Note: Descriptions are shown in the official language in which they were submitted.
ADJUSTABLE TOILET FLAPPER VALVE ASSEMBLY
This patent application claims the benefit of U.S. Provisional Patent
Application
No. 62/971,727, filed February 7, 2020, the entire teachings and disclosure of
which are
incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0001] The present invention relates generally to indoor plumbing and
gravity-operated
flush toilets. More particularly, the present invention relates to flapper
valves that are used in
such toilets and to a flapper valve and assembly of the type that has a
ballast built into it that
is adjustable to adjust to the flow of water into the ballast and to the flow
of air from the
ballast.
BACKGROUND OF THE INVENTION
[0002] Conventional gravity-operated flush toilets have several basic
components. The
porcelain or china components include a bowl and a water tank mounted on top
of a rear
portion of the bowl. The bowl and tank can be separate pieces bolted together
to form a
two-piece toilet. Other gravity-operated flush toilets are made as a one-piece
toilet in which
the bowl and tank are made as one continuous integral piece of china.
[0003] More importantly, the plumbing components of a gravity-operated
flush toilet
include a fill valve in the tank which is connected to a water supply line, a
drain hole in the
bottom of the tank that communicates with the bowl, and a flapper valve that
normally closes
and seals the drain hole.
[0004] Toilet flapper valves are typically formed as a single structure
having a rim for
sealing the drain hole with the flapper valve rim following flushing. The
flapper valve is often
formed of a soft elastomeric material and is hinged to allow the valve to be
pivotally moved
upwardly and away from the drain hole by means of a chain that is connected to
the flush
handle on the outside of the tank. Once the tank sufficiently empties, the
flapper valve then
returns to a position where it seals the drain hole.
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Date Recue/Date Received 2021-02-01
[0005] Such toilet flapper valves are also typically formed to include a
ballast structure
which is a dome-like or cone-shaped structure that controls the buoyancy of
the flapper valve.
The buoyancy of a flapper valve is an important function because it determines
how much or
how little water is emptied from the tank upon flushing, thus creating water
conservancy
issues. The buoyancy of the flapper valve is determined by how quickly air is
allowed to
escape from the ballast.
[0006] Therefore, one way that the buoyancy of the flapper valve ballast
can be controlled
is by controlling the rate at which air within the ballast can flow out of the
ballast. This can
be done by creating and/or adjusting the size of an aperture at a point within
the flapper valve
ballast. Another way that the buoyancy of the flapper valve ballast can be
controlled is by
controlling the rate at which water can flow back into the ballast.
BRIEF SUMMARY OF THE INVENTION
[0007] Embodiments of the application provide new and improved flapper
valve
assemblies that provide improvements over the current state of the art.
[0008] In an embodiment, a toilet flapper valve assembly including a
flapper, a cone and
an adjustment dial is provided. The cone is mounted to the flapper. The cone
and flapper
define a cavity. The cone has a first port and a second port. The first and
second ports fluidly
communicate the cavity with an exterior of the cone. The adjustment dial
rotatably mounts
relative to the flapper for rotation about an axis of rotation. The adjustment
dial has a first
flow adjustment region that cooperates with the first port for regulating flow
therethrough.
The adjustment dial has a second flow adjustment region that cooperates with
the second port
for regulating flow therethrough. The first and second flow adjustment regions
are fixed to
one another such that rotation of the adjustment dial about the axis of
rotation simultaneously
rotates both the first and second flow adjustment regions about the axis of
rotation relative to
the first and second ports. The first flow adjustment region includes a first
flow region that
that extends angularly about the axis of rotation. The first flow region has a
first portion that
increases in dimension when moving angularly in a first direction about the
axis of rotation to
vary a degree of exposure of the first port to fluid communication with the
exterior of the
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cone. The second flow adjustment region includes at least one flow aperture
and at least one
imperforate region adjacent the flow aperture.
[0009] In one embodiment, in a first angular position of the adjustment
dial relative to the
cone, a first section of the first flow region aligns with the first port
while the at least one flow
aperture aligns with the second port. In a second angular position of the
adjustment dial
relative to the cone, a second section of the first flow region aligns with
the first port while
the imperforate region aligns with and covers the second port.
[0010] In one embodiment, the first and second sections of the first flow
region have the
same size and expose the same amount of the first port to fluid communication
with the
exterior of the cone.
[0011] In one embodiment, the first flow region is formed by a plurality of
spaced apart
apertures extending through the adjustment dial and angularly about the axis
of rotation. The
first portion of the first flow region that increases in dimension when moving
angularly in the
first direction about the axis of rotation is provided by a plurality of
apertures that have
increase in diameters when moving angularly in the first direction about the
axis of rotation.
[0012] In one embodiment, the plurality of apertures includes at least a
first aperture and
a second aperture that have a same diameter. The first aperture re part of the
first section of
the first flow region. The second aperture are part of the second section of
the first flow
region.
[0013] In one embodiment, the first flow region is formed by a plurality of
spaced apart
apertures extending through the adjustment dial and angularly about the axis
of rotation. The
plurality of apertures includes at least a first aperture and a second
aperture that have a same
diameter. The first aperture is part of the first section of the first flow
region. The second
aperture is part of the second section of the first flow region.
[0014] In one embodiment, the adjustment dial is snap attached to the cone.
[0015] In one embodiment, the cone includes a radially extending annular
flange. The
flapper includes an opening bounded by a flange portion. The cone extends
axially through
the opening with the annular flange of the cone positioned on a first side of
the flange portion
of the flapper. The adjustment dial includes an end region that is positioned
on a second side
of the flange portion of the flapper capturing the flange portion of the
flange portion of the
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Date Recue/Date Received 2021-02-01
flapper axially therebetween in a sandwiched arrangement axially securing the
cone and
adjustment dial to the flapper.
[0016] In one embodiment, the adjustment dial is snap attached to the cone
axially
securing the adjustment dial to the cone.
[0017] In one embodiment, the radially extending flange of the cone is
proximate the
second port. The snap attachment between the adjustment dial and the cone is
proximate the
first port.
[0018] In one embodiment, the snap attachment between the cone and the
adjustment dial
maintains the end region of the adjustment dial in axial location relative to
the annular flange
of the cone and the flange portion of the flapper.
[0019] In one embodiment, a hinge component is attached to the flapper
defining a hinge
axis that is generally perpendicular to the axis of rotation. The first port
is axially offset from
the hinge axis a first distance along an offset axis that is perpendicular to
the hinge axis and
the axis of rotation. The second port is axially offset from the hinge axis a
second distance
along the offset axis.
[0020] In one embodiment, the cone extends outward from the flapper to a
free end of the
cone. The first port being positioned proximate the free end and the second
port being
positioned proximate the flapper.
[0021] In one embodiment, the second distance is greater than the first
distance.
[0022] In one embodiment, the plurality of apertures that form the first
flow region are
formed in a distal end of the adjustment dial. The at least one flow aperture
of the second
flow adjustment region is formed in an annular side of the adjustment dial.
Flow through the
plurality of apertures that form the first flow region is substantially
perpendicular to the flow
through the at least one flow aperture of the second flow adjustment region.
[0023] In one embodiment, the plurality of spaced apart apertures forming
the first flow
region includes a third aperture angularly spaced from the first and second
apertures. The third
aperture has a diameter that is greater than the diameter of the first and
second apertures.
[0024] In one embodiment, the cone is mounted to the flapper in a fixed
angular position
relative to the axis of rotation such that the first and second ports remain
in a fixed orientation
relative to the flapper regardless of the position of the adjustment dial.
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Date Recue/Date Received 2021-02-01
[0025] In an embodiment, a method of adjusting the buoyancy of a toilet
flapper valve
assembly according to any preceding embodiment is provided. The method
includes rotating
the adjustment dial about the axis of rotation relative to the cone to
simultaneously adjust
which portion of the first flow adjustment region aligns with the first port
and which portion
of the second flow adjustment region aligns with the second port.
[0026] Other aspects, objectives and advantages of the invention will
become more
apparent from the following detailed description when taken in conjunction
with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The accompanying drawings incorporated in and forming a part of the
specification illustrate several aspects of the present invention and,
together with the
description, serve to explain the principles of the invention. In the
drawings:
[0028] FIG. 1 is a perspective illustration of a flapper valve assembly
according to the
application;
[0029] FIG. 2 is an exploded illustration of the flapper valve assembly of
FIG. 1;
[0030] FIG. 3 is an exploded and cross-sectional illustration of the
flapper valve assembly
of FIG. 1; and
[0031] FIG. 4 a cross-sectional illustration of the flapper valve assembly
of FIG. 1;
[0032] FIG. 5 is an end view illustration of the adjustment dial of the
flapper valve
assembly of FIG. 1;
[0033] FIGS. 6 and 7 are side view illustrations of the adjustment dial of
the flapper valve
assembly of FIG. 1;
[0034] FIGS. 8-14 are alternative orientations of the adjustment dial
relative to the flapper
and/or cone of the flapper valve assembly of FIG. 1 that provide different
buoyancy
characteristics for the flapper valve assembly;
[0035] FIG. 15 is a perspective illustration illustrating the flapper and
cone of the flapper
valve assembly of FIG. 1; and
[0036] FIG. 16 is a cross-sectional illustration of the flapper and cone of
the flapper valve
assembly of FIG. 1.
Date Recue/Date Received 2021-02-01
[0037] While the invention will be described in connection with certain
preferred
embodiments, there is no intent to limit it to those embodiments. On the
contrary, the intent
is to cover all alternatives, modifications and equivalents as included within
the spirit and
scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0038] FIGS. 1-3 illustrate a toilet flapper valve assembly 100 (also
referred to herein as
"flapper assembly 100") for use in regulating the volume of water used when
flushing a toilet
and/or the volume of water that is dispensed into a toilet tank subsequent to
a user flushing
the toilet. The buoyancy of the toilet flapper valve assembly 100 can be
adjusted to change
the amount of water that is used during each flush.
[0039] The flapper valve assembly 100 includes a flapper 102. A seal region
104 of the
flapper 102 cooperates with the drain hole of the tank (not shown) to
selectively allow water
to drain from the tank. In this embodiment, the seal region 104 is provided
directly by an
underside 106 of the flapper 102. In other embodiments, the seal region 104
could be provided
by a separate seal member that is attached to the body of the flapper 102. As
such, the flapper
102 could be formed from a soft compliant material when it is directly used to
form a seal or
could be a more rigid material if a separate seal member is attached to the
body of the flapper
102.
[0040] In a preferred embodiment where the flapper body forms the seal, the
flapper 102
is formed from a real or synthetic rubber having a suitable durometer or
softness to provide a
sufficient seal. In a preferred embodiment, the flapper 102 is comprised of a
real rubber
material that is resistant to chemicals.
[0041] A hinge component 110 is provided that is used to operably attach
the flapper 102
to the rest of the toilet for rotation about hinge axis 112. More
particularly, when a user flushes
the toilet, a chain (not shown) connected to the flapper 102 provides a force
illustrated by
arrow 114 that causes the flapper 102 to rotate about hinge axis 112
represented by arrow 116.
This rotation of the flapper 102 causes the seal region 104 to become unseated
from the pipe
forming the drain hole of the tank allowing water within the tank to drain
therefrom and flush
the toilet.
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Date Recue/Date Received 2021-02-01
[0042] With the flapper 102 unseated and located within the water in the
tank, the time it
takes for the buoyancy of the flapper 102 drop sufficiently low that the
flapper will reseat
itself determines the amount of water that is dispensed from the tank,
assuming that all of the
water is not dispensed.
[0043] The flapper assembly 100 includes a cup shaped cone 120 (also
referred to as "cone
120") that provides a base level of buoyancy to the flapper assembly 100 and
an adjustment
dial 122 that cooperates with cone 120 to adjust the buoyancy.
[0044] Cone 120 has a sidewall 124 and bottom wall 126 that define a cone
cavity 128.
The flow of water into cone cavity 128 and the flow of air out of cone cavity
128 determines
the buoyancy of the flapper assembly 100.
[0045] Cone 120 includes a first port 130 through which water within the
toilet tank flows
into the cone cavity 128. First port 130 is formed in the bottom wall 126 and
is radially offset
from an axis of rotation 134. In this embodiment, the bottom wall 126 forms a
free end of the
cone 120. In alternative embodiments, the first port 130 could be formed in
sidewall 124, but
preferably proximate the free end of the cone, e.g. spaced away from flapper
102.
[0046] Cone 120 includes a second port 132 through which air exits the cone
cavity 128
as water flows into the cone cavity 128 through first port 130. Second port
132 is formed
through sidewall 124.
[0047] In this embodiment, flow through the first port 130 is generally
perpendicular to
the flow through second port 132 (e.g. plus or minus 15 degrees).
[0048] Cone 120 includes radially extending annular flange 136 that is
received by
annular groove 138 formed in flapper 102 to, at least in part, axially secure
the cone 120 to
the flapper 102.
[0049] With additional reference to FIGS. 15 and 16, the annular flange 136
includes at
least one radially directed notch 140 that engages a radially inward extending
nib 142 that
extends into the annular groove 138. This engagement substantially prevents
(e.g. plus or
minus 10 degrees) angular rotation of the cone 120 relative to flapper 102,
e.g. about axis 134.
This maintains the positions of the first and second ports relative to hinge
axis 112 as well as
each other.
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Date Recue/Date Received 2021-02-01
[0050] Flange 136 has an under side 146 that abuts surface 148 of radially
inward
extending flange portion 150 when cone 120 is attached to flapper 102. This
axial abutment
mounts the cone 120 to the flapper 102. Flange portion 150 defines an opening
through which
the sidewall of cone 120 extends when in a mounted state.
[0051] Adjustment dial 122 is used to selectively adjust how much of ports
130, 132 are
exposed to the exterior of cone 120, e.g. to adjust the flow area through
which fluid can flow
into and out of cone 120.
[0052] Adjustment dial 122 snap attaches to the cone 120 (see e.g. FIG. 4).
In this
embodiment, cone 120 includes an attachment pin 152 that snap engages
adjustment dial 122
by passing through aperture 154 formed in adjustment dial 122 to rotatably
secure adjustment
dial 122 to the cone 120. Attachment pin 152 has an enlarged head that secures
the adjustment
dial 122 to the cone 120.
[0053] Adjustment dial 122 rotates relative to cone 120 about axis 134.
[0054] To adjust the flow through first port 130, adjustment dial 122
includes a first flow
adjustment region 160 (illustrated between dashed lines in FIG. 5) that
cooperates with the
first port 130 of the cone 120 for regulating flow through first 130. The
first flow adjustment
region 160 extends angularly about and is radially offset from axis of
rotation 134.
[0055] The first flow adjustment region 160 includes a flow region that
extends angularly
about the axis of rotation 134. The flow region is the portion of the first
flow adjustment
region 160 that extends through the adjustment dial 122. In this embodiment,
the flow region
is provided by a plurality of angularly spaced apart apertures 162 (162A-
162G). Each aperture
162 can be viewed as a different section of the flow region of the first flow
adjustment region
160.
[0056] The flow region has a portion that increases in dimension when
moving angularly
about the axis of rotation 134 in a first direction, illustrated by arrow 164.
In this embodiment,
this portion of the flow region is provided by apertures 162A through 162F.
Here the
dimension increases when moving angularly in the direction of arrow 164 due to
the increase
in diameter of the apertures when moving in reverse order from aperture 162F
to aperture
162A in a clockwise direction in FIG. 5.
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Date Recue/Date Received 2021-02-01
[0057] The increasing diameter of apertures 162A-162F varies the degree of
exposure of
the first port 130 to the exterior of cone 120 depending on which aperture
162A-162F is
aligned with (e.g. overlapped with) first port 130. In other words, the larger
the diameter of
the aperture 162 that is aligned with port 130, the easier it is for fluid to
flow through port
130, thus reducing the buoyancy of the valve assembly 100.
[0058] It is noted that the flow region of this embodiment has a second
portion where the
dimension does not increase when moving angularly about axis of rotation 134.
In particular,
the diameter of apertures 162F and 162G are the same.
[0059] Apertures 162 are formed in an end wall 166 of adjustment dial 122.
The end wall
166 is substantially planar as well as coplanar with bottom wall 126 of cone
120.
[0060] To adjust the flow through second port 132, adjustment dial 122
includes a second
flow adjustment region 170 (the axial region of sidewall 174 of adjustment
dial 122 delineated
by bracket 170 and a dashed line in FIG. 6) that cooperates with (e.g.
overlaps with) the second
port 132.
[0061] The second flow adjustment region 170 includes a plurality of flow
apertures 176
that are angularly spaced apart and separated by a plurality of imperforate
regions 178. The
array of apertures 176 and imperforate regions 178 extends angularly about
axis of rotation
134. The apertures 176 are formed through side wall 180 of adjustment dial
122.
[0062] The exposure of the second port 132 to the exterior of cone 120 is
adjusted
depending on which portion of the flow adjustment region 170 overlaps with
second port 132.
[0063] It is noted that in this embodiment, an enlarged imperforate region
178 is provided
between one set of adjacent apertures 176. This imperforate region 178 is
illustrated in FIG.
7.
[0064] It is a feature of the present embodiment that the first and second
flow adjustment
regions 160, 170 are fixed to one another such that rotation of the adjustment
dial 122 about
axis of rotation 134 simultaneously rotates both the first and second flow
adjustment regions
160, 170 about the axis of rotation 134 relative to the first and second ports
130, 132.
[0065] The present embodiment has a plurality of different buoyancy
configuration
depending on the angular orientation of the adjustment dial 122 relative to
cone 120.
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Date Recue/Date Received 2021-02-01
[0066] FIGS. 8-14 illustrate various levels of buoyancy with FIG. 8 being
the least amount
of buoyancy and FIG. 14 having the most amount of buoyancy.
[0067] The orientation in FIG. 8 has the largest aperture 162A of the first
flow adjustment
region 160 aligned with first port 130 and one of apertures 176 of the second
flow adjustment
region 170 aligned with second port 132. As such, it is the easiest for water
to flow into port
130 as well as the easiest for air to flow out of port 132. As such, this is
the least buoyant
configuration.
[0068] The orientation of FIG. 13 has one of the smallest apertures, namely
aperture 162F
aligned with first port 130 while having one of apertures 176 aligned with
second port 132.
In this orientation, it is much more difficult for water to flow into the cone
cavity of cone 120
but still easy for air to exit cone 120. As such, the buoyancy of this
orientation is much greater
than that of the orientation of FIG. 8.
[0069] FIGS. 9-12 are at varying ranges of buoyancy between that of FIG. 8
and FIG. 13
with increasing buoyancy from FIG. 9 to FIG. 12. This is due to the increasing
diameter of
the aperture 162 aligned with first port 130 when transitioning from one
orientation to the
next.
[0070] The orientation in FIG. 14 differs from the orientation in FIG. 13
in that rather than
having an aperture 176 of the second flow adjustment region 170 aligned with
second port
132, second port 132 is aligned with imperforate region 178. As such, the
smallest aperture
162G is aligned with port 130 and the imperforate region 178 is aligned with
second port 132.
Thus, the least amount of flow of water into the cone 120 is permitted while
the least amount
of flow of air out of the cone 120 is permitted. Thus, this orientation has
the greatest amount
of buoyancy of the various orientations represented in FIGS. 8-14.
[0071] As illustrated with the various orientations of FIGS. 8-14, the user
can adjust the
buoyancy by changing the angular position of the adjustment dial relative to
the cone 120. In
some adjustments, only the size of the flow path through port is adjusted (see
e.g. transitions
between FIGS. 8-13.
[0072] In other adjustments, the change transitions from having port 132
uncovered to
having second port 132 covered while the diameter of the aperture 162 covering
first port 130
remains the same such that the same amount of the first port 130 is exposed in
either
Date Recue/Date Received 2021-02-01
orientation, e.g. transitioning from FIG. 13 to FIG. 14. These are just
representative examples.
In other situations, both the size of the aperture 162 and covering/uncovering
port 132 can
occur when transitioning from one orientation to the next.
[0073] Further, while a plurality of apertures 162 are used (e.g. one for
each orientation
in FIGS. 8-14), the ports could be replaced by a curved slot that varies in
radial dimension
when moving angularly about the axis of rotation 134.
[0074] Returning to FIG. 4, the adjustment dial includes an end region 184
that is
positioned on a second side of the flange portion 150 opposite side 148. This
captures the
flange portion 150 of flapper 102 between flange 136 and end region 184 in a
sandwiched
arrangement. The flange 136 and end region 184 need not pinch the flange
portion 150, but
can be closely positioned to prevent flange portion 150 from pulling out
between the portions
of cone 120 and adjustment dial 122.
[0075] The snap engagement and securement of adjustment dial 122 to the
cone 120
maintains the end region 184 of adjustment dial 122 axially adjacent flange
portion 150 and
flange 136.
[0076] The bottom side of the flapper 102 includes an annular channel 189
that receives
the free end of the end region 184.
[0077] With continued reference to FIG. 4, hinge axis 112 is generally
perpendicular to
axis of rotation 134 (e.g. plus or minus 15 degrees and at a minimum to allow
for
manufacturing tolerances).
[0078] It is noted that first port 130 is offset from the second port 132
relative to hinge
axis 112 along offset axis 190. In this embodiment, the first portion 130 is
positioned closer
to the hinge axis 112 than second portion 132. As such, the first port 130 is
positioned between
the hinge axis 112 and the second port 132 along offset axis 190. Offset axis
190 is generally
perpendicular to axis of rotation 134 and hinge axis 112 (e.g. plus or minus
15 degrees).
[0079] Further, the first port 130 is positioned axially further from the
seal region 104 and
flapper 102 than second port 132 along the axis of rotation 134. As such, the
second port 132
is positioned between the first port and the body of the flapper 102 along
axis of rotation 134.
[0080] However, other configurations with different relative positions of
the first and
second ports are contemplated.
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Date Recue/Date Received 2021-02-01
[0081] With reference to FIG. 3, in the illustrated embodiment, an indexing
arrangement
between the adjustment dial 122 and cone 120 is provided. The indexing
arrangement
includes a plurality of recesses 192 that cooperate with a radially extending
nib 194. The nib
and recesses could be formed in the opposite one of the adjustment dial 122
and cone 120 in
alternative arrangements.
[0082] No documents cited in spec other than in first paragraph so I've
deleted this
paragraph.The use of the terms "a" and "an" and "the" and similar referents in
the context of
describing the invention (especially in the context of the following claims)
is to be construed
to cover both the singular and the plural, unless otherwise indicated herein
or clearly
contradicted by context. The terms "comprising," "having," "including," and
"containing"
are to be construed as open-ended terms (i.e., meaning "including, but not
limited to,") unless
otherwise noted. Recitation of ranges of values herein are merely intended to
serve as a
shorthand method of referring individually to each separate value falling
within the range,
unless otherwise indicated herein, and each separate value is incorporated
into the
specification as if it were individually recited herein. All methods described
herein can be
performed in any suitable order unless otherwise indicated herein or otherwise
clearly
contradicted by context. The use of any and all examples, or exemplary
language (e.g., "such
as") provided herein, is intended merely to better illuminate the invention
and does not pose
a limitation on the scope of the invention unless otherwise claimed. No
language in the
specification should be construed as indicating any non-claimed element as
essential to the
practice of the invention.
[0083] Preferred embodiments of this invention are described herein,
including the best
mode known to the inventors for carrying out the invention. Variations of
those preferred
embodiments may become apparent to those of ordinary skill in the art upon
reading the
foregoing description. The inventors expect skilled artisans to employ such
variations as
appropriate, and the inventors intend for the invention to be practiced
otherwise than as
specifically described herein. Accordingly, this invention includes all
modifications and
equivalents of the subject matter recited in the claims appended hereto as
permitted by
applicable law. Moreover, any combination of the above-described elements in
all possible
12
Date Recue/Date Received 2021-02-01
variations thereof is encompassed by the invention unless otherwise indicated
herein or
otherwise clearly contradicted by context.
13
Date Recue/Date Received 2021-02-01
