(Us) (21) Appl. No.: 10/256,189 (57) ABSTRACT. (22) Filed: Sep. 26, 2002

Transcription

1 US A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2003/ A1 Rocheleau (43) Pub. Date: May 1, 2003 (54) HOT WATER HEATING SYSTEM AND CONNECTOR FOR USE THEREWITH (76) Inventor: John W. Rocheleau, BrentWood, NH (Us) Correspondence Address: Lawson, Philpot & Persson, PC. Suite Water Street Laconia, NH (US) (21) Appl. No.: 10/256,189 (22) Filed: Sep. 26, 2002 Related US. Application Data (63) Continuation-in-part of application No. 09/981,376,?led on Oct. 16, Publication Classi?cation (51) Int. Cl?.....F22B 15/00 (52) US. Cl / (57) ABSTRACT A hot Water heating system, coupler and integrated?ow system. The hot Water heating system includes a?rst isolator valve, a How control valve, a circulator and a second isolator valve. Each of these components is equipped With one portion of a connector on one side of the component and a mating portion of a connector on the other side. The inte grated?ow system includes a body into Which is attached at least a circulator and a How control valve.

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18 US 2003/ A1 May 1, 2003 HOT WATER HEATING SYSTEM AND CONNECTOR FOR USE THEREWITH CLAIM OF PRIORITY [0001] This application is a Continuation-in-Part of co pending US. patent application Ser. No. 09/981,376,?led Oct. 16, FIELD OF THE INVENTION [0002] The present invention relates to the?eld of con nectors and, in particular, to connectors for hot Water heating systems and heating systems utilizing these connectors. BACKGROUND OF THE INVENTION [0003] Hot Water heating systems are alternatives to other conventional heating systems such as forced hot air, steam, and electric elements. The typical hot Water heating system includes a boiler for heating Water, a?anged pump for moving the heated Water, a How control valve, and any number of isolation valves that allow the components to be isolated from a supply pipe that transfers the heated Water to a?exible heating pipe, radiator or convector. In addition, other mechanical devices that control and direct hot Water?oW through the system include?ttings such as, 90 degree elbows, tees, and adapters, as Well as air scoops and vents, manifolds, nipples, purge?ttings and valves, tempering valves, balance valves, expansion tanks, back?ow preven ters, pressure reducing valves, etc., may also be included [0004] There are a number of current hot Water heating systems utilizing the above mentioned components. One such heating system is a radiant?oor heating system in Which a?exible heating pipe is typically embedded through out, or under, the?oor of the room to be heated. Another is a hot Water system utilizing radiators or convectors in Which the hot Water is fed to steel or copper?n tube baseboard, freestanding cast iron radiator units, or a fan convector coil. In each of these systems, once the hot Water has?owed through the heating pipe, radiator or convector, the heated Water continues through a return pipe back to the boiler for reheating, thus completing the loop. [0005] One problem With current hot Water systems is the time required to install them. Typically these piping systems use?anges, threaded?ttings, black steel pipe, or sweat?t copper tubing, Which is extremely labor intensive to install. Manufactured steel and copper piping or tubing come in straight runs and?ttings for accommodating turns and curves. Each connector of a straight run With a?tting requires either a threaded or a sweat?tted solder connector and a substantial amount of installation labor is involved in making each joint. [0006] In cases Where threaded connectors are to be made, the pipe must be cut to the appropriate length, and then the threads must be cut on the end of the pipe using a pipe threading die. Next the threads must be dressed, cleaned and coated With a sealing compound, or a synthetic resinous?uorine tape, such as the product marketed by the dupont Corporation under the trademark TEFLON, to prevent leaks. Finally, the connector must be screwed to the pipe end With sufficient thread contact to prevent leaks. [0007] In the case of sweat?t solder joints, the labor is comparable in that the tubing must be cut to the proper length, the end of the tubing and the?tting must be dressed and?uxed and the joint must be heated to the proper temperature With a torch to effect a satisfactory solder joint. Once joined, the solder connection must then be cleaned of any residual?ux that, if left un-cleaned, Would corrode the joint once exposed to moisture. [0008] In the case of?anged connections, such as those found on virtually all current circulators, the attachment is even more labor intensive. Circulator?anges are typically elliptical in shape and do not readily accommodate a stan dard pipe Wrench or other tightening device. In addition, When the elliptical ends of the?ange have turned Within the 180 degrees tightening arc, the Wrench must be readjusted, necessitating many fatiguing and time consuming iterations to complete the task. Moreover, as the size of a pipe Wrench increases, the length of the handle increases proportionally. As pipe?anges must often be attached to a circulator that is extremely close to a Wall, other pipes, or even Worse, a corner, the use of a long handled pipe Wrench or a pry-bar and long stove bolts to attach the?ange to the pipe makes this job a tiring and time consuming one. Finally, once attached to the pipe, gaskets must be installed between the?anges and bolts secured to each?ange to make the con nections Watertight. The inventor s pipe?ange and sweat?ange, described and claimed in US. patent application Ser. No. 09/179,584, and US. Pat. No. 6,283,157, respectively, ease this installation job somewhat. HoWever, each still requires many of the same steps required for installing threaded or sweat copper connections, and each still requires the use of gaskets and bolts to secure the?anges to one another. [0009] Another reason for the increase in installation cost is the fact that most systems are customized for the particular location in Which they are to be installed. This requires that a variety of parts, having a variety of different connectors, be used to piece the system together. Further, careful attention must be paid to insure that all components are installed in the correct position relative to the How direction of the heating Water. Because of this, current systems must be installed by trained professionals Who have the tools and the know-how to properly assemble such customized systems. [0010] Finally, the replacement of failed components in current systems requires that pipes be cut, rusted bolts be removed, Worn gaskets be replaced, etc. This, again, increases the complexity of the Work to be performed and mandates that trained professionals undertake any repair Work on current systems. [0011] Therefore, there is a need for a hot Water heating system that is easily adapted for a variety of applications, that employs fewer joints requiring sealing compounds, solder, gasketing materials, or expensive tools to install than conventional systems, that insures that all components are in the proper position relative to Water?oW direction, and that allows failed components to be quickly and easily replaced Without the need for professional assistance. SUMMARY OF THE INVENTION [0012] The present invention is a hot Water heating sys tem, coupler and integrated?ow system that overcome the drawbacks of traditional systems. [0013] The system of the present invention utilizes male and female connectors for all main heating system compo

19 US 2003/ A1 May 1, 2003 nents and, allows the system to be completely installed using no more than two ordinary Wrenches. In its most basic form, the system of the present invention includes a?rst isolator valve, a How control valve, a circulator and a second isolator valve. Each of these components is equipped With one male portion of a connector on one side of the component and one female portion of a connector on the other side of the component, such that, for example, all in?ow sides utilize male portions of connectors and all out?ow sides utilize female of connectors portions, or vice-versa. These union connectors are sized to allow the components to be quickly and easily attached together in the proper orientation relative to one another. Further, the systematic nature of the com ponents, i.e. male on one side and female on the other side, prevents the inadvertent installation of any component in the wrong How direction. [0014] In some embodiments,?ttings, nipples, pipe, and adapters may be required to assemble the components so that hot Water may?ow throughout the heating system. In addition, an expansion tank, back?ow preventer, and pres sure reducing valve may be required to maintain the desired pressure in the system at all times. [0015] In embodiments of the system utilized With radiant manifolds and radiant heat emitters, the present invention also includes an air vent, a How control valve, a tempering valve, and a tee connector With a temperature gauge or temperature-sending unit. Each of these components is equipped With union connectors arranged in the same man ner, ie the male on in?ow side/female on out?ow side con?guration, as described above. [0016] In embodiments of the system utilized With hot Water radiator type heating systems, the present invention includes an air scoop in addition to the?rst isolator valve,?ow control valve, circulator, and second isolator valve. As Was the case above, each of these components is equipped With union connectors arranged in the same manner, ie the male on in?ow side/female on out?ow side con?guration. [0017] In one preferred embodiment of the invention, a system is sold as a kit of parts having all necessary com ponents and branch connectors to install the system. In such a kit, all components Will be?tted With male and female connectors and each may be readily installed together uti lizing no more than two Wrenches. [0018] The present invention also encompasses a connec tor system for coupling a?rst component and a second component of a hot Water heating system. The connector system includes a nipple having a locking notch and a sealing notch disposed thereon and a union coupler. The union coupler includes a sealing means dimensioned to mate With the sealing notch of the nipple and creating a Watertight seal between the nipple and the union coupler. The coupler also includes a union body having a substantially hollow cylindrical cross section forming an outer Wall and an inner Wall, at least one notch for accepting the sealing means, and at least one slot disposed through the outer Wall and the inner Wall to form at least one opening across a circumference of the union body. The notch is disposed a distance from the at least one slot that is substantially identical to a distance between the sealing notch and the locking notch of the nipple. Finally, the union coupler includes a union clamp having a substantially hollow cylindrical cross section form ing an outer Wall and an inner Wall having a diameter that is larger than a diameter of the outer Wall of union body. The union clamp includes a slit through its outer Wall and inner Wall of sufficient Width to allow the inner diameter of the ring to be adjusted, a means for retaining the union clamp in place relative to the union body, and at least one locking detail dimensioned for disposal Within the at least one slot through the union body such so as to engage the locking notch of the nipple and prevent the nipple from moving relative to the union coupler. [0019] Finally, the present invention also encompasses an integrated?ow system that includes a unitary body having an in?ow end, an out?ow end, a volute opening and a How control valve opening disposed between the in?ow end and the out?ow end. A circulator is attached to the volute opening and a How control valve attached to the How control valve opening. In some such embodiments, a pair of isolator valves are attached to valve openings formed proximate to the in?ow and out?ow ends of the body. Still other such embodiments include a tempering valve and temperature gauge that are disposed Within other central openings in the body. [0020] Therefore, it is an aspect of the invention to provide a hot Water heating system that is easily adapted for a variety of applications With minimal labor to install. [0021] It is a further aspect of the invention to provide a hot Water heating system that employs fewer joints requiring sealing compounds, solder, gasketing materials, or expen sive tools to install than conventional systems. [0022] It is a further aspect of the invention to provide a hot Water heating system that insures that all components are in the proper position relative to How direction. [0023] It is a further aspect of the invention to provide a hot Water heating system that allows failed components to be quickly and easily replaced Without the need for professional assistance. [0024] These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention Will be readily apparent to those of ordi nary skill in the art When read in conjunction With the following description, appended claims and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0025] FIG. 1 is a diagrammatic view of a radiant hot Water heating system. [0026] FIG. 2 is a view of the component and union connector arrangement for a radiant hot Water heating sys tem. [0027] FIG. 3 is a diagrammatic view of a radiator type hot Water heating system. [0028] FIG. 4 is a view of the component and union connector arrangement for a radiator type hot Water heating system. [0029] FIG. 5 is a view of the component and union connector arrangement for a radiator type hot Water heating system With the use of an offset connector. [0030] FIG. 6 is a partial cut-away view of a component and union connector assembly With the female union con

20 US 2003/ A1 May 1, 2003 nector integral With component and the male union connec tor threaded into the component. [0031] FIG. 7 is a partial cut-away view of a component and union connector assembly With nipple sections joining the male and female union connectors to the component. [0032] FIG. 8A is a cut away side view of two halves of male portion of a hand tightenable self-locking union nut in position for assembly. [0033] FIG. 8B is a cut away side view of the nut of FIG. 8A With the two halves brought together during assembly. [0034] FIG. 8C is an exploded view of the self-locking feature of the union nut of FIGS. 8A and 8B With both halves in a locked position. [0035] FIG. 9 is an exploded cross sectional view of a volute circulator and a How control valve assembly using a union connector With an inserted seat component. [0036] FIG. 10 is an exploded view of a volute circulator and How control valve assembly using a quick connect disconnect type coupling. [0037] FIG. 11 is an isometric assembly view of the preferred quick coupling system of the present invention. [0038] FIG. 12 is a cross sectional view of a union body, union clamp and a pair of nipples of the preferred quick coupling system of the present invention. [0039] FIG. 13 is an isometric assembly view of the union body, union clamp and union clip of the preferred quick coupling system of the present invention. [0040] FIG. 14 is an isometric view of an alternative embodiment of a union coupler for use With a quick connect system. [0041] FIG. 15 is a cut away side view of the union coupler of FIG. 14. [0042] FIG. 16 is a side view of an improved tempering valve in accordance With the present invention. [0043] FIG. 17 is side view of the components of FIG. 2 formed together into an integrated?ow system for a radiant hot Water heating system. [0044] FIG. 18 is side view of the components of FIG. 2 formed together into an integrated?ow system for a radiator type hot Water heating system. DETAILED DESCRIPTION OF THE INVENTION [0045] FIG. 1 is a diagrammatic representation of a radi ant hot Water heating system 100. Boiler 1 produces a hot liquid; typically Water, Which is transported through the system 100 by means of circulator 10. After leaving the boiler 1 the liquid enters connection pipe 2 and?ows into micro-bubble air vent 3 Where the liquid is de-gassed. The liquid then?ows via connection pipe 4 into a Zone distri bution manifold 5. It is noted that a system 100 such as this Will typically have two or more Zones but, for clarity, only one Zone is detailed in the FIG. 1. [0046] After leaving the Zone distribution manifold 5, the liquid?ows in series through a?rst isolator valve 6, How control valve 7, tempering unit 8, tee connection mounted temperature gauge 9, circulator pump 10, and a second isolator valve 11. After leaving the second isolator valve 11, the liquid?ows through connection pipe 12 into the radiant tube distribution manifold 13. [0047] The radiant tube distribution manifold 13 divides the liquid?ow into a plurality of radiant tubes 14, 15 and 16 respectively. Three radiant tubes 14, 15 and 16 are shown purely as an example, and the number of tubes used in an actual system is dependent on the size and shape of the area to be heated as Well as the desired emission region, e.g., from the?oor. The liquid passes through the radiant tubes 14, 15 and 16 and then enters the radiant tube return manifold 17 Where it is reunited as a single liquid?ow. [0048] The liquid leaves radiant tube return manifold 17 via return pipe 18 and?ows into tee connection 19. Aportion of the liquid?ow exits tee connection 19 via tempering feedback pipe 20 and?ows into tempering unit 8, Where it is used to reduce the temperature of the heated Water from the boiler 1 to a desired temperature. This tee connection 19 may also include all male and female portions of union connectors, or it may include a combination of union con nectors and other conventional connectors, such as solder connector, barbed connectors, threaded connectors or the like. The remainder of the liquid?ow exiting the tee connection 19?oWs into the Zone return manifold 22 via connection pipe 21. The liquid How then leaves Zone return manifold 22 via connection pipe 23 and?ows past purge valve 24 When purge valve is closed and through connection pipe 25 into boiler 1, effectively completing the How circuit. [0049] FIG. 2 shows the?rst isolator valve 6, How control valve 7, tempering unit 8, tee connection mounted tempera ture gauge 9, circulator pump 10, and second isolator valve 11 of the radiant hot Water heating system 100 of FIG. 1, and their arrangement With connectors 51, 52, 53, 54, 55, 56 and 57. The connectors 51, 52, 53, 54, 55, 56 and 57 shown in this embodiment are union type connectors. HoWever, as described below, certain other types of connectors may be utilized to achieve the desired result. [0050] In the embodiment of FIG. 2, union connector 51 joins isolator valve 6 to upstream heating components, for example to a connection pipe 50 as shown. Union connector 52 joins isolator valve 6 to How control valve 7. Union connector 53 joins?ow control valve 7 to tempering unit 8. Union connector 54 joins tempering unit 8 to tee connection mounted temperature gauge 9. Union connector 55 joins tee connection mounted temperature gauge 9 to circulator 10. Union connector 56 joins circulator 10 to isolator valve 11. Union connector 57 joins isolator valve II to downstream heating components, for example to a connection pipe 58 as shown. [0051] In the arrangement shown in FIG. 2, each compo nent 6, 7, 8, 9, 10 & 11 has a male portion of a union connector at one end and a mating female portion of a union connector a the opposite end, similar to the arrangement shown in detail in FIGS. 6 & 7. This allows the male portion of one component to easily connect to the female portion of an adjacent component, effectively forming union connec tors 51, 52, 53, 54, 55, 56 and 57 between each. It is noted that the male and female portions of the connectors 51, 52, 53, 54, 55, 56 and 57 need not be on any speci?c end, but that all upstream ends should have the same male or female portion and, likewise, all downstream ends should have an

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