Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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FLUSH VALVE DIAPHRAGM
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to flush valves, and more particularly,
to diaphragms
used in flush valves.
Description of Related Art
[0002] 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. Typically, the diaphragm is made of an elastomeric
material, such as
rubber, and includes a filter and bypass, 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. 7,516,938 and U.S. Patent No.
8,210,202.
[0003] 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.
The performance
also depends on the pressure drop between the opposite sides of the diaphragm
due to the
bypass orifice. A diaphragm with a misaligned bypass orifice can prevent water
from flowing
to the top side of the diaphragm, which results in an inadequate seal. The
correct positioning
of the bypass orifice within the flush valve is paramount to ensuring that the
proper pressure
drop is established between the opposite sides of the diaphragm.
[0004] Accordingly, there is a general need in the art for a flush valve
assembly and flush
valve diaphragm that are configured so as to ensure correct positioning of the
bypass orifice
with respect to the body of the flush valve assembly during installation of
the flush valve
diaphragm and diaphragm assembly.
SUMMARY OF THE INVENTION
[0005] The present invention provides for a diaphragm for use in a diaphragm-
type flush
valve, the diaphragm including 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, a
bypass orifice defined in the diaphragm body, and a sealing ring attached to
the outer
periphery of the flexible diaphragm body. The sealing ring defines an outer
circumferential
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surface of the diaphragm. The outer circumferential surface of the sealing
ring defines a
recessed area.
[0006] In another embodiment of the invention, the sealing ring may include an
inner ring
attached to the outer periphery of the diaphragm body and an outer ring which
defines the
outer circumferential surface of the sealing ring. The outer ring of the
sealing ring may define
the recessed area. The recessed area may be configured to engage in a keyed
relationship with
a valve body of a flush valve. A shape of the recessed area may be defined by
an indentation
in the sealing ring and an imaginary line that extends along the outer
circumferential surface
of the sealing ring from a first end of the indentation to a second end of the
indentation. The
recessed area may be substantially rectangular-shaped. The recessed area may
be defined in
the sealing ring at a predetermined angular position with respect to the
bypass orifice. The
recessed area may be positioned approximately 90 degrees from the bypass
orifice. The
recessed area may be positioned approximately 135 degrees from the bypass
orifice. The
sealing ring may be configured to create a seal between the diaphragm and a
valve body. A
first plurality of protruding ribs may include a first and a second protruding
rib on the first
side of the diaphragm body. Each of the first and second protruding ribs may
have a first end
adjacent the bypass orifice and extending in a curved line to a second end,
and a third
protruding rib on the first side of the diaphragm body that may be
substantially U-shaped
with a first end and a second end. An open end of the U-shaped third
protruding rib may be
oriented toward the center passageway. The first protruding rib and a portion
of the third
protruding rib may define a first channel therebetween, and the second
protruding rib and an
opposing portion of the third protruding rib may define a second channel
therebetween. A
second plurality of protruding ribs may be positioned on the second side of
the diaphragm
body with a first end positioned adjacent to the center passageway and a
second end
positioned adjacent to the sealing ring. The second plurality of protruding
ribs may be curved
between the first end and the second end.
[0007] Another embodiment of the invention is a flush valve that includes a
valve body
having an inlet and an outlet, a barrel section having a sealing end
positioned within the valve
body, the sealing end defined between the inlet and the outlet, wherein the
barrel section
adapts to fluidly connect the inlet to the outlet, and a diaphragm positioned
in the valve body
and separating the inlet and the outlet, the diaphragm configured to have a
pressure
differential applied across the diaphragm. The diaphragm includes a flexible
diaphragm body
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having an outer periphery, a first side, and a second side adapted to seal
against the sealing
end of the barrel section, the diaphragm body defining a center passageway and
a bypass
orifice spaced radially from the center passageway, and a sealing ring
attached to the outer
periphery of the flexible diaphragm body. The sealing ring defines an outer
circumferential
surface of the diaphragm. The diaphragm and the valve body are configured to
engage in a
keyed relationship.
[0008] The sealing ring may include an inner ring attached to the outer
periphery of the
diaphragm body and an outer ring which defines the outer circumferential
surface of the
sealing ring. The outer circumferential surface of the sealing ring may define
a recessed area.
The valve body may include a protrusion extending from an inner surface
thereof. The
recessed area and the protrusion may be configured to engage in the keyed
relationship
between the diaphragm and the valve body. A shape of the recessed area may be
defined by
an indentation in the sealing ring and an imaginary line that extends along
the outer
circumferential surface of the sealing ring from a first end of the
indentation to a second end
of the indentation. The recessed area and the protrusion may have
corresponding shapes. The
recessed area may be substantially rectangular or trapezoidal-shaped and the
protrusion may
be substantially rectangular or trapezoidal-shaped. The recessed area may be
defined in the
sealing ring at a predetermined angular position with respect to the bypass
orifice. The
recessed area may be positioned approximately 90 degrees from the bypass
orifice. The
recessed area may be positioned approximately 135 degrees from the bypass
orifice. The
sealing ring may be configured to create a seal between the diaphragm and the
valve body.
[0009] The present invention is also a method of assembling a flush valve
assembly
includes the steps of providing a flush valve diaphragm for use in a flush
valve comprising a
diaphragm body with an outer periphery, a first side, and a second side, and a
sealing ring
attached to the outer periphery of the diaphragm body, the sealing ring
defining an outer
circumferential surface of the diaphragm; providing a flush valve body having
an inlet and an
outlet; positioning the flush valve diaphragm in the flush valve body by
positioning the flush
valve diaphragm into a keyed relationship with the flush valve body; and
establishing a seal
between the sealing ring of the flush valve diaphragm and the flush valve
body.
100101 The outer circumferential surface of the sealing ring may define a
recessed area.
The flush valve body may include a protrusion extending from an inner surface.
The recessed
area and the protrusion may be configured to engage in the keyed relationship
between the
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flush valve diaphragm and the flush valve body. The recessed area of the flush
valve
diaphragm and the protrusion of the flush valve body may have corresponding
shapes. The
method may also include the step of defining a bypass orifice in the flush
valve diaphragm at
a predetermined angular distance from the recessed area of the flush valve
diaphragm.
[0011] Further details and advantages of the invention will become clear upon
reading the
following detailed description in conjunction with the accompanying drawing
figures,
wherein like parts are designated with like reference numerals throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a partial sectional elevation view of a prior art flush valve
and
conventional diaphragm assembly;
[0013] FIG. 2 is a top perspective view of a flush valve diaphragm made in
accordance
with the present invention;
[0014] FIG. 3 is a top view of the flush valve diaphragm shown in FIG. 2;
[0015] FIG. 4 is a bottom view of the flush valve diaphragm shown in FIG. 2;
[0016] FIG. 5 is a side elevation view of the flush valve diaphragm shown in
FIG. 2;
[0017] FIG. 6 is a partial sectional perspective view of a flush valve
assembly including
the flush valve diaphragm shown in FIG. 2;
[0018] FIG. 7A is a top perspective view of a flush valve assembly including
the flush
valve diaphragm shown in FIG. 2; and
[0019] FIG. 7B is a top plan view of a flush valve assembly including the
flush valve
diaphragm shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] For purposes of the description hereinafter, spatial orientation
terms, as used, shall
relate to the referenced embodiment as it is oriented in the accompanying
drawings, figures,
or otherwise described in the following detailed description. However, it is
to be understood
that the embodiments described hereinafter may assume many alternative
variations and
configurations. It is also to be understood that the specific components,
devices, features, and
operational sequences illustrated in the accompanying drawings, figures, or
otherwise
described herein are simply exemplary and should not be considered as
limiting.
[0021] 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
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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. Of course, the
body can be
made of other materials. 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.
[0022] 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 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 on to 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 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.
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[0023] FIGS. 2-4 show a flush valve diaphragm 50 made in accordance with the
present
invention. In addition to being used in a corresponding flush valve assembly
as described
below with reference to FIGS. 6-7B, the diaphragm 50 may also replace the
diaphragm 22 in
the prior art flush valve as shown, for example, in FIG. 1. The diaphragm 50
operates in an
analogous manner to the diaphragm 22 and bypass 26 as previously described.
The
diaphragm 50 includes a flexible diaphragm body 52 having a first side 54 and
a second side
56 and defining an outer periphery 58.
[0024] Referring to FIGS. 2-6, the diaphragm body 52 defines a center
passageway 60, a
bypass orifice 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,
two
protruding ribs 66A, 66B having first ends 68 and second ends 70 on the first
side 54 of the
diaphragm body 52 adjacent the bypass orifice 62, a third protruding rib 67A
having a first
end 67B and a second end 67C on the first side 54 of the diaphragm body 52
adjacent the
bypass orifice 62, and a plurality of protruding ribs 72 having a first end 74
and a second end
76 on the second side 56 of the diaphragm body 52 adjacent the protrusion 64.
The bypass
orifice 62 is adapted to receive a flush valve diaphragm orifice insert as
disclosed in U.S.
Patent No. 7,516,938 to Funari et al.
[0025] With continued reference to FIGS. 2-6, the protruding ribs 66A, 66B
each include a
first end 68 positioned adjacent the bypass orifice 62 and a second end 70,
which is radially
inwardly spaced and angularly spaced from the first end 68. The protruding
ribs 66A, 668
extend in opposing angular directions from the respective first ends 68. The
protruding rib
67A is substantially U-shaped and is positioned between the bypass orifice 62
and the center
passageway 60. The open end of the U-shaped protruding rib 67A is directed
towards the
center passageway 60 so that the first end 67B and the second end 67C of the
protruding rib
67A are positioned closer to the center passageway 60 with respect to the
center of the
protruding rib 67A. A first channel 78A is defined between the protruding rib
66A and the
protruding rib 67A and a second channel 78B is defined between the protruding
rib 66B and
the protruding rib 67A on the side opposite from the protruding rib 66A. The
channels 78A,
78B are used to direct the flow of water away from the bypass orifice 62.
[0026] With continued reference to FIGS. 2-6, the first end 74 of each second
protruding
rib 72 is positioned closer to the center passageway 60 than the second end 76
and each
protruding rib 72 extends radially outwardly and angularly in a curved line to
the respective
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second end 76 of the second protruding rib 72. The first end 74 of each second
protruding rib
72 is positioned adjacent the annular protrusion 64. The ribs 66A, 66B, 67A,
and 72 provide
strength to the diaphragm body 52 in order to prevent distortion that results
from flexing the
diaphragm body 52.
[0027] The annular protrusion 64 is defined on the second side 56 of the
diaphragm body
52 adjacent the center passageway 60. An annular seat 80 (FIG. 6) is provided
on the second
side 56 of the diaphragm body 52 adjacent the annular protrusion 64. The
annular seat 80 is
adapted to receive a sealing end 21 of a barrel section 18 in a valve body 10.
The diaphragm
body 52 (FIG. 5) can be annular shaped and made of a flexible polymeric
material, such as
rubber. Although not shown, the diaphragm 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 to Verdecchia.
[0028] With continued reference to FIGS. 2-6, the diaphragm body 52 also
includes a
sealing ring configured to establish a seal between the diaphragm body 52 and
a valve body
94 (shown in FIG. 7B). The sealing ring includes an inner ring 82 adjacent to
the outer
periphery 58 of the diaphragm body 52, an outer ring 84 at the periphery, and
a plurality of
radially-extending bands 86 between the inner ring 82 and the outer ring 84.
The outer ring
84 defines an outer circumferential surface of the sealing ring. The ends of
the bands 86 may
be formed integral with the inner ring 82 and the outer ring 84. A plurality
of cavity sections
88 may be defined between the inner ring 82 and the outer ring 84. Each cavity
section 88 is
separated by the bands 86.
10029] With continued reference to FIGS. 2-6, a recessed area 90 is defined by
the outer
ring 84 of the sealing ring of the diaphragm body 52. The term recessed area
90 is defined as
an indentation in a peripheral surface of the diaphragm 50. The recessed area
90 may be
defined by the indentation in the outer periphery of the outer ring 84 and an
imaginary line
that connects both sides of the indentation along the outer periphery of the
outer ring 84. In
one embodiment, the recessed area 90, when viewed from the top, is
substantially rectangular
or trapezoidal-shaped. It is to be understood, however, that additional
recessed area 90 shapes
are contemplated, such as, triangular, circular, spherical, hexagonal,
octagonal, or square,
among other shapes. The recessed area 90 is defined within the outer ring 84
and a cavity
section 88 of the diaphragm body 52, and extends from an outer surface of the
outer ring 84
to an outer surface of the inner ring 82. As shown in FIGS. 7A and 7B, the
recessed area 90
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is configured to engage into a keyed relationship or interlocking engagement
with a
corresponding protrusion 92 on an inner surface of the valve body 10. The
shape of the
recessed area 90 and the protrusion 92 should correspond to one another to
create the keyed
relationship. During assembly of the flush valve assembly, the diaphragm 50
cannot be fully
assembled into the valve body 10 to create a seal with the valve body 10 until
the recessed
area 90 and the protrusion 92 engage in the keyed relationship. A keyed
relationship is
understood to mean that the protrusion 92 is positioned for insertion into the
recessed area 90
of the diaphragm 50 or, alternatively, the recessed area 90 is positioned
around the protrusion
92. As shown in FIG. 6, even with the recessed area 90 being defined in the
outer ring 84 of
the diaphragm body 52, a seal is still maintained between the inner ring 82
and the valve
body 10 at point A. Therefore, the diaphragm 50 with the recessed area 90
defined therein
can also be used with valve bodies without a protrusion 92, such as pre-
existing valve bodies
that have already been installed and are using pre-existing diaphragm without
a recess.
Therefore, the diaphragm 50 includes an advantage of being capable of use with
pre-existing
valve bodies that do not include a corresponding protrusion or valve bodies 10
that are
formed with a protrusion 92. It is also contemplated that the protrusion 92
may be provided
on the diaphragm 50 and the recessed area 90 may be defined by the valve body
10 to create
a keyed relationship between the diaphragm 50 and the valve body 10.
[0030] Through the use of the keyed relationship between the recessed area 90
and the
protrusion 92, an accurate and consistent positioning of the bypass orifice 62
is achieved. By
defining the recessed area 90 at a predetermined angular position from the
bypass orifice 62
on the outer ring 84 of the diaphragm 50, an accurate positioning of the
bypass orifice 62 in
the flush valve assembly is achieved consistently through assembly of multiple
flush valves.
Therefore, every time the recessed area 90 engages in the keyed relationship
with the
protrusion 92, the bypass orifice 62 is positioned at the desired position. In
one embodiment
of the present invention, the center of the recessed area 90 of the diaphragm
50 is angularly
spaced approximately 90 degrees from the bypass orifice 62. In another
embodiment of the
present disclosure, the center of the recessed area 90 of the diaphragm 50 is
angularly spaced
approximately 135 degrees away from the bypass orifice 62. It is to be
understood, however,
that any number of positions are contemplated for the recessed area 90 and the
protrusion 92
depending on the design of the flush valve assembly.
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[0031] With reference to FIGS. 7A and 7B, a method of assembling a flush valve
assembly is also contemplated with this disclosure. This method includes
providing a
diaphragm 50 as described hereinabove including a recessed area 90 defined in
the outer ring
84 of the sealing ring of the diaphragm 50. The flush valve body 94 includes a
protrusion
extending from an inner surface of the flush valve body 94. The diaphragm 50
is positioned
in the flush valve body 94 by positioning the recessed area 90 of the
diaphragm 50 into a
keyed relationship with the protrusion 92 of the flush valve body 94. In this
keyed
relationship, the protrusion 92 extends into the recessed area 90 of the
diaphragm 50. A seal
is then established between the inner ring 82 of the sealing ring of the
diaphragm 50 and the
flush valve body 94. When assembling a flush valve assembly using this method,
the recessed
area 90 and the protrusion 92 preferably have corresponding shapes so as to
fit together in a
keyed relationship. It is also contemplated that a bypass orifice 62 may be
defined in the
diaphragm 50. The bypass orifice 62 may be positioned at a predetermined
position from the
recessed area 90 of the diaphragm 52 to ensure that the bypass orifice 62 is
accurately and
consistently positioned in the flush valve assembly.
[0032] While several embodiments of a flush valve diaphragm are shown in the
accompanying figures and described hereinabove in detail, other embodiments
will be
apparent to, and readily made by, those skilled in the art. Accordingly, the
foregoing
description is intended to be illustrative rather than restrictive.
