Reconfigurable Flapper Assembly for 2-Inch and 3-Inch Flush Valves

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Solution Overview

Problem

Conventional flush valves come in different sizes, requiring separate flappers due to differences in drain hole diameter, piping size, and flow rate, leading to inefficiencies and compatibility issues.

Innovation Solution

A flapper assembly kit with adjustable legs, buoyancy assemblies, and seal members that can be configured to fit different sized flush valves, allowing a single kit to accommodate both 2" and 3" flush valves by adjusting leg spacing, buoyancy, and seal diameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single flapper design is used for different sized flush valves, then device complexity is reduced and manufacturing cost decreases, but compatibility and sealing performance deteriorate

Engineering Contradiction:

Improveflapper design varietyVSAvoidcompatibility with different flush valve sizes

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The flapper is divided into separate modular components: a frame structure, adjustable legs with spacing mechanisms, and interchangeable seal members. This segmentation allows each component to be independently configured for different flush valve sizes while maintaining a unified base design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flapper incorporates adjustable elements including legs that can be repositioned along the frame and seal members that can be exchanged. This dynamic configurability enables the same flapper body to adapt to different drain hole diameters and valve seat configurations across 2-inch and 3-inch flush valves.

Inventive Principle:

Principle #15Dynamics

2Reliability

If buoyancy is increased to prevent premature closing in larger flush valves, then flushing reliability improves, but water conservation deteriorates due to excessive water emptying

Engineering Contradiction:

Improveflushing operation reliabilityVSAvoidwater conservation

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The buoyancy of the flapper is precisely controlled by adjusting the volume and configuration of the buoyancy chamber within the frame. This parameter adjustment allows optimization of the lift force to match the specific flow rate and drain hole size, ensuring the flapper remains open long enough for complete flushing without causing premature closure or excessive water waste.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If leg spacing is increased for 3-inch flush valves, then compatibility with larger drain holes improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecompatibility with different drain hole diametersVSAvoidleg spacing precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The leg assembly is segmented with individual legs that can be independently positioned and adjusted along the frame. Each leg includes adjustment mechanisms such as slots or threaded sections that allow precise positioning at multiple discrete locations, enabling adaptation to different drain hole diameters without requiring custom manufacturing for each size.

Inventive Principle:

Principle #1Segmentation

4Reliability

If seal diameter is increased for larger flush valves, then sealing effectiveness improves, but compatibility with smaller flush valves deteriorates

Engineering Contradiction:

Improvesealing effectivenessVSAvoidcompatibility across different valve sizes

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The seal member is designed with localized sealing surfaces that can be exchanged or adjusted to match the specific diameter of the valve seat. Different seal members with varying diameters and profiles are provided to match 2-inch versus 3-inch valve seats, ensuring optimal sealing contact at the critical sealing interface while maintaining compatibility across different flush valve sizes through interchangeability.

Inventive Principle:

Principle #3Local quality

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 a single kit to be used for both 2" and 3" flush valves, improving compatibility and water conservation by ensuring proper sealing and buoyancy, thus optimizing water usage.

Implementation Method 1

the flapper typically requires a larger amount of buoyancy for the 3" flush valve to prevent the larger flow of water from overwhelming the flapper and prematurely closing the flush valve

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS20250327288A1Reconfigurable flapper for different sized flush valves

Publication Date: 2025.10.23 LAVELLE IND INC

AI summary

A flapper assembly for a flush valve as well as method of assembly are provided. The flapper assembly includes a frame and multiple buoyancy assemblies attachable to the frame so as to adjust the buoyancy of the flapper assembly. The flapper assembly kit may have adjustable legs attachable to the frame. The flapper assembly kit may have multiple seal members for use in sealing with different sized/shaped valve seats of different sized flush valves.