Patent ID: 12214321

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Thus, any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. All of the embodiments described herein are exemplary embodiments provided to enable persons skilled in the art to make or use the invention and not to limit the scope of the invention which is defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary, or the following detailed description.

By way of overview, the present invention is directed to devices and related systems for preparing a chemical solution as well as inserts that may be installed in such devices to improve the functionality thereof. The invention is useful for water treatment, as the devices and systems may be used to prepare chemical solutions by mixing a chemical material with an aqueous fluid (e.g., water) and providing the chemical solution to water undergoing treatment. In certain embodiments, the chemical material may be calcium hypochlorite (Ca(OCl)2), also known as cal hypo. However, it should be noted that any chemical material may be used. Often, the chemical material is provided in solid form as briquettes or tablets. The devices of the present invention dissolve the briquettes or tablets to prepare a chemical solution for water treatment. Accordingly, the devices may be referred to herein as erosion feeders or chemical feeders, for example. The devices of the present invention may be particularly useful for commercial swimming pool chlorination, municipal drinking water chlorination, agricultural water chlorination, and industrial water chlorination.

FIGS.1through4show certain aspects of an embodiment of a water treatment device100consistent with the present disclosure. Certain additional aspects of the water treatment device100are disclosed in U.S. patent application Ser. No. 16/864,372 to Blanchette et al. (referred to hereinafter as Blanchette et al.), published as U.S. Patent Application Publication No. 2020/0346175, incorporated in its entirety herein.

In general, the device100includes a housing110including an upper chamber120and a lower chamber150. Chemical material in a solid form (not shown), such as briquettes or tablets, may be loaded (inserted) into the upper chamber120through an opening185at an upper portion thereof. The upper chamber120may further include a lid115for selectively covering the opening185.

FIG.2shows a cross-sectional view of the device100. InFIG.2, the lid115to the upper chamber120, or hopper, is open. A dissolving bowl125is arranged at an interface of the lower chamber150and upper chamber120. The dissolving bowl125comprises an open-ended top in communication with the upper chamber120for receiving the chemical material therefrom and a closed bottom portion129.

A grid member131is disposed within the upper chamber120and suspended above the bottom portion129of the dissolving bowl125. As shown, the grid member131is generally in the form of a disk that is shaped and/or sized to correspondingly fit within upper chamber120in a nesting arrangement, such that the grid member131is retained a distance from the bottom portion129of the dissolving bowl125. The grid member131is configured to support the solid, undissolved chemical material (of a particular size and/or dimension) on a top surface thereof and maintain physical separation of the chemical material (at its original size and/or dimension) from at least the bottom portion129of the dissolving bowl125. As shown, the grid member131comprises a central flow opening133substantially aligned with a nozzle135to allow fluid flow from the nozzle135through the grid member131. However, this arrangement is nonlimiting as the flow opening133may be in other locations of the grid member131(i.e., other than the center) and the nozzle135may be aligned with and/or directed toward the flow opening133.

The nozzle135is disposed within the dissolving bowl125and positioned proximate the bottom portion129. The nozzle135is arranged to direct flow of an aqueous fluid into the dissolving bowl125and towards the grid member131to thereby cause the aqueous fluid to contact and dissolve at least some of the solid chemical material therein and create a chemical solution of the aqueous fluid and the dissolved chemical material based, at least in part, on fluid flow from the nozzle135. In this embodiment, the nozzle135is centrally positioned within the dissolving bowl125. However, as noted previously, the nozzle135may be located in other locations within the dissolving bowl125. In some examples, the nozzle135comprises an eductor oriented to discharge fluid in a direction towards the grid member131and away from the bottom portion129of the dissolving bowl125.

The dissolving bowl125comprises an outlet175provided along a portion of a sidewall of the dissolving bowl125and proximate to the grid member131at the base of the grid member131. As shown, the outlet175is generally in fluid communication with the lower chamber150and allows for the chemical solution to flow from the dissolving bowl125into the lower chamber150. The outlet flow from the dissolving bowl125is directed to fall into the lower chamber150near a chemical solution outlet port of the device100. The lower chamber150comprises a contoured base155with a low section157defined at a center the contoured base155. The inlet flow provided to the lower chamber150functions in combination with the contoured base155to direct flow of any solid, insoluble particles included in the chemical solution towards the low section157of the contoured base155to thereby remove the insoluble particles from the chemical solution and away from the outlet port of the device100.

FIGS.3and4present aspects of the grid member131.FIG.4omits an insert200(described in more detail below) for clarity. The grid member131comprises a framework of a first set of the beams140and a second set of the beams140arranged relative to one another, each of the beams140in the first and second sets includes a substantially elliptical cross-sectional shape. The first set of the beams140are substantially parallel with and spaced apart from one another and oriented in a first direction181and the second set of the beams140are substantially parallel with and spaced apart from one another and oriented in a second direction183perpendicular to the first direction181. The first and second sets of the beams140traverse one another, thereby forming a grid. As shown, the grid member131comprises a plurality of square-shaped grid openings180defined between the first and second sets of the beams140that allow fluid to flow therethrough. In preferred embodiments, each of the grid openings180is about 0.25 square inches (1.6 square centimeters). As previously noted, the grid member131comprises the flow opening133substantially aligned with the nozzle135to allow fluid flow from the nozzle135through the grid member131. Preferably, the flow opening133is larger than the individual grid openings180.

The grid openings180in the grid member131allow sufficient fluid flow through the grid member131while holding the solid, undissolved chemical material (of a particular size and/or dimension) above the grid member131, at least until partially dissolved solid particles thereof are small enough to pass through the grid openings180. Preferably, the grid openings180are sized such that the partially dissolved solid particles that pass therethrough are sufficiently small such that as to be of no consequence, that is, to not have a negative impact on the operation of the device100. For example, if the partially dissolved solid particles are too large and fall to the bottom of the dissolving bowl125where the nozzle135is located, the nozzle135could become blocked. In particular, if the partially dissolved solid particles were too big, the nozzle135would experience diminished flow due to a blocked entrainment feature, thereby lowering the dissolving rate of the chemical material and chemical (e.g., chlorine) output rate of the device100. Preferably, the grid openings180between the beams140of the grid member131provide for a high concentration of the chemical solution without allowing solid particles large enough to impede entrainment to fall through the grid member131into the dissolving bowl125.

Certain operating parameters of the water treatment device100ofFIGS.1through4may be improved and/or adjusted by incorporation therein of the insert200located proximate to the grid member131. The insert200may modify flow of the aqueous fluid through the grid member131adjacent to the flow opening133, through the flow opening133, and/or upon exiting the flow opening133. In certain embodiments, the insert200may be capable of modifying fluid flow about the flow opening133in a manner that reduces accumulation of insoluble particles in the dissolving bowl125, reduces the likelihood of undesirable or less than optimal conditions within the upper chamber120, and/or promotes uniform contact between the aqueous fluid and the solid chemical material on the grid member131.

FIGS.3,5, and6show a nonlimiting embodiment of the insert200that includes an assembly of a flow impeding member202(FIG.5) and a flow redirecting member214(FIG.6). The flow impeding member202is disposed within the dissolving bowl125and proximate the bottom surface of the grid member131, and the flow redirecting member214is disposed within the upper chamber120and proximate the top surface of the grid member131. The flow impeding member202includes a disc-shaped portion204having upper and lower faces, and a centrally located, tubular portion206configured to be located within the flow opening133of the grid member131. The flow redirecting member214includes a rectangular lower portion216, a circular upper portion218, and sidewalls220having an annular profile between and coupling the lower portion216and the upper portion218.

The flow impeding member202and the flow redirecting member214may be secured relative to the grid member131in various manners. As a nonlimiting example,FIGS.5and6represent the flow redirecting member214as including elongated connection members224protruding from lower surfaces of the lower portion216. The connection members224are configured to be received within and extend through some of the grid openings180of the grid member131. The flow impeding member202includes engagement openings208arranged to receive distal portions of the connection members224that extend from the bottom surface of the grid member131. In combination, the connection members224and the engagement openings208may function to releasably couple the flow impeding member202and the flow redirecting member214to each other on opposite sides of the grid member131with a snap fit-type connection.

Specifically, the connection members224may be biased in a direction radially outward from a centrally located interior opening230of the flow redirecting member214and include ledges proximate to the distal ends of thereof. Upon insertion of the distal ends through the engagement openings208to an extent sufficient to locate the ledges below the lower face of the flow impeding member202, the biasing of the connection members224may cause the ledges to be located over the lower face and function as a barrier to relative movement of the flow impeding member202and the flow redirecting member214. The distal portions of the connection members224may further include chamfered edges facing radially outward from the interior opening230to promote ease of insertion of the connection members224into the engagement openings208. In this arrangement, the flow impeding member202and the flow redirecting member214are coupled to each other and retained in fixed positions relative to the grid member131without directly engaging the grid member131.

A particular benefit of the arrangement described above, that is, the flow impeding member202and the flow redirecting member214coupling to each other rather than directly to the grid member131, is that the insert200may be backward compatible with various previously existing water treatment devices, and/or compatible with the device100having various sizes and capacities.

The insert200may include alignment features configured to align the engagement openings208of the flow impeding member202with the connection members224of the flow redirecting member214. For example, radially outer surfaces of the tubular portion206of the flow impeding member202may have outwardly protruding alignment ribs210extending along a longitudinal length thereof that define therebetween valleys, and the flow redirecting member214may include inwardly protruding alignment ribs232extending along the sidewalls220between the radial openings222. During assembly of the insert200, the inwardly protruding alignment ribs232may be aligned with and inserted into the valleys thereby ensuring that the connection members224are aligned with and received within the engagement openings208. The flow impeding member202may include grid alignment pins212for orienting the flow impeding member202such that the engagement openings208align with grid openings180.

Alternatively, the flow impeding member202and the flow redirecting member214may be secured relative and/or directly to the grid member131by independent means. For example, one or both of the flow impeding member202and the flow redirecting member214may releasably couple directly with the grid member131with snap fit-type connections.

The flow redirecting member214includes the interior opening230in the lower portion216configured to receive fluid flow therethrough from a central passage213of the tubular portion206of the flow impeding member202. The fluid flowing through the interior opening230is received within an enclosure defined by interior surfaces of the upper portion218and the sidewalls220. With this arrangement, the fluid flowing through the tubular portion206of the flow impeding member202is blocked by the interior surface of the upper portion218and redirected through one or more radial openings222in the sidewalls220.

In this embodiment, the insert200is arranged to increase turbulence of fluid within the dissolving bowl125below the grid member131to reduce accumulation of insoluble particles therein, and to change the flow direction and/or reduce the velocity of the aqueous fluid exiting the flow opening133which may cause undesirable conditions within the upper chamber120.

Specifically, the flow impeding member202is arranged to partially block flow of the stream of the aqueous fluid from the nozzle135within the bottom portion129of the dissolving bowl125and thereby cause an increase in turbulence of fluid within the dissolving bowl125. The flow impeding member202allows the aqueous fluid flowing from the nozzle135to pass through a central passage213of the tubular portion206, and therefore the flow opening133, while simultaneously restricting or blocking upward fluid flow through at least some of the grid openings180adjacent to or surrounding the flow opening133. In this manner, the flow impeding member202may significantly increase turbulence of fluid within the dissolving bowl125and thereby reduce accumulation of insoluble particles therein. Such insoluble particles are preferably carried by the fluid through the outlet175and into the lower chamber150where the insoluble particles may be removed from the device100.

In addition, the flow redirecting member214is arranged to redirect the fluid flowing through the flow opening133from an original direction (e.g., aligned with the longitudinal axis of the flow opening133) to flow in one or more other directions over the top surface of the grid member131, such as in multiple directions substantially parallel to the top surface of the grid member131. As noted previously, the fluid flowing through the interior opening230is received within the enclosure defined by the interior surfaces of the upper portion218and the sidewalls220. With this arrangement, the fluid flowing through the tubular portion206of the flow impeding member202is blocked by the interior surface of the upper portion218and redirected through the radial opening(s)222in the sidewalls220. As such, the flow redirecting member214changes the flow direction and reduces the velocity of the aqueous fluid exiting the flow opening133which may reduce the likelihood of an occurrence of undesirable conditions within the upper chamber120.

The radial opening(s)222may have various sizes, shapes, and quantities which may affect the concentration of the chemical solution produced by the device100. In some embodiments, the concentration of the chemical solution may be controlled, within certain boundaries, by manipulating the position and/or size of the radial opening(s)222. In experimental investigations leading to certain aspects of the invention, it was observed that the concentration of the chemical solution was lower for embodiments comprising smaller radial opening(s)222. Preferred concentrations of the chemical solution will be dependent on the specific application. As a nonlimiting example, for embodiments that produce a chlorinated solution (e.g., to treat pool water), the chlorine concentration of the chemical solution may be equal to or less than about 0.4 wt. %, preferably between 0.2 and 1.2 wt. %, and more preferably between 0.3 and 0.7 wt. %.

The flow redirecting member214may include a tab226, optionally with a hole228therethrough. The tab226provides a fingerhold that can promote ease of installation of the flow redirecting member214.

The device100may be useful for various applications such as but not limited to commercial swimming pool chlorination, municipal drinking water chlorination, agricultural water chlorination, and industrial water chlorination. Exemplary but nonlimiting operational parameters of the device100may include fluid temperatures of between about 50 and 110° F. (10 and 43° C.), fluid flow rates of between about 0.2 and 5 gpm (0.8 and 18.9 lpm), preferably between 0.5 and 4.0 gpm (1.9 and 15.1 lpm), and fluid pressures between about 10 and 30 psi (69 and 207 kpa).

The insert200and/or the components thereof may be formed of various materials (e.g., polymeric, metallic, ceramic, or composite materials) and produced by various manufacturing processes (e.g., molding, milling, additive manufacturing, etc.). In certain embodiments, the flow impeding member202and the flow redirecting member214may both be formed of a polymeric material and produced by an injection molding process.

FIGS.7and8represent top views of the dissolving bowl125that represent exemplary accumulation of solid insoluble particles after operating the device100without and with the insert200, respectively, for a specific period of time during investigations leading to nonlimiting aspects of the present invention. As represented, operation without the insert200(FIG.7) resulted in a moderate accumulation of insoluble particles (black particulate material) in the bottom portion129of the dissolving bowl125. In contrast, operation with the insert200(FIG.8) resulted in significantly less accumulation of insoluble particles therein.

In this document, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Numerical ordinals such as “first,” “second,” “third,” etc. simply denote different singles of a plurality and do not imply any order or sequence unless specifically defined by the claim language. The sequence of the text in any of the claims does not imply that process steps must be performed in a temporal or logical order according to such sequence unless it is specifically defined by the language of the claim. The process steps may be interchanged in any order without departing from the scope of the invention as long as such an interchange does not contradict the claim language and is not logically nonsensical.

Furthermore, depending on the context, words such as “connect” or “coupled to” used in describing a relationship between different elements do not imply that a direct physical connection must be made between these elements. For example, two elements may be connected to each other physically, electronically, logically, or in any other manner, through one or more additional elements.

While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention. Finally, while the appended claims recite certain aspects believed to be associated with the invention, they do not necessarily serve as limitations to the scope of the invention.