Universal Flapper Linkage for Flush Valve Orifice Alignment
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Solution Overview
Problem
Conventional ceramic manufacturing techniques lack accurate dimensional control, and rubber flappers in flush valve systems create uneven fluid flow due to their design, leading to inefficiencies in water usage and flush performance.
Innovation Solution
A fluid valve control assembly featuring a flapper coupled with a linkage assembly that maintains the flapper's parallel orientation to the flush valve orifice, allowing for precise control and adjustment, and utilizing a flapper canister with a buoyancy control tube to assist in fluid coupling and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional rubber flappers are used to control flush flow, then the flush valve can be simple in structure, but the flapper blocks flow into the flush orifice when lifted, causing uneven water distribution and reduced flush efficiency
Solution Approach 1:
Instead of having the flapper block the orifice from above (conventional design), this invention inverts the approach by using a flapper canister that seals from the bottom and allows water to flow over its top surface. The flush orifice remains unblocked during operation, enabling even water distribution while maintaining sealing capability.
Solution Approach 2:
The invention transitions from a two-dimensional flapper sealing approach to a three-dimensional flapper canister structure that encloses the sealing surface. This dimensional change allows the seal to be formed at the bottom while the top surface remains exposed for optimal water flow distribution across the orifice.
2Manufacturing precision
If precise dimensional control is required for flapper components to ensure proper sealing, then manufacturing complexity and cost increase, but conventional ceramic techniques cannot provide the necessary precision
Solution Approach 1:
The invention changes the material parameter from traditional rubber or ceramic to a material that can be manufactured with high precision using injection molding or similar processes. This parameter change enables achieving the required dimensional control (within 0.002 inches) while simplifying the manufacturing process and reducing complexity.
Solution Approach 2:
The invention replaces the mechanically complex assembly of conventional flappers with a monolithic or integrated flapper canister design. This substitution eliminates the need for precise mechanical adjustments and complex assembly procedures, achieving high dimensional control through manufacturing process precision rather than mechanical tolerance stacking.
3Loss of substance
If flush volumes are decreased to conserve water, then water efficiency improves, but fluid flow characteristics must be significantly enhanced to maintain satisfactory flush performance
Solution Approach 1:
The invention applies local quality by designing the flapper canister with specific geometric features optimized for water flow distribution. The canister's shape and surface characteristics are locally optimized to enhance fluid dynamics, creating effective flush performance with reduced water volumes by concentrating flow where it is most needed.
Solution Approach 2:
The invention changes the fluid flow parameters by optimizing the flapper canister geometry to improve flow velocity and distribution patterns. This enables satisfactory flush performance with lower flush volumes by enhancing the efficiency of water utilization through improved hydrodynamics.
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
This solution ensures consistent and efficient fluid flow by maintaining the flapper's parallel orientation to the orifice, preventing blockages and allowing for even water distribution, thus enhancing flush performance and reducing the need for precise ceramic manufacturing.
Implementation Method 1
the flapper canister with a buoyancy control tube to assist in fluid coupling and positioning
Data Source
AI summary
Some embodiments include a fluid control assembly with a flapper canister, a linkage rotatably coupled to the flapper canister and to a support of a mount. In some embodiments, the flapper canister can be angled with respect to the mount to enable the flapper canister to be coupled to various sizes, types and orientations of flush valves. In some embodiments, by rotating the linkage about pivots coupled to the flapper canister and the support and pivoting or rotating about a motion-enabling element coupling the mount and a support, the flapper canister can be raised, lowered, and/or rotated or pivoted enabling the flapper canister to be sealed against a flush valve orifice. In some embodiments, the flapper canister includes a buoyancy control tube providing fluid coupling between one side of the flapper canister to an opposite side and enabling buoyancy-assist to the position or motion of the flapper canister.