosed embodiment, the 
"duckbill" check valve and seat 110a are formed in a single element. 
When the fluid in the vessel 42 is discharged into the brine reservoir 20, 
the ball check 122 is lifted from the seat 110a defined at the discharge 
port 110. When a regeneration cycle is commenced (by the control valve 14) 
the supply line 32 is normally depressurized and begins drawing solution 
from the brine reservoir through the inlet port 110 and check valve 122. 
As the regeneration solution is drawn from the reservoir, the level 
gradually falls causing the ball check to move towards its associated seat 
110a. As the regeneration solution level reaches the top of the seat, the 
ball check re-engages and seals port 110 preventing further flow of 
regeneration solution from the reservoir 20. When the ball 122 seals the 
port 110, a negative pressure or vacuum (with respect to ambient) will be 
developed in the supply passage. When a predetermined negative pressure is 
reached, the negative force exerted on the spool 52 (on the effective 
pressure area 102) will cause it to move to the lower position (shown in 
FIG. 1). At the conclusion of a regeneration cycle, the supply line 32 is 
normally repressurized with water and as a result, the vessel 42 again 
will fill with fluid. The fluid is ultimately discharged into the brine 
reservoir 20 after the spool 52 shifts to its upper position as explained 
above. 
Turning now to FIG. 2, an alternate embodiment of the invention is 
illustrated. In this embodiment, the amount of fluid accumulated by a 
fluid vessel 42' forming part of the brine valve assembly 30', is 
adjustable. To facilitate the explanation, components in the alternate 
embodiment that are similar in configuration and function as those in the 
first embodiment will be designated with the same reference character 
followed by an apostrophe ('). The fluid control spool in both of the 
embodiments is identical and will be designated by the same reference 
character (52). 
The alternate brine valve assembly 30' includes a brine valve unit 40' 
connected to a water softener control valve 14 by means of a supply 
conduit 32'. As in the first embodiment, the brine valve assembly 30' is 
located at the base of a brine reservoir 20 and in the preferred 
embodiment may be completely covered with a supply of salt 18'. 
In this alternate embodiment, however, a fluid accumulating vessel 42' for 
measuring and accumulating water to be discharged into the brine reservoir 
20 houses a float assembly 150. The vessel 42' is mounted to an extension 
member 152 which in turn is attached to the brine valve 30'. In the 
disclosed embodiment, the lower end of the extension member 152 is 
threadedly received by the cap-like structure 70' forming part of the 
brine valve 30'. The extension member 152 defines a short interconnecting 
fluid passage 154 for fluidly communicating the radial ports 74' formed in 
the housing 50' with the interior of the vessel 42' by way of a float 
operated shut-off valve 156. The upper end of the extension member 152 
receives and seals a downwardly depending neck 158 defined by the vessel 
42'. 
The float assembly 150 disposed within the vessel includes a float member 
170 defining a throughbore 172 through which a guide rod 174 extends. The 
position of the float with respect to the guide rod 174 is determined by a 
pair of upper and lower guide stops 176, 178 which are adjustable. The 
lower end of the guide rod mounts the valve member 156 which is engageable 
with a seat 182 defined by the extension member 152. 
As explained above, when the control spool 52' is in the lower position 
(shown in FIG. 2), fluid in the supply passage 54' can travel through the 
spool (by way of the internal passage 77') and out through the radial 
bores 74' defined in the spool housing 50'. In this embodiment, fluid 
leaving the radial bores 74' enters the passage 154 defined by the 
extension member and travels into the vessel 42' as long as the shut-off 
valve 156 is spaced from the valve seat 182. As the vessel fills with 
fluid, the top of the float 170' engages the upper stop 176 and gradually 
raises the shut-off valve 156. When the fluid reaches a predetermined 
level, the shut-off valve engages its associated seat 182 and prevents 
further flow of fluid from the passage 154 into the vessel 42'. The 
passage 154 then gradually pressurizes and as in the first embodiment, 
when fluid is no longer able to proceed into the vessel 42', the pressure 
of the supply shifts the spool member 52 upwardly to its second position 
(shown in FIG. 2). In this position, the extension member passage 154 is 
communicated with the outlet ports 76' defined in the valve housing 50'. 
Fluid in the passage 154 will discharge into the brine reservoir. As the 
passage 154 drains, the reduction of force on the shut-off valve 156 will 
cause it to open to allow fluid from the vessel to also drain into the 
brine reservoir. 
According to a feature of this embodiment, the upper region of the vessel 
42' is enclosed by a top cover 190 including a barbed discharge overflow 
port 192. The port is connected to a drain conduit 196 which in the 
preferred embodiment extends through brine reservoir tank 20' and may be 
connected to a suitable drain. With this embodiment, should a failure in 
the brine valve 30' occur that would prevent the spool 52' (or shut-off 
valve 156) from sealing off the supply of fluid, the excess fluid would be 
diverted to a drain or other suitable location and not cause an overflow 
of brine solution. 
Although the invention has been described with a certain degree of 
particularity it should be understood that those skilled in the art can 
make various changes to it without departing from the spirit or scope as 
hereinafter claimed.