Valve

Background of the Invention

1. Field of the Invention

0001The present invention relates to water control device.

2. Description of the Related Art

0002Valves for controlling the flow of water are known. Water mixing valves are also known, to mix water to desired output flow rate and/or temperature. Australian publication number <patcit id="pcit0001" dnum="AU2630792"><text>AU 26307/92</text></patcit> discloses an electronically controlled fluid mixing valve.

0003<patcit id="pcit0002" dnum="US5490535A"><text>US 5,490,535</text></patcit> discloses a valve for controlling flow of a fluid. The valve has a tubular inlet member having open outlet regions at one end, as well as a sleeve-shaped control member which surrounds, and is arranged for axial displacement along, the inlet member. When the valve is closed, the control member is located in a position such that the outlet regions of the inlet member are covered, and when it is open the control member is displaced along the inlet member so that fluid is able to flow through the outlet regions.

Brief Summary of the Invention

0004According to a first aspect of the present invention there is provided water control apparatus, in accordance with claim 1.

0005According to a second aspect of the present invention there is provided a method of controlling water flow, in accordance with claim 9.

Brief Description of the Several Views of the Drawings

0006<ul id="ul0001" list-style="none" compact="compact"><li><i>Figure 1</i> shows a flow control apparatus;</li><li><i>Figure 2</i> illustrates an embodiment of flow control apparatus;</li><li><i>Figure 3A</i> shows a flow control apparatus with a closed condition;</li><li><i>Figure 3B</i> shows the flow control apparatus of <i>Figure 3A</i> in an open condition;</li><li><i>Figure 4</i> shows an embodiment of flow control apparatus;</li><li><i>Figure 5A</i> illustrates a shut-off valve in a closed condition;</li><li><i>Figure 5</i>B illustrates a first stage of opening of the valve of <i>Figure 5A;</i></li><li><i>Figure 5</i>C illustrates a second stage of opening of the valve of <i>Figures 5A</i> and <i>5B</i>;</li><li><i>Figure 6</i> illustrates a flow control device and shut-off valve embodied in a three port valve;</li><li><i>Figure 7</i> illustrates an embodiment incorporating two fluid control devices.</li></ul>

Written Description of the Best Mode for Carrying Out the Invention

<i>Figure 1</i>

0007A water control device is shown in <i>Figure 1.</i> The device includes an elongate tube <b>101.</b> The elongate tube <b>101</b> includes a first flow opening <b>102</b> at an end of the tube. In addition, there is provided one or more second flow openings <b>103</b> along the length of the tube. In preferred embodiments three or more openings are provided which are preferably substantially equally spaced circumferentially around tube <b>101</b>. A second flow opening may for example take the form of a longitudinal slit, circular aperture or helix.

0008To effect water flow control, a sleeve <b>104</b> is arranged to slide along the tube <b>101</b> during water flow conditions, that is when water is flowing from the first opening <b>102</b> out through the second openings <b>103</b>, or vice versa. The sleeve <b>104</b> provides for modulation of water flow between a low rate of flow and a high rate of flow.

0009Between the tube <b>101</b> and the sleeve <b>104</b> is provided a gap <b>105</b>. Gap <b>105</b> is present so as to allow some water to pass through this gap so as to displace the sleeve <b>104</b> radially from the tube. In this way water is allowed to escape through the gap even when the sleeve <b>104</b> is in a fully closed condition; that is to say, portions of the sleeve <b>104</b> cover all second openings <b>103</b>.

0010During operation, movement of the sleeve is achieved by the provision of a sleeve positioning device arranged so as to position the sleeve <b>104</b> and thereby control the degree of water flow. In an embodiment, as shown in <i>Figure 1,</i> the sleeve positioning device includes at least one electric motor <b>106</b> and co-operating gears <b>107.</b> A watertight seal <b>108</b> is provided between the motor <b>106</b> and gears <b>107</b>, and a magnetically coupled seal may be used. Use of a reversible motor, which can be operated in both directions, allows the flow through the water control device to be increased and decreased using a single motor.

<i>Figure 2</i>

0011<i>Figure 2</i> shows an embodiment of water control apparatus; for clarity a sleeve positioning device is not shown.

0012A number of second openings <b>201</b> are provided along tube <b>202</b>. Sleeve <b>203</b> is arranged to slide along the tube <b>202</b> under control during operation whilst water is flowing through gap <b>204</b> between the tube <b>202</b> and the sleeve <b>203</b>. As the sleeve <b>203</b> is moved to increase the degree of cover of the second openings <b>201</b>, the degree of water flow through the second openings <b>201</b> decreases. However, when the sleeve <b>203</b> is moved into the fully closed position gap <b>204</b> allows some water flow through the second openings <b>201</b>, which acts as a lubricant to reduce resistance to the sleeve <b>203</b> being moved along the tube <b>202</b>. This minimising of resistance against positioning of the sleeve enables the use of a motor that draws low levels of power to position the sleeve under high water pressure conditions. Balancing of hydrostatic forces in the water control apparatus provides for energy savings, and use of some water as lubricant provides for further decreases in energy consumption.

0013Preferably, the tube and the sleeve of a water control device are made from stainless steel, brass, ceramic or other hardwearing material, to avoid pitting (worming). This is of particular relevance to the ends of the tube openings, where water may be forced through at high velocity, especially when the device is in the fully closed condition.

<i>Figures 3A and 3B</i>

0014In <i>Figure 3A,</i> a flow control device is shown in the fully closed condition, where water flow is minimised but not stopped. In this condition some water <b>301</b> flows between the tube and the sleeve. This flow allows the sleeve to be moved relative to the tube with low levels of force. Such flow acts to provide frictionless movement of the sleeve through hydraulically balanced water flow between the sleeve and the tube. Hydraulic balancing achieved, with respect to the central axis of a tube, is dependent upon the dimensioning and positioning of second openings of the tube.

0015The flow control device is shown in an open condition in <i>Figure 3B,</i> where water flow <b>302</b> is approaching maximised.

0016The flow control apparatus allows modulation of water flow from a low level to a higher level. Full shut-off of water flow may be effected by a separate water flow shut-off valve, which in some applications is operatively linked to the flow control device. Preferably, the shut-off valve is provided upstream of the flow control apparatus. A manually operated shut-off valve may be provided.

<i>Figure 4</i>

0017<i>Figure 4</i> shows a preferred water control apparatus. A water shut-off valve <b>401</b> is provided upstream of the water flow device <b>402</b> that is connected to the water flow device <b>402</b> by a rod <b>403</b>. The rod <b>403</b> is rigidly attached to the sleeve <b>405</b> by a pin <b>406</b> passing through second openings <b>407</b> of the tube <b>408</b>. The arrangement of the link is such that movement of the sleeve <b>405</b> causes the rod <b>403</b> to operate the shut-off valve <b>401.</b> The rod <b>403</b> is held substantially centrally within the valve <b>401</b> by a frame structure <b>409,</b> that provides axial stability, positions the rod <b>403</b> to allow it to move freely along the axis of the tube <b>408</b> and is configured to allow water to enter the valve <b>401.</b>

0018The shut-off valve <b>401</b> of <i>Figure 4</i> is a two-stage operation valve. The rod <b>402</b> is fixed to a minor seal <b>410</b> that moves in unison with the sleeve <b>405.</b> The minor seal <b>410</b> is shaped so as to act as a small, low area seal that acts on a major seal <b>411</b>. The major seal <b>411</b> floats axially on the rod <b>403</b> and is provided with at least one aperture <b>412.</b> The major seal <b>411</b> is shaped to provide a larger seal within the tube <b>408.</b> The minor seal <b>410</b> is shaped to close off the aperture(s) in the major seal <b>411</b> to provide a combined seal. Full close off of the valve <b>401</b> is effected when the combined seal abuts against a stop surface, in this example provided by toroidal shaped elastomers ('O' ring) <b>413.</b> A block <b>414</b> is fixed to the rod <b>403</b> between the major seal <b>411</b> and the pin <b>406,</b> and is located to function as a control device for water flow through the valve <b>401.</b> When the flow control device <b>402</b> is in the closed condition there is no contact between the block <b>414</b> and the major seal <b>411</b>, however, during sleeve positioning to open the flow control device <b>402</b> the block <b>414</b> pushes the major seal <b>411</b> away from the stop surface to allow water flow through the valve <b>401</b>. A gap is provided between block <b>414</b> and major seal <b>411</b> to allow movement of the minor seal <b>410</b> without moving the major seal <b>411</b>.

0019The water control apparatus is configured such that when the valve <b>401</b> is closed, the sleeve <b>405</b> is in the fully closed condition and no water passes through the valve <b>401</b> or flow control device <b>402.</b>

<i>Figures 5A, 5B and 5C</i>

0020In <i>Figure 5A,</i> a two stage-operation valve, similar in construction to valve <b>401,</b> is shown in the closed condition. The water acting against both the minor seal <b>503</b> and the larger seal <b>501</b> is sufficient to retain the seals in the shut position to prevent water flow through the valve.

0021A first stage of opening of the valve is shown in <i>Figure 5B.</i> The sleeve <b>502</b> of the water control apparatus is moved towards the valve and this causes the smaller seal <b>503</b> to open. The smaller seal <b>503</b> has a low surface area against the water and therefore a relatively small force is required to open the smaller seal <b>503</b>. Once the smaller seal <b>503</b> is in the open position, water flows through the openings of <b>504</b> of the larger seal <b>501</b> into the tube <b>505</b>. Some water will flow through the gap between the tube <b>505</b> and the sleeve <b>502</b>. This flow will facilitate sleeve positioning through reducing resistance to sleeve movement, however, the leakage rate of this flow is sufficiently low to allow the tube <b>505</b> to fill with water flowing through the larger seal <b>504</b>. This flow of water into the tube <b>505</b> causes the water pressure on either side of the larger seal <b>501</b> to equalise, enabling the larger seal <b>501</b> to be thereafter opened with minimal force.

0022A second stage of opening of the valve is shown in <i>Figure 5C.</i> Once the tube <b>505</b> is filled with water, further movement of the sleeve <b>502</b> into the open condition causes block <b>506</b> to push against the larger seal <b>501</b>. Following water pressure equalisation on either side of the larger seal <b>501,</b> the larger seal <b>501</b> is lifted into the open position with force until water flows through the shut-off valve. Subsequent movement of the sleeve <b>502</b> into the open position exposes the second openings <b>507</b> of the tube 505, thereby increasing water flow through the flow control device. Sleeve positioning can then be effected to modulate the water flow through the water control device between low flow and high flow.

0023To shut the water flow off, the sleeve <b>502</b> is returned to the closed position. This action causes the smaller seal <b>503</b> to push against the larger seal <b>501</b> to close the gaps <b>504</b> in the larger seal <b>501</b> and to move the larger seal <b>501</b> towards the stop surface provided by 'O' ring <b>508.</b> When the larger seal <b>501</b> contacts the stop surface, the water pressure causes both the larger seal <b>501</b> and the smaller seal <b>503</b> to close tightly, thereby shutting off water flow through the water control device.

0024The arrangement of the shut-off valve is such that a higher volume of water can flow through the valve with the smaller seal <b>503</b> open than through the gap between the tube <b>505</b> and the sleeve <b>502</b> of the water control apparatus.

<i>Figure 6</i>

0025A flow control device and shut-off valve can be embodied in a three port valve, as illustrated in <i>Figure 6.</i> In this illustrated example, two water control devices, providing two ports, are positioned within a housing <b>601.</b> In one application, one water control device receives hot water and the other receives cold water. Two water controllers <b>602, 603</b> are provided, one for each water control device, which are arranged to be independently controlled by individual reversible motors <b>604, 605</b> and co-operating gears <b>606, 607</b> respectively. The water controllers <b>602, 603</b> allow water entering the housing <b>601</b> to be mixed to a desired temperature. A third port <b>608</b> is provided.

0026Positioning of a sleeve over its associated tube may be determined by a microprocessor, to provide desired output water temperature and/or flow rate, which may be defined by a user or stored in the microprocessor memory. Australian publication number <patcit id="pcit0003" dnum="AU2630792"><text>AU 26307/92</text></patcit> describes use of a microprocessor. A thermistor, or mechanical thermostat, positioned downstream of a fluid mixing chamber may be provided, to produce signals for use in achieving and/or maintaining a desired fluid temperature.

<i>Figure 7</i>

0027<i>Figure 7</i> shows an embodiment in which two flow control devices <b>701, 702</b> are arranged parallel to each other within a water tight housing <b>703</b> having an exit port <b>704</b>. The tubes of the flow control devices <b>701, 702</b> are each provided with openings <b>705, 706</b> respectively, and the openings <b>705</b>, <b>706</b> are offset from each other, i.e. they are positionally staggered. The flow control devices <b>701, 702</b> are each provided with a sleeve <b>707, 708</b> respectively, and the two sleeves <b>707, 708</b> are joined together, in this example into a single sleeve block <b>709</b>. The position of the sleeve block <b>709</b> is variable, to vary the position of the sleeves <b>707, 708</b> relative to the tubes of the flow control devices <b>701, 702</b> respectively in unison, by means of operation of a lead screw <b>710</b>. The lead screw <b>710</b> enters the housing <b>703</b> through a seal <b>711</b>, and provides linear control. In an alternative arrangement, a crank drive may be used. In this example, a single motor is used to control the position of the sleeve block <b>709,</b> which controls the relative flows of water through the flow control devices <b>701, 702</b>. This embodiment may be used in a domestic tap or shower application, in which one of the water control devices delivers hot water and the other cold water. In an alternative arrangement of flow control devices, the openings are not offset, however the sleeves are offset.

0028The actual position of the sleeve block <b>709</b> may be determined by a microprocessor to provide mixed water of a desired output temperature, as defined by a user, or stored in the microprocessor memory.

0029The example shown in <i>Figure 7</i> provides control over mixed water temperature, but not flow rate. In addition, a full-shut off valve is not provided. The apparatus of <i>Figure 7</i> may however be combined with an additional flow control valve, upstream. Such a valve may take the form of a manually operated gate valve, which can be arranged to provide control of water flow through water inlet ports and to provide full water flow shut-off. Thus, a user may be provided with both electronic and manual water control, for example, electronic temperature control and manual flow control. A visual user display may be provided to supply indications of water flow settings to a user.

0030In applications where a flow control device is placed in series with a water pump, a controlling microprocessor may be used to initiate the sending of a signal to the pump to turn on, turn off, or to provide an intermediate condition. Preferably, signals are transmitted via a wireless medium, for example by electromagnetic radiation.

0031In applications of three port housing, use of a low powered motor, or motors, is preferred to control the position of the sleeve relative to the tube of a flow control device. In domestic applications, a three port valve may be operated from a power supply providing a peak power of less then 1000mW. A water control device as described may be used to control water flow through a heating system, for example in a radiator or under floor heating element.