Venturi Fill Valve Layout for Compact Low-Force Toilet Refilling
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Solution Overview
Problem
Traditional fill valves in toilets face issues such as debris and mineral deposits causing friction, requiring large space, limited flexibility in design, and inefficiencies at varying pressures, including high water hammer and short diaphragm lifespan.
Innovation Solution
A fill valve system using a piston design with a pressure chamber, diaphragms, and a venturi that operates without a moving float, allowing minimal force to open and close, maintaining flowrate across a range of pressures and occupying less space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional float architecture is used to sense water level and activate the valve, then the valve can be turned on and off automatically, but the float requires contact with water which causes friction from debris and mineral deposits, making it vulnerable to failure
Solution Approach 1:
The patent removes the float component entirely from the system. Instead of using a float that contacts water to sense water level, the invention uses a cup positioned at the bottom of the tank that detects water level through pressure or direct contact when water rises, thereby extracting the problematic floating mechanism while retaining the water level sensing function
Solution Approach 2:
The patent replaces the mechanical float-based system with a cup-and-lever mechanism. The cup remains stationary at the bottom of the tank and does not float; instead, it is connected to a lever arm that pivots when the cup is pushed up by rising water or pulled down by a spring, substituting the floating mechanical system with a stationary detection mechanism
2Force
If a traditional ballcock design with a large float and long lever arm is used, then sufficient force can be generated to overcome hydraulic force and close the valve, but a large amount of space is required in the toilet tank
Solution Approach 1:
The patent inverts the traditional approach by having the cup remain stationary at the bottom of the tank rather than floating. The lever arm pivots on a fulcrum point, and the cup is pushed upward by rising water to trigger valve closure, reversing the conventional floating mechanism and reducing space requirements
Solution Approach 2:
The patent changes the operational dimension from vertical floating motion to a pivoting rotational motion around a fulcrum. The lever arm rotates as the cup is pushed up by water, converting linear vertical displacement into rotational movement, which allows for more compact positioning within the tank geometry
3Productivity
If a pilot valve with a smaller float is used to depressurize or pressurize a control chamber, then flowrate can be improved, but the diaphragm becomes vulnerable to high pressure and chemical attacks, reducing its lifespan
Solution Approach 1:
The patent removes the diaphragm component entirely from the system. Instead of using a diaphragm to seal and control flow in a pilot valve, the invention uses a valve seat and sealing surfaces that are more resistant to high pressure and chemical degradation, thereby extracting the vulnerable diaphragm while maintaining flow control capability
Solution Approach 2:
The patent employs a valve design with robust sealing surfaces and components that are more durable and resistant to degradation. The valve seat and sealing mechanisms are designed to withstand high pressure and chemical attacks without the fragility of diaphragm materials, effectively replacing the short-lived diaphragm with longer-lasting components
4Ease of operation
If a traditional fill valve design is used, then the valve can provide water for refilling the tank, but the design is not flexible enough to fit different tank geometries
Solution Approach 1:
The patent employs a lever arm with adjustable pivot points and a cup that can be positioned at different locations. The system allows for dynamic adjustment of the lever arm length, pivot position, and cup placement to accommodate various tank shapes and sizes, making the valve adaptable to different geometries while maintaining operational effectiveness
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 system achieves efficient operation with minimal force requirements, maintaining flowrate at low pressures and reducing the risk of diaphragm failure, while being compact and flexible for different tank geometries.
Implementation Method 1
a venturi downstream of the moveable sealing member, wherein the sealing member has an air passageway therethrough from the venturi to the vacuum chamber
Implementation Method 2
a first diaphragm at a top end of the pressure chamber, wherein the sealing member is mounted to the first diaphragm such that movement of the first diaphragm causes movement of the sealing member
Data Source
Figure 1~2
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Figure 4
AI summary
A fill valve with pressure chamber having an open bottom end and a diaphragm at a top end such that falling water level in the toilet tank causes the diaphragm to flex in a first direction, thereby moving a sealing member to an open position, with a venturi in the fill valve keeping the sealing member in the open position until water refilling the tank causes the diaphragm to flex in a second direction, thereby moving the sealing member back to the closed position.