Abstract:
A flow valve assembly includes a valve operable between an open position and a closed position and a controller operatively coupled to the valve to operate the valve between the open position and the closed position. A mechanically or electrically operated assembly is provided to determine an amount of fluid flow through the valve when the valve is in the open position. A mechanically or electrically operated mechanism moves the valve from the open position to the closed position when the amount of fluid flow exceeds a predetermined value. A method of operating the valve is also provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority from U.S. Provisional Patent Application Ser. No. 61/931,567, filed on Jan. 25, 2014 and U.S. Provisional Patent Application Ser. No. 62/006,059, filed on May 31, 2014, both of which are incorporated herein by reference in their entireties. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a valve assembly with an automatic shut-off. The valve assembly can be used with a fluid, such as a liquid or a gas. 
       BACKGROUND OF THE INVENTION 
       [0003]    The Environmental Protection Agency estimates that on average a household can waste over 10,000 gallons of water a year to leaks. The two most common household wastes of water are due to leaky faucets and toilets. Unattended faucets that leak at one drop per second can waste up to 2,700 gallons of water a year, while a toilet leaking at one gallon per minute will waste 1,440 gallons per day, and 525,600 gallons a year. According to the American Water Works Association, toilets account for 26.7% of all indoor water use in a typical residence, and 20% of all toilets leak. If a home is left unattended, perhaps when the residents go on a trip or vacation, these leaks can go on for days unnoticed and unstopped. If the flow of a typical shower, 2.2 gallons per minute (GPM), is left to accumulate for a week on the floor of a 1000 ft 2  basement, residents would come back to nearly 3 feet of flooding and 22,176 extra gallons on their water bill. 
         [0004]    Typical water use through a household water main through a 24 hour period results in large periods of the day water goes unused, with the longest stretches of continuous use being typically less than thirty minutes. Water also generally flows at over one (1) GPM when in use. Unlike normal use, leaks are continuous and usually at a lower rate. A house with leaking water or running faucet would not return to zero in between uses of water. Instead a continuous flow would be detected at all times. 
         [0005]    It would be beneficial to develop a control device that can detect leaks based off long uninterrupted flow and stop such leaks. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. 
         [0007]    Briefly, the present invention provides a flow valve assembly comprising a valve operable between an open position and a closed position and a controller operatively coupled to the valve to operate the valve between the open position and the closed position. A means for determining an amount of fluid flow through the valve when the valve is in the open position and a means for operating the valve from the open position to the closed position when the amount of fluid flow exceeds a predetermined value are also provided. 
         [0008]    Further, the present invention provides a flow valve assembly comprising a valve operable between an open position and a closed position, a controller operatively coupled to the valve to operate the valve between the open position and the closed position, and a flow meter operatively disposed downstream of the valve. A processor is operatively coupled to the flow meter to receive an electronic signal from the flow meter and operatively coupled to the controller to transmit an electronic signal to the controller to operate the valve from the open position to the closed position if the flow meter does not transmit the electronic signal from the flow meter indicating zero fluid flow through the flow meter for a time period greater than a predetermined time period. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0009]    The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the presently preferred embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention. In the drawings: 
           [0010]      FIG. 1  is a schematic drawing of a control/shut-off valve assembly according to a first exemplary embodiment of the present invention mounted in a fluid system; 
           [0011]      FIG. 2  is a side sectional view of the control/shut-off valve assembly shown in  FIG. 1 , in an unblocking position; 
           [0012]      FIG. 3  is a side sectional view of the valve assembly shown in  FIG. 1 , in a blocking position; 
           [0013]      FIG. 4  is a schematic view of an alternative embodiment of a fluid system incorporating the control/shut-off valve assembly of  FIGS. 1-3 ; 
           [0014]      FIG. 5  is a schematic view of an alternative embodiment of a control/shut-off valve assembly according to the present invention; 
           [0015]      FIG. 6  is a schematic view of an alternative embodiment of a microprocessor controlled control/shut-off valve assembly according to the present invention; 
           [0016]      FIG. 7  is an enlarged schematic view of the control/shut-off valve assembly shown in  FIG. 6 ; 
           [0017]      FIG. 8  is a schematic view of a microprocessor controller used with the valve assembly shown in  FIG. 6 ; 
           [0018]      FIG. 9  is a schematic view of the control/shut-off valve assembly shown in  FIG. 6  used in conjunction with a toilet; 
           [0019]      FIG. 10  is a schematic view of the valve assembly shown in  FIG. 6  used in a building fluid supply line; 
           [0020]      FIG. 11  is a perspective view of a valve assembly according to an alternative embodiment of the present invention; and 
           [0021]      FIG. 12  is a sectional view taken along lines  12 - 12  of  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0022]    In the drawings, like numerals indicate like elements throughout. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. The terminology includes the words specifically mentioned, derivatives thereof and words of similar import. As used herein, the term “fluid” can mean and material that flows, including a liquid or a gas. The embodiments illustrated below are not intended to be exhaustive or to limit the invention to the precise form disclosed. These embodiments are chosen and described to best explain the principle of the invention and its application and practical use and to enable others skilled in the art to best utilize the invention. 
         [0023]    Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments necessarily mutually exclusive of other embodiments. The same applies to the term “implementation.” 
         [0024]    As used in this application, the word “exemplary” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion. 
         [0025]    Additionally, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. 
         [0026]    Referring to  FIG. 1 , a control/shut-off valve assembly  100  according to a first exemplary embodiment of the present invention is shown. Control/shut-off valve assembly  100  can be used to detect fluid flow downstream of valve assembly  100  and to secure, or shut-off, valve assembly  100  to prevent further fluid flow past control/shut-off valve assembly  100 . 
         [0027]    Control/shut-off valve assembly  100  has many potential uses, such as, for example, global use in a home or residential building to detect a break in a water line and take corrective action to prevent loss of fluid. Further, control/shut-off valve assembly  100  can be used locally at a particular fixture, such as a toilet, to detect excess “running” of the toilet after a flush and to shut-off flow to that toilet to prevent excessive use/waste of water. 
         [0028]    Control/shut-off valve assembly  100  can be incorporated into new construction or “backfit” into an existing fluid line. Control/shut-off valve assembly  100  is inserted between a supply line  50  that is upstream of valve assembly  100  and a discharge line  52  that is downstream of valve assembly  100 . Supply line can be in fluid communication with a source of fluid, such as a public water connection, a well, a gas main, or any other fluid source. Discharge line  52  can be in fluid communication with a device, such as a toilet, a faucet, a gas heater, or any other device to which the fluid flows. 
         [0029]    Control/shut-off valve assembly  100  can be a strictly mechanical assembly that can be used for relatively low value applications, such as, for example, a toilet.  FIG. 2  shows an enlarged schematic of an exemplary mechanical system that can be used to operate assembly  100 . 
         [0030]    Control/shut-off valve assembly  10  uses a diaphragm  112  and a piston  114  to close assembly  100  if too much fluid passes through assembly  100 . Control/shut-off valve assembly  100  includes a through-passage  116  through which the fluid flows. A vacuum chamber  118  is located outside of through-passage  116 . Diaphragm  112  makes up a wall of vacuum chamber  118 . 
         [0031]    Diaphragm is coupled to a first end of a diaphragm lever  120 . A second end of diaphragm lever  120  is coupled to a first linkage arm  122 . First linkage arm  122  is pivotally coupled at a first end to pivot point  124  and at a second end to the first end of a second linkage arm  126 . Second linkage arm  126  serves as a support to keep piston  114  out of through-passage  116  in a “no flow” condition. A first end of a first biasing member  128  biases first linkage arm  122  to the position shown in  FIG. 2 . A second end of first biasing member  128  pushes against a support  130 . 
         [0032]    Piston  114  is located inside a piston housing  132 . A second biasing member  134  biases piston  114  against the top of piston housing  132  toward through-passage  116 . O-rings  135 ,  136  around the circumference of piston  114  maintain a seal between piston  114  and piston housing  132  to prevent fluid from leaking past piston  114 . A handle  138  is connected to the top of piston  114  and extends outwardly through the top of piston housing  132 . 
         [0033]    When fluid flows from supply line  50 , through the passage  116 , to discharge line  52 , a venturi effect draws any fluid from vacuum chamber  118  into through-passage  116 , which in turn draws diaphragm  112  toward the direction of arrow A in  FIG. 2  toward the position shown in  FIG. 3 . The movement of diaphragm  116  pulls diaphragm lever  120  to the left, from the position shown in  FIG. 2  to the position shown in  FIG. 3 . 
         [0034]    As diaphragm lever  120  moves to the left, first linkage arm  120  pivots about pivot point  124  and pulls second linkage arm  126  to the left, from the position shown in  FIG. 2 . If more than a predetermined amount of fluid flows through through-passage  116 , second linkage arm  126  is pulled to the position shown in  FIG. 3 , in which second linkage arm  126  is pulled away from piston  114  and piston is forced by second biasing member  134  into through-passage  116 , thereby shutting off flow of fluid through through-passage  116 . If the flow of fluid through through-passage  116  is not excessive (i.e., within predetermined limits), then second linkage arm  126  is not pulled all of the way to the left as shown in  FIG. 3 , and maintains piston  114  within piston housing  132 . 
         [0035]    To reset piston  116  after it has been released from piston housing  132 , handle  138  is pulled outward, raining piston  114  back into piston housing. First biasing member  128  forces first linkage arm  122  back to the position shown in  FIG. 2 , which in turn moves second linkage member  126  back under piston  114  to retain piston  114  within piston housing  132 . 
         [0036]    Optionally, as shown in  FIG. 4 , control/shut-off valve assembly  100  can also include a bypass assembly  150 . Bypass assembly  150  can be used when the user intentionally plans to use an excessive amount of water for a prolonged period of time, such as, for example, for watering a lawn. Bypass assembly  150  includes a first Y-valve  152  that can be operated in a first position to direct fluid from supply line  50  through valve  110  or a second position to direct fluid around valve  110  to a bypass line  154 . Bypass assembly  150  also includes a second Y-valve  156  that can be operated in a first position to allow fluid flowing from valve  110  to flow to discharge line  52  or a second position to allow fluid to flow from bypass line  154  to discharge line  52 . 
         [0037]    First and second Y-valves  152 ,  156  can be manually operated or electrically operated. Additionally, bypass assembly  150  can include an audible alarm  158  to indicate that bypass assembly  150  is in “bypass” mode. For example, if the user is in bypass mode and is using water to water a lawn, alarm  158  can sound over intermittent time periods such as, for example, every few minutes (similar to a smoke alarm whose battery is dying), to remind the user that the fluid system is in “bypass” mode. 
         [0038]    Audible alarm  158  can be electrically connected to any part of bypass assembly  150 . Audible alarm  158  can be connected to an optional flow meter  160  in bypass line  156 . If flow meter  160  detects any fluid flow within bypass line  154 , electronics  162  trigger audible alarm  158  to activate. When Y-valves  152 ,  156  are reset to transfer fluid through valve  100 , flow meter  160  will detect no flow, and electronics  162  will no longer transmit a signal to audible alarm  158  to activate. 
         [0039]    An alternative embodiment of a valve assembly  200  according to the present invention is shown schematically in  FIG. 5 . Valve assembly  200  is an electrically operated assembly and can be used for higher value applications, such as, for example, on the supply line to an apartment or office building. Valve assembly  200  includes a valve  210  that is operable between a fully open and a fully closed position. In an exemplary embodiment, valve  210  can be a ball valve, a butterfly valve, a stop valve, a gate valve, a solenoid valve, or any other known valve that can be electrically activated to a fully closed position so that no fluid passes through valve  210 . 
         [0040]    Valve assembly  200  also includes an electronic flow detector  220  that determines whether fluid is flowing past valve  210 . Flow detector  220  can measure the delta pressure on either side of valve  210 . When fluid is not flowing through valve  210  (i.e., when discharge line  52  does not have fluid flowing therethrough), the fluid pressure on both the upstream side and downstream side of valve  210  should be the same, resulting in no delta pressure. In this condition, valve  210  is in an open position. 
         [0041]    If, however, a pressure difference of greater than zero is measured between the upstream and downstream sides of valve  210 , fluid is flowing through valve  210 . If a pressure difference of greater than zero is measured for longer than a predetermined period of time, valve  210  is automatically closed to prevent additional water flow through valve  210 . For example, if valve assembly  200  is attached to a supply for a toilet (not shown), if flow detector  220  detects fluid flow for over  10  minutes, valve assembly  200  will assume that the toilet is “running” and transmits a signal to close valve  210 . 
         [0042]    To open valve  220  to allow fluid flow therethrough after valve  220  has closed, a reset button  222  on flow detector  220  can be pushed to transmit an electronic signal to open valve  210  and allow fluid to flow through valve  210 . 
         [0043]    Referring now to  FIGS. 6 and 7 , a valve assembly  300  according to another exemplary embodiment of the present invention is shown. Valve assembly  300  is electrically operated microprocessor controlled and can be used with different fluids, such, for example, water, gas, or other such fluid. 
         [0044]    Valve assembly  300  includes a valve  310  in fluid communication with a flow meter  320 . Valve assembly  300  is installed in a fluid system between supply line  50  and discharge line  52 . In an exemplary embodiment, valve  310  can be located operationally downstream from flow meter  320 , as shown in  FIG. 6 , although those skilled in the art will recognize that valve  310  can alternatively be located operationally upstream from flow meter  320 . 
         [0045]    Valve  310  can be a ball valve, a butterfly valve, a solenoid valve, or some other type of valve that can open and close with a minimum amount of operation of a valve actuator. Valve  310  includes a valve controller  312  that operates valve  310  between an open position and a closed position. Valve controller  312  can be operated by a direct current (DC) power source, such as a battery  314  (shown in  FIG. 8 ). Due to the application of valve  310 , in an exemplary embodiment of the present invention, valve  310  is typically maintained in either a fully closed or a fully open condition. It is typically not desired to “throttle” valve  310  in a partially open condition. 
         [0046]    Flow meter  320  can include a water turbine that rotates as fluid passes through. An exemplary flow meter  320  can be a G5/4″ SEN02142B flow meter that is presently commercially available. The frequency of the rotation is measured and converted to a flow rate of the fluid through flow meter  320  by a controller  340 , such as a microprocessor, that is electronically coupled to both valve  310  and flow meter  320 . A breadboard  342  provides connections to controller  340 . Breadboard  342  is used for developmental purposes and those skilled in the art will recognize that a commercial version of valve assembly  300  can incorporate the functions of breadboard  342  into controller  340 , and breadboard  342  can be eliminated. 
         [0047]    Referring to  FIG. 8 , controller  340  is a programmable microprocessor that can be powered by a DC power source  314 , such as, for example, a 9-volt battery. In an exemplary embodiment, controller  340  can be an Arduino Uno board, although those skilled in the art will recognize that other controllers can be used. Optionally, controller  340  may be electronically coupled to an audible alarm  344  and/or a visual indicator (not shown) to alert a person that excessive fluid is flowing through valve assembly  300 . Optionally, controller  340  can also be electronically coupled to an external alarm, such as to a home security system (not shown). Controller  340  can be hard-wired to the security system or controller can be wirelessly coupled to the security system, such as by wire-free communications. Still optionally, controller  340  can be electronically coupled to a cell phone or other mobile device application (“app”) that can wirelessly transmit an electronic signal to a mobile device to alert a user that excessive fluid is flowing through valve assembly  300 . 
         [0048]    Valve controller  312  uses a known H-bridge circuit to operate a motor therein that is attached to valve  310 . In a first configuration, when voltage is applied through controller  340  to valve controller  312 , valve  310  opens to allow flow therethrough. In a second configuration, when voltage is applied through controller  340  to valve controller  312 , valve  310  closes to prevent flow therethrough. A relay  313  determines how the H-bridge circuit is configured to either open or close valve  310 . 
         [0049]    In an exemplary application, valve assembly  300  can be installed on the water supply to a toilet  60 , as shown in  FIG. 9 . Supply line  50  provides water from a household water supply to valve assembly  300 , while discharge line  52  supplies water from valve assembly  300  to toilet  60 . 
         [0050]    Flow meter  320  senses flow of water into the toilet tank from supply line  50 , through valve assembly  300 , when the tank is filling, such as, for example, after a flush. Typically, the average flow of water into the toilet tank is between about zero (0) and about three (3) gallons per minute. When fluid flow is zero gallons per minute, flow meter  320  is not operating and valve  310  is open. 
         [0051]    When flow meter  320  senses a fluid flow, such as when the toilet is flushed and the toilet tank is filling, the timer on controller  340  starts, thereby tracking the time that fluid flows through valve assembly  300 , as well as allowing controller  340  to calculate the amount of fluid flowing through valve assembly  300 , based on the time, as well as the size of flow meter  320 , supply line  50 , and discharge line  52 . 
         [0052]    If controller  340  senses that flow has stopped (i.e., toilet tank is filled and the fill valve in the toilet shuts off), then controller  340  stops measuring flow time and valve  310  stays open. If, however, controller  340  measures flow for over a predetermined period of time, such as, for example, about three (3) minutes, which may indicate that the fill valve in the toilet is defective and/or has not seated properly, allowing water to continue to fill the toilet tank, controller  340  transmits an electronic signal to valve controller  312 , closing valve  310  and stopping fluid flow through valve assembly  300 . Controller  340  also transmits an electronic signal to audible alarm  344  and/or visual indicator (not shown) to alert a person that an issue exists with regard to the water supply to the toilet. 
         [0053]    Alternatively, if controller  340  calculates that more than a predetermined flow rate of fluid is flowing past flow meter  320 , such as, for example, more than about three (3) gallons per minute, which may indicate a break in discharge line  52 , controller  340  transmits an electronic signal to valve controller  312 , closing valve  310  and stopping fluid flow through valve assembly  300 . Similarly, controller  340  also transmits an electronic signal to audible alarm  344  and/or visual indicator to alert a person that an issue exists with regard to the water supply to the toilet. 
         [0054]    Controller  340  also includes a reset button  348  that is used to reset controller  340  after valve assembly  300  closes due to a perceived leak or excessive flow through valve assembly  300 . Pressing reset button  348  transmits a signal to controller  340 , which in turn transmits a signal to relay  313  to configure the H-bridge circuit to open valve  310  and allow fluid flow through valve  310 . 
         [0055]    As shown in  FIG. 10 , valve assembly  300  can also be installed on a main water supply, such as, for example, where a water supply enters a building. Similar to the configuration of valve assembly  300  along a supply line  50  to a toilet, valve assembly  300  can be configured to monitor water flow to the building, and controller  340  can be programmed to secure valve  310  accordingly if an excessive amount of water is measured as flowing past flow meter  320 . Further, similar to  FIG. 4 , valve assembly  300  can be used with a bypass assembly  150  that allows valve assembly  300  to be bypassed, if desired by a user. 
         [0056]    For example, if controller  340  senses that flow has stopped (i.e., the flow rate is zero, meaning that no water is being used in the building), then controller  340  stops measuring flow time and valve  310  stays open. Controller  340  then resets flow time to zero. 
         [0057]    If, however, controller  340  measures flow for over a predetermined period of time, such as, for example, about forty (40) minutes, which may indicate that a user has forgotten to close a water valve, such as, for example, an outside spigot, or there is a slight leak in discharge line  52 , controller  340  transmits an electronic signal to valve controller  312 , closing valve  310  and stopping fluid flow through valve assembly  300 . Controller  340  also transmits an electronic signal to audible alarm  344  and/or visual indicator to alert a person that an issue exists with regard to the water supply to the building. 
         [0058]    Alternatively, if controller  340  calculates that more than a predetermined flow rate of fluid is flowing past flow meter  320 , such as, for example, more than about thirteen (13) gallons per minute, which may indicate a break in discharge line  52 , controller  340  transmits an electronic signal to valve controller  312 , closing valve  310  and stopping fluid flow through valve assembly  300 . Similarly, controller  340  also transmits an electronic signal to audible alarm  344  and/or visual indicator to alert a person that an issue exists with regard to the water supply to the building. 
         [0059]    While valve assembly  300  is discussed above using water as a fluid that flows through valve assembly  300 , those skilled in the art will recognize that valve assembly  300  can be coupled to a gas or other fluid supply line and used to monitor the flow of gas or other fluid through valve assembly  300 . If the flow of gas or other fluid is measured as being excessive, valve assembly  300  can activate to close valve  310 , thereby stopping the flow of the gas or other fluid through valve assembly  300 . 
         [0060]    An alternative embodiment of a valve assembly  400  according to the present invention is shown  FIGS. 11 and 12 . Valve assembly  400  is a purely mechanical device that does not necessarily use any of the electronics used in valve assembly  300 . Valve assembly  400  includes a valve body  410  that defines a fluid passage  411 . Valve body includes a plunger housing  412  extending upwardly therefrom. Plunger housing  412  houses a plunger  414  that includes a stem  416  extending upwardly therefrom and outwardly from plunger housing  412 . A porous filter block  418  is disposed within fluid passage  411  directly below plunger  414 . Filter block  418  allows fluid to pass therethrough, but provides sufficient restriction of fluid flow such that the fluid flow builds upstream of filter block  418  (from the right as shown  FIG. 12 ) and pushes filter block  418  through fluid passage  411 . 
         [0061]    A downstream end of filter block  418  includes a biasing member  420 , such as a spring, that has a first end  422  engaged with filter block  418  and a second end  424  engaged with a pin  426  located within fluid passage  411 . Pin  426  maintains second end  424  and allows biasing member  420  to compress toward pin  426  as filter block  418  is pushed downstream (to the left as shown in  FIG. 12 ) by the fluid flow within fluid passage  411 . 
         [0062]    If fluid flows through passage  411  for a period of time less than an a priori calculated amount of time, such as less than a predetermined time to allow fluid to flow through filter block  418  before plunger  414  seals passageway  411  before fluid flow stops, biasing member  420  pushes filter block  418  upstream (to the right as shown  FIG. 12 ), maintaining filter block  418  underneath plunger  414 , and allowing subsequent fluid flow through passage  411 . 
         [0063]    If, however, fluid is flowing a sufficiently long amount of time through fluid passage  411  and through filter block  418 , such as greater than the predetermined time to allow a desired amount of fluid flow past filter block  418  before plunger  414  is activated, fluid flow will have pushed filter block  418  sufficiently far enough downstream to allow plunger  414  to drop into fluid passageway  411 , stopping the flow of fluid through passageway  411 . 
         [0064]    To reset valve assembly  400 , a user grasps plunger stem  416 , and pulls plunger  414  upward. When plunger  414  is above and out of passage  411 , biasing member  420  forces filter block  422  upstream (to the right as shown  FIG. 12 ) sliding filter block  418  underneath plunger  414  to secure plunger  414  within plunger housing  412 , and allowing fluid flow through fluid passage  411 . 
         [0065]    It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.