Trip Lever Assembly Dampening for Smooth Flush Operation
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Solution Overview
Problem
Conventional trip lever assemblies in toilets often have loose tolerances, resulting in a sloppy feel and noisy operation, giving the impression of a low-budget or poorly constructed fixture.
Innovation Solution
A trip lever assembly with a stemmed handle supporting two bushings and a high viscosity dampening material, featuring close tolerances and anti-rotation mechanisms to limit play and ensure smooth rotational motion, providing a solid feel and improved operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional trip lever assemblies are manufactured with loose tolerances, then manufacturing cost is reduced, but the assembly exhibits sloppy feel, play, and noisy operation
Solution Approach 1:
The patent introduces an intermediary dampening material between the inner and outer bushings to absorb lateral play and smooth rotational motion. This mediator component allows the use of looser manufacturing tolerances in the bushings themselves while still achieving the desired smooth operation and solid feel, thereby resolving the contradiction between manufacturing precision and operational quality.
Solution Approach 2:
The patent changes the physical parameter of the bushing interface by introducing a high viscosity dampening material that fills the gap between bushings. This parameter change (from direct metal-to-metal or plastic-to-plastic contact to contact through a viscous medium) allows for reduced manufacturing precision while maintaining smooth operation and eliminating the sloppy feel associated with loose tolerances.
2Device complexity
If conventional trip lever assemblies use simple construction, then manufacturing cost is reduced, but they exhibit rattling and noisy operation
Solution Approach 1:
The dampening material serves as an intermediary element between the inner and outer bushings that absorbs vibrations and prevents rattling noises. This addition of a relatively simple intermediary component effectively eliminates the harmful noise and rattling without requiring complex construction, thus resolving the contradiction between device complexity and noise reduction.
Solution Approach 2:
The patent employs composite construction by combining different materials (metal stem, plastic bushings, and dampening material) to create an assembly that reduces noise and rattling. The composite nature of the assembly, particularly the combination of rigid structural components with the viscous dampening material, provides noise reduction without requiring overly complex construction.
3Ease of operation
If the handle rotates freely with minimal resistance, then ease of operation is improved, but the assembly loses control and returns quickly without smooth motion
Solution Approach 1:
The high viscosity dampening material acts as an intermediary that provides controlled resistance to rotational motion. It allows the handle to rotate easily while simultaneously providing just enough friction to control the return stroke, creating a smooth, deliberate motion rather than a quick, uncontrolled return. This resolves the contradiction between rotational ease and rotational control.
Solution Approach 2:
The patent changes the friction parameter at the bushing interface by introducing the dampening material. This parameter change creates an optimal balance where the friction is high enough to control the return stroke and provide smooth motion, but low enough to allow easy rotation during the flushing operation, thereby resolving the contradiction between ease of operation and rotational control.
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 achieves a more solid and smooth rotational motion, reducing play and noise, enhancing the overall feel and appearance of the trip lever assembly.
Implementation Method 1
A high viscosity dampening material can be applied between the inner and outer bushings to further reduce play, particularly in the lateral direction
Implementation Method 2
it will smooth the rotational motion of the handle and work to slow the return of the handle to its initial position
Data Source
AI summary
A trip lever assembly for initiating a flush cycle of a toilet is constructed to have a more solid and smooth feel with less play. The assembly includes a handle accessible with a stem extending into an interior of the toilet. An inner bushing fits onto the stem and inside of a fixed outer bushing. A trip arm connect the handle to a pull member operatively attached to the flush valve. The handle has an anti-rotation feature that engages an associated feature of the inner bushing so that the inner bushing mechanically couples and rotates with the handle. A high viscosity dampening grease is disposed between the inner bushing and the outer bushing to limit lateral play, and smooth the rotation of the handle.