Toilet flapper

Abstract

A system and method for controlling the flow of fluid through a discharge outlet. A flapper assembly moveable between an open position, at least one intermediate position, and a closed position. In the open position fluid is able to flow substantially unrestricted by the flapper assembly through the discharge outlet. In the closed position fluid is prevented from flowing through the discharge outlet. In the at least one intermediate position fluid is partially restricted, but not prevented, from flowing through the discharge outlet.

Description

FIELD OF THE INVENTION

[0001] This invention relates to the field of fluid valves generally with specific, but not exclusive, application to toilet flappers.

BACKGROUND OF THE INVENTION

[0002] Environmental practices such as water conservation are increasing in importance. The economic advantages of reducing water consumption are further driving this trend. In many jurisdictions, regulatory standards have been implemented governing the amount of water that toilets and other water devices and appliances may utilize.

[0003] Such regulatory standards typically apply to newly installed toilets. To achieve reduced water usage, newer toilets are often provided with smaller toilet tanks and incorporate other design efficiencies. However, many existing, older toilets continue to use large volumes of water and are much less efficient than their newer counterparts. Techniques exist for reducing the storage capacity of water tanks of older toilets, such as by putting a brick in the tank. While such techniques do reduce some water consumption, inefficiency remains.

[0004] Accordingly, the inventor has developed improved systems and methods for controlling the flow of fluids through discharge outlets.

SUMMARY OF THE INVENTION

[0005] In one aspect, the present invention is directed towards a flapper configured to seal a tank discharge opening. The flapper includes a first seal member movable between a first seal open position and a first seal closed position. The first seal member is configured to restrict the flow of fluid through a first portion of the discharge opening when the first seal member is in the first seal closed position. The flapper also includes a second seal member movable between a second seal open position and a second seal closed position, and wherein the second seal member is configured to restrict the flow of water through a second portion of the discharge opening when the second seal member is in the second seal closed position.

[0006] In another aspect, the present invention is directed towards a flapper assembly moveable between an open position, at least one intermediate position and a closed position. In the open position fluid is able to flow substantially unrestricted by the flapper assembly through a discharge outlet. In the at least one intermediate position, fluid is partially restricted, but not prevented, from flowing through the discharge outlet. In the closed position fluid is prevented from flowing through the discharge outlet.

[0007] In yet another aspect the present invention is directed towards a method of controlling a flow of water through a toilet tank discharge outlet The steps of the method include:

[0008] (a) permitting water to flow substantially unrestricted through the discharge outlet for a first period of time;

[0009] (b) partially restricting the flow of fluid through the discharge outlet for a second period of time; and

[0010] (c) sealing the discharge outlet thereby preventing the flow of fluid through the discharge outlet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present invention will now be described, by way of example only, with reference to the following drawings, in which like reference numerals refer to like parts and in which:

[0012] FIG. 1 is a top perspective view of a flapper assembly made in accordance with the present invention;

[0013] FIG. 2 is a top perspective view of the flapper assembly of FIG. 1, mounted within a toilet tank and in a fully closed position;

[0014] FIG. 3 is a top perspective view of the flapper assembly of FIG. 1, mounted within a toilet tank and in a fully open position; and

[0015] FIG. 4 is a top perspective view of the flapper assembly of FIG. 1, mounted within a toilet tank and in an intermediate position.

DETAILED DESCRIPTION OF THE INVENTION

[0016] Referring to FIG. 1, illustrated therein is a flapper assembly, referred to generally as 10, made in accordance with the present invention. The flapper 10 comprises a first seal member 12 and a second seal member 14. The second seal member 14 is pivotally coupled to the first seal member 12, typically by a hinge joint 16. The second seal member 14 preferably comprises an internal chamber 15. The internal chamber 15 is closed but has a chamber aperture 17 at a lower portion thereof. As will be understood, when the chamber 15 is filled with air, the air trapped in the chamber 15 provides buoyancy to the second seal member 14. Preferably, the first and second seal members 12, 14 are formed of rubber, silicon or other durable material capable of forming a watertight seal.

[0017] The first seal member 12 also comprises a first hinge mount 18, typically in the form of “ears”, and configured to pivotally engage a second hinge mount. As illustrated in FIG. 2, in toilet tanks, typically the second hinge mount 20 is in the form of pins located at the base of a flush valve assembly 22 mounted to the toilet tank 24.

[0018] The first seal member 12 is also provided with a ring 26 or other connection mount for attaching a chain 28 or similar connector mechanism which in turn is coupled to a toilet flush lever. The chain 28 may also be provided with a float 29.

[0019] As can be seen in FIG. 3, the flapper assembly 10, and in particular the first seal member 12 is designed to seat against the discharge outlet 30 at the bottom of the toilet tank 24, when the first seal member 12 (and the flapper assembly 10) is in the closed position shown in FIG. 2. As will be understood, the discharge outlet 30 has a discharge opening 32 through which water or other fluid stored in the tank 24 may flow.

[0020] As can be seen in FIG. 4, the first seal member 12 has an aperture or passageway 34, which is smaller in size than the discharge opening 32. The second seal member 14 is configured to form a watertight seal of the aperture 34 when the second seal member 14 is seated against the first seal member 12. The second seal member 14 preferably seats on the upper surface of the first seal member 12, rather than against the inner edges of the aperture 34, in order to facilitate freedom of movement between the first seal member 12 and second seal member 14.

[0021] Referring again to FIG. 2, in use the flapper assembly 10 is typically in its closed position sealing the discharge outlet 30 and preventing water or other fluid stored in the tank 24 from flowing through the outlet 30. When the toilet is to be flushed the flush handle is typically depressed, raising the flush lever and the attached chain 28, and thereby raising the flapper assembly 10 to an open position as illustrated in FIG. 3. When the assembly 10 is in the open position, the fluid stored in the tank 24 Is able to flow substantially unrestricted through the entire discharge opening 32.

[0022] When the toilet flush lever has been released and after a first volume of water has exited the tank 24 through the discharge outlet 30, the assembly 10 moves to its intermediate position in which the first seal member 12 is in the first seal closed position and the second seal member 14 is in the second seal open position, shown in FIG. 4. The assembly 10 pivots downwardly toward the discharge outlet 34. Under the effect of gravity, movement downward through the waer is resisited by the drag of the assembly moving through the water. Because the second seal member 14 is freely pivotally connected to the first seal member 12, the drag force acting on the second seal member 14 acts to raise it relative to the first seal member 12. In addition, the buoyancy provided by the air-filled internal chamber 15 facilitates the separation of the second seal member 14 from the first seal member 12.

[0023] In this position, fluid may flow through the aperture 34 and through the discharge opening 32. However, as will be understood, this flow rate is reduced in comparison to the flow rate when the apparatus 10 is in the open position. Since the aperture 34 is smaller in size than the opening 32. the fluid is restricted from flowing through a first portion of the discharge opening 32 which is covered by the first seal member 12 Fluid is permitted to flow through a second portion of the discharge opening 32, which coincides with the area defined by the aperture 34.

[0024] As the second seal member 14 moves to or reaches the second seal open position, some air may be released through the chamber aperture 17 and water may flow into the chamber 15, thereby reducing the buoyancy of the second seal member 14 and increasing its effective weight. After a second volume of water has flowed through the aperture 34 at a reduced rate, the second seal member 14 descends to the second seal closed position, with the apparatus 10 in the dosed position illustrated in FIG. 2 In this position, the second seal member 14 restricts, and in the illustrated embodiment, prevents fluid flowing through the second portion of the discharge opening 32, defined by the aperture 34. In this closed position, the apparatus 10 seals the discharge outlet 30, and the tank 24 may then be refilled with water or other fluid. As well, any water which has entered the internal chamber 15 is able to drain from the chamber aperture 17 through the discharge outlet 30, and following completion of the flushing process, air is able to enter the chamber 15 from the toilet bowl via the discharge outlet 30.

[0025] As will be understood, the first and second seal members 12, 14 are preferably configured such that the total volume of water flowing through the discharge outlet 30 during the flushing process described above, may be reduced from the volume of water flushing through a discharge outlet when using a standard single-piece prior an flapper assembly.

[0026] Additionally, the varying flow rates provided by the configuration of the flapper assembly 10 may provide improved flushing action over flushing an equivalent volume of water using a standard single-piece prior art flapper assembly. The flapper assembly 10 reduces the average flow rate (as compared to a standard single-piece flapper) because of the reduced effective discharge outlet size (when the assembly is in its intermediate position shown in FIG. 4) and thereby lengthens the time to drain a set volume of water through the discharge outlet 30. The flapper assembly 10 provides a large rush of water at the start of the flush, when the assembly 10 is moved to the open position illustrated in FIG. 3. After the initial surge of water is released through the discharge outlet 30, water is permitted to flow through the aperture 34 at a reduced rate when the assembly 10 is in the intermediate position illustrated in FIG. 4. This preferably enables enhanced siphoning of the toilet system.

[0027] As illustrated in FIG. 4, preferably the hinge joint 16 pivotally coupling the first 12 and second 14 seal members is positioned on the opposite side of the aperture 34 from the first hinge mount 18. The position of the hinge joint 16 forms an angle of approximately 180° through the center point of the aperture 34 and a mid-point of the first hinge mount 18. The hinge 16 may otherwise be positioned proximate the aperture 34, forming different angles through the center of the aperture 34 and the first hinge mount 18, but it is believed that the relative positioning of the hinges 16, 18 & 20 illustrated in the Figures works most effectively.

[0028] As well, with the chain 28 positioned to the rear of the hinge joint 16, the second seal member 14 is prevented from pivoting to and past the vertical as the first seal member 12 pivots down from the first seal open position to the first seal closed position. Such a constraint ensures that gravity is ultimately able to pivot the second seal member 14 to the second seal closed position illustrated in FIG. 2. Alternate means may be provided to constrain the second seal member 14 from pivoting to and past a vertical alignment.

[0029] Preferably the first hinge mount 18 and the individual components in the assembly 10 (and the first seal member 12, in particular) will be sized and configured to fit existing toilet tank 24 configurations, to facilitate replacement of old flappers with the flapper assembly 10 of the present invention, as will be understood.

[0030] Additionally, while the Figures illustrate a hinge joint 16 having “ears” and pins, between the first 12 and second 14 seal members, other methods of positioning the second seal member 14 relative to the first 12 may be used. For example, a pivot may be formed of flexible material connecting the first 12 and second 14 seal members together.

[0031] The second seal member 14 has been described as having an internal chamber 15 having a chamber aperture 17. The chamber aperture 17 allows for the exchange of air and water into the chamber 15, which adjusts the buoyancy and effective weight of the second seal member 14 and facilitates the descent of the second seal from the second seal open position to the second seal closed position. As will be understood adjustments can be made to the size and configuration of the chamber 15 and the size of the chamber aperture 17, thereby varying the buoyancy (and rate of change of buoyancy) and hence the rate of descent of the second seal member 14. Similarly, more than one chamber aperture 17 may be provided.

[0032] Additionally, while the chamber 15 has been described as having a chamber aperture 17, in alternative embodiments, the chamber 15 may not have a chamber aperture 17. In such instance, if the buoyancy provided by the chamber 15 is sufficiently high, the second seal member 14 may not be able to descend to the second seal closed position until the water level in the tank toilet tank is near the bottom of the tank. To achieve water conservation with such an embodiment, it may prove necessary to reduce the amount of water stored in the tank for example by adjusting the toilet tank float valve, or by putting bricks in the tank, or through other means.

[0033] Furthermore, in place of a chamber 15, alternate means (such as manufacturing the second seal member 14 out of sufficiently buoyant material) may be utilized for providing buoyancy to the second seal member 15, for the purpose of facilitating a sufficiently slow descent from the second seal open position to the second seal closed position and provide a sufficiently long flush period.

[0034] Thus, while what is shown and described herein constitutes preferred embodiments of the subject invention, it should be understood that various changes can be made without departing from the subject invention, the scope of which is defined in the appended claims.

Claims

1. A flapper configured to seal a tank discharge opening, the flapper comprising:

(a) a first seal member movable between a first seal open position and a first seal closed position, and wherein the first seal member is configured to restrict the flow of fluid through a first portion of the discharge opening when the first seal member is in the first seal closed position; and

(b) a second seal member movable between a second seal open position and a second seal closed position, and wherein the second seal member is configured to restrict the flow of water through a second portion of the discharge opening when the second seal member is in the second seal closed position.

2. A flapper as claimed in claim 1, wherein the first seal member and the second seal member seal the discharge opening when the first seal is in the first seal closed position and the second seal member is in the second seal closed position.

3. A flapper as claimed in claim 1, further comprising a first hinge mount configured to pivotally engage a second hinge mount, wherein the second hinge mount is operatively coupled to the toilet tank.

4. A flapper as claimed in claim 1, wherein the first seal member comprises an aperture through the first seal member, and wherein the second seal member is configured to seal the aperture when the first seal member is in the first seal closed position and the second seal member is in the second seal closed position.

5. A flapper as claimed in claim 1, wherein the second seal member is pivotally coupled to the first seal member.

6. A flapper as claimed in claim 5, comprising a hinge for pivotally coupling the second seal member to the first seal member.

7. A flapper as claimed in claim 1 wherein the first seal member defines an aperture smaller then the discharge opening and wherein the second seal member is configured to prevent the flow of fluid through the aperture when the second seal member is in the second seal closed position.

8. A flapper as claimed in claim 1, further comprising a connector for operatively coupling the toilet flapper to a flush lever.

9. A flapper as claimed in claim 8, further comprising a float attached to the connector.

10. A flapper as claimed in claim 9, wherein the connector comprises a chain.

11. A flapper as claimed in claim 1, coupled to a flush lever.

12. A flapper assembly moveable between an open position, at least one intermediate position and a closed position;

(a) wherein in the open position fluid is able to flow substantially unrestricted by the flapper assembly through a discharge outlet:

(b) wherein in the at least one intermediate position fluid is partially restricted but not prevented, from flowing through the discharge outlet; and

(c) wherein in the closed position fluid is prevented from flowing through the discharge outlet.

13. A flapper assembly as claimed in claim 12, comprising:

(a) a first seal member moveable between a first seal open position and a first seal closed position, and wherein the first seal member is configured to seat against the discharge outlet when the first seal member is in the first seal closed position;

(b) wherein the first seal member defines an aperture smaller than the discharge outlet; and

(c) a second seal member movable between a second seal open position and a second seal closed position, and wherein the second seal member is configured to prevent the flow of fluid through the aperture when the second seal member is in the second seal closed position.

14. A method of controlling a flow of water through a toilet tank discharge outlet, the steps of the method comprising:

(a) permitting water to flow substantially unrestricted through the discharge outlet for a first period of time;

(b) partially restricting the flow of fluid through the discharge outlet for a second period of time, and

(c) sealing the discharge outlet thereby preventing the flow of fluid through the discharge outlet.

15. A flapper configured to seal a tank discharge opening in a tank having only one flush lever, the flapper comprising:

(a) a first seal member movable between a first seal open position and a first seal closed position, and wherein the first seal member defines an aperture through the first seal member;

(b) a second seal member freely pivotally coupled to the first seal member and movable between a second seal open position and a second seal closed position, and wherein the second seal member is configured to seal the aperture when the second seal member Is in the second seal closed position; and

(c) wherein the flapper is provided with only one connector for coupling the flapper to said only one flush lever, wherein the connector is attached to the first seal member.

16. The flapper as claimed in claim 15, coupled to said only one flush lever.