Patent Publication Number: US-2023160489-A1

Title: Irrigation Device, Valve Assembly, And Outlet

Description:
FIELD 
     This invention relates generally to irrigation devices and, more particularly, to valve assemblies and outlets suitable for use in irrigation devices. 
     BACKGROUND 
     Irrigation devices are generally known in the field of irrigation for use in delivering irrigation water from water sources to desired areas. One example of an irrigation device is a hose end timer, which is generally known for use in delivering irrigation water at scheduled times and time intervals, thereby conserving water. In some forms, the body of the hose end timer is formed of molded plastic for convenience of manufacturing and use by consumers. The hose end timer is generally disposed at a water source and controls the flow of water from the water source via a valve. Water may be delivered at a controlled rate and at a scheduled time through a hose to emission devices, which, in turn, irrigate vegetation or targeted terrain. 
     A hose end timer may be connected at one end to a faucet spigot through which water is supplied. The other end of the hose end timer may be connected to a hose for delivery of water to emission devices. The hose end timer needs to have secure couplings at both ends in order to avoid leakage. 
     For hose end timers, it has been observed that, over time, the threaded ends of the hose end timer may deteriorate or become damaged. When fastening the hose end timer to either the faucet spigot or hose, it has been observed that constant tightening (and possibly overtightening) of the ends of the hose end timer may lead to wear and tear or cross-threading. It has also been observed that the threaded ends may become damaged when the hose end timer is first installed or due to instances of rough handling. In response to this damage, however caused, the hose end timer may leak significantly or even stop functioning properly. 
     It is desirable to avoid having to replace irrigation devices due to stress or damage at the ends of the irrigation device. Thus, there is a need for an irrigation device where threaded ends will resist this stress or damage and that will thereby extend the useful life of the irrigation device. Further, there is a need for an irrigation device where these threaded ends can be formed in combination with the molded plastic body of the device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of an embodiment of a hose end timer embodying features of the present invention; 
         FIG.  2    is a front view of the hose end timer of  FIG.  1   ; 
         FIG.  3    is a top view of the hose end timer of  FIG.  1   ; 
         FIG.  4    is a bottom view of the hose end timer of  FIG.  1   ; 
         FIG.  5    is a side elevational view of the hose end timer of  FIG.  1   ; 
         FIG.  6    is a cross-sectional view of the hose end timer of  FIG.  1   ; 
         FIG.  7    is a top exploded view of the hose end timer of  FIG.  1   ; 
         FIG.  8    is a bottom exploded view of the hose end timer of  FIG.  1   ; 
         FIG.  9    is a front view of a solenoid-actuated valve assembly of the hose end timer of  FIG.  1   ; 
         FIG.  10    is a cross-sectional view of the solenoid-actuated valve assembly of the hose end timer of  FIG.  9   ; 
         FIG.  11    is a front view of the valve body and inlet and outlet components of the hose end timer of  FIG.  1   ; 
         FIG.  12    is a side elevational view of the valve body and inlet and outlet components of  FIG.  11   ; 
         FIG.  13    is a cross-sectional view of the valve body and inlet and outlet components of  FIG.  11   ; and 
         FIG.  14    is an exploded view of the valve body and inlet and outlet components of  FIG.  11   ; 
         FIG.  15    is a perspective view of the valve body of  FIG.  11    showing the lower end of the valve body; 
         FIG.  16    is a bottom perspective view of an outlet shown in  FIG.  11   ; 
         FIG.  17    is a front view of the outlet of  FIG.  16   ; 
         FIG.  18    is a top view of the outlet of  FIG.  16   ; 
         FIG.  19    is a top perspective view of the outlet of  FIG.  16   ; 
         FIG.  20    is a perspective view of the valve body and outlet, as assembled, of  FIG.  11   ; 
         FIG.  21    is a partial cross-sectional view of  FIG.  1    showing the connection of the outlet, valve body, and housing; and 
         FIG.  22    is a cross-sectional view of the hose end timer of  FIG.  1    showing the connection of the outlet, valve body, and housing. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With respect to  FIGS.  1 - 8   , an irrigation device in the form of a hose end timer  10  is shown for use in scheduling the delivery of irrigation water or fluid from a water source and through the hose end timer  10 . In one form, it is contemplated that one end of the hose end timer  10  may be connected to a faucet spigot, such as may be located on the exterior of a house or building. The other end of the hose end timer  10  may be connected to a hose, which in turn may be coupled to an emission device. The hose end timer  10  is used to schedule and control the flow of water from the faucet spigot to and through the hose. 
     As shown in  FIGS.  1 - 8   , in one preferred form, the hose end timer  10  includes an inlet  12 , an outlet  14 , and a user interface  16 . A user may connect the inlet  12  to a standard hose faucet spigot and connect the outlet  14  to one end of a hose, such as, for example, a standard garden hose. In turn, the other end of the hose may be attached to an irrigation device. The hose end timer  10  generally allows the user to provide input through the user interface  16  to adjust various settings, such as, for example, adjusting a clock, automatic/manual operation, the time for irrigation, the duration of the irrigation, the frequency of irrigation, and a rain delay. 
     The user interface  16  preferably includes an electronic display screen  18 , a rotary dial  20  (or mode knob), and push buttons  22 . The display screen  18  is covered by a protective and transparent covering (or film)  19  and shows relevant timer information, such as, for example, time of day, day of the week, and the battery power level. The transparent covering  19  may be removed upon installation of the hose end timer. The rotary dial  20  allows a user to select a mode for setting timer information, including, for example, setting the clock, the start time, and the duration of irrigation. Push buttons  22  on the interface  16  allow the user to adjust the settings up and down. Other push buttons  22  may provide a manual override to allow the user to irrigate immediately or to set a rain delay. 
     The housing  24  of the hose end timer  10  contains and protects the components therein. As shown in  FIGS.  7  and  8   , the housing  24  is preferably composed of an upper housing  26  and a lower housing  28  that are fastened to one another by screws  30  or other fasteners. In this particular example, the hose end timer  10  also includes an inner shelf assembly  32 , a solenoid-actuated valve assembly  34 , and a removable battery tray  36  that may be inserted through the lower the housing  28 . 
     The inner shelf assembly  32  supports the rotary dial  20  and push buttons  22  thereon, and it preferably includes a circuit board disposed therein. The circuit board provides the control circuitry for opening and closing the valve assembly  34  in response to user input and commands. Among other things, the control circuitry opens and closes the valve assembly  34  to allow irrigation at predetermined times for predetermined durations. Batteries preferably provide the power source for actuation of the valve assembly  34 . The power demand of the valve assembly  26  is preferably low in order to maximize battery life. 
     Various features, settings, and functionality (such as, for example, a manual override) have been described above. It should be understood, however, that these are simply examples and are not intended as limitations on the irrigation device. Some or all of the above features and settings are not required in the irrigation device. In certain forms, it is contemplated that a limited number of features and settings may be incorporated into the irrigation device, as desired. Further, in other forms, additional or different features and settings may be utilized in the irrigation device. 
     One preferred form of a solenoid-actuated valve assembly  34  is shown in  FIGS.  9  and  10   . The figures show the inlet  12  at the top (which may be connected to an outdoor spigot) with the outlet  14  at the bottom (which may be connected to a hose). The valve assembly  34  disposed within the housing  24  preferably uses a magnetically-actuated latching solenoid  38  moving back and forth to open and close the valve  40 . 
     The valve assembly  34  includes a solenoid  38 , a valve body  39 , the inlet  12 , and the outlet  14 . In the solenoid  38 , a magnet  42  moves to the left to hold a plunger  46  in an open position (shown in  FIG.  10   ) and moves to the right (with respect to the figure) when the plunger  46  is in a closed position. When the valve  40  is in the closed position, the magnet  42  is coupled to a metal member  44 . In this rightward position, the magnet  42  is distant from the plunger  46  such that the spring  48  biases the plunger  46  to the left to close the valve  40 . 
     When the coil  50  is energized (in response to a signal to initiate irrigation), the plunger  46  is pulled to the right against the bias of the spring  48 , thereby opening the valve  40 . In this position, the plunger  46  attracts the magnet  42  such that the magnet  42  is pulled to the left away from the metal member  44 . The magnet  42  holds the plunger  46  in this open position, thereby holding the valve  40  open for the duration of irrigation. 
     When the coil  50  is energized again in the reverse direction (in response to a signal to stop irrigation), the plunger  46  is pushed to the left with the bias of the spring  48 , thereby closing the valve  40 . When the plunger  46  is in this closed position, the magnet  42  is attracted to and moves to the right to contact the metal member  44 . In this rightward position, the magnet  42  does not exert sufficient force to overcome the bias of the spring  48  on the plunger  46 , and the spring  48  continues to bias the plunger  46  to the leftward (or closed) position, holding the valve  40  closed. 
     Movement of the plunger  46  opens and closes the valve  40  by coupling the plunger  46  to a diaphragm  50  that opens and closes the valve  40 . The diaphragm  50  is spaced from a valve seat  51  in the open position and is engaged with the valve seat  51  in the closed position. The plunger  46  moves laterally in a plunger chamber  52  that is axially offset from the diaphragm  50 , i.e., the plunger chamber  52  is below and to the right of the diaphragm  50 . The plunger chamber  52  is in fluid communication with the diaphragm  50  and a pressure chamber  56 . The diaphragm  50  is biased to block flow in the conduit  54  (or flow passage) between the inlet and outlet  12 ,  14 , and the valve  40  is closed. 
     When the plunger  46  is in the leftward (or closed) position, water flows from the inlet  12  and into the pressure chamber  56  via a bleed flow passage  57 . Water can flow into the plunger chamber  52 , but when the plunger  46  is in the leftward (or closed) position, it cannot flow out to the conduit  54 . The diaphragm  50  remains biased to the closed position (to the left) against the valve seat  51 , and the valve  40  remains closed. 
     When the plunger  46  is in the rightward (or open) position, water again flows from the inlet  12  and into the pressure chamber  56  via the bleed flow passage  57  and then into the plunger chamber  52 . However, when the plunger  46  is in the rightward (or open) position, water can now flow out to the conduit  54  via a vent flow passage  59 . In other words, a certain amount of water can flow from the pressure chamber  56  to the plunger chamber  52  to the conduit  54 . This flow results in a pressure drop in the pressure chamber  56  such that pressure exerted against the diaphragm  50  from the inlet water moves the diaphragm  50  away from the valve seat  51 , thereby opening the valve  40  and allowing fluid to flow through the valve  34  from the inlet  12  to the outlet  14 . In  FIG.  10   , the plunger has just been moved to the rightward (or open) position, but the diaphragm  50  has not yet moved to an open position. 
     It should be understood that the solenoid-actuated valve assembly  34  described above is just one example of a valve assembly that may be used with the hose end timer or with other irrigation devices. Other solenoid arrangements are shown in U.S. Pat. Nos. 5,213,303; 7,201,187; and 7,503,348, which are incorporated herein by reference in their entirety. Further, in certain forms, it is contemplated that other types of valves and valve assemblies may be used with the hose end timer or with other irrigation devices that do not involve solenoids. 
       FIGS.  11 - 14    show the valve body  39  and inlet and outlet components of the valve assembly  34 . The inlet components preferably include a filter screen  58 , a collar coupler  60 , an internally threaded ring  62 , and an external collar  64 . The filter screen  58  filters out grit and other debris flowing into the inlet  12  that might otherwise clog the hose end timer  10 . The collar coupler  60  is seated within the threaded ring  62  below the threading. The filter screen  58  sits on top of the collar coupler  60  and is retained by the threading in ring  62 . The collar coupler  60  is preferably mounted to an upper portion of the valve body  39  by receiving a raised annular rim  61  of the valve body  39  therein. The threaded ring  62  is preferably formed of a suitable metal material to resist damage to the threading (such as stripped threading or cross-threading) that may occur over time. The external collar  64  is preferably formed of a plastic and/or rubber material that is preferably bonded around the threaded ring  62 . The external collar  64  allows the user to rotate the internally threaded ring  62  onto the external threading of a faucet spigot. 
       FIG.  15    shows a view of the unassembled valve body  39 , and  FIGS.  16 - 20    show various views of the unassembled outlet body  66 . The valve body  39  is preferably formed of a plastic material, while the outlet body  66  is formed of a metal material. The valve body  39  and the outlet body  66  are preferably bonded to one another by an insert molding process. More specifically, the outlet body  66  (which functions as an externally threaded metal collar) is inserted in the mold for the valve body  39  and molded onto the valve body  39  during the molding process. This insertion molding process makes the bodies  39 ,  66  an integral component, thereby creating strength as well as sealing the flow through the outlet  14 . Additionally, the housing  24  includes structure to help locate and retain the outlet body  66  in the correct position. 
     As shown in  FIG.  22   , the upper housing  26 , the lower housing  28 , the valve body  39 , and the outlet body  66  cooperate to create a secure coupling. The upper housing  26  and lower housing  28  each include a semicircular rim  68  such that, when assembled, the two pieces define an outlet aperture  69  of a predetermined radius. As shown in  FIG.  22   , this radius is selected such that semicircular rims  68  engage upwardly projecting towers  70  of the outlet body  66 . Further, when assembled, these semicircular rims  68  are disposed between portions of the valve body  39  and the outlet body  66 , as addressed further below, to establish a secure coupling of these components. 
     As shown in  FIGS.  14  and  15   , the lower end of the valve body  39  includes an annular cylindrical portion  72  that defines part of the conduit  54 . An annular flange  73  projects radially outwardly and is adjacent to and above tabs  74 . In this preferred form, the height of each tab  74  corresponds generally to the thickness of the semicircular rims  68  of the upper and lower housings  26 ,  28 . 
     The tabs  74  are preferably spaced equidistantly about the annular cylindrical portion  72  and project radially outwardly therefrom. In this form, there are four tabs  74  that are spaced circumferentially about the annular cylindrical portion  72  so as to form gaps through which portions of the outlet body  66  extend. More specifically, the tabs  74  are sized and spaced to allow a tower  70  to extend upwardly between each set of two adjacent tabs  74 . 
       FIGS.  16 - 19    show different views of the outlet body  66 . The outlet body  66  includes external threading  75  for coupling to the internal threading of a hose. The outlet body  66  is preferably in the form of a castellated insert that includes a certain number of towers  70  that project upwardly from an annular ledge  76 . The number of towers  70  preferably corresponds to the number of tabs  74 , and in this example, there are four towers  70 . Each tower  70  includes an upright portion  78  that extends upwardly a predetermined vertical distance from the annular ledge  76 . Each upright portion  78  extends between adjacent tabs  74  and terminates in an overhanging portion  80 . In this example, the overhanging portions  80  extend radially outwardly such that they overhang the annular ledge  76 . The overhanging portion  80  may extend in a direction parallel to the annular ledge  76  or in another direction that otherwise embeds it in the valve body  39 . 
     As shown in  FIGS.  20 - 22   , the towers  70  on the castellated outlet body  66  hold the outlet body  66  relative to the valve body  39 . The spaces between the upright portions  78  of the towers  70  are preferably filled with plastic material of the valve body  39 , i.e., tabs  74 , to prevent the outlet body  66  from rotating. As can be seen in  FIG.  21   , the overhangs  80  are encapsulated within the annular flange  73  of the valve body  39 . Thus, the overhangs  80  at the top of the towers  70  are supported by plastic material below the overhangs  80  to prevent the outlet body  66  from pulling off of the valve body  39 . Next, the housing  24  also fills a portion of the gap between the over-molded plastic about the overhang  80  and the annular ledge  76  of the outlet body  66 . Also, when assembled, the semicircular rims  68  (of the upper and lower housings  26 ,  28 ) are received between the annular flange  73  (of the valve body  39 ) and the annular ledge  76  (of the outlet body  66 ). 
     As shown in  FIGS.  13  and  22   , the annular cylindrical portion  72  of the valve body  39  has a smaller radius than the outlet body  66  such that this annular cylindrical portion  72  engages an inner surface of the outlet body  66 . In other words, the annular cylindrical portion  72  is disposed within the outlet body  66 . Further, the annular cylindrical portion  72  and the outlet body  66  are coextensive in length. More specifically, the annular cylindrical portion  72  extends, at least, to the bottom of the outlet body  66  so that the flow path is not compromised by a metal to plastic interface that could result in leakage. In other forms, the annular cylindrical portion  72  may extend slightly beyond the outlet body  66  so that water flowing along the flow path is completely encased by the plastic interface. In addition, the thickness of the annular cylindrical portion  72  preferably decreases towards the bottom end of the outlet body  66  to allow clearance for a mating connection with a hose. 
     One advantage of this design is that it minimizes the machining necessary to produce the outlet body  66 . For example, a lathe can create the overall shape and threads, and the castellation can be created on a mill by cutting two channels. Other designs require significantly more work to produce. Although minimizing the needed machinery, the outlet body  66 , in combination with the valve body  39  and the housing  24 , results in a secure coupling. Further, this outlet body  66  reduces leakage that may otherwise occur over time. 
     It should be understood that the hose end timer  10  described above is just one example of an irrigation device that may utilize some of the claimed subject matter. It is also contemplated that other irrigation devices might also be used. It is contemplated that other irrigation devices may includes two housing portions configured for engagement with one another to define a housing and that together define an inlet and an outlet. Further, other irrigation devices may utilize a molded body disposed within the housing and defining a flow passage from the inlet to the outlet and may utilize a metal outlet body comprising a threaded portion and at least one projection embedded at least partially into the molded body for coupling the metal outlet body to the molded body. 
     It will be understood that various changes in the details, materials, and arrangements of parts and components which have been herein described and illustrated in order to explain the nature of the irrigation devices, irrigation valve assemblies, and outlets may be made by those skilled in the art within the principle and scope of the irrigation devices and components thereof, as expressed in the appended claims. Furthermore, while various features have been described with regard to a particular embodiment or a particular approach, it will be appreciated that features described for one embodiment also may be incorporated with the other described embodiments.