Rigid Piston Flush Valve Assembly for Low-Pressure Sealing
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Solution Overview
Problem
Conventional diaphragm flush valves suffer from clogging, inefficient flushing cycles, and poor sealing at low water pressures, leading to water wastage and the need for improved sealing and electronic operation.
Innovation Solution
A rigid piston assembly with a solenoid is introduced, featuring a central opening, by-pass orifice, guide members, and a flow ring to regulate water flow, along with a piston seal and retaining ring for sealing, and a by-pass device for fluid communication, allowing for efficient and electronic control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a diaphragm is used in a flush valve, then the valve can control water flow, but the by-pass orifice can become clogged with debris preventing water flow
Solution Approach 1:
The patent replaces the flexible diaphragm with a rigid piston assembly that has a by-pass orifice. The rigid piston is less susceptible to clogging by debris compared to the flexible diaphragm, as the rigid structure maintains its shape and flow characteristics even when debris is present in the system.
Solution Approach 2:
The patent changes the material parameter from flexible rubber diaphragm to rigid piston material. This parameter change makes the by-pass orifice more resistant to clogging, as the rigid structure does not deform or collapse when debris accumulates, maintaining reliable water flow control.
2Productivity
If a diaphragm flush valve is used, then the valve can operate, but the flushing cycle takes approximately seven seconds resulting in water wastage
Solution Approach 1:
The patent replaces the diaphragm-based mechanical system with a rigid piston system that responds more quickly to pressure changes. This substitution reduces the flushing cycle time from approximately seven seconds to a shorter duration, improving productivity and reducing water wastage during the sealing process.
Solution Approach 2:
The rigid piston design anticipates and prevents the slow response issue by using a structure that responds immediately to pressure differentials. The rigid piston quickly equalizes pressure between chambers, preventing the prolonged flushing cycle associated with flexible diaphragms that slowly deform during operation.
3Reliability
If a diaphragm flush valve is used, then the valve can control flow, but sealing is difficult at water pressures below 35 psi
Solution Approach 1:
The patent replaces the flexible diaphragm sealing mechanism with a rigid piston sealing system. The rigid piston maintains consistent sealing contact with the valve seat even at low water pressures below 35 psi, overcoming the limitation of diaphragm-based systems that struggle to seal effectively under low pressure conditions.
Solution Approach 2:
The patent changes the sealing mechanism from flexible material deformation to rigid geometric sealing. This parameter change enables effective sealing at low pressures by relying on precise geometric fit and pressure distribution rather than material elasticity, which is insufficient below 35 psi.
4Productivity
If a rigid piston assembly with solenoid is used, then electronic operation and efficient flushing are achieved, but the device complexity increases
Solution Approach 1:
The rigid piston assembly is designed to perform multiple functions: it controls water flow, provides sealing, enables electronic operation through solenoid integration, and maintains efficient flushing. This multi-functionality justifies the increased device complexity by consolidating multiple capabilities into a single integrated assembly rather than separate components.
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 rigid piston assembly provides quicker, more efficient flushing with reduced water usage, effective sealing at low pressures, and electronic operation, while being easily retrofittable into existing flush valves.
Implementation Method 1
A rigid piston assembly with a solenoid is introduced, featuring a central opening, by-pass orifice, guide members, and a flow ring to regulate water flow
Implementation Method 2
effective sealing at low pressures
Data Source
AI summary
A rigid piston assembly for use in a conventional flush valve includes a rigid piston and a solenoid configured to fixedly engage within the valve body. A flush valve for a plumbing fixture as well as a method of retrofitting a piston valve into a diaphragm flush valve body which includes a rigid piston and solenoid configuration.