Offset Outlet Flush Valve Overflow Capacity
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Solution Overview
Problem
Conventional flush valves in gravity-operated toilets have restricted overflow capacity due to the impingement of the flapper valve bulb on the flow area between the overflow tube and the flush valve outlet, and are difficult to manufacture as a one-piece item using conventional plastic molding processes.
Innovation Solution
A flush valve with an offset outlet from the central aperture, positioned partly underneath the overflow tube, which simplifies the molding process and reduces costs by eliminating the need for complex mold cores, while maintaining compatibility with existing flapper valves and allowing for adjustable overflow tube height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flush valve outlet is positioned conventionally aligned with the overflow tube, then the manufacturing process becomes complex requiring special mold cores, but the overflow capacity is restricted due to flapper valve bulb impingement on the flow area
Solution Approach 1:
The outlet aperture is repositioned from a conventional vertical alignment to an offset position that is both vertically and horizontally displaced relative to the overflow tube inlet. This dimensional repositioning moves the outlet away from the flapper valve bulb's path, eliminating impingement on the overflow flow area while maintaining manufacturing simplicity through standard mold cores.
Solution Approach 2:
The outlet aperture is designed with asymmetric positioning relative to the overflow tube, creating an offset configuration that optimizes the flow path. This asymmetric arrangement ensures the outlet is positioned to avoid flapper valve bulb interference while maintaining ease of manufacture through conventional molding processes.
2Productivity
If the outlet aperture is offset from the overflow tube inlet, then overflow capacity is improved by eliminating flapper valve bulb impingement, but the manufacturing process becomes more complex
Solution Approach 1:
The outlet aperture is repositioned from a conventional vertical alignment to an offset position that is both vertically and horizontally displaced relative to the overflow tube inlet. This dimensional repositioning moves the outlet away from the flapper valve bulb's path, eliminating impingement on the overflow flow area while maintaining manufacturing simplicity through standard mold cores.
3Reliability
If the flapper valve bulb is positioned to seal the inlet effectively, then sealing performance is improved, but it blocks the overflow flow area between the overflow tube and flush valve outlet
Solution Approach 1:
The outlet aperture is repositioned from a conventional vertical alignment to an offset position that is both vertically and horizontally displaced relative to the overflow tube inlet. This dimensional repositioning moves the outlet away from the flapper valve bulb's path, eliminating impingement on the overflow flow area while maintaining manufacturing simplicity through standard mold cores.
Data Source
AI summary
An offset outlet flush valve has a valve body, the valve body having an inlet comprising an inlet aperture, an overflow tube socket comprising an overflow tube aperture, and an outlet comprising an outlet aperture. The outlet aperture of the valve body, and the wall that defines it, intersects a portion of the inlet aperture and a portion of the overflow tube aperture and the walls that define them. In this way, a water flow continuum is created between the inlet aperture and the outlet aperture and between the overflow tube aperture and the outlet aperture. A number of alternative embodiments of an overflow tube socket and overflow tube are also provided depending upon OEM or after-market application of the offset outlet flush valve.