RESIDENTIAL HYDRONIC MAGNETIC, SEDIMENT, AND AIR SEPARATION DEVICE WITH MAINTENANCE INDICATOR

Abstract

A separation device features a coalescing media and a magnetic separation insert. The coalescing media includes vertically assembled perforated sheets having surfaces with openings. The sheets form a coalescing media interior space in the separation chamber, and are configured and shaped to slow down hydronic fluid and enable entrained gasses, ferromagnetic or ferritic particles and other solids to coalesce and come out of a hydronic fluid via a coalescing action caused by the hydronic fluid contacting and flowing through the coalescing media. The magnetic separation insert is coupled to a bottom portion of the separation device and arranged in the coalescing media interior space and has a non-magnetic sleeve that surrounds a removable magnet insert that generates a magnetic field to attract and collect the ferromagnetic or ferritic particles on the non-magnetic sleeve that coalesce and come out of the hydronic fluid, and can be removed from inside the non-magnetic sleeve to release the ferromagnetic or ferritic particles attracted and collected on the non-magnetic sleeve so released ferromagnetic or ferritic particles fall to the bottom portion of the separation chamber.

Claims

1. A separation device having a tank wall and top and bottom portions that combine to form a separation chamber for processing a hydronic fluid, comprising: a coalescing media including vertically assembled perforated sheets having surfaces with a multiplicity of openings, the vertically assembled perforated sheets configured to form a coalescing media interior space in the separation chamber, and also configured and shaped to slow down the hydronic fluid and enable entrained gasses, ferromagnetic or ferritic particles and other solids to coalesce and come out of the hydronic fluid via a coalescing action caused by the hydronic fluid contacting and flowing through the coalescing media; and a magnetic separation insert coupled to the bottom portion of the separation device and arranged in the coalescing media interior space, having a non-magnetic sleeve that surrounds a removable magnet insert, the removable magnet insert configured to generate a magnetic field to attract and collect the ferromagnetic or ferritic particles on the non-magnetic sleeve that coalesce and come out of the hydronic fluid, and also configured to be removed from inside the non-magnetic sleeve to release the ferromagnetic or ferritic particles attracted and collected on the non-magnetic sleeve so that released ferromagnetic or ferritic particles can fall to the bottom portion of the separation chamber.

2. A separation device according to claim 1, wherein the separation device comprises a bottom coupling member configured on the bottom portion of the separation device; and the non-magnetic sleeve comprises a sleeve coupling member configured to detachably couple to the bottom coupling member for coupling the magnetic separation insert to the bottom portion of the separation device.

3. A separation device according to claim 2, wherein the non-magnetic sleeve comprises a non-magnetic surface configured to collected the ferromagnetic or ferritic particles attracted to the removable magnet insert by the magnetic field.

4. A separation device according to claim 2, wherein the removable magnet insert comprises a handle having an insert coupling member; and the sleeve coupling member is configured to receive the insert coupling member and couple the removable magnet insert to the non-magnetic sleeve when the removable magnet insert is inserted into the non-magnetic sleeve.

5. A separation device according to claim 4, wherein the removable magnet insert comprises a rod connected to the handle; and an alternating stack of magnets and spacers configured to slide onto the rod and be retained by a bolt fastened to an end of the rod.

6. A separation device according to claim 5, wherein the alternating stack of magnets comprise opposite magnetic poles arranged so that like magnetic poles face each other and are separated by a spacer.

7. A separation device according to claim 5, wherein the non-magnetic insert is made of stainless steel; or the spacers are made of carbon steel; or the non-magnetic insert is made of stainless steel and the spacers are made of carbon steel.

8. A separation device according to claim 1, wherein the vertically assembled perforated sheets are made from stainless steel.

9. A separation device according to claim 8, wherein the vertically assembled perforated sheets have a vertical diamond shape with angled edges configured to direct the hydronic fluid to pass through the coalescing media and into the coalescing media interior space, and having reverse angled edges configured to direct the hydronic fluid to pass from the coalescing media interior space to an outlet or a discharge nozzle, leave the separation chamber and allow a pressure drop to recover.

10. A separation device according to claim 1, wherein the vertically assembled perforated sheets are configured as corrugated sheets having peaks, crests and surfaces between the peaks and crests.

11. A separation device according to claim 10, wherein the vertically assembled perforated sheets are formed and assembled either from a single sheet having two ends that join to form a diamond shape, or from multiple sheets having corresponding ends that join to form the diamond shape.

12. A separation device according to claim 1, wherein the coalescing media interior space is an open space that is 58% or greater than the volume of the separator chamber in order to improve pressure drop characteristics of the separation device.

13. A separation device according to claim 1, wherein the separation device includes a well assembly at the bottom portion of the separation chamber configured to collect the released ferromagnetic or ferritic particles.

14. A separation device according to claim 1, wherein the separation device comprises a chamber head at the top portion and a support ledge at the bottom portion configured to retain the coalescing media in the separation chamber.

15. A separation device according to claim 1, wherein the separation device comprises a maintenance indicator configured to respond to a magnetic flux generated by the magnetic separation insert and provide maintenance indicator signaling containing information about maintenance being needed on the separation device, including where the maintenance indicator signaling includes audio and/or visual signaling.

16. A separation device according to claim 15, wherein the maintenance indicator is configured to respond to a reduced magnetic flux when the released ferromagnetic or ferritic particles are removed from the bottom portion of the separation chamber, and provide a corresponding maintenance indicator signaling that contains information that maintenance is not needed.

17. A separation device according to claim 15, wherein the maintenance indicator comprises a circuit having a magnetic sensor configured to respond to the magnetic flux.

18. A separation device according to claim 17, wherein the magnetic sensor comprises a Reed Switch or a Hall Effect sensor.

19. A separation device according to claim 17, wherein the circuit comprises a light configured to provide visual maintenance indicator signaling, including where the light turns ON/OFF, blinks or changes color.

20. A separation device according to claim 17, wherein the magnetic sensor is configured to respond to the magnetic flux that exceeds a desired magnetic flux threshold.

21. A separation device according to claim 20, wherein the desired magnetic threshold depends and is based upon the amount of ferromagnetic or ferritic particles attracted and collected onto the non-magnetic sleeve.

22. A separation device according to claim 1, wherein the separation device comprises a residential hydronic magnetic, sediment and air separation device that includes: a separator tank having a separator input or inlet nozzle configured to receive the hydronic fluid, having the tank wall configured to form a volume/chamber inside the separator chamber to process the hydronic fluid, and having a separator output or discharge nozzle configured to provide processed hydronic fluid having at least some of the entrained gas, the ferromagnetic or ferritic particles and the other solid removed.

23. A separation device according to claim 1, wherein the separation device comprises a blow down valve configured at the bottom portion of the separation chamber to open and drain the released ferromagnetic or ferritic particles.

24. A separation device according to claim 1, wherein the separation device comprises an air vent configured at the top portion of the separation chamber to vent the entrained gasses that come out of the hydronic fluid.

25. A separation device according to claim 1, wherein the multiplicity of openings formed in the surfaces of the vertically assembled perforated sheets also coalesce the gasses and the other solids in the hydronic fluid.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0043] The drawing, which is not necessarily drawn to scale, includes the following Figures:

[0044] FIG. 1 is a side cross-sectional view of a residential hydronic magnetic, sediment and air separation device having coalescing media with a removable magnet insert arranged therein, according to some embodiments of the present invention.

[0045] FIG. 2 is a diagram showing a top down cross-sectional view of the residential hydronic magnetic, sediment and air separation device having the coalescing media with the removable magnet insert arranged therein consistent with that shown in FIG. 1, and also showing a sensor with an indicator light, according to some embodiments of the present invention.

[0046] FIG. 3 is a perspective view of diamond coalescing media that forms part of the residential a top cross-sectional view of the hydronic air and sediment separation device shown in FIG. 1.

[0047] FIG. 4 is a diagram of a typical magnet and spacer arrangement for the removable magnet insert shown in FIG. 1, and according to some embodiments of the present invention.

[0048] FIG. 5 is a cross-sectional view of the removable magnet insert shown in FIG. 1, according to some embodiments of the present invention.

[0049] FIG. 6 is a diagram of a circuit having a Reed Switch based visual maintenance indicator, according to some embodiments of the present invention.

[0050] FIG. 7 is a diagram of a circuit having a Hall Effect based visual maintenance indicator, according to some embodiments of the present invention.

[0051] FIG. 8 is a diagram showing a top down cross-sectional view of the residential hydronic magnetic, sediment and air separation device shown in FIG. 2, and also showing a magnetic field and magnetic particle captured, according to some embodiments of the present invention.

[0052] FIG. 9A is a side view of an individual corrugation that forms part of the coalescing media shown herein.

[0053] FIG. 9B is a top down view of the individual corrugation shown in FIG. 9A.

[0054] Similar parts or components in Figures are labeled with similar reference numerals and labels for consistency. Every lead line and associated reference label for every element is not included in every Figure of the drawing to reduce clutter in the drawing as a whole.

DETAILED DESCRIPTION OF THE INVENTION

[0055] According to some embodiments, and consistent with that shown in FIGS. 1-5 and 8, 9A and 9B, the present invention may take the form of a separation device generally indicated as 10 that has a tank wall 12, a top portion 14 and a bottom portion 16 that combine to form a separation chamber 18 (FIG. 2) for processing a hydronic fluid F, and that features a coalescing media 20 (FIGS. 3 and 9A-9B) and a magnetic separation insert 30 (FIG. 5). By way of example, the hydronic fluid F may include water entrained with gasses and particulate matter (e.g., including ferromagnetic or ferritic particles FP like magnetite or iron oxide).

[0056] The coalescing media 20 includes vertically assembled perforated sheets 22 having surfaces 22a with a multiplicity of openings 22b, e.g., as shown in FIGS. 3, 9A and 9B. The vertically assembled perforated sheets 22 are configured to form a coalescing media interior space 22c (FIGS. 2 and 3) in the separation chamber 18, and also configured and shaped to slow down the hydronic fluid F and enable entrained gasses, ferromagnetic or ferritic particles FP and other solids to coalesce and come out of the hydronic fluid F via a coalescing action caused by the hydronic fluid F contacting and flowing through the coalescing media 20, e.g., including contacting the surfaces 22a and flowing through the openings 22b.

[0057] The magnetic separation insert 30 is coupled to the bottom portion 14 of the separation device 10 and arranged in the coalescing media interior space 22c and has a non-magnetic sleeve 32 that surrounds a removable magnet insert 34, e.g., as shown in FIG. 1. The removable magnetic insert 34 is configured to generate a magnetic field MF to attract and collect the ferromagnetic or ferritic particles FP on the non-magnetic sleeve 32 that coalesce and come out of the hydronic fluid F, e.g., as shown in FIG. 8. The removable magnetic insert 34 is also configured to be removed from inside the non-magnetic sleeve 32 to release the ferromagnetic or ferritic particles FP attracted and collected on the non-magnetic sleeve 32 so that released ferromagnetic or ferritic particles FP can fall to the bottom portion 16 of the separation chamber 12, e.g., into a well assembly Was described below.

The Magnetic Separation Insert

[0058] Consistent with that shown in FIGS. 1, 4 and 5, the separation device 10 may include a bottom coupling member 14a configured on the bottom portion 16 of the separation device 10; and the non-magnetic sleeve 32 may include a sleeve coupling member 32a configured to couple to the bottom coupling member 14a for coupling the magnetic separation insert 30 to the bottom portion 16 of the separation device 10, including where an O-ring or sealing gasket 32b is arranged inbetween the coupling members 14a, 32a. By way of further example, and consistent with that set forth herein, embodiments are envisioned, and the scope of the invention is intended to include, e.g., implementations where the non-magnetic sleeve 32 of the magnetic separation insert 30 is coupled to the bottom portion 16 of the separation device 10 via welding; or where the non-magnetic sleeve 32 of the magnetic separation insert 30 and the bottom portion 16 of the separation device 10 are formed and coupled together as an integral unit, or where the sleeve coupling member 32a is detachably coupled to the bottom coupling member 14a via a friction fit for coupling the magnetic separation insert 30 to the bottom portion 16 of the separation device 10. In either case, the removable magnetic insert 34 may be configured to be removed from inside the non-magnetic sleeve 32 to release the ferromagnetic or ferritic particles FP attracted and collected on the non-magnetic sleeve 32 so that released ferromagnetic or ferritic particles FP can fall to the bottom portion 16 of the separation chamber 12, e.g., into the well assembly Was described below.

[0059] The non-magnetic sleeve 32 may include a non-magnetic surface 32c configured to collect the ferromagnetic or ferritic particles FP attracted to the removable magnet insert 34 by the magnetic field MF.

[0060] Consistent with that shown in FIG. 5, the removable magnet insert 34 may include a handle portion 34a having an insert coupling member 34b; and the sleeve coupling member 32a may be configured to receive the insert coupling member 34b and couple the removable magnet insert 34 to the non-magnetic sleeve 32 when the removable magnet insert 34 is inserted into the non-magnetic sleeve 32, including where an O-ring or sealing gasket is arranged inbetween the coupling members 32a, 34b. By way of example, and consistent with that set forth herein, embodiments are envisioned, and the scope of the invention is intended to include, e.g., implementations where the sleeve coupling member 32a may be configured to receive the insert coupling member 34b via a friction fit in order to couple the removable magnet insert 34 to the non-magnetic sleeve 32, as well as by using other detachably coupling techniques either now known or later developed in the future for removably coupling together the sleeve coupling member 32a and the insert coupling member 34b.

[0061] The removable magnet insert 34 may include a rod 34c connected to the handle 34a; and an alternating stack of magnets M and spacers S configured to slide onto the rod 34c and be retained by a bolt 34d fastened to an end of the rod 34c.

[0062] The alternating stack of magnets M may include opposite magnetic poles N, S arranged so that like magnetic poles (N, N; S, S) face each other and are separated by a respective spacer S, e.g., consistent with that shown in FIGS. 1 and 4-5.

[0063] The non-magnetic insert 32 may be made of stainless steel; and the spacers S may be made of carbon steel.

The Vertically Assembled Perforated Sheets

[0064] The vertically assembled perforated sheets 22 (FIGS. 3 and 9A, 9B) may be made from stainless steel.

[0065] The vertically assembled perforated sheets 22 may have a vertical diamond shape with angled edges like E1 (FIG. 2) configured to direct the hydronic fluid F to pass from an inlet I, through the coalescing media 20 and into the coalescing media interior space 22c, and having reverse angled edges like E2 (FIG. 2) configured to direct the hydronic fluid F to pass from the coalescing media interior space 22c to an outlet O or a discharge nozzle, leave the separation chamber 10 and allow a pressure drop to recover, e.g., as shown in FIG. 2. In FIG. 1, the inlet I and outlet O are retained by union end connections.

[0066] The vertically assembled perforated sheets 22 may be configured as corrugated sheets (FIG. 9A, 9B) having peaks 22d, crests 22e and surfaces 22f inbetween.

[0067] The vertically assembled perforated sheets 22 may be formed and assembled either from a single sheet having two ends that join to form a diamond shape, e.g., consistent with that shown in FIG. 3; or from multiple sheets having corresponding ends that join to form the diamond shape, e.g., consistent with that shown in FIGS. 9A, 9B.

[0068] The coalescing media interior space 22c may be formed as an open space, e.g., that is 58% or greater than the volume of the separator chamber 18 in order to improve pressure drop characteristics of the separation device 10.

The Maintenance Indicator

[0069] Consistent with that shown in FIGS. 2 and 6-7, the separation device 10 may include a maintenance indicator S configured on the outside of the separation device 10 to respond to a magnetic flux generated by the magnetic separation insert 30 and provide maintenance indicator signaling containing information about maintenance being needed on the separation device 10, including where the maintenance indicator signaling includes audio and/or visual signaling.

[0070] The maintenance indicator S may be configured to respond to a reduced magnetic flux when the released ferromagnetic or ferritic particles are removed from the bottom portion 16 of the separation chamber 18, as described below, and provide a corresponding maintenance indicator signaling that contains information that maintenance is not needed, e.g., by changing colors, turning off, stop beeping, etc.

[0071] The maintenance indicator S may include a circuit like that shown in FIGS. 6-7 having a magnetic sensor configured to respond to the magnetic flux. The magnetic sensor may include a Reed Switch (FIG. 6) or a Hall Effect sensor (FIG. 7). By way of example, the circuit in FIG. 6 includes the Reed Switch, a resistor, an LED and power source arranged in series. By way of further example, the circuit in FIG. 7 includes the Hall Effect sensor and a power source arranged in parallel with a resistance and LED combination.

[0072] Each circuit may include the light (e.g., LED) configured to provide visual maintenance indicator signaling, including where the light or LED turns ON/OFF, blinks or changes color.

[0073] The magnetic sensor may be configured to respond to the magnetic flux that exceeds a desired magnetic flux threshold. The desired magnetic threshold may depend and be based upon the amount of ferromagnetic or ferritic particles attracted and collected onto the non-magnetic sleeve.

Other Features of the Separation Device

[0074] The separation device 10 may include a well assembly W at the bottom portion 16 of the separation chamber 10 configured and shaped to collect the released ferromagnetic or ferritic particles.

[0075] The separation device may include a chamber or retaining head at the top portion 14 and a support or retaining ledge at the bottom portion 16 configured to retain fixedly the coalescing media 20 in the separation chamber 10, e.g., so it does not move, rotate, etc.

[0076] The separation device 10 may include or take the form of a residential hydronic magnetic, sediment and air separation device, e.g., that may be used residentially, and that may include a separator tank having a separator input I or inlet nozzle configured to receive the hydronic fluid F, having the tank wall 12 configured to form a volume/chamber inside the separator chamber 18 to process the hydronic fluid F, and having a separator output O or discharge nozzle configured to provide processed fluid, e.g., consistent with that shown in FIGS. 1-2

FIG. 9A, 9B: Vertically Aligned Corrugated Perforated Sheets

[0077] FIGS. 9A and 9B show the vertically aligned corrugated perforated sheets 22 in the form of vertically aligned corrugated perforated sheets that may have peaks 22d, crests 22e and surfaces 22f inbetween, and may be assembled to each other where a peak 22d of one corrugation is assembled to a crest 22e of another corrugation. Alternatively, the series of vertically aligned corrugated perforated sheets 22 having the peaks 22d and crests 22e may be assembled to each other peak-to-peak and crest-to-crest. In other words, the scope of the invention is not intended to be limited to any particular alignment of peaks and crests of the vertically aligned corrugated perforated sheets 22. In FIGS. 9A and 9B, each vertically aligned corrugated perforated sheet 22 has three (3) peaks 22d, four (4) crests 22e and six (6) surfaces 22f inbetween. (The terms peaks and crests may be used interchangeably within the spirit of the invention.)

The Vertically Aligned Perforated Sheets

[0078] The series of vertically aligned corrugated perforated sheets 22 may have multiple openings or perforations 22b that provide multiple surfaces for dissolved gasses and solids or particles to coalesce around. By way of example, and consistent with that shown in FIGS. 9A, 9B, the multiple openings or perforations 22b may be circular openings or perforations and the multiple surfaces may be circular or cylindrical surfaces, e.g., so as to be uniformly configured on the vertically aligned corrugated perforated sheets 32. However, the scope of the invention is intended to include, and embodiments are envisioned that include, the multiple openings or perforations 22b and the multiple surfaces having different types or kinds of shapes and surfaces within the spirit of the underlying invention, e.g., including a triangular shape and surface, a rectangular shape and surface, a square shape and surface, a hexagon shape and surface, etc. In other words, the scope of the invention is not intended to be limited to the shape of the opening or perforation 22b and its associated surface. For example, in one type of application the multiple openings or perforations 34 may have one shape and surface, while in another another application, the multiple openings or perforations 22b may have another shape and surface, as one skilled in the art would appreciate.

[0079] Moreover, and by way of further example, and consistent with that shown in FIGS. 9A, 9B, the multiple openings or perforations 22b may be configured or dimensioned having the same size, e.g., so as to be uniformly distributed on the vertically aligned corrugated perforated sheets 22. However, the scope of the invention is intended to include, and embodiments are envisioned that include, the multiple openings or perforations 22b having different sizes within the spirit of the underlying invention. Moreover, the scope of the invention is not intended to be limited to the size of the multiple openings or perforations 22b, e.g., which may be configured or dimensioned with a particular size based upon a particular application as one skilled in the would appreciate. For example, in one type of application the multiple openings or perforations 22b may have one size or dimension, while in another another application, the multiple openings or perforations 22b may have another and different size or dimension.

[0080] Moreover still, and by way of still further example, and consistent with that shown in FIGS. 9A, 9B, the multiple openings or perforations 22b may be configured, dimensioned or spaced in relation to one another having the same distance inbetween, e.g., so as to be uniformly distributed on the vertically aligned corrugated perforated sheets 22. However, the scope of the invention is intended to include, and embodiments are envisioned that include, the multiple openings or perforations 22b having different distances inbetween within the spirit of the underlying invention. Moreover, the scope of the invention is not intended to be limited to any particular distances inbetween the multiple openings or perforations 22b, e.g., which may be configured or dimensioned with a particular distance inbetween based upon a particular application as one skilled in the would appreciate. For example, in one type of application the multiple openings or perforations 22b may have one distance inbetween, while in another application, the multiple openings or perforations 22b may have another and and different distance inbetween.

[0081] The series of vertically aligned corrugated perforated sheets 22 may have angled corrugations that direct the fluid to pass through the coalescing media 20 where greatest surface contact occurs. By way of example, and consistent with that shown in FIGS. 9A and 9B, the vertically aligned corrugated perforated sheets 22 have angled corrugations with a 90 angle (i.e. right angle). As the fluid has completed its pass through the coalescing media 20, the angled corrugations may direct the fluid to the separator output O to leave the coalescing removal separator 10 and allow a pressure drop to recover. However, the scope of the invention is intended to include, and embodiments are envisioned that include, the angled corrugations having a different angle within the spirit of the underlying invention. For example, the scope of the invention is intended to include, and embodiments are envisioned that include, the angled corrugations being more or less than 90, e.g., so as to be configured or dimensioned with a particular angled corrugation based upon a particular application as one skilled in the would appreciate. For example, in one type of application the angled corrugation may have one angle, while in another another application, the angled corrugation may have another and different angle.

The Assignee's Other Related Technology

[0082] This application also relates to patent application serial no. 17/204,141, filed 17 May 2021, as well as patent application Ser. No. 17/518,698, filed 4 Nov. 2021, which are both assigned to the assignee of the instant application, and which are both hereby incorporated by reference in their entirety.

The Scope of the Invention

[0083] The embodiments shown and described in detail herein are provided by way of example only; and the scope of the invention is not intended to be limited to the particular configurations, dimensionalities, and/or design details of these parts or elements included herein. In other words, one skilled in the art would appreciate that design changes to these embodiments may be made and such that the resulting embodiments would be different than the embodiments disclosed herein, but would still be within the overall spirit of the present invention.

[0084] It should be understood that, unless stated otherwise herein, any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein.

[0085] Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention.