US20180087676A1

US20180087676A1 - Low-Torque Valve and Assemblies Including Said Valve

Info

Publication number: US20180087676A1
Application number: US15/715,640
Authority: US
Inventors: Michael A. Funari; Marc G. Block
Original assignee: Zurn Industries LLC
Current assignee: Zurn Water LLC
Priority date: 2016-09-26
Filing date: 2017-09-26
Publication date: 2018-03-29
Also published as: US20180087252A1; CA2980708A1; US10753075B2; US20200385971A1; CA2980338A1; US20230125815A1; US11739512B2; US11536014B2

Abstract

A low-torque valve for regulating fluid flow between a valve inlet and a valve outlet is disclosed. The low-torque valve has a stationary valve element and a rotatable valve element. The stationary valve element and the rotatable valve element each may have a respective axially-facing mating surface in contact with each other. At least one opening in the rotatable valve element is rotationally positionable with respect to at least one opening in the stationary valve element between an open position and a closed position in order to regulate fluid flow from the valve inlet to the valve outlet based on an alignment of the openings of the stationary valve element and the rotatable valve element. In some forms, a torque threshold that is required to rotate the rotatable valve element into the open position from the closed position is less than 10 ounce-inches.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/399,807 filed on Sep. 26, 2016, the contents of which are incorporated by reference for all purposes as if set forth in their entirety herein.

STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF INVENTION

This disclosure relates to a low-torque valve and the operation thereof.

BACKGROUND

Motor-driven valves are known for the automated operation of valves in many applications. Typically, a power source, such as mains power or a battery, selectively drives the motor to open or close the valve in the presence of some condition (e.g., a controller receives a signal that a condition has been met and the motor is driven to a particular position to alter the state of the valve).
In many applications, installation of mains electricity to the motor-driven valve can be quite expensive, especially where mains power is not currently run to the physical location at which the motor-driven valve is to be used. In such situations, the cost of running mains power to the location versus the cost of consumable battery usage and maintenance must be weighed against one another and further must be compared against the design consideration of not implementing a motor-driven valve at all.
Unfortunately, in those situations, limited battery life provides a hard constraint on the convenience of and/or the ability to use such motor-driven valves when mains power is not a viable option. For example, in a battery-powered motor-driven valve, the valve will stop working once the battery is consumed which effectively halts the operation of the valve. Thus, it becomes essential to either routinely replace the batteries before they are consumed (which is highly inefficient) or to provide just-in-time replacement of batteries when they are consumed. In either case, there are significant maintenance costs associated with monitoring and replacing batteries.
Such maintenance and cost issues associated with batteries have prevented wider adoption of battery-driven motor-driven valves for applications when use of mains power is not a viable option.

SUMMARY OF THE INVENTION

Proposed herein are various designs for a low-torque valve that requires less power and torque to operate the valve which can thereby prolong the operational life of a device implementing the valve between battery changes are required. This can make the use of batteries in a motor-driven valve viable in contexts where it would be commercially unacceptable to need to replace batteries frequently (e.g., faucets, flush valves, and so forth). However, such low-torque valves could be equally powered by mains power.
According to one aspect, a low-torque valve for regulating fluid flow between a valve inlet and a valve outlet is disclosed. The low-torque valve comprise a stationary valve element and a rotatable valve element. The stationary valve element and the rotatable valve element each may have a respective axially-facing mating surface in contact with each other. The stationary valve element and the rotatable valve element also each have at least one opening. The stationary valve element and the rotatable valve element are rotationally positionable relative to one another between an open position and a closed position in order to regulate fluid flow from the valve inlet to the valve outlet based on an alignment of the openings of the stationary valve element and the rotatable valve element. A torque threshold to rotate the rotatable valve element into the open position from the closed position is less than 10 ounce-inches.
In some forms, the low-torque valve may further have a valve housing that has an internal chamber that receives the stationary valve element and the rotatable valve element. The internal chamber may have at least one opening in a peripheral wall providing or defining the valve outlet. The low-torque valve may further have an O-ring seal dimensioned to be received around the valve housing configured to form a seal between the valve housing and a structure into which the valve housing is adapted for reception.
In some forms, the opening(s) in the peripheral wall of the valve housing may extend in a radial direction to accommodate fluid flow in a U-shaped manner up (i.e., one in which the water flows in one direction and then is re-directed, at least in part, in a direction roughly parallel and opposite to that direction) through the valve elements of the low-torque valve, radially out the opening(s) in the peripheral wall to bend the flow, and down between an outer radial wall of the valve housing and a structure into which the valve housing is adapted for reception.
In some forms, the respective axially-facing mating surfaces of the stationary valve element and the rotatable valve element may contact each other to form a dynamic seal therebetween.
In some forms, a total torque threshold that may be required to complete a valve cycle may be less than 12 ounce-inches. The valve cycle includes the rotatable valve element being moved from the closed position to the open position and then back to another, different closed position in a single direction of rotation of the rotatable valve element.
In some forms, the opening(s) in the stationary valve includes an inlet opening and an outlet opening in which the inlet opening is in constant fluid communication with the valve inlet and the outlet opening is in constant fluid communication with the valve outlet.
In some forms, the rotatable valve element may have a patterned recess on the axially-facing mating surface for selectively placing the inlet opening and the outlet opening in fluid communication with one another based on a rotational position of the rotatable valve element relative to the stationary valve element. In the open position, the inlet opening and the outlet opening may be placed in fluid communication with one another by the patterned recess such that the valve inlet to the valve outlet are placed in fluid communication with one another. The patterned recess may, in some forms, include a plurality of channels outwardly extending from a centrally-connected location with the plurality of channels being in fluid communication with one another at the centrally-connected location. The patterned recess may, in some forms, be rotationally symmetrical about a central axis of the rotatable valve element.
In some forms, only small angular adjustments of the rotatable valve element may be necessary to go from a closed to an open to a closed position. For example, the inlet openings and the outlet openings may be selectively aligned at 45 or, alternatively, 60 degree incremented positions of the rotatable valve element. For example, in the case of a patterned recess, the movement of the valve from the closed position to an open position may occur over 45 degrees of clockwise rotation of the rotatable valve element, and a further 45 degrees of clockwise rotation of the rotatable valve element may move the valve from the open position back into a closed position. Thus, over a single continuous arc 360 degrees of motion in one direction, such a valve may be closed and opened four times. Likewise, at 60 degree increments, the valve may be opened and closed three times. This design helps to reduce travel distance between the open and closed positions, which reduced the energy required to activate the valve and, according, reduces power consumption and prolongs the operational life with a fixed amount of available power (as is the case when batteries are used).
In some forms, in the open position, there may be two points of communication at the axially-facing mating surfaces between the patterned recess in the rotatable valve element and a pair of openings in the stationary valve element.
The total torque threshold to complete a valve cycle may be dependent on the particular low torque design employed. In some forms, a total torque threshold required to complete a valve cycle is less than 19 ounce-inches. In some forms, a total torque per a valve cycle threshold is less than 9 ounce-inches. In some forms, an outer diameter of the stationary valve element and the rotatable valve element may be less than 0.5 inches.
In some forms, the rotatable valve element and the stationary valve element may comprise a ceramic material.
According to another aspect, a flush valve assembly is provided. The flush valve assembly includes a fluid passageway between an assembly inlet and an assembly outlet, a chamber positioned along the fluid passageway, and a low-torque valve according to any of the previous aspects. The diaphragm assembly is positioned in the chamber and bifurcate the chamber into an upper chamber and a lower chamber. The diaphragm assembly has a diaphragm having a bypass opening that places the upper chamber and the lower chamber in fluid communication with one another.
The diaphragm assembly is selectively received at a diaphragm seat to regulate flow between the assembly inlet and the assembly outlet during a flush cycle by controlling fluid communication between the lower chamber and an outlet chamber that connects the lower chamber to the assembly outlet. The low-torque valve is operable as a pilot valve to control a flush cycle by placing the upper chamber and the outlet chamber in selective fluid communication with one another. When the low-torque valve is in the open position, a fluid pressure from the upper chamber may be released through the low-torque valve to unseat the diaphragm assembly from the diaphragm seat to initiate the flush cycle. When the low-torque valve in the closed position, the diaphragm assembly may re-seat on the diaphragm seat due to an increased fluid pressure on the diaphragm assembly from the upper chamber to end the flush cycle.
In some forms, the low-torque valve may be axially offset from an axis of the assembly outlet.
In some forms, a rotational axis of the low-torque valve is oriented transverse to the assembly outlet.
In some forms, the valve changes the direction of fluid flow within the valve itself.
In some forms, a power source may be connected to a motor, the motor providing rotational control to the rotatable valve element to selectively rotate the rotatable valve element into an open position in which the at least one opening in the rotatable valve element aligns with the at least one opening in the stationary valve element thereby providing fluid communication therebetween. Although it is contemplated that mains power could power the motor, it is contemplated that an electrochemical device or battery could be this power source and—in such a power-constrained or power-limited scenario—the low torque valve design may provide exceptional benefit because it improves the length of time the valve can be operated using the battery (or set of batteries), before requiring replacement due to reduced power consumption per operational cycle.
Although the use of a valve assembly is described, it should be appreciated that the valve assembly is not limited to use in a flush valve assembly or in a relief valve assembly. The valve assemblies disclosed herein can have a wide variety of implementations. Some non-limiting examples of implementations of the valve assemblies disclosed may include faucets, mixing valves, flush valves, shower applications, plumbing fixtures, and non-plumbing fixtures and applications.
In yet another more specific aspect, a low-torque ceramic valve for regulating fluid flow between a valve inlet and a valve outlet is disclosed. The low-torque valve may comprise a stationary disc valve element, a rotatable disc valve element, a valve housing, and an O-ring seal. The stationary disc valve element and the rotatable disc valve element may be positioned along a valve axis and each having a respective axially-facing mating surface in contact with each other, the respective axially-facing mating surfaces of the stationary disc valve element and the rotatable disc valve element contact each other to form a dynamic seal therebetween that prevents fluid communication external a flow path through the valve. The stationary disc valve element and the rotatable disc valve element each may have at least one opening in which the stationary disc valve element and the rotatable disc valve element are rotationally positionable relative to one another between an open position and a closed position in order to regulate fluid flow. The valve housing may have an internal chamber that receives the stationary valve element and the rotatable valve element, the internal chamber having at least one opening in a peripheral wall, the at least one opening in the peripheral wall of the internal chamber provides fluid communication between the rotatable valve element and the valve outlet. The O-ring seal dimensioned to be received around the valve housing and dimensioned to prevent fluid communication external to a flow path through the valve. A torque threshold to rotate the rotatable valve element into the open position from the closed position may be less than 10 ounce-inches.
These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of some preferred embodiments of the present invention. To assess the full scope of the invention, the claims should be looked to as these preferred embodiments are not intended to be the only embodiments within the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a relief valve in a flush valve assembly.

FIG. 2 is an exploded view of the flush valve assembly of FIG. 1.

FIG. 3 is a perspective view of a relief valve housing.

FIG. 4 is a sectional view of the relief valve from area 4-4 of FIG. 1.

FIG. 5 is an exploded view of the relief valve.

FIG. 6 is a sectional view of an area A-A from FIG. 1 of the flush valve in the closed position.

FIG. 7 is a sectional view of an area A-A of the flush valve just after a relief valve is opened.

FIG. 8 is a sectional view of an area A-A of the flush valve in the open position.

FIG. 9 shows relief valve results of torque in ounce inches versus water pressure.

FIG. 10 is a sectional view of a relief valve positioned in a flush valve assembly.

FIG. 11 is an exploded view of a relief valve and an assembly frame.

FIG. 12A is an exploded view of a relief valve that can be received in the assembly frame of FIG. 11.

FIG. 12B is a top exploded view of relief valve elements of FIG. 12A.

FIG. 13 shows relief valve results of torque in ounce inches versus water pressure for the relief valve of FIG. 12A.

FIG. 14 is an exploded view of a relief valve that can be received in the upper housing of FIG. 11.

FIG. 15 is a top exploded view of relief valve elements of FIG. 14.

FIG. 16 shows relief valve results of torque in ounce inches versus water pressure for the relief valve of FIGS. 14 and 15.

FIG. 17 is a sectional view of a valve positioned in a flush valve assembly.

FIG. 18 is an exploded view of a valve that can be received in flush valve of FIG. 17.

FIG. 19 is an exploded view of the flush valve of FIG. 17.

FIG. 20 shows valve results of torque in ounce inches versus water pressure for the valve of FIGS. 17-19.

DETAILED DESCRIPTION

Embodiments of the disclosure may be further understood with reference to the figures.
FIGS. 1 and 2 illustrate one exemplary embodiment of a flush valve assembly 20. Although a flush valve assembly is shown, it is to be appreciated that the disclosure is not limited to flush valves, flushing mechanisms, or the like.
The flush valve assembly 20 has a housing that includes an upper housing body 22 and a lower housing body 24 that may be connected such that the upper housing body 22 and lower housing body 24 enclose the flush valve assembly 20. In a non-limiting example, the upper housing body 22 may be threaded into connection with the lower housing body 24. The lower housing body 24 may have an inlet 28, an outlet 32, and a cap over an opening 34 that would traditionally accommodate a mechanical flush lever. The inlet 28 to the lower housing body 24 may connect the lower housing body 24 to a fluid source and provide fluid communication therebetween. The inlet 28 may be secured to a fluid source via a nut 36 that circumferentially extends around an inlet extension 40, an O-ring 46, and a locking ring 48. The inlet extension 40 may be cylindrical in shape and defines a hollow inner chamber 42 for the passage of water. The lower housing body 24 receives the inlet extension 40, which extends perpendicularly outward from the lower housing body 24. The connection of the inlet extension 40 and the lower housing body 24 connects the inner chamber 42 of the inlet extension to a lower chamber 44 within the lower housing body 24. The lower chamber 44 of the housing circumferentially surrounds a valve seat 84.
A diaphragm assembly 52 is disposed within the upper housing body 22 and the lower housing body 24 between the inlet 28 and the outlet 32 and includes a diaphragm 56 and a disc 60. The diaphragm assembly 52 positioned in a chamber and bifurcating the chamber into an upper chamber 88 and the lower chamber 44. The diaphragm assembly 52 has a diaphragm assembly opening 64 and a bypass opening 68. As illustrated, the diaphragm assembly opening 64 is centrally located on the diaphragm assembly 52 and the bypass opening 68 may be peripherally located on the diaphragm assembly 52; however, they may be otherwise geometrically disposed. The diaphragm 56 and the disc 60 extend circumferentially outward, each defining an outer diameter. The outer diameter of the diaphragm 56 is larger than the outer diameter of the disc 60. The disc 60 is received in a central opening in the diaphragm 56 that aligns with the opening 64 in the diaphragm assembly 52. The diaphragm 56 receives a base end 72 of the disc 60 in the central opening in the diaphragm 56 while an outward protrusion 76 of the disc 60 is disposed above a portion of a top surface of the diaphragm 56. The base 72 of the disc 60 is threadably connected to a cylinder guide 80.
A bottom surface of the outward protrusion 76 of the disc 60 may be fixed to a top surface of the diaphragm 56. The outward protrusion 76 of the disc 60 has a raised inner area 164 that has a thickness greater than the thickness of the outward protrusion 76. The disc 60 surrounds a lower body 128 of a bypass extension 122 of the assembly frame 96 that is centrally positioned through the diaphragm assembly 52. The bypass extension 122 extends through the upper chamber 88 into the diaphragm assembly 52.
The cylinder guide 80 is positioned below the diaphragm 56 and the disc 60 and is cylindrical. The cylinder guide 80 defines a peripheral chamber 82 between an outer wall of the cylinder guide 80 and an inner wall of the valve seat 84 that extends upward in the housing as a cylindrical column.
The cylinder guide 80 extends below the diaphragm 56 and features a diaphragm assembly extension upper support 244 and one or more diaphragm assembly extension lower supports 248. A bottom surface of the diaphragm assembly extension upper support 244 is fixed to a top surface of one or more diaphragm assembly extension lower supports 248. The diaphragm assembly extension upper support 244 is cylindrical in shape and wraps around the cylinder guide 80 while leaving a gap 246 around an outer surface of the cylinder guide 80. The one or more diaphragm assembly lower supports 248 are rectangular and are positioned vertically on the outer surface of the cylinder guide 80. The one or more diaphragm assembly lower supports 248 are spaced radially around the perimeter of the cylinder guide 80. The one or more diaphragm assembly lower supports 248 may be placed at 90 degree intervals around an outer surface of the cylinder guide 80.
The diaphragm assembly 52 contacts a top surface of the valve seat 84 and the cylinder guide 80 extends into the lower housing body 24. When the flush valve assembly 20 is in the closed position as is illustrated in FIG. 1, the diaphragm assembly 52 is positioned on a top lip of the valve seat 84 which places the diaphragm assembly 52 in a sealing position between the inlet 28 and the outlet 32. An upper chamber 88 is positioned above the diaphragm assembly 52 and is in fluid communication with the lower chamber 44 via the bypass opening 68 of the diaphragm 56.
A relief valve assembly 92 is positioned within and supported by an assembly frame 96 that is secured between the upper housing body 22 and lower housing body 24. The relief valve assembly 92 may be offset from an outlet passageway 132 of the flush valve assembly 20. An inner surface of the assembly frame 96 may also provide a top wall of the upper chamber 88 that provides a fluid boundary that prevents fluid from communicating outside of the assembly frame 96. Fluid communication is provided to the relief valve assembly 92 from the upper chamber 88 via an inlet opening 134 in the assembly frame 96.
The relief valve assembly 92 includes a motor 100 connected to a power source 102 positioned outside of the assembly frame 96. In a non-limiting example, the power source 102 may be one or more batteries. The motor 100 has a shaft 104 that extends out of the motor 100 and connects to a driving member 108. The driving member 108 is connected to a rotatable valve element 112 that is positioned below the driving member 108 and the shaft 104. The rotatable valve element 112 is positioned above a stationary valve element 116 (both of which are in the shape of discs). Illustratively, it should be appreciated that the rotatable valve element 112, which is shown in greater detail in FIGS. 3-5 and discussed more below, may be a moveable valve element and/or a translatable valve element. A relief valve housing 120 receives the driving member 108, the rotatable valve element 112, and the stationary valve element 116.
The relief valve assembly 92 may be received within the upper housing body 22. The motor 100 may be secured to the assembly frame 96 via screws 216 fixed to a top surface of an upper body 228 of the assembly frame 96. The upper body 228 of the assembly frame 96 may extend vertically from a lower body 232 of the assembly frame 96. The upper body 228 of the assembly frame 96 may be cylindrical having a hollow inner chamber configured to receive an O-ring 236 and the relief valve housing 120. The lower body 232 of the assembly frame 96 may extend radially outward from a bottom surface of the upper body 228 of the assembly frame 96.
The relief valve assembly 92 is positioned above the diaphragm assembly 52 within the upper housing body 22.
In some embodiments, the flush valve assembly 20 may further include a manual actuation assembly 140 received in the assembly frame 96. The manual actuation assembly 140 can include an actuation interface 144 and an actuation member 148. The actuation interface 144 may extend outside of the upper housing body 22 and may be linked to the actuation member 148. The actuation member 148 may be fixed to the actuation interface 144 and may extend to the top wall of the upper chamber 88 to provide a manual override to the relief valve assembly.
The upper housing body 22 has a sensor opening 188 and which may be any appropriate shape. As shown in a non-limiting example, the sensor opening 188 may be rectangular with rounded edges oriented vertically on the upper housing body 22. The sensor opening 188 may be any appropriate shape to receive a sensor that that may be positioned within the upper housing body 22 or to permit the sensor to sense therethrough. In the form illustrated, the upper housing body 22 is configured to contain the diaphragm assembly 52, the relief valve assembly 92, the power source 102 and a sensor.
Referring now to FIGS. 3-5, the relief valve assembly 92 may be assembled with the shaft 104 of the motor 100 extending into the driving member 108. In some embodiments, a bottom surface of the shaft 104 may be fixed to a top surface of the driving member 108. In other embodiments, the shaft 104 and the driving member 108 may be connected by a keyed connection, D-shape connection, geared connection, or any other suitable connection between a motor shaft and a driving member. An O-ring 264 is positioned between driving member ring 252 that extends radially outward from a driving member body 256. The driving member body 256 may be cylindrical in shape and may receive the O-ring 264 around an outer surface of the driving member body 256 below the driving member ring 252. A driving member arm 254 is rectangular in shape and has rounded ends and extends along the bottom surface of the driving member body 256. A friction washer (not shown) having, for example, the shape of a flat disc with a central opening can be positioned between the relief valve housing 120 and the driving member ring 252, the friction washer reducing friction between the driving member ring 252 and the relief valve housing 120.
The driving member arm 254 is received within one or more rotatable valve element walls 260 that extend vertically from the rotatable valve element 112. A top surface of the rotatable valve element 112 has a shape that is concave up thereby recessing away from the driving member arm 254. The driving member arm 254 has a length that allows the driving member arm 254 to be received within the rotatable valve element walls 260. The rotatable valve element walls 260 extend vertically from the top surface of the rotatable valve element 112. The rotatable valve element walls 260 are positioned in order to receive the driving member arm 254 in a gap in each of the rotatable valve element walls 260.
The rotatable valve element 112 may be a rotatable disc valve element that may have openings 272 through the rotatable valve element 112 that selectively align with one or more openings 276 in the stationary valve element 116. The openings 272 of the rotatable valve element 112 may be positioned opposite each other, each having a tapered oblong shape that widens towards an exterior portion of the rotatable valve element 112. Put another way, the openings 272 may have a tear-drop shape that is wider near an exterior portion of the rotatable valve element 112. As illustrated, there may be two openings 272 in the rotatable valve element positioned at 180 degrees from each other through the rotatable valve element 112. A bottom surface profile 274 may be cut into the bottom surface of the rotatable valve element 112, the bottom surface profile 274 may have two semi-circular regions connected by a narrowed central portion positioned between the openings 272. Among other things, the large amount of recessed surface or absent surface (especially that formed by the recessed bottom surface profile 274) reduces the overall surfaces area of bearing between the valve elements, which can help minimize the friction required to turn the elements with respect to one another.
As illustrated, the openings 276 in the stationary valve element 116 have a tapered oblong shape that widens towards an exterior portion of the stationary valve element 116 and sized to match or approximately match the size and/or shape of the openings 272 in the rotatable valve element 112. Put another way, the openings 276 may have a tear-drop shape that is wider near an exterior portion of the stationary valve element 116. In one example, there may be four openings 276 through the stationary valve element 116, even though, by design only two openings 276 may have active flow through them at a given moment in time. The openings 276 may be cut normally through a top and bottom surface of the stationary valve element 116. The openings 276 are oriented at or approximately 90 degrees apart such that the openings 276 are symmetrical about a relief valve axis 126 across the stationary valve element 116. The stationary valve element 116 may be a stationary disc valve element that has a cylindrical shape with the openings 276 cut therethrough. The stationary valve element 116 has tabs 292 extending from the outer surface that are configured to secure the stationary valve element 116 in a rotationally fixed position.
The stationary valve element 116 has a mating surface 280 that is axially-facing and mates with a mating surface 282 of the rotatable valve element 112, the respective axially-facing mating surfaces 280, 282 are in contact with each other. The mating surfaces 280, 282 of the stationary valve element 116 and the rotatable valve element 112 contact each other to form a dynamic seal therebetween that prevents fluid communication external a flow path through the relief valve assembly 92.
An inlet gasket 220 of the relief valve assembly 92 is positioned below the stationary valve element 116 within the relief valve housing 120. Fluid communication is provided to the relief valve assembly 92 from the upper chamber 88 via an inlet opening 134 in the assembly frame 96 and through the inlet gasket 220. The inlet gasket 220 provides a reduced diameter of fluid communication from the inlet opening 134 to the stationary valve element 116. The inlet gasket 220 provides compressive forces to ensure the rotatable valve element 112 and the stationary valve element 116 remain in contact with one another creating a fluid tight seal.
The relief valve housing 120 receives the driving member 108, the rotatable valve element 112, the stationary valve element 116, and the O-ring 264. A portion of the relief valve housing 120 has an outer surface 124 which may be fixed within the assembly frame 96 to secure the relief valve housing 120 to the assembly frame 96. The outer surface 124 is positioned below an upper extension 268 of the relief valve housing 120. The upper extension 268 extends radially outward from the relief valve housing 120 and has two flattened surfaces 270 positioned on opposing sides of the upper extension 268. Below the outer surface 124 of the relief valve housing are two peripheral openings 266 in the relief valve housing 120. The peripheral openings 266 extend in a radial direction around the relief valve housing 120 and providing the relief valve outlet. The O-ring 236 may be received around the relief valve housing 120 between the outer surface 124 and the upper extension 268. The O-ring 236 is dimensioned to be received around the relief valve housing 120 and configured to form a seal between the relief valve housing 120 and the assembly frame 96 into which the relief valve housing 120 is adapted for reception.
The relief valve outlet at the peripheral openings 266 in the relief valve housing 120 provides selective fluid communication between the relief valve assembly 92 and a circumferential passageway 240 positioned around the circumference of the relief valve housing 120 and between the assembly frame 96 and the relief valve housing 120. The circumferential passageway 240 is connected with an actuation passageway 242 defined between the circumferential passageway 240 and the manual override assembly 140 in the assembly frame 96. The actuation passageway 242 is in fluid communication with the outlet passageway 132 through the lower body 128 of the bypass extension 122 of the assembly frame 96. The lower body 128 of the bypass extension 122 is centrally positioned through the diaphragm assembly 52, which connects the actuation passageway 242 with the outlet passageway 132.
Now that the components of the relief valve assembly 92 and the flush valve assembly 20 have been described in detail, their respective functionalities may be appreciated. Referring to FIGS. 3-5 the motor 100 may be configured to generate rotational motion that is translated to the shaft 104. Rotational motion of the shaft 104 translates rotational motion to the driving member 108 and, consequently, the driving member arm 254. The driving member arm 254 received within the rotatable valve element walls 260 causes rotation of the rotatable valve element 112.
Rotation of the rotatable valve element 112 may change the rotational position of the openings 272 of the rotatable valve element 112. Selective movement of the openings 272 through the rotatable valve element 112 defines a plurality of positions of the relief valve assembly 92. A first position of the relief valve assembly 92 is an open position defined by the openings 272 through the rotatable valve element 112 aligning with an opposing pair of the openings 276 in the stationary valve element 116. Alignment of the openings 272 in the rotatable valve element 112 with the openings 276 in the stationary valve element 116 allows fluid communication through the relief valve assembly 92 in which the flow of fluid goes up the valve elements and radially out of the peripheral openings 266.
A second position of the relief valve assembly 92 is a closed position defined by the openings 272 through the rotatable valve element 112 not aligning with the openings 276 in the stationary valve element 116. In the closed position, the openings 276 in the stationary valve element 116 are covered by rotatable valve element 112 such that the bottom surface profile 274 places all of the openings 276 in communication with one another but not with the openings 272. Since the openings 276 in the stationary valve element 116 only serve as potential inlets, but do not flow unless they are in communication with the openings 272 of the rotatable valve element 116, this rotational configuration of the disc elements with respect to one another stops flow therethrough. Thus, in the closed position, fluid communication is prohibited to pass through the relief valve assembly 92. Based on the illustrated geometry, the opened position and the closed position are approximately 45 degrees from one another, meaning that for every 90 degrees of rotation, the valve can be moved from closed to open and back to closed. Given the number of openings this means a full 360 degrees of rotation will have four full cycles of opening and closing associated with it.
Illustratively, the relief valve assembly 92 may include one or more moveable and/or translatable valve elements. The one or more moveable and/or translatable valve elements may be selectively moved or translated with respect to one or more stationary valve elements. Movement of the one or more moveable and/or translatable valve elements selectively provides fluid communication between the upper chamber 88 and the outlet passageway 132.
Now with reference to FIGS. 6-8, the initiation of a flush cycle by temporarily actuating the relief valve assembly 92 from the closed position to the opened position is illustrated. The relief valve assembly 92 may generally function as a pilot valve to initiate a flush cycle as shown. This brief opening of the relief valve assembly 92 will cause the entire diaphragm assembly 52 to lift, permitting water to travel from the inlet 28 to the outlet 32.
FIG. 6 shows a detailed area A-A of the flush valve assembly 20 in a closed position with fluid retained in the flush valve assembly 20 and is unable to enter the outlet chamber 136 because the diaphragm assembly 52 remains sealed against the upper lip of the valve seat 84. Fluid provided through the inlet 28 (not shown in FIG. 6, but found in prior figures) into the inner chamber 42 which is in fluid communication with the lower chamber 44. The lower chamber 44 surrounds outside wall the valve seat 84 and is in fluid communication with the upper chamber 88 via the bypass opening 68 in the diaphragm 56. The bypass opening 68 places the lower chamber 44 in fluid communication with the upper chamber 88.
In the position illustrated in FIG. 6, the relief valve assembly 92 is in the closed position defined by the openings in the stationary valve element 116 being covered by the rotatable valve element 112 thereby preventing fluid from flowing past the stationary valve element 116. Fluid communication is provided to the relief valve assembly 92 from the upper chamber 88 via an inlet opening 134 in the assembly frame 96 and through the inlet gasket 220.
As mentioned above, the diaphragm assembly 52 is in a closed position while the relief valve assembly 92 is in the closed position. The closed position of the diaphragm assembly 52 is defined by the diaphragm assembly 52 being received against the valve seat 84 creating a seal therebetween. The diaphragm assembly 52 may be held in a closed position by the force of fluid in the chamber 88, exerting a downward force on the diaphragm 56 and the disc 60, thereby pressing the diaphragm assembly 52 against the valve seat 84.
FIG. 7 shows the area A-A of the flush valve assembly 20 just after the relief valve assembly 92 has been opened to initiate the opening of the flush valve assembly 20, but before water was passed entirely through the relief valve assembly 92 to permit the diaphragm assembly 52 to lift. The open position of the flush valve assembly 20 is achieved when the motor 100 selectively rotates the rotatable valve element 112 such that the openings in the rotatable valve element 112 align with the openings in the stationary valve element 116 creating fluid communication through the relief valve assembly 92 such that water may pass from the upper chamber 88 into the outlet chamber 136.
The relief valve outlet at the peripheral openings 266 in the relief valve housing 120 is in fluid communication with the circumferential passageway 240 with the relief valve assembly 92 in the open position. The circumferential passageway 240 changes the direction of fluid flow in a U-shaped manner up through the stationary valve element 116 and the rotatable valve element 112, radially out the peripheral openings 266 in the peripheral wall of the relief valve housing 120 to bend the flow, and down into the circumferential passageway 240 between an outer radial wall of the relief valve housing 120 and the assembly frame 96. The circumferential passageway 240 is connected with the actuation passageway 242 that is in fluid communication with the outlet passageway 132 through the lower body 128 of the bypass extension 122 of the assembly frame 96.
Just after the relief valve assembly 92 has been opened, the diaphragm assembly 52 may briefly remain in the closed position. The diaphragm assembly 52 may remain in the closed position just after the relief valve assembly 92 opens because the pressure exerted on the diaphragm assembly 52 temporarily holds it on the valve seat 84 as the pressure has not been relieved through the outlet chamber 136.
FIG. 8 shows the area A-A of the flush valve assembly 20 where the relief valve assembly 92 has remained opened and the diaphragm assembly 52 has lifted such that the flush valve assembly 20 is in the open position. The open position of the flush valve assembly 20 is achieved when the fluid from the upper chamber 88 is allowed to flow through the outlet passageway 132 and into the outlet chamber 136 for a sufficient duration of time to break the seal at the valve seat 84. Fluid flow through the outlet passageway 132 into the outlet chamber 136 relieves pressure in upper chamber 88 exerted on the diaphragm assembly 52. Under this change in pressure, the diaphragm 56 is flexible in an upward direction and causes vertical translation of the diaphragm assembly 52 away from the valve seat 84 to break the seal. Vertical translation of the diaphragm assembly 52 away from the valve seat 84 provides direct fluid communication between the lower chamber 44 and the outlet chamber 136 via the peripheral chamber 82. Put another way, with the diaphragm assembly 52 unseated from the valve seat 84, the inlet 28 and the outlet 32 are placed in direct fluid communication with one another past the upper opening in the valve seat 84.
To close the flush valve assembly 20, the motor 100 or the actuation member 148 rotates the rotatable valve element 112 such that the one or more openings in the stationary valve element 116 are covered by the rotatable valve element 112 thereby preventing fluid from flowing past the stationary valve element 116 (i.e., the relief valve assembly 92 is closed). After returning to the closed position, the pressure will rise in upper chamber 88 as fluid passes through the bypass opening 68 once fluid communication between upper chamber 88, the outlet passageway 132, and the outlet chamber 136 are shut off. The increased pressure in upper chamber 88 translates the diaphragm assembly 52 back down into a closed position by pressing the diaphragm assembly 52 against the valve seat 84, as shown in FIG. 6. The closed position of the diaphragm assembly 52 again, at least temporarily, prevents fluid communication between the lower chamber 44, the peripheral chamber 82, and the outlet chamber 136 until the next activation command is given.
The flush valve assembly 20 may be selectively in the open position for a pre-defined or selected period of time and that period of time may define a flush cycle. The period of time may be an appropriate amount of time to generate fluid flow through the flush valve assembly 20 given the fixture on which the valve is received such as a urinal or toilet. A non-limiting example of a period of time range the relief valve assembly 92 may be in an open position for may be 0.5 to 3 seconds which may result in the flush valve to be open from 3 to 10 seconds. The time the relief valve assembly 92 is selectively in an open position may not be the time required to complete a flush, as the flush valve assembly 20 may be in a closed position while residual fluid may flush.
A flush cycle may be initiated manually or automatically. An automatic flush cycle may occur when the sensor 196 detects a user has approached the flush valve assembly 20 and will actuate the cycle when the identified user has left the flush valve assembly 20. The sensor may communicate control instructions to the motor 100 to selectively rotate the relief valve assembly 92 into the open position in order to initiate a flush cycle. Alternatively, a flush cycle may be initiated manually using the manual actuation assembly 140. A user may use the actuation interface 144 to initiate a flush cycle where at least a portion of the manual actuation assembly 140 may selectively be actuated into the upper chamber 88 such that fluid communication may be provided between the upper chamber 88 and the actuation passageway 242. The manual actuation assembly 142 may be actuated at the actuation interface 144 which may extend out a top surface of the upper housing body 22. The manual actuation assembly 142 may initiate a flush cycle in the absence of power.
The relief valve assembly 92 is a low-torque implementation of a relief valve. The rotatable valve element 112 and the stationary valve element 116 may be manufactured, machined, or formed out of a ceramic material to precise measurements such that a low amount of torque is required to rotate the rotatable valve element 112 against the stationary valve element.
FIG. 9 shows exemplary results for the low torque relief valve as described above and shown in FIGS. 1-8 in which the effect of water pressure on the torque to operate the valve is illustrated. The relief valve assembly 92 may generally function as a pilot valve to initiate a flush cycle as shown, and achieve the torque results depicted in FIG. 9. Generally, the relief valve assembly may require 13.3 ounce-inches (oz-inch) of torque to complete a relief valve cycle, on the high end of the test results. One of skill in the art will readily recognize the results show the relief valve can achieve torque values below 13.3 oz-inch. The relief valve cycle includes the rotatable valve element 112 being moved from the closed position to the open position and then back to another, different closed position in a single direction of rotation of the rotatable valve element 112. Typical ceramic disc torque data may be twice or more of these values.
The results further show that the upper limit the relief valve assembly may require 8.3 oz-inch at 120 psi of fluid pressure versus a typical torque of 16 oz-inch of torque to open the relief valve assembly where the rotatable valve element 112 is moved from the closed position to the open position. The relief valve assembly may require less torque to open, for example, the relief valve assembly may require 2.54 oz-inch of torque to open. The upper limit the relief valve assembly may require 3.3 oz-inch of torque to close where the rotatable valve element 112 is rotated from an open position to a closed position in a single direction of rotation of the rotatable valve element 112. Additionally, the total torque that may be required to complete a relief valve cycle may be 11.6 oz-inch of torque per cycle, or less. The relief valve assembly may require less torque to close, for example, the relief valve assembly may require 2.32 oz-inch of torque to close.
The low-torque relief valve assembly 92 provides a number of advantages over relief valves with high torque requirements. The low-torque relief valve is impervious to water conditions, presents improved durability with ceramic components, presents low defective parts per million levels, and allows for longer battery life due to reduced energy consumption.
Referring now to FIGS. 10 and 11, a relief valve assembly 392 according to another aspect of this disclosure is shown in the flush valve assembly 20. The flush valve assembly 20 is similar to the flush valve of FIGS. 1, 2, and 6-8, but the relief valve assembly 392 in the flush valve assembly 20 may be the relief valve assembly 392 shown in FIG. 12A or the relief valve assembly 492 shown in FIGS. 14 and 15.
Accordingly, the flush valve assembly 20 shown in FIG. 10 includes a housing that includes the upper housing body 22 and the lower housing body 24 that may be connected such that the upper housing body 22 and lower housing body 24 enclose the flush valve assembly 20. The diaphragm assembly 52 is disposed within the upper housing body 22 and the lower housing body 24 between the inlet 28 and the outlet 32 and includes the diaphragm 56 and the disc 60. The flush valve assembly 20 may further include a manual actuation assembly 140 received in an assembly frame 296. The assembly frame 296 may be modified to receive the relief valve assembly 392 at a central location of the assembly frame 296 as opposed to an offset location as shown in FIGS. 1 and 2. A relief valve inlet 334 is positioned in the assembly frame 296 that provides fluid communication from the upper chamber 88 through the assembly frame 296 and into the relief valve assembly 392.
Referring now to FIGS. 12A and 12B, the relief valve assembly 392 may be assembled with the shaft 104 of the motor 100 extending into the driving member 408. In some embodiments, a bottom surface of the shaft 104 may be fixed to a top surface of the driving member 408. In other embodiments, the shaft 104 and the driving member 408 may be connected by a keyed connection, D-shape connection, geared connection, or any other suitable connection between a motor shaft and a driving member.
The driving member 408 may have an upper body extension 452 that extends radially outward from the driving member 408. The driving member extension 452 may have curved protrusions 454 that extend outward from the upper body extension 452. The curved protrusions 454 may be positioned at symmetrical locations around a circumference of the upper body extension 452. The driving member 408 has a driving member body 456 that extends downwardly away from the upper body extension 452 into a relief valve housing 420. The driving member body 456 may be cylindrical in shape and extend into contact with the rotatable valve element 412 via driving member arms 458 that extend from a bottom surface of the driving member body 456. As shown, the driving member arms 458 may be cylindrical in shape and may be spaced apart on the bottom surface of the driving member body 456 such that rotational motion from the motor 100 can be translated through the driving member arms 458. Notably, the driving member 408 may not feature an O-ring seal along the driving member 408.
The relief valve housing 420 may be cylindrical in shape having an inner wall 421 and a hollow lower chamber 422. The inner wall 421 extends radially inward into the relief valve housing 420 to support the driving member body 456. The relief valve housing 420 may have an outer surface 424 adapted for reception in the assembly frame 296. The hollow lower chamber 422 receives a valve collar 410 and a rotatable valve element 412.
The valve collar 410 is positioned around a top surface of the rotatable valve element 412, the valve collar 410 and the rotatable valve element 412 being received within the relief valve housing 420. The valve collar 410 has an opening through a top surface of the valve collar 410 that allows the driving member body 456 to extend into contact with the rotatable valve element 412 via driving member arms 458 that extend from the bottom surface of the driving member body 456.
The rotatable valve element 412 may be cylindrical in shape, having a top surface 440 and a mating surface 476. In a non-limiting example, the rotatable valve element 412 may have a diameter of 0.456″. The top surface 440 of the rotatable valve element 412 may have driving member openings 444 that are dimensioned to receive the driving member arms 458 of the driving member 408. The mating surface 476 of the rotatable valve element 412 may be axially-facing and mates with a mating surface 484 of a stationary valve element 416, the respective axially-facing mating surfaces 476, 484 are in contact with each other. The mating surfaces 476, 484 of the rotatable valve element 412 and the stationary valve element 416 contact each other to form a dynamic seal therebetween that prevents fluid communication external a flow path through the relief valve assembly 392.
The mating surface 476 of the rotatable valve element 412 may have a patterned recess 442 that includes a plurality of channels 446 that extend outwardly from a centrally-connected location 448. The plurality of channels 446 may be in fluid communication with one another at the centrally-connected location 448. As shown, the plurality of channels 446 shown includes four channels that extend outwardly from the centrally-connected location 448 to create a cross-pattern of the pattered recess 442 that may be X-shaped. Accordingly, the patterned recess 442 may be rotationally symmetrical about a central axis 430 of the rotatable valve element 412. The pattered recess 442 may have a recess depth that is less than a thickness of the rotatable valve element 412. Although a patterned recess 442 is shown as an X-pattern, any appropriate pattern could be used, including symmetrical patterns and asymmetrical patterns.
The stationary valve element 416 may be cylindrical in shape, having the mating surface 484 and a bottom surface 486. In a non-limiting example, the stationary valve element 416 may have a diameter of 0.456″. The stationary valve element 416 may have an inlet opening 490 and an outlet opening 488, the inlet opening 490 and the outlet opening 488 extending through the stationary valve element 416 between the bottom surface 486 and the mating surface 484. Although an inlet opening 490 and an outlet opening 488 are shown, a plurality of inlet openings and a plurality of outlet openings could be employed in the stationary valve element 416. The plurality of openings could be arranged in any appropriate pattern, shape, and/or size.
A valve seal 494 is positioned between the stationary valve element 416 and the assembly frame 296. The valve seal 494 may have an inlet opening 496 and an outlet opening 498 that align with the inlet opening 490 and the outlet opening 488 of the stationary valve element 416, respectively. The outlet opening 498 may define the valve outlet. The valve seal 494 may be cylindrical in shape surrounding each of the inlet opening 496 and the outlet opening 498 and can be connected at an intermediate location 500 such that an outer profile of the valve seal 494 features a figure-eight shape.
Referring now to FIGS. 14 and 15, another embodiment of the relief valve assembly 492 is shown. The relief valve assembly 492 has many components of the relief valve assembly 392. The relief valve assembly 492 has the driving member 408, the relief valve housing 420, the valve collar 410, and the valve seal 494 described with respect to the relief valve assembly 392. The stationary valve element 516 and the rotatable valve element 512 differ slightly from the stationary valve element 416 and the rotatable valve element 512 of the relief valve assembly 392.
The rotatable valve element 512 may be cylindrical in shape, having a top surface 540 and a mating surface 576. In a non-limiting example, the rotatable valve element 512 may have a diameter of 0.400″. The top surface 540 of the rotatable valve element 512 may have driving member openings 544 that are dimensioned to receive the driving member arms 458 of the driving member 408. The mating surface 576 of the rotatable valve element 512 may be axially-facing and mates with a mating surface 584 of a stationary valve element 516, the respective axially-facing mating surfaces 576, 584 are in contact with each other. The mating surfaces 576, 584 of the rotatable valve element 512 and the stationary valve element 516 contact each other to form a dynamic seal therebetween that prevents fluid communication external a flow path through the relief valve assembly 492.
The mating surface 576 of the rotatable valve element 512 may have a patterned recess 542 that includes a plurality of channels 546 that extend outwardly from a centrally-connected location 548. The plurality of channels 546 may be in fluid communication with one another at the centrally-connected location 548. As shown, the plurality of channels 546 shown includes three channels that extend outwardly from the centrally-connected location 548 to create triangular pattern of the pattered recess 542, each channel being positioned at or approximately 120 degrees apart from the other channels. The pattered recess 542 may have a recess depth that is less than a thickness of the rotatable valve element 512. Although a patterned recess 542 is shown as a triangular Y-pattern, any appropriate pattern could be used, including symmetrical patterns and asymmetrical patterns.
The stationary valve element 516 may be cylindrical in shape, having the mating surface 584 and a bottom surface 586. In a non-limiting example, the stationary valve element 516 may have a diameter of 0.400″. The stationary valve element 516 may have an inlet opening 590 and an outlet opening 588, the inlet opening 590 and the outlet opening 588 extending through the stationary valve element 516 between the bottom surface 586 and the mating surface 584. The mating surface 584 may have a mating recess 524. The mating recess 524 can be a curved profile that extends around the inlet opening 590 that provides fluid communication to a greater area at the mating surface 584. The curved profile of the mating recess 524 can extend around at any appropriate width and angle. Illustratively, the mating recess curves to an angle less than 180 degrees of a diameter of the mating surface 584. An angle of curvature of the curved profile of the mating recess 584 can similarly be any appropriate angle, and, as shown, can be approximately 120 degrees. The mating recess 524 can have a depth that is less than a thickness of the stationary valve element 516. Alternatively, the mating recess 524 can extend through the stationary valve element 516, and, accordingly being one with the inlet opening 590.
Although an inlet opening 590 and an outlet opening 588 are shown, a plurality of inlet openings and a plurality of outlet openings could be employed in the stationary valve element 516. The plurality of openings could be arranged in any appropriate pattern, shape, and/or size. Similarly, the mating recess 524 is shown to be connected with the inlet opening 590; however, the mating recess 524 can be positioned at the outlet opening 592.
Now that the components of the relief valve assemblies 392 and 492 their respective functionalities can be appreciated. The functionalities of the relief valve assemblies 392, 492 will be described with reference to the flush valve assembly 20. It is to be appreciated that their function is not limited to use within a flush valve. The use in a flush valve is one example of a use for the relief valve assemblies 392, 492. The relief valve assemblies 392, 492 could also be used in faucets, plumbing fixtures, mixing valves, and any other appropriate application.
Referring to FIGS. 10-12, 14 and 15, although the relief valve assembly 392 and its respective components are labeled, it is to be appreciated that the relief valve assembly 492 may be similarly received within the flush valve assembly 20 as shown in FIGS. 10 and 11.
The relief valve inlet 334 is positioned in the assembly frame 296 and provides fluid communication from the upper chamber 88 through the assembly frame 296 and into the relief valve assembly 392. Fluid is communicated from the upper chamber 88 through the valve inlet 334 to the inlet opening 496 in the valve seal 494 which communicates fluid to the inlet opening 490 in the stationary valve element 416. The inlet opening 490 in the stationary valve element 416 is in selective fluid communication with the patterned recess 442 of the rotatable valve element 412 based on a rotational position of the rotatable valve element 412 relative to the stationary valve element 416. The rotational position of the rotatable valve element 412 may be controlled by the driving member 456 via the motor 100. The patterned recess 442 on the axially-facing mating surface 476 selectively places the inlet opening 490 and the outlet opening 488 in fluid communication with one another based on a rotational position of the rotatable valve element 412 relative to the stationary valve element 416.
In an open position, the inlet opening 490 and the outlet opening 488 are placed in fluid communication with one another by the patterned recess 442 such that the relief valve inlet 334 to the valve outlet 498 are placed in fluid communication with one another. In the relief valve assembly 392, the inlet opening 490 and the outlet opening 488 may be selectively aligned at 45 degree incremented positions of the rotatable valve element 412 due to the angular position of the patterned recess 442. The outlet opening 488 is axially aligned with the outlet passageway 132 of the flush valve assembly 20, thereby communicating fluid to the outlet chamber 136.
In a closed position, the inlet opening 490 and the outlet opening 488 are not in fluid communication with one another due to the patterned recess 442 lacking alignment with the inlet opening 490 thereby preventing fluid communication past the inlet opening 490.
The relief valve assembly 492 operates in a similar manner to the relief valve assembly 392. The inlet opening 590 in the stationary valve element 516 is in selective fluid communication with the patterned recess 542 of the rotatable valve element 512 based on a rotational position of the rotatable valve element 512 relative to the stationary valve element 516. The rotational position of the rotatable valve element 512 may be controlled by the driving member 456 via the motor 100. The patterned recess 542 on the axially-facing mating surface 576 selectively places the inlet opening 590 and the outlet opening 588 in fluid communication with one another based on a rotational position of the rotatable valve element 512 relative to the stationary valve element 516.
In an open position, the inlet opening 590 and the outlet opening 588 are placed in fluid communication with one another by the patterned recess 442 such that the relief valve inlet 334 to the valve outlet 498 are placed in fluid communication with one another. In the relief valve assembly 492, the inlet opening 590 and the outlet opening 588 may be selectively aligned at 60 degree incremented positions of the rotatable valve element 512 due to the angular position of the patterned recess 542. In the open position, there may be two points of communication at the axially-facing mating surfaces 576, 584 between the recess profile 542 in the rotatable valve element 412 and the inlet opening 490 and the mating recess 524 in the stationary valve element 516.
In a closed position, the inlet opening 590 and the outlet opening 588 are not in fluid communication with one another due to the patterned recess 542 lacking alignment with the inlet opening 590 thereby preventing fluid communication past the inlet opening 590.
The relief valve assemblies 392, 492 may be implemented within the flush valve assembly 20 as a pilot valve to initiate a flush cycle as discussed above with reference to FIGS. 6-8.
The relief valve assemblies 392, 492 are low-torque implementations of a relief valve. The rotatable valve element 412, 512 and the stationary valve element 416, 516 may be manufactured, machined, or formed out of a ceramic material to precise measurements such that a low amount of torque is required to rotate the rotatable valve element 412, 512 against the stationary valve element 416, 516.
FIG. 13 shows exemplary results for the low torque relief valve assembly 392 as described above and shown in FIGS. 10-12. The relief valve assembly 392 may generally function as a pilot valve to initiate a flush cycle as shown, and achieve the torque results depicted in FIG. 13. Generally, the relief valve assembly 392 may require 8.9 ounce-inches (oz-inch) of torque to complete a relief valve cycle, on the high end of the test results. One of skill in the art will readily recognize the results show the relief valve can achieve torque values below 8.9 oz-inch. The relief valve cycle includes the rotatable valve element 412 being moved from the closed position to the open position and then back to another, different closed position in a single direction of rotation of the rotatable valve element 412.
The results further show that the upper limit the relief valve assembly may require 5.0 oz-inch of torque to open the relief valve assembly 392 where the rotatable valve element 412 is moved from the closed position to the open position. The relief valve assembly may require less torque to open, for example, the relief valve assembly may require 3.80 oz-inch of torque to open. The upper limit the relief valve assembly may require 3.9 oz-inch of torque to close where the rotatable valve element 412 is rotated from an open position to a closed position in a single direction of rotation of the rotatable valve element 412. The relief valve assembly may require less torque to close, for example, the relief valve assembly may require 3.24 oz-inch of torque to close.
FIG. 16 shows exemplary results for the low torque relief valve assembly 492 as described above and shown in FIGS. 14-15. The relief valve assembly 492 may generally function as a pilot valve to initiate a flush cycle as shown, and achieve the torque results depicted in FIG. 16. Generally, the relief valve assembly 492 may require 18.8 ounce-inches (oz-inch) of torque to complete a relief valve cycle, on the high end of the test results. One of skill in the art will readily recognize the results show the relief valve can achieve torque values below 18.8 oz-inch. The relief valve cycle includes the rotatable valve element 512 being moved from the closed position to the open position and then back to another, different closed position in a single direction of rotation of the rotatable valve element 512.
The results further show that the upper limit the relief valve assembly may require 9.2 oz-inch of torque to open the relief valve assembly 492 where the rotatable valve element 512 is moved from the closed position to the open position. The relief valve assembly may require less torque to open, for example, the relief valve assembly may require 4.64 oz-inch of torque to open. The upper limit the relief valve assembly may require 9.6 oz-inch of torque to close where the rotatable valve element 512 is rotated from an open position to a closed position in a single direction of rotation of the rotatable valve element 512. The relief valve assembly may require less torque to close, for example, the relief valve assembly may require 3.92 oz-inch of torque to close.
The low-torque relief valve assemblies 392, 492 provide a number of advantages over relief valves with high torque requirements. The low-torque relief valves retain performance features associated with ceramic relief cartridges such as being impervious to water conditions, presenting improved durability with ceramic components, presenting low defective parts per million levels, and eliminating drive shaft O-rings.
Referring now to FIGS. 17-20, a valve assembly 692 according to another aspect of this disclosure is shown in the flush valve assembly 20. The flush valve assembly 20 shares similar features to the flush valve of FIGS. 1, 2, and 6-8. The valve assembly 692; however, as shown, has a lower profile than the flush valve assembly 20 as discussed above. This low-profile flush valve assembly 20 is achieved by changes in the flush valve assembly above the upper chamber 88.
Accordingly, the flush valve assembly 20 shown in FIG. 17 includes the lower housing body 24 that may be connected to an upper housing body 622 such that the upper housing body 622 and lower housing body 24 enclose the flush valve assembly 20. The diaphragm assembly 52 is disposed within the upper housing body 622 and the lower housing body 24 between the inlet 28 and the outlet 32 and includes the diaphragm 56 and the disc 60.
An assembly frame 696 may be connected to the bypass extension 120 that extends downwardly from the assembly frame 696 through the upper chamber 88 and into the diaphragm assembly 52. An upper body 628 of the assembly frame 696 may extend vertically from a lower body 632 of the assembly frame 696. The upper body 628 of the assembly frame 696 may be cylindrical having a hollow inner chamber that defines a top wall of the upper chamber 88. The lower body 632 of the assembly frame 96 may extend radially outward from a bottom surface of the upper body 628 of the assembly frame 696.
A relief valve inlet 534 is positioned in the assembly frame 696 that provides fluid communication from the upper chamber 88 through the assembly frame 696 and into a valve frame 698 and into valve assembly 692.
The valve frame 698 is connected to a top surface of the upper body 628 of the assembly frame 696 at an offset position from the outlet passageway 132 of the flush valve assembly 20. The valve frame 698 may have a valve chamber 720 and an actuation chamber 722, each chamber may have an a diameter and extend into the valve frame 698 in a direction transverse to the bypass extension 120 that extends downwardly from the assembly frame 696 through the upper chamber 88 and into the diaphragm assembly 52. In some forms, the diameter of the valve chamber 720 and the diameter of the actuation chamber 722 may be equal. The valve chamber 720 may receive the valve assembly 692. The actuation chamber 722 may receive an actuation assembly 640 that includes an actuation member 642, a spring 644, and a release element 646.
The valve assembly 692 may have a driving member 708, a rotatable valve element 712, a stationary valve element 716, and a valve seal 736. The valve seal 736 is positioned between the stationary valve element 716 and the valve frame 698.
The driving member 708 may be connected to a shaft 704 of a motor 700. The motor 700 may be mounted to a top surface of the upper body 628 of the assembly frame 696 in an orientation transverse to the bypass extension 120, and aligned with the valve assembly 692. A driving member body 756 may be cylindrical in shape and have radial recesses 658 configured to receive one or more O-ring seals 788 between the motor 700 and a driving member extension 752. A friction washer 798 may be positioned against the driving member extension 752 between the driving member extension 752 and the radial recesses 658. The driving member extension 752 extends radially outward from the driving member body 756.
The driving member 708 may further include an inlet opening 742 and an outlet opening 744. The inlet opening 742 of the driving member 708 may be positioned on a driving surface 750 that contacts the rotatable valve element 712. The outlet opening 744 of the driving member 708 may be positioned on the driving member body 756 between the driving member extension 752 and the driving surface 750. The inlet opening 742 and the outlet opening 744 being in constant fluid communication with one another. The driving member 708 may have a driving arm 754 positioned on the driving surface 750, the driving arm 754 engages the rotatable valve element 712 to selectively rotate the rotatable valve element 712. The driving arm 754 may extend a radial location of the driving surface 750 such that the driving arm 754 can contact side surface of the rotatable valve element 712.
The rotatable valve element 712 may be cylindrical in shape, having opposing flattened driven surfaces 740 and a mating surface 776. In a non-limiting example, the rotatable valve element 712 may have a diameter of 0.250″. The mating surface 776 of the rotatable valve element 712 may be axially-facing and mates with a mating surface 784 of a stationary valve element 716, the respective axially-facing mating surfaces 776, 784 are in contact with each other. The mating surfaces 776, 784 of the rotatable valve element 712 and the stationary valve element 716 contact each other to form a dynamic seal therebetween that prevents fluid communication external a flow path through the relief valve assembly 692. The rotatable valve element 712 may have at least one opening 772 in fluid communication with the inlet opening 742 of the driving member 708, the opening 772 being placed at a radial position from the center of the rotatable valve element 712.
The stationary valve element 716 may be cylindrical in shape, having the mating surface 784 and an inlet surface 786. In a non-limiting example, the stationary valve element 716 may have a diameter of 0.250″. The stationary valve element 716 may have an inlet opening 790 extending through the stationary valve element 716 between the inlet surface 786 and the mating surface 784. Although an inlet opening 790 is shown, a plurality of inlet openings could be employed in the stationary valve element 716. The plurality of openings could be arranged in any appropriate pattern, shape, and/or size.
Fluid is communicated from the valve assembly 692 to the outlet passageway 132 through the assembly frame 696 and the valve chamber 720. The outlet opening 744 in the driving member 708 is connected with an actuation passageway 746 through the valve frame 698, the actuation passageway 746 is defined between the valve chamber 720 and the outlet passageway 132 and the manual override assembly 640 in the assembly frame 696. The actuation passageway 746 is in fluid communication with the outlet passageway 132 through the lower body 128 of the bypass extension 122 of the assembly frame 96. The lower body 128 of the bypass extension 122 is centrally positioned through the diaphragm assembly 52, which connects the actuation passageway 746 with the outlet passageway 132.
The relief valve inlet 534 positioned in the assembly frame 696 provides fluid communication from the upper chamber 88 through the assembly frame 696 and into the valve assembly 692. In a closed position, the inlet opening 790 and the opening 772 are not in fluid communication with one another due to the opening 772 lacking alignment with the inlet opening 790 thereby preventing fluid communication past the inlet opening 790.
In an open position, fluid is communicated from the valve inlet 534 to the inlet opening 790 in the stationary valve element 716. The inlet opening 790 in the stationary valve element 716 is in selective fluid communication with the opening 772 of the rotatable valve element 712 that is in fluid communication with the inlet opening 742 of the driving member 708 based on a rotational position of the rotatable valve element 712 relative to the stationary valve element 716. The rotational position of the rotatable valve element 712 may be controlled by the driving member 708 via the motor 700. Fluid communication is provided through the driving member 708 between the inlet opening 742 and the outlet opening 744. The outlet opening 744 is in fluid communication with the actuation passageway 746 which is in fluid communication with the outlet passageway 132.
The valve assembly 692 may be implemented within the flush valve assembly 20 as a pilot valve to initiate a flush cycle as discussed above with reference to FIGS. 6-8.
The relief valve assembly 692 are low-torque implementations of a valve. The rotatable valve element 712 and the stationary valve element 716 may be manufactured, machined, or formed out of a ceramic material to precise measurements such that a low amount of torque is required to rotate the rotatable valve element 712 against the stationary valve element 716.
FIG. 20 shows exemplary results for the low torque valve assembly 692 as described above and shown in FIGS. 17-19. The relief valve assembly 692 may generally function as a pilot valve to initiate a flush cycle as shown, and achieve the torque results depicted in FIG. 20. Generally, the relief valve assembly 692 may require 16.1 ounce-inches (oz-inch) of torque to complete a relief valve cycle, on the high end of the test results. One of skill in the art will readily recognize the results show the relief valve can achieve torque values below 16.1 oz-inch. The relief valve cycle includes the rotatable valve element 712 being moved from the closed position to the open position and then back to another, different closed position in a single direction of rotation of the rotatable valve element 712.
The results further show that the upper limit the relief valve assembly may require 8.2 oz-inch of torque to open the relief valve assembly 692 where the rotatable valve element 712 is moved from the closed position to the open position. The relief valve assembly may require less torque to open, for example, the relief valve assembly may require 2.90 oz-inch of torque to open. The upper limit the relief valve assembly may require 7.9 oz-inch of torque to close where the rotatable valve element 712 is rotated from an open position to a closed position in a single direction of rotation of the rotatable valve element 712. The relief valve assembly may require less torque to close, for example, the relief valve assembly may require 2.84 oz-inch of torque to close.
It should be appreciated that various other modifications and variations to the preferred embodiments can be made within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced.

Claims

What is claimed is:

1. A low-torque valve for regulating fluid flow between a valve inlet and a valve outlet, the low-torque valve comprising:

a stationary valve element;

a rotatable valve element, the stationary valve element and the rotatable valve element each having a respective axially-facing mating surface in contact with each other and further each having at least one opening in which the stationary valve element and the rotatable valve element are rotationally positionable relative to one another between an open position and a closed position that regulate fluid flow from the valve inlet to the valve outlet based on an alignment of the openings of the stationary valve element and the rotatable valve element;

wherein a torque threshold required to rotate the rotatable valve element into the open position from the closed position is less than 10 ounce-inches.

2. The low-torque valve of claim 1 further comprising:

a valve housing having an internal chamber that receives the stationary valve element and the rotatable valve element, the internal chamber having at least one opening in a peripheral wall providing the valve outlet;

an O-ring seal dimensioned to be received around the valve housing configured to form a seal between the valve housing and a structure into which the valve housing is adapted for reception.

3. The low-torque valve of claim 2 wherein the at least one opening in the peripheral wall of the valve housing extends in a radial direction to accommodate fluid flow in a U-shaped manner up through the valve elements of the low-torque valve, radially out the at least one opening in the peripheral wall to bend the flow, and down between an outer radial wall of the valve housing and a structure into which the valve housing is adapted for reception.

4. The low-torque valve of claim 1 further comprising:

the respective axially-facing mating surfaces of the stationary valve element and the rotatable valve element contact each other to form a dynamic seal therebetween.

5. The low-torque valve of claim 1 wherein a total torque threshold required to complete a valve cycle is less than 12 ounce-inches in which the valve cycle includes the rotatable valve element being moved from the closed position to the open position and then back to another, different closed position in a single direction of rotation of the rotatable valve element.

6. The low-torque valve of claim 1:

wherein the at least one opening in the stationary valve includes an inlet opening and an outlet opening in which the inlet opening is in constant fluid communication with the valve inlet and the outlet opening is in constant fluid communication with the valve outlet;

wherein the rotatable valve element has a patterned recess on the axially-facing mating surface for selectively placing the inlet opening and the outlet opening in fluid communication with one another based on a rotational position of the rotatable valve element relative to the stationary valve element;

wherein in the open position, the inlet opening and the outlet opening are placed in fluid communication with one another by the patterned recess such that the valve inlet to the valve outlet are placed in fluid communication with one another.

7. The low-torque valve of claim 6 wherein patterned recess includes a plurality of channels outwardly extending from a centrally-connected location with the plurality of channels being in fluid communication with one another at the centrally-connected location.

8. The low-torque valve of claim 7 wherein the patterned recess is rotationally symmetrical about a central axis of the rotatable valve element.

9. The low-torque valve of claim 6 wherein the inlet openings and the outlet openings are selectively aligned at 60 degree incremented positions of the rotatable valve element.

10. The low-torque valve of claim 6 wherein the inlet openings and the outlet openings are selectively aligned at 45 degree incremented positions of the rotatable valve element.

11. The low-torque valve of claim 6 wherein, in the open position, there are two points of communication at the axially-facing mating surfaces between the patterned recess in the rotatable valve element and one of the at least one openings in the stationary valve element.

12. The low-torque valve of claim 1, wherein a total torque threshold required to complete a valve cycle is less than 19 ounce-inches.

13. The low-torque valve of claim 1, wherein, a total torque per a valve cycle threshold is less than 9 ounce-inches.

14. The low-torque valve of claim 1, wherein an outer diameter of the stationary valve element and the rotatable valve element is less than 0.5 inches.

15. The low-torque valve of claim 1, wherein the rotatable valve element and the stationary valve element comprise a ceramic material.

16. A flush valve assembly comprising:

a fluid passageway between an assembly inlet and an assembly outlet;

a chamber positioned along the fluid passageway;

a diaphragm assembly positioned in the chamber and bifurcating the chamber into an upper chamber and a lower chamber in which the diaphragm assembly has a diaphragm having a bypass opening that places the upper chamber and the lower chamber in fluid communication with one another, the diaphragm assembly selectively being received at a diaphragm seat to regulate flow between the assembly inlet and the assembly outlet during a flush cycle by controlling fluid communication between the lower chamber and an outlet chamber that connects the lower chamber to the assembly outlet;

the low-torque valve of claim 1, in which low-torque valve is operable as a pilot valve to control a flush cycle by placing the upper chamber and the outlet chamber in selective fluid communication with one another so that, when the low-torque valve is in the open position, a fluid pressure from the upper chamber is released through the low-torque valve to unseat the diaphragm assembly from the diaphragm seat to initiate the flush cycle and, when the low-torque valve in the closed position, the diaphragm assembly re-seats on the diaphragm seat due to an increased fluid pressure on the diaphragm assembly from the upper chamber to end the flush cycle.

17. The flush valve assembly of claim 16 wherein the low-torque valve is axially offset from an axis of the assembly outlet.

18. The flush valve assembly of claim 16 wherein a rotational axis of the low-torque valve is oriented transverse to the assembly outlet.

19. The flush valve assembly of claim 16 wherein the valve changes the direction of fluid flow within the valve itself.

20. The flush valve assembly of claim 16 further comprising:

a power source connected to a motor, the motor providing rotational control to the rotatable valve element to selectively rotate the rotatable valve element into an open position in which the at least one opening in the rotatable valve element aligns with the at least one opening in the stationary valve element thereby providing fluid communication therebetween.

21. A low-torque ceramic valve for regulating fluid flow between a valve inlet and a valve outlet, the low-torque valve comprising:

a stationary disc valve element;

a rotatable disc valve element, the stationary disc valve element and the rotatable disc valve element positioned along a valve axis and each having a respective axially-facing mating surface in contact with each other, the respective axially-facing mating surfaces of the stationary disc valve element and the rotatable disc valve element contact each other to form a dynamic seal therebetween that prevents fluid communication external a flow path through the valve, further the stationary disc valve element and the rotatable disc valve element each having at least one opening in which the stationary disc valve element and the rotatable disc valve element are rotationally positionable relative to one another between an open position and a closed position that regulate fluid flow;

a valve housing having an internal chamber that receives the stationary valve element and the rotatable valve element, the internal chamber having at least one opening in a peripheral wall, the at least one opening in the peripheral wall of the internal chamber provides fluid communication between the rotatable valve element and the valve outlet;

an O-ring seal dimensioned to be received around the valve housing and dimensioned to prevent fluid communication external to a flow path through the valve;

wherein a torque threshold required to rotate the rotatable valve element into the open position is less than 10 ounce-inches.