CROSS-REFERENCE TO RELATED APPLICATION This application is a non-provisional of, and claims priority to, U.S. Provisional Application No. 63/456,148, filed Mar. 31, 2023, which prior application is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION This disclosure relates to pressure assisted flushing systems for toilets, and more specifically to assemblies for such flushing systems to control flow of water and air, including air inducer assemblies, flush valves, and tank structural features.
BACKGROUND Pressure assisted flushing systems for toilets use a pressure tank which may be positioned within the tank of the toilet. Water at line pressure flows into the pressure tank, such that the water within the tank is at line pressure. When the toilet is flushed and the flush valve within the pressure tank is operated, the water is forced from the pressure tank into the toilet bowl for rapid and complete flushing of its contents. Such systems also include an air inducer assembly, which draws air into the pressure tank to create an air head that is used to provide the pressure for discharging the water in the tank. The air inducer assembly connects to the inlet water conduit and to air at atmospheric pressure, such that the flow of water from a conventional water supply will draw air into the tank to pressurize the tank. Improving the air drawing capabilities of the air inducer assembly can achieve greater air volume and lower water volume being drawn into the tank, thereby reducing flush volume. This can have numerous benefits, including increased water conservation. Other modifications to components of a pressure-assisted flushing system may achieve further reduced flush volumes. As one example, flush volumes as low as 0.8 gallons per flush (GPF) or lower have not been reliably achieved by such systems, particularly over a long period and/or multiple cycles.
The present disclosure is provided to address this need and other needs in existing pressure-assisted flushing systems. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF SUMMARY Aspects of the disclosure relate to a tank for a pressure-assist toilet flush system, including a base having an outlet configured for discharging water from the tank and a cover connected to an upper end of the base, such that the cover and the base define a cavity configured to hold water to be discharged through the outlet. The base includes a pair of first sidewalls extending downward from an upper end of the base along a length of the base, a pair of second sidewalls extending between the first sidewalls and downward from the upper end of the base, and a bottom wall connected to the first sidewalls and the second sidewalls, where the outlet is defined in the bottom wall. The tank has a wall extending upward from the bottom wall of the base and at least partially surrounding the outlet, where the wall has a passage therethrough, and the wall is configured such that at least a portion of the water flowing to the outlet while discharging the water from the tank is configured to flow through the passage toward the outlet. The wall may be configured to restrict a volume of water flowing through the outlet while water is discharging through the outlet. The base may also include a plurality of ribs connected to the first sidewalls and extending inwardly from the first sidewalls in some configurations.
According to one aspect, the wall extends completely around the outlet. In one configuration, the wall is a cylindrical wall.
According to another aspect, the wall has a height configured to be higher than a level of water in the tank.
According to a further aspect, the passage is positioned at a juncture between the wall and the bottom wall of the base.
According to yet another aspect, the wall has a second passage positioned on an opposite side of the outlet from the passage. In one configuration, the wall is a cylindrical wall, and the passage and the second passage are positioned on opposite sides of the outlet along the length of the base.
According to a still further aspect, the tank is configured to hold a replaceable flush cartridge having a plunger accessible above a top of the cover and configured to selectively seal the outlet to control discharge of the water from the tank.
According to an additional aspect, the base further includes a first cross-rib and a second cross-rib extending between the first sidewalls, and the wall is located between the first cross-rib and the second cross-rib.
Additional aspects of the disclosure relate to a tank for a pressure-assist toilet flush system, including a base having an outlet configured for discharging water from the tank and a cover connected to an upper end of the base, such that the cover and the base define a cavity configured to hold water to be discharged through the outlet. The base includes a pair of first sidewalls extending downward from an upper end of the base along a length of the base, a pair of second sidewalls extending between the first sidewalls and downward from the upper end of the base, and a bottom wall connected to the first sidewalls and the second sidewalls, where the outlet is defined in the bottom wall. The tank further includes a tray engaged with the base and positioned within the cavity, the tray having a bottom tray wall spaced upward from the bottom wall of the base. The base may also include a plurality of ribs connected to the first sidewalls and extending inwardly from the first sidewalls in some configurations.
According to one aspect, the tank includes a second tray engaged with the base and positioned within the cavity, the second tray having a second bottom tray wall spaced upward from the bottom wall of the base. In one configuration, the tray and the second tray are positioned on opposite sides of the outlet.
According to additional aspects, the tray may have side walls extending upward from the base to define a tray cavity with an open top, or the tray may define a closed volume.
According to another aspect, the tank includes pegs extending upward from the bottom wall of the base and fixed to the bottom tray wall to engage the tray with the base.
According to a further aspect, the base further includes a first rib and a second rib connected to the first sidewalls and extending inwardly in opposite directions from the first sidewalls, and the tray has a first slot on a first side and a second slot on a second side opposite the first side. The first rib is received in the first slot, and the second rib is received in the second slot, and the tray is engaged with the base by engagement of the first and second ribs with the first and second slots. In one aspect, the first slot and the second slot are vertical slots extending vertically along the first and second sides of the tray. In this aspect, the first slot may be formed by a pair of first vertical ribs extending outward from the first side of the tray, and the second slot may be formed by a pair of second vertical ribs extending outward from the second side of the tray. In another aspect, the first slot has a pair of first flared ribs extending at angles outward at a bottom end thereof, and the second slot has a pair of second flared ribs extending at angles outward at a bottom end thereof.
According to yet another aspect, the tray has a hole extending through the bottom wall. In a configuration where the tank includes a second tray, one or both of the tray and the second tray may have a hole.
According to a still further aspect, the tray has a fitting projection extending outward from a periphery of the tray, such that the fitting projection resists insertion of the tray into the base in an incorrect position.
Further aspects of the disclosure relate to an air inducer assembly that includes a housing having one or more walls defining a chamber, an outlet located downstream from the chamber and configured for connection to an inlet of a flush tank, a water inlet in communication with the chamber and configured for connection to a water inlet conduit for introducing water into the chamber, and an air inlet in communication with the chamber and configured to be in communication with a source of air. The assembly also includes a tube extending into the chamber and toward the outlet, the tube having a passage therethrough extending from the water inlet through the tube to place the water inlet in communication with the outlet. The tube is configured such that water from the water inlet flows through the passage to the outlet, and the tube is further configured to permit air to be drawn from the air inlet into the outlet by a flow of the water out of a distal end of the tube.
According to one aspect, the assembly further includes a check valve connected to the housing at the air inlet and configured to permit the air to flow through the air inlet and into the passage and to resist air flow out of the air inducer assembly through the air inlet.
According to another aspect, the tube is a cylindrical tube and the passage is a cylindrical passage.
According to a further aspect, the water inlet is positioned at a top of the housing, and the outlet is positioned at a bottom of the housing. In one aspect, the one or more walls defining the chamber may include a top wall, and the tube extends vertically downward from the top wall.
Still further aspects of the disclosure relate to a tank for a pressure-assist toilet flush system that includes any combination of a wall extending upward from a bottom wall of the base, as disclosed herein, a tray as disclosed herein, and an air inducer assembly as disclosed herein. The tank according to these aspects permits an average flush volume of no more than 0.8 GPF to be achieved.
Other features and advantages of the disclosure will be apparent from the following description taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS To allow for a more full understanding of the present disclosure, it will now be described by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of one embodiment of a prior art pressure-assisted flushing system configured for use with a toilet;
FIG. 2 is a cross-section view of a portion of the system of FIG. 1, with a prior art air inducer assembly;
FIG. 3 is a cross-section view of an air inducer of the air inducer assembly of FIG. 2;
FIG. 4 is a cross-section view of the internal volume of the air inducer assembly of FIG. 2, with velocities at air inlet and liquid outlet illustrated quantitatively;
FIG. 5 is a perspective view of one embodiment of a pressure-assisted flushing system configured for use with a toilet, according to aspects of the disclosure;
FIG. 6 is a perspective view of one embodiment of an air inducer assembly of the system of FIG. 5, according to aspects of the disclosure;
FIG. 7 is a cross-section view of the air inducer assembly of FIG. 6;
FIG. 8 is a perspective view of another embodiment of an air inducer assembly usable in connection with the system of FIG. 5, according to aspects of the disclosure;
FIG. 9 is a cross-section view of the air inducer assembly of FIG. 8;
FIG. 10 is a cross-section view of another embodiment of an air inducer assembly usable in connection with the system of FIG. 5, according to aspects of the disclosure;
FIG. 11 is a cross-section view of another embodiment of an air inducer assembly usable in connection with the system of FIG. 5, according to aspects of the disclosure;
FIG. 12 is a cross-section view of another embodiment of an air inducer assembly usable in connection with the system of FIG. 5, according to aspects of the disclosure;
FIG. 13 is a cross-section view of another embodiment of an air inducer assembly usable in connection with the system of FIG. 5, according to aspects of the disclosure;
FIG. 14 is a cross-section view of the pressure-assisted flushing system of FIG. 5;
FIG. 15 is a magnified view of a portion of FIG. 14;
FIG. 16 is a top perspective view of the pressure-assisted flushing system of FIG. 5, with components removed to show internal detail;
FIG. 17 is a cross-section view of the pressure-assisted flushing system of FIG. 5, with components removed to show internal detail;
FIG. 18 is a top perspective view of a flush actuator of the pressure-assisted flushing system of FIG. 5;
FIG. 19A is a cross-section view of the flush actuator of FIG. 18;
FIG. 19B is a cross-section view of the flush actuator of FIG. 18 mounted within a tank of the pressure-assisted flushing system FIG. 5, illustrating flow through an outlet of the tank when the flush actuator is open;
FIG. 20 is a top perspective view of another embodiment of a flush valve usable with the actuator of FIG. 18;
FIG. 21 is a top perspective view of another embodiment of a pressure-assisted flushing system configured for use with a toilet, according to aspects of the disclosure, with components removed to show internal detail;
FIG. 22 is a cross-section of the pressure-assisted flushing system of FIG. 21;
FIG. 23 is a cross-section of a tank and a retention tray of the pressure-assisted flushing system of FIG. 21;
FIG. 24 is a top perspective view of the pressure-assisted flushing system of FIG. 21, with additional components removed to show detail;
FIG. 25A is a top perspective view illustrating a first step of one embodiment of a method of manufacture of the pressure-assisted flushing system of FIG. 21, according to aspects of the disclosure;
FIG. 25B is a magnified view of Area A of FIG. 25A;
FIG. 26A is a top perspective view illustrating a second step of the method of manufacture of the pressure-assisted flushing system of FIG. 21, following the first step of FIG. 25A;
FIG. 26B is a magnified view of Area B of FIG. 26A;
FIG. 27 is a side view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 28 is a top view of the retention try of FIG. 27;
FIG. 29 is a side view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 30 is a top view of the retention try of FIG. 29;
FIG. 31 is a side view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 32 is a top view of the retention try of FIG. 31;
FIG. 33 is a side view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 34 is a side view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 35 is a side view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 36 is a side view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 37 is a cross-section view of a tank of a pressure-assisted flushing system engaged with the retention tray of FIG. 36;
FIG. 38 is a top view of a portion of the tank and the retention tray of FIG. 37;
FIG. 39 is a perspective view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 40 is a perspective view of another embodiment of a retention tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 41 is a perspective view of a base of a tank of a pressure-assisted flushing system engaged with the retention trays of FIGS. 40 and 41;
FIG. 42 is a perspective view of the base of the tank and the retention trays of FIG. 41, with the retention trays improperly installed;
FIG. 43 is a perspective view of one embodiment of a volume occupying tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 44 is a perspective view of another embodiment of a volume occupying tray usable with a pressure-assisted flushing system, according to aspects of the disclosure;
FIG. 45 is a top perspective view of a base of a tank of a pressure-assisted flushing system engaged with the volume occupying trays of FIGS. 43 and 44.
DETAILED DESCRIPTION While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will herein be described in detail example embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the following description of various example structures according to the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example devices, systems, and environments in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, example devices, systems, and environments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.
Referring initially to FIGS. 1-4, there is shown an example of an existing pressure assist toilet flush system 10 that includes a tank or tank assembly 11 defining an internal cavity, with an inlet 12 and an outlet 13 for intake and discharge of water, and a flush actuator 14 configured for selectively opening and closing a valve leading to outlet 13 to control discharge of water. The flush actuator 14 may be in the form of a replaceable flush cartridge mounted within a receiver 15 in the tank 11, such that a portion of the flush cartridge is accessible outside the tank 11 and the actuator 14 is positioned within the cavity to interact with an internal seal surface around the outlet 13. The tank 11 may be constructed of a lower housing or base 16 forming a bottom portion of the tank 11, and an upper housing or cover 17 forming a top portion of the tank 11, such that the base 16 and the cover 17 combine to define the internal cavity. The base 16 and the cover 17 may be made from plastic (including, e.g., fiber-reinforced plastic). The outlet 13 is typically connected to a toilet bowl (not shown), such that water discharged from the outlet 13 accomplishes flushing of the bowl.
The system 10 also includes an air inducer assembly 19 connected to the inlet 12 and to a water inlet conduit 18, the assembly 19 configured to introduce liquid (e.g., water) and gas (e.g., air) into the tank 11. Air is drawn into and through the assembly 19 as the water passes through the assembly 19 from the water inlet conduit 18, e.g., by the Venturi effect, such that water and air pass through the inlet 12 into the tank 11. This pressurizes the tank 11, such that water can be forced into the toilet for improved flushing.
FIGS. 2-4 illustrate an example of a prior art air inducer assembly 19, which includes an air inducer 20 having a housing 24 with a chamber 26 formed therein and defined by one or more outer walls 27, with a water inlet 28 and an outlet 30 in communication with the chamber 26. The chamber 26 in FIGS. 2-4 has a cylindrical outer wall 27 defining the chamber as a circular or cylindrical chamber 26. The water inlet 28 is connected to the water inlet conduit 18, and the outlet 30 is connected to the inlet 12 of the tank 11 for discharging water and air into the tank 11. The water inlet 28 is oriented transversely to the direction of the chamber 26 and the outlet 30, and the water inlet 28 is in fluid communication with the chamber 26 via an opening 22 in the wall(s) 27 of the chamber 26. The water inlet 28 may include ribbing and/or other structures for engagement with the water inlet conduit 18. The outlet 30 is internally threaded for connection to the inlet 12 of the tank 11. The assembly 19 also has a vacuum breaker valve 25 that will open to relieve any vacuum in the tank. The air inducer 20 in FIGS. 2-4 is formed of a single molded piece.
The air inducer 20 in FIGS. 2-4 also has an air inlet 32 in fluid communication with a passage 34 that extends into the chamber 26. A tube 36 extends downward into the chamber 26 from the top wall 38 of the chamber 26 and terminates within the chamber 26, and the passage 34 extends through the tube 36. In other configurations, the tube 36 may extend through the chamber 26 and terminate within the outlet 30. The tube 36 extending into and through the chamber 26 creates an annular shape for at least a portion of the chamber 26. The chamber 26 may have a fully cylindrical portion located below the tip of the tube 36 and the outlet of the passage 34 into the chamber 26. The chamber 26 also includes a recess 37 with a larger diameter than the remainder of the chamber 26 and the outlet 30, for holding an O-ring, gasket, or other sealing member. A fitting 40 is connected to the air inlet 32 by threaded engagement with the housing 24, and the fitting 40 has an opening 42 in communication with the passage 34. A check valve 44 is connected to the housing 24 at the air inlet 32 by engagement between the fitting 40 and the housing 24, and the check valve 44 is at least partially received within the air inlet 32 in FIGS. 2-4. The check valve 44 in FIGS. 2-4 is in the form of a duckbill valve, formed of a flexible elastomeric or rubberlike material, which permits air flow into the passage 34 and resists air flow out of the passage 34 through the opening 42. The air inlet 32 is a cylindrical chamber in the configuration of FIGS. 2-4.
In the air inducer assembly 19 illustrated in FIGS. 2-4, the flow of water from the water inlet 28, through the opening 22 and into and through the chamber 26 and toward the outlet 30 will create a Venturi effect relative to the end of the tube 36 and the passage 34. In other words, the area directly adjacent the end of the tube 36 and the passage 34 will be at a pressure less than atmospheric, whereas, the air outside of the tank 11 and at the air inlet 32 is at atmospheric pressure. This positive pressure differential will cause air to flow through the opening 42 and the check valve 44, through the passage 34 and into the chamber 26 and/or the outlet 30. Thus, the air drawn into the chamber 26 via this Venturi effect is entrained in the water flowing out of outlet 30.
FIG. 5 illustrates one embodiment of a pressure assist toilet flush system 110 that includes certain features that have been added or modified relative to the system 10 in FIG. 1. The system 110 includes a tank 111 defining an internal cavity, with an inlet 112 and an outlet 113 for intake and discharge of water, and a flush actuator 114 configured for selectively opening and closing a valve leading to outlet 113 to control discharge of water. The flush actuator 114 in this embodiment may be in the form of a replaceable flush cartridge mounted within a receiver 115 in the tank 111, such that a portion of the flush cartridge is accessible outside the tank 111 and the actuator 114 is positioned within the cavity to interact with an internal seal surface around the outlet 113. FIGS. 14-17 illustrate additional features of the system 110 and the tank 111, and FIGS. 21-26B illustrate another embodiment of a system 110 including many features in common with the system 110 and the tank 111 of FIGS. 5 and 14-17. The flush actuator 114 of the system 110 of FIG. 5 is shown in greater detail in FIGS. 14-15 and 18-19, and it is understood that other flush actuators may be used in connection with the system 110 of FIG. 5, including the flush actuator 14 of FIG. 1. The tank 111 may be constructed of a lower housing or base 116 forming a bottom portion of the tank 111, and an upper housing or cover 117 forming a top portion of the tank 111, such that the base 116 and the cover 117 combine to define the internal cavity. The base 116 and the cover 117 may be made from plastic (including, e.g., fiber-reinforced plastic). The outlet 113 is typically connected to a toilet bowl (not shown), such that water discharged from the outlet 113 accomplishes flushing of the bowl. In one embodiment, the tank 111 may be configured as shown and described in U.S. Patent Application Publication No. 2022/0372742 A1, published May 20, 2022, the entire disclosure of which is incorporated by reference herein.
The base 116 of the tank 111 has sidewalls defining a peripheral shape that is generally the same peripheral shape as the tank 111 and the cover 117, including two first or longer sidewalls 101 and two second or shorter sidewalls 102 extending between the first sidewalls 101. The tank 111, the cover 117 and the base 116 may have generally trapezoidal shapes (with the second sidewalls 102 being obliquely angled to each other) or a generally rectangular shape (with the second sidewalls 102 being generally parallel to each other). The corners where the sidewalls 101, 102 meet are rounded. It is understood that the tank 111, the cover 117, and the base 116 may have different peripheral shapes in other embodiments, such as an elliptical or obround shape or other shape.
The base 116 of the tank 111 includes multiple reinforcing members to provide strength and rigidity to the base 116. Examples of such reinforcing members include a plurality of ribs, including sidewall ribs 150 extending along the inner surfaces of the sidewalls 101, 102 and cross ribs 151 extending between the sidewalls. In the embodiment of FIGS. 5 and 14-17, the sidewall ribs 150 extend vertically along the inner surfaces of the first sidewalls 101 and are spaced along the lengths of the first sidewalls 101. As seen in FIGS. 14-17, the sidewall ribs 150 in this embodiment are arranged as opposed pairs extending outward (or inward with respect to the base 116) toward each other from the opposed first sidewalls 101. Each of the opposed pairs of sidewall ribs 150 may be arranged to extend outward from the first sidewalls 101 in generally the same plane transverse to the first sidewalls 101. The sidewall ribs 150 in FIGS. 5 and 14-17 extend to the top ends of the first sidewalls 101, and each sidewall rib 150 further has a transverse portion 152 that extends along the bottom 153 of the base 116. The sidewall ribs 150 aligned with the outlet 113 have the transverse portions 152 extending along only a short distance along the bottom 153, while the remaining sidewall ribs 150 have the transverse portion 152 extending upward from the inner surface of the bottom 153, having a curved fillet configuration. The sidewall ribs 150 provide additional rigidity to the first sidewalls 101, which undergo the greatest amount of localized stress and strain during pressurizing and depressurizing of the tank 111 due to their longer lengths. In other embodiments, the sidewall ribs 150 may be differently configured and/or distributed.
The base 116 in FIGS. 5 and 14-17 has a plurality of cross ribs 151 connected to the first sidewalls 101 and extending between the first sidewalls 101 in a direction transverse to the first sidewalls 101. In the embodiment of FIGS. 5 and 14-17, two cross ribs 151 are located on opposite sides of the outlet 113 for the flush actuator 114, and spaced equal distances on either side of the outlet 113. Each cross rib 151 in this embodiment has two sidewall portions 154 that each extends vertically along one of the first sidewalls 101 and extends inwardly from the respective sidewall 101, and a bridge portion 155 that extends transversely between the two sidewall portions 154. The sidewall portions 154 in FIGS. 5 and 14-17 each have a curved fillet configuration at the bottom 153, similar to the sidewall ribs 150. The bridge portion 155 of each cross rib 151 has defines an opening 156 between the bottom 153 and the bottom edge of the bridge portion 155. These openings 156 improve fluid flow and do not obstruct fluid flow into the outlet 113.
In one embodiment, the plurality of ribs (e.g., sidewall ribs 150 and cross ribs 151) are substantially evenly spaced along the first sidewalls 101, i.e., the distances between adjacent ribs vary by no more than 10%. This substantially even spacing distributes stress evenly around the periphery of the base 116 and avoids areas of high stress concentration that may shorten fatigue life.
The tank 111 includes seating and sealing components for the flush actuator 114 that are configured to hold the flush actuator 114 in place and ensure reliable operation of the flushing action. The cover 117 has a threaded opening 186 configured to be threadably engaged by the flush actuator 114 to mount the flush actuator 114 in place within the tank 111. The base 116 includes one or more seating members 158 around the outlet 113 that form a seat for a portion of the flush actuator 114, to stabilize the lower end of the flush actuator 114 within the tank 111. The tank 111 in FIGS. 14-15 includes four seating members 158 in the form of ribs extending upward from the bottom 153 of the base 116 around the outlet 113, that engage the flush actuator 114 both vertically and horizontally. The base 116 in FIGS. 14-15 has four seating members 158 distributed at approximately 90° intervals around the outlet 113. The base 116 also has a valve seat 159 extending radially inward around the outlet 113 for sealing with the flush actuator 114. The valve seat 159 is angled for improved sealing with the flush actuator 114. The base 116 is configured to retain a maximum pressure of 20 psi or less in one embodiment, in order to reduce flush volume at higher pressures.
The system 110 also includes an air inducer assembly 119 connected to the inlet 112 and to a water inlet conduit 18, the assembly 119 configured to introduce liquid (e.g., water) and gas (e.g., air) into the tank 111. Air is drawn into and through the assembly 119 as the water passes through the assembly 119 from the water inlet conduit 118, e.g., by the Venturi effect, such that water and air pass through the inlet 112 into the tank 111. This pressurizes the tank 111, such that water can be forced into the toilet for improved flushing. The tank 111 therefore includes a mixture of air and water within the internal cavity. It is understood that the comparative proportions of air and water within the tank 111 can affect flush volume. More specifically, proportionally greater amounts of air and smaller amounts of water can decrease flush volume, and proportionally smaller amounts of air and greater amounts of water can increase flush volume.
FIGS. 6-13 illustrate embodiments of air inducers 120, 220, 320, 420, 520, 620 that are usable as part of an air inducer assembly 119 in connection with the system 110 and the tank 111 of FIG. 5 according to aspects of the present disclosure, all of which have one or more features different from the air inducer 20 in FIGS. 2-4. Each of these embodiments in FIGS. 6-13 includes some components that are structurally and/or functionally similar or identical to components described herein with respect to the air inducer assembly 19 and the air inducer 20 in FIGS. 2-4, and such similar or identical components may not be described again in detail with respect to the embodiments of FIGS. 6-13 and may not be identified by reference numbers in FIGS. 6-13. FIGS. 6 and 8 illustrate examples of the external appearance of an air inducer 120, 220 that may be used for any of the embodiments of FIGS. 6-13, illustrating the air inlet 132, 232, the water inlet 128, 228, the outlet 130, 230, and a connection 139, 239 for the vacuum breaker valve 125, 225. The positions of various components of the air inducer assemblies and other structures are indicated with relevant reference numbers in these figures. Like the air inducer 20 in FIGS. 2-4, the air inducers 120, 220, 320, 420, 520, 620 in FIGS. 6-13 are each formed of a single molded piece, but it is understood that multiple pieces could be used in another embodiment.
The embodiments of FIGS. 6-13 differ from the air inducer 20 of FIGS. 2-4 in that the orientations and positions of the water inlet 28 and the air inlet 32 are reversed in the embodiments of FIGS. 6-13 relative to the air inducer 20 of FIGS. 2-4. Some of the embodiments of FIGS. 8-13 may differ from the air inducer 120 of FIGS. 6-7 and/or from each other in the length L of the tube 136 (measured from the top wall 138 of the chamber 126), the outer diameter DT of the tube 136, and/or the inner diameter DO of the opening 122 between the air inlet 132 and the chamber 126. In the embodiment of FIGS. 6-7, the length L of the tube 136 is 0.380 inch, the diameter DT of the tube 136 is 0.160 inch, and the diameter DO of the opening 122 is 0.125 inch. These parameters L, DT, and DO are labeled for reference in FIG. 7, and it is understood that these parameters L, DT, and DO are defined in the same manner for the embodiments of FIGS. 6-13. It is also understood that if differences in these parameters are not disclosed herein with respect to any of FIGS. 6-13, it can be presumed that the parameters are the same as disclosed herein with respect to FIGS. 6-7.
The performance of the air inducers 120, 220, 320, 420, 520, 620 described herein can be measured by calculation of the mass flow balance comparing the mass flow of air through the air inlet 132 to the total mass flow out through the outlet 130. For example, the following formula may be used to calculate the percentage of air passing into the tank 111, with reference to the air inducer inlet mass flow, the water inlet mass flow, and the vessel inlet mass flow, as illustrated in FIG. 4:
Air Inducer Inlet Mass Flow Vessel Inlet Mass Flow The air percentage value calculated using this equation is evaluated such that a higher positive value is desirable. In one embodiment, the air inducer assembly may produce a value of at least +35% or at least +40%.
FIGS. 6-7 illustrate one embodiment of an air inducer assembly 119, which includes an air inducer 120 having a housing 124 with a chamber 126 formed therein and defined by one or more outer walls 127, with a water inlet 128, an air inlet 132, and an outlet 130 in communication with the chamber 126. The chamber 126 in FIGS. 6-7 has a cylindrical outer wall 127 defining the chamber as a circular or cylindrical chamber 126. The water inlet 128 is connected to the water inlet conduit 118, and the outlet 130 is connected to the inlet 112 of the tank 111 for discharging water and air into the tank 111. The water inlet 128 is oriented transversely to the direction of the chamber 126 and the outlet 130, and is positioned at the top of the air inducer 120 and above the top wall 138 of the chamber 126. The water inlet 128 is in fluid communication with the chamber 126 via a passage 134 that extends into the chamber 126. The water inlet 28 may include ribbing and/or other structures for engagement with the water inlet conduit 18. A tube 136 extends downward into the chamber 126 from the top wall 138 of the chamber 126 and terminates within the chamber 126, and the passage 134 extends through the tube 136. In other embodiments, the tube 136 may extend through the chamber 126 and terminate within the outlet 130. The tube 136 extending into and through the chamber 126 creates an annular shape for at least a portion of the chamber 126. The tube 136 in the embodiment of FIGS. 6-7 terminates within the chamber 126 and above the outlet 130. The chamber 126 may have a fully cylindrical portion located below the tip of the tube 136 and the outlet of the passage 134 into the chamber 126, in this embodiment. The passage 134 has a diameter that is smaller than the diameter of the chamber 126, e.g., less than half of the diameter of the chamber 126.
The air inducer 120 in FIGS. 6-7 also has an air inlet 132 in fluid communication with an opening 122 in the wall(s) 127 of the chamber 126. The air inlet 132 in the embodiment of FIGS. 6-7 is located along the side of the chamber 126 and is oriented transversely to the direction of the chamber 126 and the outlet 130. A fitting 140 is connected to the air inlet 132 by threaded engagement with the housing 124, and the fitting 140 has an opening 142 in communication with the air inlet 132. The opening 142 may have a smaller diameter than the air inlet 132. A check valve 144 is connected to the housing 124 at the air inlet 132 by engagement between the fitting 140 and the housing 124, and the check valve 144 is at least partially received within the air inlet 132 in the embodiment of FIGS. 6-7. The check valve 144 in FIGS. 6-7 is in the form of a duckbill valve, formed of a flexible elastomeric or rubberlike material, which permits air flow into the air inlet 132 and resists air flow out of the air inlet 132 through the opening 142. The air inlet 132 is a cylindrical chamber in the embodiment of FIGS. 6-7, and the opening 122 has a diameter that is smaller than the diameter of the air inlet 132, e.g., less than half of the diameter of the air inlet 132.
The outlet 130 is internally threaded for connection to the inlet 112 of the tank 111. The chamber 126 also includes a recess 137 with a larger diameter than the remainder of the chamber 126 and the outlet 130, for holding an O-ring, gasket, or other sealing member 131. Additionally, the air inducer assembly 119 has a vacuum breaker valve 125 that will open to relieve any vacuum in the tank.
In the configuration illustrated in FIGS. 6-7, the flow of water from the water inlet 128, through the tube 136 and into and through the chamber 126 and toward the outlet 130 will create a Venturi effect between the end of the tube 36 and the opening 122. In other words, the area directly adjacent the opening 122 will be at a pressure less than atmospheric, whereas, the air outside of the tank 111 and at the air inlet 132 is at atmospheric pressure. This positive pressure differential will cause air to flow through the opening 142 and the check valve 144, through the air inlet 132 and the opening 122 and into and through the chamber 126 to the outlet 130. Thus, the air drawn into the chamber 126 via this Venturi effect is entrained in the water flowing out of outlet 130. The air inducer 120 in FIGS. 6-7 exhibited the best mass flow balance of the embodiments tested, and superior mass flow balance to the air inducer 20 of FIGS. 2-4. For example, the air inducer 120 of FIGS. 6-7 may produce improved air draw, improved air/water draw ratios, and/or increased cycle times relative to the air inducer 20 of FIGS. 2-4, at various different inlet pressures such as 25 psi, 50 psi, and 80 psi. Such improvements may be vast (e.g., over 80% increase in air draw and air/water ratio) at lower inlet pressures such as 25 psi.
FIGS. 8-9 illustrate an embodiment of an air inducer 220 configured similarly to the air inducer 120 of FIGS. 6-7, in which the length L of the tube 236 is longer than in the air inducer of FIGS. 6-7, and the diameters DT, DO of the tube 236 and the opening 222 are the same as the air inducer 120 of FIGS. 6-7. In the embodiment of FIGS. 8-9, the length L of the tube 236 is 0.630 inch, the diameter DO of the opening 222 is 0.125 inch, and the diameter DT of the tube 236 is 0.120 inch. The tube 236 in this embodiment terminates approximately at the lower end of the chamber 226, and the end portion of the tube 236 may extend beyond the chamber 226 and into the outlet 230. This embodiment exhibited superior mass flow balance performance relative to the air inducer 20 of FIGS. 2-4.
FIG. 10 illustrates an embodiment of an air inducer 320 configured similarly to the air inducer 120 of FIGS. 6-7, in which the length L of the tube 336 is longer than in the air inducer of FIGS. 6-7, and the diameters DT, DO of the tube 336 and the opening 322 are greater than those of the air inducer 120 of FIGS. 6-7. Additionally, the width of the tube 336 is slightly tapered to be wider at the water inlet 328 and slightly narrower at the distal end of the tube 336. In the embodiment of FIG. 10, the length L of the tube 336 is 0.629 inch, the diameter DO of the opening 322 is 0.200 inch, and the diameter DT of the tube 336 (measured at the top end) is 0.228 inch. The tube 336 in this embodiment terminates approximately at the lower end of the chamber 326, and the end portion of the tube 336 may extend beyond the chamber 326 and into the outlet 330. This embodiment exhibited superior mass flow balance performance relative to the air inducer 20 of FIGS. 2-4.
FIG. 11 illustrates an embodiment of an air inducer 420 configured similarly to the air inducer 120 of FIGS. 6-7, in which the length L of the tube 436 is longer than in the air inducer of FIGS. 6-7, the diameter DT of the tube 436 is the same as that of the air inducer 120 in FIGS. 6-7, and the diameter DO of the opening 422 is greater than that of the air inducer 120 of FIGS. 6-7. Additionally, the width of the tube 436 is slightly tapered to be wider at the water inlet 428 and slightly narrower at the distal end of the tube 436. In the embodiment of FIG. 11, the length L of the tube 436 is 0.629 inch, the diameter DO of the opening 422 is 0.200 inch, and the diameter DT of the tube 436 (measured at the top end) is 0.108 inch. The tube 436 in this embodiment terminates approximately at the lower end of the chamber 426, and the end portion of the tube 436 may extend beyond the chamber 426 and into the outlet 430. This embodiment exhibited superior mass flow balance performance relative to the air inducer 20 of FIGS. 2-4.
FIG. 12 illustrates an embodiment of an air inducer 520 configured similarly to the air inducer 120 of FIGS. 6-7, in which the length L of the tube 536 is longer than in the air inducer of FIGS. 6-7, the diameter DT of the tube 536 is larger than that of the air inducer 120 in FIGS. 6-7, and the diameter DO of the opening 522 is the same as that of the air inducer 120 of FIGS. 6-7. Additionally, the width of the tube 536 is slightly tapered to be wider at the water inlet 528 and slightly narrower at the distal end of the tube 536. In the embodiment of FIG. 12, the length L of the tube 536 is 0.629 inch, the diameter DO of the opening 522 is 0.125 inch, and the diameter DT of the tube 536 (measured at the top end) is 0.228 inch. The tube 536 in this embodiment terminates approximately at the lower end of the chamber 526, and the end portion of the tube 536 may extend beyond the chamber 526 and into the outlet 530. This embodiment exhibited superior mass flow balance performance relative to the air inducer 20 of FIGS. 2-4.
FIG. 13 illustrates an embodiment of an air inducer 620 configured similarly to the air inducer 120 of FIGS. 6-7, in which the length L of the tube 636 is longer than in the air inducer of FIGS. 6-7, and the diameter DT of the tube 636 and the diameter DO of the opening 622 are the same as those of the air inducer 120 of FIGS. 6-7. Additionally, the width of the tube 636 is slightly tapered to be wider at the water inlet 628 and slightly narrower at the distal end of the tube 636. In the embodiment of FIG. 12, the length L of the tube 636 is 0.629 inch, the diameter DO of the opening 622 is 0.125 inch, and the diameter DT of the tube 636 (measured at the top end) is 0.148 inch. The tube 636 in this embodiment terminates approximately at the lower end of the chamber 626, and the end portion of the tube 636 may extend beyond the chamber 626 and into the outlet 630. This embodiment exhibited superior mass flow balance performance relative to the air inducer 20 of FIGS. 2-4.
In various embodiments, the tank 111 includes features to achieve decreased flush volume, which may include a volume reduction means or mechanism 160 positioned at least partially around the outlet 113 and the receiver 115 for the flush actuator 114. The volume reduction mechanism 160 is configured for permitting fluid flow to the outlet 113 while restricting the rate and/or volume of fluid flow through at least a portion of the flush cycle, thereby decreasing flush volume.
The tank 111 of FIG. 5 is shown in more detail in FIGS. 14-17, and in this embodiment, the volume reduction mechanism 160 includes a wall 161 at least partially surrounding the outlet 113 having one or more passages 162 therethrough. The wall 161 in this embodiment is a vertical, cylindrical wall that extends upward from the bottom all 153 of the base 116 and has two passages 162 in the form of apertures defined through the wall 161 at or near the juncture between the wall 161 and the bottom 153 of the base 116. The passages 162 are located on opposite lateral sides of the outlet 113. The wall 161 completely surrounds the outlet 113, such that any liquid flow from the tank 111 through the outlet 113 must travel over the top end 163 of the wall 161 or through the passages 162. The height of the wall 161 may be configured to be higher than the liquid level in the tank 111, such that all liquid to the outlet 113 must flow through the passages 162, or may alternately be configured to be lower than the liquid level in the tank 111 such that some initial liquid flow to the outlet 113 passes over the top end 163 of the wall 161 and the remaining liquid flow passes through the passages 162. In one embodiment, the height of the wall 161 is at least as great or greater than the height of the bottom edge of the bridge portion 155 of the adjacent cross rib 151 or the top of the opening 156 through the cross rib 151. The passages 162 are sized and distributed to restrict the rate of liquid flow through the outlet 113 as desired. In other embodiments, the passage(s) 162 may be configured differently. For example, the wall 161 may have a different number, size, or distribution of one or more passages 162. It is understood that the passage(s) 162 may not be a fully defined aperture in some embodiments, and may instead be a slot that is open on one or more sides.
In another embodiment, shown in FIGS. 21-26B, the tank 111 has features to achieve decreased flush volume that include one or more retention trays 170, 171 mounted within the tank 111. The tank 111 of FIGS. 21-26B has two retention trays 170, 171 mounted to the base 116 on opposite sides of the outlet 113 within the tank 111. Each retention tray 170, 171 has a bottom wall (also referred to as a bottom tray wall) 172 with a plurality of side walls 173 extending upward to define a tray cavity with an open top 174. As illustrated in FIGS. 22-23, the side wall 173 closest to the outlet 113 in both trays 170, 171 is angled outward at the top 174, and the other side walls 173 are generally vertical. Both retention trays 170, 171 are generally trapezoidal and cover most of the bottom 153 of the base 116, and one of the trays 171 is cut out at one corner to accommodate the components of the inlet 112. In one embodiment, the trays 170, 171 have holes 175 that are sized to permit controlled discharge of liquid from the tray 170, 171. The trays 170, 171 in the embodiment of FIGS. 21-26B have drain holes 175 in the bottom wall 172, and it is understood that the trays 170, 171 may have a different number and size of holes 175 and/or holes in other locations (e.g., the side walls 173) in other embodiments. The heights of the side walls 173 and the number and sizes of the holes 175 function to limit and control the amount of liquid available for flow through the outlet 113, thereby limiting flush volume. If the heights of the side walls 173 are greater than the liquid level of the tank 111, then flow of liquid through the outlet 113 will consist only of liquid located below the trays 170, 171 and potentially liquid released through the holes 175 during the flush cycle. If the heights of the side walls 173 are lower than the liquid level of the tank 111, then the flush cycle may include a larger initial flow through the outlet 113 until the liquid level drops below the tops 174 of the trays 170, 171, at which point only liquid passing through the holes 175 may flow through the outlet 113. The trays 170, 171 in FIGS. 21-26B collectively have a volume of 0.250 gallons, which permits achieving reduced flush volumes of 0.8 GPF (or potentially 0.7 GPF or 0.66 GPF or lower), particularly when used with the air inducer assembly 119 of FIGS. 6-7. It is understood that the trays 170, 171 can produce decreased flush volumes when used with other air inducer assemblies and tanks 111 having different features, and that the volume and existence or configuration of the holes 175 may be modified for a particular application.
The trays 170, 171 in FIGS. 21-26B are mounted in the tank 111 by pegs 176 that extend upward from the bottom 153 of the base 116 and are engaged with the bottom wall 172 of the respective tray 170, 171. In one embodiment, the pegs 176 may be fixedly and/or integrally connected to the trays 170, 171 using a heat staking process. FIGS. 25A-26B illustrate an embodiment of a heat staking process used with the trays 170, 171 in FIGS. 21-26B. Each of the trays 170, 171 has two openings 177 in the bottom wall 172 that receive two pegs 176, which are integrally molded with or otherwise fixed to the bottom 153 of the base 116, as shown in FIGS. 25A-B. The end of each peg 176 is then heated to achieve at least partial local melting of the peg 176 and thereby form a retaining button 178 that retains the tray 170, 171 in place, as shown in FIGS. 26A-B. The retaining button 178 deforms during melting to be wider than the opening 177 and resist pulling the peg 176 back through the opening 177. Each peg 176 in this embodiment has a shoulder 179 that is also wider than the opening 177, such that the bottom wall 172 of the tray 170, 171 rests on the shoulder 179 and is sandwiched between the shoulder 179 and the retaining button 178 to securely hold the tray 170, 171 in place. The trays 170, 171 do not contact the sidewall ribs 150 in this embodiment, but the sidewall ribs 150 may be directly or indirectly engaged by the trays 170, 171 in another configuration. In other embodiments, the trays 170, 171 may be mounted and/or configured differently.
FIGS. 27-45 illustrate additional embodiments of trays 270, 370, 470, 570, 571, 670, 671, 770, 771, 870, 871 that are usable in connection with a tank 111 as described herein. The trays 270, 370, 470, 570, 571, 670, 671, 770, 771, 870, 871 in FIGS. 27-45 contain many features in common with the trays 170, 171 in FIGS. 21-26B, and the such common features may not be fully disclosed herein again for the sake of brevity. As such, the trays 270, 370, 470, 570, 571, 670, 671, 770, 771, 870, 871 in FIGS. 27-45 may be disclosed primarily with respect to their differences from the trays 170, 171 of FIGS. 21-26B. The trays 270, 370, 470, 570, 571, 670, 671, 770, 771, 870, 871 in FIGS. 27-45 include shapes and/or mounting features that are different from the trays 170, 171 in FIGS. 21-26B. Nevertheless, it is understood that the structures and/or the mounting features of the trays 170, 171 in FIGS. 21-26B may be used in connection with these additional embodiments. The trays 270, 370, 470, 570, 571, 670, 671, 770, 771, 870, 871 in FIGS. 27-45 can each be designed to collectively have a volume and configuration that permits achieving reduced flush volumes of 0.8 GPF (or potentially 0.7 GPF or 0.66 GPF or lower) as described above with respect to the trays 170, 171 of FIGS. 21-26B, e.g., 0.250 gallons. As also described above, it is understood that the trays 270, 370, 470, 570, 571, 670, 671, 770, 771, 870, 871 can produce decreased flush volumes when used with other air inducer assemblies and tanks 111 having different features, and that the volume and existence or configuration of the holes 175 may be modified for a particular application.
FIGS. 27-28 illustrate another embodiment of a tray 270 in which all side walls 273 of the tray 270 are generally vertical, rather than angled outward at the top 274. Additionally, the tray 270 is mounted on the base 116 by the use of feet 264 extending downward from the bottom wall 272 of the tray 270 to rest on the bottom 153 of the base 116, as well as rib-engaging members 267 on the side walls 273 to engage the sidewall ribs 150 of the base 116. The engagement of feet 264 on the base 116 and the engagement of the rib-engaging members 267 with the sidewall ribs 150 may be similar to the engagements shown in FIGS. 37 and 38. The feet 264 are molded with the tray 270 or otherwise integrally connected to the tray 270 and rest freely on the base 116. The rib-engaging members 267 in this embodiment are pairs of ribs 268 defining a slot 269 between them, and the slot 269 receives one of the sidewall ribs 150 of the base 116. The combination of the feet 264 and the rib-engaging members 267 in this embodiment are sufficient to hold the tray 270 in place within the base 116. Additionally, the tray 270 is depicted in FIG. 28 with no drain holes in the bottom wall 272; however, one or more holes may be used if desired, such as the holes 175 in the trays 170, 171 of FIGS. 21-26B. Furthermore, while only a single tray 270 is depicted in FIGS. 27-28, it is understood that a second tray may be created with similar mounting and drain holes (if any) for placement on the other side of the tank 111. Such a second tray may be configured similarly to the tray 171 of FIGS. 21-26B, including having a similar peripheral shape with a cut out.
FIGS. 29-30 illustrate another embodiment of a tray 370 in which the side wall 373 closest to the outlet 113 is angled outward at the top 374, and all other side walls 373 are generally vertical. Additionally, the tray 370 is mounted on the base 116 similarly to the tray 270 of FIGS. 27-28, by the use of feet 364 extending downward from the bottom wall 372 of the tray 370 and rib-engaging members 367 on the side walls 373 to engage the sidewall ribs 150 of the base 116. The rib-engaging members 367 in this embodiment are pairs of ribs 368 defining a slot 369 between them. The tray 370 is depicted in FIG. 30 with no drain holes in the bottom wall 372; however, one or more holes may be used if desired, such as the holes 175 in the trays 170, 171 of FIGS. 21-26B. Furthermore, while only a single tray 370 is depicted in FIGS. 29-30, it is understood that a second tray may be created with similar mounting and drain holes (if any) for placement on the other side of the tank 111. Such a second tray may be configured similarly to the tray 171 of FIGS. 21-26B, including having a similar peripheral shape with a cut out.
FIGS. 31-32 illustrate another embodiment of a tray 470 in which the side wall 473 closest to the outlet 113 is angled outward at the top 474, and all other side walls 473 are generally vertical. Additionally, the tray 470 is mounted on the base 116 similarly to the tray 270 of FIGS. 27-28, by the use of feet 464 extending downward from the bottom wall 472 of the tray 470 and rib-engaging members 467 on the side walls 473 to engage the sidewall ribs 150 of the base 116. The rib-engaging members 467 in this embodiment are pairs of ribs 468 defining a slot 469 between them. In the embodiment of FIGS. 31-32, the tray 470 has a channel 487 on the bottom wall 472 extending in a straight line toward the center of the tank 111 and toward the outlet 113. The bottom wall 472 of the tray 470 in this configuration has two bulbous or rounded portions 484 with the channel 487 running between them. The channel 487 may assist in casing flow of liquid beneath the tray 470 to the outlet 113. This configuration creates two internal troughs 485 within the tray 470 with a ridge 486 between them. The tray 470 is depicted in FIG. 32 with no drain holes in the bottom wall 472; however, one or more holes may be used if desired, such as the holes 175 in the trays 170, 171 of FIGS. 21-26B. Furthermore, while only a single tray 470 is depicted in FIGS. 29-30, it is understood that a second tray may be created with similar mounting and drain holes (if any) for placement on the other side of the tank 111. Such a second tray may be configured similarly to the tray 171 of FIGS. 21-26B, including having a similar peripheral shape with a cut out.
FIGS. 33-34 illustrate another embodiment of trays 570, 571 where all side walls 573 are generally vertical. The trays 570, 571 are configured for use together, similarly to the trays 170, 171 in FIGS. 5 and 14-17, and have similar peripheral shapes to the trays 170, 171, including the second tray 171 having a cut out. Each of the trays 570, 571 in this embodiment has an internal partition 589 dividing each tray 570, 571 into two separate chambers 588. The trays 570, 571 in FIGS. 33-34 are mounted on the base 116 similarly to the tray 270 of FIGS. 27-28, by the use of feet 564 extending downward from the bottom wall 572 of each tray 570, 571 and rib-engaging members 567 on the side walls 573 to engage the sidewall ribs 150 of the base 116. The rib-engaging members 567 in this embodiment are pairs of ribs 568 defining a slot 569 between them. In the embodiment of FIGS. 33-34, the tray 570 has a channel 587 and rounded portions 584 externally, with a corresponding internal ridge (not shown) and troughs (not shown) internally, on the bottom wall 572 as similarly described herein with respect to FIGS. 31-32. These structures extend transversely to the partition 589 and across both of the chambers 588 in this embodiment. Drain holes are not visible in the trays 570, 571 of this embodiment; however, one or more holes may be used if desired, such as the holes 175 in the trays 170, 171 of FIGS. 21-26B. In one example, the chambers 588 may include different drain hole configurations, such as having different sizes and/or numbers of drain holes in each chamber 588, or only one of the chambers 588 of each tray 570, 571 having a drain hole.
FIGS. 35-38 illustrate another embodiment of trays 670, 671 in which the side wall 673 closest to the outlet 113 is angled outward at the top 674, and all other side walls 673 are generally vertical. The trays 670, 671 are configured for use together, similarly to the trays 170, 171 in FIGS. 5 and 14-17, and have similar peripheral shapes to the trays 170, 171, including the second tray 171 having a cut out. The trays 670, 671 in FIGS. 37-38 are mounted on the base 116 similarly to the tray 270 of FIGS. 27-28, by the use of feet 664 extending downward from the bottom wall 672 of each tray 670, 671 and rib-engaging members 667 on the side walls 673 to engage the sidewall ribs 150 of the base 116. In the embodiment of FIGS. 35-38, the rib-engaging members 667 are pairs of ribs 668 defining a slot 669 between them, with gripping members 690 extending inward from the ribs 668 to engage the sides of the sidewall ribs 150. As shown in FIG. 38, the gripping members 690 may be configured to engage runners 147 on the sidewall ribs 150 that have slightly larger widths than the sidewall ribs 150 themselves. The trays 670, 671 in this embodiment have drain holes 675 in the bottom wall 672, but other configurations are possible.
FIGS. 39-42 illustrate another embodiment of trays 770, 771 in which the side wall 773 closest to the outlet 113 is angled outward at the top 774, and all other side walls 773 are generally vertical. The trays 770, 771 are configured for use together, similarly to the trays 170, 171 in FIGS. 5 and 14-17, and have similar peripheral shapes to the trays 170, 171, including the second tray 771 having a cut out. The trays 770, 771 in FIGS. 39-41 are mounted on the base 116 similarly to the tray 270 of FIGS. 27-28, by the use of feet 764 extending downward from the bottom wall 772 of each tray 770, 771 and rib-engaging members 767 on the side walls 773 to engage the sidewall ribs 150 of the base 116. In the embodiment of FIGS. 39-42, the rib-engaging members 767 are pairs of ribs 768 defining a slot 769 between them, with gripping members 790 extending inward from the ribs 768 to engage the sides of the sidewall ribs 150. As shown in FIG. 41, the gripping members 790 may be configured to engage runners 147 on the sidewall ribs 150 that have slightly larger widths than the sidewall ribs 150 themselves. The trays 770, 771 in this embodiment are depicted with no drain holes in the bottom wall 772; however, one or more holes may be used if desired, such as the holes 175, 675 in the trays 170, 171 of FIGS. 21-26B and the trays 670, 671 of FIGS. 35-38.
The trays 770, 771 may also include features to assist in inserting the trays 770, 771 into the base 116 and to ensure proper positioning of the trays 770, 771 within the base 116. In the embodiment of FIGS. 39-42, the trays 770, 771 have guide ribs 745, 746 to aid insertion of the sidewall ribs 150 into the slots 769 between the ribs 768, and fitting projections 748 that are configured to engage the sidewalls 101, 102 and resist insertion of the trays 770, 771 in an improper position or orientation. The guide ribs in this embodiment include flared guide ribs 745 that extend outward and downward at the bottom end of each slot 769 and blocking guide ribs 746 that extend horizontally in the space between some of the slots 769. The flared guide ribs 745 are positioned at the bottom ends of the ribs 768 that define the sides of each slot 769, and the flared guide ribs 745 in the trays 770, 771 of FIGS. 39-42 are integral with the ribs 768. The flared guide ribs 745 are angled both horizontally and vertically with respect to the ribs 768 and the slots 769. In this configuration, the angled orientation of the flared guide ribs 745 causes a portion of the force from the sidewall ribs 150 engaging the flared guide ribs 745 during insertion of the trays 770, 771 to be exerted to move the tray 770, 771 and/or the base 116 laterally or rotationally to align the slots 769 with the sidewall ribs 150. As seen in FIGS. 39-42, one of the sidewalls 773 of each tray 770, 771 has one slot 769 (and one corresponding pair of flared guide ribs 745), and one of the sidewalls 773 of each tray 770, 771 has two parallel slots 769 (and two corresponding pairs of flared guide ribs 745). The sidewall 773 of each tray 770, 771 in this embodiment that has two slots 769 also has a blocking guide rib 746 that extends across at least a portion of the space between the slots 769. In the embodiment of FIGS. 39-42, each blocking guide rib 746 is integral with (or otherwise connected to) the distal ends of the adjacent flared guide ribs 745 from the two slots 769 and bridges the gap between the flared guide ribs 745. The blocking guide rib 746 helps to ensure that the sidewall ribs 150 are blocked from entering the space between the slots 769, thereby further decreasing the likelihood of improper insertion of the tray 770, 771.
While the entire configurations of the flared guide ribs 745 and the blocking guide ribs 746 are not shown in FIGS. 39-40, it is understood that the structures of the two flared guide ribs 745 and the blocking guide rib 746 on the rear facing side of the tray 770 in FIG. 39 are similar or identical to the structures of the two flared guide ribs 745 and the blocking guide rib 746 on the forward facing side of the tray 771 in FIG. 40. It is likewise understood that the structure of the flared guide rib 745 on the rear side of the tray 771 in FIG. 40 is similar or identical to the structure of the flared guide rib 745 on the rear side of the tray 770 in FIG. 39.
In one embodiment, each tray 770, 771 also includes a fitting projection 748 that projects from one or more sidewalls 773 of the tray 770, 771. The trays 770, 771 in FIGS. 39-42 each have a fitting projection 748 in the form of a finger that extends at an angle from the corner of the tray 770, 771 most distal from the outlet 113. The fitting projections 748 are integrally formed (e.g., by molding) with the respective tray 770, 771 in this embodiment. When the tray 770, 771 is properly inserted within the base 116, as shown in FIG. 41, the fitting projections 748 fit within the space between the tray 770, 771 and the walls 101, 102 of the base 116. However, when a user attempts to improperly install one of the trays 770, 771 by transposing the two trays 770, 771 between their designed positions, the fitting projections 748 will engage the sidewalls 101, 102 of the base 116 and prevent insertion of the tray 770, 771. The engagement of the sidewall 101, 102 by the fitting projections 748 is illustrated in FIG. 42, although it is understood that this depiction is schematic in nature, and the trays 770, 771 could not be fully inserted as shown in FIGS. 21-42, due to the obstruction from the fitting projections 748. In other embodiments, the trays 770, 771 may include a different configuration and/or a different number of fitting projections 748.
FIGS. 43-45 illustrate another embodiment of trays 870, 871, in which the trays 870, 871 are designed to occupy a proportion of the liquid volume in the tank 11, rather than to hold liquid as in the retention trays 170, 171, 270, 370, 470, 570, 571, 670, 671, 770, 771 in FIGS. 21-42. The trays 870, 871 are configured for use together, similarly to the trays 170, 171 in FIGS. 5 and 14-17 and the trays 770, 771 of FIGS. 39-42, and have similar peripheral shapes to the trays 770, 771, including the second tray 871 having a cut out. However, the trays 870, 871 have no open top as do the trays 770, 771 of FIGS. 39-42. The trays 870, 871 have substantially the same mounting structure as the trays 770, 771 in FIGS. 39-41, including the rib-engaging members 867 in the form of pairs of ribs 868 defining a slot 869 between them, with gripping members 890 extending inward from the ribs 868 to engage the sides of the sidewall ribs 150. The trays 870, 871 also have substantially the same insertion assisting structures as the trays 770, 771 in FIGS. 39-41, including guide ribs 845, 846 to aid insertion of the sidewall ribs 150 into the slots 869 between the ribs 868, and fitting projections 848 to resist improper placement of the trays 870, 871. In this embodiment, the trays 870, 871 are depicted with no drain holes because liquid retention is not intended; however, one or more holes may be used if desired, such as holes allowing liquid to flow into and/or out of the enclosed interior of the tray 870, 871, or holes allowing liquid to flow through the body of the tray 870, 871. The trays 870, 871 occupy internal volume of the tank 11 and therefore permit decreased flush volumes to be achieved. However, this reduction in volume also reduces the total liquid volume stored in the tank 11, unlike the retention trays, which only marginally reduce the total liquid volume. This reduction in volume of the tank 11 may reduce the stored energy of compressed gas within the tank 11 and thereby achieve lower flushing power than the same configuration with an open retention tray.
FIGS. 18-19B illustrate one embodiment of a flush actuator 114 for use with a tank 111 as described herein, or with another tank, such as the tank 11 shown in FIG. 1. FIGS. 14-16 and 21-22 also illustrate this embodiment of the flush actuator 114. The flush actuator 114 generally includes a cap 180 having threading for threadably engaging the cover 117 to retain the flush actuator 114 within the receiver 115, a jacket 181 connected to the cap 180, a plunger 182 extending through the cap 180 and moveably mounted on the cap 180, a stem 183 connected to the end of the plunger 182, and a flush valve 184 moveably mounted within the jacket 181. The cap 180 has a threaded portion 185 for engaging a threaded opening 186 on the cover 117 such that the lower portions of the flush actuator 114 extend into the cavity of the tank 111, as well as a seal 187 in the form of a static O-ring for scaling against the cover 117. The plunger 182 extends through the cap 180 and has a head 188 configured for engagement by a mechanical flushing mechanism to initiate flushing by the flush actuator 114. The jacket 181 defines a relief chamber 189 located above the flush valve 184, in combination with the bottom of the cap 180. The flush valve 184 is moveable vertically within the jacket 181 and includes a disc 190 that engages the jacket 181 and borders the relief chamber 189 and an inner passage 193 having a narrowed neck 192. The stem 183 is fixedly connected to the lower end of the plunger 182 such that the plunger and the stem 183 move linearly together. The stem 183 is positioned within the inner passage 193 of the flush valve 184 and has a sealing portion 191 (which may include an O-ring or other seal 196) configured for engaging the inner surface of the neck 192 to seal the relief chamber 189. The sealing portion 191 may be enlarged radially with respect to the main portion of the stem 183, as shown in FIGS. 19A-B and 22.
In this configuration, downward movement of the plunger 182 actuates downward movement of the stem 183, separating the sealing portion 191 from the flush valve 184 and permitting liquid to flow from the relief chamber 189 through the inner passage 193 to the outlet 113 of the tank 111. This evacuates the relief chamber 189 and causes the flush valve 184 to move upward into the relief chamber 189. The flush valve 184 also includes a radial flange or wing 165 extending outward from the outer surface below the neck 192. A spring 199 engages the plunger 182 and the cap 180 to cause the plunger 182 and the stem 183 to return to the upward positions after force on the plunger 182 is released. The flush valve 184 has a scaling portion 194 that may have a dynamic O-ring 195 or other seal to engage the base 116 around the outlet 113 to resist liquid flow from the tank 111 through the outlet 113. The seating members 158 of the base 116 engage the wing 165 of the flush valve 184 both vertically and horizontally, to stabilize the flush valve 184. Additionally, the sealing portion of the flush valve 184 engages the valve seat 159 around the outlet 113 to improve sealing. When the flush valve 184 moves upward upon evacuation of the relief chamber 189, the sealing portion 194 disengages from the valve seat 159 and permits liquid flow outward from the tank 111 through the outlet 113.
Fluid gradually passes through the disc 190 to refill the relief chamber 189, such as by passing slowly around the disc 190 or through a valve (not shown) in the disc 190. The flush actuator 114 includes a spring 197 engaging the cap 180 and the flush valve 184 to force the flush valve 184 back downward to seal with the base 116 as the pressure in the relief chamber 189 equalizes with the tank 111. In one embodiment, this spring 197 has increased stiffness in order to shorten the flush cycle and reduce flush volume.
The stem 183 also includes a snubber portion 198 that is enlarged radially with respect to the main portion of the stem 183, as shown in FIGS. 19A-B and 22. The snubber portion 198 may also be enlarged with respect to the sealing portion 191. The snubber portion 198 constricts liquid flow through the inner passage 193 of the flush valve 184 to control the rate at which the relief chamber 189 is evacuated. In the embodiment of FIGS. 18-19B, the stem 183 has a shorter length relative to existing stems of pressure assisted flush actuator cartridges, e.g., a length of 4.172 inches in one embodiment. As shown in FIGS. 19A-B, the snubber portion 198 is immediately adjacent to the sealing portion 194 and is directly connected to the bottom of the sealing portion 194, such that the sealing portion 194 and the snubber portion 198 form a unitary section having a minimal diameter that is larger than the diameter of a majority of the length of the stem 183. Additionally, the snubber portion 198 forms the distal end of the stem 183. In this configuration, the shorter length of the stem 183 permits the distal end of the stem 183 to be moved completely out of the outlet 113 during flushing, such that the stem 183 does not obstruct the outlet 113 during flushing. The distance between the valve seat 159 and the flush valve 184 therefore controls the rate of flow through the outlet 113 in this embodiment.
FIG. 20 illustrates another embodiment of a flush valve 184 that is usable with the flush actuator 114 of FIGS. 18-19B, or another flush actuator, such as the flush actuator 14 of FIG. 1. In this embodiment, the flush valve 184 has a second radial flange or wing 166 extending outward from the outer surface below the neck 192. The second wing 166 is located above the first wing 165 that is present in the flush valve 184 in FIGS. 18-19B and is located between the first wing 165 and the neck 192 of the flush valve 184. In the embodiment of FIG. 20, the second wing 166 is located immediately at the lower end of the neck 192. The use of the combined first and second wings 165, 166 increases the lifting force on the flush valve 184 after the relief chamber 189 is evacuated. This increased lift, in turn, keeps the flush valve 184 suspended slightly longer and can improve air draw into the tank through the air inducer 120.
Various embodiments of pressure-assisted flushing systems, as well as components of such systems, such as air inducers, air inducer assemblies, tanks, and flush actuators, have been described herein, which include various components and features. In other embodiments, these pressure-assisted flushing systems and sub-components thereof may be provided with any combination of such components and features. It is also understood that in other embodiments, the various devices, components, and features of the devices and systems described herein may be constructed with similar structural and functional elements having different configurations, including different ornamental appearances.
Numerous benefits and advantages are achieved by the pressure-assisted flushing systems and components thereof described herein. For example, the increased air draw of the air inducer assemblies described herein permits lower liquid levels to exist in the tank, which results in decreased flush volume. As another example, the flow restriction to and through the outlet provided by the various volume reduction mechanisms described herein also decreases flush volume. As a further example, the improved functioning provided by the flush actuators described herein may also permit decreased flush volume and/or improved flushing to be achieved. The combination of the increased air draw, the flow restriction, and the improved flush performance provided by using all of these components together allows drastically decreased flush volumes to be achieved. In certain embodiments, flush volumes of 0.8 GPF or lower (including potentially 0.7 GPF or 0.66 GPF or lower) can be achieved. For example, in one embodiment, consistent flush volumes of below 0.85 GPF (e.g., 0.7 GPF to 0.85 GPF) can be achieved at various different water inlet pressures, including 25 psi, 50 psi, and 80 psi. These flush volumes may be achievable with an air inducer 20 of FIGS. 2-4 and/or the air inducers 120, 220, 320, 420, 520, 620 in FIGS. 6-13. As another example, in one embodiment, average flush volumes below 0.8 GPF (e.g., 0.70 to 0.80 GPF) or below 0.75 GPF (e.g., 0.70 GPF to 0.75 GPF) can be achieved at various different water inlet pressures, including 25 psi, 50 psi, and 80 psi, using the air inducer 120 of FIGS. 6-7. Still further benefits are readily recognizable to those skilled in the art.
Several alternative embodiments and examples have been described and illustrated herein. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. The terms “top,” “bottom,” “front,” “back,” “side,” “rear,” “proximal,” “distal,” and the like, as used herein, are intended for illustrative purposes only and do not limit the embodiments in any way. Nothing in this specification should be construed as requiring a specific three dimensional orientation of structures in order to fall within the scope of this invention, unless explicitly specified by the claims. When used in description of a method or process, the term “providing” (or variations thereof) as used herein means generally making an article available for further actions, and does not imply that the entity “providing” the article manufactured, assembled, or otherwise produced the article. The term “approximately” as used herein implies a variation of up to 10% of the nominal value modified by such term, or up to 10% of a midpoint value of a range modified by such term. Additionally, the term “plurality,” as used herein, indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying claims.
