Water softener abstract
A water softener system including a hard water flow pipe through
which hard water flows, a modular water softener assembly, and a
regeneration tank is provided. The modular water softener assembly
includes an elongated tube having a first end, a second end, a length
extending therebetween, and a predetermined inner volume for storing
an amount of water softening particles. The water softener assembly
also includes a first end cap coupled to the tube at the first end
having a first port in flow communication with the hard water flow
pipe and a second port in flow communication with an outlet pipe
through which soft water flows. The water softener assembly is supported
by the hard water flow pipe and the outlet pipe. The regeneration
tank contains a regenerate for regenerating the water softening
particles and is in flow communication with the water softener assembly.
Water softener claims
What is claimed is:
1. A water softener system comprising: a hard water flow pipe through
which hard water flows; a modular water softener assembly comprising
an elongated tube having a first end, a second end, a length extending
therebetween, and a predetermined inner volume for storing an amount
of water softening particles, said water softener assembly further
comprising a first end cap coupled to said tube at said first end
having a first port in flow communication with said hard water flow
pipe and a second port in flow communication with an outlet pipe
through which soft water flows, said water softener assembly supported
by said hard water flow pipe and said outlet pipe; and a regeneration
tank positioned outside said water softener assembly and in flow
communication with said water softener assembly, said regeneration
tank containing a regenerate for regenerating said water softening
particles, said regeneration tank comprises a first end coupled
to said tube second end such that said regeneration tank is supported
by said water softener assembly.
2. A system in accordance with claim 1 wherein said water softener
assembly system further comprises a riser pipe extending longitudinally
within said water softener tube and comprising a first distributor
end adjacent said first tube end having a first distributor, and
a second distributor end adjacent said second tube end having a
second distributor, said first and second distributors are flow
reversible, said first distributor is in flow communication with
said riser pipe, said tube first port, said tube second port, and
said predetermined inner volume, said second distributor is in flow
communication with said riser pipe and said predetermined inner
volume.
3. A system in accordance with claim 1 wherein said water softener
system further comprises a water softening capacity, said water
softening capacity equals a volumetric flow rate at which said water
softener assembly having a predetermined inner volume can effectively
convert hard water into soft water.
4. A system in accordance with claim 1 wherein said water softening
particles comprise water softening mineral beads forming a water
softening mineral bed.
5. A system in accordance with claim 1 wherein said water softening
particles comprise water softening resin beads forming a water softening
resin bed.
6. A system in accordance with claim 1 wherein said tube predetermined
inner volume is based on a desired water softening capacity from
said water softener system.
7. A system in accordance with claim 6 wherein said desired water
softening capacity can be increased by increasing said tube length
such that said predetermined inner volume and said amount of water
softening particles are increased.
8. A system in accordance with claim 6 wherein said desired water
softening capacity ranges between approximately a 2000 grain capacity
and approximately a 9000 grain capacity.
9. A system in accordance with claim 8 wherein said desired water
softening capacity ranges between approximately a 2500 grain capacity
and approximately a 6000 grain capacity.
10. A system in accordance with claim 9 wherein said desired water
softening capacity is approximately a 3000 grain capacity.
11. A water softener system comprising: a hard water flow pipe
through which hard water flows; a modular water softener assembly
comprising an elongated tube having a first end, a second end, a
length extending therebetween, and a predetermined inner volume
for storing an amount of water softening particles, said water softener
assembly further comprising a first end cap coupled to said tube
at said first end having a first port in flow communication with
said hard water flow pipe and a second port in flow communication
with an outlet pipe through which soft water flows, said water softener
assembly supported by said hard water flow pipe and said outlet
pipe; a water softening capacity of about a 3000 grain capacity;
and a regeneration tank positioned outside said water softener assembly
and in flow communication with said water softener assembly, said
regeneration tank containing a regenerate for regenerating said
water softening particles, said regeneration tank comprises a first
end coupled to said tube second end such that said regeneration
tank is supported by said water softener assembly.
12. A system in accordance with claim 11 wherein said tube length
is about 18 inches.
13. A hot-side water softener system comprising: a hard water flow
pipe through which hard water flows; a water heater comprising a
tank for holding a quantity of water, a cold water inlet pipe in
flow communication with said tank, a hot water outlet pipe extending
in communication with said tank, and a burner configured to heat
said water held in said tank; a modular water softener assembly
comprising an elongated tube having a first end, a second end, a
length extending therebetween, and a predetermined inner volume
for storing an amount of water softening particles, said water softener
assembly further comprising a first end cap coupled to said tube
at said first end having a first port in flow communication with
said hard water flow pipe and a second port through which soft water
flows in flow communication with said water heater cold water inlet
pipe; and a regeneration tank positioned outside said water softener
assembly and in flow communication with said water softener assembly,
said regeneration tank containing a regenerate for regenerating
said water softening particles, said regeneration tank comprises
a first end coupled to said tube second end such that said regeneration
tank is supported by said water softener assembly.
14. A system in accordance with claim 13 wherein said water softener
assembly is supported by said hard water flow pipe and said water
heater cold water inlet pipe.
15. A system in accordance with claim 13 wherein said water softener
assembly is configured to be supported by said water heater.
16. A system in accordance with claim 13 wherein said water softener
system converts hard water supplied by said hard water flow pipe
into soft water by passing hard water through said water softening
particles within said tube, soft water supplied to said water heater
through said cold water inlet pipe.
17. A system in accordance with claim 16 wherein said water softening
particles comprise water softening mineral beads forming a water
softening mineral bed.
18. A system in accordance with claim 16 wherein said water softening
particles comprise water softening resin beads forming a water softening
resin bed.
19. A system in accordance with claim 13 wherein said water softener
system further comprises a water softening capacity, said water
softening capacity equals a volumetric flow rate at which said water
softener assembly having a predetermined inner volume can effectively
convert hard water into soft water.
20. A system in accordance with claim 13 wherein said tube predetermined
inner volume is based on a desired water softening capacity from
said water softener system.
21. A system in accordance with claim 20 wherein said desired water
softening capacity can be increased by increasing said tube length
such that said predetermined inner volume and said amount of water
softening particles are increased.
22. A system in accordance with claim 20 wherein said desired water
softening capacity ranges between approximately a 2000 grain capacity
and approximately a 9000 grain capacity.
23. A system in accordance with claim 22 wherein said desired water
softening capacity ranges between approximately a 2500 grain capacity
and approximately a 6000 grain capacity.
24. A system in accordance with claim 23 wherein said desired water
softening capacity is approximately a 3000 grain capacity.
25. A hot-side water softener system comprising: a hard water flow
pipe through which hard water flows; a water heater comprising a
tank for holding a quantity of water, a cold water inlet pipe in
flow communication with said tank, a hot water outlet pipe extending
in communication with said tank, and a burner configured to heat
said water held in said tank; a modular water softener assembly
comprising an elongated tube having a first end, a second end, a
length extending therebetween, and a predetermined inner volume
for storing an amount of water softening particles, said water softener
assembly further comprising a first end cap coupled to said tube
at said first end having a first port in flow communication with
said hard water flow pipe and a second port through which soft water
flows in flow communication with said water heater cold water inlet
pipe, said water softener assembly is supported by at least one
of said hard water flow pipe, said water heater cold water inlet
pipe, and said water heater; a water softening capacity of about
a 3000 grain capacity; and a regeneration tank positioned outside
said water softener assembly and in flow communication with said
water softener assembly, said regeneration tank containing a regenerate
for regenerating said water softening particles, said regeneration
tank comprises a first end coupled to said tube second end such
that said regeneration tank is supported by said water softener
assembly.
26. A system in accordance with claim 25 wherein said tube length
is about 18 inches.
27. A method for installing a modular water softener assembly between
and supported by a hard water flow pipe and an outlet pipe, the
water softener assembly including an elongated tube having a first
end, a second end, a length extending therebetween, and a predetermined
inner volume for storing an amount of water softening particles,
the water softener assembly further including a first end cap coupled
to the tube at the first end having a fist port and a second port,
said method comprising: providing the hard water flow pipe through
which hard water flows; providing the outlet pipe through which
soft water flows; coupling the first port to the hard water flow
pipe such that the first port is in flow communication with the
hard water flow pipe; coupling the second port to the outlet pipe
such that the second port is in flow communication with the outlet
pipe; coupling an external regeneration tank outside and in flow
communication with the water softener assembly; and coupling a first
end of the external regeneration tank to the second end of the tube
such that the regeneration tank is supported by the water softener
assembly.
28. A method in accordance with claim 27 wherein installing the
water softener assembly further comprises installing a water softener
assembly having a predetermined inner volume that is based on a
desired water softening capacity from said water softener assembly.
29. A method in accordance with claim 28 wherein installing the
water softener assembly further comprises installing a water softener
assembly configured to allow for an increase in the desired water
softening capacity by increasing the tube length such that the predetermined
inner volume and the amount of water softening particles are increased.
30. A method in accordance with claim 29 wherein installing the
water softener assembly further comprises installing a water softener
assembly having a desired water softening capacity of about 3000
grains.
Water softener description
BACKGROUND OF THE INVENTION
This invention relates generally to water softeners and, more particularly,
to a modular water softener system installed on a hot-side of a
water supply.
At least some known water softeners are configured to pass hard
water through an ion exchange resin or mineral bed to remove hardness
ions from the water. The ion exchange resin or mineral, to a limited
extent, also removes dissolved iron through an ion exchange process.
The ion exchange resin or mineral bed is recharged to restore its
hardness and iron removal capability by passing brine through the
resin or mineral bed and by backwashing.
In at least some known installations, however, an existing plumbing
system might not allow for the installation of a water softener
that treats both the cold and hot water supply without considerable
modification that is often cost prohibitive. To offer most of the
benefits of a whole-home water softener without significant plumbing
modifications, a water softener can be used to soften only the hot
water supply for the home. Such a water softener can be installed
just prior to a water heater within the home. Unfortunately, these
water softeners are relatively large (15000 to 40000 grain capacity)
and are significantly over-sized when just treating a hot water
supply for a typical home. Consequently, a home owner must incur
an increased cost for installing and purchasing such a water softener,
and must have sufficient room in close proximity to the water heater
to allow for the installation.
BRIEF DESCRIPTION OF THE INVENTION
In one aspect, a water softener system including a hard water flow
pipe through which hard water flows, a modular water softener assembly,
and a regeneration tank is provided. The modular water softener
assembly includes an elongated tube having a first end, a second
end, a length extending therebetween, and a predetermined inner
volume for storing an amount of water softening particles. The water
softener assembly also includes a first end cap coupled to the tube
at the first end having a first port in flow communication with
the hard water flow pipe and a second port in flow communication
with an outlet pipe through which soft water flows. The water softener
assembly is supported by the hard water flow pipe and the outlet
pipe. The regeneration tank contains a regenerate for regenerating
the water softening particles and is in flow communication with
the water softener assembly.
In another aspect, a water softener system with a water softening
capacity of about 3000 grains that includes a hard water flow pipe
through which hard water flows, a modular water softener assembly,
and a regeneration tank is provided. The modular water softener
assembly includes an elongated tube having a first end, a second
end, a length extending therebetween, and a predetermined inner
volume for storing an amount of water softening particles. The water
softener assembly also includes a first end cap coupled to the tube
at the first end having a first port in flow communication with
the hard water flow pipe and a second port in flow communication
with an outlet pipe through which soft water flows. The water softener
assembly is supported by the hard water flow pipe and the outlet
pipe. The regeneration tank contains a regenerate for regenerating
the water softening particles and is in flow communication with
the water softener assembly.
In another aspect, a hot-side water softener system including a
bard water flow pipe through which hard water flows, a water heater,
a modular water softener assembly, and a regeneration tank is provided.
The water heater includes a tank for holding a quantity of water,
a cold water inlet pipe in flow communication with the tank, a hot
water outlet pipe extending in communication with the tank, and
a burner configured to heat the water held in the tank. The modular
water softener assembly includes an elongated tube having a first
end, a second end, a length extending therebetween, and a predetermined
inner volume for storing an amount of water softening particles.
The water softener assembly also includes a first end cap coupled
to the tube at the first end having a first port in flow communication
with the hard water flow pipe and a second port through which soft
water flows in flow communication with the water heater cold water
inlet pipe. The regeneration tank contains a regenerate for regenerating
the water softening particles and is in flow communication with
the water softener assembly.
In another aspect, a hot-side water softener system with a water
softening capacity of about 3000 grains that includes a hard water
flow pipe through which hard water flows, a water heater, a modular
water softener assembly, and a regeneration tank is provided. The
water heater includes a tank for holding a quantity of water, a
cold water inlet pipe in flow communication with the tank, a hot
water outlet pipe extending in communication with the tank, and
a burner configured to heat the water held in the tank. The modular
water softener assembly includes an elongated tube having a first
end, a second end, a length extending therebetween, and a predetermined
inner volume for storing an amount of water softening particles.
The water softener assembly also includes a first end cap coupled
to the tube at the first end having a first port in flow communication
with the hard water flow pipe and a second port through which soft
water flows in flow communication with the water heater cold water
inlet pipe. The water softener assembly is supported by at least
one of the hard water flow pipe, the water heater cold water inlet
pipe, and the water heater. The regeneration tank contains a regenerate
for regenerating the water softening particles and is in flow communication
with the water softener assembly.
In another aspect, a method for installing a modular water softener
assembly between and supported by a hard water flow pipe and an
outlet pipe is provided. The water softener assembly employs an
elongated tube having a first end, a second end, a length extending
therebetween, and a predetermined inner volume for storing an amount
of water softening particles. The water softening assembly further
employs a first end cap coupled to the tube at the first end having
a first port and a second port. The method includes providing the
hard water flow pipe through which hard water flows, providing the
outlet pipe through which soft water flows, coupling the first port
to the hard water flow pipe such that the first port is in flow
communication with the hard water flow pipe, and coupling the second
port to the outlet pipe such that the second port is in flow communication
with the outlet pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a modular water softener system.
FIG. 2 is a schematic view illustrating the operation of the water
softener system shown in FIG. 1 during a water softening cycle.
FIG. 3 is a schematic view illustrating the operation of the water
softener system shown in FIG. 1 during a brine fill stage of a regeneration
cycle.
FIG. 4 is a schematic view illustrating the operation of the water
softener system shown in FIG. 1 during a brining stage of a regeneration
cycle.
FIG. 5 is a schematic view illustrating the operation of the water
softener system shown in FIG. 1 during a backwash stage of a regeneration
cycle.
FIG. 6 is a schematic view illustrating the operation of the water
softener system shown in FIG. 1 during a fast rinse stage of a regeneration
cycle.
FIG. 7 is a partial cross-sectional view of the modular water softener
assembly shown in FIG. 1 attached to a water heater.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a cross-sectional view of a modular water softener system
10 including a hard water flow pipe 12 through which hard water
14 flows, a water softener assembly 16 and a regeneration tank
18. Water softener assembly 16 includes an elongated tube 20 that
has a length 22 and a predetermined inner volume 24 therein for
storing an amount 26 of water softening particles 28 that form a
water softening bed 29. In at least one embodiment, water softening
particles 28 are water softening mineral beads that form a water
softening mineral bed within predetermined inner volume 24. In an
alternative embodiment, water softening particles 28 are water softening
resin beads that form a water softening resin bed within predetermined
inner volume 24. Tube 20 also has a first end 30 and a second end
32. A first end cap 34 having a valve assembly 36 coupled thereto
is coupled to tube 20 at first end 30. First end cap 34 has a first
port 38 in flow communication with hard water flow pipe 12 and a
second port 40 in flow communication with an outlet pipe 42 through
which soft water 44 flows. Valve assembly 36 includes a plurality
of valves (not shown) and piping (not shown). In an exemplary embodiment,
and as described in more detail below, valve assembly 36 controls
the flow of hard water 14 and soft water 44 to and from water softener
assembly 16.
Regeneration tank 18 which is in flow communication with water
softener assembly 16 contains a regenerate 46 for regenerating
water softening bed 29. In an exemplary embodiment, regeneration
tank 18 has a first end 47 that is coupled to tube second end 32
such that regeneration tank 18 can be supported by water softener
assembly 16.
In an exemplary embodiment, a riser pipe 50 extends longitudinally
within water softener tube 20. Riser pipe 50 includes a first distributor
end 52 adjacent to first end 30 having a first distributor 54 coupled
thereto, and a second distributor end 56 adjacent to second end
32 having a second distributor 58 coupled thereto. First distributor
54 is in flow communication with riser pipe 50 first port 38 second
port 40 and predetermined inner volume 24. First distributor 54
is configured to be able to reverse its flow direction. Second distributor
58 is in flow communication with riser pipe 50 and predetermined
inner volume 24 and is also configured to be flow reversible.
Water softener system 10 has a water softening capacity that equals
the volumetric flow rate at which water softener assembly 16 having
predetermined inner volume 24 and length 22 can effectively convert
hard water 14 into soft water 44. In at least one embodiment, a
home owner selects a water softener system 10 based on a desired
water softening capacity. The water softening capacity of water
softener system 10 is based on predetermined inner volume 24 such
that, for example, if a home owner wanted to increase the water
softening capacity of water softener system 10 the home owner would
only have to increase predetermined inner volume 24 and amount 26
of water softening particles 28. In an exemplary embodiment, water
softener assembly 16 is modular, and accordingly, a home owner could
increase predetermined inner volume 24 and amount 26 of water softening
particles 28 by increasing tube length 22 either with an additional
section of tube 20 or by replacing tube 20 with a tube having an
increased length 22. Additionally, since water softener assembly
16 is modular, assuming water softener assembly 16 becomes defective
or requires replacement, water softener assembly 16 can be easily
removed and a new water softener assembly 16 can be installed without
having to install the other parts of water softener system 10.
In an exemplary embodiment, water softener system 10 has a water
softening capacity that ranges between approximately 2000 grains
and approximately 9000 grains. More specifically, in an exemplary
embodiment, water softener system 10 has a water softening capacity
of about 3000 grains and tube length 22 of about 18 inches.
FIGS. 2-6 are schematics illustrating the operation of an exemplary
embodiment of water softener system 10. Water softener system 10
can be placed in either a "Softening Cycle" 100 or a "Regeneration
Cycle" 102. FIG. 2 illustrates the operation of an exemplary
embodiment of water softener system 10 during Softening Cycle 100.
During Softening Cycle 100 hard water 14 flows through hard water
flow pipe 12 first port 38 valve assembly 36 and first distributor
54 into tube 20. Hard water 14 then passes through water softening
bed 29 downwardly toward second end 32. The water softening process,
a known ion exchange process, occurs as hard water 14 passes through
water softening bed 29 converting hard water 14 into soft water
44. Soft water 44 enters second distributor 58. Soft water 44 travels
upwardly through riser pipe 50 to outlet pipe 42. Soft water 44
flows through outlet pipe 42 to a desired location. In at least
one embodiment, soft water 44 flows through outlet pipe 42 to a
water heater (not shown in FIG. 2).
Briefly, ion exchange is a reversible chemical process of exchanging
hard water ions for soft water ions. Calcium and magnesium are typically
considered the hardness ions, while sodium is typically considered
the softness ions. In at least some known water softeners, ion exchange
takes place in a mineral or resin bed made up of a tiny bead-like
material that can include styrene, divynlbenzene, or zeolites. The
beads, having a negative charge, attract and hold positively charged
ions such as sodium, but will exchange them whenever the beads encounter
another positively charged ion such as calcium or magnesium minerals.
This ion exchange happens relatively easily since the sodium ions
have a positive charge of only one, while the magnesium and calcium
have a more powerful positive charge of two.
FIG. 3 illustrates the operation of an exemplary embodiment of
water softener system 10 during a "Brine Fill Stage" 104
of Regeneration Cycle 102. During Brine Fill Stage 104 soft water
44 is diverted by valve assembly 36 into regeneration tank 18 and
mixes with regenerate 46 such that regenerate 46 is placed in a
liquid solution. In at least some known water softener systems,
regenerate 46 is sodium or salt. Salt dissolved in water is known
as brine. Therefore, this stage of Regeneration Cycle 102 when
soft water 44 is diverted into regeneration tank 18 to mix with
regenerate 46 e.g., to make brine, is referred to as Brine Fill
Stage 104.
FIG. 4 illustrates the operation of an exemplary embodiment of
water softener system 10 during "Brining Stage" 106 of
Regeneration Cycle 102. Brining Stage 106 typically follows Brine
Fill Stage 104 (shown in FIG. 3) during Regeneration Cycle 102.
During Brining Stage 106 water softener assembly 16 is taken "offline"
from hard water flow pipe 12. Valve assembly 36 diverts hard water
14 from hard water flow pipe 12 to outlet pipe 42. Thus, during
Brining Stage 106 soft water 44 (not shown in FIG. 4) is, at least
temporarily, no longer generated by water softener assembly 16.
Rather, after water softener assembly 16 is taken offline, water
softener assembly 16 reverses flow direction and regenerate 46 flows
from regeneration tank 18 through valve assembly 36 and into riser
pipe 50. Regenerate 46 then flows through riser pipe 50 to second
distributor 58 and into tube 20. Regenerate 46 then flows upwardly
through water softening bed 29 such that water softening bed 29
is regenerated to facilitate future water softening processes. After
regenerate 46 regenerates water softening bed 29 valve assembly
36 closes a valve (not shown) to regeneration tank 18 and opens
a valve (not shown) that allows regenerate 46 from within tube 20
to be discharged from tube 20.
FIG. 5 illustrates the operation of an exemplary embodiment of
water softener system 10 during a "Backwash Stage" 108
of Regeneration Cycle 102. Backwash Stage 108 typically follows
Brining Stage 106 (shown in FIG. 4) during Regeneration Cycle 102.
During Backwash Stage 108 water softener assembly 16 remains offline
from hard water flow pipe 12. Valve assembly 36 continues to divert
hard water 14 from hard water flow pipe 12 to outlet pipe 42. Thus,
during Backwash Stage 108 soft water 44 (not shown in FIG. 5) is,
at least temporarily, no longer generated by water softener assembly
16. Rather, during Backwash Stage 108 water softener assembly 16
continues in a reverse flow direction. However, regenerate 46 no
longer flows from regeneration tank 18 into water softener assembly
16. Rather, hard water 14 flows quickly through first port 38 and
into valve assembly 36. A portion of hard water 14 entering valve
assembly 36 is directed into riser pipe 50. Hard water 14 then flows
through riser pipe 50 to second distributor 58 and into tube 20.
Hard water 14 then flows upwardly through water softening bed 29
such that accumulated iron, dirt, and sediment are removed from
water softening bed 29 and is discharged from tube 20.
FIG. 6 illustrates the operation of an exemplary embodiment of
water softener system 10 during "Fast Rinse Stage" 110
of Regeneration Cycle 102. Fast Rinse Stage 110 typically follows
Backwash Stage 108 (shown in FIG. 5) during Regeneration Cycle 102.
During Fast Rinse Stage 110 water softener assembly 16 packs water
softening bed 29 prior to being brought back "on-line."
Hard water 14 flows quickly through hard water flow pipe 12 first
port 38 valve assembly 36 and first distributor 54 into tube 20.
Hard water 14 then passes quickly through water softening bed 29
toward second end 32 such that water softening bed 29 is compacted
within predetermined inner volume 24 of tube 20. Rinse water is
discharged from tube 20. Thus, during Fast Rinse Stage 110 water
softener assembly 16 remains offline and a portion of hard water
14 flows through pipe 12 to outlet pipe 42.
After Fast Rinse Stage 110 is completed, water softener assembly
16 returns to Softening Cycle 100 and soft water 44 is generated
by water softener assembly 16.
FIG. 7 is a partial cross-sectional view of modular water softener
assembly 16 attached to a water heater 200. Water heater 200 includes
a tank 202 for holding a quantity of water, a cold water inlet pipe
204 in flow communication with tank 202 a hot water outlet pipe
206 extending in communication with tank 202 a burner 208 configured
to heat the water held in tank 202 and a stack 210 coupled to tank
202.
Hard water flow pipe 12 through which hard water 14 flows is in
flow communication with water softener assembly 16. Regeneration
tank 18 is also in flow communication with water softener assembly
16. Regeneration tank 18 which is partially shown in FIG. 7 has
first end 47 which is coupled to water softener assembly 16 at tube
second end 32. Water softener assembly 16 includes elongated tube
20 that has length 22 and a predetermined inner volume 24 therein
for storing water softening particles 28 (not shown in FIG. 7).
Tube 20 also has first end 30 and second end 32. A first end cap
34 having a valve assembly 36 coupled thereto is coupled to tube
20 at first end 30. First end cap 34 has a first port 38 in flow
communication with hard water flow pipe 12 and second port 40 in
flow communication with cold water inlet pipe 204 through which
soft water 44 flows. Valve assembly 36 includes a plurality of valves
(not shown) and piping (not shown). In an exemplary embodiment,
and as described in more detail hereinabove, valve assembly 36 controls
the flow of hard water 14 and soft water 44 to and from water softener
assembly 16.
In an exemplary embodiment, water softener assembly 16 is coupled
to and supported by at least one of hard water flow pipe 12 cold
water inlet pipe 204 and stack 210. More specifically, in at least
one embodiment, water softener assembly 16 is coupled to hard water
flow pipe 12 at first port 38 and is coupled to cold water inlet
pipe 204 at second port 40 such that water softener assembly 16
is supported by either hard water flow pipe 12 cold water inlet
pipe 204 or both hard water flow pipe 12 and cold water inlet pipe
204. In other words, water softener assembly 16 is coupled in-line
with hard water flow pipe 12 and cold water inlet pipe 204 such
that water softener assembly 16 is supported by water flow pipe
12 and cold water inlet pipe 204. In at least another embodiment,
water heater 200 has stack 210 that is configured such that tube
20 and regeneration tank 18 which is coupled to tube 20 is inserted
within stack 210 and coupled to stack 210 such that water softener
assembly 16 and regeneration tank 18 are supported by stack 210.
Because water softener assembly 16 is relatively small, it can
be supported by at least one of hard water flow pipe 12 cold water
inlet pipe 204 and stack 210. Consequently, a home owner will experience
a significant time and cost savings by installing water softener
system 10 as compared to the known larger water softener systems.
Moreover, a home owner would only need a relatively small amount
of floor space near water heater 200 to install water softener system
10 because regeneration tank 18 can be located under water softener
assembly 16. Whereas, with the known larger water softener systems,
a home owner must have a significant amount of floor space near
the water heater to position the entire, much larger, water softener
system.
In an exemplary embodiment, water softener system 10 has a water
softening capacity that equals the volumetric flow rate at which
water softener assembly 16 having predetermined inner volume 24
and length 22 can effectively convert hard water 14 into soft water
44. In at least one embodiment, a home owner selects a water softener
system 10 based on a desired water softening capacity. The water
softening capacity of water softener system 10 is based on predetermined
inner volume 24 such that, for example, if a home owner wanted to
increase the water softening capacity, the home owner could increase
predetermined inner volume 24 and amount 26 of water softening particles
28. In one embodiment, a home owner could increase predetermined
inner volume 24 and amount 26 of water softening particles 28 by
increasing tube length 22 either with an additional section of tube
20 or by replacing tube 20 with a tube having an increased length
22.
In at least one embodiment, water softening particles 28 that form
water softening bed 29 are water softening mineral beads that form
a water softening mineral bed within predetermined inner volume
24. In an alternative embodiment, water softening particles 28 are
water softening resin beads that form a water softening resin bed
within predetermined inner volume 24.
In an exemplary embodiment, water softener system 10 has a water
softening capacity that ranges between approximately 2000 grains
and approximately 9000 grains. More specifically, in an exemplary
embodiment, water softener system 10 has a water softening capacity
of about 3000 grains and tube length 22 of about 18 inches. A water
softener system having a 3000 grain capacity with a tube length
of about 18 inches is based on the assumptions that a typical home
will on average use approximately 48 gallons per day of hot water,
the water has a hardness of about 10 grains per gallon, and the
water softener assembly tube has a diameter of about 3 inches. As
stated above, at least some known water softener systems are sized
to soften both cold and hot water. These water softener systems
are very large and typically have a water softening capacity of
between 15000 and 40000 grains. Thus, these known water softener
systems are significantly over-sized for a typical home owner that
only wants to soften a home's hot water. Accordingly, just from
an operational standpoint, water softener system 10 will also provide
a home owner with significant savings as compared to operating a
known larger water softener systems.
In operation, during Softening Cycle 100 hard water 14 flows through
hard water flow pipe 12 first port 38 valve assembly 36 and first
distributor 54 (not shown in FIG. 7) into tube 20. Hard water 14
then passes through water softening mineral bed 29 (not shown in
FIG. 7) downwardly toward second end 32. The water softening process
occurs as hard water 14 passes through water softening bed 29 converting
hard water 14 into soft water 44. Soft water 44 enters second distributor
58 (not shown in FIG. 7). Soft water 44 travels upwardly through
riser pipe 50 (not shown in FIG. 7) to first distributor 54 which
directs soft water 44 to cold water inlet pipe 204. Soft water 44
then enters tank 202 where it is heated by burner 208. After soft
water 44 is heated within tank 202 soft water 44 exits tank 202
through hot water outlet pipe 206 which carries heated soft water
44 throughout a home or office. During Regeneration Cycle 102 water
softener system 10 undergoes Brine Fill Stage 104 Brining Stage
106 Backwash Stage 108 and Fast Rinse Stage 110 so that water
softening bed 29 is regenerated to be used in future water softening
processes.
Water softener system 10 offers most of the benefits of a whole-home
water softener system without requiring significant plumbing modifications.
More specifically, water softener system 10 can be coupled to and
supported by existing plumbing and used to soften just the hot water
supply for a home or office. Thus, water softener system 10 provides
significant time and cost savings to the home owner through both
its installation and operation. Water softener system 10 is also
relatively small and can be sized for a particular home or office
based on the home or office's hot water usage. Moreover, water softener
system 10 is modular, and therefore, its water softening capacity
can be increased or decreased as needed.
While the invention has been described in terms of various specific
embodiments, those skilled in the art will recognize that the invention
can be practiced with modification within the spirit and scope of
the claims. |