Concealed Three-Port Flushometer for In-Wall Service Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In-wall flushometers face challenges with access for maintenance and replacement due to their design requiring more space and material, and they perform poorly in low flush volume environments, leading to water wastage and potential overflow issues.
Innovation Solution
A flushometer system with a valve body, sleeve, piston valve assembly, and actuation module that includes a relief valve and locking mechanism, allowing for adjustable access and improved performance in low flush volume environments by integrating the control stop within the valve and using a flow control with snubber and plug portions to manage flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a four-port valve body design with control stop is used, then the flushometer can be isolated from water supply and maintained, but the freedom of access and working space required becomes much larger than typically available for in-wall installations
Solution Approach 1:
The control stop is integrated within the valve body as an internal component rather than an external attachment. The valve body incorporates a recess that receives the control stop, allowing the isolation function to be nested within the existing valve structure. This eliminates the need for additional external space while maintaining the ability to isolate and maintain the flushometer.
Solution Approach 2:
The control stop function is merged with the valve body structure. The valve body is designed with an integrated control stop mechanism that combines the isolation valve function with the main valve assembly. This merging reduces the overall space requirement by eliminating separate components and their associated mounting space.
2Ease of repair
If a control stop is positioned immediately upstream of the water supply, then the valve can be isolated from the water supply line, but both a larger volume of area that must be accessed and further increases the mass of material that must be placed behind or in the wall
Solution Approach 1:
The control stop is nested within the valve body structure, with the valve body incorporating a recess that receives the control stop. This internal nesting arrangement allows the isolation capability to be achieved without adding external volume or requiring additional material to be placed behind the wall.
Solution Approach 2:
The valve body is designed to serve multiple functions: it acts as both the main valve housing and the structural containment for the control stop. This multi-functionality eliminates the need for separate isolation valve assemblies, reducing the total material volume required while maintaining isolation capability.
3Device complexity
If typical flushometer design is used in low flush volume environment, then the valve structure remains simple, but the valve exhibits harmful shock to the system upon opening and closing due to abrupt change in flow
Solution Approach 1:
A flow control valve is positioned upstream of the main valve to preliminarily regulate the water flow before it reaches the main valve. This preliminary flow control prevents abrupt flow changes by gradually increasing flow rate as the valve opens, thereby reducing water hammer and shock effects on the system while maintaining a relatively simple overall valve structure.
Solution Approach 2:
The flow control valve acts as an intermediary component between the water supply and the main valve. It mediates the flow transition by providing a controlled, gradual opening sequence that prevents direct abrupt flow changes from reaching the main valve, thereby reducing harmful shock effects without significantly complicating the main valve structure.
4Device complexity
If typical flushometer design is used, then the valve body is simple, but if the valve fails and remains open, the valve is at its highest flow rate resulting in large amount of wasted water and increased potential for overflow
Solution Approach 1:
The flow control valve serves as an intermediary safety mechanism positioned upstream of the main valve. In the event that the main valve fails and remains open, the flow control valve limits the maximum flow rate to a controlled level, preventing catastrophic water waste and overflow while maintaining a simple overall valve body design.
Solution Approach 2:
The flow control valve provides beforehand cushioning by establishing a maximum flow rate limit before any potential valve failure occurs. This preliminary flow restriction acts as a safety buffer that prevents excessive water flow even if the main valve fails, thereby reducing the consequences of failure while keeping the valve body structure simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances access for maintenance, reduces water wastage, and improves performance in low flush volume environments by gradually controlling water flow, preventing overflow and optimizing water usage.
Implementation Method 1
A flow control extends from the piston assembly, the flow control comprising a snubber portion, a flush profile portion, and a plug portion
Implementation Method 2
An actuation module is engaged with the sleeve and has a relief valve, the actuation module secured at the actuation opening with a locking mechanism
Data Source
AI summary
A flushometer system having an integrated control stop and three ports. The piston or flush control device is accessible through an actuation opening. The flushometer system may be utilized in a behind-the-wall installation with a face plate exterior for user interaction. The interior of the flushometer may be accessed through the actuation opening behind the face plate.