Note: Descriptions are shown in the official language in which they were submitted.
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FLUSH VALVE DIAPHRAGM ORIFICE INSERT AND RIB DESIGN
BACKGROUND OF THE INVENTION
Cross-Reference to Related Applications
[0001] This application is a divisional of Application No. 2,434,609, filed
July 8,
2003.
Field of the Invention
[0002] The present invention relates, in general, to a flush valve diaphragm
for
urinals and other plumbing equipment and, more particularly, to a flush valve
diaphragm rib design and bypass orifice filter insert.
Description of Related Art
[0003] Typical diaphragm-type flush valves for use on toilet devices, such as
urinals and water closets, utilize a flexible diaphragm to establish and to
seal off the
connection between an inlet and outlet of a flush valve. Typically, the
diaphragm is
made of an elastomeric material, such as rubber, and includes a filter and a
bypass
orifice which provides fluid communication between the inlet side of the flush
valve
and an upper chamber of the flush valve. Such flush valve diaphragms are
described
in U.S. Patent No. 6,299,128 B1.
[0004] The performance of prior art diaphragm-type flush valves can depend
upon
how well the diaphragm seals off the connection between the inlet and the
outlet.
Inadequate sealing of the diaphragm can occur when a diaphragm loses its
elasticity
and becomes distorted due to the constant flexing of the diaphragm after
extensive
use. The performance also depends on the pressure drop between the opposite
sides
of the diaphragm due to the bypass orifice. A clogged bypass orifice can
prevent
water from flowing to the top side of the diaphragm, which results in an
inadequate
seal. It is desirable to provide a filtering element with the bypass orifice
in order to
eliminate effectively particulates, which may clog the water passageway of the
bypass
orifice. In addition, water hammer resulting from the diaphragm closing too
quickly
against the valve body can also be a problem that affects the performance of
the flush
valve.
[0005] It is, therefore, an object of the present invention to eliminate the
above-
mentioned deficiencies by providing a diaphragm assembly with improved
performance, longer useful life, and service in diaphragm-type flush valves.
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SUMMARY OF THE INVENTION
[0006] The present invention provides for a bypass orifice filter insert for
use in a
flush valve diaphragm that includes an annular-shaped first body having ends
and a
tapered or a frusto-conical-shaped second body attached to the first body. The
first
body having a flange attached to each end defines an orifice. The second body
which
is attached to the first body via the flange defines a slit, wherein the slit
of the second
body is in fluid communication with the orifice in the first body. The bypass
orifice
filter insert can be made from a unitary piece of molded material.
[0007] The present invention also provides for a diaphragm for use in a
diaphragm-
type flush valve. The diaphragm includes a flexible diaphragm body having a
first
side and a second side and defining an outer periphery, a center passageway
defined
in the diaphragm body, an annular protrusion defined on the second side of the
diaphragm body adjacent the center passageway, and a plurality of protruding
ribs
having a first end and a second end defined on the second side of the
diaphragm body
adjacent the protrusion. The first end of each rib extends radially outward
away from
the center passageway toward the second end of the rib. A recess area is
defined
between the first end of the rib and the protrusion. When a pressure
difference is
applied across said diaphragm body, the second side of the diaphragm body is
concave and the first side of the diaphragm body is convex, whereby a distance
between the first end of the rib and the protrusion decreases. An opening
adapted to
receive a bypass orifice filter insert can be defined in the diaphragm body.
The
diaphragm body can also include an inner ring attached to the outer periphery
of the
diaphragm body, an outer ring, and a plurality of longitudinally-extending
bands
connected to the inner ring and the outer ring.
[0008] The present invention provides for a flush valve diaphragm assembly for
use
in a flush valve. The assembly includes a flexible diaphragm body as
previously
discussed and a bypass orifice filter insert as previously discussed mounted
within the
diaphragm body.
[0009] The present invention provides for a flush valve that includes a valve
body
having an inlet and an outlet, and a barrel section having a sealing end
positioned
within the valve body. The sealing end is defined between the inlet and the
outlet,
wherein the barrel section adapts to fluidly connect the inlet to the outlet.
The flush
valve also includes a diaphragm assembly as previously discussed positioned in
the
valve body and separating the inlet and the outlet. The diaphragm assembly is
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configured to have a pressure difference applied across the diaphragm
assembly,
wherein the second side of the diaphragm body is concave and the first side of
the
diaphragm body is convex. The second side of the diaphragm assembly is adapted
to
seal against the sealing end of the barrel section. The recessed area is
adapted to
receive the sealing end of the barrel section, whereby a distance between the
first end
of the rib and the protrusion decreases as the diaphragm body is flexed,
thereby
causing the protrusion and the first end of each rib to squeeze against the
barrel
section, thus preventing the recessed area of said diaphragm body from sealing
too
quickly against the sealing end of the barrel section.
[0010] The present invention provides for a method of compensating for a fluid
pressure difference across a flush valve diaphragm separating fluid within a
flush
valve as previously discussed. First, a flush valve diaphragm assembly as
previously
discussed is provided. Second, the flush valve diaphragm assembly is
positioned in
the flush valve between the inlet and the outlet of the flush valve. Third, a
pressure
difference is applied across the diaphragm body such that the pressure on the
first side
of the diaphragm body is lower than the pressure on the second side of the
diaphragm
body. Fourth, the diaphragm body is flexed such that the second side of the
diaphragm body is concave and the first side of the diaphragm body is convex,
wherein the recessed area is adapted to receive the sealing end of the barrel
section,
whereby a distance between the first end of the rib and the protrusion changes
as fluid
flows through the bypass orifice filter insert.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Fig. 1 is a partial sectional view of a prior art flush valve and
conventional
diaphragm assembly;
[0012] Fig. 2 is a top perspective view of a flush valve diaphragm assembly
made
in accordance with the present invention;
[0013] Fig. 3 is a top plan view of a diaphragm body of the diaphragm assembly
shown in Fig. 2;
[0014] Fig. 4 is a bottom plan view of the diaphragm body shown in Fig. 3;
[0015] Fig. 5 is a top perspective view, partially in section, of the
diaphragm
assembly shown in Fig. 2 in a first position seated in a valve body;
[0016] Fig. 6 is a sectional view of a portion of the diaphragm assembly shown
in
Fig. 2 with the diaphragm body in a first position;
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[0017] Fig. 7 is a sectional view of a portion of the diaphragm body in a
first
position as shown in Fig. 6 sealed against a sealing end of a barrel section
in the valve
body shown in Fig. 5;
[0018] Fig. 8 is a sectional view of a portion of the diaphragm assembly shown
in
Fig. 2 with the diaphragm body in a second position;
[0019] Fig. 9 is a sectional view of a portion of a diaphragm body in a second
position as shown in Fig. 8 with a rib and protrusion of the diaphragm body
contacting a barrel section;
[0020] Fig. 10 is a top perspective view of a bypass orifice filter insert of
the
diaphragm assembly as shown in Fig. 2;
[0021] Fig. 11 is a top perspective view, partially in section, of the bypass
orifice
filter insert shown in Fig. 10; and
[0022] Fig. 12 is a sectional view taken along lines XII-XII of the diaphragm
assembly shown in Fig. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Flush valves in water closets, urinals, and other plumbing devices
which
utilize a flexible diaphragm to establish and to seal off the connection
between the
inlet and outlet are well known in the art. Fig. 1 illustrates a typical prior
art flush
valve and diaphragm assembly. The flush valve has a hollow valve body 10,
generally made of brass, which includes an inlet 12, an outlet 14, and a
handle
connection 16. A barrel section 18 is positioned within the flush valve such
that the
connection between the inlet 12 and the outlet 14 is through the barrel
section 18. An
annular main valve seat 20 is formed on a top or sealing end 21 of the barrel
section
18. The annular main valve seat 20 is normally closed by a diaphragm 22
extending
across the body 10 and defining an upper chamber 24. The diaphragm 22 has a
bypass 26 which provides fluid communication between the inlet 12 of the flush
valve
and the upper chamber 24. The diaphragm 22 is attached at its outer edge to
the valve
body 10 and is clamped in place by an annular clamping rim on an outer cover
11 of
the body 10. The diaphragm 22 has an opening which allows for fluid
communication between the upper chamber 24 and the outlet 14. A relief valve
28
normally closes the opening at the center of the diaphragm 22.
[0024] The operation of the flush valve is generally as follows. In the
normally
closed position shown in Fig. 1, water pressure at the valve inlet 12 is
communicated
to the upper chamber 24 through a bypass 26 defined in the diaphragm 22.
Because
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the surface area which is subjected to water pressure is greater on the upper
side of the
diaphragm 22, the water pressure forces the diaphragm 22 down onto the sealing
end
21 of the barrel section 18 (i.e., main valve seat 20), thus preventing water
from
flowing to the outlet 14. When the user moves a handle 30 in any direction, a
plunger
32 moves inwardly tilting a stem 34 of the relief valve 28. This releases the
pressure
in upper chamber 24 by allowing water to flow through a guide member 36. With
the
upper chamber pressure relieved, the inlet water pressure forces the diaphragm
22
upwardly, off the main valve seat 20, allowing water to flow directly from the
inlet 12
through the barrel section 18 to the outlet 14. When the diaphragm 22 and the
relief
valve 28 move upwardly, the relief valve 28 resets itself, closing off the
upper
chamber 24. Water will then flow through the bypass 26 into the upper chamber
24
until the diaphragm 22 is again forced against the main valve seat 20, thereby
closing
the valve. The guide member 36 moves with the diaphragm 22 and includes
outwardly-extending radial wing members 38 which engage the inner surface of
the
barrel section 18 to guide the guide member 36 and the attached diaphragm 22,
as the
diaphragm 22 moves up and down. The diaphragm 22 defining a central passageway
39 (i.e., hole) is radially spaced from the central passageway 39.
[0025] Fig. 2 shows a flush valve diaphragm assembly 50 made in accordance
with
the present invention. The diaphragm assembly 50 is designed to replace the
diaphragm 22 and bypass 26 in the prior art flush valve as shown, for example,
in Fig.
1. The diaphragm assembly 50 operates in an analogous manner to the diaphragm
22
and bypass 26 as previously described. Like reference numerals refer to like
parts
throughout. The diaphragm assembly 50 includes a flexible diaphragm body 52
having a first side 54 and a second side 56 and defining an outer periphery 58
and a
bypass orifice filter insert 90 defined in the diaphragm body 52.
[0026] Referring to Figs. 2-5, the diaphragm body 52 defines a center
passageway
60, an opening 62 spaced radially from the center passageway 60, an annular
protrusion 64 on the second side 56 of the diaphragm body 52 adjacent the
center
passageway 60, and a plurality of protruding ribs 66 having a first end 68 and
a
second end 70 on the second side 56 of the diaphragm body 52 adjacent the
protrusion
64. The opening 62 can be adapted to receive the bypass orifice filter insert
90 as
shown in Fig. 2. The ribs 66 can be evenly circumferentially spaced from one
another.
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[0027] With continued reference to Figs. 2-5, the first end 68 of each rib 66
extends
radially outward away from the center passageway 60 toward the second end 70
of the
rib 66. The first end 68 of each rib 66 also extends axially outward away from
the
second side 56 of the diaphragm body 52 and tapers off toward the second end
70 of
the ribs 66, thereby defining a general L-shaped profile as shown in Fig. 5.
The
annular protrusion 64 is defined on the second side 56 of the diaphragm body
52
adjacent the center passageway 60. The first end 68 of each rib 66 and the
protrusion
64 define a recess area 72 therebetween. The ribs 66 provide strength to the
diaphragm body 52 in order to prevent distortion that results from flexing of
the
diaphragm body 52 due to compression. The recess area 72 is adapted to receive
a
sealing end 21 of a barrel section 18 in a valve body 10 as shown in Fig. 5.
The
diaphragm body 52 can be annular shaped and made of a flexible polymeric
material,
such as rubber. Although not shown, the diaphragm assembly 50 can be connected
to
a barrel, which can be integrally formed thereto or attached as a separate
piece, as
shown in U.S. Patent No. 6,299,128 B1.
[0028] With continued reference to Figs. 2-5, the diaphragm body 52 can also
include an inner ring 74 attached to the outer periphery 58 of the diaphragm
body 52,
an outer ring 76, and a plurality of longitudinally-extending bands 78
connected to the
inner ring 74 and the outer ring 76. A plurality of cavity sections 80 can be
defined
between the inner ring 74 and the outer ring 76. Each cavity section 80 is
separated
by the bands 78.
[0029] Figs. 6 and 7 show a portion of the diaphragm body 52 in an unflexed
position (i.e., normal or first position), wherein pressure P1 on the first
side 54 and
pressure PZ on the second side 56 of the diaphragm body 52 are the same or
approximately the same. This condition exists when the diaphragm assembly 50
is
seated on the valve seat 20 (i.e., sealing end 21 of the barrel section 18)
before the
flush valve (shown in Fig. 1 ) is activated. The distance D between the first
end 68 of
the ribs 66 and the protrusion 64 is such that the sealing end 21 of the
barrel section
18 can be received by the recess area 72 of the diaphragm body 52 as shown in
Fig. 7.
[0030] Figs. 8 and 9 show a portion of the diaphragm body 52 in a flexed
position
(i.e., second position) having a pressure difference 0P (P2 > P1) across the
diaphragm
body 52, wherein the pressure PZ on the second side 56 of the diaphragm body
52 is
greater than the pressure P~ on the first side 54 of the diaphragm body 52.
When this
pressure difference occurs, the second side 56 of the diaphragm body 52 is
concave
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and the first side 54 of the diaphragm body 52 is convex. As can be seen in
Fig. 8, the
distance D between the first end 68 of the ribs 66 and the protrusion 64
decreases due
to the flexing of the diaphragm body 52. This condition exists immediately
after the
flush valve is activated. During the period of time after the flush valve is
activated,
water flows through the bypass orifice filter insert 90 in the diaphragm body
52 (not
shown). As the diaphragm body 52 begins to force itself against the sealing
end 21 of
the barrel section 18 (i.e., the main valve seat 20), the first end 68 of the
ribs 66 and
the protrusion 64 squeeze against the barrel section 18 before the sealing end
21 of the
barrel section 18 is received within the recess area 72 of the diaphragm body
52. This
squeezing of the barrel section 18 helps prevent the diaphragm assembly 50
from
closing too quickly against the sealing end 21 of the barrel section 18, thus
preventing
water hammer of the flush valve. As pressure P1 and pressure P2 become
approximately equal due to water flowing to the upper chamber 24 through the
bypass
orifice filter insert 90, the diaphragm body 52 closes on the valve seat 20.
[0031] Referring to Figs. 10 and 11, the bypass orifice filter insert 90
includes an
annular-shaped first body 92 having a first end 94 and a second end 96 and
defining
an orifice 98 integrally attached to a tapered or frusto-conical-shaped second
body
106. Alternatively, the second body 106 may include other shapes other than
frusto-
conical, such as frusto-spherical, or frusto-pyramidical shaped. In this
manner, a first
diameter end 108 tapers to a second diameter end 110 of the second body 106,
wherein an outer diameter M1 at the first diameter end 108 is greater than an
outer
diameter M2 at the second diameter end 110 of the second body 106 (shown in
Fig.
10). This tapered surface allows debris to fall off easier than with a planer
surface.
Also, the bypass orifice filter insert 90 is easier to assemble when passing
the tapered
second body 106 through the opening 62 in the diaphragm body 52. The first
body 92
includes a first flange 100 attached to the first end 94 of the first body 92
and a second
flange 102 attached to the second end 96 of the first body 92. A cruciform-
shaped
recess 101 (shown in phantom) can be defined on a surface of the first flange
100.
The recess 101 can have a depth of several thousandth inch. In some instances,
the
bypass orifice filter insert 90 may abut against the outer cover 11 of the
valve body 10
after flushing, thereby covering the orifice 98. The cruciform-shaped recess
101 then
permits water to flow therethrough while the upper chamber 24 fills with water
until
the orifice 98 is not blocked by the outer cover 11, so that water may flow
radially
therethrough out the perimeter of the first flange 100 as indicated by arrows
A. A
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recessed area 104 is defined between the first flange 100 and the second
flange 102 of
the first body 92. The diameter of the orifice 98 may, for example, range from
0.014
to 0.022 inch, preferably 0.018 inch. The second body 106 defines a slit 112
attached
to the second flange 102 of the first body 92, wherein the slit 112 is in
fluid
communication with the orifice 98 in the first body 92. The second body 106
can also
define a hole 114 (shown in Fig. 11 ), wherein the orifice 98 of the first
body 92 is in
fluid communication with the slit 112 in the second body 106 via the hole 114
in the
second body 106. The width W of the slit 112 may, for example, range from
0.006 to
0.014 inch, preferably 0.010 inch. Preferably, the width W of the slit 112 is
not the
same as the diameter of the orifice 98. For example, the width W of the slit
112 can
be less than the diameter of the orifice 98. The slit 112 in the second body
106 acts as
a filter protecting the orifice 98 from getting clogged with debris from fluid
passing
through the bypass orifice filter insert 90. The first body 92 and the second
body 106
of the bypass orifice filter insert 90 can be made from a rigid plastic
material and from
a unitary piece of molded material.
[0032] Fig. 12 shows a sectional view of the bypass orifice filter insert 90
inserted
into the opening 62 of the diaphragm body 52, wherein the bypass orifice
filter insert
90 extends from the first side 54 to the second side 56 of the diaphragm body
52. The
first body 92 is defined on the first side 54 of the diaphragm body 52 and the
second
body 106 of the orifice filter insert 90 is defined on the second side 56 of
the
diaphragm body 52, wherein the recessed area 104 receives an outer edge 63 in
the
opening 62 of the diaphragm body 52.
[0033] In operation, the diaphragm assembly 50 provides sealing in diaphragm-
type flush valves as in Fig. 1 of the prior art. Because compression is needed
in order
for the diaphragm assembly 50 to seal, the diaphragm assembly 50 must be
flexible
enough to flex in two directions and strong enough to withstand the
compression
forces. The ribs 66 and annular protrusion 64 give the diaphragm assembly 50
strength and rigidity, thus helping to prolong the service life of the
diaphragm
assembly 50. The bypass orifice filter insert 90 determines the rate at which
water
flows into the upper chamber 24 (shown in Fig. 1 ) of a flush valve above the
diaphragm assembly 50. The orifice filter insert 90 also determines the water
pressure
within the upper chamber 24 which causes the diaphragm assembly 50 to close on
the
valve seat 20.
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[0034] A normally closed position (i.e., first position) of a flush valve is
where the
pressure P1 on the first side 54 of the diaphragm assembly 50 is the same or
approximately the same as the pressure PZ on the second side 56, whereby the
pressure P1 forces the diaphragm assembly 50 on the sealing end 21 of the
barrel 18
(shown in Figs. 5 and 7), thus terminating the operation of the flush valve.
In the
normally closed position, the diaphragm assembly 50 is relatively flat,
wherein the
sealing end 21 is received in the recess area 72 of the diaphragm body 52.
When a
flush valve trip mechanism is activated, this relieves pressure P1 in the
upper chamber
24 by allowing water to flow through the passageway 39 and to the flush valve
outlet
14 (shown in Fig. 1). With the upper chamber 24 pressure P1 relieved, the
inlet water
pressure forces the diaphragm assembly 50 upward, off of the valve seat 20. In
this
open position (i.e., second position), the diaphragm assembly 50 is flexed,
wherein
the second side 56 is concave and the first side 54 is convex. In this second
position,
the distance D between the first end 68 of each rib 66 and the protrusion 64
is
decreased. As water flows through the bypass orifice filter insert 90, the
diaphragm
assembly 50 moves toward the sealing end 21 of the barrel section 18 (shown in
Fig.
9) while still in the flexed position. The first end 68 of each rib 66 and the
protrusion
64 squeeze against the barrel section 18 which helps prevent the diaphragm
assembly
50 from closing too quickly against the sealing end 21 of the barrel section
18, thus
preventing water hammer of the flush valve. As pressure P1 and pressure PZ
become
approximately equal due to water flowing to the upper chamber 24 through the
bypass
orifice filter insert 90, the diaphragm body 52 closes on the valve seat 20.
[0035] It will be readily appreciated by those skilled in the art that
modifications
may be made to the invention without departing from the concepts disclosed in
the
foregoing description. Accordingly, the particular embodiments described in
detail
herein are illustrative only and are not limiting to the scope of the
invention, which is
to be given the full breadth of the appended claims and any and all
equivalents
thereof.
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