U.S. patent application number 17/316011 was filed with the patent office on 2021-08-26 for flush valve with relief valve having axially-translatable valve element.
The applicant listed for this patent is Zurn Industries, LLC. Invention is credited to Marc G. Block, Michael A. Funari, Roy F. Leviner, III.
Application Number | 20210262211 17/316011 |
Document ID | / |
Family ID | 1000005570043 |
Filed Date | 2021-08-26 |
United States Patent
Application |
20210262211 |
Kind Code |
A1 |
Funari; Michael A. ; et
al. |
August 26, 2021 |
Flush Valve With Relief Valve Having Axially-Translatable Valve
Element
Abstract
A flush valve has a relief valve including a stationary relief
valve housing and an axially-translatable valve element. The
axially-translatable valve element has an axial end that can be
selectively translated to unseal an upper opening in a relief
passageway through the stationary relief valve housing in order to
permit fluid flow therethrough in order to initiate a flush cycle
by the lifting of a diaphragm assembly. The axially-translatable
valve element may include lead screw-like features which can be
used to axially drive the axially-translatable valve element
relative to the stationary relief valve housing to open or close
the relief valve.
Inventors: |
Funari; Michael A.; (Apex,
NC) ; Leviner, III; Roy F.; (Aberdeen, NC) ;
Block; Marc G.; (Apex, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Zurn Industries, LLC |
Milwaukee |
WI |
US |
|
|
Family ID: |
1000005570043 |
Appl. No.: |
17/316011 |
Filed: |
May 10, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16696401 |
Nov 26, 2019 |
11001998 |
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17316011 |
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15890673 |
Feb 7, 2018 |
10487486 |
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16696401 |
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62456237 |
Feb 8, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E03D 1/35 20130101; E03D
3/06 20130101; E03D 1/36 20130101; G02B 6/2558 20130101 |
International
Class: |
E03D 1/35 20060101
E03D001/35; E03D 3/06 20060101 E03D003/06; E03D 1/36 20060101
E03D001/36; G02B 6/255 20060101 G02B006/255 |
Claims
1. A flush valve comprising: a valve housing defining a fluid
passageway between a fluid inlet and a fluid outlet, the fluid
passageway having a diaphragm valve seat disposed between the fluid
inlet and the fluid outlet; a diaphragm assembly including a
diaphragm and a disc, the diaphragm having a primary opening and a
bypass opening, the primary opening receiving the disc therein and
the bypass opening allowing water under pressure supplied to the
fluid inlet to pass from a fluid inlet side of the diaphragm into a
chamber in the fluid passageway established by a presence of the
diaphragm assembly in the fluid passageway, wherein the diaphragm
assembly is disposed in the fluid passageway and is movable between
an opened position in which the disc of the diaphragm assembly is
not in contact with the diaphragm valve seat and a closed position
in which the disc of the diaphragm assembly is in contact with the
diaphragm valve seat; and a relief valve configured to selectively
control fluid flow from the chamber to the fluid outlet, the relief
valve comprising a stationary relief valve housing and an
axially-translatable valve element, the stationary relief valve
housing having a relief passageway and the axially-translatable
valve element having an axial end positionable to selectively seal
an upper opening in the relief passageway of the relief valve
housing to regulate fluid flow therethrough; wherein, in the closed
position of the diaphragm assembly and with the relief valve
closed, the disc contacts the diaphragm valve seat to form a seal
therebetween and wherein, when the flush valve is activated and the
relief valve is opened by lifting the axial end of the
axially-translatable valve element from the upper opening of the
relief passageway, a flow of water from the chamber into the fluid
outlet via the relief passageway occurs thereby relieving a fluid
pressure in the chamber and causing the diaphragm assembly to move
from the closed position to the opened position such that the disc
is unseated from the diaphragm valve seat further permitting water
to pass from the fluid inlet to the fluid outlet in a space between
the disc and the diaphragm valve seat.
2. The flush valve of claim 1, further comprising a motor wherein
an axial position of the axially-translatable valve element
relative to the stationary relief valve housing is configured to be
controlled by the motor and a drive train that includes a lead
screw part that is integral with the axially-translatable valve
element.
3. The flush valve of claim 2, wherein the lead screw part that is
integral with the axially-translatable valve element is a male lead
screw part, wherein the drive train further comprises a female
driving part positioned to selectively drive the male lead screw
part, and wherein the axially-translatable valve element is
restricted from angular rotation such that driving of the male lead
screw part by the female driving part displaces the
axially-translatable valve element axially, but not angularly.
4. The flush valve of claim 3, wherein the female driving part is
rotationally driven and meshes with the male lead screw part to
provide axial translation of the axially-translatable valve
element.
5. The flush valve of claim 1, wherein, when the diaphragm assembly
is in the open position and the relief valve is returned to the
closed position, fluid pressure builds in the chamber thereby
causing the disc to contact the diaphragm valve seat thereby
reforming a seal therebetween, returning the diaphragm assembly to
the closed position.
6. The flush valve of claim 1, wherein the chamber in the fluid
passageway is established by a presence of the diaphragm assembly
in the fluid passageway and a fixed member disposed within the
valve housing, the fixed member contacts the diaphragm in at least
one radial position and has an extension that extends away from the
diaphragm assembly, the extension of the fixed member has an inner
chamber.
7. The flush valve of claim 6, wherein the inner chamber of the
fixed member is configured to support at least the stationary
relief valve housing of the relief valve assembly.
8. The flush valve of claim 7, wherein the stationary relief valve
housing is threadably connected to the fixed member and wherein
threads of the stationary relief valve housing have at least one
planar flat surface formed therein to create fluid communication
between a volume of an upper chamber between the fixed member and
the diaphragm assembly and a volume between the stationary relief
valve housing and the axial-translatable valve element.
9. The flush valve of claim 6, wherein the fixed member is
configured to ensure accurate flush volume.
10. The flush valve of claim 1, wherein the diaphragm valve seat
defines a peripheral fluid passageway wherein the peripheral fluid
passageway is in fluid communication with the fluid inlet and the
fluid outlet when the diaphragm assembly is in the open position
thereby allowing additional fluid to flow from the fluid inlet to
the fluid outlet.
11. The flush valve of claim 1, wherein the open position of the
relief valve occurs when the axial end of the axially-translatable
valve element is translated out of contact with the stationary
relief valve housing.
12. The flush valve of claim 1, wherein the diaphragm is
flexible.
13. The flush valve of claim 1, wherein the diaphragm is configured
to bend to allow the diaphragm assembly to move from the closed
position to the open position.
14. The flush valve of claim 1, wherein the disc has a circular
outer periphery.
15. The flush valve of claim 1, wherein the relief valve assembly
is configured to be in an open position from 0.5 to 3 seconds which
results in the flush valve being open from 3 to 10 seconds.
16. The flush valve of claim 1, wherein the axial end of the
axially-translatable valve element has an elastomeric element on a
tip thereof that seals the opening of the relief passageway of the
stationary relief valve housing when the relief valve is in the
closed position.
17. A method for operating a flush valve, the method comprising the
steps of: (a) providing a fluid under pressure to a fluid
passageway in a valve housing via a fluid inlet; (b) communicating
the fluid through a bypass opening in a diaphragm assembly into a
chamber, the diaphragm assembly being disposed in the fluid
passageway and being movable between an opened position in which
the diaphragm assembly is not in contact with a diaphragm valve
seat and a closed position in which the diaphragm assembly is in
contact with the diaphragm valve seat, wherein the chamber is
established by a presence of the diaphragm assembly in the fluid
passageway; (c) communicating the fluid in the chamber into a
relief valve, the relief valve comprising a stationary relief valve
housing and an axially-translatable valve element, the stationary
relief valve housing having a relief passageway and the
axially-translatable valve element having an axial end positionable
to selectively seal an upper opening in the relief passageway of
the stationary relief valve housing to regulate fluid flow
therethrough; (d) translating the axially-translatable valve
element into an open position such that the upper opening in the
relief valve housing is unsealed by the axial end of the
axially-translatable valve element; (e) communicating the fluid
through the relief valve to a fluid outlet; and (f) translating the
diaphragm assembly from the closed position to the open position
such that the diaphragm assembly is unseated from the diaphragm
valve seat permitting water to pass from the fluid inlet to the
fluid outlet in a space between the diaphragm assembly and the
diaphragm valve seat.
18. The method of claim 17, wherein the axially-translatable valve
element includes a male lead screw part and a drive train of the
flush valve includes a female driving part and wherein the step of
translating the axially-translatable valve element involves driving
the female driving part such that the female driving part meshes
with the male lead screw part to translate the axially-translatable
valve element.
19. The method of claim 18, wherein, during the step of translating
the axially-translatable valve element, the axially-translatable
valve element is restricted from angular rotation such that driving
of the male lead screw part by the female driving part displaces
the axially-translatable valve element axially, but not angularly.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. Provisional Patent Application No. 62/456,237 entitled "Flush
Valve With Relief Valve Having Axially-Translatable Valve Element"
filed on Feb. 8, 2017, which is hereby incorporated by reference
for all purposes as if set forth in its entirety herein.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
FIELD OF INVENTION
[0003] This disclosure relates to a flush valve and the operation
thereof, which allows the actuation of a flush cycle.
BACKGROUND
[0004] Manual flush valves for use in urinals, water closets, and
toilets are well known in the art. Two common types of flush valves
are diaphragm flush valves and piston flush valves. Diaphragm flush
valves typically include a fluid inlet and a fluid outlet separated
by a diaphragm that selectively prevents fluid from flowing from
the fluid inlet to the fluid outlet. The diaphragm of a flush valve
selectively prevents fluid from flowing from the fluid inlet to the
fluid outlet by being disposed on a valve seat of the fluid outlet.
The diaphragm of the flush valve includes a refill orifice that
allows fluid flowing from the fluid inlet to flow into a top
chamber above the diaphragm. Fluid in the top chamber above the
diaphragm applies pressure to seat the diaphragm onto the valve
seat of the fluid outlet. The diaphragm of the flush valve further
includes a relief valve which selectively allows fluid to pass from
the fluid inlet to the fluid outlet. The relief valve commonly
features a valve stem that extends downward into the fluid outlet.
The valve stem interfaces with a plunger connected to a manual
lever arm. The manual lever arm is actuated by a user which pushes
the plunger into contact with the valve stem. The contact of the
plunger with the valve stem laterally displaces the valve stem
which causes the relief valve to slightly open fluid communication
between the fluid inlet and the fluid outlet. The slight opening in
fluid communication caused by the displacement of the valve stem
reduces pressure pressing the diaphragm onto the valve seat which
allows the diaphragm to unseat from the valve seat. The unseating
of the diaphragm from the valve seat allows additional fluid to
flow from the fluid inlet to the fluid outlet. When the user
releases the manual lever arm, the plunger returns to its original
position. The valve stem returns to its original position when it
is not being actuated by the plunger, and when the valve stem is in
its original position, the relief valve is closed. Fluid pressure
builds on the diaphragm with the relief valve closed. The increase
in pressure on the diaphragm due to the closing of the relief valve
presses the diaphragm onto the valve seat. Fluid communication
between the inlet and the outlet is thereby closed with the
diaphragm disposed on the valve seat and the relief valve
closed.
[0005] Automated flush valves are also well known in the art.
Automated flush valves commonly rely on sensors that detect the
presence of a user in order to initiate a flush as opposed to a
manual lever arm that requires actuation by a user. Automated flush
valves have similar internal structures to manual flush valves. As
noted with manual diaphragm flush valves, automated flush valves
include a fluid inlet and a fluid outlet separated by a diaphragm
that selectively prevents fluid from flowing from the fluid inlet
to the fluid outlet. The diaphragm of the flush valve includes a
refill orifice that allows fluid flowing from the fluid inlet to
flow into a top chamber above the diaphragm. Fluid in the top
chamber above the diaphragm applies pressure to seat the diaphragm
onto the valve seat of the fluid outlet. The diaphragm of the flush
valve selectively prevents fluid from flowing from the fluid inlet
to the fluid outlet by being disposed on a valve seat of the fluid
outlet. The diaphragm of a flush valve includes a relief valve
which selectively allows fluid to pass from the fluid inlet to the
fluid outlet. The relief valve commonly features a valve stem that
extends downward into the fluid outlet. The valve stem interfaces
with a plunger connected to an automated actuation mechanism. The
automated actuation mechanism is configured to push the plunger
into contact with the valve stem. The automated actuation mechanism
most commonly utilizes a solenoid, while alternative embodiments
can utilize a motor coupled to a gear train or other automated
actuation mechanisms. The contact of the plunger with the valve
stem laterally displaces the valve stem which causes the relief
valve to slightly open fluid communication between the fluid inlet
and the fluid outlet. The slight opening in fluid communication
caused by the displacement of the valve stem reduces pressure
pressing the diaphragm onto the valve seat which allows the
diaphragm to unseat from the valve seat. The unseating of the
diaphragm from the valve seat allows additional fluid to flow from
the fluid inlet to the fluid outlet. When the automated actuation
mechanism releases from contact with the plunger, the plunger
returns to its original position. The valve stem returns to its
original position when it is not being actuated by the plunger, and
when the valve stem is in its original position, the relief valve
is closed. Fluid pressure builds on the diaphragm with the relief
valve closed. The increase in pressure on the diaphragm due to the
closing of the relief valve presses the diaphragm onto the valve
seat. Fluid communication between the inlet and the outlet is
thereby closed with the diaphragm disposed on the valve seat and
the relief valve closed.
[0006] The actuation of the valve stem by the plunger causes the
valve stem to be at an angle with respect to the valve seat. The
angle of the valve stem selectively opens the relief valve by
tilting the relief valve at an angle relative to the valve seat.
The selective opening of the relief valve is unpredictable due to
variations in pressure applied to the diaphragm caused by fluid
communicated into the upper chamber via the bypass opening in
addition to the variation in the actuation by a user or an
automated actuation mechanism. The unpredictability of the opening
causes control and precision problems. The amount of fluid flowing
through the opening is correlated to the size of the opening in the
relief valve. The amount of fluid flowing through the flush valve
is difficult to control due to the unpredictability of the opening
in the relief valve. The timing of a flush cycle is also correlated
to the size of the opening allowing water to pass through the
relief valve. The unpredictability of the opening in the relief
valve also makes the timing of a flush cycle difficult to
control.
[0007] Additional disadvantages arise with commonly utilized
solenoids for automated actuation of the plunger. First, solenoids
and their components tend to corrode in the presence of hard water.
Second, solenoids exhibit inconsistent performance at varying
pressures that may cause the plunger to bounce in response to a
high or a low pressure. Third, solenoids have an increased
sensitivity to manufacturing tolerances (e.g. spring forces,
magnetic force, etc.). Each of these disadvantages, alone or in
combination with one another, may cause undesirable performance and
maintenance issues.
[0008] It is therefore desirable for a flush valve to more
precisely control the opening in the relief valve and improve
durability of the components in the flush valve.
SUMMARY OF THE INVENTION
[0009] Proposed herein is an alternative design for a flush valve,
and in some aspects an alternative design for flush valve internals
(i.e. a relief mechanism). The proposed design may be a retrofit
design to replace an existing flush valve. The proposed design may
also be a stand-alone unit or employ any other installation
methods. The proposed design features an alternative flush valve
that can utilize an alternative relief valve that allows for
precise control of the opening of the relief valve, increases
durability of the components in the flush valve, and removes
components from the fluid outlet flow path.
[0010] According to one aspect, the flush valve has a valve housing
that defines a fluid passageway between a fluid inlet and a fluid
outlet. The fluid passageway has a diaphragm valve seat disposed
between the fluid inlet and the fluid outlet. The flush valve also
has a diaphragm assembly that includes a diaphragm and a disc. The
diaphragm has a primary opening and a bypass opening. The primary
opening receives the disc therein and the bypass opening allows
water under pressure supplied to the water inlet to pass from a
fluid inlet side of the diaphragm into a chamber in the fluid
passageway established by a presence of the diaphragm assembly in
the fluid passageway. The diaphragm assembly is disposed in the
fluid passageway and is movable between an opened position in which
the disc of the diaphragm assembly is not in contact with the
diaphragm valve seat and a closed position in which the disc of the
diaphragm assembly is in contact with the diaphragm valve seat. The
flush valve also includes a relief valve configured to selectively
control fluid flow from the chamber to the fluid outlet. The relief
valve comprises a stationary relief valve housing and an
axially-translatable valve element. The stationary relief valve
housing has a relief passageway and the axially-translatable valve
element has an axial end positionable to selectively seal an upper
opening in the relief passageway of the relief valve housing to
regulate fluid flow therethrough. In the closed position of the
diaphragm assembly and with the relief valve closed, the disc
contacts the diaphragm valve seat to form a seal therebetween. When
the flush valve is activated and the relief valve is opened by
lifting the axial end of the axially-translatable valve element
from the upper opening of the relief passageway, a flow of water
from the chamber into the fluid outlet via the relief passageway
occurs thereby relieving a fluid pressure in the chamber and
causing the diaphragm assembly to move from the closed position to
the opened position such that the disc is unseated from the
diaphragm valve seat further permitting water to pass from the
fluid inlet to the fluid outlet in a space between the disc and the
diaphragm valve seat.
[0011] In some forms, the flush valve may further include a motor
in which an axial position of the axially-translatable valve
element relative to the stationary relief valve housing is
controlled by the motor and a drive train that includes a lead
screw part that is integral with the axially-translatable valve
element. The lead screw part that is integral with the
axially-translatable valve element may a male lead screw part, the
drive train may include a female driving part positioned to
selectively drive the male lead screw part, and the
axially-translatable valve element may be restricted from angular
rotation such that driving of the male lead screw part by the
female driving part displaces the axially-translatable valve
element axially, but not angularly. The female driving part may be
rotationally driven and mesh with the male lead screw part to
provide axial translation of the axially-translatable valve
element.
[0012] In some forms, when the diaphragm assembly is in the open
position and the relief valve is returned to the closed position,
fluid pressure may build in the chamber thereby causing the disc to
contact the diaphragm valve seat thereby reforming a seal
therebetween, returning the diaphragm assembly to the closed
position.
[0013] In some forms, the chamber in the fluid passageway may be
established by a presence of the diaphragm assembly in the fluid
passageway and a fixed member disposed within the valve housing.
The fixed member may contact the diaphragm in at least one radial
position and may have an extension that extends away from the
diaphragm assembly. The extension of the fixed member may have an
inner chamber. The inner chamber of the fixed member may support at
least the stationary relief valve housing of the relief valve
assembly. In some forms, the stationary relief valve housing may be
threadably connected to the fixed member and the threads of the
stationary relief valve housing may have at least one planar flat
surface formed therein (or other shaped sections removed
therefrom). These removed sections or flats of the threads may
create fluid communication between a volume of an upper chamber
between the fixed member and the diaphragm assembly and a volume
between the stationary relief valve housing and the
axial-translatable valve element.
[0014] In some forms, the presence of the fixed member may be used
to help ensure accurate flush volume.
[0015] In some forms, the diaphragm valve seat may define a
peripheral fluid passageway in which the peripheral fluid
passageway is in fluid communication with the fluid inlet and the
fluid outlet when the diaphragm assembly is in the open position
thereby allowing additional fluid to flow from the fluid inlet to
the fluid outlet.
[0016] In some forms, the open position of the relief valve may
occur when the axial end of the axially-translatable valve element
is translated out of contact with the stationary relief valve
housing.
[0017] In some forms, the diaphragm may be flexible. The diaphragm
may be configured to bend to allow the diaphragm assembly to move
from the closed position to the open position.
[0018] In some forms, the disc may have a circular outer
periphery.
[0019] In some forms, the relief valve assembly may be configured
to be in an open position from 0.5 to 3 seconds which results in
the flush valve being open from 3 to 10 seconds.
[0020] In some forms, the axial end of the axially-translatable
valve element may have an elastomeric element on a tip thereof that
seals the opening of the relief passageway of the stationary relief
valve housing when the relief valve is in the closed position.
[0021] According to another aspect, a method for operating a flush
valve is disclosed. A fluid under pressure is provided to a fluid
passageway in a valve housing via a fluid inlet. The fluid is
communicated through a bypass opening in a diaphragm assembly into
a chamber in which the diaphragm assembly is disposed in the fluid
passageway. The diaphragm assembly is also movable between an
opened position in which the diaphragm assembly is not in contact
with a diaphragm valve seat and a closed position in which the
diaphragm assembly is in contact with the diaphragm valve seat, in
which the chamber is established by a presence of the diaphragm
assembly in the fluid passageway. The fluid in the chamber is
communicated into a relief valve having a stationary relief valve
housing and an axially-translatable valve element. The stationary
relief valve housing has a relief passageway and the
axially-translatable valve element has an axial end positionable to
selectively seal an upper opening in the relief passageway of the
stationary relief valve housing to regulate fluid flow
therethrough. The axially-translatable valve element translates
into an open position such that the upper opening in the relief
valve housing is unsealed by the axial end of the
axially-translatable valve element. The fluid is communicated
through the relief valve to a fluid outlet. The diaphragm assembly
translates from the closed position to the open position such that
the diaphragm assembly is unseated from the diaphragm valve seat
permitting water to pass from the fluid inlet to the fluid outlet
in a space between the diaphragm assembly and the diaphragm valve
seat.
[0022] In some forms, the axially-translatable valve element may
include a male lead screw part and a drive train of the flush valve
may include a female driving part. The step of translating the
axially-translatable valve element may involve driving the female
driving part such that the female driving part meshes with the male
lead screw part to translate the axially-translatable valve
element.
[0023] In some forms, during the step of translating the
axially-translatable valve element, the axially-translatable valve
element may be restricted from angular rotation such that driving
of the male lead screw part by the female driving part displaces
the axially-translatable valve element axially, but not
angularly.
[0024] These and still other advantages of the invention will be
apparent from the detailed description and drawings. What follows
is merely a description of some preferred embodiments of the
present invention. To assess the full scope of the invention, the
claims should be looked to as these preferred embodiments are not
intended to be the only embodiments within the scope of the
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a sectional view of the flush valve.
[0026] FIG. 2 is a perspective sectional view of the flush valve of
FIG. 1.
[0027] FIG. 3 is an exploded view of the flush valve.
[0028] FIG. 4 is a detailed sectional view of the relief valve.
[0029] FIG. 5 is an exploded side view of the relief valve and the
drive train in isolation from the rest of the flush valve.
[0030] FIG. 6 is a side-by-side top view of a male lead screw part
and a female driving part.
[0031] FIG. 7 is a side view of the relief valve assembly and drive
train in a closed position in isolation from the remainder of the
flush valve.
[0032] FIG. 8 is a side view of the relief valve assembly in an
open position in isolation from the remainder of the flush
valve.
[0033] FIG. 9 is a detailed sectional view of an area A-A of the
flush valve in the closed position.
[0034] FIG. 10 is a detailed sectional view of an area A-A of the
flush valve just after the relief valve enters the open position,
but prior to the flush valve lifting.
[0035] FIG. 11 is a detailed sectional view of an area A-A of the
flush valve in the open position.
DETAILED DESCRIPTION
[0036] Embodiments of the disclosure may be further understood with
reference to the figures.
[0037] FIGS. 1 through 3 illustrates one exemplary embodiment of a
flush valve 20. The flush valve 20 has a housing that includes an
upper housing body 22 and a lower housing body 24 (see FIG. 3) that
may be connected such that the upper housing body 22 and lower
housing body 24 enclose the flush valve 20. In a non-limiting
example, the upper housing body 22 may be threaded into connection
with the lower housing body 24, and the upper housing body 22 may
have a cap 26 threaded into the top of the upper housing body 22.
The lower housing body 24 may have an inlet 28, an outlet 32, and a
cap 34 over an opening that would traditionally accommodate a
mechanical flush lever. The inlet 28 to the lower housing body 24
may connect the lower housing body 24 to a fluid source and provide
fluid communication therebetween. The inlet 28 may be secured to a
fluid source via a nut 36 that circumferentially extends around an
inlet extension 40, an O-ring 46, and a locking ring 48. The inlet
extension 40 may be cylindrical in shape and defines a hollow inner
chamber 42 for the passage of water. The lower housing body 24
receives the inlet extension 40, which extends perpendicularly
outward from the lower housing body 24. The connection of the inlet
extension 40 and the lower housing body 24 connects the inner
chamber 42 of the inlet extension to a lower chamber 44 within the
lower housing body 24.
[0038] A diaphragm assembly 52 is disposed within the upper housing
body 22 and the lower housing body 24 between the inlet 28 and the
outlet 32 and includes a diaphragm 56 and a disc 60. The diaphragm
assembly 52 has a diaphragm assembly opening 64 and a bypass
opening 68. As illustrated, the diaphragm assembly opening 64 is
centrally located on the diaphragm assembly 52 and the bypass
opening 68 may be peripherally located on the diaphragm assembly
52; however, they may be otherwise geometrically disposed. The
diaphragm 56 and the disc 60 extend circumferentially outward, each
defining an outer diameter. The outer diameter of the diaphragm 56
is larger than the outer diameter of the disc 60. The disc 60 is
received in a central opening in the diaphragm 56 that aligns with
the opening 64 in the diaphragm assembly 52. The diaphragm 56
receives a base 72 of the disc 60 in the central opening in the
diaphragm 56 while an outward protrusion 76 of the disc 60 is
disposed above a portion of a top surface of the diaphragm 56. The
base 72 of the disc 60 is threadably connected to a diaphragm
assembly extension 80. The diaphragm assembly extension 80 is
positioned below the diaphragm 56 and the disc 60 and is
cylindrical. The diaphragm assembly extension 80 defines a
peripheral chamber 82 between an outer wall of the diaphragm
assembly extension 80 and an inner wall of a valve seat 84 that
extends upward in the housing as a cylindrical column. When the
flush valve 20 is in the closed position as is illustrated in FIG.
1, the diaphragm assembly 52 is positioned on a top lip of the
valve seat 84 which places the diaphragm assembly 52 in a sealing
position between the inlet 28 and the outlet 32. An upper chamber
88 is positioned above the diaphragm assembly 52 and is in fluid
communication with the lower chamber 44 via the bypass opening 68
of the diaphragm 56.
[0039] Above and downwardly extending into the upper chamber 88,
there is a relief valve assembly 92. The relief valve assembly 92
is positioned within and supported by a fixed member 96 that is
secured between the upper housing body 22 and lower housing body
24, and an inner surface of the fixed member 96 may also provide a
top wall of the upper chamber 88 that provides a fluid boundary
that prevents fluid from communicating outside of the fixed member
96. The fixed member 96 may include an extension 98 that extends
vertically from a radial position of the fixed member 96. The
relief valve assembly 92 includes a motor 100 connected to a power
source 102 positioned outside of the fixed member 96. In a
non-limiting example, the power source 102 may be one or more
batteries.
[0040] The motor 100 has a shaft that extends out of the motor 100
and connects to a gear train 104 (which may also be referred to as
a drive train) which ultimately toggles whether the relief valve 92
is opened or closed. The gear train 104 shown features simple gears
and compound gears. One skilled in the art would appreciate the
gear train 104 shown is not limiting and could be modified in a
variety of applications. The gear train 104 connects to a driven
shaft 106 that extends away from the gear train 104. The driven
shaft 106 has a driven shaft extension 108 that extends
perpendicularly outward from the driven shaft 106 that selectively
contacts a rotational stop 110 that may be hemi-cylindrical in
shape to surround a portion of the driven shaft 106. The rotational
stop 110 can be supported by the fixed member extension 98. A
female driving member 112 receives an axially-translatable valve
element 114 that has a male lead screw part 116 positioned to be
received in the female driving member or part 112 and a seal body
118 on a bottom portion of the axially-translatable valve element
114 that selectively contacts a top surface of a stationary relief
valve housing 120. Although the male lead screw part 116 is
described in detail, alternative embodiments, which may feature a
male worm gear part, are possible. The stationary relief valve
housing 120 extends away from the axially-translatable valve
element 114 through the chamber 88 and into the diaphragm assembly
opening 64. The stationary relief valve housing 120 features an
upper body 124 that is received in the fixed member 96 (by threads
in the illustrated embodiment) and a lower body 128 that is
received in the diaphragm assembly opening 64. The stationary
relief valve housing 120 features a relief valve chamber or relief
passageway 132 that extends through the upper body 124 and the
lower body 128. The relief valve chamber 132 opens to an outlet
chamber 136 that is positioned below the relief valve assembly 92
in the lower housing body 24.
[0041] As best seen in FIG. 2, an inlet opening 152 in the housing
receives the inlet extension 40. The inlet opening 152 fixes the
inlet extension 40 to the lower housing body 24 and provides fluid
communication between the inner chamber 42 of the inlet extension
40 and the lower chamber 44 of the lower housing body 24. The lower
chamber 44 of the housing circumferentially surrounds the valve
seat 84.
[0042] An outer diaphragm groove 156 may allow the diaphragm 56 to
be secured between the upper housing body 22 and the lower housing
body 24. The outer diaphragm groove 156 may be within an outer
diaphragm profile 160 which provides an increased thickness around
the outer circumference of the diaphragm 56. The outer diaphragm
groove 156 may be in the top surface and bottom surface of the
outer diaphragm profile 160. In some embodiments, the outer
diaphragm groove 156 on the bottom surface of the diaphragm profile
160 is secured by the lower housing body 24 and the outer diaphragm
groove 156 on the top surface of the diaphragm profile 160 may be
secured by the fixed member 96 as best depicted in FIG. 1.
[0043] A bottom surface of outward protrusion 76 of the disc 60 may
be fixed to a top surface of the diaphragm 56. The outward
protrusion 76 of the disc 60 has a raised inner area 164 that has a
thickness greater than the thickness of the outward protrusion 76.
The disc 60 surrounds the lower body 128 of the stationary relief
valve housing 120 that is centrally positioned through the
diaphragm assembly 52 and is sealingly engaged therewith with an
O-ring 236 forming a seal between the diaphragm assembly opening 64
and the lower body 128 of the stationary relief valve housing
120.
[0044] Referring now to FIG. 3, the upper housing body 22 has a
sensor opening 188 that may be any appropriate shape. As shown in a
non-limiting example, the sensor opening 188 may be rectangular
with rounded edges oriented vertically on the upper housing body
22. The sensor opening 188 may be any appropriate shape to receive
a sensor 196 that is positioned within the upper housing body 22 or
to permit the sensor 196 to sense therethrough. The sensor 196 may
have an outward protrusion 200 that may be configured to fit within
the sensor opening 188 for purposes of assembly or construction. In
the form illustrated, the upper housing body 22 is configured to
contain the diaphragm assembly 52, the relief valve assembly 92,
and the sensor 196.
[0045] The power source 102 (see FIG. 1) is received within the
upper housing body 22. As best depicted in FIG. 3, the power source
102 may include a battery housing 204, one or more batteries 208,
and a battery housing cover 212. The battery housing 204 may have a
curved structure that is configured to fit within an inner wall of
the upper housing body 22. The battery housing 204 may be
configured to contain one or more batteries 208 within one or more
battery chambers 206 within the battery housing 204. In some
embodiments, the batteries 208 may be arranged vertically within
the battery housing 204. The battery housing cover 212 may be
configured to close the battery housing 204 with a shape that may
match the curved structure of the battery housing 204. A bottom
surface of the battery housing cover 212 may contact a top surface
of the battery housing 204 and may be secured thereon.
[0046] The relief valve assembly 92 (see FIG. 2) may be received
within the upper housing body 22. The motor 100 may be positioned
above the gear train 104 and the rotational stop 110. The gear
train 104 may be secured to the extension 98 of the fixed member 96
via fasteners fixed to a top surface of the extension 98 of the
fixed member 96. A plate 216 is positioned above the stationary
relief valve housing 120 and receives the female driving member 112
in an interior opening of the plate 216. The plate 216 is secured
to plate extensions 220 that extend from the top fixed member 96.
The plate extensions 220 may be cylindrical in shape and provide
clearance for the female driving member 112 over a top surface of
an upper body 228 of the fixed member 96. The relief valve assembly
92 is received in an opening 222 in the top of the fixed member
96.
[0047] The upper body 228 of the fixed member 96 may extend
vertically from a lower body 232 of the fixed member 96. The upper
body 228 of the fixed member 96 may be cylindrical having a hollow
inner chamber configured to receive at least the stationary relief
valve housing 120. The lower body 232 of the fixed member 96 may
extend radially outward from a bottom surface of the upper body 228
of the fixed member 96.
[0048] The female driving member 112 may be positioned around the
axially-translatable valve element 114 that is positioned above the
stationary relief valve housing 120. O-ring 236 is received at the
bottom of the stationary relief valve housing 120 and forms a
sliding seal between the diaphragm assembly opening 64 and the
lower body 128 of the stationary relief valve housing 120. A top
surface of the stationary relief valve housing 120 may have an
extension 238 that includes a relief valve inlet 240. In some
embodiments, the extension 238 is conical in shape and is
configured to be received in the seal body 118 of the
axially-translatable valve element 114. In other embodiments, the
extension 238 may be cylindrical, semi-spherical, or any other
appropriate shape than can be sealed by the seal body 118.
[0049] With additional reference back to FIGS. 1 and 2 in
combination with FIG. 3, the relief valve assembly 92 is positioned
above the diaphragm assembly 52 at least partially within the upper
housing body 22. The diaphragm assembly extension 80 extends below
the diaphragm 56 and features a diaphragm assembly upper support
244 and one or more diaphragm assembly guides 248. A bottom surface
of the diaphragm assembly upper support 244 is fixed to a top
surface of one or more diaphragm assembly guides 248. The diaphragm
assembly upper support 244 is cylindrical in shape and wraps around
the diaphragm assembly extension 80 while leaving a gap 246 around
an outer surface of the diaphragm assembly extension 80. The one or
more diaphragm assembly guides 248 are rectangular and are
positioned vertically on the outer surface of the diaphragm
assembly extension 80. The one or more diaphragm assembly guides
248 are spaced radially around the perimeter of the diaphragm
assembly extension 80. The one or more diaphragm assembly guides
248 may be placed at 90 degree intervals around an outer surface of
the diaphragm assembly extension 80. The diaphragm assembly 52
contacts a top surface of the valve seat 84 and the diaphragm
assembly extension 80 extends into the lower housing body 24.
[0050] Referring now to FIGS. 4-6, the relief valve assembly 92 may
be assembled with the gear train 104 positioned below the motor 100
and above the rotational stop 110. The driven shaft extension 108
is cylindrical in shape and extends perpendicularly outward from
the driven shaft 106 to selectively contact a face of the
rotational stop 110, depending on the rotational position of the
driven shaft 106 with respect to the rotational stop 110. The
driven shaft 106 has a gear 252 positioned near a bottom end of the
driven shaft 106 that drives a gear 254 on the exterior surface of
the female driving member 112. The female driving member 112 is
generally cylindrical in shape and has interior threads 258
positioned around the interior of an opening 260 in the female
driving member 112. The opening 260 and the interior threads 258
selectively receive the male lead screw body 116 of the
axially-translatable valve element 114.
[0051] The seal body 118 of the axially-translatable valve element
114 is positioned near a bottom end of the axially-translatable
valve element 114. The axially-translatable valve element 114 may
also feature one or more flat surfaces 256 on the exterior face of
the axially-translatable valve element 114 near the bottom surface
of the axially-translatable valve element 114. In some embodiments,
the seal body 118 may feature sealing surface 119 that selectively
seals the relief valve assembly 92 by contacting the extension 238
on the top surface of the stationary relief valve housing 120 and
the relief valve inlet or opening 240 (see FIG. 3), in particular.
In some embodiments, the sealing surface 119 may be made of an
elastomeric material. The relief valve inlet 240 is connected to
the relief valve chamber or passageway 132 that extends through the
interior of the stationary relief valve housing 120. The stationary
relief valve housing 120 has threads 262 around an outer surface
near the top of the stationary relief valve housing 120 that are
received by the fixed member 96 in order to secure the stationary
relief valve housing 120. One or more flat surfaces 264 (or other
removed sections) may be positioned near the top end of the
stationary relief valve housing 120 in the axial region of the
threading 262. As shown, the relief valve assembly 92 is offset
from the motor 100. In other embodiments, the relief valve assembly
92 can be coaxial with the motor 100.
[0052] Now that the components of the flush valve 20 have been
described in detail, their respective functionalities may be
appreciated and described more fully. Referring to FIGS. 4-8, the
motor 100 may be configured to generate rotational motion that is
translated through the gear train 104 to the driven shaft 106 and
the gear 252. The rotational motion of the driven shaft 106 causes
rotational motion of the gear 252 which meshes with the gear 254
connected to the female driving member 112 and consequently causes
rotational motion of the female driving member 112. The interior
threads 258 rotate with the female driving member 112 and
selectively engage the male lead screw body 116 of the
axially-translatable valve element 114 thereby selectively turning
the rotational motion from the motor 100 into axial translation of
the axially-translatable valve element 114.
[0053] Rotation of the female driving member 112 with respect to
the axially-translatable valve element 114 may change the position
of the axially-translatable valve element 114 due to the connection
between the male lead screw body 116 and the interior threads 258
of the female driving member 112. The flat surfaces 256 of the
axially-translatable valve element 114 engage an inner surface of
the fixed member 96 in order to prevent rotational movement of the
axially-translatable valve element 114. However, engagement between
the flat surfaces 256 and the fixed member 96 still allow the
axially-translatable valve element 114 to translate vertically due
to the rotation of the female driving member 112 and the engagement
between the interior threads 258 and the male lead screw body
116.
[0054] Selective movement of the axially-translatable valve element
114 defines a plurality of positions of the relief valve assembly
92. A first position of the relief valve assembly 92 shown in FIG.
7 is a closed position defined by the seal body 118 of the
axially-translatable valve element 114 being in sealed contact with
the extension 238 and relief valve inlet or opening 240 (see FIG.
8) of the stationary relief valve housing 120. In the closed
position, fluid communication is prohibited to pass through the
relief valve assembly 92. A second position of the relief valve
assembly 92 shown in FIG. 8 which is an open position defined by
the seal body 118 of the axially-translatable valve element 114
being axially translated away from the relief valve inlet 240
positioned near a top end of the stationary relief valve housing
120. Translation of the seal body 118 of the axially-translatable
valve element 114 away from the extension 238 and relief valve
inlet 240 of the stationary relief valve housing 120 allows fluid
communication through the relief valve assembly 92 via the relief
valve inlet 240 and the relief valve chamber 132.
[0055] Now with reference to FIGS. 9-11, the initiation of a flush
cycle by temporarily actuating the relief valve assembly 92 from
the closed position to the opened position is sequentially
illustrated. This brief opening of the relief valve assembly 92
will cause the entire diaphragm assembly 52 to lift, permitting
water to travel from the inlet 28 to the outlet 32.
[0056] FIG. 9 shows a detailed area A-A of the flush valve 20 in a
closed position with fluid retained in the flush valve 20 and is
unable to enter the outlet chamber 136 because the diaphragm
assembly 52 remains sealed against the upper lip of the valve seat
84. Fluid provided through the inlet 28 (not shown in FIG. 9, but
found in prior figures) into the inner chamber 42 which is in fluid
communication with the lower chamber 44. The lower chamber 44
surrounds an outside of wall the valve seat 84 and is in fluid
communication with the chamber 88 via the bypass opening 68 in the
diaphragm 56. The bypass opening 68 places the lower chamber 44 in
fluid communication with the upper chamber 88. The relief valve
inlet 240 is in selective fluid communication with the relief valve
chamber 132. The flat surfaces 264 of the stationary relief valve
housing 120 produce a gap between the flat surfaces 264 and the
fixed member 96. The gap between the one or more flat surfaces 264
and the fixed member 96 provide fluid communication between the
upper chamber 88 and the relief valve assembly 92 via the relief
valve inlet 240. In the position illustrated in FIG. 9, the relief
valve assembly 92 is in the closed position defined by the seal
body 118 of the axially-translatable valve element 114 being in
sealed contact with the extension 238 and relief valve inlet 240 of
the stationary relief valve housing 120. In the closed position,
fluid communication is prohibited to pass through the relief valve
assembly 92.
[0057] As mentioned above, the diaphragm assembly 52 is in a closed
position while the relief valve assembly 92 remains in the closed
position. The closed position of the diaphragm assembly 52 is
defined by the diaphragm assembly 52 being received against the
valve seat 84 creating a seal therebetween. The diaphragm assembly
52 may be held in a closed position by the force of fluid in the
chamber 88, exerting a downward force on the diaphragm 56 and the
disc 60, thereby pressing the diaphragm assembly 52 against the
valve seat 84.
[0058] FIG. 10 shows the area A-A of the flush valve 20 just after
the relief valve assembly 92 has been opened to initiate the
opening of the flush valve 20, but before water was passed entirely
through the relief valve assembly 92 to permit the diaphragm
assembly 52 to lift. The open position of the flush valve is
achieved when the motor 100 translates the seal body 118 of the
axially-translatable valve element 114 away from the extension 238
and relief valve inlet 240 positioned near a top end of the
stationary relief valve housing 120. Translation of the seal body
118 of the axially-translatable valve element 114 away from the
extension 238 and relief valve inlet 240 of the stationary relief
valve housing 120 allows fluid communication through the relief
valve assembly 92 via the relief valve inlet 240 and the relief
valve chamber 132. This creates fluid communication through the
relief valve assembly 92 such that water may pass from the upper
chamber 88 into the outlet chamber 136. Just after the relief valve
assembly 92 has been opened, the diaphragm assembly 52 may briefly
remain in the closed position. The diaphragm assembly 52 may remain
in the closed position just after the relief valve assembly 92
opens because the pressure exerted on the diaphragm assembly 52
temporarily holds it on the valve seat 84 as the pressure has not
been relieved through the outlet chamber 136.
[0059] FIG. 11 shows the area A-A of the flush valve 20 where the
relief valve assembly 92 has remained opened and the diaphragm
assembly 52 has lifted such that the flush valve 20 is now in the
open position. The open position of the flush valve 20 is achieved
when the fluid from the upper chamber 88 is allowed to flow through
the relief valve chamber 132 and into the outlet chamber 136 for a
sufficient duration of time to break the seal at the valve seat 84.
Fluid flow through the relief valve chamber 132 into the outlet
chamber 136 relieves pressure in chamber 88 exerted on the
diaphragm assembly 52. Under this change in pressure, the diaphragm
56 is flexible upward which causes vertical translation of the
diaphragm assembly 52 away from the valve seat 84 to break the
seal. Vertical translation of the diaphragm assembly 52 away from
the valve seat 84 provides direct fluid communication between the
lower chamber 44 and the outlet chamber 136 via the peripheral
chamber 82. Put another way, with the diaphragm assembly 52
unseated from the valve seat 84, the inlet 28 and the outlet 32 are
placed in direct fluid communication with one another past the
upper opening in the valve seat 84.
[0060] To close the flush valve 20, the motor 100 translates the
seal body 118 of the axially-translatable valve element 114 into
the closed position where the seal body 118 is in sealed contact
with the extension 238 and relief valve inlet 240 of the stationary
relief valve housing 120. In the closed position, fluid
communication is prohibited to pass through the relief valve
assembly 92. After returning to the closed position, the pressure
will rise in upper chamber 88 as fluid communication between upper
chamber 88, the relief valve chamber 132, and the outlet chamber
136 are shut off while the bypass opening 68 provides fluid
communication from the lower chamber 44 to the upper chamber 88.
The increased pressure in upper chamber 88 flexes the diaphragm
assembly 52 back down into a closed position by pressing the
diaphragm assembly 52 against the valve seat 84, as shown in FIG.
7. The closed position of the diaphragm assembly 52 again, at least
temporarily, prevents fluid communication between the lower chamber
44, the peripheral chamber 82, and the outlet chamber 136.
[0061] The flush valve 20 may be selectively in the open position
for a pre-defined or selected period of time and that period of
time may define a flush cycle. The period of time may be an
appropriate amount of time to generate fluid flow through the flush
valve 20 given the fixture on which the valve is received such as a
urinal or toilet. A non-limiting example of a period of time range
the relief valve assembly 92 may be in an open position for may be
0.5 to 3 seconds which may result in the flush valve to be open
from 3 to 10 seconds. The time the relief valve assembly 92 is
selectively in an open position may not be the time required to
complete a flush, as the flush valve 20 may be in a closed position
while residual fluid may flush.
[0062] A flush cycle may be initiated manually or automatically. An
automatic flush cycle may occur when the sensor 196 detects a user
has approached the flush valve 20 and will actuate the cycle when
the identified user has left the flush valve 20. The sensor may
communicate control instructions to the motor 100 to selectively
rotate the relief valve assembly 92 into the open position in order
to initiate a flush cycle. Alternatively, a flush cycle may be
initiated manually using a manual actuation assembly (not
shown).
[0063] It should be appreciated that various other modifications
and variations to the preferred embodiments can be made within the
spirit and scope of the invention. Therefore, the invention should
not be limited to the described embodiments. To ascertain the full
scope of the invention, the following claims should be
referenced.
* * * * *