Patent Publication Number: US-2017362101-A1

Title: Water softener valve mechanism and system thereof

Description:
CROSS REFERENCE 
     This application claims the priority of Chinese Application No. 201610426978.3, filed on 
     June  17 ,  2016  and the entirety thereof is herein incorporated with reference. 
     TECHNICAL FIELD 
     The preferred embodiment of the present invention is related to a field of water softener and, more particularly, to a water softener valve mechanism and system thereof. 
     BACKGROUND OF THE INVENTION 
     Nowadays, the presence of certain metal ions like calcium and magnesium principally as bicarbonates, chlorides, and sulfates in water causes a variety of problems. Hard water leads to the buildup of limescale, which can foul plumbing, and promote galvanic corrosion. In industrial scale water softening plants, the effluent flow from the re-generation process can precipitate scale that can interfere with sewage systems. Water softening is the removal of calcium, magnesium, and certain other metal cations in hard water. The resulting soft water is more compatible with soap and extends the lifetime of plumbing. Water softening is usually achieved using lime softening or ion-exchange resins. Water softeners are well known in the art and typically include a raw water source, a treatment tank containing an ion exchange resin, a brine tank containing a brine solution, and a control valve for directing fluids between the source, the tanks and a drain or other output. 
     Water softening occurs by running water through the ion exchange resin, which replaces the calcium and magnesium cations in the water with sodium cations. As the ion exchange process continues, the resin eventually loses its capacity to soften water and must be replenished with sodium cations. The process by which the calcium and magnesium ions are removed, the capacity of the ion exchange resin to soften water is restored, and the sodium ions are replenished is known as regeneration. 
     Periodically, these ion exchange resins must be regenerated. Typically, this regeneration is accomplished utilizing a brine solution such as sodium or potassium chloride. In a typical regeneration process, the brine solution is slowly pumped through the resin bed. Through a chemical exchange process, the calcium and magnesium ions which were adsorbed onto the resin are stripped off and replaced with sodium or potassium ions. 
     The existing art, for example, U.S. Pat. No. 8,535,540 (&#39;540) describes a control valve device for a water softener and the system thereof, wherein the system includes a piston, wherein movement of the piston between a plurality of different positions is operative to change the flow of water through the orifices. 
     From the above description abstracted from &#39;540 patent, it is to be noted that the patent is focused on the piston to control open or close of variety of orifices as well as different fluid communication between pipes or conduits. 
     Another art involving a valve mechanism related to a water softening process is U.S. Pat. No. 8,580,118 (&#39;118). It is noted from the context that this patent is directed to a water softening system, which includes apparatus and process that recycles a substantial percentage of the brine. This system conventionally includes a brine tank and a softening tank through which hard water from a source passes during normal operation. During the regeneration cycle, the brine solution in the brine tank passes through the softening tank acquiring hardness ions, and then through a nano-filter that passes a much higher proportion of the brine ions than the hardness ions. The hardness ions flow from the upstream end of the nano-filter into a drain. The liquid passing through the nano-filter contains salt that returns to the brine tank for reuse. 
     After study current art, it is noted that numerous valve structures are provided commercially. However, they are either complicated in structure or require additional control modules to control various water softening processes. 
     SUMMARY OF THE INVENTION 
     It is an objective of the preferred embodiment of the present invention to provide a water softener valve mechanism adapted to be in fluid communication with a resin tank containing therein resins for softening hard water and a brine tank containing therein salt water for regenerating resins in the resin tank after a period of time using the resin. 
     Another objective of the present invention is that the water softener valve mechanism includes a body provided with a main inlet, a main outlet and a discharge. The body further has therein a static valve plate provided with a first passage, a second passage, a third passage, a fourth passage, a blind fifth passage and a sixth passage respectively and radially defined through a surface of the static valve plate and a seventh passage defined through a central portion of the static valve plate to have the first passage, the second passage, the third passage, the fourth passage, the blind fifth passage and the sixth passage radially located around the seventh passage; and a dynamic plate rotatable relative to the static plate and having an elongated blind hole defined in a side face of the dynamic plate to allow a portion of which aligns with the seventh passage and remainder of which to selectively align with the blind fifth passage, the sixth passage, the first passage and the second passage and an aligning hole defined to selectively communicate with the first passage, the second passage, the third passage, the fourth passage and the sixth passage of the static valve plate; and a driving device mounted inside the body to drive the dynamic valve plate to rotate. 
     Still another objective of the preferred embodiment of the present invention is that the driving device includes a step motor, a master gear securely connected to the step motor to be driven by the step motor to rotate, and a planetary gear meshed with the master gear to be driven by the master gear, the planetary gear is securely connected to the dynamic valve plate to provide a driving force to the dynamic valve plate to rotate relative to the static valve plate to allow the aligning hole to selectively and respectively align with the first passage, the second passage, the third passage, the fourth passage and the sixth passage of the static valve plate. 
     Still another objective of the preferred embodiment of the present invention is that a plurality photo sensors are mounted inside the body and pads are mounted on the planetary gear to allow the photo sensors to detect angular positions of the dynamic valve plate after rotation. 
     Still another objective of the preferred embodiment of the present invention is that a water softener valve mechanism is composed of a body having a main inlet, a main outlet, a discharge, a static valve plate immovably located inside the body and having a first passage, a second passage, a third passage, a fourth passage, a blind fifth passage, a sixth passage and a seventh passage radially defined through a face of the static valve plate and a dynamic valve plate rotatable relative to the static plate and having an aligning hole selectively communicating with the first passage, the second passage, the third passage, and the fourth passage and an elongated blind hole with a portion thereof aligned and communicating with the blind fifth passage, the sixth passage, the first passage, and the second passage while the other portion of which is aligned and communicating with the seventh passage of the static valve plate such that filtering phase, reverse phase, regenerating phase, cleansing phase and water supplementing phase are respectively processed via the correlation between the static valve plate and the dynamic valve plate. 
     Still another objective of the preferred embodiment of the present invention is that a driving device mounted inside the body to drive the dynamic valve plate to move. 
     Still another objective of the preferred embodiment of the present invention is that the driving device includes a step motor, a master gear securely connected to the step motor to be rotatable relative to the step motor, and a planetary gear meshed with the master gear to be driven by the master gear, the planetary gear is securely connected to the dynamic valve plate to provide a driving force to the dynamic valve plate to rotate relative to the static valve plate. 
     Still another objective of the preferred embodiment of the present invention is that the dynamic valve plate is rotated to a position to undergo a filtering phase, where the aligning hole is aligned and communicating with the first passage of the static valve plate and the elongated blind hole is aligned with the fifth passage of the static valve plate such that water from a main inlet is flowing through the aligning hole of the dynamic valve plate for entering a resin tank. 
     Still another objective of the preferred embodiment of the present invention is that the dynamic valve plate is rotated to a position to undergo a reverse cleaning phase, where the aligning hole is aligned with the second channel of the static valve plate and the elongated blind hole is aligned with the sixth channel. 
     Still another objective of the preferred embodiment of the present invention is that the dynamic valve plate is rotated to a position where the aligning hole aligns with the third passage and the elongated blind hole is aligned with the first passage. 
     Still another objective of the preferred embodiment of the present invention is that the dynamic valve plate is rotated to a position where the aligning hole aligns and communicates with the third passage and the elongated blind hole is aligned with the first passage. 
     Still another objective of the preferred embodiment of the present invention is that the dynamic valve plate is rotated to a position where t the aligning hole is aligned and communicating with the fourth passage and the elongated blind hole is on top of the second passage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective view of the water softener valve mechanism constructed in accordance with the preferred embodiment of the present invention; 
         FIG. 2  is a top plan view showing arrangement of the driving device inside the valve body; 
         FIG. 3  is a top plan view of the static valve plate of the preferred embodiment of the present invention; 
         FIG. 4  is a top plan view of the dynamic valve plate of the preferred embodiment of the present invention; 
         FIG. 5  is a schematic cross sectional view showing the movement of fluid inside a water softener in a filtration process; 
         FIG. 6  is a cross sectional view according to line A-A of  FIG. 5 ; 
         FIG. 7  is a schematic top plan view showing the cooperation between the static valve plate and the dynamic valve plate in the filtration process in the preferred embodiment of the present invention; 
         FIG. 8  is a schematic side plan view showing the fluid movement in the filtration process of the preferred embodiment of the present invention; 
         FIG. 9  is a schematic top plan view showing the cooperation between the static valve plate and the dynamic valve plate in the filtration process in the preferred embodiment of the present invention; 
         FIG. 10  is a schematic side view showing the fluid movement corresponding to the reverse process in the preferred embodiment of the present invention; 
         FIG. 11  is a schematic side plan view showing another view of the reverse process in the preferred embodiment of the present invention; 
         FIG. 12  is a top plan view showing the correlation between the static valve plate and the dynamic valve plate in the regeneration process in the preferred embodiment of the present invention; 
         FIG. 13  is another side plan view showing the fluid movement in the water supplementing process in the preferred embodiment of the present invention; 
         FIG. 14  is a top plan view showing the correlation between the static valve plate and the dynamic valve plate in the water supplementing process in the preferred embodiment of the present invention; 
         FIG. 15  is a schematic side plan view showing the fluid movement in the cleansing process in the preferred embodiment of the present invention; and 
         FIG. 16  is a schematic top plan view showing the correlation between the static valve plate and the dynamic valve plate in the cleaning process in the preferred embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Preferred embodiment(s) of the present invention in combination with the attached drawings shall be provided in detail in the following description. However, the given description is for example purpose only and should not be deemed as a limiting to the scope of the present invention in any way. 
     In order to make it easy to carry out the preferred embodiment of the present invention, a detailed description of the parts of the invention, supported with figures is provided here. As each part of the preferred embodiment of the present invention has many features, it is made easy to read, by referring to each feature with a number included in the parts description text. The number of the parts feature(s) is indicated here by starting it sequentially from the number  10 , wherever a part feature appears in a text, an associated serial number is directly assigned. 
     With reference to  FIGS. 1, 2, 3, 4 and 5 , the water softener valve mechanism constructed in accordance with the present invention has a body  10  provided with therein a main inlet  11 , a main outlet  12  and a discharge  13  respectively and laterally extending out from the body  10 . The body  10  of the valve mechanism of the preferred embodiment of the present invention further has an outer channel  14  and an inner channel  15  longitudinally extending from a bottom of the body  10 . The water softener valve mechanism is adapted to connect to a resin tank  70  and has an ejector  20  adapted to connect to a brine tank  110  (shown in  FIG. 6 ) having salt water therein. The ejector  20  has a salt inlet  16 , an ejection inlet  17  and an ejection outlet  18 . Still, an electromagnetic valve  30  is provided alongside the ejector  20 . 
     In addition, a static valve plate and a dynamic valve plate  50  are provided inside the body  10  of the water softener valve mechanism of the preferred embodiment of the present invention. The dynamic valve plate  50  is rotatably operative relative to the static valve plate so as to channel different waterways to process different phases of the water softening. Furthermore, to drive the dynamic valve plate  50  to rotate according to different requirements in various water softening phases of the water softener, a step motor  62  is provided inside the body  10  to drive a master gear  63  which is meshed with a planetary gear  64 . The planetary gear  64  has an axis  68  connected to the dynamic valve plate  50  such that operation of the step motor  62  is able to drive the dynamic valve plate  50  to rotate accordingly. Still, inside the body  10 , there are provided with first photo sensors  66 , second photo sensors  67  respectively located inside different locations inside the body  10  and optical sensitive pads  65  are spatially separated from each other and mounted on a face of the planetary gear  64  such that when the planetary gear  64  is rotated due to the operation of the step motor  62  and both the first photo sensors  66  and the second photo sensors  67  detect the angular position of the planetary gear  64  via the pads  65 , the valve mechanism of the preferred embodiment of the present invention is ready for a filtering process. Thereafter, by way of the operation of the step motor  62 , different waterways can be channeled to undergo different processes. 
     Referring especially to  FIGS. 3 and 4 , it is noted that the static valve plate could be in any shape. The static valve plate has a first passage  41  defined to selectively communicate with the outer channel  14 , a second passage  42  defined to selectively communicate with the inner channel  15 , the main outlet  12  and the electromagnetic valve  30 , a third channel second  43  defined also to selectively communicate with the salt inlet  16  and the ejection inlet  17 , a fourth channel  44  defined to selectively communicate with the outer channel  14 , a fifth passage  45  being a closed channel, a sixth channel  46  defined to selectively communicate with the outer channel  14  and a seventh channel  47  communicating with the discharge  13 . The dynamic valve plate  50  has an aligning hole  51  defined to selectively align with different passages of the static valve plate and an elongated blind hole  52  defined to selectively align with different passages of the static valve plate. 
     In the preferred embodiment of the present invention, it is noted that the dynamic valve plate  50  is provided on top of the static valve plate and both are made of ceramic material to reduce the possibility of bacteria existence. Still, the outer channel  14  as well as the inner channel  15  is provided below the body  10  for connection and communication with a resin tank  70 . The outer channel  14  is connected to and communicating with an interior of the resin tank  70  and the inner channel  15  is connected to and communicating with a central tube  80  extending into the interior of the resin tank  70 . The resin tank  70  has therein resin  71  and quartz sand  72 . A free end of the central tube  80  is then provided with a distributor  81 . The body  10  further has an outer threading  19  formed for connection to different tanks and a cap  90  provided below the outer threading  19 . 
     Furthermore, it is understood that there are filtering phase, reverse cleaning phase, regenerating phase, cleaning phase and water supplementing phase in a water softener. The following description is aimed at providing a detailed operational process of the relationship between the static valve plate and the dynamic valve plate  50  as well as the waterways in the valve mechanism of the preferred embodiment of the present invention. 
     Filtering Phase (with the Electromagnetic Valve Off): 
     With reference to  FIGS. 5, 6 and 7 , when the valve mechanism of the embodiment of the present invention is in a filtering phase, the dynamic valve plate  50  is rotated via the driving device to a position where the aligning hole  51  is aligned and communicating with the first passage  41  of the static valve plate and the elongated blind hole  52  is aligned with the fifth passage  45  of the static valve plate. In this status, water from the main inlet  11  is flowing through the aligning hole  51  of the dynamic valve plate  50  and the outer channel  14  to directly enter the resin tank  70 . After being filtered by the resin  71  and the quartz sand  72 , the filtered water flows via the assistance of the distributor  81  as well as the central tube  80  to the inner channel  15  and out of the valve mechanism from the main outlet  12 . 
     Reverse Cleaning (with the Electromagnetic Valve Off) 
     With reference to  FIGS. 8 and 9 , when the valve mechanism of the embodiment of the present invention is in a reverse cleaning phase, the dynamic valve plate  50  is rotated to a position where the aligning hole  51  is aligned with the second channel  42  of the static valve plate and the elongated blind hole  52  is aligned with the sixth channel  46 , which allows water from the main inlet  11  passes through the inner channel  15 , the central tube  80  and reaches to the distributor  81 . After being filtered by the quartz sand  72  and the resin  71 , waste water flows through the outer channel  14  and into the discharge  13  to be away from the valve mechanism of the preferred embodiment of the present invention. 
     Regenerating Phase (with the Electromagnetic Valve On) 
     With reference to  FIGS. 10 ˜ 12 , when the valve mechanism of the embodiment of the present invention is in a regenerating phase, the dynamic valve plate  50  is rotated to a position where the aligning hole  51  aligns with the third passage  43  and the elongated blind hole  52  is aligned with the first passage  41 . When the correlation between the static valve plate and the dynamic valve plate  50  is in the above status, water from the main inlet  11  flows through the ejection inlet  17  and the salt inlet  16 , which allows the salt water inside the brine tank  110  to be sucked out of the brine tank  110  to mix with the water from the main inlet  11 . After the salt water from the brine tank  110  is mixed with the water from the main inlet  11 , the mixed water flows through the ejection outlet  18 , the electromagnetic valve  30 , the outer channel  15  and enters the resin tank  70 . Inside the resin tank  70 , the mixed water is then filtered by the resin  71  as well as the quartz sand  72  and exits from the discharge  13 . 
     Water Supplementing Phase (with the Electromagnetic Valve Off) 
     With reference to  FIGS. 13 and 14 , when the valve mechanism of the embodiment of the present invention is in a cleansing phase, the dynamic valve plate  50  is rotated to a position where the aligning hole  51  aligns and communicates with the third passage  43  which communicates with the ejection inlet  17  of the ejector  20  and the elongated blind hole  52  is aligned with the first passage  41 , water from the main inlet  11  flows through the ejection inlet  17  and the salt inlet  16  to enter the brine tank  110  to finish the phase. 
     Cleansing Phase (with the Electromagnetic Valve Off) 
     With reference to  FIGS. 15 and 16 , when the valve mechanism of the embodiment of the present invention is in a cleansing phase, the dynamic valve plate  50  is rotated to a position where the aligning hole  51  is aligned and communicating with the fourth passage  44  and the elongated blind hole  52  is on top of the second passage  42 , water from the main inlet  11  passes the outer channel  14  and enters the resin tank  70 . Thereafter, the water flows through the inner channel  15  and exits from the discharge  13 . 
     After a detailed description of the preferred embodiment(s) has been provided, any skilled person in the art would easily understand the description so provided is for example purpose only. The scope for protection of the present invention is defined by the attached claims. Any skilled person in the art would easily amend, modify or alter the elements/devices of the present invention without departing from the principle essence and spirit of the present invention. However, the amendment, modification or alteration shall fall within the protection scope sought of the present invention.