Controller Assembly for Manual to Automatic Flush Valve Conversion

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Solution Overview

Problem

Existing flush valves cannot be easily converted from manual to automatic, leading to waste of resources and money when consumers want to switch from manual to automatic flushing.

Innovation Solution

A controller assembly that integrates a battery set, sensor, solenoid valve, and membrane with a foundation, ring, and sleeve, allowing for easy assembly and disassembly on existing valve bodies to convert between manual and automatic flush valve configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a conventional manual flush valve is replaced with an automatic flush valve, then automatic flushing function is achieved, but the existing valve body is wasted and additional cost is incurred

Engineering Contradiction:

Improveautomatic flushing functionVSAvoidvalve body waste

Core Design Contradiction:

Extent of automationVSLoss of substance

Solution Approach 1:

The automatic flush valve is divided into a reusable valve body portion and a replaceable controller assembly portion. The controller assembly includes the sensor, battery set, solenoid valve, and membrane, which can be detached and replaced independently from the valve body. This segmentation allows the valve body to be reused while only replacing the automated control components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The valve body is designed with a standardized foundation structure that can accommodate different controller assemblies. The foundation includes a socket that receives the solenoid valve and membrane assembly, and a threaded connection for the ring assembly. This universal interface allows the same valve body to be converted between manual and automatic modes by simply changing the controller assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Extent of automation

If a conventional manual flush valve is replaced with an automatic flush valve, then automatic flushing function is achieved, but additional cost is incurred

Engineering Contradiction:

Improveautomatic flushing functionVSAvoidmoney waste

Core Design Contradiction:

Extent of automationVSLoss of energy

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design enables recovery and reuse of the valve body, which is typically the most expensive component. Only the controller assembly (sensor, battery, solenoid, membrane) needs to be replaced when converting from manual to automatic operation, significantly reducing the overall cost compared to replacing the entire valve assembly.

Inventive Principle:

Principle #34Discarding and recovering

3Extent of automation

If the controller assembly is designed with multiple components (battery set, sensor, solenoid valve, membrane), then automatic flushing function is achieved, but device complexity increases

Engineering Contradiction:

Improveautomatic flushing functionVSAvoidcontroller assembly structure

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The sensor, battery set, solenoid valve, and membrane are merged into a single integrated controller assembly that functions as one removable unit. The base holds the battery set and sensor together, the solenoid valve is mounted on the foundation, and the membrane is positioned below the solenoid valve. This merging simplifies installation and maintenance, as the entire controller assembly can be replaced as a single unit without handling individual components separately.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The controller assembly components are nested within each other in a compact arrangement. The battery set and sensor are housed together in the base, the solenoid valve is mounted on the foundation structure, and the membrane is positioned below the solenoid valve within the same assembly space. This nested configuration reduces the overall footprint and simplifies the structural design.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

Enables convenient and economical transformation between automatic and manual flush valves, allowing consumers to reuse existing valve bodies without replacement.

Implementation Method 1

a solenoid valve as well as a membrane provided below the combination

Methodology Applied

Scientific EffectSolenoid: Solenoid

Data Source

PatentUS9528253B2Controller assembly for automatic flush valve

Publication Date: 2016.12.27 FLUSHTECH CORP

AI summary

A controller assembly for an automatic flush valve provides economical approach to transforming a manual flush valve into an automatic flush valve. The controller assembly includes a base for holding a battery set and a sensor into a combination, and a cap covering the combination. A solenoid valve and a membrane below the combination are receiving in a socket of a foundation. A ring is rotatably mounted around a bottom of the foundation. A sleeve passing the cap is mounted around the foundation and stands on the ring. The ring allows the controller assembly to be easily assembled with a valve body of any type into an automatic flush valve or to be easily removed from the automatic flush valve and replaced by a manual controller assembly so as to form a manual flush valve. Thereby, the transformation can be economical accomplished without replacing the existing valve body.