U.S. patent number 3,693,649 [Application Number 05/024,247] was granted by the patent office on 1972-09-26 for water control for toilet tanks.
This patent grant is currently assigned to American Standard Inc.. Invention is credited to Frederick Armstrong Gordon, James Richard Griffin, John Joseph Pezzarossi.
United States Patent |
3,693,649 |
Gordon , et al. |
September 26, 1972 |
WATER CONTROL FOR TOILET TANKS
Abstract
Covers a water control valve for a water tank which is
associated with a conventional toilet bowl. The water control valve
includes a valve structure mounted on a vertical water inlet pipe
and a float structure which moves vertically along the inlet pipe
to control the valve structure. The float structure includes two
cup-shaped elements, one positioned vertically above the other,
both moving along the inlet pipe in response to any change in the
water level within the water tank. The valve structure includes a
flexible diaphragm which is normally positioned upon a seat at the
upper opening of the inlet pipe and blocks the flow of water into
the tank, and a pilot valve to control the movement of the flexible
diaphragm. The pilot valve is mechanically coupled to the float
structure so that, as the float structure descends toward the
bottom of the tank, the pilot valve will be opened and, in turn,
allow the diaphragm to be flexed upwardly to allow the entry of
water into the tank. When the float structure reaches an upper
predetermined position, the pilot valve will be closed and the
diaphragm will be returned to its normal position to block the flow
of water into the flush tank.
Inventors: |
Gordon; Frederick Armstrong
(Louisville, KY), Griffin; James Richard (Louisville,
KY), Pezzarossi; John Joseph (Louisville, KY) |
Assignee: |
American Standard Inc. (New
York, NY)
|
Family
ID: |
21819609 |
Appl.
No.: |
05/024,247 |
Filed: |
March 31, 1970 |
Current U.S.
Class: |
137/414;
73/322.5; 251/45; 137/432 |
Current CPC
Class: |
F16K
31/34 (20130101); Y10T 137/7374 (20150401); Y10T
137/7433 (20150401) |
Current International
Class: |
F16K
31/18 (20060101); F16K 31/34 (20060101); F16k
031/18 () |
Field of
Search: |
;137/408,414,424,429,430,432,442 ;73/322.5 ;251/45,46,245 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Nelson; M. Cary
Assistant Examiner: Matthews; David R.
Claims
What is claimed is:
1. Water control mechanism for a tank comprising a substantially
vertical water inlet pipe mounted within said tank, a substantially
vertical movable float structure comprising a buoyant main body
portion and an open ended top portion, the latter portion having a
bleed hole therein, said float structure being mounted
concentrically about said inlet pipe and being vertically movable
to be substantially level with the water within said tank, a pilot
valve having a piston which is substantially vertically movable and
is coupled by a lever which is extended downwardly to the float
structure, said mechanism also having a flexible diaphragm and a
stationary retainer for peripherally holding said diaphragm, said
diaphragm being relatively thin and substantially uniform in
thickness and positioned on one side of said piston and fluidically
coupled to the piston through a cavity in said retainer located on
one side of the diaphragm and freely responsive to the movement of
the piston to control the flow of water through said cavity, the
diaphragm responding to the movement of the piston in one direction
to reduce the water pressure on one side of said diaphragm and
allow the diaphragm to be deflected in one direction to open said
valve so that water may freely flow through said cavity into the
open-ended float structure, the diaphragm also responding to the
movement of the piston in the opposite direction to cause the
diaphragm to be deflected in the opposite direction to close the
valve by closing said cavity so that the flow of water through said
cavity into said open-ended float structure may be reduced and then
stopped, the diaphragm having a central aperture, and means fixedly
mounted within said movable diaphragm aperture for cleaning said
aperture during each deflection of said diaphragm, the discharge of
water through the bleed hole as the float structure rises
substantially increasing the buoyancy of the float structure.
2. Water control mechanism according to claim 1 in which the
cleaning means comprises a stationary pin made of steel and
exteriorly grooved and continually positioned immovably within the
movable diaphragm aperture for removing foreign material as the
diaphragm is deflected along the external surface of said pin.
3. Water control mechanism according to claim 2 in which the valve
is normally seated upon the vertical inlet pipe above the normal
water level within the tank, the flow of water through the inlet
pipe being controlled by the deflection of the diaphragm of the
valve.
4. Water control mechanism according to claim 1 in which the float
structure comprises two cylindrical cup-shaped members which are
vertically arranged and vertically movable as a unit so that the
upper cup member is open at the top and the lower cup member is
open at the bottom and the upper cup member receives water
discharged through the valve and has the bleed hole adjacent the
bottom thereof to relay the received water to the tank.
5. Water control mechanism for a tank comprising a substantially
vertical pipe positioned within the tank so that water may be
supplied under pressure to the tank, a valve mechanism normally
seated on the upper end of the vertical pipe and above the water
level within the tank and having a thin, freely flexible diaphragm
having an aperture, said diaphragm being of substantially uniform
thickness so as to be flexible for the rapid control of the flow of
water through the vertical pipe, a stationary retainer for
peripherally holding said diaphragm while permitting the center of
said diaphragm to be deflected, said valve mechanism incorporating
a pilot valve positioned on one side of said diaphragm above the
water level within the tank, said retainer having an opening
therein for fluidically coupling the pilot valve to said diaphragm
for controlling the movement of the diaphragm, a float structure
having an open top cup with a bleed hole and an inverted bottom
cup, both cups being concentrically arranged about the vertical
pipe but below said valve mechanism and movable in response to
changes in the level of the water within the tank, the diaphragm
having a substantially central aperture, a substantially vertical
pin fixedly mounted within a sleeve of said retainer so that the
pin will be stationary and within said diaphragm aperture and
remaining stationary as the diaphragm deflects in either direction
about said pin, and means responsive to the movement of the float
structure in one direction for operating the pilot valve for
changing the pressure on the diaphragm and deflecting the diaphragm
of the valve mechanism so as to allow water to enter the float
structure, the pilot valve being opened and the diaphragm being
elevated when the level of the water in the tank has dropped only a
small distance to permit the flow of water through the vertical
pipe into the tank, the pilot valve being closed and the diaphragm
being deflected in the opposite direction to reduce the flow of
water into the float structure and then stop the flow of water
through the vertical pipe when the level of the water in the tank
has reached a predetermined upper level, the discharge of water
through the bleed hole of the open top cup increasing the buoyancy
of the float structure as it rises so as to improve the closing
action of the pilot valve.
6. Water control mechanism according to claim 5, in which the
vertically arranged continuously stationary pin positioned within
the aperture of the diaphragm is grooved, so that as the diaphragm
moves in either direction, foreign matter deposited or to be
deposited within said aperture will be displaced from said
aperture.
7. Water control mechanism according to claim 5 in which the pilot
valve includes a substantially vertically moving plunger which is
coupled by a lever extending downwardly to the float structure.
8. Water control mechanism according to claim 5 in which the pilot
valve has a piston positioned adjacent the opening in the retainer
and movable to control the pressure applied to the diaphragm to
thereby control its deflection.
9. A water control valve for a tank, including within said tank a
substantially vertically arranged water inlet supply pipe, a valve
normally seated adjacent the upper end of said inlet pipe and
continuously positioned above the water level within said tank, an
open-top float structure concentrically arranged about the inlet
pipe for receiving some of the water discharged from said valve and
for responding to the level of the water within the tank, said
valve having a stationary retainer for a peripherally retained
thin, easily flexible diaphragm of substantially uniform thickness
and having a concentric aperture and including means to seal the
upper end of the inlet pipe, a pilot piston mechanism to control
the operation of the diaphragm, said retainer having an opening
therein aligned with the pilot mechanism to control pressure on the
diaphragm, means responsive to the downward movement of the float
structure to operate the pilot mechanism and in turn relieve the
pressure on the diaphragm so as to elevate the diaphragm and allow
water to flow through the inlet pipe and through the valve into the
open-top float structure and into the flush tank, and responsive to
the movement of the float structure to a predetermined upper level
to close the pilot mechanism and return the diaphragm to its normal
position to cause the diaphragm to be re-seated adjacent to and
atop of the inlet pipe, a pin fixedly held by said retainer and
mounted so as to be spaced within the aperture of the diaphragm for
preventing the clogging of the aperture as water flows therethrough
with each movement of the diaphragm about said pin, and means to
improve the buoyancy of the float structure, said means including a
bleed hole in said float structure to release water therefrom as
the float structure rises in said tank.
10. A water control valve according to claim 9, in which the float
structure includes two cup-shaped members which are substantially
vertically arranged, the upper cup-shaped member being open at the
top for receiving water discharged from the valve and having a
bleed hole for discharging the received water, the lower cup-shaped
member being open at the bottom and substantially responsive to the
level of the water within the flush tank to raise the float
structure and cause the operation of the valve.
11. A water control valve according to claim 9, in which the pilot
mechanism includes a piston which is positioned adjacent the
opening in the retainer and is coupled by a lever extending
downwardly to the float structure and moves substantially
vertically.
12. A water control valve according to claim 11, in which the
piston of the pilot mechanism is fluidically spaced from and
coupled to the diaphragm.
13. Fluid control mechanism for a tank, comprising a substantially
vertically moving float mechanism composed of two cup-like members
one of which is open at the top with a bleed hole therein adjacent
its bottom and the other is open at the bottom, a valve mechanism
having an apertured retainer supporting a stationary vertical
externally grooved pin and a substantially vertically moving
piston-like element and a substantially uniformly thin flexible
diaphragm peripherally held by said retainer and spaced from the
fluidically coupled to said element by and through said aperture in
said retainer which separates said element from said diaphragm,
means for mechanically coupling said float mechanism to said
element of said valve mechanism so that said float mechanism and
said element move only in opposite directions, said diaphragm
having a central opening within which said pin is spacedly
positioned and remains stationary as the diaphragm moves in either
direction about said pin, said aperture in said retainer and said
opening in said diaphragm being spaced from each other by a
substantially unobstructed path, and means responsive to the
lowering of the float mechanism to operate the valve mechanism to
permit fluid to enter the cup-like member which is open at the top
and the tank through said unobstructed path and responsive to the
return of said float mechanism to its original position to release
the valve mechanism to interrupt the flow of fluid into the latter
cup-like member and into the tank through said unobstructed path,
the bleed hole exiting water into said tank to increase the
buoyancy of the float mechanism as it is returned to its original
position.
Description
This invention relates to water control valves which are used in
and in conjunction with a flush tank associated with a conventional
toilet bowl for controlling the flow of water into the flush tank
after the toilet bowl has been flushed.
Various arrangements have heretofore been proposed for controlling
the flow of water into the flush tank associated with a toilet
bowl. One of the most common types of control mechanisms includes a
vertical water inlet pipe, which may be connected to the water
supply system for receiving water whenever required to refill the
tank, along with an inlet water valve and a conventional float
coupled to the inlet valve by the usual long substantially
horizontal rod. In such mechanisms, the float is usually
ball-shaped and floats on the water surface within the tank. When
the tank is in its substantially filled position, the inlet water
valve will be closed to block the inflow of water through the inlet
pipe and into the tank. After a flushing operation during which the
water level has dropped almost to the bottom of the tank, the
float, in its receded position near the bottom of the tank, will
cause the inlet valve to be opened so that the tank may be
refilled. After the water within the tank has reached its assigned
upper level, the float mechanism will cause the inlet valve to
become closed, thereby blocking any further inflow of water into
the tank.
The ball float type of structure above referred to has several
significant limitations. It requires considerable space for the
operation of the lever mechanism interconnecting and coupling the
ball float to the inlet valve. It is also slow in operation and,
moreover, it is noisy, ofttimes producing a hissing sound which can
be disturbing to those in the vicinity.
Other types of water control valves have also been proposed
heretofore. One of these other types embodies a pair of flexible
diaphragms which are intended to respond to the level of the water
within the tank or to the water pressure in the vicinity of the
diaphragms. When deflected, these diaphragms operate an input valve
for conrolling the inflow of water to the water tank. Such
structures are rather complex and therefore difficult to
manufacture. They are expensive and subject to operating failures
which introduce maintenance problems.
In accordance with this invention, a new form of water control
valve is provided which includes a vertically arranged water inlet
pipe or shank extension connected, for example, to the city water
supply system, a main valve structure mounted fixedly at or near
the top of the shank extension and a relatively small float
structure which moves vertically and is closely spaced from but
moves along the shank extension or sheath tube, if employed. The
float structure includes two cup-shaped elements, one surmounted
vertically above the other, the upper cup-shaped member being open
at the top while the lower cup-shaped member is open at the bottom.
The double-cupped float structure is mechanically coupled to the
main valve mechanisms by means of a vertical rod which responds to
and continually follows the vertical movement of the float
structure. A lever is employed to couple the vertical rod to a
pilot valve element in the main valve structure and in turn it
controls the pilot valve. The pilot valve includes a piston-like
element which moves vertically to initiate the inflow of water
through the shank extension and into the main valve, together with
a single flexible diaphragm which is normally seated on the inlet
seat located generally at the upper end of the shank extension and
is controlled by the pilot valve. When the water within the tank
falls below its normal upper level immediately following a flushing
operation, the lever-controlled pilot element will be raised and,
in turn, actuate the diaphragm so as to elevate the diaphragm above
the inlet seat. This will allow water to flow freely through the
main valve and into the tank. When the water level is risen
sufficiently within the tank, the lever-controlled pilot element
will be returned to its former or lowered position, thereby causing
the flexible diaphragm to be repositioned on the inlet seat to shut
off the flow of water into the tank. The operational structures and
features will be outlined hereinafter.
This invention, together with its objects and features, will be
better and more clearly understood from the following description
and explanation, when read in connection with the accompanying
drawing in which:
FIG. 1 illustrates a side elevational view, partly in section, of
the principal mechanism of this invention;
FIG. 2 shows a top plan view of the arrangement of FIG. 1;
FIG. 3 shows a partial cross-sectional view taken along the lines
3--3 of FIG. 2, this figure showing the main valve mechanism in its
closed position;
FIG. 4 is a view similar to that of FIG. 3, in which the main valve
mechanism is shown in its open position;
FIG. 5 shows a cross-sectional view of the float structure per
se;
FIGS. 6A and 6B show two views of the diaphragm retainer, which is
one of the components of this invention, FIG. 6A showing a view
from the underside of the retainer while FIG. 6B shows a side view
of the retainer;
FIG. 7A shows a cross-sectional view of a portion of the diaphragm
of the main valve mechanism of this invention, and FIG. 7B shows a
plan view of the same diaphragm;
FIGS. 8A and 8B show two views of the diaphragm valve seat-body,
FIG. 8A showing a cross-sectional view of the valve seat-body and
FIG. 8B a plan view of the valve seat-body; and
FIG. 9 shows a cross-sectional view of a portion of the lower cap
structure .
Referring to FIG. 1 of the drawing, there is shown part of a flush
tank 2 which is normally mounted somewhat above pg,5 the toilet
bowl (not shown) with which the flush tank 2 is to be associated.
The float structure 5 includes two cup-shaped chambers 4 and 6
which are separated by a horizontal wall or barrier 8. The float
structure 5, therefore, is vertically movable as a unitary
structure about the vertical sheath tube 10 which is vertically
supported on a cylindrical shoulder 12 of a sheath tube shank 14. A
shank extension 15 is mounted concentrically within the sheath tube
10 and its lower end is threadedly connected to an opening in the
shank 16. The sheath tube shank 14 is mounted on a circular
peripheral washer 20 which is mounted on the inner bottom wall of
tank 2. The lower end of the shank 16 extends through the bottom
opening of tank 2 as shown and is held in place by a nut 13 which
may have conventional bleed holes 13'. The function of the bleed
hole 13' will be subsequently explained. The sheath tube shank 14
is threadedly connected to a flanged portion of shank 16 as
shown.
The main valve mechanism 26 is fixedly mounted at or upon the upper
end of shank extension 15. The main valve mechanism 26 includes two
cap members, an upper cap 28 and a lower cap 30. A flexible
diaphragm 32, as is more clearly shown in FIGS. 3 and 4, is
peripherally held between the two cap members 28 and 30 and the
diaphragm is so held by screws 34. Because the diaphragm 32 is held
peripherally by the two cap members 28 and 30, the central part of
the diaphragm 32 is therefore free to move upwardly or downwardly
against a valve seat structure 31, as will be explained. The
diaphragm 32 has a central opening 35 positioned about a pin 40
which is vertically disposed therein, as shown. A diaphragm
retainer 42 has a central aperture 44 for receiving and permanently
holding the upper end of the pin 40. The retainer 42 is maintained
in a stationery position and hence the pin 40 is vertically
positioned within the aperture of diaphragm 32 and is immovable.
Thus, the diaphragm 32 can be moved alternately and repeatedly up
and down in a vertical position about the stationary pin 40
throughout the repeated operations of the main valve 26.
As shown in FIGS. 1, 3 and 4, the chambers 4 and 6 of the float
structure 5 are mechanically coupled to a vertical rod 50 so that,
as the float structure moves upwardly or downwardly, the rod will
likewise move upwardly or downwardly over the same vertical
distance. The float rod 50 is shown mechanically coupled to a
substantially horizontal lever 54 which is pivoted at 58 to a
plunger element 60 which is retained and controlled by the lever
54. The plunger 60 is part of a pilot valve which is within the
main valve 26 and is intended to move in a substantially vertical
direction in response to the angular displacement of lever 54 about
its pivot 58.
A hush tube designated 64 is provided, as shown in FIGS. 1 to 4, to
release water via the main valve 26 into the flush tank 2. A
convention refill tube designated 80 is provided to feed some of
the water into the toilet bowl near the end of each flushing
operation, as is well known. This fluid is employed as a seal in
the toilet bowl.
We shall now consider the general operation and the features of the
mechanism of the invention.
Upon the operation of the conventional external handle or lever
(not shown) on the outside of the flush tank 2 to flush the toilet
bowl, the water previously accumulated within the flush tank 2 will
be released into the toilet bowl through a flush valve (not shown)
which is positioned in the bottom of the tank 2. The float
structure 5, continually occupying a position dependent upon, and
responding to, the level of the water within the flush tank 2, will
move downwardly to the limit of its fixed travel. This downward
movement of the float structure 5 will cause a corresponding
downward movement of the float rod 50, which is coupled to the
float structure 5 as shown. Hence the lever 54 will be moved about
its pivot 58 in a clockwise direction (when viewed in FIG. 1). This
causes the plunger 60, which is mechanically coupled to the lever
54, to be raised so as to open the pilot hole or aperture 56. It
will be noted in FIGS. 3 and 4 that a small drop in the water line
W will cause full opening of the pilot hole 56, the advantage of
which will be hereinafter described. This allows water within the
cavity 62 above the diaphragm to travel through the pilot hole 56
provided in the diaphragm retainer 42 through passage 68 formed in
the cap 28, and into the upper chamber 4 of the float structure 5.
This discharge of water in cavity 62 to atmosphere reduces the
pressure on the upper side of diaphragm 32, thereby allowing the
incoming water from shank extension 15 to lift diaphragm 32 above
the valve seats 33, 33'. Water will now flow through the shank
extension 15 and over the main valve seats 33, 33', then along the
underside of diaphragm 32, then through the discharge ports 72 and
passageways 74 and through hush tube 64 into the flush tank 2. This
is the main water supply to flush tank 2 for the refill
operation.
Some of the water reaching the upper chamber 4 will be discharged
through a bleed hole 70 at or near the bottom of the upper
container 4 but the flow of water through the bleed hole 70 will be
at a restricted rate due to the relatively small size of the bleed
hole 70. Any recess or overflow of water above the volume
retainable by the upper container 4 will always be released into
the flush water tank 2 for filling the tank.
As pointed out hereinabove, a small drop in the water line W and a
corresponding drop of float 5 will cause the full opening of the
pilot hole 56. This has the advantage in that the pressure in
chamber 62 is immediately reduced, causing virtually instantaneous
full flow of refill water through the valve 26 to tank 2. This
refill water, added to that already in the tank 2, generally causes
a more complete and improved flushing action of the toilet bowl.
Conventional ball-type valves do not allow full flow until the ball
has dropped to its lowest level.
When the water within flush tank 2 rises to a sufficient level, the
resulting elevated position of the float rod 50 will move the lever
54 about its pivot 58 in a counter clockwise direction, thereby
moving the plunger 60 of the pilot valve downwardly to partially
close the pilot hole 56. As soon as the flow of water through the
pilot hole 56 becomes less than the flow of water through the
generally annular opening formed between pin 40 and the central
opening 35 of diaphragm 32, the diaphragm 32 will move downwardly
to cover discharge ports 72 and also seats 33 and 33' and stop the
flow of water through hush tube 64 and to refill tube 80. As water
is released through the bleed hole 70, the weight of the float
structure will be correspondingly reduced, thereby adding buoyancy
to the float structure 5. After an interval determined by the inlet
water pressure and the relative proportions of the different
associated parts, the float rod 50 will be moved upward
sufficiently so as to firmly close the plunger 60 against its seat
110 and thereby completely shut off the water flow through the
pilot hole 56.
It is noted, therefore, that upon the upward flexure of the
diaphragm 32, a sufficient volume of water will be received from
the shank extension 15 and promptly released through the discharge
ports 72, then through the passageway 74 and then through the hush
tube 64 into the flush tank 2 as already explained. At the same
time, some of the water entering from the shank extension 15 will
be discharged through the refill tube 80 to provide a seal for the
toilet bowl in the conventional manner.
The diaphragm 32 will close the cylindrically arranged discharge
ports 72 before the central section of the diaphragm 32 is brought
to rest on the pitched circular seats 33 and 33' at the upper side
of the valve seat body 31 and at the upwardly extending center
portion of lower cap 30. The general contour of circular seat 33 of
the valve seat body 31 is seen in FIG. 8A. The general contour of
circular seat 33' is seen in FIG. 9. As seen in FIG. 4, the
flexible diaphragm 32 will be deflected to the greatest extent at
its central region adjacent to the pin 40. The diaphragm 32 will
come to rest against the valve seats 33 and 33' and shut off the
water supply. The closure of the peripherally arranged discharge
ports 72 before diaphragm 32 is brought to rest against the valve
seats 33 and 33' may cause oscillatory driving forces to act upon
the diaphragm 32 to render it into vibratory motion thereby
producing what is generally known as "water hammer". To reduce or
eliminate the tendency toward the production of "water hammer", the
radial passages 120 (see FIG. 8b) are especially provided in the
valve seat body 31. These passages, which will preferably
correspond in size and number to the discharge ports 72, effect a
smoother closure of the diaphragm 32 against the main valve inlet
seats 33 and 33'. It is a feature of this invention to secure the
properly timed and smooth closure of the inlet seats 33 and 33'
after the discharge ports 72 have been closed by diaphragm 32.
The plunger 60 of the pilot valve has a groove 90 so that it may
receive and retain the fingers of the lever 54. A limited amount of
lateral movement is provided by the spaces between the plunger 60
and the lever 54. Thus, the lever 54 may be rotated about its axis
58 in response to the vertical movement of float 5 as the water
level rises and falls within the tank 2. This will cause the
plunger 60 to be pushed down or pulled up substantially along a
vertical path. In other words, the construction of the plunger 60
and lever 54 is arranged to enable the plunger 60 to be moved
substantially vertically in response to the angular motion of lever
54 about its pivot 58. This facilitates a more precise opening and
closing of the vertical pilot hole 56 by the plunger 60 of the
pilot valve structure with a minimum of leakage.
The plunger 60 has a segment 92, preferably a flexible or rubber
segment, affixed to its lower end so that the flexible or rubber
segment will be firmly seated against the elevated seat 110 at the
upper end of pilot hole 56 when the valve 26 is to be closed and
leakage prevented. The rubber attachment 92 should be shaped so as
to seal the upper cap 28 and thereby prevent any fluid within the
main valve chambers from being released through the spaces provided
around plunger 60. Thus, any spray or unintended discharge of water
from the valve mechanism 26 is eliminated.
As already suggested, the upper cap 28 provides the main passageway
through which water flowing through the pilot hole 56 may be
discharged into the upper chamber 4 of the float structure 5. Water
flowing upwardly through the pilot hole 56 and through the passage
68 formed in the upper cap 28 will be received in the upper chamber
4 of the float structure 5 only during the time when the flush tank
2 is to be refilled.
The diaphragm retainer 42 is positioned within the upper cap 28
which is so shaped internally as to provide a large contact area
with the upper surface of the diaphragm retainer 42 to establish a
good physical support for the diaphragm 32 in its upper position.
In the absence of adequate support, the diaphragm retainer 42 might
be flexed beyond its limit and possibly cracked due to the stresses
applied.
The diaphragm retainer 42, as already noted, fixedly supports the
central pin 40 in a continuously stationary position and remains
inserted within the aperture 35 of the diaphragm 32 as it is flexed
upwardly. Radial grooves 140 formed in the underside of diaphragm
retainer 42 prevent the cohesion of the diaphragm 32 to the
underside of the diaphragm retainer when the main valve is in its
open position. Such cohesion would cause the malfunction of the
main valve structure. The adherence of the diaphragm 32 to retainer
42 can cause an oversupply of water to the flush tank 2 and
possibly also a flooding of the bathroom. Another function of
radial grooves 140 is to provide adequate distribution of water
above diaphragm 32 to assure sufficient driving force on the upper
surface of the diaphragm when pilot hole 56 is closed.
As will be more clearly seen in FIGS. 3 and 4, the upper surface of
the diaphragm retainer 42 is provided with a pitched seat 110 for
receiving the resilient attachment 92 of the plunger 60, the edges
of the seat being fairly sharp. The downward movement of the
plunger 60 is physically limited by the projecting region of seat
110. The relatively sharp-edged configuration of pilot seat 110
allows for the smallest practical pilot hole area possible to
assure the minimal pressure required to positively close off the
pilot hole area.
The pin 40 may be any linear pin which can be conveniently
press-fitted into the diaphragm retainer 42 and yet it should be of
a size to be enterable into the aperture of the diaphragm 32 and
interpose little or no friction as it moves up or down. The pin 40
may preferably be a grooved stainless steel pin, for example, a pin
which is commercially known as "Driv-Lok". Although slots or
grooves on pin 40 are not indispensible to the practice of the
invention, they are preferable especially because they aid in
establishing positive cleaning or wiping action to remove particles
of dirt or other material from being deposited on the central
opening 35 of the diaphragm 32 as it is flexed during each
operation of the main valve. The grooves provide a scraping action
and also maintain constant the size of the central aperture of the
diaphragm 32 for the free movement of water upwardly through the
spaces between the outer regions of the pin and the walls of the
aperture into the upper chamber 62 of the valve.
The plunger 60 to which the flexible or elastic attachment 92 is
affixed is so arranged that, at the moment when the main valve is
to be closed, there will be relatively light closing pressure
applied by plunger 60 against the seat 110. Thus, as the flow of
water through the pilot hole 56 is sufficiently reduced, the
diaphragm 32 will begin moving in a downward direction to close
discharge ports 72 and the main valve seats 33 and 33'. Under
conditions of excessively high inlet pressure or when certain
relationships exist between the effective areas of the pilot hole
56 and aperture 35 of diaphragm 32, some of the water will leak
through the pilot hole 56 until the float structure 5 is buoyed up
sufficiently to supply the additional force downwardly directed to
more firmly close the plunger 60 against the seat 110. In order to
keep the pilot hole closing time as short as possible, the float
structure 5 has been arranged and proportioned so that all of the
water in the upper chamber 4 of the float structure will drain
through the bleed hole 70 into the flush tank 2. Thus, the loss of
water from chamber 4 will add buoyancy to the float structure to
raise the float structure sufficiently so as to fully shut off the
pilot hole 56 and any further inflow of water. The quantity of
water lost from chamber 4 will not appreciably raise the water line
W after the main valve mechanism 26 has been closed off.
The pilot hole 56 is the first passage to be opened when the flush
tank 2 is to be refilled and it is likewise the first passage to be
closed when the refilling operation is to cease. The diaphragm 32
is raised as the pilot hole is opened to allow water to enter the
tank 2 rapidly and it is likewise closed as the pilot hole 56 is
closed to stop the water flow.
FIGS. 3 and 4 show the flexible backflow washer 98. When the main
valve mechanism is in the shut-off state as shown in FIG. 3, the
backflow washer 98 assumes a generally horizontal relaxed position
just below the bottom surface of the valve seat body 31. When the
main valve mechanism is in the "on" or open position, as shown in
FIG. 4, the water being discharged through discharge ports 72
forces the backflow washer 98 downward against the sloping surface
of lower cap 30 to allow the water to pass on to the hush tube 64
and to the refill tube 80.
If a sub-atmospheric pressure should develop in the shank extension
15 due, for example, to the connection of a pump to the city supply
system on account of a fire or other contingency, the backflow
washer 98 will be sucked upwardly against the underside of the
discharge ports 72 to block the return flow of water from tank 2 to
shank extension 15. Were it possible to return any of the tank
water to the city supply system, contamination of the water supply
might occur and possibly become a dangerous health factor. Thus,
while water is traveling upwardly through the shank extension 15
through the valve mechanism 26 and then through the hush tube 64
into the tank 2, it will nevertheless be impossible for water to be
returned from tank 2 to the shank extension 15 to contaminate the
city water supply when suction is developed in shank extension 15
due to the interposition of the backflow washer 98.
Air holes or openings 130 are provided in the sloping surface of
the lower cap 30 as shown in FIGS. 3 and 4. When the main valve
mechanism 26 is in the open or "on" position, as shown in FIG. 4,
the backflow washer 98 is forced downward as previously described.
Thus, the air holes 130 may be sealed off by the backflow washer 98
whenever required, thereby preventing the discharge of water
through the openings 130.
If foreign particles prevent the closure of the discharge ports 72
by the backflow washer 98 at a time when sub-atmospheric pressure
conditions exist in the shank extension 15, actual backflow of
water from tank 2 will be prevented because air would be pulled
into the air holes 130 from the surrounding atmosphere. The total
area of the air holes 130 is sufficient to supply enough air to the
cavity below the backflow washer 98 to prevent the siphoning of
water from tank 2 through the hush tube 64 or the refill tube
80.
All of the ports of the valve mechanism 26 of this invention,
although shown as relatively small, have been made sufficiently
large so as to enable free and easy passage of the kinds of foreign
matter normally expected to be found in the usual water supply.
Moreover, the central aperture 35 of the diaphragm 32 is
maintained, by means of pin 40, in a relatively clean condition at
all times so as to avoid or remove any scale deposits in or near
the diaphragm opening 35. Such scale deposits on pin 40 or on the
walls of aperture 35 would reduce the efficiency of the valve
mechanism 26 and ultimately clog the central opening 35. This would
reduce the efficiency of the main valve 26 and perhaps render it
inoperative. The continuously maintained cleanliness of the central
aperture 35 is an important feature in the operativeness and the
minimal maintenance requirements of this structure.
While a hush tube 64 is shown as a conventional pipe or conduit for
simplicity of explanation and illustration, it may be any form of
chamber, whether a swirl chamber or not, for supplying water to a
water tank or reserve cistern or a toilet bowl. The hush tube 64
may, if desired, be filled with a foam material so as to improve
the quietness of the water flow therethrough into main tank 2. The
mechanism of this invention will operate at a relatively low noise
factor.
It will be apparent that water fed from the city water supply
upwardly through the shank extension 15 will be supplied both
through the hush tube 64 to fill the tank 2 and through the refill
tube 80 to the toilet bowl to provide the desired water seal in the
toilet bowl. When the water within the tank 2 is at its normal or
assigned upper level ready to be discharged to the toilet bowl by
the conventional lever (not shown) wherever this is required, the
diaphragm 32 will be, and will remain, in its lower position to
block the influx of water through the main valve seats 33 and 33'
and, at the same time, the plunger 60 and its flexible or elastic
attachment 92 will be seated on and held against the pilot valve
seat 110. No water will be traveling through either the hush tube
64 or the refill tube 80. In other words, no water will be
traveling through the valve equipment 26.
However, after the control valve or hand lever on the outside of
the tank 2 (not shown) is manipulated by the user to discharge the
water accumulated in tank 2 into the toilet bowl, the float
mechanism 5 will cause the pilot plunger 60 to open the pilot hole
56 which in turn relieves the pressure above diaphragm 32 so that
water may enter the tank 2. Water can enter the tank 2 in volume
only after the diaphragm 32 has been raised above the main valve
seat 33 and 33. When this occurs, the upwardly flowing water will
be directed over the valve seat 31 into the discharge ports 72
leading to the hush tube 64 and to the refill tube 80. Some water
will also travel upward through the central aperture 35 of the
diaphragm 32 into the chamber 62 below the retainer 42 through the
pilot hole 56. While the float structure 5 remains below its
uppermost position, the flow through the pilot hole 56 will be
released through passage 68 formed in the upper cap 28 into the
upper chamber 4 of the float structure 5. Water will continue to
flow through the hush tube 64 and the refill tube 80 until the
float structure 5 has risen substantially to its uppermost
position. When the uppermost position is reached, both the pilot
seat 110 and the main valve seats 33 and 33' will be sealed again,
the diaphragm 32 will also be back to its normal or lower position
and the plunger 60 will be back to its lower position.
There is a controllable, very small, timed relation, i.e., a
predetermined small time interval, between the initial downward
movement of the float mechanism 5 and the corresponding upward
movement of plunger 60. The plunger 60 will be displaced from its
seat 110 whenever the float mechanism 5 is spaced even by a small
distance from its normal upper position. The flow of water into the
flush tank 2 will be maximized almost from the initial displacement
of plunger 60. But when the float mechanism 5 is returned
substantially to its normal upper position, the plunger 60 will be
returned promptly to its pilot valve seat 110, thereby locking the
main valve 26. This correspondingly introduces a substantially
sudden closure of the main valve mechanism 26.
Both the float structure 5 and the plunger 60 are assigned to, and
travel over, substantially parallel paths. The mechanism which
interconnects these two structures is arranged to maintain
substantially linear vertical travel at all times.
In the vent that the shank extension 15 becomes fractured or broken
even to a limited or small extent, the water within the shank
extension 15 will then flow into the very narrow space between the
shank extension 15 and the sheath tube 10. The water will then be
drained through the space between the shank 16 and the sheath tube
shank 14. The water will then travel through the opening in the
bottom of the tank 2 at the periphery of the shank 16 and be
discharged through the bleed holes 13' of the nut 13. The water
will leak to the floor.
If back flow conditions exist in the water distribution system at
the time a hole or crack is present in the wall of the shank
extension 15, water cannot be sucked from tank 2 because of the
barrier afforded by sheath tube 10. Thus, contamination of the city
water system will not be possible.
Backflow prevention is shown and described herein because it is
required in many localities. However, this feature may be omitted,
if desired.
While the invention and its features have been shown and described
in certain particular arrangements for illustration and
explanation, it will be clearly understood that the general
features and objectives of this invention may be organized in many
different arrangements without departing from the spirit of the
invention.
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