Abstract:
A full flow water connector assembly has a connector with prongs of a certain length that are separated by notches. The end of the connector with the prongs is passed through an opening in a diaphragm and the prongs protrude through respective slots in a diffuser/retainer member. The prongs are then bent so as to press the diffuser/retainer member so as to secure the diaphragm and hold the connector assembly together. The diffuser/retainer member has segments between the slots, the segments contacting the notches when the diffuser/retainer member is pressed sufficiently far. The length of the prongs beyond the notches limits the maximum amount of compression that the diffuser/retainer member can exert against the diaphragm material, thereby minimizing the chance of cracking and subsequent failure of the diaphragm material.

Description:
This application claim benefit to provisional application Ser. No. 60/050,875 filed Jun. 26, 1997. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to water connector assemblies. More specifically, the invention relates to full flow water connector assemblies that are useful with double diaphragm tanks, and whose installation does not damage the diaphragm through which the connector assembly is installed. 
     2. Related Art 
     Various arrangements are known in the art for fluid connectors, pipe joints, and couplings, including those applicable to tanks having an inner diaphragm of a flexible or an elastomeric material. 
     Holtsclaw (U.S. Pat. No. 4,653,663) discloses a flexible liner 42 inserted into a storage tank 19 and a clamp assembly for securing the liner 42 to the tank. The clamping assembly includes a rigid base plate 2, an elastomeric base support 4, an elastomeric clamp plate 8, and a rigid clamp plate 6. A mounting plate 16 attached to the surface of the tank 19 supports pipes 12 and 14 which extend through aligned holes through the base plate 2, base support 4, clamp plate 8, and clamp plate 6. See columns 2-4 and FIG. 2. 
     Frank et al. (U.S. Pat. No. 3,802,464) discloses an air and water impervious flexible bag or diaphragm 5 mounted in a tank 1 which is closed by a head 4. The head 4 is provided with an opening 11 bordered by an annular, downwardly extending flange 12. The diaphragm 5 has a neck formed with an enlarged bead that is sealed between a V-shaped recess formed in the flange 12 and an annular groove formed in the upper surface of an adapter 19. The adapter 19 is also provided with a central bore 27, and a disc 28 is located at the upper end of the bore 27 and is provided with a series of holes 29. A water line 30 is threaded within the lower end of the bore 27. The adapter is clamped in place by a circumferential clamping ring 23. 
     Purvis (U.S. Pat. No. 1,939,611) discloses a storage and dispensing apparatus for carbon dioxide having a bag 13 clamped to a container wall by a fitting 14 and a nut 15. See page 1. 
     Mitchell et al. (U.S. Pat. No. 3,756,367) discloses a hydraulic brake system bleeder having a bladder 13 wrapped around a ring 44 and compressed between a flange 42 and an inner tank wall. See column 2 and FIG. 1. 
     Mackal et al. (U.S. Pat. No. 3,754,731) discloses an inflation manifold valve and flange assembly having a sidewall separated into a plurality of prongs and bent radially outwardly. See columns 3 and 4 and FIGS. 2-7. 
     Sirosh (U.S. Pat. No. 5,494,188) discloses a fluid impermeable liner 94 disposed inside a shell 84, and an end boss 104 disposed in the adjacent openings 88 and 98 of the shell 84 and the liner 94, respectively. The boss 104 includes a generally cylindrical neck portion 112 which fits in the opening 88, and an annular collar or flange portion 116 extending radially outwardly from the lower end of the neck portion 112. The portion of the liner 94 that surrounds the opening 98 is formed into a dual-lip arrangement which includes an upper lip segment 124 and a lower lip segment 128 which extends from the underside of the upper lip segment 124 radially inwardly under the lower surface of the flange portion 116, and then upwardly into hollow along the inner walls 118 of the flange portion 116. See columns 4-5 and FIG. 4. 
     Zahid (U.S. Pat. No. 4,344,458) discloses a bladder assembly 18 connected to the shell 11 of a pressure vessel by a mounting stem assembly 22. The mounting stem 22 includes a generally cylindrical body portion 23 having an external thread 24. A radially extending stop flange 25 is formed on the outer surface of the stem 22 spaced from the innermost end 26 of the stem. A compression flange 27 is formed at the innermost end of the stem 22, the spaced flanges 25 and 27 defining an outwardly facing annular groove 28 between them into which the annular lip 30 of the bladder assembly 18 is inserted. See columns 2-3 and FIG. 2. 
     Martin et al. (U.S. Pat. No. 2,266,611) discloses a pipe connection for the shell 2 of a hot water tank. The connection comprises a fitting 1 secured to the opening 7 of the shell 2 by a weld 3. The fitting has a cylindrical skirt 6 which extends through an opening in a packing washer 10. A metal washer 11 is placed over the packing washer 10. The projection 6 is flared out at the end to engage the flange 12 and cause the washer 11 to uniformly compress against the tank wall. See columns 1-2 and FIGS. 2, 3, and 5. 
     Mazur et al. (U.S. Pat. No. 5,551,590) discloses a tank 48 having a water impermeable liner or diaphragm 27 and a non-metallic fitting 20 at the aligned openings of the tank 48 and the liner 27. The fitting 20 comprises three components: an internal fitting 46, a grommet 26, and a snap retainer 23. The internal fitting 46 has a central body portion 22 and a flange 28. The grommet 26 is U-shaped with a central opening through which the central body portion 22 of internal fitting 22 is inserted and an annular groove for receiving the lip at the opening of the liner 27. The grommet 26 is held against the inner wall of the tank 48 by the flange 28 of the internal fitting 22. The snap retainer 23 fits over the central body portion 22 on the exterior of the tank 48. 
     Kamack (U.S. Pat. No. 2,005,087) shows a fitting for a tank. 
     Ipcinski (U.S. Pat. 5,216,316) shows a material held in place between two domed structures. 
     However, during installation of certain couplings through bladders or diaphragms made of flexible materials, excessive compression of the diaphragm material accelerates the process by which the material cracks and causes early failure of the diaphragm. It is not believed that known systems have dealt with the problem of preventing application of excessive pressure during installation of couplings. It is to solve this problem that the present invention is directed. 
     SUMMARY OF THE INVENTION 
     The present invention provides a full flow water connector assembly for providing water flow across a diaphragm, while safely maintaining the seal separating the two sides of the diaphragm. The assembly has a connector element and a first retainer and a second retainer, compressing a diaphragm gasket, or seal, material between them. The connector has a seal portion extending through an opening through the diaphragm, the seal portion having a plurality of axially extending members extending beyond a plurality of transverse stop surfaces, located intermediate the locator members, and a transverse support member located a predetermined distance below the transverse stop surfaces, on the other side of the diaphragm. The second retainer surrounds the seal portion and rests against the transverse support member; the diaphragm seal material rests on the second retainer and the first retainer presses the diaphragm seal material into the second retainer and against the outer surface of the seal portion. The respective locator members extend through mating openings in the first retainer, and are locked so as to secure the first retainer and maintain the desired predetermined pressure on the diaphragm gasket, which defines the opening through the diaphragm. Significantly, a maximum pressure that the first retainer may exert against the diaphragm gasket is limited by the extent of travel permitted the first retainer, i.e., when the first retainer contacts the transverse stop surfaces; the stop surfaces are at a predetermined distance above the transverse support member on the connector. 
     The preferred embodiment of the present invention provides a full flow water connector assembly having a connector with a circumferential support flange, and locator prongs that are separated by notches, the notch stop surfaces being a specified distance above the circumferential flange; a second retainer rests upon the flange. The end of the connector including the prongs extends through the gasket opening in the diaphragm, and the locator prongs protrude through respective slots in a diffuser/retainer member, or first retainer. The locator prongs are then swaged so as to press the diffuser/retainer member against the diaphragm gasket, holding the connector assembly together and thus forming a seal. 
     The preferred diffuser/retainer member has segments between the slots, which are arcuate in shape, the segments contacting the notch stop surfaces when the diffuser/retainer member is pressed sufficiently far. The distance between the notch stop surfaces and the circumferential flange determines the minimum distance between the two retainer opposing surfaces, and thus sets the desired predetermined compression against the diaphragm, and also limits the maximum compression that the diffuser/retainer member can exert against the diaphragm gasket material. This minimizes the chance of cracking and subsequent failure of the diaphragm material, and also provides a visual indication of when the pressure is correct, thus insuring a proper seal. 
     Other objects, features and advantages of the invention will be apparent to those skilled in the art upon a reading of the following detailed description when read in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention is better understood by reading the following Detailed Description of the Preferred Embodiments with reference to the accompanying drawing figures, in which like reference numerals refer to like elements throughout, and in which: 
     FIG. 1 illustrates a preferred embodiment of the full flow water connector assembly according to the present invention, installed in a double-diaphragm tank; 
     FIG. 2 is an exploded perspective view of a preferred embodiment of the full flow water connector assembly according to the present invention.; 
     FIGS. 3A and 3B are an end and a side cross-section views of a preferred embodiment of a full flow water connector assembly according to the present invention; 
     FIGS.  4 A— 4 C are side cross-section and plan views, respectively, of a preferred embodiment of a full flow water connector that is part of the full flow water connector assemble according to the present invention; 
     FIGS. 5A and 5B are side cross-section and plan views, respectively, of a preferred embodiment of a lower retainer ring that is part of the full flow water connector assembly according to the present invention; 
     FIG. 6A is a side cross-section view of a preferred embodiment of a diaphragm in the full flow water connector assembly according to the present invention, and 
     FIG. 6B shows a detail thereof. It is understood that the preferred diaphragm is circumferentially symmetric and therefore no plan view thereof is necessary; and 
     FIGS. 7A and 7B are side cross-section and plan views, respectively, of a preferred embodiment of a diffuser/retainer that is part of the full flow water connector assembly according to the present invention. 
     FIG. 8 is a side cross-section view of another embodiment of this invention, with a separate O-ring. 
    
    
     Elements of the drawings are intended to be proportionate within any particular drawing of the preferred embodiment, but are not necessarily to scale between different drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In describing the preferred embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each element of the assembly includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. 
     The following description assumes that the full flow water connector assembly is connected to the bottom of a tank, and descriptors such as “top” and “bottom” are used as relative terms, merely for ease of reference, and not to limit the scope of the invention or the application of its principles. The full flow water connector according to the invention may be used in orientations other than that particularly described herein and shown in the accompanying drawings; it is the geometric relationships among the parts, not the orientation of the assembly, that is crucial. 
     FIG. 1 illustrates a preferred embodiment of the full flow water connector assembly  1  according to the present invention, installed in a double-diaphragm tank. FIG. 2 is an exploded perspective view of the assembly. 
     The full flow water connector assembly  1  connects an elbow  2  to the interior volume of a double-diaphragm tank, i.e., the volume defined and sealed by the two diaphragms. The tank includes a dome  3 , a first diaphragm  600  having a gasketed opening through a central portion, and a second diaphragm  8 . A tank support structure and skirt  9 , not essential to the full flow water connector assembly itself, is also illustrated in FIG.  1 . Alternatively, and preferably in certain circumstances, the elbow is replaced by a bent pipe, which extends to beyond the skirt  9 , where it joins with a flow system through a union coupling. After installation of the full flow water connector assembly, there is a water flow pathway from the volume defined by the pair of diaphragms  600  and  8 , through holes in the diffuser/retainer  700 , through an opening in the diaphragm  600 , past the location of the lower retainer ring  500 , and through the full flow connector  400  to the elbow  2 . 
     For installation, as shown more clearly in the two side cross-section views of FIGS. 3A and 3B, the lower retainer ring  500  is placed around the top portion  430  of the full flow water connector  400 , so that the lower circumferential portion  516  rests on the circumferential flange  425 , and the top portion  430  of the connector  400  is inserted through an opening in diaphragm  600  (see FIG.  2 ). A sealing gasket  640  surrounds the opening through the diaphragm  600 ; the gasket  640  being held between the lower retainer  500  and the top portion  430 . The prongs  431 - 434  on the top portion of connector  400  are inserted through the arcuate slots  731 - 734  in the diffuser/retainer  700 , and the diffuser/retainer  700  is pressed downwardly until the bottom surfaces of the radial segments  721 - 724  press against the notch stop surfaces  441 - 444  between the prongs. The prongs are bent outwardly, or swaged, to secure the diffuser/retainer in place, thereby compressing the diaphragm gasket  640  between the diffuser/retainer  700  and the lower retainer ring  500 , to a precise and predetermined compression. Finally, the full flow water connector  400  is welded to both dome  3  to secure the connector in place, and to elbow  2  to seal the water flow path. 
     FIGS. 4A and 4B are side cross-section and plan views, respectively, of a preferred embodiment of the full flow water connector  400 . A lower, narrower-diameter cylindrical portion  410  is adapted to sealably connect with elbow  2 , such as, for example, by welding. A conical portion  420  connects the narrower-diameter cylindrical portion  410  and the wider-diameter cylindrical portion  430 . The wider portions  430  and conical portion  420  are separated by the circumferential ridge, or flange,  425  that extends outward from the outer surface. 
     Preferably, the connector  400  is welded to dome  3  along the conical portion  420 ; the conical portion  420  is retained within a conical portion  31 , formed in the dome  3 . This cone-within-cone arrangement is shown in FIGS. 3A and 3B, and provides for proper alignment of the parts of the assembly. In this manner, any downward forces acting on the connector  1  tend to press it further into secure engagement with the dome  3 . In the installed connector assembly, the lower retainer ring  500  rests upon the side of the flange portion  425 . Thus, flange  425 , and the cone-within-cone arrangement of elements  420  and  3 , ensure that downward pressure on the assembly cannot force the connector entirely through the hole in the dome, and accurately juxtapose the elements forming the assembly. 
     The upper wider portion  430  is provided with a series of upwardly-extending prongs  431 ,  432 ,  433 ,  434  whose edges are separated by respective notches  441 ,  442 ,  443 ,  444 . As will become clearer from the discussion of FIGS. 7A and 7B, the upper portion  430  of the connector extends through the lower retainer ring  500  and diaphragm  600 , and prongs  431 ,  432 ,  433 ,  434  project through respective slots  731 ,  732 ,  733 ,  734  in diffuser/retainer  700 . The prongs  431 - 434  are bent radially outwardly so that the assembly  400 ,  500 ,  600 ,  700  is held together. 
     Significantly, the distance between the notches surfaces  441 ,  442 ,  443 ,  444  and the circumferential flange  425  is selected to provide the desired predetermined pressure that can be exerted on the diaphragm gasket  640  during installation of the connector assembly; the extent of travel permitted the diffuser/retainer  700  when radial segments  721 ,  722 ,  723 ,  724  contact the respective notches surfaces  441 ,  442 ,  443 ,  444 , determines the pressure. This feature also provides a direct visual means of assuring proper compression of the diaphragm seal. In prior arrangements, there has been no such limit on the pressure that might be applied to the diaphragm gasket; as a result, it is difficult to avoid excessive pressure being applied, resulting in brittleness, and early failure of the diaphragm, or, on the other hand, insufficient pressure, resulting in leakage. However, according to the present invention, limiting the pressure applied to the diaphragm during the assembly process helps to prevent the diaphragm gasket  640  from becoming brittle, thus extending its useful life. 
     FIGS. 5A and 5B are side cross-section and plan views, respectively, of a preferred embodiment of a lower retainer ring  500  that is part of the full flow water connector assembly according to the present invention. The lower retainer ring  500  is a generally annular metal piece surrounding a central opening  505 , defined by the axial surface  515 , through which passes the top portion  430  of the full flow water connector  400 . As seen most clearly in the side cross-section view of FIG. 5A, the ring is formed of an upwardly-sloped outer ramp  510  that connects with a downwardly-sloped inner ramp  512 . Inner ramp  512  connects with a horizontal platform having top surface  514  and bottom surface  516 , and axial surface  515 . Collectively, the ramp  512  and the platform top surface  514  form a support for a bottom portion of the diaphragm gasket  600 . 
     FIG. 6A is a side cross-section view of a preferred embodiment of a diaphragm  600 , and FIG. 6B shows a detail of the gasket portion thereof. It is understood that the preferred diaphragm gasket is circumferentially symmetric and therefore no plan view thereof is necessary. 
     The diaphragm  600  is one of two large nonporous membranes separating a water holding portion of a tank from the atmosphere; the second, distant membrane is shown as diaphragm  8 ; the two diaphragms  600 , 8  are joined together within the tank by known means. An opening is provided through the diaphragm  600 , defined by a gasket  620 , having a cylindrical side wall  640  suitable to allow passage of the top portion  430  of full flow water connector  400 . In this case, the gasket  620  is formed integral with the diaphragm material  600 . Surrounding the gasket  620  is an annular boundary region  614 , having a thickness greater than that of the rest of the diaphragm  600 . The boundary region  614  of the diaphragm merges into the thinner major portion of the diaphragm  600  by an annular ramped surface  612 . on the lower surface of the diaphragm. In this embodiment, a second ramp  622  is formed on the upper surface, near the outer edge of the gasket region  634 , where the gasket region thickness is initially reduced to the thickness of the boundary region  614 . 
     The inner side wall  620  of the gasket material extends downwardly from the main plane of the diaphragm  600 . Diaphragm gasket bottom surfaces  630 ,  632  matingly engage respective top surfaces  512 ,  514  of the lower retaining ring  500 . 
     FIGS. 7A and 7B are side cross-section and plan views, respectively, of a preferred diffuser/retainer ring  700 . The preferred diffuser/retainer ring has a generally flat, disk-shaped central portion,  702  surrounded by an annular ridge  713  that extends axially downwardly from the flat portion  702 . The diffuser/retainer ring&#39;s inner area includes a plurality of holes  741 - 747  for diffusing water, as well as circumferentially-arranged slots  731 ,  732 ,  733 ,  734 , that are separated by respective radial segments  721 ,  722 ,  723 ,  724 . The slots serve to diffuse water as well as receive the respective prongs  431 - 434  from the connector  400 . The annular circumferential ridge  713  on the diffuser/retainer  700 , mates with the annular depression  622 , serving to force the gasket  620  against the outer circumferential surface  439  of the flow connector  400 . 
     When the diffuser/retainer  700  is accurately placed on the diaphragm, the connector prongs  431 ,  432 ,  433 ,  434  are inserted upwardly through respective slots  731 ,  732 ,  733 ,  734 , and are bent radially outwardly and downwardly so as to press the diffuser/retainer ring  700  into the diaphragm  600 . The annular ridge portion  713  is pressed atop the diaphragm gasket portion by the pressure exerted by the bent prongs  431 - 434 , holding the diaphragm in place above the lower retaining ring  500 , and forming a tight seal against the outer circumferential surface of the flow connector. 
     The following provides detailed measurements (in inches unless otherwise noted) of a preferred embodiment of the invention, it being understood that the scope of the invention should not be limited to any particular measurements, configurations, or compositions, except as defined by the claims and their equivalents. 
     The permitted compressive travel of the retainer ring is a function of the relationship between the thickness of the diaphragm at the location of the compression, and the material of the diaphragm gasket. Suitable materials for the diaphragm include elastomers such as butyl rubber, EPDM, SBR, natural rubber, and silicone rubber, and other compressible elastic materials. Although the example described above shows the gasket as being formed integral with the diaphragm, and of the same material, i.e., butyl rubber, the diaphragm can be formed of a different material, and/or as a separate member, such as an O-ring, made of the elastomers listed above for the diaphragm, or other materials, such as Buna-N, or other commonly used materials for O-rings. 
     FIG. 8 shows an embodiment where the gasket is an O-ring, made of Buna-N rubber, and the diaphragm is another polymer, such as polyethylene. 
     The usual travel distance, i.e., the difference between the thickness of the diaphragm gasket section and the full distance between the notch stop surfaces  441 - 444  and the circumferential flange  425  (“travel distance”) is in the range of from about 0.03 to about 0.05 inches for this embodiment. The travel distance can vary depending upon the material selected, and the ratio between the gasket thickness and the full distance and should be less than the height of the prongs. 
     The full flow water connector has thickness of 0.0650 inches, and is made of 304SS welded tube. The outside diameter of lower portion  410  is 1.3 inches, and the outside diameter of upper portion  430  is 1.8 inches. The middle portion  420  flares at a 25 degree angle between the outer portions  410  and  430 . The flange  425  has an outer diameter of 1.9 inches and is 0.1 inch thick. Portions  410 ,  420  (including flange  425 ), and  430  have longitudinal lengths of 0.5 , 0.6, and 0.6 inch, respectively. Notches  441 - 444  are 0.3 inch wide, and prongs  431 - 434  extend a distance  450  of 0.17 inch. 
     The lower retainer ring is preferably composed of 0.08-inch thick low carbon steel. Outer ramp  510  is oriented at a 45 degree angle from the horizontal, and inner ramp is oriented at a 60 degree angle from the horizontal. The outer diameter of the outer ramp  510  is 2.7 inches. The inner diameter of the outer ramp, being the outer diameter of the inner ramp  512 , is 2.4 inches. The inner diameter of the inner ramp, which is the outer diameter of the flat surface  514 , is 2 inches. The inner diameter of flat surface  514 , defining the ring&#39;s opening  505 , is 1.8 inches. The height of the ring is 0.261 inches. 
     The thickness of the diaphragm  600  in areas  610  distant from the opening is 0.078 inch, with a thickness of 0.12 inch in the boundary area  614 . The bottom surface of ramped region  612  is oriented at 15 degrees, from the horizontal, and has an inside diameter of 3.4 inches. The opening has a diameter of 1.8 inches, and the gasket material  640  has an axial length of 0.4 inches. The outer diameter of the downwardly projecting gasket  640  is 2.5 inches. 
     The preferred diffuser/retainer ring  700  is composed of 304SS steel, of 0.06 inch thickness. Its extreme outer diameter is 2.6 inches. The outer ramp has an inner diameter of 2.4 inches, and slopes upward at a 30 degree angle from the horizontal. The ridge  713  has a height of about 0.04 inches. Diffuser holes  741 - 747  are 0.30 inches in diameter, with hole  747  being centered in the ring, and with the centers of holes  741 - 746  located at a radial distance from the center of 0.40 inches. Holes  741 - 746  are located at regular 60 degree angles circumferentially. Slots  731 - 734  extend from a radius of 0.663 inches to a radius of 0.91 inches. The slots are located at regular 90 degree intervals circumferentially, separated by the radial segments  721 - 724  of width 0.3 inches. 
     Modifications and variations of the above-described embodiments of the present invention are possible, as appreciated by those skilled in the art in light of the above teachings. For example, the orientation, composition, and dimensions of one or more elements of the full flow water connector assembly may vary while still remaining within the scope of the invention; the manner of connecting or joining individual elements to form the assembly can also be varied, e.g., using flanged joints instead of welding. It is therefore to be understood that, within the scope of the appended claims and their equivalents, the invention may be practiced otherwise than as specifically described.