Abstract:
The present invention relates generally to a water conditioning apparatus that is compact and easily recharged without removal from the installation location. In one embodiment, the present invention relates to a water conditioning apparatus that is generally rectangular in shape and is configured to fit into rectangularly shaped spaces of limited size. In another embodiment, the water conditioning apparatus is configured to fit in a corner location. In still another embodiment, the water conditioning apparatus is of modular configuration and includes a self-contained selector valve system.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 60/156,371 filed Sep. 28, 1999. 
    
    
     TECHNICAL FIELD 
     This invention relates generally to a compact and self-contained apparatus for water conditioning. More particularly, the compact water conditioning apparatus described herein allows the installation and operation of a water conditioning device in limited spaces typically encountered in the food service industry. 
     BACKGROUND OF THE INVENTION 
     The requirement for conditioned water in the food service industry is well known. For example, conditioned water is often employed in dishwashing, in order to avoid the undesirable appearance of mineral or detergent residue. Further applications exist in beverage preparation, such as soft drinks, or in coffee preparation, in order to improve taste, and to avoid undesirable mineral deposits in dispensing machines. 
     Increasingly, an important conditioned water consumer in the food service industry is a food-steaming device, which is used to heat prepared food in food service establishments. When unconditioned domestic water is vaporized in these devices, they are particularly prone to fouling due to the accretion of mineral deposits in the steamer. Mineral fouling from unconditioned domestic water may result in increased energy costs in operation, and if not curtailed may eventually culminate in the complete failure of the steamer. As a result, manufacturers of food steamers frequently require that conditioned water be used in steamers, even in areas where the domestic water supply is relatively free of dissolved minerals. 
     Commercially available water conditioning devices are well known to those skilled in the art. Generally, prior art water conditioning devices are attached to the domestic water supply line, and allow mineral laden domestic water to flow through a bed of cation exchange resin beads to produce conditioned water. According to this method, the undesirable metallic ions present in the water, usually calcium, are exchanged for sodium ions embedded in the resin beads. When depletion of the available sodium ions in the resin beads occurs, exposing the resin beads to a sodium chloride solution, which is later discarded, recharges the unit. After recharging, the unit is then available for another water conditioning cycle. 
     Water conditioning units of this type are usually connected directly to the domestic water main, causing substantial internal pressures to result. Consequently, prior art water conditioning devices have generally favored the use of a cylindrical container for the cation exchange resin beads. A significant drawback associated with the use of cylindrical containers is an inefficient use of space, thereby compromising the favorable objective of compactness. For example, U.S. Pat. No. 4,855,043 issued to Dalton (“the Dalton patent”) on Aug. 8, 1989 discloses a compact water conditioning apparatus that purports to be particularly suited to applications in the food service industry. However, the Dalton patent relies on a cylindrical container for the cation exchange resin beads. Similarly, U.S. Pat. No. 3,960,721 issued to Heskett on Jun. 1, 1976 discloses a water conditioning apparatus that also relies on cylindrical containers to withstand the internal pressure. 
     Accordingly, in view of the increasing use of food steamers in food service establishments and commercial kitchens, conventional water conditioning devices that are housed within large cylindrical containers according to the prior art are increasingly impractical since they compete for increasingly limited amounts of floor space in the kitchen area. More favorable utilization of space in food service establishments is achievable if the water conditioning apparatus container can be made to fit in a rectangularly shaped space. Moreover, it is advantageous to have the water conditioning apparatus rechargeable by on site kitchen personnel since the unit is frequently installed in a remote location, such as behind the conditioned water consumer. Such remote locations generally preclude convenient removal and replacement of the unit with a similar unit that has been recharged off-site. U.S. Pat. No. 5,552,043 to Noordhoff issued Sep. 3, 1996, discloses a water conditioning apparatus that uses a rectangular shaped container for containment of the cation exchange resin beads, thus achieving the favorable result of compactness, but lacks the important feature of self-contained serviceability, since it fails to disclose a salt solution tank and the necessary plumbing to achieve recharging in place. 
     Accordingly, there is a need in the food service industry for a water-conditioning apparatus that is compact, reliable, easily recharged without removal and relatively inexpensive to manufacture. 
     SUMMARY OF THE INVENTION 
     Briefly, and in general terms, the present invention relates generally to a water conditioning apparatus that is compact and easily recharged without removal from the installation location. In one aspect, the present invention relates to a water conditioning apparatus that is generally rectangular in shape and is configured to fit into rectangularly shaped spaces of limited size. In another aspect, the water conditioning apparatus is configured to fit in a corner location. In still another aspect, the water conditioning apparatus is of modular configuration and includes a self-contained selector valve system. 
    
    
     Other advantages will become apparent based on the description of the invention provided below when read with reference to the drawing figures. The present invention can be best understood through the following description and accompanying drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of an embodiment of the water conditioning apparatus. 
     FIG. 2 is an isometric view of an embodiment of the water conditioning apparatus that shows internal details. 
     FIG.  3 ( a ) is an isometric view of an embodiment of the water conditioning apparatus that shows a schematic representation of plumbing details. 
     FIG.  3 ( b ) is an isometric view of an embodiment of the water conditioning apparatus that shows a schematic representation of plumbing details. 
     FIG. 4 is a schematic representation of an alternative embodiment of the water conditioning apparatus. 
     FIG. 5 is an isometric exploded view of still another embodiment of the water conditioning apparatus. 
     FIG. 6 is a frontal cross sectional view of the lower portion showing inner details of still another embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is generally directed to a compact and self-contained apparatus for water conditioning. Many of the specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 1 through 6 to provide a thorough understanding of such embodiments. One skilled in the art will understand, however, that the present invention may have additional embodiments, or that the present invention may have additional embodiments, or that the present invention may be practiced without several of the details described in the following description. Furthermore, for purposes of the following description, it is understood that specific dimensions and other physical characteristics related to different embodiments are not to be considered limiting unless the claims expressly state otherwise. 
     FIG. 1 illustrates a water conditioning apparatus  10  according to an embodiment of the invention. The water conditioning apparatus  10  is housed in a container  15  that is substantially rectangular in planform, and in cross section, and having an internal volume. The container  15  is further comprised of a top wall  14  having a resealable opening  13  that is fluid tight that may be removed to access the internal volume of the container  15 , and a bottom wall  20  that has a fluid inlet pipe  11  and a fluid outlet pipe  12 . The container  15  may optionally include a plurality of mounting lugs  40  to attach the apparatus  10  to a mounting surface  110 . 
     Turning now to FIG. 2, a cutaway view of the water conditioning apparatus  10  according to an embodiment of the invention is shown. The internal volume of the water conditioner  10  is subdivided into internal chambers  70 ,  71 ,  72  and  80  having substantially a height H by internal dividers  16 ,  17  and  18  that extend across the width W of the apparatus  10  to sealably abut the side walls  112  and  115 . The internal chambers  70 ,  71  and,  72  are at least partially filled with a water conditioning material, preferably cation exchange resin beads. The internal chamber  80  does not contain the water softening beads. Internal divider  16  sealably abuts the bottom wall  20  and extends upwardly toward the top wall  14  to form a top edge  21  spaced apart from the top wall  14  by a distance d 1  to establish a first flow gap  22 . Internal divider  17  sealably abuts the top wall  14  and extends downwardly towards the bottom wall  20  to form a bottom edge  24  spaced apart from the bottom wall  20  by a distance d 2  to establish a second flow gap  25 . Internal divider  18  sealably abuts the top wall  14  and extends downwardly towards the bottom wall  20  to sealably abut the bottom wall  20 . Internal divider  18  is further comprised of a fine screen  26  located in a top aperture  30  that projects through the divider  18 . The screen  26  prevents the passage of resin beads into the chamber  80 . The apparatus  10  may be fabricated from conventional materials, such as stainless steel, aluminum, or various polymers, but preferably is fabricated by an investment die casting technique that uses a foam material to form the internal spaces of the container. During this process, the foam investment material is consumed. Use of this technique in fabrication will allow significant cost reductions to occur when compared to other possible fabrication techniques. 
     Still referring to FIG. 2, chamber  70  is further comprised of a sieve  29  positioned on the inlet pipe  11 . Similarly, chamber  80  is further comprised of a sieve  116  positioned at the outlet pipe  12 . Preferably, the sieve  29  is fabricated from a woven wire material having a mesh size small enough to preclude the passage of water softening resin beads through the sieve  29 . Similarly, the mesh filter  116  is preferably fabricated from a woven wire material having a mesh size at least sufficient to exclude the passage of salt crystals that are commonly used in water softening devices. 
     During normal operation of the water conditioner apparatus  10 , domestic water  41  enters the apparatus though an inlet pipe  11  and flows through the apparatus  10  in a labyrinth course through internal chambers  70 ,  71 ,  72  and  80  in a normal flow direction  117  and exits the unit through an outlet pipe  12  as conditioned water  42 . Fluid communication between internal chambers  70 ,  71 ,  72  and  80  is accomplished through openings  22 ,  24  and  26 . For purposes of this description, domestic water generally refers to mineral laden water obtained from a source such as a municipal water system, or from a water well. Conditioned water refers to domestic water that has been subjected to treatment sufficient to reduce the concentration of undesirable minerals in the domestic water to an acceptable level. Water is conditioned in the water conditioner apparatus  10  through exposure to a bed of cation exchange resin beads that substantially occupy internal chambers  70 ,  71  and  72 . For clarity of illustration, the resin beads in the chambers  70 ,  71  and  72  are not shown. When the exchange capability of the resin beads has been substantially depleted, the resin beads are generally restored to their initial state through exposure to a sodium chloride solution. Accordingly, chamber  80  does not contain resin beads and serves as a receiver for the introduction of sodium chloride in crystalline form into the water conditioner  10 . By continuously flushing the sodium chloride solution through the water conditioner apparatus  10  in a flow direction opposite to that of the normal flow direction  117 , the resin beads may be substantially restored to their initial state. As described above, to retain the resin beads within the water conditioning apparatus  10 , a sieve  29  is provided at the water inlet  11 , to prevent resin beads from migrating out of the apparatus  10 . Similarly, a screen  26  is placed in internal divider  18  to prevent migration of resin beads into chamber  80 . The sieve  29  and the screen  26  also prevent resin bead migration during the recharging cycle. The mesh size of the sieve  29  and the screen  26  is determined by the size of the resin beads employed in the apparatus. 
     The inclusion of the internal chamber  80  in the apparatus  10  thus advantageously allows this important recharging function to be accomplished in situ, so that removal of the apparatus  10  from the installation location is not required. 
     The dimensions of the internal chambers  70 ,  71 ,  72  and  80  may be advantageously tailored to meet a specific water conditioning requirement. For example, alteration of the physical dimensions H and W, as shown in FIG. 2, will allow the water  41  undergoing treatment to have a greater residence time in the cation exchange resin bed. Since the undesirable mineral content in domestic water is relatively constant in a particular geographical location, it is envisioned that the dimensions H and W may be advantageously adjusted for water conditioning applications in specific areas. Alternatively, dimensions H and W may also be varied to meet particular space requirements. Similarly, the first flow gap  22  and second flow gap  25  may be changed by altering the dimensions d 1  and d 2  respectively to advantageously achieve a desired fluid flow rate or water conditioning requirement. 
     Although the water conditioning apparatus  10  is subdivided into four chambers, as shown in FIG. 2, with chambers  70 ,  71  and  72  filled with cation exchange resin beads, chamber  80  contains no resin beads, and is used as a salt solution tank for recharging the unit. During recharging, opening  31  provides a means for introducing the crystalline salt into the unit. A cap  13  provides a pressure tight closure for the opening  31 . Domestic water is introduced into the apparatus  10  through outlet pipe  12 , forming the recharging solution in the salt solution tank. During recharging, the fluid motion through the apparatus is in the opposite direction to that shown by  25 , so that the salt solution is transported back through the cation exchange resin beads. 
     Although the water conditioning apparatus  10  as depicted in FIG. 2 has four internal chambers, it is understood that alternative embodiments of the invention may utilize a plurality of resin containing chambers, depending on the water conditioning requirement. Moreover, other chambers may be added that contain other water conditioning substances. For example, an alternative embodiment may contain at least one chamber containing activated carbon, or other substances capable of removing undesired properties. However, it is understood that at least one of the internal chambers in the apparatus  10  must be used for mixing and containing a salt solution for recharging Consequently, it cannot be filled with cation exchange resin beads. 
     As previously noted, a principal advantage of the present invention is the ability to recharge the water conditioning apparatus without removing the apparatus from its installation position. FIGS.  3 ( a ) and  3 ( b ) show the water conditioning apparatus  10  with a schematic view of the plumbing connections necessary to achieve both normal and backflushing operations. Two main water lines  50  and  58  are used, with two additional lines  54  and  64  branching therefrom, as shown. Valves  52 ,  56 ,  60  and  62  are required to control fluid flows in lines  50 ,  58 ,  54  and  64 . 
     FIG.  3 ( a ) shows the water conditioning apparatus  10  configured for normal operation. Accordingly, domestic water enters line  50  and passes through valve  52 , which is open. Valve  56  is closed, preventing water from escaping into waste line  54 . Conditioned water leaves the unit  85  through line  58  and valve  60 , which is in the open position. Line  64  is connected to a supply of domestic water for backflushing operation. During normal operation, valve  62  is fully closed. 
     When the cation absorption capacity of the resin beads within the water conditioning apparatus has been exhausted, recharging is required, as previously described. The water conditioning apparatus  10  shown in FIG.  3 ( b ) is configured for the recharging operation. Subsequent to the introduction of a measured amount of a crystalline salt into the salt solution tank through opening  31 , cap  13  is replaced, and valves  52  and  60  are closed. Domestic water is introduced into the brine tank through line  64  when valve  62  is in the open position. The domestic water thus introduced forms a salt solution with the salt that is carried into the cation exchange resin beds. Excess salt solution is discarded through waste line  54  when valve  56  is open. The valves and delivery lines shown in FIGS.  3 ( a ) and  3 ( b ) may consist of discrete valves and delivery lines, or, preferably may be comprised of multi-position or “ganged” valves whereby a single setting on the valve handle achieves either the valve setting shown in FIG.  3 ( a ) or in FIG.  3 ( b ) through a single valve position setting. An example of such a multi function valve is Model No. 200C-N Panel Mount Ball Valve manufactured by the Anderson Brass Company. The amount of salt required for the backflushing operation is typically predetermined by calculation. As an alternative, however, a brine metering system with a programmable timer could be employed to implement the recharging process automatically. 
     FIG. 4 is an isometric view of an alternative embodiment according to the invention. The water conditioning apparatus  20  shown therein is configured to fit in a corner space. Since it is recognized that significant space limitations presently exist in food service establishments, this embodiment may find particular utility. 
     FIG. 5 is an isometric, exploded view of still another alternative embodiment according to the invention. The water conditioning apparatus  30  as shown therein is of modular design, and is comprised of a removable top portion  200 , a middle channeled portion  300 , and a removable bottom portion  400 . The top portion  200  has a top wall  202 , and a pair of opposing side walls  210  that are joined to a pair of end walls  211 . The top wall includes a resealable opening  204 , and further has an opposing peripheral sealing surface  212  that extends around the lower periphery of the top portion  200 . The top portion also has internal dividers  206  and  208  that extend between the opposing side walls  210 . The internal divider  206  extends downwardly from the top wall  202  to form a lower edge  216 . Similarly, internal divider  208  extends downwardly to form a lower edge  217 . The internal divider  208  further has an aperture  215  that projects through the internal divider  208  and has a sieve  209  mounted therein. 
     Still referring to FIG. 5, the middle channeled portion  300  is comprised of a pair of opposing side walls  304  joined to a pair of end walls  302 . The middle channeled portion  300  further includes an upper peripheral sealing surface  312  disposed on an upper edge of the middle channeled portion  300 , and a lower sealing surface  313  disposed on a lower edge of the middle channeled portion  300 . The side walls  304  and end walls  302  enclose the internal dividers  306 ,  308  and  310  that extend between the side walls  304 . The internal divider  310  further projects upwardly from a lower edge  317  to form a top edge  315  that is located a distanced d 1  above the upper sealing surface  312 . The internal divider  308  projects downwardly from an upper end  320  to form a lower edge  316  that is located a distanced d 2  above lower sealing surface  313 . The internal divider  306  extends from an upper edge  319  downwardly to a lower edge  318 . The arrangement of internal dividers  306 ,  308  and  310  form internal chambers  350 ,  351 ,  352  and  353  in the middle channeled portion  30 . Chambers  350 ,  352  and  353  are adapted to receive resin beads. Chamber  351  serves as a salt receiving tank, as in previous embodiments. 
     A bottom portion  400  is comprised of a top surface  405 , a front wall  402 , a first side wall  403  and a second side wall  404  opposite the first side wall  403 . The top surface  405  further includes a peripheral mating surface  406  and internal mating surfaces  407  and  408 . Projecting through the top surface  405  of the bottom portion  400  is an inlet port  413 . A filtration sieve  412  preferably covers the inlet port  413 . The top surface  405  also includes an outlet port  411  that is also preferentially covered by a filtration sieve  410 . The front wall  402  further includes a selector valve  416  that controls the routing of fluids within the bottom portion  400 . The internal details of the bottom portion  400  will be described in detail later. The first side wall  403  includes a discharge port  415  adapted to fluidly connect to a wastewater disposal system. The second side wall  404  includes a conditioned water supply port  414  that is adapted to fluidly connect to a conditioned water consumer. 
     With reference still to FIG. 5, the water conditioning apparatus  30  is assembled by sealably joining the peripheral sealing surface  212  on the top portion  200  to the upper peripheral sealing surface  312  on the middle channeled portion  300 . During this assembly step, the lower edges  216  and  217  of the top portion  200  are joined to upper edges  319  and  320  on the middle channeled portion  300 . Assembly of the apparatus  30  further includes sealably joining the peripheral mating surface  406  on the bottom portion  400  to the lower sealing surface  313  on the middle channeled portion  300 . When the middle channeled portion  300  is joined to the bottom portion  400  in this manner, internal mating surfaces  407  and  408  on the top surface  405  of bottom portion  400  sealably join with lower edges  317  and  318  on the middle channeled portion  300 . 
     The apparatus  30  thus assembled has a height H, and a width W that may be advantageously adjusted for water conditioning applications in specific areas. Further, the dimensions H and W may also be adjusted to meet specific space requirements. Similarly, the internal dimensions d 1  and d 2  may be adjusted to meet flow requirements. The top portion  200 , middle channeled portion  300  and bottom portion  400  may be joined by conventional fastening means to form a pressure tight assembly. As an example, through bolts that project through the bottom portion  400 , into and through the middle channeled portion  300 , and threadably connect to the top portion  200  may be used. Alternatively, the top portion  200 , middle channeled portion  300  and bottom portion  400  may be joined by a suitable adhesive such as an epoxy resin. In addition, the peripheral sealing surfaces  312  and  313  in the middle channeled portion  300  may further include resilient o-rings disposed within retaining grooves (not shown) to sealably join the top portion  200  and bottom portion  400  to the middle channeled portion  300 . Additionally, resilient gaskets may also be used. 
     Turning now to FIG. 6, the internal details of the bottom portion  400  will now be described in detail. As shown therein, the bottom portion is further comprised of a selector valve  416  with a frontally positioned selector handle  580 . The selector valve  416  is capable of selecting one of four positions A, B, C and D, as shown, which correspond to ports A, B, C and D, when the selector handle  580  is rotated. The selector valve  416  is structured to fluidly connect ports A, B or C to port D when the selector handle  580  is moved to the position corresponding to that port. For example, when position A is selected, port D is fluidly connected to port A. When position B is selected, port D is fluidly connected to port B, etc. When position D is selected, the selector valve is not fluidly connected to any other port, and is therefore “off”. An example of such a selector valve is the Model No. 200C-N Panel Mount Ball Valve manufactured by the Anderson Brass Company. The bottom portion  400  also includes an internal passage  550  that is fluidly connected to port A on valve  416  and extends to discharge port  414 . The internal passage  55  also connects to internal passage  560  and extends to outlet port  411 . Internal passage  500  is fluidly connected to port B on the valve  416 , and further includes a flow restriction. Preferably, this flow restriction is comprised of a fluid passage with a small internal diameter. The passage  500  also fluidly connects with internal passage  560 . A further internal passage  530  extends from port C on the valve  416  to the discharge port  415 , and is further fluidly connected to an internal passage  540  that extends to inlet port  413 . An additional internal passage  570  is fluidly connected to port D on the selector valve and extends to a water inlet port  520 . 
     With reference to FIGS. 5 and 6, the operation of the apparatus  30  will now be described. With water inlet port  520  fluidly connected to a source of unconditioned water (not shown), and the selector valve  416  positioned at C, unconditioned water is directed from water inlet port  520  to port  413 , thus entering the first chamber  350  (shown in FIG.  5 ), and subsequently moving to other chambers in the apparatus  30 . Conditioned water then exits the chamber  351  (also shown in FIG. 5) through port  411  to emerge from the apparatus  30  through discharge port  414 , to be directed to a conditioned water consumer. When regeneration of the apparatus  30  is required, the chamber  351  is loaded with the appropriate amount of salt through the resealable opening  204 . Valve  416  is then moved to the B position, thus allowing a metered flow of water to enter the chamber  351  and dissolve the crystalline salt solution deposited therein. After the salt has substantially dissolved in the water, the valve  416  may be moved to the A position to flush the salt solution through the resin beads (not shown) located in chambers  350 ,  352  and  353 . The flushing is continued until substantially all of the salt solution is flushed from the apparatus  30 . Returning the selector valve  416  to the C position will restore the apparatus to its normal water conditioning function. 
     The above description is considered to be that of the preferred embodiments only. Modification of the disclosed invention will occur to those skilled in the art and to those who make and use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and are not intended to limit the scope of the invention.