Note: Descriptions are shown in the official language in which they were submitted.
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SUPPLY MANIFOLD FOR HYDRONIC SYSTEM
TECHNICAL FIELD
[0001] The present invention relates generally to hydronic
heating or cooling systems and, more particularly, to supply
manifolds for hydronic heating or cooling systems.
BACKGROUND
[0002] Hydronic heating or cooling systems deliver warm or
cool liquid through conduits to heat or cool surfaces such as
floors (radiant floor heating/cooling) or walls (radiant wall
heating/cooling). Some such systems deliver liquid through
conduits to multiple zones. In conventional systems, multiple
zone valves are used to regulate the flow of liquid to each of
the conduits. In other words, there is one zone valve for
every zone in the dwelling.
[0003] A problem with these multi-zone hydronic systems is
that the supply manifold is complex and expensive, requiring
individual actuators to actuate each of the zone valves.
[0004] In view of this shortcoming, an improvement on this
prior art would thus be highly desirable.
SUMMARY
[0005] The present invention provides, in general, a novel
supply manifold having a single displaceable actuator that may
be displaced to individually actuate any desired one of a
plurality of valves. This novel manifold may be incorporated
within a hydronic heating system, a hydronic cooling system, a
fire sprinkler system, or any other apparatus where a manifold
employs multiple valves to control the flow of a liquid.
Related to this novel manifold is a novel method of operating
a hydronic heating or cooling system.
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[0006] In accordance with one main aspect of the present
invention, a novel supply manifold for a hydronic heating or
cooling system, fire sprinkler or other such liquid
distribution apparatus, includes a housing having an inlet and
an internal chamber for receiving a heating or cooling liquid.
The manifold also includes a plurality of valves disposed on
respective outlets of the housing in a linear arrangement.
Each outlet is adapted to connect to a respective conduit for
delivering the heating or cooling liquid to a respective zone.
Each of the plurality of valves controls a flow of the heating
or cooling liquid from the internal chamber into each
respective conduit. The manifold has but a single actuator
for individually actuating one of the valves (rather than
having one actuator per valve) The manifold has a first
displacement mechanism, e.g. a screw drive driven by an
electric motor, for displacing the actuator along a
longitudinal axis that is parallel to the linear arrangement
of the valves to thereby access any one of the valves. The
manifold also has a second displacement mechanism, e.g. a
solenoid, for displacing the actuator orthogonally to the
longitudinal axis to thereby cause engagement or disengagement
of the actuator with a selected one of the valves for opening
or closing.
[0007] In accordance with another main aspect of the present
invention, a method for operating a hydronic heating or
cooling system entails steps of delivering a heating or
cooling liquid into a supply manifold having a housing and a
plurality of valves disposed on respective outlets of the
housing in a linear arrangement, connecting each outlet to a
respective conduit for delivering the heating or cooling
liquid to a respective zone, and controlling each of the
plurality of valves using the supply manifold. The manifold
has but a single actuator unlike conventional manifolds which
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employ one actuator per valve. The method thus entails a step
of displacing the actuator along a longitudinal axis that is
parallel to the linear arrangement of the valves to thereby
access any one of the valves. This may be done using a screw
drive. The method further entails displacing the actuator
orthogonally to the longitudinal axis to thereby cause
engagement or disengagement of the actuator with a selected
one of the valves for opening or closing. This may be
accomplished, for example, using a solenoid. Finally, the
method entails a step of causing the selected valve to rotate
one quarter turn by further displacing the actuator along the
longitudinal axis to thereby open or close the selected valve.
This latter step may be accomplished, for example, by further
advancing the screw drive once the solenoid is engaged.
[0008] In accordance with yet another main aspect of the
present invention, a novel hydronic heating or cooling system
includes a heater for heating a heating liquid (or a cooling
apparatus for cooling the liquid), a pump for displacing the
liquid through conduits to various zones, and a novel supply
manifold. The novel manifold has a housing, a plurality of
valves disposed on respective outlets of the housing in a
linear arrangement, each outlet being adapted to connect to
one of the conduits, and only a single actuator for
individually actuating one of the valves. The manifold
includes a first displacement mechanism, e.g. an electrically
powered screw drive, for displacing the actuator along a
longitudinal axis that is parallel to the linear arrangement
of the valves to thereby access any one of the valves. The
manifold includes a second displacement mechanism, e.g. a
solenoid, for displacing the actuator orthogonally to the
longitudinal axis to thereby cause engagement or disengagement
of the actuator with a selected one of the valves for opening
or closing.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Further features and advantages of the present
technology will become apparent from the following detailed
description, taken in combination with the appended drawings,
in which:
[0010] FIG. 1 is an isometric view of a novel supply manifold
for a hydronic heating or cooling system in accordance with an
embodiment of the present invention;
[0011] FIG. 2 is an isometric view of the novel supply
manifold shown in FIG. 1 but with the carriage and screw drive
partially cut away to reveal the details of the solenoid and
cross gear;
[0012] FIG. 3 is an enlarged isometric view of the actuator-
displacing mechanism showing the details of the solenoid,
cross gear and valve;
[0013] FIG. 4 is a top plan view of the novel supply manifold
of FIG. 1; and
[0014] FIG. 5 is a side cross-sectional view of the novel
supply manifold of FIG. 1.
[0015] It will be noted that throughout the appended
drawings, like features are identified by like reference
numerals.
DETAILED DESCRIPTION
[0016] The present invention is directed to a novel supply
manifold for a hydronic heating system, hydronic cooling
system, fire sprinkler system or any other analogous liquid-
distribution apparatus.
[0017] One exemplary embodiment of this novel supply manifold
is depicted in FIGS. 1-5. It should be understood that this
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exemplary embodiment represents only one way of implementing
this technology. In other words, many variations,
modifications and refinements may be made to the mechanisms
presented herein without departing from the fundamental
inventive concept.
[0018] In general, and with reference to all five figures,
the novel supply manifold in accordance with one exemplary
embodiment of the present invention has a housing which is
designated by reference numeral 1. A carriage 2 (which
carries the actuator) is displaced along a longitudinal axis
by a screw drive mechanism (or simply a screw drive). This
screw drive comprises a bottom guide rail 3, a top guide rail
4 and a screw 5 (or threaded rod). A nut 6 (shown in FIG. 2)
is connected to the carriage 2 and is used to drive the
carriage along the screw 5. The actuator, which is carried by
the carriage 2, may be, for example, a solenoid 7, as also
shown in FIG. 2. This solenoid 7 has a ball bearing 9 (or
roller bearing or equivalent) at its tip (forward end) as
shown by way of example in FIG. 3. The solenoid 7 causes this
bearing 9 to engage a cross gear 13 connected to a respective
zone valve 12. In this particular example implementation, as
the screw drive is advanced, the bearing 9 causes the cross
gear 13 to rotate ninety degrees (one quarter turn) . This
quarter-turn rotation causes the quarter-turn ball valve 12 to
open (if it was closed) or to close (if it was open). Once
the cross gear 13 has been rotated one quarter turn the
bearing 9 is disengaged from the cross gear by the solenoid
(or other actuator). The screw drive can be then actuated to
move the actuator (solenoid) to another valve for opening or
closing as required. The single actuator can thus be
displaced to any desired one of the zone valves by the screw
drive. Once the screw drive has positioned the actuator in
the correct position, the solenoid 7 is actuated to engage the
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gear cross 13 connected to the zone valve that is to be opened
or closed.
[0019] Further details of the design and construction of this
exemplary supply manifold will now be described with reference
to FIG. 1. As shown in this figure by way of example, the
housing has a pair of end brackets 14, 15. This housing (or
case) may be made of metal, plastic or any other suitable
material. In this particular implementation, the guide rails
3, 4 and the screw 5 are mounted to the housing. A guide rail
glider 8, depicted by way of example in FIG. 3, may be
provided to ensure smooth motion of the carriage along the
rails. Also mounted to this housing by way of example are the
gears 16, 17, 18 and electric motor 19. In this particular
implementation, the motor 19 has an output shaft upon which
gear 18 is mounted coaxially. As illustrated by way of
example, gear 18 drives gear 17 which, in turn, drives gear
16. In this specific implementation, gear 16 is mounted
coaxially to the screw 5.
[0020] The housing 1 also has an inlet and an internal
chamber for receiving a heating liquid for a hydronic heating
system (or a cooling liquid for a hydronic cooling system).
The internal chamber may be, in one exemplary implementation,
a flattened copper tubing 10 shown in FIG. 2 and also shown in
FIG. 3. The internal chamber is in fluid communication with a
linear arrangement of outlets. Each outlet of the manifold
has its own inline zone valve 12 as illustrated in FIG. 3.
There are ten outlets (and thus ten valves) in the specific
manifold presented by way of example in these figures.
However, it should be expressly understood that the number of
outlets (and associated valves) may be varied.
[0021] Each outlet is adapted to connect to a respective
conduit or tubing (not shown) for delivering the heating or
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cooling liquid to a respective zone of the dwelling or
building. Each of the plurality of valves controls the flow
of heating or cooling liquid from the internal chamber 10 into
each respective conduit via holes 11 in the flattened copper
tube 10. An O-ring 20 (or other sealing element) provides a
fluid-tight seal between the valve body and the upper rim of
the hole 11 as illustrated by way of example in FIG. 3.
[0022] In this particular implementation, the zone valves are
quarter-turn ball valves. Such valves can be opened or closed
by a ninety-degree rotation of the ball inside the valve.
Accordingly, the cross gear 13 attached to each respective
valve has four receptacles for receiving the bearing 9. On
each side of the receptacles are outwardly slanted surfaces
that terminate in one of four points. This construction
ensures that the bearing 9 cannot get stuck on the cross gear
13. In other words, regardless where the bearing 9 engages
along the side surface of the cross gear 13, the bearing 9
will be forced into proper engagement with one of the four
receptacles.
[0023] In one example implementation, the ball bearing (or
roller bearing) 9 may be attached to a roller nut and screw.
The roller bearing pushes one leg of the cross gear when
required to open or close the valve. This will always ensure
quarter-turn intervals. In other words, this cross gear acts
as an indexing mechanism, rotating in ninety-degree
increments. Because of the ball bearing or roller bearing,
the mechanism will also have a longer service life.
Optionally, sensors (not illustrated but well known in the
art) may be attached to the tips of the cross gear 13 to
provide signals to a microcontroller. The microcontroller (or
microprocessor) can then determine a position of the valve
based on the signals received. Any suitable control system
and control algorithm can be adapted to operate this
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mechanism, as is known in the art. The control system may be
implemented in hardware, software, firmware or any suitable
combination thereof.
[0024] Further details of the manifold are now described with
reference to FIG. 4. Because the valves in the manifold are
in a linear arrangement, the actuator can be moved to access
any desired valve by simply translating the carriage back and
forth along the screw. Since the valves are quarter-turn
valves, it does not matter whether the actuator engages from
the left or from the right to either open or close any given
valve.
[0025] Further details are now described with reference to
FIG. 5. As illustrated, the manifold may include a flanged
holding groove 21 to hold the valve body within the housing.
Optionally, the ball valve (zone valve) may be manually
operated by providing a suitable drive socket 22 which can be
adapted to receive an Allan key, wrench, handle, etc. Also
shown by way of example in FIG. 5 is the fitting 23 for
connecting to the tubing or conduit. This fitting extends
upwardly from the valve as shown by way of example in the
figures.
[0026] It should be understood that the manifold depicted in
FIGS. 1-5 is presented by way of example only. This
particular design of the manifold is believed to be the best
mode of implementing the present invention but it should be
appreciated that many variations in the mechanism(s) presented
herein may be effected to achieve essentially the same
objective, i.e. displacing a single actuator to actuate any
one of a plurality of in-line zone valves.
[0027] VARIATIONS AND OTHER EMBODIMENTS
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[0028] In broad terms, the manifold may have any mechanism or
combination of mechanisms that enable a single actuator to
actuate each one of a plurality of zone valves. In the
exemplary embodiment described above and illustrated in the
appended figures, the manifold employs two mechanisms: a first
mechanism for positioning the actuator (i.e. aligning the
actuator with a particular valve) and a second mechanism for
engaging the actuator. In this exemplary implementation, the
first mechanism is also used to rotate the cross gear and thus
open (or close) the valve. However, many variations and other
embodiments are possible. Some of these variations are
described below for the purposes of illustration.
[0029] For example, in another embodiment, a first mechanism
is used to position the actuator and a second mechanism is
used to both engage and open (or close) the valve (i.e.
without further displacing the first mechanism) The first
mechanism could be, for example, a screw drive, belt drive,
pulley system, rack and pinion, etc. The second mechanism
could be, for example, a motor mounted on the carriage that
drives a worm into engagement with a worm gear attached to the
zone valve. Alternatively, as will be appreciated, any
suitable combination of gears and/or mechanical linkages can
be used to convert the rotational motion of the output shaft
of an electric motor into rotation of a gear affixed to a zone
valve.
[0030] In another embodiment, a single mechanism may be used
to position the actuator and to also actuate the valve. For
example, a single motor may be mounted on the carriage
(instead of mounted to the housing as shown in the exemplary
embodiment illustrated in the drawings). This single motor
may be coupled via appropriate gears to two drive shafts with
can be selectively operated using clutches. When the first
clutch is engaged for the first drive shaft, the carriage is
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displaced longitudinally. When the second clutch is engaged
for the second drive shaft, the carriage is displaced
orthogonally to engage and open the valve.
[0031] In another embodiment, the entire carriage may be
movable toward the valve as opposed to just the actuator
carried by the carriage.
[0032] In another embodiment, the valve may be movable into
engagement with the actuator as opposed to the actuator being
moved into engagement with the valve.
[0033] Many variations in the components and mechanisms are
also possible. For example, instead of a screw drive, the
first displacement mechanism could use a chain drive, belt
drive, pulley system, rack and pinion, or any other known
mechanism for positioning the carriage. Instead of a
solenoid, as illustrated in the exemplary embodiment, any
suitable actuator may be used. In other words, the solenoid
could be replaced by an electric motor, hydraulic actuator,
pneumatic actuator, shape-memory alloy actuator, or any other
type of device that is capable of generating a sufficient
force or torque to open and close the valve.
[0034] In the exemplary embodiment illustrated in the
drawings, a cross gear is used to interact with the bearing
tip to open and close the valve. In another embodiment of
this invention, the cross gear may be replaced by a standard
gear that meshes with a corresponding gear carried by the
carriage. In this embodiment, the carriage moves the
"carriage gear" into mesh with the "valve gear" (i.e. the gear
that is attached to the zone valve) . Advancement of the
carriage then causes the carriage gear to rotate the valve
gear.
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[0035] In another embodiment of the invention, the ball valve
could be replaced by another type of valve which is not
necessarily a quarter-turn valve.
[0036] Although there are many variations possible, as
evidenced by the further example embodiments described in the
foregoing paragraphs, this novel supply manifold can be
understood in broad terms as an apparatus that uses but a
single actuator instead of employing multiple actuators (i.e.
instead of having one actuator per valve). This novel
manifold is thus less complex and expensive to manufacture.
[0037] METHOD
[0038] This technology also enables a novel method of
controlling operation of a hydronic system. This method
entails delivering water (or any other liquid) into the novel
supply manifold, connecting each outlet of the manifold to a
respective conduit for a respective zone, and then
individually and independently controlling each of the
plurality of valves using the single actuator of the supply
manifold. Unlike conventional manifolds which have one
actuator per valve, this novel manifold has but a single
actuator that moves to the valve that it is to open or close.
The novel method thus entails a step of displacing the
actuator (e.g. solenoid) along a longitudinal axis, e.g. using
a screw drive. When the solenoid is at the correct position,
the bearing tip of the solenoid is moved (orthogonally to the
longitudinal axis) into engagement with one of the four
receptacles of the cross gear. The screw drive is then
actuated again to advance the carriage and solenoid to thereby
turn the cross gear one quarter turn. This opens or closes
the valve. The bearing tip of the solenoid is then disengaged
from the cross gear. The screw drive may be actuated again to
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move the solenoid to a new location for actuating a different
valve.
[0039] THE MANIFOLD IN A HYDRONIC SYSTEM
[0040] This novel supply manifold may be incorporated into a
hydronic heating or cooling system. This system includes a
heater (e.g. boiler) for heating a heating liquid (e.g. water)
or alternatively a cooling apparatus for cooling the liquid.
The hydronic system also includes a pump for displacing the
heating or cooling liquid through the conduits to the various
zones.
[0041] THE MANIFOLD IN A FIRE SPRINKLER SYSTEM
[0042] In another implementation, the manifold may be used
for a fire sprinkler system. In this implementation, the
outlets would be connected to various conduits or tubing that
are in turn connected to sprinkler heads. As will be
appreciated, the novel supply manifold may be used for
applications other than hydronic heating or hydronic cooling,
i.e. any liquid distribution system where a manifold includes
a plurality of independently operable valves.
[0043] The embodiments of the invention described above are
intended to be exemplary only. As will be appreciated by
those of ordinary skill in the art, to whom this specification
is addressed, many obvious variations, modifications, and
refinements can be made to the embodiments presented herein
without departing from the spirit and scope of the invention.
The scope of the exclusive right sought by the applicant(s) is
therefore intended to be limited solely by the appended
claims.
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