Abstract:
The present invention provides a water treatment system, such as a water softener, with a resin tank having a top distributor with a preliminary screen and second screen. The preliminary screen provides added protection by reducing the chance of larger particles from entering the various valves and screens. Prior to the regeneration cycle, an additional back wash and fast rinse cycle are added to rinse sediment to the drain and to clean the preliminary screen.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit of U.S. Provisional Application No. 60/590,524, filed Jul. 23, 2004. 

   FIELD OF THE INVENTION 
   The invention relates generally to water treatment systems and particularly to water softeners having a top regulator. 
   BACKGROUND OF THE INVENTION 
   Domestic water softeners remove hardness from raw water by passing it through a tank containing a liquid treatment medium bed, typically formed of resin beads. A salt solution, that is brine, is passed through the resin bed to restore its softening capacity. The brine is formed in a container which is connected by a liquid flow passage to the tank containing the resin beads. The flow of liquid through the liquid flow passage is regulated by a control valve which is actuated by an electronic regeneration control circuit. 
   Salt, typically in the form of chunks or pellets, is placed in the container. Under the control of the electronic regeneration control circuit, the control valve allows a predetermined amount of water to enter the container. Provided enough salt is present, the water and salt form a saturated salt solution, or brine, which is the regenerant for the resin bed. Again, under the control of the electronic regeneration control circuit, the control valve is actuated to cause the brine to be withdrawn from the container and circulated through, and thereby regenerate, the resin in the tank. 
   The flow control valve for such apparatus must accurately control the volume and velocity of liquid flowing through the resin particles in the treatment tank and in the brining system during each of four or more cycles. The regeneration cycle preferably includes the following steps: (1) fill; (2) brine draw; (3) slow rinse; (4) backwash; and (5) fast rinse. 
   U.S. Pat. Nos. 4,136,032, 5,162,080 and 6,696,963 are directed to water treatment systems and are incorporated herein by reference. The patents disclose water treatment systems and water softeners. The prior art includes water softeners wherein the resin tank is located adjacent the salt storage or brine tank, and water softeners wherein the resin tank is located in the brine tank. 
   The prior art includes a top distributor located in the resin tank. While the water softener is in service, hard water enters the resin tank via the control valve and the top distributor. Any particulates or contaminants located in the hard water will ideally be trapped within the lower recess of the top distributor. The lower recess is often in an area between two walls having a spaced apart relation which narrows in the direction downward and towards the lower recess. 
   SUMMARY OF THE INVENTION 
   The present invention includes a water softener, comprising a resin tank having an upper opening, a top distributor located at the upper opening. The top distributor having an generally cylindrical-shaped outer wall and a generally cylindrical-shaped inner wall. A first fluid channel is formed by the outer and inner wall and includes a generally annular shape. The first fluid channel having a first opening and a second opening. A second fluid channel is formed by the inner wall. A preliminary screen is located at the first opening, and a second screen located at the second opening. The second fluid channel having a first opening and a second opening. A control valve is coupled to the resin tank and the top distributor. A pipe having one end coupled to the second opening of the second fluid channel of the top distributor and another pipe end extending downwardly from the top distributor. A bottom distributor is coupled to the other end of the pipe. 
   In one embodiment, the preliminary screen includes a new molded and stainless steel screen which fits into a molded plastic top distributor. In one embodiment, the molded plastic basket provides long slots which are coarser in comparison to the stainless steel screen. The preliminary screen reduces the chance of larger particles from entering the systems various valves and screens. 
   The present invention also provides a method of regeneration of a water softener, wherein the water softener includes a top distributor with a preliminary screen. The method includes a back wash step, a fast rinse step, a fill step, a brine draw step, a slow rinse step, a back wash step, and a fast rinse step. The initial back wash and fast rinse steps rinses particles to the drain before the regeneration steps, and rinses the preliminary screen. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic diagram of a water softener with the top distributor in accordance with the present invention, showing the water flow direction while the system is in service. 
       FIG. 2  is a cross sectional diagram of the upper section of the brine tank and top distributor with preliminary screen of  FIG. 1 , in accordance with the present invention. 
       FIG. 3  is a partial lower view of a side view of the top distributor showing the perforated wall and ribs. 
       FIG. 4  is a perspective view of a preliminary screen of  FIG. 2 , in accordance with the present invention. 
       FIG. 5  is a side view of the preliminary screen of  FIG. 3 . 
       FIG. 6  is a top plan view of the preliminary screen of  FIG. 3 . 
       FIG. 7  is a cross sectional view of the preliminary screen taken along line  6 - 6  of  FIG. 5 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  shows a water softener  10  in accordance with one embodiment of the present invention. A resin tank  12  is located within a salt storage or brine tank  14 . A brine valve  16  couples the brine  18  to the resin tank. The resin tank includes an upper opening  20  wherein a top distributor  22  and a valve controller  24  are secured. A pipe  26  extends from the top distributor down to a bottom distributor  28  located in a resin bed  30 .  FIG. 1  shows the fluid flow direction while the water softener is in service. The valve controller includes an inlet  32  for receiving hard water. The hard water enters the valve controller and then the top distributor via a first fluid channel  34 , whereupon the hard water enters the resin tank. Soft water enters the bottom distributor and flows up the pipe through a second fluid channel  36  of the top distributor. The soft water then enters the valve controller and exists via an outlet, whereupon the soft water is stored in a storage tank (not shown) and made available for use on demand. 
     FIG. 2  is a cross sectional diagram of the upper section of the brine tank and top distributor with preliminary screen  40 , in accordance with one embodiment of the present invention. The top distributor includes a generally cylindrical shaped outer wall  42  which includes a portion having a conical shape which tapers in a downward direction as viewed in  FIG. 2 . The top distributor includes a generally cylindrical shaped inner wall  44  which includes a portion having a conical shape which tapers in an upward direction. The first fluid channel  34  is formed between the inner and outer walls. The top distributor includes a first opening  48  to the first fluid channel. A first screen or the preliminary screen  40  is located at the first opening. The outer wall includes a portion having a perforated wall  50  which provides a second opening and a second screen for the first fluid channel. An end wall  52  extending between the inner wall and outer wall closes off the bottom portion of the first fluid channel. 
   The outer wall includes an outer face  54  and an inner face  56 . Ribs  58  extend in a longitudinal direction along the inner face and terminate at an abutment  60 . 
   The inner wall provides a bore or second fluid channel  62 . The lower portion of the second fluid channel provides a first opening  64  of the second fluid channel. The upper portion of the second fluid channel provides a second opening  66 . It can be seen in the embodiment of  FIG. 2  that one end  68  of the pipe extends through the second fluid channel. Three seals or O-rings  70  are shown to seal the various components shown in  FIG. 2  and the valve controller (not shown in  FIG. 2 ). 
     FIG. 2  shows one embodiment, wherein the preliminary screen includes a molded body with the steel screen molded within the body. The preliminary screen is separate from the other features of the top distributor which are formed of a single molded component. 
     FIG. 3  is a partial lower side view of the top distributor of one embodiment, wherein the outer face includes longitudinal ribs  72  which may continue to the ribs  58  on the inner face. Longitudinal slots  74  are shown which provide the perforated wall. However, the perforated wall can take other forms. 
     FIG. 4  shows a perspective view of a preliminary screen  40  of  FIG. 2 , in accordance with the present invention. In one embodiment, the screen includes a molded body  80  with a stainless steel screen  82  molded within the body.  FIG. 5  is a side view of the preliminary screen,  FIG. 6  is a top plan view and  FIG. 7  is a cross sectional view taken along line  7 - 7  of  FIG. 6 . Referring to  FIGS. 4-7 , it can be seen that the preliminary screen includes an outer annular wall  84  which is dimensioned to be received by the outer wall  42  of the top distributor. 
   The outer annular wall  84  includes a lower edge  86 . An inner annular wall  88  is generally axially displaced from the outer annular wall  84  and forms a generally conical shaped annular opening  90 . A plurality of inclined ribs  92  extend between and connect the outer annular wall  84  and the inner annular wall  88 . The stainless steel screen  82  may be embedded within the ribs  92  during the molding of the preliminary screen body  80 . The inner annular wall  88  includes a lower opening  94  which has a conical profile and is dimensioned to received an upper portion of the inner wall  44 . A flexible self-aligning lip seal  96  extends about the periphery of the outer annular wall  84  and provides a self-aligning seal feature with the inner face  56  of the outer wall  42 . 
   The regeneration cycle preferably includes the following steps: (1) back wash; (2) fast rinse; (3) fill; (4) brine draw; (5) slow rinse; (6) backwash; and (7) fast rinse. The initial back wash and fast rinse steps rinses particles to the drain before the regeneration steps, and rinses the preliminary screen.