CROSS-REFERENCE TO RELATED APPLICATION

This is a division of application Ser. No. 11/032,310 filed 9 Jan. 2005 (U.S. Pat. No. 7,571,741 issued 11 Aug. 2009). This application further claims the benefit of U.S. Provisional Application No. 60/535,463, filed 9 Jan. 2004, and U.S. Provisional Application No. 60/579,921, filed 14 Jun. 2004, and is a continuation-in-part of the following provisional and nonprovisional applications: Ser. No. 10/647,603, filed 25 Aug. 2003; Ser. No. 10/744,708, filed 23 Dec. 2003; Application No. 60/535,463, filed 9 Jan. 2004; and any of their predecessor applications.

REFERENCE REGARDING FEDERAL SPONSORSHIP

Not Applicable

REFERENCE TO MICROFICHE APPENDIX

Not Applicable

1. Field of the Invention

The present invention relates to a flow trap, such as a cartridge used in water-free urinals having an odor preventing closure mechanism and, in particular, to improvements in the internal liquid flow path and sealant integrity of such a cartridge and, additionally, to improving flow trap life and usability, including a reduction in the need for the servicing and replacement of such cartridges.

2. Description of Related Art and Other Considerations

In existing water-free urinals, the life and usability of cartridges employed in water-free urinals has been found to be dependent, in part, upon the need for their servicing and replacement when debris and matter are deposited therein. For example, in the cartridges described in U.S. Pat. Nos. 6,053,197, 6,245,411, 6,644,339 and 6,______ [Ser. No. 09/855,735 (filed 14 May 2001)] and U.S. patent application Ser. No. 10/143,103 (filed 7 May 2002), as the liquids flow from the inlet compartment to the outlet compartment and thence to an external drain, the flow is sufficiently gentle that solid matter contained in the fluid deposits in the pan of the bottom portion and eventually builds up to block flow from the inner compartment to the outlet compartment. As a consequence, the cartridge needs to be replaced. Further, it has been observed that unequal pressures between the two compartments create syphoning therebetween and, particularly, of syphoning of sealant from the inlet compartment to the outlet compartment, which leads to premature failure and a reduction in the usable life of the cartridge.

SUMMARY OF THE INVENTION

These and other problems are successfully addressed and overcome by the present invention, along with attendant advantages, by equalizing the pressures and by increasing the flow rate between the inlet and outlet compartments. Such pressure equalizing is effected preferably by establishing substantially equal volumes in the two compartments and, specifically, by use of a separator. Such increased flow rate is effected by use of a baffle positioned at the bottom of the cartridge adjacent the pan, which baffle is so configured as to provide a constriction that increases the flow velocity of the urine and thus to use the fluid flow to effect a flow path or channel of least resistance through any solid matter in the bottom pan and thus to remove or carry away or displace solids that may be or have been in the wastewater or urine and thus not deleteriously affect or otherwise substantially deter flow into the outlet compartment. Such action may also otherwise avoid the build up of deposits on the bottom portion. In addition, it is preferred to locate the entry to the inlet compartment centrally of the cartridge so that a diverter may be placed above the entry and thereby to create a circuitous path for preventing turbulence or a disturbing impingement of the urine onto the sealant contained in the inlet compartment. To accommodate the centrally placed entry and its placement vis-a-vis the inlet compartment, the separator is bowed at its location adjacent the entry and towards the outlet compartment. To fit the configuration of the baffle, the separator is curved generally in a likewise manner.

Several advantages are obtained derived from these arrangements. The life and usability of the cartridge is extended. Sealant is conserved. Deposits of solid matter within the cartridge are at least minimized. Of importance, the fluid flow effects a flow path or channel of least resistance through any solid matter in the bottom pan.

Other aims and advantages, as well as a more complete understanding of the present invention, will appear from the following explanation of an exemplary embodiment and the accompanying drawings thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a flow trap cartridge usable in a water-free urinal;

FIG. 2 is an exploded view, in perspective, of the cartridge shown in FIG. 1;

FIGS. 3-6 are, respectively, two side views taken 180Â° from one another, a top view and a bottom view of the cartridge;

FIG. 7 is a cross-sectional view of the cartridge taken along line 7-7 of FIG. 3;

FIG. 8 is a cross-sectional view of the cartridge taken along line 8-8 of FIG. 4;

FIG. 9 is a cross-sectional view of the cartridge taken along line 9-9 of FIG. 6;

FIG. 10 is a cross-sectional enlarged view of the cartridge taken along cutaway line 10 of FIG. 7;

FIGS. 11 and 12 are perspective views of the bottom portion of the cartridge viewed respectively from its top and bottom;

FIG. 13 is a side view of the cartridge bottom portion;

FIG. 14 is a cross-sectional view of the bottom portion taken along line 14-14 of FIG. 13;

FIG. 15 is a cross-sectional enlarged view of the cartridge top portion taken along cutaway line 15 of FIG. 14;

FIG. 16 is a cross-sectional enlarged view of the cartridge taken along cutaway line 16 of FIG. 7;

FIG. 17 a cross-sectional enlarged view of the cartridge taken along cutaway line 17 of FIG. 9;

FIG. 18 is a perspective enlarged view of the cartridge taken from its top side with a portion cutaway to expose its inner structure;

FIGS. 19 and 20 are perspective views of the top portion of the cartridge taken respectively from its top and bottom;

FIGS. 21-23 respectively are top, side and bottom views of the cartridge top portion;

FIG. 24 is a cross-sectional view of the cartridge top portion taken along line 24-24 of FIG. 21;

FIG. 25 is a cross-sectional view of the cartridge top portion taken along line 25-25 of FIG. 22;

FIG. 26 is a cross-sectional view of the cartridge top portion taken along line 26-26 of FIG. 23;

FIG. 27 is a cross-sectional enlarged view of the cartridge top portion taken along cutaway line 27 of FIG. 24;

FIG. 28 is a perspective view of the baffle, in the interior of the cartridge, viewed towards its top surface;

FIG. 29 is a perspective view of the baffle viewed towards its lower surface;

FIGS. 30-32 respectively are a top view and two side views, taken orthogonally with respect to one another, of the baffle;

FIG. 33 is a cross-sectional view of the baffle taken along line 33-33 of FIG. 30;

FIG. 34 is a cross-sectional view of the baffle taken along line 34-34 of FIG. 30;

FIG. 35 is a cross-sectional enlarged view of the baffle taken along cutaway line 35 of FIG. 33;

FIG. 36 is a cross-sectional view of a cartridge, such as depicted in FIG. 1 et seq., with a first embodiment of a urine diverter secured to its top wall;

FIG. 37 is a side view of the diverter illustrated in FIG. 36;

FIG. 38 is an enlarged view of a spacing standoff taken along cutaway line 38 of FIG. 37;

FIG. 39 is a perspective view of the diverter shown in FIG. 36 viewing its underside;

FIG. 40 is a side view of a second embodiment of a diverter which is useful as an alternate to that depicted in FIG. 36;

FIG. 41 is a top view of the diverter shown in FIG. 40;

FIG. 42 is a cross-sectional view of the diverter taken along line 42-42 of FIG. 41;

FIG. 43 is an enlarged view of a spacing standoff taken along cutaway line 43 of FIG. 40; and

FIG. 44 is a perspective of the cartridge, such as depicted in FIG. 36, placed in a urinal housing for coupling of the cartridge to a drain pipe.

DETAILED DESCRIPTION

Accordingly, referring to FIGS. 1-27, a cartridge assembly 100, acting as a flow trap for urine or other generally fluid waste products, comprises a top portion 102 (FIGS. 19-27) and a bottom portion 104 (FIGS. 11-15). A fluid 103 with urine therein and an oily sealant 105 atop the fluid is contained within the cartridge, as illustrated in FIGS. 7 and 9.

Top portion 102 has a cylindrical configuration defined by a tubular wall 106 terminated by an opening 108 at its lower end and a top wall 110 at its upper end. The top wall is sloped downwardly to a flat, generally horizontal flat center portion 112 in which an entry opening 114 is disposed, to act as a urine inlet. As depicted in FIG. 5, opening 114 comprises a tripartite arrangement of three arced slots 114a, 114b and 114c. A hole 115 is centrally positioned within center portion 112. As will be described with respect to FIGS. 36-43, slots 114a, 114b and 114c and hole 115 are adapted to hold either of the two diverters to cartridge 100. Top portion 102 is further provided with three keys 116 of which one may be of different length than the other two (e.g., see FIG. 2) for purposes of properly placing and orienting cartridge 100 within a urinal, as more fully described in U.S. Pat. No. 6,644,339 (the parent application of above-noted Ser. No. 10/647,603).

Top wall 110 is provided with a recess 117 as shown in FIGS. 7, 9, 24, 26 and 44 at its outer periphery to accept a seal, such as O-ring seal 228 (see FIG. 44). Recess 117 has a small dimension sufficient to minimize the trapping of urine therein.

Top wall 110 of top portion 102 is further provided with three openings 118 which act as air vents that communicate with the interior of cartridge 100. In the event that one of the openings becomes clogged, such as by urine when the urinal is in use, there will be at least one that remains open. Openings 118 also provide a means by which a tool may be inserted therein for the purpose of inserting and removing the cartridge into and from a urinal, as also described in above-noted co-pending provisional application No. 60/535,463, now patent application Ser. 11/032,508. Accordingly, for purposes of their use as tool engagement means, it is preferred that the outermost two openings be approximately diagonally opposed to one another. However, the placement or use of these openings may be otherwise designed to accommodate other tool configurations.

The interior of top portion 102 is divided by a bowed vertical separator 120 (e.g., see FIGS. 2, 8 and 18) into two compartments, respectively an inlet compartment 122 and an outlet compartment 124 (e.g., FIG. 8). Vertical separator 120 is secured or molded to the interior surface of tubular wall 106 and to the underside of top wall 110 at a terminus 121a (e.g., see FIG. 9) in any convenient manner. The bottom end of the vertical separator terminates in an end or terminus 121b (e.g., FIG. 2) which is disposed to be connected to a baffle 150 which, in turn, will be presently described fully in FIGS. 28-35. When top and bottom portions 102 and 104 are placed together and a discharge section 128 (FIGS. 7, 8 and 11-14) of bottom portion 104 extends into outlet compartment 124, inlet compartment 122 and outlet compartment 124 have generally equal volumes. It is important that the compartment volumes be made as equal as possible to ensure that the pressures on both sides of vertical separator 120 remain equal during use of the cartridge. Such pressure equality helps to minimize syphoning or, alternatively, to maximize resistance to syphoning between the compartments and, of particular importance, of sealant 105 from the inlet compartment to the outlet compartment. Thus, the usable life of the cartridge is improved by avoiding premature failure thereof. Additionally, any impediment to liquid flow in minimized.

Vertical separator 120 is bowed, e.g., curved or bent, to accommodate centrally positioned entry opening 114 which needs to fully communicate with inlet compartment 122. The illustrated curved bowing of the vertical separator further enables air vent openings 118 also to communicate with the inlet compartment, as best seen in FIGS. 23 and 25. It is to be understood, however, that the vertical separator need not be curved as illustrated; it may take any configuration that will effect its purpose, that is, to provide equally volumed compartments and to oblige the communications of openings 114 with the inlet compartment. Therefore, for example, if the air vent openings were not used as a means to cooperate with a cartridge inserting and removing tool, as above described, and/or entry opening 114 were not centrally positioned in top wall 110, or for any other reason apart from its compartment volume-defining purpose, vertical separator 120 may be otherwise configured.

Bottom portion 104, as depicted in FIGS. 11-15, comprises a pan 126 and discharge section 128 extending upwardly therefrom. The upper surface of pan 126 defines a bottom wall 127 of cartridge 100; bottom wall 127 may be likened as being the mate to top wall 110. The pan includes a side wall 130 terminating at an edge 132 (FIGS. 14 and 15) which provides a tongue-in-groove engagement with tubular wall 106 at its lower end opening 108, as best seen in FIGS. 16 and 17 to provide a fluid-tight engagement between top and bottom portions 102 and 104. The inner surfaces of pan 126 are rounded to prevent sharp-angled corners and are smoothed to enhance fluid flow and to discourage build up of matter and bacteria or other debris.

Upwardly extending discharge section 128, which as described above extends into outlet compartment 124 of top portion 102, includes a tube 134 (as best seen in FIGS. 11 and 14) that communicates with outlet compartment 104 and opens at an exit port area 136 (FIGS. 2, 12 and 14) through pan 126 for discharge of fluids, e.g., fluid 103, and other undesired matter from the outlet compartment to a drain 220 (FIG. 44). The discharge section also includes a pair of tubular chambers 138 (e.g., FIGS. 8, 12, 14 and 44) for receipt of post-treatment chemicals for treating the exiting urine, as contained in control stick 224 or pellets, as more fully described in copending application Ser. No. 11/032,508 (provisional application No. 60/579,921). Chambers 138 are closed at wall 140 (see FIGS. 11 and 14) at one of their ends at the uppermost part of upwardly extending discharge section 128 to prevent flow of fluids thereinto from the outlet compartment, and are open at their other ends 142 (see FIG. 14).

As shown in FIGS. 7, 14, 16 and 44, a flow director 144 in tube 134 adjacent exit port area 136 comprises an angled part which is adapted to direct fluid flow towards ends 142 of tubular chambers 138 for impacting control stick 224, as presently described. A pair of longitudinally extending ribs 145 (see FIGS. 11 and 14) are formed in and extend along the length of conduit 134 and terminate adjacent to tubular chamber ends 142 and act further as flow directors also to direct fluid flow towards ends 142.

As shown in FIGS. 7, 14, 16 and 44, a key 146 and a keyway 148 are provided respectively on the interior surface of tubular wall 106 (see FIGS. 8, 20, 23, 25 and 26) and on the backside of upwardly extending discharge section 128 (see FIGS. 8 and 11-14). The key and keyway are disposed to provide an orientation and proper alignment between top and bottom portions 102 and 104 and, through the orienting mechanism of keys 116 with the urinal, to place exit port area 136 adjacent exterior drain 220 from cartridge 100.

As depicted in FIGS. 2, 7-10, 12, 17 and 18 and, more in detail in FIGS. 28-35, a baffle 150 is disposed to be secured to curved vertical separator 120 (FIGS. 2, 7 and 10) and acts as a mechanism for improved direction and flow of wastewater fluids through the cartridge in a region from inlet compartment 122 to outlet compartment 124. The baffle comprises a curved base 152 from which a center wall 154 and side walls 156a and 156b upwardly extend. Wall 154, which terminates in a groove 158 at its upper edge, has the same curvature as that of curved vertical separator 120 so that groove 158 will mate with and fit securely within vertical separator end 121b, such as illustrated in FIGS. 10 and 17. Walls 156a and 156b are curved similarly as or otherwise contoured in conformance with the inner wall of tubular wall 106, and the top and bottom walls may be accordingly shaped differently from that as shown and as dictated by wall 106. Further, the dimension of baffle 150 between walls 156a and 156b is sized to form a snug, fluid-tight fit of the baffle within tubular wall 106, also as shown in FIGS. 8 and 17. Therefore, fluids within inlet compartment 122 are forced to flow onto the surface of curved base 152.

With respect to the curvature of base 152, which acts as a weir, the base is carefully configured to effect several desired results. The curved base has a lowermost segment 160, which is slightly lower at its center part or point 160a than at its adjacent side parts or points 160b. Base 152 curves generally at 90Â° from generally upstanding wall 154, and all parts 160a and 160b rise to an undulated termination or terminal edge 162. Termination 162 has a center part 162a which is slightly elevated from its neighboring side parts 162b. This curved configuration of the baffle directs fluid 103 (e.g., as shown in FIGS. 7 and 9) to flow in the directions generally portrayed by arrow-headed lines 164, that is, from center part 160a to side parts 162b and thence under the baffle, between its underside 166 and the upper surface of bottom portion pan 126. The fluids then exit into outlet compartment 124 as portrayed generally by arrow-headed lines 168, as depicted in FIG. 30. The directed flow paths, as represented by arrow-headed lines 164 and 168 provide a constriction that increases the flow velocity and avoids the resistance of flow due to deposits on bottom portion 104 generally within the region from inlet compartment 122 to outlet compartment 124. The increased velocity thus effects channels of least resistance through any solid matter deposited in the region between the inlet and outlet compartment and at least minimizes any deposit of such solid matter. The above-described components or parts of baffle 150 may therefore be defined as channeling media.

Reference is now made to FIGS. 36-43, and to a urine diverter whose two illustrative embodiments are shown as diverters 170 and 270. For the first embodiment shown in FIGS. 36-39, a pretreatment control tablet 172 is held within a tablet retainer mechanism 174 for holding the tablet within the diverter. Diverter 170, as generally depicted in FIG. 36, is positionable atop wall 110 of top portion 102 for protectively covering entry opening 114 (e.g., see also FIG. 5) and for providing a circuitous path for flow of urine to the opening. Therefore, urine is prevented from directly contacting and entering into opening 114 and impinging upon sealant 105 within the cartridge. Diverter 170, which includes a shell 176, is slightly spaced from top portion top wall 110 to assure a clear path for flow of the urine and to space retainer 174 and tablet 172 from the top wall. Such spacing is effected by use of standoffs 178 (as best shown in FIG. 38), which depend from shell 176 and comprises a large portion 178a and a smaller portion 178b. Portion 178b is made to be as small as possible to permit the smallest contact of the diverter with the top wall and, therefore, to provide the largest possible unobstructed flow path.

As depicted also in FIGS. 37 and 39, shell 176 comprises an upper surface 180, terminated by a periphery 182 with a downwardly depending flange 184. Upper surface 180 slopes downwardly towards periphery 182 to encourage flow of urine towards the periphery. Inwardly-facing bumps 186 are formed on large portion 178a of standoffs 178 for holding tablet retainer 174 to the inside of shell 176.

A tubular housing 188 preferably of cylindrical configuration is secured at one end to the center of the under surface of shell 176 and terminates in a latching mechanism 190 at its second end 192 which has a bi-level shape. The second end is also formed with cutaway portions 194, as configured by the shape of bi-level end 192, into legs 196 to permit a bending of the latching mechanism. Latching mechanism 190 comprises pairs of facing teeth 198 at the ends of legs 196 which are adapted to latch into arced slots 114a, 114b and 114c of top wall 110 for securing diverter 170 to top portion 102.

Tablet retainer 174 is more fully disclosed in provisional application No. 60/535,463 and its non-provisional application Ser. No. 11/032,508, filed on 9 Jan. 2005 whose contents are incorporated herein as if set forth in haec verba.

A pair of post-treatment discharge control sticks 224 or pellets are disposed to be placed within tubular chambers 138 and may include a biocide and cleaning agents held in a time-release binder. Its use is primarily as a descaling agent to help maintain a clean drain pipe, and especially in environments where the cartridge use pattern is such that additional descaling is needed. The post-treatment discharge control sticks or pellets may be used alone or in conjunction with pretreatment control tablet 172. Like tablet retainer 174, the post-treatment discharge control stick or pellets is more fully disclosed in provisional application No. 60/535,463 and its non-provisional application Ser. No. 11/032,508, filed on 9 Jan. 2005 whose contents are incorporated herein as if set forth in haec verba.

The second embodiment of the diverter, diverter 270, is shown in FIGS. 40-43. This diverter is positionable atop wall 110 of top portion 102 and protectively covers entry opening 114 (e.g., see also FIG. 5) in a manner similar to that shown for diverter 170 in FIG. 36, and provides a circuitous path for flow of urine to the opening. Therefore, urine is prevented from directly contacting and entering into opening 114 and impinging upon and agitating sealant 105 within the cartridge. In addition, a pretreatment control tablet may be held within a tablet retainer for holding the tablet within the diverter, again as described above. Diverter 270, which includes a shell 276, is slightly spaced from top portion top wall 110 to assure a clear path for flow of the urine and to space the retainer and its retained tablet from the top wall. Such spacing is effected by use of standoffs 278 (as best shown in FIG. 43), which depend from shell 276 and comprises a large portion 278a and a smaller portion 278b. Portion 278b is made to be as small as possible to permit the smallest contact of the diverter with the top wall and, therefore, to provide the largest possible unobstructed flow path.

As depicted also in FIGS. 40-42, shell 276 comprises an upper surface 280, terminated by a periphery 282 with a downwardly depending flange 284. Upper surface 280 slopes downwardly towards periphery 282 to encourage flow of urine towards the periphery. Inwardly-facing bumps 286, which are more elongated than previously described bumps 186, are formed on large portion 278a of standoffs 278, as well as on other inner parts of flange 284, for holding the tablet retainer, such as previously described retainer 174, to the inside of shell 276.

A base 288, preferably of cylindrical configuration, is secured at one end to the center of the under surface of shell 276 and terminates in a fastener 290 at its second end 292. The fastener is formed as a post 296 terminating in a beveled end 298. Fastener 290 is sized to form an interference fit within hole 115 of top wall 110 for securing diverter 270 to top portion 102.

When all the above-described components are assembled together, they form cartridge 100 as depicted, for example, in FIGS. 1 and 36. This assembled cartridge is then adapted to be placed within a urinal 226 (FIG. 44) which, in turn, is coupled to drain 220 with exit port area 136 as provided through the orienting mechanism of keys 116. An O-ring seal 228 is sealingly placed within recess 117 in the periphery of top wall 110.

While separator 120, baffle 150 and other components are described as providing a preferred cooperative arrangement, it is to be understood that these individual components may be employed separately should the user so choose.

Accordingly, although the invention has been described with respect to particular embodiments thereof, it should be realized that various changes and modifications may be made therein without departing from the spirit and scope of the invention.