Abstract:
In a urine cartridge or wastewater trap, equalized pressures and increased flow rate between its inlet and outlet compartments increases the life of the cartridge. The pressure equalizing is effected by placement of a separator between the two compartments to provide them with substantially equal volumes. The increased flow rate is created by a uniquely configured baffle positioned adjacent a pan at the bottom of the cartridge. The baffle configuration is shaped to provide a constriction that increases the flow velocity of the urine so that the fluid flow effects a channel along the bottom pan and through any solids deposited on the bottom pan. A diverter may be placed above the centrally located entry to the inlet compartment to create a circuitous path for preventing a disturbing impingement of the urine onto the sealant contained in the inlet compartment. To accommodate the centrally placed entry and its placement vis-a-vis the inlet compartment, the separator is bowed at its location adjacent the entry and towards the outlet compartment. To fit the configuration of the baffle, the separator is curved generally in a likewise manner.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This is a division of application Ser. No. 11/032,310 filed 9 Jan. 2005 (U.S. Pat. No. 7,571,741 issued 11 Aug. 2009). This application further claims the benefit of U.S. Provisional Application No. 60/535,463, filed 9 Jan. 2004, and U.S. Provisional Application No. 60/579,921, filed 14 Jun. 2004, and is a continuation-in-part of the following provisional and nonprovisional applications: Ser. No. 10/647,603, filed 25 Aug. 2003 now U.S. Pat. No. 6,973,939; Ser. No. 10/744,708, filed 23 Dec. 2003 now abandoned; Application No. 60/535,463, filed 9 Jan. 2004; and any of their predecessor applications. 
    
    
     REFERENCE REGARDING FEDERAL SPONSORSHIP 
     Not Applicable 
     REFERENCE TO MICROFICHE APPENDIX 
     Not Applicable 
     1. Field of the Invention 
     The present invention relates to a flow trap, such as a cartridge used in water-free urinals having an odor preventing closure mechanism and, in particular, to improvements in the internal liquid flow path and sealant integrity of such a cartridge and, additionally, to improving flow trap life and usability, including a reduction in the need for the servicing and replacement of such cartridges. 
     2. Description of Related Art and Other Considerations 
     In existing water-free urinals, the life and usability of cartridges employed in water-free urinals has been found to be dependent, in part, upon the need for their servicing and replacement when debris and matter are deposited therein. For example, in the cartridges described in U.S. Pat. Nos. 6,053,197, 6,644,339 and 6,425,411 and U.S. patent application, Ser. No. 10/143,103 (filed 7 May 2002), as the liquids flow from the inlet compartment to the outlet compartment and thence to an external drain, the flow is sufficiently gentle that solid matter contained in the fluid deposits in the pan of the bottom portion and eventually builds up to block flow from the inner compartment to the outlet compartment. As a consequence, the cartridge needs to be replaced. Further, it has been observed that unequal pressures between the two compartments create syphoning therebetween and, particularly, of syphoning of sealant from the inlet compartment to the outlet compartment, which leads to premature failure and a reduction in the usable life of the cartridge. 
     SUMMARY OF THE INVENTION 
     These and other problems are successfully addressed and overcome by the present invention, along with attendant advantages, by equalizing the pressures and by increasing the flow rate between the inlet and outlet compartments. Such pressure equalizing is effected preferably by establishing substantially equal volumes in the two compartments and, specifically, by use of a separator. Such increased flow rate is effected by use of a baffle positioned at the bottom of the cartridge adjacent the pan, which baffle is so configured as to provide a constriction that increases the flow velocity of the urine and thus to use the fluid flow to effect a flow path or channel of least resistance through any solid matter in the bottom pan and thus to remove or carry away or displace solids that may be or have been in the wastewater or urine and thus not deleteriously affect or otherwise substantially deter flow into the outlet compartment. Such action may also otherwise avoid the build up of deposits on the bottom portion. In addition, it is preferred to locate the entry to the inlet compartment centrally of the cartridge so that a diverter may be placed above the entry and thereby to create a circuitous path for preventing turbulence or a disturbing impingement of the urine onto the sealant contained in the inlet compartment. To accommodate the centrally placed entry and its placement vis-a-vis the inlet compartment, the separator is bowed at its location adjacent the entry and towards the outlet compartment. To fit the configuration of the baffle, the separator is curved generally in a likewise manner. 
     Several advantages are obtained derived from these arrangements. The life and usability of the cartridge is extended. Sealant is conserved. Deposits of solid matter within the cartridge are at least minimized. Of importance, the fluid flow effects a flow path or channel of least resistance through any solid matter in the bottom pan. 
     Other aims and advantages, as well as a more complete understanding of the present invention, will appear from the following explanation of an exemplary embodiment and the accompanying drawings thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a flow trap cartridge usable in a water-free urinal; 
         FIG. 2  is an exploded view, in perspective, of the cartridge shown in  FIG. 1 ; 
         FIGS. 3-6  are, respectively, two side views taken 180° from one another, a top view and a bottom view of the cartridge; 
         FIG. 7  is a cross-sectional view of the cartridge taken along line  7 - 7  of  FIG. 3 ; 
         FIG. 8  is a cross-sectional view of the cartridge taken along line  8 - 8  of  FIG. 4 ; 
         FIG. 9  is a cross-sectional view of the cartridge taken along line  9 - 9  of  FIG. 6 ; 
         FIG. 10  is a cross-sectional enlarged view of the cartridge taken along cutaway line  10  of  FIG. 7 ; 
         FIGS. 11 and 12  are perspective views of the bottom portion of the cartridge viewed respectively from its top and bottom; 
         FIG. 13  is a side view of the cartridge bottom portion; 
         FIG. 14  is a cross-sectional view of the bottom portion taken along line  14 - 14  of  FIG. 13 ; 
         FIG. 15  is a cross-sectional enlarged view of the cartridge top portion taken along cutaway line  15  of  FIG. 14 ; 
         FIG. 16  is a cross-sectional enlarged view of the cartridge taken along cutaway line  16  of  FIG. 7 ; 
         FIG. 17  a cross-sectional enlarged view of the cartridge taken along cutaway line  17  of  FIG. 9 ; 
         FIG. 18  is a perspective enlarged view of the cartridge taken from its top side with a portion cutaway to expose its inner structure; 
         FIGS. 19 and 20  are perspective views of the top portion of the cartridge taken respectively from its top and bottom; 
         FIGS. 21-23  respectively are top, side and bottom views of the cartridge top portion; 
         FIG. 24  is a cross-sectional view of the cartridge top portion taken along line  24 - 24  of  FIG. 21 ; 
         FIG. 25  is a cross-sectional view of the cartridge top portion taken along line  25 - 25  of  FIG. 22 ; 
         FIG. 26  is a cross-sectional view of the cartridge top portion taken along line  26 - 26  of  FIG. 23 ; 
         FIG. 27  is a cross-sectional enlarged view of the cartridge top portion taken along cutaway line  27  of  FIG. 24 ; 
         FIG. 28  is a perspective view of the baffle, in the interior of the cartridge, viewed towards its top surface; 
         FIG. 29  is a perspective view of the baffle viewed towards its lower surface; 
         FIGS. 30-32  respectively are a top view and two side views, taken orthogonally with respect to one another, of the baffle; 
         FIG. 33  is a cross-sectional view of the baffle taken along line  33 - 33  of  FIG. 30 ; 
         FIG. 34  is a cross-sectional view of the baffle taken along line  34 - 34  of  FIG. 30 ; 
         FIG. 35  is a cross-sectional enlarged view of the baffle taken along cutaway line  35  of  FIG. 33 ; 
         FIG. 36  is a cross-sectional view of a cartridge, such as depicted in  FIG. 1  et seq., with a first embodiment of a urine diverter secured to its top wall; 
         FIG. 37  is a side view of the diverter illustrated in  FIG. 36 ; 
         FIG. 38  is an enlarged view of a spacing standoff taken along cutaway line  38  of  FIG. 37 ; 
         FIG. 39  is a perspective view of the diverter shown in  FIG. 36  viewing its underside; 
         FIG. 40  is a side view of a second embodiment of a diverter which is useful as an alternate to that depicted in  FIG. 36 ; 
         FIG. 41  is a top view of the diverter shown in  FIG. 40 ; 
         FIG. 42  is a cross-sectional view of the diverter taken along line  42 - 42  of  FIG. 41 ; 
         FIG. 43  is an enlarged view of a spacing standoff taken along cutaway line  43  of  FIG. 40 ; and 
         FIG. 44  is a perspective of the cartridge, such as depicted in  FIG. 36 , placed in a urinal housing for coupling of the cartridge to a drain pipe. 
     
    
    
     DETAILED DESCRIPTION 
     Accordingly, referring to  FIGS. 1-27 , a cartridge assembly  100 , acting as a flow trap for urine or other generally fluid waste products, comprises a top portion  102  ( FIGS. 19-27 ) and a bottom portion  104  ( FIGS. 11-15 ). A fluid  103  with urine therein and an oily sealant  105  atop the fluid is contained within the cartridge, as illustrated in  FIGS. 7 and 9 . 
     Top portion  102  has a cylindrical configuration defined by a tubular wall  106  terminated by an opening  108  at its lower end and a top wall  110  at its upper end. The top wall is sloped downwardly to a flat, generally horizontal flat center portion  112  in which an entry opening  114  is disposed, to act as a urine inlet. As depicted in  FIG. 5 , opening  114  comprises a tripartite arrangement of three arced slots  114   a ,  114   b  and  114   c . A hole  115  is centrally positioned within center portion  112 . As will be described with respect to  FIGS. 36-43 , slots  114   a ,  114   b  and  114   c  and hole  115  are adapted to hold either of the two diverters to cartridge  100 . Top portion  102  is further provided with three keys  116  of which one may be of different length than the other two (e.g., see  FIG. 2 ) for purposes of properly placing and orienting cartridge  100  within a urinal, as more fully described in U.S. Pat. No. 6,644,339 (the parent application of above-noted Ser. No. 10/647,603). 
     Top wall  110  is provided with a recess  117  as shown in  FIGS. 7 ,  9 ,  24 ,  26  and  44  at its outer periphery to accept a seal, such as O-ring seal  228  (see  FIG. 44 ). Recess  117  has a small dimension sufficient to minimize the trapping of urine therein. 
     Top wall  110  of top portion  102  is further provided with three openings  118  which act as air vents that communicate with the interior of cartridge  100 . In the event that one of the openings becomes clogged, such as by urine when the urinal is in use, there will be at least one that remains open. Openings  118  also provide a means by which a tool may be inserted therein for the purpose of inserting and removing the cartridge into and from a urinal, as also described in above-noted co-pending provisional application No. 60/535,463, now patent application Ser. 11/032,508. Accordingly, for purposes of their use as tool engagement means, it is preferred that the outermost two openings be approximately diagonally opposed to one another. However, the placement or use of these openings may be otherwise designed to accommodate other tool configurations. 
     The interior of top portion  102  is divided by a bowed vertical separator  120  (e.g., see  FIGS. 2 ,  8  and  18 ) into two compartments, respectively an inlet compartment  122  and an outlet compartment  124  (e.g.,  FIG. 8 ). Vertical separator  120  is secured or molded to the interior surface of tubular wall  106  and to the underside of top wall  110  at a terminus  121   a  (e.g., see  FIG. 9 ) in any convenient manner. The bottom end of the vertical separator terminates in an end or terminus  121   b  (e.g.,  FIG. 2 ) which is disposed to be connected to a baffle  150  which, in turn, will be presently described fully in  FIGS. 28-35 . When top and bottom portions  102  and  104  are placed together and a discharge section  128  ( FIGS. 7 ,  8  and  11 - 14 ) of bottom portion  104  extends into outlet compartment  124 , inlet compartment  122  and outlet compartment  124  have generally equal volumes. It is important that the compartment volumes be made as equal as possible to ensure that the pressures on both sides of vertical separator  120  remain equal during use of the cartridge. Such pressure equality helps to minimize syphoning or, alternatively, to maximize resistance to syphoning between the compartments and, of particular importance, of sealant  105  from the inlet compartment to the outlet compartment. Thus, the usable life of the cartridge is improved by avoiding premature failure thereof. Additionally, any impediment to liquid flow in minimized. 
     Vertical separator  120  is bowed, e.g., curved or bent, to accommodate centrally positioned entry opening  114  which needs to fully communicate with inlet compartment  122 . The illustrated curved bowing of the vertical separator further enables air vent openings  118  also to communicate with the inlet compartment, as best seen in  FIGS. 23 and 25 . It is to be understood, however, that the vertical separator need not be curved as illustrated; it may take any configuration that will effect its purpose, that is, to provide equally volumed compartments and to oblige the communications of openings  114  with the inlet compartment. Therefore, for example, if the air vent openings were not used as a means to cooperate with a cartridge inserting and removing tool, as above described, and/or entry opening  114  were not centrally positioned in top wall  110 , or for any other reason apart from its compartment volume-defining purpose, vertical separator  120  may be otherwise configured. 
     Bottom portion  104 , as depicted in  FIGS. 11-15 , comprises a pan  126  and discharge section  128  extending upwardly therefrom. The upper surface of pan  126  defines a bottom wall  127  of cartridge  100 ; bottom wall  127  may be likened as being the mate to top wall  110 . The pan includes a side wall  130  terminating at an edge  132  ( FIGS. 14 and 15 ) which provides a tongue-in-groove engagement with tubular wall  106  at its lower end opening  108 , as best seen in  FIGS. 16 and 17  to provide a fluid-tight engagement between top and bottom portions  102  and  104 . The inner surfaces of pan  126  are rounded to prevent sharp-angled corners and are smoothed to enhance fluid flow and to discourage build up of matter and bacteria or other debris. 
     Upwardly extending discharge section  128 , which as described above extends into outlet compartment  124  of top portion  102 , includes a tube  134  (as best seen in  FIGS. 11 and 14 ) that communicates with outlet compartment  104  and opens at an exit port area  136  ( FIGS. 2 ,  12  and  14 ) through pan  126  for discharge of fluids, e.g., fluid  103 , and other undesired matter from the outlet compartment to a drain  220  ( FIG. 44 ). The discharge section also includes a pair of tubular chambers  138  (e.g.,  FIGS. 8 ,  12 ,  14  and  44 ) for receipt of post-treatment chemicals for treating the exiting urine, as contained in control stick  224  or pellets, as more fully described in copending application Ser. No. 11/032,508 (provisional application No. 60/579,921). Chambers  138  are closed at wall  140  (see  FIGS. 11 and 14 ) at one of their ends at the uppermost part of upwardly extending discharge section  128  to prevent flow of fluids thereinto from the outlet compartment, and are open at their other ends  142  (see  FIG. 14 ). 
     As shown in  FIGS. 7 ,  14 ,  16  and  44 , a flow director  144  in tube  134  adjacent exit port area  136  comprises an angled part which is adapted to direct fluid flow towards ends  142  of tubular chambers  138  for impacting control stick  224 , as presently described. A pair of longitudinally extending ribs  145  (see  FIGS. 11 and 14 ) are formed in and extend along the length of conduit  134  and terminate adjacent to tubular chamber ends  142  and act further as flow directors also to direct fluid flow towards ends  142 . 
     As shown in  FIGS. 7 ,  14 ,  16  and  44 , a key  146  and a keyway  148  are provided respectively on the interior surface of tubular wall  106  (see  FIGS. 8 ,  20 ,  23 ,  25  and  26 ) and on the backside of upwardly extending discharge section  128  (see FIGS.  8  and  11 - 14 ). The key and keyway are disposed to provide an orientation and proper alignment between top and bottom portions  102  and  104  and, through the orienting mechanism of keys  116  with the urinal, to place exit port area  136  adjacent exterior drain  220  from cartridge  100 . 
     As depicted in  FIGS. 2 ,  7 - 10 ,  12 ,  17  and  18  and, more in detail in  FIGS. 28-35 , a baffle  150  is disposed to be secured to curved vertical separator  120  ( FIGS. 2 ,  7  and  10 ) and acts as a mechanism for improved direction and flow of wastewater fluids through the cartridge in a region from inlet compartment  122  to outlet compartment  124 . The baffle comprises a curved base  152  from which a center wall  154  and side walls  156   a  and  156   b  upwardly extend. Wall  154 , which terminates in a groove  158  at its upper edge, has the same curvature as that of curved vertical separator  120  so that groove  158  will mate with and fit securely within vertical separator end  121   b , such as illustrated in  FIGS. 10 and 17 . Walls  156   a  and  156   b  are curved similarly as or otherwise contoured in conformance with the inner wall of tubular wall  106 , and the top and bottom walls may be accordingly shaped differently from that as shown and as dictated by wall  106 . Further, the dimension of baffle  150  between walls  156   a  and  156   b  is sized to form a snug, fluid-tight fit of the baffle within tubular wall  106 , also as shown in  FIGS. 8 and 17 . Therefore, fluids within inlet compartment  122  are forced to flow onto the surface of curved base  152 . 
     With respect to the curvature of base  152 , which acts as a weir, the base is carefully configured to effect several desired results to provide an undulated, non-planar or like configuration of baffle  150 . The curved base has a lowermost segment  160 , which is slightly lower at its center part or point  160   a  than at its adjacent side parts or points  160   b . Base  152  curves generally at  90  from generally upstanding wall  154 , and all parts  160   a  and  160   b  rise to an undulated termination or terminal edge  162 . Termination  162  has a center part  162   a  which is slightly elevated from its neighboring side parts  162   b . This curved configuration of the baffle directs fluid  103  (e.g., as shown in  FIGS. 7 and 9 ) to flow in the directions generally portrayed by arrow-headed lines  164 , that is, from center part  160   a  to side parts  162   b  and thence under the baffle, between its underside  166  and the upper surface of bottom portion pan  126 . The fluids then exit into outlet compartment  124  as portrayed generally by arrow-headed lines  168 , as depicted in  FIG. 30 . The directed flow paths, as represented by arrow-headed lines  164  and  168  provide a constriction that increases the flow velocity and avoids the resistance of flow due to deposits on bottom portion  104  generally within the region from inlet compartment  122  to outlet compartment  124 . The increased velocity thus effects channels of least resistance through any solid matter deposited in the region between the inlet and outlet compartment and at least minimizes any deposit of such solid matter. The above-described components or parts of baffle  150  may therefore be defined as channeling media. 
     Reference is now made to  FIGS. 36-43 , and to a urine diverter whose two illustrative embodiments are shown as diverters  170  and  270 . For the first embodiment shown in  FIGS. 36-39 , a pretreatment control tablet  172  is held within a tablet retainer mechanism  174  for holding the tablet within the diverter. Diverter  170 , as generally depicted in  FIG. 36 , is positionable atop wall  110  of top portion  102  for protectively covering entry opening  114  (e.g., see also  FIG. 5 ) and for providing a circuitous path for flow of urine to the opening. Therefore, urine is prevented from directly contacting and entering into opening  114  and impinging upon sealant  105  within the cartridge. Diverter  170 , which includes a shell  176 , is slightly spaced from top portion top wall  110  to assure a clear path for flow of the urine and to space retainer  174  and tablet  172  from the top wall. Such spacing is effected by use of standoffs  178  (as best shown in  FIG. 38 ), which depend from shell  176  and comprises a large portion  178   a  and a smaller portion  178   b . Portion  178   b  is made to be as small as possible to permit the smallest contact of the diverter with the top wall and, therefore, to provide the largest possible unobstructed flow path. 
     As depicted also in  FIGS. 37 and 39 , shell  176  comprises an upper surface  180 , terminated by a periphery  182  with a downwardly depending flange  184 . Upper surface  180  slopes downwardly towards periphery  182  to encourage flow of urine towards the periphery. Inwardly-facing bumps  186  are formed on large portion  178   a  of standoffs  178  for holding tablet retainer  174  to the inside of shell  176 . 
     A tubular housing  188  preferably of cylindrical configuration is secured at one end to the center of the under surface of shell  176  and terminates in a latching mechanism  190  at its second end  192  which has a bi-level shape. The second end is also formed with cutaway portions  194 , as configured by the shape of bi-level end  192 , into legs  196  to permit a bending of the latching mechanism. Latching mechanism  190  comprises pairs of facing teeth  198  at the ends of legs  196  which are adapted to latch into arced slots  114   a ,  114   b  and  114   c  of top wall  110  for securing diverter  170  to top portion  102 . 
     Tablet retainer  174  is more fully disclosed in provisional application No. 60/535,463 and its non-provisional application Ser. No. 11/032,508, filed on 9 Jan. 2005 whose contents are incorporated herein as if set forth in haec verba. 
     A pair of post-treatment discharge control sticks  224  or pellets are disposed to be placed within tubular chambers  138  and may include a biocide and cleaning agents held in a time-release binder. Its use is primarily as a descaling agent to help maintain a clean drain pipe, and especially in environments where the cartridge use pattern is such that additional descaling is needed. The post-treatment discharge control sticks or pellets may be used alone or in conjunction with pretreatment control tablet  172 . Like tablet retainer  174 , the post-treatment discharge control stick or pellets is more fully disclosed in provisional application No. 60/535,463 and its non-provisional application Ser. No. 11/032,508, filed on 9 Jan. 2005 whose contents are incorporated herein as if set forth in haec verba. 
     The second embodiment of the diverter, diverter  270 , is shown in  FIGS. 40-43 . This diverter is positionable atop wall  110  of top portion  102  and protectively covers entry opening  114  (e.g., see also  FIG. 5 ) in a manner similar to that shown for diverter  170  in  FIG. 36 , and provides a circuitous path for flow of urine to the opening. Therefore, urine is prevented from directly contacting and entering into opening  114  and impinging upon and agitating sealant  105  within the cartridge. In addition, a pretreatment control tablet may be held within a tablet retainer for holding the tablet within the diverter, again as described above. Diverter  270 , which includes a shell  276 , is slightly spaced from top portion top wall  110  to assure a clear path for flow of the urine and to space the retainer and its retained tablet from the top wall. Such spacing is effected by use of standoffs  278  (as best shown in  FIG. 43 ), which depend from shell  276  and comprises a large portion  278   a  and a smaller portion  278   b . Portion  278   b  is made to be as small as possible to permit the smallest contact of the diverter with the top wall and, therefore, to provide the largest possible unobstructed flow path. 
     As depicted also in  FIGS. 40-42 , shell  276  comprises an upper surface  280 , terminated by a periphery  282  with a downwardly depending flange  284 . Upper surface  280  slopes downwardly towards periphery  282  to encourage flow of urine towards the periphery. Inwardly-facing bumps  286 , which are more elongated than previously described bumps  186 , are formed on large portion  278   a  of standoffs  278 , as well as on other inner parts of flange  284 , for holding the tablet retainer, such as previously described retainer  174 , to the inside of shell  276 . 
     A base  288 , preferably of cylindrical configuration, is secured at one end to the center of the under surface of shell  276  and terminates in a fastener  290  at its second end  292 . The fastener is formed as a post  296  terminating in a beveled end  298 . Fastener  290  is sized to form an interference fit within hole  115  of top wall  110  for securing diverter  270  to top portion  102 . 
     When all the above-described components are assembled together, they form cartridge  100  as depicted, for example, in  FIGS. 1 and 36 . This assembled cartridge is then adapted to be placed within a urinal  226  ( FIG. 44 ) which, in turn, is coupled to drain  220  with exit port area  136  as provided through the orienting mechanism of keys  116 . An O-ring seal  228  is sealingly placed within recess  117  in the periphery of top wall  110 . 
     While separator  120 , baffle  150  and other components are described as providing a preferred cooperative arrangement, it is to be understood that these individual components may be employed separately should the user so choose. 
     Accordingly, although the invention has been described with respect to particular embodiments thereof, it should be realized that various changes and modifications may be made therein without departing from the spirit and scope of the invention.