Toilet Flush Valve Assembly with Radiused Inlet and Buoyant Float
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Solution Overview
Problem
Existing flush valve designs for high-efficiency toilets face challenges in maintaining effective water flow and closure with standard flapper-type valve covers, especially when using elevated valve bodies with radiused inlets, leading to premature closure and reduced hydraulic energy due to turbulence upon impact with the toilet bowl inlet chamber.
Innovation Solution
A flush valve assembly with a radiused inlet and a downwardly linearly tapered valve body, combined with a buoyant float and a detachable flush valve cover, allows for efficient water flow and extended valve opening, overcoming the issues of premature closure and turbulence by maintaining the valve open during high flow rates and reducing hydraulic losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a standard flapper-type valve cover is used with an elevated valve body with radiused inlet, then the valve structure is simple and easy to manufacture, but the valve closes prematurely and creates turbulence upon impact with the toilet bowl inlet chamber
Solution Approach 1:
The patent transitions from a static flapper-type valve cover to a dynamic piston valve that moves vertically within the valve body. The piston is guided by side walls and responds dynamically to water pressure changes, opening fully during flush and closing smoothly without premature shutdown. This dynamic mechanism eliminates the turbulence problem while maintaining manufacturing feasibility through molded plastic construction.
Solution Approach 2:
The patent changes the operational parameters of the valve by using a piston design with specific dimensional relationships (piston diameter slightly less than inlet diameter, piston height relative to valve body height). The piston's vertical movement range and sealing surface geometry are optimized to control water flow parameters, ensuring full opening during flush and smooth closure without impact, thereby resolving the premature closure and turbulence issues.
2Productivity
If water flow rate is increased to improve flushing performance, then waste removal effectiveness is improved, but hydraulic energy losses increase due to turbulence
Solution Approach 1:
The patent incorporates a radiused inlet portion in the valve body that curves smoothly to guide water flow. This curved geometry eliminates sharp edges and abrupt directional changes that cause turbulence. The smooth transition from the inlet opening through the piston to the outlet maintains laminar flow conditions, allowing high flow rates for effective waste removal while minimizing hydraulic energy losses from turbulence.
3Productivity
If the valve opening is extended to maintain peak flow rates, then flushing performance is improved, but the valve structure becomes more complex
Solution Approach 1:
The piston valve serves multiple functions within a single component: it acts as the closing element, the flow regulator, and the actuator. The buoyant float provides automatic actuation of the piston, eliminating the need for separate mechanical linkages, springs, or cam mechanisms. This multi-functional design extends the valve opening duration to maintain peak flow rates while avoiding excessive structural complexity.
Solution Approach 2:
The piston valve system is self-actuating through the buoyant float mechanism. During flush, water pressure and float buoyancy automatically move the piston to the open position and keep it open throughout the flush duration. The piston returns to closed position automatically when water pressure equalizes, without requiring external actuators or complex control mechanisms. This self-service operation extends peak flow rate duration while maintaining simple structure.
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 enhances flushing performance by maintaining peak flow rates and improving hydraulic energy efficiency, effectively removing waste while adhering to low water volume regulations, such as 1.6 gallons per flush or less.
Implementation Method 1
a radiused inlet to increase the discharge coefficient of the valve opening
Implementation Method 2
The float is preferably sufficiently buoyant so as to be capable of resisting the force of flowing water, keeping the flush valve cover open
Implementation Method 3
reducing hydraulic losses... due to turbulence upon impact with the toilet bowl inlet chamber
Data Source
AI summary
Flush valve assemblies are described herein which include a valve body; a flush valve cover detachably connected to a flush line; a pivot mechanism capable of opening and closing the flush valve cover upon actuation; wherein the flush line is connected at a first end to a flush actuating device and at a second end to the flush valve cover, the line being capable of raising and lowering the cover upon actuation; and a float situated above the cover and connected to the flush line at a point between the first and the second ends of the flush line or by a separate float line connected to the cover. The float is sufficiently buoyant and capable of resisting the force of flowing water and keeping the flush valve cover open to allow flush water to pass through the valve body before closing the cover when the valve body is installed on a toilet.