Piston Cap Center Vent for Flushometer Air Removal
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Solution Overview
Problem
Air presence in the control chamber of flushometers leads to inconsistent gallons per flush (GPF) due to the combination of compressible air and incompressible water, requiring a method to effectively remove air to restore consistent operation.
Innovation Solution
A flushometer design featuring a piston cap with a central exhaust passage that establishes fluid communication between the upper pressure chamber and the piston interior chamber, allowing for the evacuation of air through a low-pressure location, thereby refilling the chamber with water and minimizing air content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air is present in the control chamber, then the flushometer can operate with some consistency, but the gallons per flush becomes inconsistent due to the combination of compressible air and incompressible water
Solution Approach 1:
The patent extracts air from the control chamber by providing a passage through the piston cap that allows air to escape from the control chamber to the exterior. This extraction of the harmful component (air) resolves the contradiction by removing the source of GPF inconsistency while maintaining the water-filled stable environment needed for reliable operation.
2Reliability
If a domed inner cover is used to define the control chamber, then the outer cover can be made from a wider range of materials and reliability is improved, but air tends to accumulate at the top of the domed inner cover
Solution Approach 1:
The piston cap with its integrated air escape passage acts as an intermediary element that allows the domed inner cover structure to be maintained for reliability benefits, while simultaneously providing a pathway for air to escape. The passage through the piston cap mediates between the sealed control chamber needed for reliability and the need to prevent air accumulation.
3Reliability
If air is removed slowly over many flush cycles, then the air gradually dissolves and is removed, but this requires over 50 flush cycles to restore normal operation
Solution Approach 1:
The patent implements preliminary action by providing a dedicated air escape pathway that allows air to be removed proactively rather than waiting for slow dissolution over many cycles. The passage enables air to be evacuated during normal operation or maintenance activities, restoring reliable GPF performance much faster than the natural slow dissolution process.
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 effectively removes air from the control chamber, ensuring consistent GPF performance by evacuating gas and refilling with water, thus improving the reliability and efficiency of flushometer operations.
Implementation Method 1
The control chamber can be pressurized to substantially the pressure of the inlet via communication through the bypasses. As the line pressure in the control chamber acts on a larger topside area of the piston or diaphragm than the inlet line pressure acts on smaller underside area of the piston, the valve remains closed under equal pressures.
Implementation Method 2
The relief valve is actuated, placing the piston interior chamber in fluid communication with the outlet. A low pressure location is formed at a location within the exhaust passage. Gas is moved in the control chamber to the low pressure location.
Data Source
AI summary
A flushometer having a cap with a substantially central exhaust passage adapted to remove air from the control chamber. The exhaust passage provides for communication between an upper pressure chamber and an interior piston chamber wherein during a flush cycle a portion of the contents of the upper pressure chamber is evacuated through the exhaust passage into the interior piston chamber and ultimately through the outlet of the flushometer.