Remote Air Gap Assemblies

This application claims the benefit of U.S. Provisional Application Ser. No. 63/653,311, filed May 30, 2024, which is herein incorporated by reference in its entirety.

The present disclosure generally relates to fluid backflow prevention systems for plumbing fixtures. More specifically, the present disclosure relates to fluid backflow prevention systems that may prevent wastewater or gray water from mixing with potable water.

Plumbing fixtures may require protection against fluid backflow (i.e., the reversal of normal fluid flow in a system) to satisfy various safety and health requirements. For example, dishwashing devices are generally connected to a drain line which diverts wastewater from cleaning operations to a sewage system for removal, and sinks also may employ backflow prevention mechanisms which are intended to eliminate or reduce wastewater or gray water from flowing back into a clean waterway, eliminate or reduce hot water draining through the sink and into a cold-water supply pipe, or both. Backflow prevention mechanisms for sinks may include check valves incorporating air-gap features such as a spring and ball element to prevent or allow fluid flow through an opening by blocking or unblocking the opening with the ball element. An air-gap device may be installed upstream of a drain and may prevent backflow by utilizing the pressure differential between the unpressurized air gap and the pressurized fluid flowing through a hose leading to the sink drain.

In a non-limiting example, an air gap assembly for use with a plumbing fixture may include an air gap housing including a floor, and a sidewall extending from the floor to define a housing cavity, an inlet extending from the air gap housing and in fluid communication with housing cavity, an outlet extending from the air gap housing, a weep hole extending from the outlet and in fluid communication with the outlet, and a check valve positioned in the outlet. The check valve may be shiftable between a first position such that an exit of the outlet and the housing cavity are in fluid communication, and a second position such that the exit of the outlet and the housing cavity are not in fluid communication. When the check valve is in the second position, fluid may be routed through the weep hole.

In another non-limiting example, an air gap assembly for use with a fixture may include an air gap housing, an inlet extending from the air gap housing in fluid communication with an interior of the housing, an outlet extending from the air gap housing, the outlet including an outlet cap coupled to an end of the outlet opposite the air gap housing, a weep hole extending from the outlet and in fluid communication with the outlet cavity, and a check valve positioned in the outlet. The outlet cap may be configured to be coupled to a fluid outlet line.

In yet another non-limiting example, a plumbing system may include a sink system mounted to a counter, a plumbing fixture operably coupled to the sink, and an air gap assembly coupled to the counter below the sink. The air gap assembly may include an air gap housing, an inlet extending from the air gap housing and in fluid communication with an interior of the housing, an outlet extending from the air gap housing, a weep hole extending from the outlet and in fluid communication with the outlet, and a check valve positioned in the outlet. The check valve may shift between being configured to shift between a first position and a second position.

The above summary is not intended to describe each illustrated example or every implementation of the subject matter hereof. The figures and the detailed description that follow more particularly exemplify various examples.

While various examples are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed inventions to the particular examples described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

Referring to, an exploded perspective view of a remote air gap assemblymay generally including an air gap housinghaving a housing floor, and one or more sidewalls, defining a housing cavity. A covermay be removably or permanently coupled to the air gap housingsuch that the housing cavitymay be enclosed between the coverand air gap housing. Further, the covermay include a cover edgepositioned along a perimeter of the cover. In a non-limiting example, the coverand the air gap housingmay be rectangular in shape, however, other geometries may be considered, such as, for example, square, circular, triangular, or any shape. For example, in some implementations, the air gap housingand covermay be custom-shaped to fit in a specific location. Further, in some implementations, the covermay be removably coupled to the air gap housingby using a compression (“snap”) fit, or fasteners, like screws. In other implementations, the covermay be fixed more permanently to the air gap housing, by using an adhesive, ultrasonic welding, or similar fixing technologies, for example.

The cover edgemay include a seal (not shown), such that when the coveris coupled to the air gap housing, a water-tight seal may be formed between the coverand air gap housing. In an example, the seal may be a rubber or silicone o-ring or gasket. In another example, the cover edgemay include a compressible material such that when the coveris coupled to the air gap housing, a seal may be formed without an o-ring or gasket.

The remote air gap assemblymay include an inletdefining an inlet cavitywhich may be in fluid communication with the housing cavity. The inletmay be configured to extend outward from the floorof the air gap housing. In a non-limiting example, the inletmay be shaped as a female or male connector, such that PEX/flexible tubing may be attached to the inlet. In other implementations, the inletmay be configured to receive other sizes of tubing, or other standard plumbing fixtures and connectors.

The remote air gap assemblymay include an outletdefining an outlet cavity. The outletmay be configured to extend outwards from air gap housingand the outlet cavitymay be in fluid communication with the housing cavity. In an example, the outletmay extend from the air gap housingin the same direction and same length as the inlet. The outletmay be shaped as a female or male connector, such that tubing or other plumbing fixtures, connectors, pipes, or tubing of various sizes (male or female) may be coupled to the outlet.

The remote air gap assemblymay include a check valvehaving an air gap housing sidein fluid communication with the housing cavityand an outlet sidein fluid communication with the outlet cavity. The check valvemay be configured to fit between the air gap housingand outletsuch that any fluid moving between the outletand air gap housingmoves through the check valve. Additionally, the check valvemay be configured to unidirectionally restrict flow from the outletto the air gap housing, while allowing flow from the air gap housingto the outlet. The check valvemay be a swing check valve, lift check valve, ball check valve, dual plate check valve, diaphragm check valve, tilting disc check valve, stop check valve, or any other type of valve that allows flow in one direction, while eliminating or restricting flow in the other direction. The check valvemay be configured to fit between the outletand air gap housingby a compression or interference fit, adhesive, threaded connection, or other coupling mechanisms. In a non-limiting, the check valvemay include an o-ring or gasket to form a radial or facial seal to prevent fluid from bypassing the check valve.

The remote air gap assemblymay include a weep holedefining a weep hole cavity. The weep hole cavitymay be in fluid communication with the outlet cavityand positioned on the sideof the check valve. In a non-limiting example, the weep holemay be orthogonally connected to the outlet, although other configurations, e.g., angled or non-orthogonally, may be considered. The weep holemay be shaped (male or female) to receive tubing, or other standard plumbing fixtures, connectors, pipes, or tubing of various sizes (corresponding male or female).

The remote air gap assemblymay include an outlet capthat may couple to the outletat end opposite of the end coupled to the housing. The outlet capmay define an outlet cap opening. The outlet capmay be a seal, such as a gasket or o-ring, to create a sealed connection when coupled to the outlet such that fluid may not escape or enter between the outlet capand outletinterface. Additionally or alternatively, the outlet capmay be formed of a compressible material capable of forming a seal when coupled to the outlet. The outlet capmay be shaped or otherwise configured to make a male or female connection with the outlet. In some implementations, the outlet capmay be removably coupled to the outlet, for example by forming a connection or interference fit or threaded connection. In some implementations, an adhesive, ultrasonic welding, or other connection technique could be used to create a more permanent coupling.

The outlet capand outlet cap openingmay be used to reduce the size of the outlet. The outlet cap opening, for example, may be shaped to couple to tubing or other standard sized plumbing fixtures. In a non-limiting example, various interchangeable outlet capsmay define different types of outlet cap openingssuch that the remote air gap assemblymay interface with different kinds of plumbing fixtures. In examples, the outlet capmay be configured to provide support to the check valveonce the outlet capis coupled to the outlet.

In examples, the air gap assemblymay be formed of a polymer or plastic material that may be 3-D printed, injection molded, cast, or otherwise formed or combinations thereof. In one example, in which the air gap assembly is 3-D printed, the shape, the positioning of the inlet, outlet, and weep hole, or both of the remote air gap assembly may be customized to fit a desired location for installation. Additionally or alternatively, the air gap assemblymay be formed of a metal, metal alloy, or composite thereof, and can be machined, tooled, or otherwise formed or combinations thereof.

When assembled, in a non-limiting example, the air gap assemblymay be installed such that the inletand outletare both facing in a downward direction, towards the ground or floor. As previously mentioned, in an example, the weep holemay be positioned orthogonal to the outlet. Alternatively, other configurations may be considered in which the inletand the outletare facing in different directions, the weep holeis non-orthogonal to the outlet, or both.

Referring to, operation of the remote air gap assemblyis depicted by arrows to show the flow of a fluid throughout the remote air gap assembly. In an exemplary use, the fluid may be brine water that comes from a filtration system to be dispensed through a main drain line. In another example, the fluid may be used dishwasher fluid or grey water being dispensed to a main drain line. In other exemplary uses, the fluid may be any fluid to be dispensed in a main drain line while preventing an undesirable backflow from contaminating appliances or other clean fluid sources.

In a non-limiting example, and referring to, under normal operating conditions, fluid (F) may flow into the inlet. The fluid may then flow into the air gap housingtowards the outlet. The fluid may pass through the check valve (not pictured), which is in a position (e.g., open) configured to allow fluid to pass in this direction, and then exit the outlet, where it may be dispensed into a drain line, for example.

In a non-limiting example, and referring to, a backflow condition may occur, for example, due to a backflow from the municipality that plumbing is connected to, in which drain water flow may reverse, posing a potential contamination threat to plumbing fixtures and appliances connected to the drain line. Drain water may enter the remote air gap assemblythrough the outlet. The drain water may fill the outlet cavity (not pictured) where it then exits the remote air gap assemblythrough the weep hole. The check valvemay shift to a position (e.g., closed) to stop or block the drain water from flowing into the air gap housingand inlet, thereby preventing the possible contamination of water supplies or devices in fluid communication with the remote air gap assembly.

In this use, the check valvemay allow the weep holeto drain to a higher elevation, such as into a sink basin, than if no check valve were implemented, allowing the remote air gap assemblyto be placed in remote locations, such as under a counter, in a drawer or tip-out apron, or other remote locations. In an exemplary use, the remote air gap assemblymay be placed under a counter and the weep holemay be connected to a drain of a sink above. The check valvemay then prevent back pressure from the higher elevation fluid from moving the backflow drain water into the air gap housing, out the inlet, and then into a clean device like water filtration system or dishwasher, for example.

In examples where the weep holeis configured to drain to a lower elevation, the check valvemay act as a safety backup, because in this configuration, the air gap between the weep hole and air gap housingshould prevent the fluid from rising above the weep hole.

In a non-limiting example, and referring to, a blocked outletcondition may arise, for example, if there was a blockage in the outlet cap opening (not pictured). Another example when a blocked outlet condition may arise is if there is a blockage somewhere further down the drain line causing a backup such that no more fluid may enter the drain line. In this operating condition, fluid may enter the remote air gap assemblythrough the inletand then into the air gap housing. The fluid may then move through the check valve (not pictured) and out the weep hole.

In, a plumbing schematic of an exemplary plumbing systemis depicted and may include a remote air gap assemblywith a filtered faucetthat may not include a weep hole. In a normal operating condition (), a water linemay be connected to a water filter system. The water filter systemmay filter the water and dispense filtered waterout the filtered faucet. Wastewater, or brine water, may be a biproduct of the water filter systemfrom filtering the water. The brine watermay be dispensed into the inletof the remote air gap assembly, which may be installed remotely, such as under the sink, or on top of the counter, for example. The brine watermay exit the remote air gap assemblythrough the outlet. The outletmay be fluidly connected to the drain water line(either directly or indirectly), allowing the brine waterto be discarded.

In a backflow condition, in which the drain water linereverses direction, the check valve (not pictured) of the remote air gap assemblymay prevent drain water from entering the air gap housingand inlet, as previously described above. In such an exemplary use, the remote air gap assemblymay prevent drain water and/or brine waterfrom entering into the water filter system, which could potentially damage the water filter systemor contaminate filtered water. The drain water instead may exit the weep holeof the remote air gap assembly. The weep holemay be plumbed to a sink, which may allow the backflowing drain water to bypass the water filter system.

In a blocked outlet condition, the brine waterfrom the water filter systemmay enter the remote air gap assemblythrough the inlet. After moving across the air gap housing, the brine watermay enter the outlet, where a blockage in the outlet cap opening or drain water linemay restrict or stop further flow. The brine watermay then be expelled through the weep hole, which may be connected to a sink(directly or indirectly). In such an operation, the bypass of the drain water linemay prevent a potential backflow of brine waterinto the water filter system, which may damage the systemor contaminate filtered water.

Referring to, a plumbing schematic of an exemplary plumbing systemis depicted and may include a remote air gap assemblywith a filtered faucetwith a weep hole. In normal operating conditions, water from a water linemay be fluidly connected to a water filter system. The water filter systemmay filter the water and the filtered wateris configured to be dispensed out the filtered faucetwith a weep hole. Wastewater, or brine water, may be a biproduct of the water filter systemfrom filtering the water. The brine watermay be dispensed into the inletof the remote air gap assembly, which may be installed remotely, such as under the sink, or on top of the counter, for example. The brine watermay exit the remote air gap assemblythrough the outlet, which may fluidly connected (directly or indirectly) to the drain water line, allowing the brine waterto be discarded.

In a backflow condition, in which the drain water linereverses direction, the check valve (not pictured) of the remote air gap assemblymay prevent drain water from entering the air gap housingand inlet, as previously described above. In such an example, the remote air gap assemblymay prevent drain water and/or brine waterfrom entering the water filter system, which could potentially damage the water filter systemor contaminate filtered water. The drain waterinstead may exit the weep holeof the remote air gap assembly. The weep holemay be plumbed via a weep hole lineto the weep hole (not shown) formed in the filtered faucet. The weep hole in the filtered faucet, for example, may dispense the drain water into the sink.

In a blocked outlet condition, the brine waterfrom the water filter systemmay enter the remote air gap assemblythrough the inlet. After moving across the air gap housing, the brine watermay enter the outlet, where a blockage in the outlet cap opening (not pictured) or drain linemay restrict or stop further flow. The brine watermay then be expelled through the weep hole, into the weep hole lineto the weep hole (not pictured) in the filtered faucet. In such an operation, the bypass of the drain water linemay prevent a potential backwash of brine waterinto the water filter system, which may damage the systemor contaminate filtered water.

The schematics ofare provided as non-limiting exemplary uses of the remote air gap assembly. It is to be appreciated that the remote air gap assemblymay also be used with other devices, like a dishwasher or garbage disposal, to prevent backflow or blockages from contaminating the device.

The present disclosure relates to fluid backflow prevention systems and associated operational modes for use with common household plumbing fixtures, such as sinks, filter systems, garbage disposals, water softeners, and dishwashers, to name a few. In an example, a remote air gap assembly may be installed in a new or existing plumbing system to prevent fluid backflow and subsequent contamination. The presently disclosed remote air gap assemblies may be placed below or above the counter and may be retrofittable with faucets. As a result, faucets may utilize sleeker designs because they no longer need an internal air gap. Additionally, the design and manufacturing costs of new faucets may be reduced because the internal air gap system is no longer needed. Also, the remote air gap assembly, when placed below the counter, may increase counter space and provide a more aesthetically pleasing kitchen design. Further, maintenance to a remote air gap assembly may be simpler, and if needed, it may be cheaper to replace a remote air gap assembly than replace an entire faucet with an internal air gap system.

The disclosure may be embodied in other specific forms without departing from the essential attributes. Therefore, the illustrated examples should be considered illustrative and not restrictive in all respects. Any claims provided herein are to ensure adequacy of the present application for establishing foreign priority and for no other purpose.

Various examples of systems, devices, and methods have been described herein. These examples are given only be way of example and are not intended to limit the scope of the claimed disclosures. It should be appreciated, moreover, that the various features of the examples that have been described may be combined in various ways to produce numerous additional examples. Moreover, while various material, dimensions, shapes, configurations, locations, etc. have been described for use with disclosed examples, others besides those disclosed may be utilized without exceeding the scope of the claimed disclosures.

Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual example described above. The examples described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the examples are not mutually exclusive combinations of features; rather, the various examples may comprise a combination of different individual features selected from different individual examples, as understood be persons of ordinary skill in the art. Moreover, elements described with respect to one example may be implemented in other examples even when not described in such examples unless otherwise noted.

Any incorporation of reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112 (f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.