SEDIMENT FILTER WITH INTERNAL DRAIN TUBE

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 60/757,753, filed January 10, 2006, of which is incorporated herein by reference.

TECHNICAL FIELD

[0002] The present invention relates to sediment filters used in water treatment systems and, in particular, to an apparatus and method for rinsing sediment out of a sediment filter.

BACKGROUND OF THE INVENTION

[0003] The prior art includes sediment filters in both residential and commercial applications. Sediment filters are used to remove suspended material such as sand, silt, loose scale, clay or organic material from the water. For example, where the source of water is a well, the lining or casing of the well breaks down over time and debris from the lining falls off into the well water. Sediment is also present in applications where the source of water may be city water. Sediment may enter the city water through various ways, such as during heavy construction of homes or the like.

[0004] Sediment filters may be point-of-use devices that can be installed under the sink, attached to a tap, or used as a pre-filter for other water treatment processes to increase their effectiveness and longevity. For example, the sediment filter may be installed in front of a water softener to protect the softener bed. In some instances where the sediment may pose a problem for water-using appliances, such as dishwashers, washing machines, and hot water heaters, sediment filters may be point-of-entry devices that treat all water at its entry point into the home.

[0005] One example of prior are sediment filters includes a filter head having an inlet for the water source and an outlet for the filtered water. A sump is located below the filter head and includes a filter element. The filter element may include a cylindrical filter element having a filter screen for receiving the incoming unfϊltered water. The filter material or screen may be paper, ceramic, polypropylene, string, spun cellulose, rayon, or granular media. It may be wound or corrugated around a tubular opening to form a cylinder. The water is passed

through the filter media and exits the filter back into the filter head, whereupon the filtered water is available at the outlet. It will be understood that the sediment is trapped by the filer media and by gravity accumulates at the bottom of the sump.

[0006] The sediment filter has the greatest effectiveness when the filter media is new. Water flow through the filter is the greatest when the filter media is new. Water flow gradually decreases as trapped material continues to accumulate and eventually the filter media requires cleaning or replacement. The prior sediment filters typically have a removable sump or other means of facilitating the replacement of the filter media. The prior art often provides a removable sump which is periodically removed to dispose of sediment which has accumulated in the sump. The prior art may also include a drain port at the bottom of the sump for removal of the sediment. This drain at the bottom of the sump is designed to be opened periodically to allow water to flush over the surface of the screen, or in the case of back flushing, backwards through the screen, in order to clean the filter screen and flush the material out of the system. Often a valve and a drain line are located at the drain port at the bottom of the sump to facilitate the cleaning and removal of the material. The drain line may be routed to a drain.

[0007] Screen type sediment filters as describe above that have a drain port and drain valve in the bottom of he sump are common. However, when a drain line is attached to the drain port at the bottom of the sump, it becomes more difficult to remove the sump for the filter screen maintenance or replacement of the screen, often requiring that the drain line be disconnected before the sump can be removed. In addition, where a shut-off is located at the drain port, sediment and other material may form on the valve shut-off surface or form corrosion on the shut-off surface. Over time, such accumulating of material on the shut-off surface may impair the operation of the valve. Alternatively, a bucket may be used in place of the drain line. However, the use of the bucket is not always a practical alternative to the drain line.

[0008] The present invention is directed to avoiding the prior art problems which are noted are suggested above.

SUMMARY OF THE INVENTION

[0009] It is an object of the present invention to provide a sediment filter having improved system of cleaning the filter media.

[0010] It is an object of the present invention to provide a sediment filter having a system which provides greater ease in replacing the filter media.

[0011] It is an object of the present invention to provide a sediment filter having a system which reduces corrosion and other build up on the shut-off surface of the drain valve.

[0012] The present invention therefore provides a sediment filter having a filter head having an inlet opening, an outlet opening, a drain outlet, and a sump connector, the sump connector includes a first opening in fluid communication with the inlet opening and a second opening in fluid communication with the outlet opening, a cylindrical filter having a cylindrical screen, an upper end having a filter outlet opening, and a lower end having a tube opening, the filter outlet opening in fluid communication with the sump connector second opening, a sump receptacle having a lower end having a sump and an upper end having an opened end, the open end having a head connector for coupling with the sump connector; and a tube having a lower end and an upper end, the tube extends through the cylindrical filter, with the lower end ending into the sump and the upper end extending into the filter head, with the upper end in fluid communication with the drain outlet, whereby sediment may be drained from the sediment filter with water flow from the head inlet opening, down into the sump, up through the tube and out the head drain outlet.

[0013] The present invention also provides a sediment filter having a filter head having an upper portion having an upper surface, a lower portion having an annular flange, the annular flange includes a threaded portion, a filter bayonet fitting which extends from the upper surface of the filter head downward toward the annular flange, a filter connector which extends from the upper surface of the filter head downward towards the annular flange, the annular flange, bayonet fitting and filter connector having a substantially common longitudinal axis, a head inlet opening, a head outlet opening, a drain outlet, the bayonet fitting defines an annular or first opening in fluid communication with the head inlet opening, and a bore or second opening in fluid communication with the head outlet opening, a drain passage way extends between the filter connector and the drain outlet, a cylindrical filter

having a cylindrical screen, an upper end having a filter outlet opening, and a lower end having a wall with a centrally located tube opening, the filter outlet opening in fluid communication with the second opening of the bayonet fitting, a sump receptacle having a lower end having a sump and an upper end having an opened end, the open end having a thread portion for removably coupling with the threaded portion of the head annular flange, and a tube having a lower end and an upper end, the tube extends through the cylindrical filter, with the lower end ending into the sump and the upper end extending into the filter head and coupled to the filter connector, the tube providing fluid communication between the sump and the drain outlet, whereby sediment may be drained from the sediment filter with water flow from the head inlet opening, down into the sump, up through the tube and out the head drain outlet.

[0014] The present invention further provides a process for draining sediment from a sediment filter, the process including the steps of directing the flow of water from the water source into the head inlet opening, directing the flow of water from the head inlet opening into the sump, directing the flow of water from the sump up through the cylindrical filter along a longitudinal axis extending through the cylindrical filter, directing the flow of water from the cylindrical filter into the filter head, and directing the flow of water from the filter head out a drain outlet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 shows a perspective view of a first embodiment of a sediment filter in accordance with the present invention, having the drain outlet extending vertically upward from the filter head.

[0016] Figure 2 shows a front cross sectional view of the sediment filter of Figure 1.

[0017] Figure 3 shows a side cross sectional view of the sediment filter of Figure 1.

[0018] Figure 4 shows an exploded view of the sediment filter of Figure 1.

[0019] Figure 5 shows an exploded perspective view of a second embodiment of a sediment filter, in accordance with the present invention, having the drain outlet extending horizontally outward from the filter head.

[0020] Figure 6 shows an exploded front view of the sediment filter of Figure 5.

[0021] Figure 7 shows a front cross sectional view of the sediment filter of Figure 5.

[0022] Figure 8 shows a front cross section schematic view of a third embodiment of the sediment filter, in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0023] Figures 1-4 show a perspective view of a sediment filter 10 in accordance with the first embodiment of the present invention. The sediment filter includes a filter head 12 having a water source inlet port 14, a filter water outlet port 16, an upper portion 18 of the filter head having a drain outlet port 20 which extends upwardly in a vertical direction, and a lower portion 22 which provides an annular flange 24. The lower annular flange provides for removable coupling to a sump receptacle 26. A cylindrical filter 28 can be seen extending downwardly from the head and into the sump receptacle. A tube 30 is shown extending downwardly from the cylindrical filter into the sump 32 of the sump receptacle.

[0024] The drain outlet port 20 further includes a drain outlet 34 and a ball valve 36 such as shown in Figures 2-4. An electrical motor and motor control 38 is also shown in Figures 1-4. The electrical motor and motor control includes power cord 40. In this particular application, the ball valve is a high torque ball valve. However, it will be understood that the motor may be driven by batteries in which instance the ball valve will be a low torque ball valve. It will be further understood that the ball valve may be manually operated instead of via an electric motor and controller. Further, the ball valve may not be located integral to the head. Rather, the ball valve may be located in a drain tube downstream from the application as shown in Figures 1-4. Still further, the valve may be of a form other than a ball valve, as understood by one skilled in the art.

[0025] Referring still to Figures 1-4, the head is shown to include an inlet opening 42 at the inlet port and an outlet opening 44 at the outlet port. A bayonet fitting 46 defines an annular

or first opening 48 at the annular flange and an inlet passage way 50 which provides fluid communication between the inlet opening and the first opening. The bayonet fitting further defines a bore or second opening 52 and an outlet passage way 54 which provides fluid communication between the second opening and the outlet opening. The annular flange is shown to include a threaded portion 56. An upper surface 58 of the filter head includes a tube connector 60 in the form of a cylindrical bayonet connector. As best seen in Figure 4, it can be seen that the cylindrical filter includes a housing structure 62, a cylindrical screen 64, a lower end 66 having an end wall or a capped wall 68, with flanges or stops 70 extending radially outwardly from the end cap, a filter outlet opening 72 at a upper end of the cylindrical filter, with an annular groove 74 at the upper end which receives an o-ring 76. Figures 2 and 3 show how the upper end of the cylindrical filter is received by the bayonet fitting. While not shown in Figures 2 and 3, the bayonet fitting may include an internal seat (not shown) to limit insertion of the cylindrical filter into the head. The o-ring is shown to seal the cylindrical filter with an internal wall 78 of the bayonet fitting. It can also be seen from Figures 1-3, that the sump receptacle includes a step portion 80 which provides a ridge 82. The stops at the lower end of the cylindrical filter engage the ridge and limit downward movement of the cylindrical filter. The stops also form a plurality of flow channels 84. The lower end of the cylindrical filter is also shown to include a tube opening 86 at the end wall. It can be seen that a tube 88 having a upper end 90 and a lower end 92 extends through a cylindrical filter, with the lower end extending into the sump and the upper end extending into the filter head and coupled with the tube connector.

[0026] Figure 3 shows that the sump receptacle includes a rib 94 molded in the bottom of the sump receptacle to limit downward movement of the tube. The rib may take various forms including a bead or other means which limit movement of the tube yet does not block flow through the tube. For example, a screened filter cap may be provided at the bottom of the tube which limits downward movement of the tube yet allows flow through the tube. It will be appreciated that the tube connector 60 at the upper surface of the filter head limit upward movement of the tube. It can also be seen that the tube connector 60 is coupled to a tube flow channel 96 and the drain outlet port 20.

[0027] Figure 4 shows that the ball valve is located in the drain outlet port and is sealed by means of seals 98. A ball valve stem 100 engages the ball valve and the electric motor to provide rotational movement of the ball valve. The ball valve is shown in Figures 2-4 to be

in the opened position. In particular, the ball valve passage 102 is shown to be in line with the flow channel 96 and drain outlet opening 34. It will be appreciated that with the ball valve rotated 90 degrees from the position shown in Figure 2, that flow through the flow channel 96 and drain outlet opening 34 will be blocked.

[0028] Figure 4 clearly shows that the upper end of the sump receptacle includes a threaded portion 104 and an annular seat 106 which receives an o-ring 108. Figures 2 and 3 show that the threaded portion of the sump receptacle mates with the threaded portion of the head. Further, the o-ring provides a seal between the head and the sump receptacle. The head includes an abutment surface 110 which limits rotational engagement of the sump receptacle into the filter head. The drain outlet is shown to include a lower portion 112 which is integral with the head and receives the ball valve and seals. The lower portion further includes a side portion 114 which receives the ball valve stem and seals 116. An upper portion 118 of the drain outlet engages the lower portion and retains the ball valve mechanism in place. The upper and lower portions may be attached in various means such as welding, adhesives, snap fit, threaded or other arrangement as one skilled in the art will appreciate.

[0029] Figures 5-7 show a sediment filter in accordance with the second embodiment of the present invention. The sediment filter of Figures 5-7 are substantially similar to the first embodiment. However, the second embodiment provides a drain .outlet or a drain port which extends horizontally from the filter head. This is in contrast to the drain outlet of the first embodiment which extends vertically upward from the filter head. Figure 7 shows a front sectional view of the sediment filter of Figure 5. It shows that the filter includes a threaded nozzle 120 which is secured to the filter head via mating threaded portion 122 in the filter head, so as to retain the ball valve. The ball valve stem extends downwardly into the ball valve from the motor assembly.

[0030] The arrangement of the horizontal drain port of the second embodiment allows the drain line to be routed in a manner consistent with the outlet line and in a less cluttered and lower profile than perhaps the first embodiment. The specific application will of course dictate a preference.

[0031] In both the first and second embodiment, the ball valve of the drain outlet is typically closed, while source water is routed into the inlet port, down into the sump receptacle, and through the filter screen whereupon sediment is blocked and falls downward into the bottom of the sump. The filtered water continues through the cylindrical screen and exits the filter outlet opening into the filter head. The filtered water is then routed through the outlet port. In the event the sediment is to be removed from the bottom of the sump or the cylindrical filter is to be cleaned, all taps at the outlet port are closed and the drain valve is opened, either via electrical control or manual operation. Source water is again allowed to flow into the inlet port and down into the sump receptacle. The source water flows along the outer perimeter of the cylindrical filter cleaning the filter screen. Any material which accumulates on the filter screen is washed down into the bottom of the sump. The sediment, and material from the cylindrical screen are routed into the tube at the lower end and up through the tube. The water and sediment and other material are further routed through the drain outlet, and through the drain line (not shown) or as desired.

[0032] Thereafter, the drain valve is closed, and normal operation of the sediment filter resumes. Further, in the event the sump receptacle is to be removed, it will be appreciated that, after shutting off the water source, the sump receptacle may be easily removed without the burden of a drain port or other mechanisms located at the bottom of the sump receptacle.

[0033] Figure 8 shows a sediment filter in accordance with the third embodiment of the present invention. The third embodiment is similar to the first and second embodiment with the exception that a back flush channel 124 and back flush port 126 are provided. Normal operation is similar to the first and second embodiments. Three ball valves 128, 130, 132 are shown all coupled via a common shaft 134 to an electrical motor 136. Again, the ball valves could be controlled manually in the alternative. During normal operation, the shaft is rotated 90 degrees from that shown in Figure 8, with the inlet ball valve 128 in an open position and the back flush valve 130 and the drain valve 132 in closed positions. During the back flush operation, the shaft is rotated to the position shown in Figure 8, with the inlet ball valve in the closed position and the drain ball valve and back flush ball valve in the open position. During the back flush process, water is routed at the inlet port through a side channel 134 into the back flush channel, down into the interior of the cylindrical filter, through the filtered screen, and downward into the bottom of the sump. The water, sediment and other material is then routed upward through the tube and out the drain port.

[0034] In a fourth embodiment, the flow of water is the reverse as that described in the foregoing embodiments. For example, with reference to Figure 7, the fourth embodiment provides an inlet opening as identified on the right side in Figure 7 by the reference numeral 16, and an outlet opening is identified on the left side of Figure 7 by the reference number 14. In addition, the interference fit between the tube and the lower end of the filter is eliminated. In particular, the tube opening is enlarged in the fourth embodiment so that there is an annular opening between the exterior of the tube and the tube opening in the end cap. In addition, the flow channels provided between the stops 70 are closed so as to block all fluid communication between the annular space above the end cap and the sump below the end cap. Thus, during normal service operation, the water source enters the inlet 16 on the right side of Figure 7, then flows downward internally of the filter, then through the filtered screen into the annular space whereupon it exits up and out the outlet opening 14 to the left of Figure 7. During the cleaning phase, all the taps at the outlet 14 are closed and the position of the ball valve is moved from the closed position to the open position (such as shown in Figure 7). Water is again directed into the inlet 16 and down internally within the filter, through the annular space between the tube and the tube opening, and into the sump. The water and sediment and other material is then directed upwardly from the sump, through the tube and out the drain port.