Recirculating Shower System

Abstract

There is described a shower system that includes a showerhead fixture and a base connected by conduits. The showerhead fixture includes an inlet for receiving pressurized water. A diverter is configured to divert at least a portion of the pressurized water to the base. The showerhead fixture also includes a second inlet fluidly connected to a recirculating showerhead portion with a plurality of showerhead jets for expelling mixed water received from the base. The base is configured to create a reservoir of water on a shower floor and includes a venturi pump capable of using pressurized water from the showerhead fixture to draw in water from the reservoir into the stream of pressurized water. The mixed water is sent from the base to the jets in the showerhead fixture to thereby increase the volume of water expelled from the showerhead.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation-in-part of U.S. Provisional Patent Application No. 63/383,060, filed Nov. 9, 2022, and entitled “Recirculating Shower System,” the entire disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The systems, devices, and methods described herein relate generally to the concurrent recycling of a fluid. More particularly, the systems, devices, and methods described herein relate to recirculation showers.

BACKGROUND

People in many parts of the world bathe by showering. This often involves positioning oneself under falling water in a basin that collets the water into a drain. The water helps wet one's body and is used to rinse dirt, soap, and other items from the body while cleaning oneself.

Water conservation is a significant concern for many people, especially those who live in a dry climate or do not have constant access to municipal or well water. Another group is those who are concerned about water disposal, such as those who are not constantly connected to a sewer system like people with septic systems or grey water storage tanks. One group affected by both limited access to water and limited access to water disposal is those who travel with RV's and camper trailers. Both types of accommodation generally provide self-contained living arrangements and have tanks to carry limited volumes of clean water, grey, and/or black water.

SUMMARY

There is described a shower system that includes a showerhead fixture, a base and first and second conduits running therebetween. The showerhead fixture includes a first showerhead fixture inlet for receiving a supply of pressurized water. A diverter is configured to divert at least a portion of the pressurized water through an outlet into a first end of the first conduit. The showerhead fixture also includes a second inlet for receiving mixed water into a recirculating showerhead portion from a second end of a second conduit, as well as a plurality of showerhead jets for expelling mixed water received into the recirculating showerhead portion. The base is configured to rest on a shower floor and includes a first base inlet for receiving the at least a portion of the pressurized water through a second end of the first conduit. The base also includes a venturi pump that receives the at least a portion of the pressurized water at its inlet and draws water from the shower floor through an intake, which drawn water had been previously expelled from the showerhead fixture. The base further includes a base mix chamber, wherein the at least a portion of pressurized water and the drawn water from the shower floor are mixed, together with a base outlet through which the water mixed in the base mix chamber exits into the first end of the second conduit. In operation, the at least a portion of the pressurized water and the venturi pump are used to draw water from the shower floor and thus mix the at least a portion of the pressurized water with the drawn water to thereby provide an increased volume of water expelled through the showerhead jets.

Further aspects and embodiments are provided in the foregoing drawings, detailed description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are provided to illustrate certain embodiments described herein. The drawings are merely illustrative and are not intended to limit the scope of claimed inventions and are not intended to show every potential feature or embodiment of the claimed inventions. The drawings are not necessarily drawn to scale; in some instances, certain elements of the drawing may be enlarged with respect to other elements of the drawing for purposes of illustration.

FIG. 1 is an isometric view showing a top, front, and side view of a first embodiment of a shower system.

FIG. 1A is an isometric view showing a top, front, and side view of a second embodiment of a shower system.

FIG. 2 is a top, front, and side isometric view showing an embodiment of a base that can be used in the shower system in FIG. 1.

FIG. 3 is a rear cross-sectional view of the venturi pump of FIG. 2.

FIG. 4 depicts an exploded view of an embodiment of a base, as viewed from underneath.

FIG. 5 depicts a bottom view of portions of the base in FIG. 4.

FIG. 6 depicts a front view of an embodiment of a showerhead with separate portions for freshwater and recirculated water.

FIG. 7 depicts a cross section of the showerhead in FIG. 6.

FIG. 8 depicts, in isometric view, multiple embodiments of nozzles used in conjunction with a venturi pump in an embodiment of a base of a recirculating shower.

FIG. 9 depicts, in cross section, two states of an embodiment of a nozzle used in an embodiment of a shower system.

FIG. 10 is a top, front, side isometric view showing the top of an embodiment of a base of a recirculating shower.

FIG. 11 is a bottom, front, side isometric view of the bottom of the base of FIG. 10.

DETAILED DESCRIPTION

The following description recites various aspects and embodiments of the inventions disclosed herein. No particular embodiment is intended to define the scope of the invention. Rather, the embodiments provide non-limiting examples of various compositions, and methods that are included within the scope of the claimed inventions. The description is to be read from the perspective of one of ordinary skill in the art. Therefore, information that is well known to the ordinarily skilled artisan is not necessarily included.

Definitions

The following terms and phrases have the meanings indicated below, unless otherwise provided herein. This disclosure may employ other terms and phrases not expressly defined herein. Such other terms and phrases shall have the meanings that they would possess within the context of this disclosure to those of ordinary skill in the art. In some instances, a term or phrase may be defined in the singular or plural. In such instances, it is understood that any term in the singular may include its plural counterpart and vice versa, unless expressly indicated to the contrary.

As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, reference to “a substituent” encompasses a single substituent as well as two or more substituents, and the like.

As used herein, “for example,” “for instance,” “such as,” or “including” are meant to introduce examples that further clarify more general subject matter. Unless otherwise expressly indicated, such examples are provided only as an aid for understanding embodiments illustrated in the present disclosure, and are not meant to be limiting in any fashion. Nor do these phrases indicate any kind of preference for the disclosed embodiment.

As used herein, “fresh water” and “pressurized water” are meant to refer to water that flows into the recirculating shower system from the upstream supply of fresh water. It is generally pressurized above the environmental, atmospheric pressure the shower system operates in.

As used herein, “gpm” and “GPM” are an abbreviation for “gallons per minute”, a fluid flow rate expressed in gallons per minute. In other words, it is how many gallons of a fluid pass through a portion of a fluid system. GPM is typically used to describe liquid flow, but not very often to describe gas flow. GPM is often a good estimate for how much material a liquid system is processing. But because the density of a gas is significantly affected by its pressure, gpm doesn't provide an easy-to-understand estimate of material processed in gas systems. As a general example, consider a connector with 2 inlets and 1 outlet. If the first inlet is receiving 1 gpm of water and the second inlet is receiving 2 gpm of water, then 3 gpm of water is going out the outlet.

As used herein, “mph” and “MPH” are an abbreviation for miles per hour, a measure of velocity expressed in miles per hour.

As used herein, “showerhead” is meant to refer to a device which receives a fluid at an inlet and expels the fluid into the environment outside the showerhead, such as through one or more nozzle, jet, or hole (nozzle and jet can be used interchangeably). A shower head may include a mix chamber. The mix chamber often has a different cross-sectional area from the inlet and/or nozzle(s), jet(s), or hole(s), which causes the fluid to mix with itself before going out of the showerhead. For bathing showers, the fluid is water and the water is generally expelled into air to fall down to a tub, basin, or other surface that catches and controls the flow of the water.

As used herein, “venturi effect” is meant to refer to the phenomenon where a fluid flows through a constriction, causing the fluid's pressure to drop. This can happen, for example, if a fluid flows through a tube, the tube necks down, and the necked-down portion has a smaller cross-sectional area and has a lower pressure than the upstream portions of tube. The venturi effect can be used to passively draw additional fluid (liquid or gas fluid) or other materials into the fluid stream.

Recirculating showers are a common means to reduce the consumption of a reusable fluid. They are commonly used in water showers when water supplies are low or are hard to replenish. Some recirculating showers requires a pump to move fluid from the bottom of the tub or basin that collects and contains the wastewater from the shower. Pumps typically require electrical power to move a motor that drives the pump. In some of the most common applications of recirculating showers, power is also a limited resource. In such scenarios, recirculating the water becomes a balancing act between the consumption of two limited resources—water and electricity.

Herein we disclose a recirculating shower system that does not require the use of electricity and maintains the benefits of reducing fluid consumption. Additionally, we decrease mechanical complexity over motor driven pumps by using the venturi effect to power the pump.

In general terms, the recirculating shower system comprises a showerhead fixture and a base. The fixture has an inlet that receives pressurized water. Downstream from the inlet is a diverter which can selectively divert water to a showerhead and/or to a conduit through which the pressurized water travels to the base. A second conduit directs a mixture of pressurized water and recirculated water drawn from the shower floor back to the fixture. The second conduit feeds either the same showerhead as the diverter or a second showerhead. By feeding a second showerhead, the second showerhead can be one which can better handle the increased fluid flow coming from the base. For example, the second showerhead may provide more and/or larger shower jets for the mixture to leave the showerhead than were present on the first showerhead.

In one embodiment, the fixture has a showerhead with separate portions feeding separate sets of jets; one portion receiving a flow of pressurized water from the diverter and another receiving a combined flow of pressurized and recirculated water. This embodiment may have a smaller portion for the pressurized water than for the combined flow. It may also have smaller, fewer, or lower flow jets, nozzles, or other openings. In one embodiment, the portion for the pressurized flow and the portion for the combined flow are separated with a double wall design and the space or cavity formed by the double wall may have an opening to drain any pressurized or combined water that may leave its respective portion.

In an alternative embodiment, the fixture is configured with a first showerhead mounted to the diverter by a rigid conduit which both holds the showerhead and transports fluid from the diverter to the first showerhead. In one embodiment, the fixture is configured so a second showerhead is fed by a conduit from the base, but allows the second showerhead to mount to a structure supported by the diverter.

The conduit is anything which provides a fluid pathway between the showerhead fixture and the base and generally preserves the pressure and flow rate of the fluid between the fixture and base. Examples of a conduit include a hose, a line, a pipe, or custom hydraulic system with an inlet and outlet. Preferably, the conduit is a plastic clad hose, with the plastic being chrome plated.

The base sits in a reservoir. The reservoir is typically formed on the shower floor, which may be a basin, tub, or other surface. The base receives pressurized water from the first conduit, uses the pressurized water to create a venturi effect which draws water into the pressurized water stream from a reservoir fed by the showerhead(s), and feeds the showerhead(s) with the mixture of pressurized water and recirculated water through a second conduit.

FIGS. 1 and 1A show embodiments of a recirculating shower system 100 and 100A, basin 190, and upstream mixing valve 015. In FIG. 1, recirculating shower system 100 includes diverter 110, freshwater showerhead 120, freshwater supply line 130, base 140, return line 150, and recirculation showerhead 160.

In FIG. 1A, recirculation shower system 100A includes diverter 110A, showerhead 121A, freshwater supply line or conduit 130A, base 140A, and return line or conduit 150A. Showerhead 121A includes freshwater portion 120A and recirculation portion 160A. Additionally, FIG. 1A depicts a hose management system that includes attachments, such as clips 132 that capture freshwater supply line 130A and the return line 150A.

Mixing valve 015 is upstream from recirculating shower system 100 and controls the flow of fresh water to recirculating shower system 100. As is typical, the mixing valve 015 mixes the cold and hot water supply to thereby adjust the temperature of the water reaching the shower system. Fresh water enters recirculating shower system 100 at diverter 110. During use, water exits shower system 100 through freshwater showerhead 120 and/or recirculation showerhead 160 and collects in basin 190. Base 140 covers the drain in basin 190, forming a reservoir of water in the basin from which to draw for recirculation. A drain on base 140 controls the height of the reservoir. Recirculation shower system 100A operates similarly to recirculation shower system 100. A notable exception is that freshwater showerhead 120 and recirculation showerhead 160 are integrated into a single showerhead, showerhead 121A, with freshwater portion 120A and recirculation portion 160A replacing their respective showerheads.

When recirculation showerhead 160 is receiving recirculated water, diverter 110 directs pressurized freshwater into supply line or conduit 130, base 140, and return line or conduit 150. Return line 150 feeds recirculating showerhead 160. As the pressurized water passes through base 140, it powers a venturi pump inside base 140. The venturi pump mixes reservoir water with the stream of fresh water to increase the amount of water flowing to return line 150 and recirculating showerhead 160. Again, recirculation system 100A operates similarly to recirculation system 100 with recirculation portion 160A replacing recirculation showerhead 160.

When recirculation showerhead 160 is not receiving recirculated water, water that is instream between diverter 110 and recirculating showerhead 160 may drain out through the portion of base 140 that intakes water from the basin. This drainage may serve to backflush or backwash any filtering system that helps clean the water in the basin before the water gets recirculated to the recirculation showerhead 160 while the recirculation system is operating. In some embodiments, pressurized freshwater may be used to backwash the filtering system that helps clean the basin water before it recirculates. This may be done by restricting the flow from base 140 out recirculation showerhead 160. Another way to do this is to force pressurized freshwater into base 140 from the side of the venturi pump that feeds return line 150. Alternatively, the base is designed with a removable, washable mesh or screen which can be rinsed, washed by hand, put in the laundry, or replaced. In one preferred embodiment, a mesh screen is used that has a threshold around 25-35 microns, preventing anything that size or larger from passing from the reservoir into the base. Alternatively, a mesh screen is used that has a threshold around 40-125 microns. The mesh can be made from many materials and of many designs. In one embodiment, a mesh screen is used which is made of Nylon, such as a 25 or 35 micron Nylon mesh screen. In another embodiment, the mesh screen is metal, such as 40-125 micron stainless steel over molded with a silicone frame. Again, recirculation system 100A operates similarly to recirculation system 100 with recirculation portion 160A replacing recirculation showerhead 160.

FIGS. 2 and 3 depict an embodiment of base 200, which sits in a reservoir when recirculating water. FIG. 2 shows an isometric view of base 200, as shown from above, with the front edge depicted in the bottom left portion of the figure, inlet 210 on the left, outlet 220 on the right, portion 230 near the top right, and dam 240 on the top of base 200. FIG. 3 shows base 200 from behind with a cross-section cut through portion 230 and components of base 200 on the same geometric plane. Inlet 210 is on the right side of the figure, outlet 220 is on the left side of the figure, and lower dam 260 is on the underside of base 200. Lower dam 260 lines up with dam 240. More preferably, lower dam 260 is concentric with dam 240, but because of the angle in which lower dam 260 expands in the downward direction, lower dam 260 cannot be seen through the hole in base 200 inside dam 240. In one embodiment, the exterior shape of lower dam 260 is conical. Preferably, the interior of lower dam 260 is conical. In one embodiment, the slope of the interior cone is within 10 degrees of the slope of the exterior cone.

Base 200 receives pressurized water at inlet 210 and expels a mixture of pressurized and reservoir water at outlet 220. In some embodiments, having inlet 210 and outlet 220 on opposing sides of dam 240 provide stability to the base. Piping or other internal pathways fluidly connect inlet 210 to portion 230 and portion 230 to outlet 220. Portion 230 houses components which operate as a venturi pump to create the venturi effect, draw reservoir water into the freshwater stream, and send the mixture of reservoir and fresh water to outlet 220. In other words, within portion 230, the pressurized water received from inlet 210 is used to create a venturi effect which draws water from the reservoir into the stream of outgoing water. The mixture of pressurized and reservoir water then flows to outlet 220 where it exits base 200.

There are many ways to connect fluid hoses to each other or a device such as base 200, a diverter, or a showerhead. In one preferred embodiment, inlet 210 and outlet 220 are thread so hoses can thread onto them and respectively act as a freshwater supply line and a return line.

In one preferred embodiment of base 200, the piping connecting inlet 210 with portion 230 and the piping connecting portion 230 to outlet 220 have the same internal diameter. However, the threading on outlet 220 is larger than the threading on inlet 210 to accommodate using a hose with a larger diameter for the return line to feed the recirculating showerhead than the fresh water supply line coming from the diverter. Alternatively, the pathways are different sizes. For example, the pathway from inlet 210 to portion 230 may be approximately the same size as a hose that connects to inlet 210 while the pathway connecting outlet 220 and portion 230 may be approximately the same size as a larger hose that connects to outlet 230.

Visible on the top side of base 200 is the ring-shaped dam 240. Alternatively, dam 240 is flush with or lower than the surrounding elements of base 200. Preferably, dam 240 and lower dam 260 are positioned above the open drain in the basin. As the reservoir level rises, the reservoir approaches dam 240 from outside the ring. Once the reservoir reaches the height of the top of dam 240, the reservoir flows over and into the ring. Additionally, the design of dam 240 allows foam, froth, oil, and particulates floating on the reservoir to decant into the basin drain.

Many drains are of a standard 1.5″ diameter size. Sometimes, a drain plug or stopper is installed in a drain and can be used to selectively stop water from draining from a basin. Alternatively, a plug or stopper is installed to stop water from draining and removed to allow water to drain. Preferably, the combination of dam 240 and lower dam 260 have a large enough diameter or cone to fit over a drain and any device used to stop the flow of water into the drain. More preferably, the dam has an inner diameter of 2.5″ going through the top of the base.

The underside of base 200 is generally open to the reservoir of water in the basin. Preferably this opening is covered by a filtering system, such as a screen or filter to prevent debris and other contaminates from being recirculated. In one preferred embodiment, the filtering system comprises a screen which covers the bottom of base 200 during use, but is removable for maintenance. This maintenance could involve cleaning or replacing the screen. The maintenance could also involve accessing, cleaning, and/or clearing the intake to the venturi pump. It may also include doing the same inside the venturi pump.

There is an opening between the underside of base 200 and portion 230 which serves as an intake. The intake feeds reservoir water into a mix chamber where reservoir water can enter the water stream going to the recirculation showerhead.

When backwashing the filtering system, there are multiple ways to force pressurized freshwater out the inlet within portion 230. One embodiment includes a valve which restricts or stops flow to outlet 220 being built into base 200 on or downstream from portion 230. This would allow pressurized freshwater to enter portion 230 and exit base 200 to the reservoir through the intake and filtering system. Alternatively, a valve may be used downstream from outlet 220 which restricts or stops flow out of outlet 220 and similarly forces freshwater out of base 200 through the reservoir intake to backwash the filtering system. Alternatively, pressurized freshwater may be diverted into outlet 220 instead of inlet 210. This will result in at least some of the fresh water exiting base 200 through the intake in portion 230. And as mentioned elsewhere herein, turning off the flow of pressurized water to base 200 could allow water in the hose(s) to drain through the intake of base 200.

FIG. 3 shows base 200 with a cross-section cut through portion 230 and components of base 200 on the same geometric plane. It shows that the pressurized water entering base 200 at inlet 210 gets necked down through nozzle 232, increasing the velocity of the pressurized water as it enters mix chamber 234. The high velocity stream of water is directed at and passes through throat 235 and into expansion chamber 236. Mix chamber 234 is fluidly connected to the reservoir of water through intake 238 in interior surface 242, filter or screen 280, and the open space between filter or screen 280 and interior surface 242. As the high velocity stream passes through mix chamber 234, it forces reservoir water toward and through throat 235, adding recirculated reservoir water to the water leaving base 200 through outlet 220.

As mix chamber 234 narrows to throat 235, the resulting venturi effect draws additional reservoir water into the stream of water, significantly increasing the amount of water that gets recirculated in a given time period. For example, real world tests consistently showed that 1 gpm of pressurized water going in inlet 210 can result in 1.5 gpm to 3.5 gpm of water going out outlet 220 to the recirculating showerhead. These results vary, in part, depending on the pressure of the water supply and the design dimensions for the geometry of base 200 and its manufacturing material(s), method(s), and quality.

Preferably, the space between interior surface 242 and filter or screen 280 is filled by the reservoir of water feeding intake 238—this space may be thought of as a reservoir chamber. Preferably, this optimally uses the suction created by the venturi pump to pull reservoir water into the mixture of water exiting base 200 through outlet 220. In one preferred embodiment, the distance between interior surface 242 and filter or screen 280 is 0.1″.

There are many possible geometries for the base, diverter, showerhead(s), and hoses/lines. The possibilities include the lengths and internal diameters for the sections that carry fluid; the connectors of the various parts of the recirculation shower system; the angles and lengths of flow diversion, constriction, and expansion; the shape of the various chambers (include the mix chamber, expansion chamber, and reservoir chamber); and the roughness and other finishes applied to the various surfaces. The selection of the various geometries within the system depends on many factors, some of which are beyond the scope of the invention, including engineering design, external market conditions and restraints, available manufacturing and production options and their relative costs in time and money.

In one embodiment, the diameter going from inlet 210 to nozzle 232 is constant. Preferably, the diameter is at least 0.25″. Preferably, inlet 210 connects to a standard 0.5″ shower hose, which has an internal diameter of 0.25″. For application with a bathing shower, a smaller diameter may restrict the flow, resulting in energy loss and a potentially slower jet from nozzle 232 into mix chamber 234.

In one embodiment, the exit diameter of nozzle 232 is 0.075″. For this application of the invention, this diameter plays a significant role in determining the consumption of pressurized water by the recirculation shower system.

In FIG. 3, both the inside and outside of nozzle 232 are depicted as tapering down to the exit into mix chamber 234. The angle is generally between 30 degrees and 50 degrees, though other angles can be used. The inside taper could be removed (as with a flat face that has an exit hole going to the exit of nozzle 234) without affecting the consumption of pressurized water. This also suggests that this smaller diameter run does not have to be straight but could be curved. The taper of the outside of nozzle 232 is also not necessary. Tests with this geometry have shown the conic shape on the outside of nozzle 232 helps control the suction of reservoir water from intake 238 into mix chamber 234.

FIGS. 4 and 5 depict an embodiment of base 400, which is similar to base 200. FIG. 4 depicts an exploded view of base 400 as viewed from below. It includes housing 414, nozzle 432, diffuser 437, gasket 439, midsection 442, filter 480, and lower dam 460. Housing 414 includes inlet 410, outlet 420, and dam 440. Midsection 442 includes intake 438, which is an opening that can fluidly connect spaces on either side of intake 438, such as the space between nozzle 432 and diffuser 437.

FIG. 5 is a bottom view of nozzle 432 and diffuser 437 in housing 414. Diffuser 437 includes necking portion 434, throat 435, and expansion chamber 436. Inlet 410 fluidly connects to an opening on the right-hand side of nozzle 432. An opening on the left-hand side of nozzle 432 fluidly connects with and points toward throat 435. The space between nozzle 432 and necking portion 434 fluidly connects nozzle 432, throat 435, and intake 438. Outlet 420 fluidly connects with the left-hand side of diffuser 436. Notable differences of base 400 relative to base 200 include the method of construction, the general size, changes in the location of the venturi pump relative to the dam, the exit opening of nozzle 432 being inside the space created by necking portion 434, nozzle 432 and diffuser 437 each being independently removable from base 400, and the depiction of an alternative assembly method using screws.

One embodiment of Filter 480 includes frame 484 supporting mesh 482. For example, frame 484 could be attached to or formed around mesh 842. Many materials could work for either the frame or the mesh. In one embodiment, mesh 482 is a fine mesh of a durable material such as plastic or metal—the material and filter material size threshold should be selected, at least partially, based on the application as well as manufacturing processes. For higher heat processes, metal such as aluminum or stainless steel may be the best choice. In one embodiment, frame 484 is overmolded around mesh 482. In one embodiment, frame 484 is silicone or another similar material that can be deformed to fit around a portion of base 400 to attach filter 484 to base 400. In one embodiment, frame 484 attaches to or near the bottom of base 400.

FIGS. 6 and 7 depict an embodiment of a single showerhead that has two different portions. Each portion has a set of nozzles or jets to expel water which are separate from those of the other portion. The number of nozzles, jets, and other orifices; their size(s); and their locations depend on various design characteristics, including desired flow and pressure exiting the showerhead. FIG. 6 depicts the front of showerhead 621. In the depicted showerhead, the fresh water nozzles 624 are arranged in an inner circle of the showerhead. Recirculation nozzles 664 are arranged in a concentric outer circle. Six outlet nozzles are also located in the outer ring. Alternatively, there are no nozzles in the outer ring.

FIG. 7 depicts a cross section of showerhead 621. Showerhead 621 includes freshwater section 620 and recirculation section 660. Recirculation intake 662 fluidly connects with the plurality of recirculation nozzles 664 in recirculation section 660. Recirculation intake 662 is designed to attached with a hose or other conduit from the base. In one embodiment, intake 662 has threads to facilitate attaching to a hose or other conduit. The threading may be of non-standard size to accommodate a larger hose size. Freshwater intake 622 fluidly connects with a plurality of freshwater nozzles 624 in freshwater section 620 and is designed to attach to a pipe, hose, or other conduit from the freshwater supply. Surfaces of freshwater section 620 and recirculation section 660 are separated by cavity 680, which prevents water in either recirculation section 660 or freshwater section 620 from entering into the other if the barrier between them fails. Cavity drain 682 allows fluids in cavity 680 to drain out and maintain atmospheric pressure in the cavity.

FIGS. 8A and B depict two styles of nozzle that could be integrated into the shower system, including the venturi pump in the base. Each nozzle has an opening at the exit and the size of the opening determines the size of the jet exiting the nozzle. FIG. 8A shows nozzle 810 with base 816 and exit 818. If nozzle 810 is made from a single, rigid material, then exit 818 will have a roughly fixed exit diameter. If nozzle 810 is made from a somewhat flexible material, then the exit diameter could change in response to the pressure of the fluid or gas exiting nozzle 810. FIG. 8B shows nozzle 850 with base 856, diaphragm 852, exit 858, and housing 854. Housing 854 is made from a relatively rigid material. Diaphragm 852 is made from a relatively flexible material and the diameter of exit 858 can change depending on the pressure applied to diaphragm 852. There are many acceptable material choices for both the rigid and flexible materials. Preferable, each material will be selected based on the specifics of the application. For example, metal, plastic, rubbers, and ceramics could all work well. In one preferred embodiment, rigid parts are made from steel, aluminum, or plastic. In one preferred embodiment, rigid parts of the nozzle are made from ABS. In one preferred embodiment, flexible parts are made from rubber, plastic, or thin metal. In one preferred embodiment, the flexible portion is rubber. More preferably, it is EPDM with a hardness of about 60A durometer. The operation of nozzle 852 is described in greater detail below with reference to FIG. 9.

FIGS. 9A and 9B depict cross sections showing two states of a diaphragm or gasket in an embodiment of nozzle 850 in FIG. 8B. FIG. 9A depicts nozzle 850 with minimal to no pressure differential being applied to diaphragm 852A. FIG. 9B depicts nozzle 850 with a pressure differential being applied to diaphragm 852B: higher pressure 901 being applied to the left side of diaphragm 852B pushes diaphragm 852B to the right, causing it to deform and changing the diameter from exit 858A to exit 858B. As diaphragm 852B deforms, the opening in the diaphragm decreases, constricting the flow of material from left to right as the pressure differential increases. For example, in one embodiment, the opening diameter is approximately 0.11″ without a pressure differential, but a pressure differential of 80 psi reduces the opening diameter to approximately 0.075″. When the nozzle is used to create the jet of high velocity water which operates the venturi pump, the dynamic size reduction caused by the pressure differential helps to provide a consistent amount of water consumption across varying supply pressures. Preferably, the design is custom, based on the application. Incorporated herein by reference are nozzles by Nelson Irrigation Corp. called FCN® Flow Control Nozzle, including a pdf describing them found at https://nelsonirrigation.com/library/IM_FLOW-CONTROL.pdf.

In embodiments similar to that depicted in FIG. 3, the design of the mix chamber may have a significant effect on the overall performance of the recirculating shower system. In one preferred embodiment, the mix chamber wall is designed generally with a circular arc. More preferably, the mix chamber wall is designed with a 0.325″ circular arc. In designs similar to FIG. 3 have shown a circular arc of 0.325″ provides optimal flow out of the outlet.

The geometry of throat 235, particularly the cross-sectional area open to the flow of the mixed water, affects the flow performance of the recirculating shower system. In one embodiment, throat 235 is cylindrical. In one embodiment, the diameter of throat 235 is approximately 0.2″. In one embodiment, the length of throat 235 is 0.5″ long. This diameter and length is optimal for the scale and design depicted in FIG. 3.

The angle of the walls of expansion chamber 236 relative to throat 235 helps with the gradual change in the velocity of the water mixture. Namely, going into throat 235, the jet of pressurized water exiting nozzle 232 is high velocity and the reservoir water being sucked into mix chamber 234 through intake 238 is low velocity. Preferably, expansion chamber 236 grows from the diameter of the exit of throat 235 to the inside diameter of outlet 220. Most preferably, the angle of expansion chamber 236 is 16 degrees.

Preferably, the internal diameter of outlet 220 is larger than the internal diameter of inlet 210. More preferably, the internal inlet diameter is 0.25″ from the opening of 210 to nozzle 232 and the internal outlet diameter is 0.55″ between expansion chamber 236 and the exterior opening of outlet 220. Other diameters can work. One reason for these diameters is in anticipation of the recirculation showerhead being about 6 feet above the basin. Preferably, the water has about 8-10 psi as it leaves expansion chamber 236. This 8-10 psi is used to lift the water up to the recirculating showerhead and then provide the water with at least some velocity as it exits the recirculation showerhead. In this scenario, the preferred diameter of intake 238 is 0.55″. In another preferred embodiment, the internal diameter of outlet 220 is the same size as the internal diameter of inlet 210. Alternatively, the internal diameter of outlet 220 is smaller than the internal diameter of inlet 210.

There are many possible materials from which the components of the recirculating shower system can be made. The selection of which materials to make the various parts from and the manufacturing processes to use will depend upon many factors, some of which are outside the scope of invention, including the geometry of the base and its subcomponents, the fluid being recirculated, the environment in which the recirculating system is operating, the temperature of the operating fluid, desired life of the parts, ability of the parts to perform primary and secondary functions, the relative availability and costs of the materials and associated manufacturing process options, geopolitics and production locations, shipping costs, cosmetic appeal, and other market constraints, to name a few. At present, it is preferred that all visible parts are made from a rigid plastic and chrome plated.

Regarding the base, its primary functions include being submersed in a reservoir of fluid, i.e. the basin of a shower stall or bathtub, controlling the flow of pressurized fluid, and using the pressurized fluid to operate a venturi pump to draw fluid from the reservoir into the outgoing stream. These functions have the potential of transferring high stresses to the base material and subjecting it to various types of physical and chemical wear. There are many materials and accompanying manufacturing processes that will allow the base to withstand these effects for its desired life. As noted above, some of the factors which drive the selection of the material or materials and manufacturing processes used to make the base are outside the scope of the invention. Preferably, the base is made from metal and/or plastic parts.

In one preferred embodiment for a bathing recirculating water shower, the base is made of plastic. More preferably, the base is made of ABS or TPU. An alternative preferred material for the base is metal. More preferably, the metal is aluminum or stainless steel. One preferred manufacturing method is injection molding. An alternative preferred manufacturing process is 3D printing. With one preferred manufacturing process, the base is first created as subcomponents and then assembled. Alternatively, the base is manufactured as a single piece.

Regarding the diverter and showerheads, their functions include directing the flow of pressurized water (sometimes selectively), mounting to a fixed pipe or fixture, and spraying fluid into the air to create the shower of water. Again, the material(s) selected and accompanying manufacturing processes are dependent on some factors outside the scope of the invention. In one preferred embodiment, one or both showerheads and/or diverter are plastic with a chrome finish, preferably applied by electroplating. In another alternative embodiment, one or both showerheads and/or diverter are stainless steel. In one preferred embodiment, the nozzles on the showerhead are silicone and inserted into the showerhead.

The freshwater showerhead, such as 120 in FIG. 1 or 620 in FIG. 6, receives a portion or all of the pressurized water. Preferably, the freshwater showerhead has a lower design flow rate than the recirculation showerhead. More preferably, the freshwater showerhead is designed for a flow rate between 0.8 gpm to 2.0 gpm. Still more preferably, the freshwater showerhead has a design flow rate of 1.0 gpm to 1.5 gpm. In one preferred embodiment, the design flow rate of the freshwater showerhead is 1.2 gpm.

Preferably, the recirculation showerhead has a higher design flow rate than the freshwater showerhead. More preferably, the recirculation showerhead is designed for a flow rate between 1.2 gpm to 4.5 gpm. Still more preferably, the recirculation showerhead has a design flow rate of 2.4 gpm to 3.6 gpm. In one preferred embodiment, the design flow rate of the recirculation showerhead is 3.0 gpm.

In one preferred embodiment, the diverter is an industry standard diverter or is similar in structure, material, and function to an industry standard diverter, but with design characteristics specifically for use with the recirculating shower system. In one embodiment, one design characteristic is the ability to hold the recirculation showerhead, such as a holding arm.

Regarding the hoses or lines connecting the diverter, base, and showerhead, their functions include transporting fluid from one device to the next, being long enough to reach from the diverter to the base in the basin and back to the recirculation showerhead. An optional secondary function includes being flexible enough to allow the base to be moved around the basin or elsewhere in or around the shower area.

In one preferred embodiment, the lines are flexible piping. More preferably, the outer portion of the lines is stainless steel with chrome finish. Preferably, the inner portion of the line is a flexible tube. More preferably, the inner, flexible tube is thermoplastic vulcanizate rubber (TPV) or ethylene propylene diene monomer rubber (EPDM).

In one preferred embodiment, the supply line is an industry standard ½″ G thread pipe. In one preferred embodiment, the return line is a ¾″ G threaded pipe, which is not necessarily an industry standard.

FIG. 10 is a top, front, and right-side isometric view of one embodiment of the base of a recirculating shower. In a preferred embodiment, base 1000 is put in the bottom of an existing tub or shower basin to retrofit an existing shower. In this view we can see adjustable drain 1020 with movable weir 1024 that can move up and down within base 1000, thereby helping control the height of the reservoir. In a preferred embodiment, collar 1022 around the cutout that leads to the drain in the basin. Collar 1022 acts as a support for adjustable drain 1020. The cut-out also provides access to adjustable drain 1020 so the standing water in the tub can be drained without full access to the bottom of the base. In a more preferred embodiment, collar 1022 is below the top of base 1000.

Referring to FIG. 10, base 1000 includes water input port 1010 and discharge port 1030. Pressurized water flows in from a source, like an RV water tank or bathroom plumbing, into input port 1010. As it flows through base 1000, it may be mixed with water from the bottom of the tub and then exit discharge port 1030 to go to the showerhead.

FIG. 11 shows a bottom isomeric view of the same embodiment of the base of a recirculating shower as in FIG. 10. After water flows in through input port 1010, as described above, it flows through venturi pump 1040. The flow of the water through the venturi pump creates suction at “Suction In” port 1042, pulling in standing water from the bottom of the tub.

The bottom section of adjustable drain 1020 has an O-ring slot, and in a preferred embodiment O-ring 1026 creates a seal around the drain and forces a minimum depth of standing water in the bottom of the tub to the height of the weir above the O-ring. This puts the opening of “Suction In” port 1042 below the minimum depth of the water. The water from the bottom of the tub mixes with the water from the supply in and is then passed through discharge port 1030 and fed into a showerhead.

The use of a venturi pump allows for the recirculation of some of the standing water in the tub without the use of a local power supply. This kind of recirculation pump could be used in a shower fed by a tank located in a higher position, reducing the amount of water used in a shower while not using any electricity. This could be a preferred embodiment for use in a cabin or a camper that does not have electricity or an external, pressurized source of water. The use of a venturi pump also reduces mechanical complexity, which reduces maintenance costs of the recirculating shower. Slots cut into the side of base 1000 allow for free fluid flow into the base from the rest of the tub or basin.

Speaking more generally, there are many configurations of the position of the base inlet and outlet relative to the portion housing the elements that make up the venturi pump. The selection of how to configure the relative positions of the inlet, outlet, and portion containing the venturi pump will depend on a number of factors, some of which are outside the scope of the invention. These factors including the geometry of the elements making up the venturi pump, various costs, material selection, selection of manufacturing processes, design of the other elements of the recirculating shower system, and any geometry or space constraints of the basin the base is used with. As depicted in FIGS. 2 & 3, inlet 210 and outlet 220 are in front of portion 230 and open vertically while in FIGS. 1A, 4 & 5 the inlets and outlets are behind where the venturi pump is located in the base. In FIG. 1, they are in-line with the portion containing the venturi pump—the inlet opening is facing left and the outlet opening is facing right. In other embodiments similar to the base depicted in FIGS. 1-3, the inlet and outlet turn upward from either side of the portion containing the venturi pump. In other embodiments, like the one depicted in FIGS. 10-13, the base has a U-shaped portion containing the venturi pump and the inlet and outlet are positioned next to each other. Selection of the location of the inlet and outlet depends in part on the geometry of the base and internal components, the recommended hoses (or other conduits), and various other aspects outside the scope of the invention.

The mechanically simple design could also be used where fouling of a pump is a concern.

In some embodiments, alternate fluids may be used. In one embodiment, a small version of this recirculating shower is used to shower a freshly 3d printed resin miniature in isopropyl alcohol. A tank suspended above a tub provides a gravity fed supply of isopropyl alcohol. As the isopropyl alcohol flows from the shower, it cleans excess resin off of the miniature and collects in the bottom of the tub, where the venturi pump can then mix it with fresh isopropyl alcohol. This reduces the consumption of isopropyl alcohol while cleaning a resin miniature without the use of extra electricity or direct agitation by the user. This allows for lower maintenance costs and reduced exposure of the user to the resin or the resin-contaminated isopropyl alcohol. If significant fouling were to occur by resin build up within the venturi pump, a new venturi pump could be 3D printed whole and replace the fouled pump, further decreasing maintenance costs. When combined with a 3D printed showerhead, the whole system becomes easier and cheaper for a hobbyist to maintain without professional help. In this scenario, the basin may have an optionally open drain or no drain.

In some embodiments, the opening in the top of the base which is positioned over the drain in the basin is covered by an adjustable dam mechanism and blocks direct fluid flow to the drain.

In some embodiments, the venturi pump and base are built into the tub or basin.

In some embodiments, the part designs are optimized for additive manufacturing.

In some embodiments, the dam is adjustable and can alter the minimum depth of the standing water without providing free flow of water to the drain. Additionally, the dam may have one or more relatively small openings near the bottom to allow the reservoir to drain when the shower is off.

Use of the recirculating shower system can provide significant energy savings. For an example set in the mountain west of the United States, ground or tap water is 53° F., a water heater increases the temperature of the water to 103° F., a typical shower with a standard head uses up to 2.5 gpm, and a 10-minute shower will use approximately 3.1 kW/hr to heat the water. This is roughly 27 kW of power. By switching to a venturi pump recirculating shower system using 1.0 gpm, the power consumption will be approximately 2.5 times less.

During an 8-minute shower with a typical residential shower system, more than 20 gallons of water are used. Instead, using an embodiment of the venturi pump recirculating shower system can reduce this to less than 10 gallons. This is more than a 50% savings on water consumption while providing approximately 150% of flow from the recirculating showerhead compared to the typical residential shower.

In one preferred embodiment, using the recirculation showerhead results in the water expelled from the showerhead fixture being at a lower temperature relative to the pressurized freshwater because it is being mixed with water from the basin. In such cases, a user may prefer to increase the temperature of the incoming freshwater. In some tests, users preferred the incoming freshwater temperature to be around 130 degrees Fahrenheit.

In one preferred embodiment, the recirculation function can be turned off, allowing the user to rinse off with fresh water instead of recirculated water.

In one preferred embodiment, replacing an existing showerhead with the recirculating shower system involves providing the recirculating shower system preassembled, replacing the existing showerhead with the portion of the recirculating shower system comprising the diverter, and placing the base in the shower basin with the drain opening of the base positioned over the drain in the basin. Alternatively, various elements of the recirculating shower system are not preassembled, requiring they be assembled as part of installation. Alternatively, the basin does not have an open drain and the base is placed in a reservoir within the basin.

In an alternative use case, the base is not placed in a reservoir of raw, recently caught water from the recirculation showerhead. For example, the base may be placed into a different reservoir, including one which is not in the basin capturing the water from the recirculation showerhead. In this case, the recirculating shower system is adding fluid from this different reservoir. This different reservoir could still be fed from the water captured in the basin, but may perform additional processes to the water before it is recirculated, such as filtering, cleaning, changing the temperature, adding soap or other body cleaners, etc. Alternatively, the different reservoir does not include water captured from the recirculation showerhead.

In one preferred embodiment, a portion of the venturi pump in the base accelerates the freshwater stream to 70 mph. Again, the increase in velocity creates a venturi effect where the pressure in the pump is reduced and the reduced pressure sucks water from the reservoir into the stream of water exiting the base through the outlet. Additionally, the venturi pump reheats the reservoir water which has lost some of its heat after leaving the showerhead.

In one preferred embodiment, the system does not include a heat source besides the reheating inherent to mixing water in the base with the venturi pump to reheat the recirculated water. Alternatively, there are many ways to reheat water or additionally heat the water which can be integrated into the shower system. For example, there are electrically powered systems common throughout the world which use electricity to heat water. There are also fuel powered systems which burn fuel to heat the water. Other systems use a heat exchanger where a hot fluid is put in contact with a housing or piping containing the water.

In one preferred embodiment, if there is not a reservoir supplying the intake of the base, the base will not recirculate water to the showerhead fixture, but the pressurized water will still return to the showerhead fixture. This could happen if a reservoir has not formed in the basin around the base. It could also happen if the base is removed from the reservoir.

The invention has been described with reference to various specific and preferred embodiments and techniques. Nevertheless, it is understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.

Claims

1. A shower system comprising:

a showerhead fixture comprising: a first showerhead fixture inlet for receiving pressurized water; a diverter for diverting at least a portion of the pressurized water into a first end of a first conduit; a second inlet for receiving mixed water into a recirculating showerhead portion from a second end of a second conduit; and a plurality of showerhead jets for expelling mixed water received into the recirculating showerhead portion;

a base configured to rest on a shower floor, the base comprising: a base inlet for receiving the at least a portion of the pressurized water through a second end of the first conduit; a venturi pump receiving the at least a portion of the pressurized water at its inlet and drawing water from around the base on the shower floor through an intake in the base; a base mix chamber wherein the at least a portion of pressurized water and the drawn water are mixed to provide mixed water; and a base outlet through which the mixed water can exit the base into a first end of the second conduit;

whereby, in operation, the portion of the pressurized water and the venturi pump are used to draw water from the shower floor and thus mix the drawn water with the at least a portion of pressurized water, to thereby produce an increased volume of water expelled through the showerhead jets.

2. The system of claim 1, further comprising a freshwater showerhead downstream from the diverter and wherein the diverter selectively diverts the pressurized water to at least one of the freshwater showerhead and the base.

3. The system of claim 1, wherein the diverter selectively diverts the pressurized water to at least one of the recirculating showerhead portion and the base.

4. The system of claim 1, wherein the diverter can be changed by a shower system user to a non-recirculation position wherein none of the pressurized water is diverted to the base, the venturi pump is not operated, and none of the water from the shower floor is recirculated to the recirculating showerhead portion.

5. The system of claim 4, wherein the diverter can be changed by the shower system user between the non-recirculation position and multiple other positions, wherein different amounts of the pressurized water are diverted to the base and the amount of the drawn water recirculated to the recirculating showerhead portion is contingent upon the amount of pressurized water diverted to the base.

6. The system of claim 1, wherein the base further comprises a dam and wherein the dam is configured to be positioned around a drain in the shower floor and thereby create a reservoir of water around the base on the shower floor; and wherein the base is configured so the reservoir supplies the water drawn into the venturi pump through the intake.

7. The system of claim 6, wherein the dam is formed with a height selected to provide an optimum height of the reservoir while allowing suds and any debris floating on the reservoir to spill over a top of the dam and into the drain.

8. The system of claim 6, wherein the dam includes one or more holes configured to allow the reservoir to drain to the drain.

9. The system of claim 1, further comprising a filtering system upstream from the intake in the base.

10. The system of claim 9, wherein the filtering system comprises a screen integrated into the base.

11. The system of claim 10, wherein the screen is removable from the base for maintenance.

12. The system of claim 1, wherein the pressurized water has a supply flow rate going into the showerhead fixture and the supply flow rate is approximately between 0.8 and 2.0 gallons per minute.

13. The system of claim 12, wherein the supply flow rate of the pressurized water is approximately 1.2 gallons per minute.

14. The system of claim 1 wherein the showerhead fixture further comprises a recirculation showerhead, the recirculation showerhead comprises the recirculating showerhead portion, the mixed water expelled from the recirculation showerhead has a total flow rate, and the total flow rate is approximately between 1.2 and 4.5 gallons per minute.

15. The system of claim 14 wherein the total flow rate is approximately 3 gallons per minute.

16. The system of claim 1, further comprising a flow ratio comparing a fluid flow rate of water expelled from the showerhead fixture to a fluid flow rate of the pressurized water and wherein the flow ratio is between approximately 1.2 and 4.

17. The system of claim 16, wherein the flow ratio is approximately 3.5.

18. A method of recirculating bathing water comprising:

providing a venturi pump with an inlet capable of receiving pressurized water, an intake capable of drawing water from a reservoir of bathing water into the flow of pressurized water passing through the venturi pump, and an outlet capable of expelling a combination of mixed water and reservoir water from the venturi pump.

19. The method of claim 18 further comprising providing a showerhead fixture comprising a recirculation portion to be fluidly connected downstream from the outlet of the venturi pump, out of which water expelled from the venturi pump can be expelled in a shower.

20. The method of claim 18 further comprising providing a diverter to be upstream from the inlet of the venturi pump which is capable of receiving pressurized water and selectively diverting the pressurized water between two outlets, one of which outlets is to be fluidly connected to the inlet of the venturi pump.