Abstract:
A sprinkler includes a compartment that surrounds its riser portion in an offset or asymmetrical configuration. More specifically, the distance of the compartments walls from those of the riser vary (i.e., increase or decrease) at different locations surrounding the riser. Put another way, the riser is closer to one side of the compartment than other sides of the compartment. This non-concentric configuration allows larger components to fit inside the compartment than would otherwise fit if the riser was symmetrically surrounded by the compartment.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 14/280,113, filed May 16, 2014 entitled Sprinkler with Internal Compartments, which claims benefit of U.S. Provisional Application Ser. No. 61/824,212 filed May 16, 2013 entitled Sprinkler with Internal Compartments, both of which are hereby incorporated herein by reference in their entireties. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    Sprinkler systems for turf irrigation are well known. Typical systems include a plurality of valves and sprinkler heads in fluid communication with a water source, and a centralized controller connected to the water valves. At appropriate times the controller opens the normally closed valves to allow water to flow from the water source to the sprinkler heads. Water then issues from the sprinkler heads in predetermined fashion. 
         [0003]    There are many different types of sprinkler heads, including above-the-ground heads and “pop-up” heads. Pop-up sprinklers, though generally more complicated and expensive than other types of sprinklers, are thought to be superior. There are several reasons for this. For example, a pop-up sprinkler&#39;s nozzle opening is typically covered when the sprinkler is not in use and is therefore less likely to be partially or completely plugged by debris or insects. Also, when not being used, a pop-up sprinkler is entirely below the surface and out of the way. 
         [0004]    The typical pop-up sprinkler head includes a stationary body and a “riser” which extends vertically upward, or “pops up,” when water is allowed to flow to the sprinkler. The riser is in the nature of a hollow tube which supports a nozzle at its upper end. When the normally-closed valve associated with a sprinkler opens to allow water to flow to the sprinkler, two things happen: (i) water pressure pushes against the riser to move it from its retracted to its fully extended position, and (ii) water flows axially upward through the riser, and the nozzle receives the axial flow from the riser and turns it radially to create a radial stream. A spring or other type of resilient element is interposed between the body and the riser to continuously urge the riser toward its retracted, subsurface, position, so that when water pressure is removed the riser assembly will immediately return to its retracted position. 
         [0005]    The riser assembly of a pop-up or above-the-ground sprinkler head can remain rotationally stationary or can include a portion that rotates in continuous or oscillatory fashion to water a circular or partly circular area, respectively. More specifically, the riser of the typical rotary sprinkler includes a first portion (e.g. the riser), which does not rotate, and a second portion, (e.g. the nozzle assembly) which rotates relative to the first (non-rotating) portion. 
         [0006]    The rotating portion of a rotary sprinkler riser typically carries a nozzle at its uppermost end. The nozzle throws at least one water stream outwardly to one side of the nozzle assembly. As the nozzle assembly rotates, the water stream travels or sweeps over the ground. 
         [0007]    The non-rotating portion of a rotary sprinkler riser assembly typically includes a drive mechanism for rotating the nozzle. The drive mechanism generally includes a turbine and a transmission. The turbine is usually made with a series of angular vanes on a central rotating shaft that is actuated by a flow of fluid subject to pressure. The transmission consists of a reduction gear train that converts rotation of the turbine to rotation of the nozzle assembly at a speed slower than the speed of rotation of the turbine. 
         [0008]    During use, as the initial inrush and pressurization of water enters the riser, it strikes against the vanes of the turbine causing rotation of the turbine and, in particular, the turbine shaft. Rotation of the turbine shaft, which extends into the drive housing, drives the reduction gear train that causes rotation of an output shaft located at the other end of the drive housing. Because the output shaft is attached to the nozzle assembly, the nozzle assembly is thereby rotated, but at a reduced speed that is determined by the amount of the reduction provided by the reduction gear train. 
         [0009]    Another feature of many prior art sprinklers is the use of electrically actuated pilot valves which connect in-line with the irrigation water supply and a sprinkler, allowing the water flow to an individual sprinkler to be turned on or off, preferably from a distant central control system. Typically, these pilot valves are located partially or even completely outside the sprinkler body. Thus, when the pilot valve needs adjustment or replacement, a user must shut off the water supply leading to the pilot valve, dig around the sprinkler to find the pilot valve, replace the pilot valve, rebury it, then turn the water supply back on. Since the main water supply must be shut off, other sprinklers will not function during this time consuming repair and may interrupt preprogrammed watering cycles. 
       SUMMARY OF THE INVENTION 
       [0010]    In one embodiment, the present invention is directed to a sprinkler having a compartment that surrounds its riser portion in an offset or asymmetrical configuration. More specifically, the distance of the compartments walls from those of the riser vary (i.e., increase or decrease) at different locations surrounding the riser. Put another way, the riser is closer to one side of the compartment than other sides of the compartment. This non-concentric configuration allows larger components to fit inside the compartment than would fit if the riser was symmetrically surrounded by the same size compartment. 
         [0011]    In another aspect of the present invention, the compartment further comprises a check valve and a pressure receptacle that are located in proximity to each other to allow connection to each by a pilot valve. The check valve and pressure receptacle are also preferably shaped and oriented to allow the pilot valve to be upwardly removed from the compartment of the sprinkler. Preferably, the pressure receptacle is mechanically fastened over an injection-molded aperture into the riser cavity. 
         [0012]    In another aspect of the present invention, the sprinkler includes a metal communication tube that is injection molded into a fin or rib extending away from a lower portion of the riser housing. Preferably, the communication tube is partially exposed near its lower end to help accommodate for warping or shrinking that is sometimes inherent in the injection molding process. 
         [0013]    In another aspect of the present invention, the sprinkler cavity may include a wireless communication module. This module may be configured to communicate with a nearby sensor, such as a soil moisture sensor and relay data back to a central controller. This module may also be configured as a node in a mesh network. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which: 
           [0015]      FIG. 1  illustrates a perspective view of a top accessible sprinkler according to the present invention. 
           [0016]      FIG. 2  illustrates a perspective view of a sprinkler compartment housing according to the present invention. 
           [0017]      FIG. 3  illustrates a bottom perspective view of the sprinkler of  FIG. 1 . 
           [0018]      FIGS. 4 and 5  illustrate a top view of the sprinkler compartment according to the present invention. 
           [0019]      FIG. 6  illustrates a side cross sectional view of the sprinkler of  FIG. 1 . 
           [0020]      FIG. 7  illustrates a magnified view of the check valve of  FIG. 6 . 
           [0021]      FIG. 8  illustrates a side cross sectional view of the sprinkler of  FIG. 1 . 
           [0022]      FIG. 9  illustrates a magnified view of a pilot valve connection port of  FIG. 8 . 
           [0023]      FIG. 10  illustrates a side cross sectional view of the sprinkler of  FIG. 1 . 
           [0024]      FIGS. 11 and 12  illustrates magnified views of portions of  FIG. 10 . 
           [0025]      FIGS. 13 and 14  illustrates cross sectional views taken along the lines in  FIG. 12 . 
           [0026]      FIG. 15  illustrates a perspective view of an interior of the sprinkler compartment. 
           [0027]      FIG. 16  illustrates a side perspective view of a pilot valve port. 
           [0028]      FIG. 17  illustrates a side cross sectional view of a portion of the sprinkler of  FIG. 1 . 
           [0029]      FIG. 18  illustrates a perspective view of the interior of the sprinkler compartment of  FIGS. 4 and 5 . 
           [0030]      FIG. 19  illustrates a communication device for communicating with a sensor and relaying data over a network. 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
       [0031]    Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements. 
         [0032]    One embodiment of the present invention is directed to a sprinkler  100  having one or more internal compartments that are configured for storing various sprinkler components and allowing those components to be accessed through a top of the sprinkler  100 . This allows a user to easily access and replace certain components within the sprinkler. 
         [0033]    As seen best in  FIGS. 1-3 , the sprinkler  100  includes an outer housing  102  and a riser portion  106 . The riser portion  106  has a cylindrical shape and is fixed within a tubular passage  102 A of the outer housing  102 . The tubular passage  102 A is preferably offset from a center of the housing  102  or asymmetrically positioned relative to the outer walls of the housing  102 . As best seen in  FIGS. 4 and 5 , the offset arrangement of the passage  102 A creates an internal compartment area  102 D that can accommodate larger components than would otherwise fit if the passage  102 A was centrally located in the same diameter housing  102 . For example, a pilot valve  120 , decoder  122 , and water-resistant wire connection tubes  124  can be located within the compartment area  102 D. 
         [0034]    The compartment area  102 D can be divided into two or more distinct compartments (e.g., 2, 3, 4, or 5 compartments) with dividing walls. In the present embodiment, wall  118  creates compartments  102 B and  102 A, allowing components and wiring to be better separated from each other. 
         [0035]    As seen in  FIGS. 1-2 , the sprinkler  100  preferably includes a cover  110  having a similar size and offset aperture placement as housing  102 . The cover  110  can be a single component or can include multiple cover components (e.g., two) that can each be separately removed. Preferably, the cover  110  is secured in place via screws through apertures  112 , however, other mechanisms of removably-securing the cover  110  to the housing  102  are also possible (e.g., latches or detents). 
         [0036]    Preferably, the cover  110  includes an angled or tapered ring  110 A (seen best in  FIGS. 6 and 8 ), which fits against a reciprocally angled side surface  104 B at the top of the riser housing  104 . For example, the ring  110 A increases its diameter in the downward direction while the side surface  104 B has an oppositely angled surface that increases its diameter in the upward direction. This engagement allows the cover  110  to support the radial loads/stress in the riser housing  104  that might otherwise require support by an integral flange on the riser housing  104 . The radial loads and stress in the riser housing  104  can result in fatigue failure at the riser snap ring groove without adequate support (e.g., due to the pop-up impact of the riser  106  that is transmitted through the riser snap ring every time the sprinkler turns on). Hence, the surfaces  110 A and  104 B allow the cover  110  to be removed easily (it is not pressed onto a straight diameter) and does not have a flange, partial flange, higher strength material requirement, or an additional part which might reduce access to the compartment and increase the cost to manufacture the sprinkler. 
         [0037]    As seen in  FIG. 4 , the compartment area  102 D may contain a pilot valve  120 , a decoder  122 , and wire connectors  124 , each of which can be easily removed from the top of the sprinkler  100 , as seen in  FIG. 5  (components removed). However, as discussed elsewhere in this specification, other components may also be located within the compartment area  102 D. 
         [0038]    The sprinkler  100  includes a valve assembly  126 , seen best in  FIGS. 6 and 8 , which is controlled by the decoder  122  and pilot valve  120 . The valve assembly  126  includes a metering pin  134  which allows a small amount of water to enter into valve chamber  133 . As pressure builds in the valve chamber  133 , it forces down a valve seat  132 , maintaining the valve assembly  126  in a closed position. 
         [0039]    The valve chamber  133  also includes a communication aperture  131  which connects to the communication tube  128 . The tube  128  passes through the rigid outer fin  114  and into a bottom portion of the housing  102 . As best seen in  FIGS. 7, 12, 13, 14, and 18 , the tube  128  is connected to a check valve  140  inside the compartment area  102 D, which blocks flow of water through it until the first communication port  150  of the pilot valve  120  is connected to it. Preferably, a top of the tube  128  is positioned within the interior of the check valve  140 . 
         [0040]    The check valve  140  is maintained in a desired position in the compartment area  102 D by a lower, circular-shaped wall  157  that is fixed to or unitary with the floor of the area  102 D. An upper cylindrical retainer  155  is sized to fit over and around the wall  157 , trapping an enlarged base portion or flanged region  1446  of the check valve housing  144 . The base portion  144 B is also positioned over the end of the communication tube  128  and is further sealed between the base portion  144 B and the base of the communication tube  128  by o-ring  146 . In this respect, the check valve  140  can be removed and replaced by first removing the upper cylindrical retainer  155 . 
         [0041]    The valve mechanism within the check valve housing  144  comprises a spring  148  configured to push or bias a valve ball  142  upwards against a narrowed region  144 A of the internal passage of the valve housing  144 . The bottom surface of the narrowed region  144 A forms a valve seat against which the valve ball  142  presses against, thereby stopping water flow. When the first communication port  150  of the pilot valve  120  is inserted into the top opening of the housing  144 , it pushes the ball  142  downward, allowing water to flow through one or more side passages  152  into the port  150  (e.g., 1, 2, 3, or 4 side passages). In this respect, water can freely flow into the pilot valve  120 . The water flow through the pilot valve is further controlled by movement of a plunger against a seat within a central fluid passageway inside the pilot valve  120 . This plunger can be moved by either an attached electronic solenoid  170  or by turning a manual actuator (not shown). 
         [0042]    As seen in  FIG. 11 , the pilot valve  120  also includes a second communication port  162  through which water pressure can be communicated to the pilot valve  120  and relieved when the valve  126  is directed to be opened. As seen best in  FIGS. 5, 9, 11, 15, 16, and 18 , the second communication port  162  connects to a receptacle  160  which is in fluid communication with an interior of the sprinkler body or riser housing  104  (i.e., the passage in which the riser  106  moves upwards during irrigation and downwards when not irrigating). 
         [0043]    Preferably, an aperture or passage  130  is molded into the wall of the riser housing  104  (i.e., is part of the injection mold) to maintain a relatively smooth inner surface of the riser passage of the housing  104 . Drilling or otherwise puncturing the wall of the housing  104  after the interior passage is molded can result in small portions around the aperture  130  to protrude into the passage of housing  104 , especially if the pilot valve  120  is configure to be screwed into this hole. Since the riser  106  includes a seal to prevent water leakage around the base of the riser  106  as it rises upwards during irrigation, any such protrusions or irregularities can damage this seal and/or can prevent the riser  106  from smoothly rising and falling. 
         [0044]    The receptacle  160  preferably removably attaches to the outer surface of the wall of the riser housing  104 . Specifically, the receptacle  160  includes an upper flange  160 D that fits within a downwardly-facing gap created by retaining member  163 . Similarly, the bottom portion of the receptacle  160  is sized to fit within a gap  161 , thereby retaining the receptacle against the outer wall of the riser housing  104 . Preferably, the retaining member  163  and gap  161  are positioned to align the inner receptacle passage  160 B with the wall passage  130 . To further maintain the seal between the receptacle  160  and the outer wall of the riser housing  104 , the receptacle includes a recessed area around the end of passage  160 B, which contains a resilient o-ring  158  that is compressed against the outer wall. 
         [0045]    The inner receptacle passage  160 B also connects to a cylindrical cavity  160 C which is open at its top. The second communication port  162  is sized to fit within this cavity  160 C, further connecting the passages  130 ,  1606  to the passages of the pilot valve  120 . To enhance the ease of connection and maintain a proper seal, the end of the second communication port  162  includes a tapered end  162 A or nozzle and an o-ring  163 . 
         [0046]    It should be further noted that the check valve  140  and the receptacle are positioned within proximity of each other and preferably oriented in the same or similar direction (e.g., upwards), as seen in  FIGS. 5 and 15 . This spacing allows the first and second ports  150  and  162  of the pilot valve  120  to have similar spacing and an opposite orientation, allowing a user to easily remove the valve  120  (e.g., by simply pulling upwards on the valve  120 ) and easily installing a new valve  120  (e.g., by simply pushing a new valve  120  downwards). Hence, the pilot valve  120  can be quickly replaced from a top of the sprinkler  100 . 
         [0047]    The decoder  122 , seen best in  FIG. 4 , communicates over a wire pair with an irrigation controller (e.g., such as a central irrigation controller or a satellite irrigation controller) and thereby selectively applies power to the solenoid  170  of the pilot valve  120 , ultimately controlling irrigation of the valve. The wire pair enter the compartment area  102 D via wire port  105  (seen best in  FIG. 5 ) where they are connected to the wires of the decoder  122 . Preferably, both sets of wires are each connected via an electrical wire nut  125 , which is then further enclosed by a water-resistant tube  124  (see  FIG. 4 ). The water-resistant tubes  124  are filled with a thick, hydrophobic material, such as grease, so as to prevent water contact with any exposed metal and further prevent corrosion. Hence, two water-resistant tubes  124  can be used between the wire of the decoder  111  and the controller&#39;s wire pair. 
         [0048]    As best seen in  FIGS. 4 and 5 , the compartment area  102 D preferably includes several vertical ridges that are sized to retain the decoder  122  when slid vertically down at a certain location within the compartment area  102 D. Hence, a user can slide a decoder  122  in or out of the compartment area  102 D from the top of the sprinkler  100 . 
         [0049]    Turning to  FIG. 17 , the riser housing  104  is preferably injection molded. Additionally, the fin portion  114  of the riser housing  104  preferably is molded around the communication tube  128 , which is preferably composed of a metal, such as stainless steel. In this respect, the communication tube  128  can maintain a bent shape and yet still have substantially no gaps between its outer surface and the body of the riser housing  104 . Preferably, the fin portion  114  also includes an open region  114 A which exposes a portion of the communication tube  128 . This open region  114 A may help prevent or limit unwanted shrinkage or warping that is sometimes inherent in the injection molding process. Additionally, the open region  114 A allows the tube  128  to be directly supported by the injection mold against the high pressures of molten plastic during the injection molding process. Without such support, the tube  128  might otherwise bend or deform without providing substantially increased support, such as a stronger material or thicker walled tube. In an alternate embodiment, the open region  114 A may be relatively small (e.g., less than an inch) or may extend to just below the bottom of outer housing  102 . In another alternate embodiment, the communication tube  128  is connected to the fin portion  114  after the injection molding of the riser housing  104 . 
         [0050]    As seen in  FIG. 18 , the outer housing  102  is preferably connected to the riser passage housing  104  via a plurality of screws that pass through several radially-extending apertures  104 A. In one alternate embodiment, the outer housing  102  can be optionally added to an existing riser  106  and riser housing  104 , allowing users to upgrade existing sprinklers. In such an alternate embodiment, the apertures  104 A may be part of an add-on ring that connects to an existing riser housing or may include other mechanical linking mechanisms, such as a clamp or latching mechanism. 
         [0051]    In one alternate embodiment shown in  FIG. 19 , the compartment of the sprinkler  100  may also contain a communication device  170  for communication with sensor  172 . For example, the sensor may be a soil moisture sensor (e.g., the sensors of U.S. Pat. Nos. 7,719,432; 7,788,970; and 7,789,321; each of which are incorporated herein by reference); a weather station, or a rain sensor. The communication device  170  may include a wireless transmitter to wirelessly communicate with the sensor  172  and either wirelessly relay the data to network node  174  (which is either a repeater or gateway) or can relay the data via the decoder  122 . 
         [0052]    In one embodiment, a plurality of sprinklers, or even all sprinklers, may include their own communication device  170 , forming a wireless mesh communication network. This network may relay command signals from a central irrigation controller, thereby eliminating the need for the two-wire decoder  122 . 
         [0053]    In another embodiment, the soil sensor  172  may be hard-wired to the sprinkler  100  and the communication device  170 , allowing the sprinkler to power the sensor  172  and transmit its data. 
         [0054]    In another example, the communication device  122  may wirelessly communicate with a remote control, allowing a user to send individual start/stop commands to each sprinkler  100  (e.g., for testing purposes). The communication device  122  would either directly control the pilot valve  120  or send control signals to the decoder  122 . 
         [0055]    In yet another example, device  170  may be any of the sensors described in U.S. Pub. No. 20120043395, which is hereby incorporated by reference. For example, the sensors may include an acoustic feedback sensor, an accelerometer, a gyroscope, a water sensor, a pressure sensor or a turbine. Each of these sensors can be configured to provide feedback as to whether the sprinkler&#39;s riser has “popped up” and is irrigating properly. 
         [0056]    U.S. Pat. Nos. 7,631,813; 6,854,664; and 5,899,386 are hereby incorporated by reference. 
         [0057]    Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.