Abstract:
A modular manifold assembly includes at least one barbed distribution connector disposed on a modular manifold body. Individual modular manifold assemblies are assembled into various lengths as required to accommodate multiple different desired fluid distribution system configurations. The modular manifold body employs a tubular design with a D-shaped cross-section that allows ease of assembly. The at least one barbed distribution connector attaches to at least one distribution line to distribute fluid throughout a fluid distribution system.

Description:
[0001]     The application claims priority to U.S. Provisional Application No. 60/613,159, which was filed on Sep. 24, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention is directed to a modular manifold assembly for a fluid distribution system and a method of economically manufacturing a desired fluid distribution system including the modular manifold assembly.  
         [0003]     Known fluid distribution systems are constructed from standard manifolds. Known standard manifolds are typically made from copper and are manufactured in various standard lengths. To accommodate a variety of desired fluid distribution system configurations including, for example, hydronic heating systems and/or potable water systems, the various standard lengths are cut to size and assembled as required to achieve the desired fluid distribution system configuration. This process requires a significant amount of additional time and labor. In addition, fluid distribution system component wholesalers must carry a large inventory of each of the many different standard length manifolds and branch connectors in order to accommodate the variety of desired fluid distribution system configurations.  
         [0004]     As such, it would be desirable to provide a modular manifold assembly for a fluid distribution system, which is flexible, requires less labor to assemble, is less expensive to construct, and eliminates the need to stock multiple individual standard length manifolds in inventory.  
       SUMMARY OF THE INVENTION  
       [0005]     A modular manifold assembly of the present invention includes at least one distribution connector attached to a modular manifold body. Individual modular manifold assemblies are assembled into various lengths as required to accommodate multiple different desired fluid distribution system configurations. The modular manifold body employs a tubular design with a D-shaped cross-section that allows ease of assembly. The at least one distribution connector attaches to at least one distribution line to distribute fluid throughout a fluid distribution system.  
         [0006]     A desired fluid distribution system is manufactured by assembling modular manifold assemblies together with standard branch connectors to form the desired fluid system configuration. Each D-shaped end of the modular manifold body is flared to form a circular opening which facilitates joining multiple modular manifold assemblies, standard branch connectors or a termination and allows each individual modular manifold assembly to rotate in any direction.  
         [0007]     These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]      FIG. 1  schematically illustrates an example fluid distribution system;  
         [0009]      FIG. 2  illustrates example floor geometries;  
         [0010]      FIG. 3  illustrates a modular manifold assembly according to one embodiment of the present invention;  
         [0011]      FIG. 4  illustrates an example fluid distribution system according to one embodiment of the present invention;  
         [0012]      FIG. 5  illustrates a cross-section of one embodiment of a modular manifold assembly of the present invention through a Section A-A shown in  FIG. 3 ; and  
         [0013]      FIG. 6  illustrates a cross-section of one embodiment of a modular manifold assembly of the present invention through a Section B-B shown in  FIG. 3 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0014]      FIG. 1  schematically illustrates an example fluid distribution system  10 . A main fluid distribution system  12  distributes a fluid, for example, water, to a main supply manifold  14  including a plurality of distribution tubes  16  extending from the main supply manifold  14  to a main return manifold  18 . The fluid is distributed from the main fluid distribution system  12  to the main supply manifold  14 . The main supply manifold  14  distributes the fluid to each of the plurality of distribution tubes  16 . The fluid circulates through each of the plurality of distribution tubes  16  to the main return manifold  18 . The fluid from the plurality of distribution tubes  16  is consolidated within the main return manifold  18  and returned to the main fluid distribution system  12 .  
         [0015]     The main fluid distribution system  12 , for example, may include provisions to heat the fluid and provide heated fluid through the fluid distribution system  10  to warm a floor  20 . The number of distribution tubes  16  required and the configuration of the distribution tubes  16  is determined by the shape and size of a desired surface area of the floor  20  to be heated.  
         [0016]     In the illustrated example, there are six distribution tubes  16  that require connection to both the main supply manifold  14  and the main return manifold  18 . The illustrated floor  20  has a rectangular shape that requires the main supply manifold  14  and the one main return manifold  18  to include six distribution connectors (not shown) each for connection to each of the six distribution tubes  16 . However, more complex floor shapes  20  A-C, examples of which are illustrated as  FIG. 2 , require longer main supply manifolds  14 , longer main return manifolds  18  and additional distribution tubes  16  to direct the fluid flow to accommodate the various floor geometries.  
         [0017]      FIG. 3  shows an example modular manifold assembly  30  of the present invention. The modular manifold assembly  30  includes a male end  32 , a female end  34  and a body  36  disposed between the male end  32  and the female end  34 . The body  36  includes a D-shaped cross-section as shown in  FIG. 5 . Three distribution connections  38  or barbed ends are disposed along a length of the body  36 . A fluid flows through the body  36  and is distributed to the distribution connections  38  for further distribution to distribution tubes (not shown).  
         [0018]     The male end  32  and the female end  34  are pre-formed on the modular manifold assembly  30 . The male end  32  and the female end  34  are flared to have a circular cross-section as shown in  FIG. 6 , which facilitates joining multiple modular manifold assemblies  30 , a termination and/or attachment to a main fluid distribution system as illustrated in  FIG. 4 . The male end  32  and the female end  34  are designed complementary to each other, i.e. a diameter associated with the circular cross-section of the male end  32  is smaller than a diameter associated with the female end  34 . The male end  32  and the female end  34  of each modular manifold assembly  30  are preferably flared to conform to ANSI B16.22 for wrought copper and bronze solder-joint drainage fittings.  
         [0019]     Standard branch connectors (not shown), which include but are not limited to a standard “T” and a 90° elbow, are easily assembled to the modular manifold assemblies  30  by localized brazing within the circular openings of the male end  32  and the female end  34 . Sweat soldering or brazing is also employed to assemble the various components together to form the desired fluid system configuration for standard baseboard heating or, alternatively, PEX, that is, cross-linked polyethylene fittings, may be employed to accommodate PEX systems.  
         [0020]      FIG. 4  shows an example fluid distribution system  50  including four modular manifold assemblies  30 A- 30 D attached to a main fluid distribution system  12 . Modular manifold assemblies  30 A and  30 B are supply manifolds, which supply a fluid to the fluid distribution system  50 . The fluid travels through the distribution tubes  16  into modular manifold assemblies  30 C and  30 D, which are return manifolds. The fluid is consolidated within the return manifolds  30 C and  30 D and returned to the main fluid distribution system  12 . Supply manifold  30 A is connected to supply manifold  30 B such that the distribution tubes  16  that extend from supply manifold  30 A extend in a direction opposite that of the distribution tubes  16  extending from supply manifold  30 B. This allows the main fluid distribution system  12  to be centralized to accommodate fluid distribution to areas in opposite directions from the main fluid distribution system  12 .  
         [0021]      FIG. 5  shows a cross-section of one embodiment of a modular manifold assembly  30  of the present invention through a Section A-A shown in  FIG. 3 . Section A-A is drawn through a body  26  which includes a D-shaped cross-section that has a first portion  62  that is substantially circular and a second portion  64  that is substantially linear. A distribution connector  38  is disposed on the body  36 . The distribution connector  38  includes a barbed-end for connection to a distribution tube  16 , as previously shown in  FIG. 4 .  
         [0022]      FIG. 6  shows a cross-section of one embodiment of a modular manifold assembly  30  of the present invention through Section B-B shown in  FIG. 3 . Section B-B is drawn through a female end  34 , which includes a substantially circular cross-section  66 . A distribution connector  38  is disposed on the body  36  (not shown).  
         [0023]     Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.