Pilot Operated Diaphragm Fill Valve Bridge Design
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Solution Overview
Problem
Conventional fill valves in toilets experience reduced cycle life and water 'hammer' or hydrostatic shock due to increased water pressures and the use of higher durometer materials, which lead to diaphragm degradation and abrupt shut-off.
Innovation Solution
A fill valve assembly using a softer durometer EPDM rubber diaphragm and a 'bridge' structure to prevent abrasion, combined with a radial design that allows slow shut-off, reducing the impact of high pressures and preventing water hammer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If higher durometer materials are used in the diaphragm, then the valve can shut off more effectively, but water hammer or hydrostatic shock occurs and cycle life is reduced
Solution Approach 1:
The patent changes the durometer parameter of the diaphragm material from high (70) to low (55-62), fundamentally altering the mechanical properties to enable gradual shut-off rather than abrupt closure, thereby eliminating water hammer while maintaining reliable valve function
Solution Approach 2:
The patent introduces a bridge structure positioned between the diaphragm and valve seat that provides gradual compression and cushioning during the shut-off process, preventing abrupt closure and the resulting water hammer effect
2Stress or pressure
If higher water pressures are used, then water can be moved farther and higher, but the cycle life of the diaphragm valve is significantly reduced
Solution Approach 1:
The patent changes the material parameter (durometer) to be more resilient and abrasion-resistant, allowing the diaphragm to withstand high water pressures (up to 170 psig) without degradation, thereby extending cycle life while maintaining functionality under elevated pressure conditions
3Productivity
If a thinner diaphragm section is used, then the valve can operate more efficiently, but the diaphragm becomes susceptible to abrasion and damage from high pressures
Solution Approach 1:
The bridge structure is positioned beforehand to provide protective cushioning to the thin diaphragm section, preventing direct exposure to high-pressure abrasion while allowing the diaphragm to maintain its efficient thin design for optimal valve operation
Solution Approach 2:
The bridge acts as an intermediary element between the diaphragm and the harsh high-pressure environment, shielding the thin diaphragm from direct abrasion while still allowing it to function efficiently in controlling water flow
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
The solution extends the cycle life of the fill valve and eliminates water hammer by using a softer diaphragm material and a bridge to protect against abrasion, ensuring smooth operation under high pressures.
Implementation Method 1
A fill valve assembly using a softer durometer EPDM rubber diaphragm and a 'bridge' structure to prevent abrasion, combined with a radial design that allows slow shut-off, reducing the impact of high pressures and preventing water hammer
Data Source
AI summary
The fill valve and assembly provides an elongated cylindrical water supply tube and a valve seat disposed atop the water supply tube. The valve seat comprises a circular inner valve seat portion and a circular outer valve seat portion between which extend support structures in the form of a plurality of lands and spokes. A bridge is disposed in the center of the valve seat structure about the inner valve seat portion and atop the plurality of lands and spokes. A main diaphragm valve is disposed atop the valve seat structure such that the bridge is disposed between the valve seat structure and the main diaphragm valve. The present invention provides for a thinner and softer durometer EPDM material for the main diaphragm which is advantageous for improved function while the bridge prevents the thin section of the main diaphragm valve from being abraded or cut when high pressures try to push the diaphragm into the spokes.