Patent Publication Number: US-2005133463-A1

Title: Water filter manifold with integral valve

Description:
RELATED APPLICATIONS  
      The present application is a continuation-in-part of and claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 60/512,574, entitled “WATER FILTER MANIFOLD WITH INTEGRAL VALVE,” filed Oct. 17, 2003, the disclosure of which is hereby incorporated by reference to the extent not inconsistent with the present disclosure. 
    
    
     BACKGROUND OF THE DISCLOSURE  
      The present disclosure relates generally to the field of water filtration systems. More specifically, the present disclosure relates to a monolithic filter manifold comprising an integral valve flow block to facilitate installation of a water filtration system, such as a residential water filtration system.  
      Water filtration systems designed for use in the home, such as refrigerator and under-sink systems can be used to remove contaminants from water supplies. Due to increasing quality and health concerns with regard to municipal and well-water supplies, the popularity of such filtrations systems has increased markedly in recent years. For example, the inclusion of water filtration systems in refrigerators, once considered a luxury feature, is now included as a standard feature in all but entry level refrigerator designs.  
      A typical residential water filtration system generally includes a distribution manifold configured to accept a prepackaged cartridge filter. The distribution manifold is typically adapted to connect either directly or indirectly to the residential water supply and to points of use and may even allow for a drain connection. Generally, the prepackaged cartridge filter sealingly engages the distribution manifold such that an inlet flow channel connecting the residential water supply and the cartridge filter is defined, and at least one outlet flow channel connecting the cartridge filter and the points of use and/or the drain is defined.  
      In some current water filtration system designs, the distribution manifold includes a pair of outlet flow paths for distributing filtered water. Generally, one of the outlet flow paths supplies water to an automated ice maker while the second outlet flow path supplies water to a user operated faucet for delivering filtered water for drinking, cooking or a variety of alternative uses. To properly channel filtered water through the appropriate filtered water outlet channel, water filtration systems typically include valves mounted between the distribution manifold and the points of use. These valves are separately installed and require additional time to individually wire and leak check.  
     SUMMARY OF THE DISCLOSURE  
      A distribution manifold of the present disclosure provides for faster and more reliable installation of water filtration systems within appliances. Generally, the distribution manifold is manufactured as a monolithic assembly having a valve flow block as an integral component of the distribution manifold such that additional downstream valves may not be used. The valve flow block is a portion of the ultimate valve structure generally with the valve seat, but as a part of the unitary, monolithic structure, the valve flow block is only a portion of the monolith with this valve component. The monolithic distribution manifold can comprise a plug connector or the like, wired to a valve structure to promote a quick, simple and reliable electrical interconnection between the distribution manifold and a control system. The valve flow block can be a component of a valve structure incorporating suitable valve designs, for example, solenoid valves. When the valve structure comprises solenoid valves, the valve structure can further incorporate rectifiers or the solenoid valves can be configured for DC power such that the solenoid valves provide for quiet operation with less heat generation. While the monolithic manifold can be held together with reversible fasteners in some representative embodiments, as described below, the monolithic structure is distinguishable from a non-monolithic structure in that the monolithic structure comprises a single unit having no flow connections within the monolithic structure that connect tubing, piping or the like with a flow channel.  
      In one representative embodiment, the present disclosure describes a monolithic manifold assembly. The monolithic manifold assembly can incorporate a variety of integral components such as an inlet, an outlet, a flow channel, a filter receiver and a valve flow block. The monolithic manifold assembly can comprise an electrical connector for interconnecting a valve structure with a control element to selectively allow flow through the valve flow block. The monolithic manifold assembly can comprise a stacked plate arrangement for partially defining the flow channel.  
      In another representative embodiment, the present disclosure describes a water filtration system comprising a monolithic manifold assembly and a replaceable cartridge filter. The monolithic manifold assembly can comprise a filter receiver allowing for quick and convenient attachment of the cartridge filer, for example through rotatable or slidable connecting members.  
      In another representative embodiment, the present disclosure describes a method for reducing the potential for leak point in a water filtration system by eliminating the need for downstream distribution valves. A monolithic manifold assembly can be fabricated to include an integral valve flow block such that downstream distribution valves may not be used or needed. The monolithic manifold assembly can be permanently connected, for example by suitable welding, molding or adhesive joining techniques, as would be known to those skilled in the art and all new techniques that may be subsequently developed that perform the same function. Alternatively, the monolithic manifold assembly can be detachable connected, for example through the use of suitable clamps, bolts or other connectors, allowing for the replacement of components, as would be known to those skilled in the art and all new techniques that may be subsequently developed that perform the same function.  
      In still another representative embodiment, the present disclosure describes an appliance, such as, for example, a refrigerator comprising a water filtration system designed to reduce the potential for downstream system leakage. The water filtration system can comprise a valve flow block to selectively distribute a filtered water stream to points-of-use on the appliance, such as, for example, a manual water dispenser or tap in a refrigerator door or an automated device, such as, for example, an icemaker.  
      The above summary of the various aspects of the present disclosure is not intended to describe in detail each illustrated representative embodiment or the details or every possible implementation of the present disclosure. The figures in the detailed description that follow more particularly exemplify these representative embodiments. These, as well as other objects and advantages of the present disclosure, will be more completely understood and appreciated by referring to the following more detailed description of the described representative, exemplary embodiments of the present disclosure in conjunction with the accompanying drawings.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is an exploded, perspective view of an embodiment of a monolithic manifold assembly of the present invention with hidden springs shown for later reference.  
       FIG. 2  is an alternative exploded, perspective view of the monolithic manifold assembly of  FIG. 1 .  
       FIG. 3  is a second alternative exploded, perspective view of the monolith manifold assembly of  FIG. 1 .  
       FIG. 4  is an exploded, perspective view of a filtration system according to an embodiment of the invention.  
       FIG. 5  is an end view of a valve flow block according to an embodiment of the invention.  
       FIG. 6  is a top view of the valve flow block of  FIG. 5 .  
       FIG. 7  is a section view of the valve flow block of  FIG. 5  taken along line  7 - 7  of  FIG. 6 .  
       FIG. 8  is a partial section view of an appliance including a filtration system according to an embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF PRESENTLY PREFERRED REPRESENTATIVE EMBODIMENTS  
      An improved monolithic manifold assembly for use in filtration systems comprises a valve flow block to selectively direct a filtered water flow to a desired point-of-use. Generally, the monolithic manifold assembly can be fixedly attached to a surface, such as the interior of an appliance or a cabinet. Replaceable cartridge filters can be connected and removed appropriately, for example, rotatably or slidingly in a longitudinal, a lateral or angled direction, from the manifold. In particular, a cartridge filter can be replaced as the filtering capacity of the cartridge filter is consumed or exhausted. The manifold assembly can comprise a fastener component that cooperates with a compatible fastener component on the cartridge filter to create an operable water filtration system with flow channels passing through the manifold and the cartridge filter. The manifold assembly also comprises inlet and outlet flow channels that define continuous flow paths from a water source, through the water filtration system and to one or more points of use or to drain at the direction of the valve flow block. The term “block” in valve flow block does not indicate any particular shape or the separate assembly into the monolithic structure, but the valve flow block as a feature of the monolithic manifold contributes a portion of the ultimate valve structure, such as generally the valve seat.  
      The monolithic manifold assembly as described herein comprises an integral valve flow block located to interface with the inlet flow channels or outlet flow channels. A valve structure can comprise at least one valve to selectively allow filtered water to flow through the valve flow block and to points of use based on an input from an external control. The external control can receive signals from various points-of-use including a water tap or automated ice machine requesting filtered water flow.  
      The valve flow block is an integral component of the monolithic manifold assembly such that no significant additional installation time is required to install downstream distribution valves at the time of installation of the water filtration system. Through the elimination of downstream distribution valves, the number of potential leak points within the water filtration system is reduced. The entire valve assembly can be installed on the valve flow block.  
      The monolithic manifold assembly can further comprise a plug-style connector for completing a control circuit between a control unit and a valve assembly interfacing with the valve block flock structure to further simplify wiring requirements between the control unit and the valve. The control unit can be mounted, for example, on the monolithic manifold structure, in an appliance associated with the manifold or remotely. In one representative embodiment, the valve assembly can comprise a pair of solenoid valves that sealing interface with the valve flow block. The valve assembly can be fabricated to reduce operating temperature by, for example, operating on DC power or to reduce operation noise through the inclusion of rectifiers on the solenoid valves. In alternative representative embodiments, alternative valve designs having suitable performance and assembly characteristics could be used with the valve assembly.  
      As illustrated in one representative embodiment of  FIGS. 1, 2  and  3 , a monolithic manifold assembly  100  comprises a manifold body  102 , a first flow plate  104 , a second flow plate  106 , a valve flow block  107  and a valve assembly  108 . Manifold body  102  has a mounting surface  110 , an unfiltered water inlet  112  and a filter interface surface  114 . Water inlet  112  is fluidly connected to an inlet flow channel  116 . Manifold body  102  also includes a filtered water manifold outlet  118 . Manifold assembly  102  is comprised of a metal, a ceramic, a polymeric material or a combination thereof, as would be appreciated by those skilled in the art and all new materials that may be subsequently developed that are capable of performing the same function. Suitable polymers include polyolefins such as polypropylene, polyethylene, polycarbonate or combinations thereof, as would be appreciated by those skilled in the art and all new polymers that may be subsequently developed that are capable of performing the same function.  
      Manifold body  102  is generally adapted to connect with a cartridge filter  120  to form a filtration system  122  as depicted in  FIG. 4 . Cartridge filter  120  can comprise a unitary structure formed by a cartridge housing  124  and a cartridge cap  126 . Cartridge cap  126  can comprise a connecting member  128 , such as, for example, angled tabs or ramps that cooperatively interface with a ramp  130  on filter interface surface  114  to promote connection of the manifold body  102  and cartridge filter  120 . Suitable interconnection members and methods for rotatable interconnection are further disclosed in U.S. patent application Ser. Nos. 09/618,686, 10/196,340, 10/202,290, 10/406,637 and 10/838,140, each of which is incorporated by reference to the extent not inconsistent with the present disclosure.  
      In another alternative representative configuration, cartridge cap  126  and filter interface surface  114  may include attachment features to promote linear, slidable attachment of the manifold body  102  with cartridge filter  120 , as described in U.S. patent application Ser. No. 10/210,890, which is herein incorporated by reference to the extent not inconsistent with the present disclosure.  
      Cartridge filter  120  can comprise any suitable filtering media. For example, cartridge filer  120  can comprise various types of suitable filtration media, such as, for example, powdered and granular activated carbon media, ceramic filtration media, powdered polymeric filtration media, manganese greensand, ion exchange media, cross-flow filtration media, polymeric barrier filtration or media, mineral-based fibers, granules and powders and combinations thereof, as would be appreciated by those skilled in the art and all new filtration media that may be subsequently developed that are capable of performing the same filtration function.  
      Referring again to  FIGS. 1, 2  and  3 , first flow plate  104  comprises a first connector surface  132  and a first flow surface  134 . A first throughbore  136  extends through first flow plate  104  and connects first connector surface  132  with first flow surface  134 . First flow plate  104  also includes a first outlet  138  and a second outlet  140 . First flow surface  134  includes a first outlet bore  142  and a second outlet bore  144 .  
      As depicted in  FIGS. 1, 2  and  3 , second flow plate  106  comprises a second connector surface  146  and a second flow surface  148 . A second throughbore  150  extends through second flow plate  106  and connects second connector surface  146  with the second flow surface  148 . Second flow surface  148  comprises a first flow recess  152 , a second flow recess  154  and a third flow recess  156 . Third flow recess  156  is fluidly connected to second throughbore  150 . Second connector surface  146  comprises a first bore  158  fluidly connected to first flow recess  152  as well as a second bore  160  fluidly connected to second flow recess  154 .  
      Representative valve assembly  108  comprises a bracket  164 , a pair of diaphragms  166   a ,  166   b , a pair of valve plungers  168   a ,  168   b , a pair of springs  170   a ,  170   b , a pair of guides  172   a ,  172   b  and a pair of solenoid coils  174   a ,  174   b . A pair of guide seals  175   a ,  175   b , such as, for example, O-rings or integrally molded seals conform to the guides  172   a ,  172   b . Diaphragms  166   a ,  166   b  each comprise a diaphragm throughbore  176 . Valve plungers  168   a ,  168   b  each comprise a sealing tip  178 . Sealing tip  178  is dimensioned to sealingly engage the diaphragm throughbore  176 . In an alternative representative embodiment, valve plungers  168   a ,  168   b  can comprise integral seals to directly engage the valve flow block  107 . Solenoid coils  174   a ,  174   b  can be encased and packaged as a single component including a power connector  180  wired to the solenoid coils  174   a ,  174   b . In alternative representative embodiments, valve assembly  108  can further comprise components that can provide for cooler and quieter operation, for example, the use of rectifiers and DC powered solenoid coils to reduce current draw and eliminate oscillation. Although valve assembly  108  is described with respect to utilizing solenoid valves, it will be understood that any suitable automatically actuatable valve could be used as well, such as, for example, pneumatic or hydraulically actuated valves as would be appreciated by those skilled in the art and all new valves that may be subsequently developed that are capable of performing the same function.  
      As illustrated in  FIGS. 5, 6  and  7 , valve flow block  107  comprises a valve inlet bore  182  and a pair of valve outlet bores  184   a ,  184   b . Valve flow block  107  also includes a pair of valve bores  186   a ,  186   b . Valve bores  186   a ,  186   b  each include a valve flange  188   a ,  188   b  adapted to sealingly interface with the guide seals  175   a ,  175   b . Valve flow block  107  further includes a pair of internal flow channels  190   a ,  190   b  fluidly connecting valve inlet bore  182  with corresponding valve outlet bores  184   a ,  184   b . For example, internal flow channel  190   b  is defined by the interaction of valve inlet bore  182 , valve bore  186   b  and valve outlet bore  184   b , as illustrated in  FIG. 7 . It will be understood that internal flow channel  190   a  is similarly defined by valve inlet bore  182 , valve bore  186   a  and valve outlet bore  184   a . Internal flow channels  190   a ,  190   b  include channel flanges  192   a ,  192   b  adapted to sealingly interact with the corresponding diaphragms  166   a ,  166   b  and valve plungers  168   a ,  168   b . While the manifold assembly has been described with respect to the figures as having two outlets, similar structures with one outlet, three outlets or more outlets can be formed based on the teachings herein. Similarly, while a valve flow block has been depicted with two valve seats, separate flow blocks can be formed for a plurality of valve structures and a variety of configurations can be adapted from the teachings herein.  
      Prior to use, components of monolithic manifold assembly  100  are assembled to form a unitary assembly. First flow plate  104  and second flow plate  106  are positioned with first flow surface  134  and second flow surface  148  in proximity such that first throughbore  136  and second throughbore  150  are substantially in alignment while first outlet bore  142  is located proximally to first flow recess  152  and second outlet bore  144  is located proximally to second flow recess  154 . First flow plate  104  and second flow plate  106  are then operatively connected through a suitable bonding process, such as, for example, permanent joining through the use of adhesives, appropriate welding technologies such as sonic welding, molding such as injection molding or through the use of snap-fit members as would be appreciated by those skilled in the art and all new bonding processes that may be subsequently developed that are capable of performing the same joining function. Alternatively, first flow plate  104  and second flow plate  106  can be detachably joined through the use of suitable clamps, bolts or other fasteners. In an alternative representative embodiment, first flow plate  104  and second flow plate  106  can be integrally molded to form a single, unitary flow plate. Once first flow plate  104  and second flow plate  106  are joined, an inlet circuit is defined by first throughbore  136  and second throughbore  150 , a first outlet circuit is defined by first bore  158 , first flow recess  152  and first outlet  138  while a second outlet circuit is defined by second bore  160 , second flow recess  154  and second outlet  140 .  
      Valve flow block  107  and valve assembly  108  can be operably connected by placing diaphragm  166   a  within the corresponding valve bore  186   a . An end opposed to sealing tip  178  of plunger  168   a  is directed into guide  172   a  such that plunger  168   a  is in contact with spring  170   a . Guide  172   a  is operatively positioned through the center opening on solenoid coil  174   a . Sealing tip  178  can be operatively positioned within valve bore  186   a  such that sealing tip  178  is in proximity to diaphragm throughbore  176 . The process can be similarly repeated with diaphragm  166   b  placed within valve bore  186   b . An end opposed to sealing tip  178  of plunger  168   b  is directed into guide  172   b  such that plunger  168   b  is in contact with spring  170   b . Guide  172   b  is positioned within the center opening on solenoid coil  174   b . Sealing tip  178  can be positioned within valve bore  186   b  such that sealing tip  178  is in proximity to diaphragm throughbore  176 . The order of assembly for valve flow block  107  and valve assembly  108  as described above is for descriptive purposes only and it will be understood that a user might select any number of possible alternative orders of assembly without departing from the spirit and scope of the present invention.  
      Valve flow block  107  can then be positioned with respect to second flow plate  106 . Specifically, valve inlet bore  182  can be aligned with second throughbore  150  while valve outlet bore  184   a  can be aligned with first bore  158 . In addition, valve outlet bore  184   b  can be aligned with second bore  160 . Valve flow block  107  is then coupled to second flow plate  106 . Valve flow block  107  can be permanently attached to second flow plate  106  through a suitable molding, welding, snap-fit or adhesive joining process, as would be appreciated by those skilled in the art and all new boding processes that may be subsequently developed that are capable of performing the same bonding function. Alternatively, valve flow block  107  can be removably attached to second flow plate  106 , for example through the use of suitable clamps, bolts or other fasteners, as would be appreciated by those skilled in the art and all fasteners that may be subsequently developed that are capable of performing the same fastening function. Alternatively, valve flow block  107  and second flow plate  106  can be integrally molded as a single, unitary component.  
      Also, first flow plate  104  can be positioned with respect to manifold body  102 . First throughbore  136  is aligned with water manifold outlet  118 . First flow plate  104  is then coupled to manifold body  102 . First flow plate  104  can be permanently attached to manifold body  102  through a suitable molding, welding, snap-fit or adhesive joining process, as would be appreciated by those skilled in the art and all new bonding processes that may be subsequently developed that are capable of performing the same joining function. Alternatively, first flow plate  104  can be removably attached to manifold body  102 , for example through the use of suitable clamps, bolts or other fasteners, as would be appreciated by those skilled in the art and fasteners that may be subsequently developed that are capable of performing the same fastening function. Alternatively, first flow plate  104  and manifold body  102  can be integrally molded as a single, unitary component.  
      After permanently or reversibly assembling monolithic manifold assembly  100  as described above, the monolithic manifold assembly  100  can be operatively positioned using mounting surface  110  for use in an appliance such as a refrigerator. A cartridge filter  120  can be sealingly coupled, such as, for example, slidingly or rotationally as previously described, to filter interface surface  114 . Once the cartridge filter  120  has been attached to the monolithic manifold assembly  100 , two flow channels are defined; one extending from unfiltered water inlet  112  to first outlet  138  while the other extends from unfiltered water inlet  112  to second outlet  140 .  
      In use, supply water enters monolithic manifold assembly  100  through unfiltered water inlet  112 . Water then flows through inlet flow channel  116  and into cartridge filter  120  wherein the water is filtered to remove contaminants. Filtered water flows out of water manifold outlet  118 , through first throughbore  136 , into third flow recess  156 , out of second throughbore  150  and into valve flow block  107  through valve inlet bore  182 . Flow into respective outlets is controlled with valve assemblies  108 .  
      Using power connector  180 , the solenoid coils  174   a ,  174   b  can be wired to a control unit  194  within an appliance  196  as illustrated in  FIG. 8 . Control unit  194  can comprise any suitable control element such as a Programmable Logic Controller (PLC), a microprocessor, a logic circuit comprising relays and/or a terminal block. Appliance  196  can be selected from suitable appliances such as refrigerators and water coolers. Control unit  194  can selectively control the flow of water through monolithic manifold assembly  100  based upon manual or automated signals from the control unit  194  to the monolithic manifold assembly  100 . In some representative embodiments, control unit  194  can be mounted itself onto monolithic manifold assembly  100  with appropriate connections to receive input signals. Furthermore, components of control unit  194  can be mounted at different physical locations with appropriate communication between the components.  
      When an input to the control unit  194  indicates that filtered water is desired, the control unit  194  can individually or simultaneously energize solenoid coils  174   a ,  174   b . When solenoid coils  174   a ,  174   b  are not energized, springs  170   a ,  170   b  bias the sealing tip  178  of valve plungers  168   a ,  168   b  such that the diaphragm throughbore  176  of diaphragms  166   a ,  166   b  remain closed preventing filtered water from flowing past the valve flow block  107 . When the control unit  194  signals that filtered water is desired, the control unit  194  energizes the appropriate solenoid coil. For example, the control unit  194  energizes solenoid coil  174   b  resulting in plunger  168   b  withdrawing the sealing tip  178  from diaphragm throughbore  176  of diaphragm  166   b  such that filtered water flows through diaphragm throughbore  176 , through the internal flow channel  190   b  into out the valve outlet bore  184   b . Filtered water from valve outlet bore  184   b  flows into second bore  160 , through second flow recess  154  and to points of use through second outlet  140 . As would be understood by one skilled in the art, a similar process occurs with respect to energizing solenoid coil  174   a  such that filtered water can subsequently flow to points of use through first outlet  138 . As shown in  FIG. 5 , first outlet  138  can supply a refrigerator  198  having a door mounted faucet  200  for supplying filtered water for domestic consumption while second outlet  140  can supply an automated feature such as an icemaker  202 .  
      While the use and assembly of the present invention has been described, it will be obvious to one skilled in the art that various modifications and additions can be incorporated without departing from the spirit and scope of the present invention.