Patent Application
20240271402
The disclosure relates to a flush valve for a toilet or a urinal, in particular to a composite flush valve.
Modern commercial sanitaryware often includes a flushometer flush valve apparatus. A flushometer may require a large water supply line to operate properly. A flushometer may employ water pressure from a source water supply line to provide a high-pressure flush.
Automatic flush valves may include a diaphragm or piston separating an upper chamber (or back-pressure chamber) from a lower chamber and a water supply. When a flush valve is in a steady state (not cycling through a flush), water pressure in an upper chamber is in equilibrium with water pressure in a lower chamber, and presses down on a diaphragm or piston in a closed position. To initiate a flush cycle in an automatic flush valve, a solenoid valve is opened, allowing water to be released from an upper chamber through the main flush valve. This results in a drop in water pressure in an upper chamber, causing a diaphragm or piston to lift, creating an opening to a main water supply, allowing water from a main water supply to flow through the main valve to a sanitaryware bowl to flush the bowl. To end a flush cycle, the solenoid valve is closed, an upper chamber is refilled with water through a small hole in a diaphragm or piston, and the diaphragm or piston returns to a closed rest position, shutting off the water supply to the sanitaryware.
Flush valves may typically be prepared from casted brass via a machining process. Resulting valves are heavy and costly to produce. Casted brass may also be subject to degradation if exposed to grey water. Flush valves also require high precision during manufacturing to provide required flush performance.
Desired are flush valves that are lightweight, are more easily manufactured with high tolerance, and which will not degrade when exposed to grey water.
Accordingly, disclosed is a flush valve assembly, comprising an inlet configured to receive inlet source water; an outlet configured to deliver flush water to a sanitaryware fixture; a housing; and a waterway insert configured to be positioned within the housing, wherein the housing comprises a first side opening configured to align with the flush valve assembly inlet, the housing comprises a bottom opening configured to align with the flush valve assembly outlet, the waterway insert comprises a first side opening configured to align with the housing first side opening, and the waterway insert comprises a bottom opening configured to align with the housing bottom opening.
In some embodiments, a housing may comprise zinc. In some embodiments, a waterway insert may comprise a thermoplastic. In other embodiments, a waterway insert may comprise stainless steel.
This disclosure is illustrated by way of example and not by way of limitation in the accompanying figures. For simplicity and clarity of illustration, features illustrated in the figures are not necessarily drawn to scale. For example, the dimensions of some features may be exaggerated relative to other features for clarity. Further, where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements.
Waterway insert 115 comprises first side opening 151 which aligns with flush valve assembly inlet 103. Waterway insert 115 comprises bottom opening 115B which aligns with flush valve assembly outlet 104. Housing 102 comprises first side opening 153 which aligns with flush valve assembly inlet 103. Housing 102 comprises bottom opening 102B which aligns with flush valve assembly outlet 104. Waterway insert comprises upper opening 115U configured to receive piston valve assembly 125. Housing 102 comprises upper opening 102U aligned with upper opening 115U. Waterway insert comprises second side opening 150 configured to receive manual actuator assembly 140. Housing 102 comprises second side opening 152 aligned with second side opening 150.
In some embodiments, a flush valve assembly housing may comprise a metal, for example die-cast zinc, brass, or stainless steel. In some embodiments, a waterway insert may comprise a thermoplastic polymer or a metal. A waterway insert may comprise an engineering thermoplastic. A waterway insert may comprise a glass-filled thermoplastic. A waterway insert may for example comprise a polyphenylene sulfide, a polyphthalamide, a polyamide, a polyester, a polycarbonate, a polyacetal, an acrylonitrile-butadiene-styrene, copolymers thereof, or blends thereof. A waterway insert comprising a thermoplastic may be prepared via a molding process, for example injection molding. A manufacturing precision of injection molded thermoplastic may advantageously be improved over that of brass casting, a typical method to prepare a flush valve.
A waterway insert may comprise a unitary construct, that is, may comprise a single part. A flush valve assembly housing may comprise a unitary construct, or may comprise a sectional construct, that is, may comprise two or more parts. Unitary and sectional constructs are illustrated in the figures.
In other embodiments, a waterway insert may comprise stainless steel. A flush valve housing may comprise a same or a different material than a waterway insert. In some embodiments, features referred to in the figures, for example a bonnet nut, radial adapter, inlet adapter, and outlet adapter, may comprise a thermoplastic or brass. In some embodiments, an outer overmold layer, positioned adjacent an outer surface of a housing, may comprise a same or a different material than that of the housing. For example, an outer overmold layer may comprise zinc. An “overmold” layer may refer to an outer layer molded over another surface.
In some embodiments, a waterway insert may comprise most or all functional inner features of a typical flush valve housing. For example, a waterway insert may comprise an inlet to receive source water, and an outlet to deliver flush water to a sanitaryware fixture (e.g. a toilet or a urinal). In some embodiments, a waterway insert may comprise a valve seat. A piston or diaphragm valve assembly will rest on a valve seat in a closed position, and be lifted off a valve seat in an open position. In some embodiments, a waterway insert may comprise an upper opening configured to receive a piston or a diaphragm valve assembly. A waterway insert may comprise a side opening configured to receive a manual actuator assembly. In some embodiments, a waterway insert may comprise a channel (a water channel) associated with a manual actuator assembly, and configured to allow water to be delivered from an upper chamber to initiate a manual flush. In some embodiments, one or more of a waterway insert upper opening, bottom opening, first side opening to receive inlet source water, and second side opening to receive a manual flush actuator, may each be aligned with corresponding openings of a housing within which a waterway insert is positioned. In some embodiments, when openings are aligned, this may mean they share a central axis.
In some embodiments, a waterway insert may comprise a rib positioned near a source water inlet. A rib may extend in a vertical direction, perpendicular to a flow direction of inlet source water. In some embodiments, a rib may extend from an upper inlet opening downward. In some embodiments, a rib may extend about 25%, about 30%, about 35%, about 40%, about 50%, about 55%, about 60%, or more, of a diameter of an inlet opening. In some embodiments, a rib may comprise a horizontal extension. A horizontal extension may extend from the rib towards a flow direction of inlet source water. A rib or a rib having a horizontal extension may serve to protect a valve assembly from a force of flow of inlet source water during a flush cycle.
In some embodiments, a waterway insert may comprise features configured to couple to a pipe, for example an inlet or an outlet pipe. For instance, a waterway insert may comprise an outer or an inner threaded surface positioned at an inlet or outlet and configured to couple to a pipe or an adapter.
In some embodiments, a flush valve assembly comprises a presence sensor and a solenoid actuator in electrical communication, configured to facilitate an automatic flush. A presence sensor and a solenoid actuator may be in electrical communication with a battery. A flush valve assembly may comprise an upper housing and a lower housing. In some embodiments, an upper housing may comprise a presence sensor, a battery, and optionally a manual actuator assembly. In some embodiments, a lower housing may comprise an inlet, an outlet, a piston or diaphragm valve assembly, and optionally a manual actuator assembly. In the disclosure, a lower housing may simply be referred to as a “housing”.
In some embodiments, an assembly may comprise a bonnet nut coupled to an upper opening of a waterway insert, which may serve to help maintain a position of a valve assembly. In some embodiments, a bonnet nut may comprise a thermoplastic, brass, zinc, or stainless steel.
Following are some non-limiting embodiments of the disclosure.
In a first embodiment, disclosed is a flush valve assembly, comprising an inlet configured to receive inlet source water; an outlet configured to deliver flush water to a sanitaryware fixture; a housing; and a waterway insert configured to be positioned within the housing, wherein the housing comprises a first side opening configured to align with the flush valve assembly inlet, the housing comprises a bottom opening configured to align with the flush valve assembly outlet, the waterway insert comprises a first side opening configured to align with the housing first side opening, and the waterway insert comprises a bottom opening configured to align with the housing bottom opening.
In a second embodiment, disclosed is a flush valve assembly according to the first embodiment, wherein the waterway insert comprises an upper opening configured to receive a piston or a diaphragm valve assembly. In a third embodiment, disclosed is a flush valve assembly according to embodiments 1 or 2, wherein the housing comprises an upper opening configured to align with the waterway insert upper opening.
In a fourth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the waterway insert comprises a second side opening configured to receive a manual actuator assembly. In a fifth embodiment, disclosed is a flush valve assembly according to embodiment 4, wherein the housing comprises a second side opening configured to align with the waterway insert second side opening. In a sixth embodiment, disclosed is a flush valve assembly according to embodiment 5, comprising a manual actuator assembly configured to couple to the waterway insert second side opening and to the housing second side opening.
In a seventh embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the waterway insert includes a valve seat. In an eighth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the waterway insert comprises a channel configured to be associated with a manual actuator assembly. In a ninth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the waterway insert comprises a vertical rib configured to protect a piston or diaphragm valve assembly from a force of the inlet source water. In a tenth embodiment, disclosed is a flush valve assembly according to embodiment 9, wherein the vertical rib comprises a horizontal extension, the horizontal extension extending in the flow direction of the inlet source water.
In an eleventh embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, comprising a bonnet nut configured to couple to the waterway insert upper opening. In a twelfth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, comprising an inlet adapter configured to couple to the housing first side opening and the waterway insert first side opening.
In a thirteenth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the waterway insert bottom opening comprises an outer and/or inner threaded surface. In a fourteenth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, comprising a radial adapter configured to couple to the housing first side opening, to the waterway insert first side opening, and to an inlet adapter. In a fifteenth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, comprising an outlet adapter configured to couple to the waterway insert bottom opening and to the housing bottom opening.
In a sixteenth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the housing comprises a first material, the waterway insert comprises a second material, and the first material is the same or different than the second material.
In a seventeenth embodiment, disclosed is a flush valve assembly according to embodiment 16, wherein the first material comprises a metal and the second material comprises a thermoplastic. In an eighteenth embodiment, disclosed is a flush valve assembly according to embodiments 16 or 17, wherein the waterway insert comprises an engineering thermoplastic. In a nineteenth embodiment, disclosed is a flush valve assembly according to any of embodiments 16 to 18, wherein the waterway insert comprises a glass-filled thermoplastic. In a twentieth embodiment, disclosed is a flush valve assembly according to any of embodiments 16 to 19, wherein the waterway insert comprises a polyphenylene sulfide, a polyphthalamide, a polyamide, a polyester, a polycarbonate, a polyacetal, an acrylonitrile-butadiene-styrene, copolymers thereof, or blends thereof.
In a twenty-first embodiment, disclosed is a flush valve assembly according to embodiment 16, wherein the waterway insert comprises stainless steel. In a twenty-second embodiment, disclosed is a flush valve assembly according to any of embodiments 16 to 21, wherein the housing comprises zinc.
In a twenty-third embodiment, disclosed is a flush valve assembly according to any of embodiments 16 to 22, wherein the housing comprises an overmold outer layer. In a twenty-fourth embodiment, disclosed is a flush valve assembly according to embodiment 23, wherein the overmold outer layer comprises a third material, and wherein the third material is the same as the first material. In a twenty-fifth embodiment, disclosed is a flush valve assembly according to embodiment 23, wherein the overmold outer layer comprises a third material, and wherein the third material is different than the first material. In a twenty-sixth embodiment, disclosed is a flush valve assembly according to any of embodiments 16 to 25, wherein the overmold outer layer comprises zinc.
In a twenty-seventh embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the housing comprises a unitary construct. In a twenty-eighth embodiment, disclosed is a flush valve assembly according to any of embodiments 1 to 26, wherein the housing comprises a sectional construct. In a twenty-ninth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the waterway insert comprises a unitary construct.
In a thirtieth embodiment, disclosed is a flush valve assembly according to any of the preceding embodiments, wherein the housing comprises an overmold outer layer. In a thirty-first embodiment, disclosed is a flush valve assembly according to embodiment 28, wherein the housing comprises an overmold outer layer.
In a thirty-second embodiment, disclosed is a waterway insert according to any of the preceding embodiments. In a thirty-third embodiment, disclosed is a housing according to any of the preceding embodiments, and configured to receive a waterway insert at an interior space thereof.
The term “flow communication” or “fluid communication” means for example configured for liquid or gas flow therethrough and may be synonymous with “fluidly coupled”. The terms “upstream” and “downstream” indicate a direction of gas or fluid flow, that is, gas or fluid will flow from upstream to downstream.
Likewise, “electrical communication” may mean “electrically coupled”. Electrical communication may be via wired connection or may be wireless.
The terms “coupled” or “connected” may mean that an element is “attached to” or “associated with” another element. Coupled or connected may mean directly coupled or coupled through one or more other elements. An element may be coupled to an element through two or more other elements in a sequential manner or a non-sequential manner. The term “via” in reference to “via an element” may mean “through” or “by” an element. Coupled or connected or “associated with” may also mean elements not directly or indirectly attached, but that they “go together” in that one may function together with the other.
The term “towards” in reference to a of point of attachment, may mean at exactly that location or point or, alternatively, may mean closer to that point than to another distinct point, for example “towards a center” means closer to a center than to an edge.
The term “like” means similar and not necessarily exactly like. For instance “ring-like” means generally shaped like a ring, but not necessarily perfectly circular.
The articles “a” and “an” herein refer to one or to more than one (e.g. at least one) of the grammatical object. Any ranges cited herein are inclusive. The term “about” used throughout is used to describe and account for small fluctuations. For instance, “about” may mean the numeric value may be modified by ±0.05%, ±0.1%, ±0.2%, ±0.3%, ±0.4%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, ±6%, ±7%, ±8%, ±9%, ±10% or more. All numeric values are modified by the term “about” whether or not explicitly indicated. Numeric values modified by the term “about” include the specific identified value. For example “about 5.0” includes 5.0.
The term “substantially” is similar to “about” in that the defined term may vary from for example by ±0.05%, ±0.1%, ±0.2%, ±0.3%, ±0.4%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, ±6%, ±7%, ±8%, ±9%, ±10% or more of the definition; for example the term “substantially perpendicular” may mean the 90° perpendicular angle may mean “about 90°”. The term “generally” may be equivalent to “substantially”.
Features described in connection with one embodiment of the disclosure may be used in conjunction with other embodiments, even if not explicitly stated.
Embodiments of the disclosure include any and all parts and/or portions of the embodiments, claims, description and figures. Embodiments of the disclosure also include any and all combinations and/or sub-combinations of embodiments.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/034234 | 6/21/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63219194 | Jul 2021 | US | |
| 63213552 | Jun 2021 | US |
