Patent Application
20110126348
The present disclosure relates to flush tanks, and more particularly, to the valve assembly associated with toilet bowl flush tanks.
Both consumer and institutional toilets can be ordered in a wide variety of sizes, styles, and colors. Regardless of this wide variety of available options, most toilets are operated by a valve assembly installed at the discharge hole of the flush tank. Some discharge holes have a smaller diameter than others, resulting in a slower rate of flushing when the valve is opened. A toilet with a slower flush rate is less effective at flushing debris, leaving it more susceptible to plumbing blockages. One common “smaller” size of toilet tank discharge hole has a two inch diameter.
There is a need for a valve assembly for installation into flush tanks with small (for example, two inch diameter) discharge holes that increases the rate of flushing when the valve is opened. The present disclosure is directed to a single piece valve assembly for installation in smaller discharge holes that increases the flush flow rate of water when the valve is opened. Installing the disclosed flush valve assembly allows one to increase the inlet opening of a tank discharge hole without replacing the tank and/or plumbing, resulting in an increased flow rate out of the tank when flushed.
According to one disclosed embodiment, a flush valve assembly has an upper portion and a lower portion. The upper portion has a generally cylindrical upper wall that defines an upper bore and an inlet with a sloped open face. The upper bore has a diameter D1. A generally L-shaped passage extends from a lateral opening in the upper wall. A lower radial shoulder extends inwardly from the upper wall opposite the inlet. The radial shoulder defines a substantially circular transition opening. The lower portion has a generally cylindrical lower wall that is sized to mate with a discharge hole of a particular diameter. The lower wall extends from the transition opening substantially coaxial to the upper wall. The lower wall defines a lower bore and an outlet. The lower bore has a diameter D2 that is less than D1. The upper and lower bores are fluidly connected through the transition opening and collectively define a discharge conduit.
In another embodiment of the flush valve assembly, an upper wall defines an upper bore with a diameter D1 and an inlet with a sloped open face. A radial shoulder extends inwardly from the upper wall opposite the inlet. The radial shoulder is substantially perpendicular to the upper wall and defines central circular opening. A passage extends from a lateral opening in the upper wall. A generally cylindrical lower wall extends from the radial shoulder substantially coaxial to the upper wall. The lower wall defines a lower bore with a diameter D2 that is 80% or less of D1. The lower wall is configured for insertion into the discharge hole of a flush tank. The upper and lower bores are fluidly connected via the circular opening and collectively define a discharge conduit. The lower wall can be inserted into the discharge hole of a flush tank to create a fluid tight seal between the tank and the discharge conduit. A generally circular flapper has a projection configured for swingable attachment to the outer surface of the valve assembly. The outer radial edge of the flapper extends radially beyond the upper wall. The flapper is configured to abut the upper wall at the inlet in a fluid tight seal when in a closed position. With application of a force F on the flapper in the direction away from the inlet, the flapper can swing between a closed position abutting the inlet and an open position raised from the inlet. The abutment of the flapper and the upper wall in the closed position fluidly seals the tank from the discharge conduit. The raised position allows fluid communication between the tank and the discharge conduit.
In yet another embodiment, a method of increasing the rate of flow of a fluid out of a flush tank through a discharge hole is disclosed. A flush valve assembly defining a discharge conduit is selected. The flush valve assembly has an upper portion with a generally cylindrical upper wall. The upper wall defines an upper bore with a diameter D1 and an inlet with a sloped open face. A passage extends from a lateral opening in the upper wall. A radial shoulder extends inwardly from the upper wall opposite the inlet and defines a transition opening. A lower portion has a generally cylindrical lower wall that extends from the transition opening. The lower wall defines a lower bore with a diameter D2 that is less than D1 and an outlet. The lower wall is substantially coaxial to the upper wall and is configured for insertion into the discharge hole of a flush tank. The lower portion of the flush valve assembly is inserted into the discharge hole of a flush tank, creating a fluid tight seal between the tank and the discharge conduit. A generally circular flapper is attached to the assembly such that the flapper can swing relative thereto. The flapper is positioned in a closed position abutting the upper wall at the inlet in a fluid tight seal. The flush tank is filled at least partially with a fluid. The flapper is swung from the closed position to a raised opened position via application of a force on the flapper in the direction away from the inlet.
Aspects of the preferred embodiment will be described in reference to the Drawing, where like numerals reflect like elements:
With reference to the drawing wherein like numerals represent like parts throughout the Figures, a flush valve assembly and a corresponding method of increasing the rate of flow of a fluid out of a flush tank with a discharge hole (i.e., a traditional toilet bowl tank) are disclosed. Embodiments allow installers to use a single piece to install or replace tank valves in tanks to achieve an increased flow rate out of tanks having relatively small discharge hole sizes.
In a preferred embodiment, the flush valve assembly 10 has an upper portion 12 and a lower portion 14. The upper portion 12 has a generally cylindrical upper wall 16 and an inwardly extending lower radial shoulder 18. The upper wall 16 defines an upper bore 17 with a diameter D1 and has a sloped opened face that defines an inlet 20. As depicted, the inlet 20 slopes from a high edge 21 to a low edge 23 of the upper wall 16. A passage 22 extends from a lateral opening 24 in the upper wall 16. In the depicted embodiment, the passage 22 is generally L-shaped and has an open upper end 38 configured for engagement with an adjustable overflow tube 40 or similar component.
As depicted in
As shown, the upper and lower bores, 17 and 29, are fluidly connected via the transition opening 26. The fluidly connected upper and lower bores, 17 and 29, collectively define a discharge conduit that extends from the inlet 20 to the outlet 30.
This particular embodiment of the flush valve assembly 10 includes a radial projection 34 extending from the outer surface of the upper wall 16. A ring-like sealing member 36 is positioned generally around the radial shoulder 18 abutting the lower surface of the projection 34. The sealing member 36 assists in creating a fluid tight connection between the flush tank and the discharge conduit. Alternatively, a smaller sealing member can be positioned around the lower wall 28 abutting the lower surface of the radial shoulder 18. Another alternative depicted in
As noted above, this embodiment has an L-shaped passage 22 extending from a lateral opening 24 in the upper wall 14 generally below the high edge 21 of the inlet 20. The upper end 38 of the L-shaped passage 22 is configured for engagement with an adjustable overflow tube 40 or like component. The L-shaped passage has an outer surface 42 that is configured for swingable attachment to a generally circular flapper 32. This embodiment features substantially identical projections 44 positioned on opposite lateral sides of the L-shaped passage 22 (second projection 44 not shown). However, the attachment of a flapper is not limited in this way.
The flapper 32 may be included in a “kit” with the flush valve assembly 10 or may be a conventional commercially available flush valve flapper suitable for swingable attachment to the assembly. As can be seen in
One typical type of flush tank has a discharge hole with an approximately two inch diameter. Two inch discharge holes are smaller than other common sizes, and thus the rate of discharge flow is generally slower. An embodiment of the flush valve assembly 10 is configured especially for engagement with a two inch discharge hole and configured to effect an increase in flow rate.
As depicted in the embodiment of
Though not shown in the Figures, the embodiment of
In the embodiment depicted in
In common toilet tank configurations, the chain 54 depends from a flush rod that extends from a lever (not pictured). Opposite the flush rod, the chain 54 is attached to the flapper 32. When the lever is depressed, the rod pulls the chain 54 upwards and applies a force F on the flapper 32. It is noteworthy that the disclosed embodiments are not limited to the described lever-chain-flapper configuration. Other known means for applying a force on the flapper in the direction away from the inlet can be implemented.
As depicted in
Due to the discharge conduit having an upper bore 17 with a larger diameter (D1) than the lower bore 29 (D2), fluid discharges from the tank at a faster rate than it would through an opening with a diameter substantially equal to D2. Thus, installing the valve assembly 10 depicted in the Figures into a tank with an approximately two inch discharge hole will result in increased flow due to the wider inlet 20 and upper bore 17. In a preferred embodiment, the lower wall 28 is configured for insertion into a discharge hole with an approximately two inch diameter and the upper bore diameter D1 is approximately 125-175% of the lower bore diameter D2. D1 is approximately 150% of D2 in yet another preferred embodiment. While the disclosed embodiments generally concentrate on a conventional tank with a two inch discharge hole, embodiments are not limited as such.
The assembly 10 can comprise a single moulded piece of rigid, resilient material, such as plastic, or multiple individual components joined together by welding, soldering, adhesive or the like. Further, the assembly 10 can come packaged alone or in a kit including an overflow tube and/or other pieces for incorporation into the valve assembly system. Likewise, a similar kit can include a flapper similar to that depicted as Reference Numeral 36.
As described herein, the disclosed embodiments of the flush valve assembly 10 enable increased flow to be achieved out of flush tanks, thus increasing the flush effectiveness and reducing the likelihood of plumbing blockage while keeping the volume of fluid discharged constant.
While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the claimed coverage.
