Automatic Flush Actuation Unit and Automatic Flush Detection Sensors

This application is a non-provisional of, and claims priority to, U.S. Provisional Application No. 63/687,119, filed Aug. 26, 2024, and U.S. Provisional Application No. 63/572,456, filed Apr. 1, 2024, both of which prior applications are incorporated by reference herein and made part hereof.

This disclosure relates to automatic flush actuation units for pressure-assisted flush tanks, and more specifically to an actuation unit having greater mounting versatility and/or a lower profile when installed, and low-power flush detection sensors for automatic flush actuation units.

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 compressed, such that the compressed air provides the energy and pressure for discharging the water in the tank, and a flush cartridge that operates to open and close the discharge opening of the tank. Various different tank sizes and configurations may be used in pressure-assisted flushing systems, which may provide different flush volume capabilities. Some such systems include an automatic flush actuator, which uses an automated mechanism to actuate the flush cartridge to initiate the flush cycle. An automatic flush actuator may be activated by a manual input (e.g., a push button) and/or an electronic input (e.g., an infrared user sensor) that may be activated based on sensing user presence, hand gestures, etc. Examples of pressure-assisted flushing systems are available from Flushmate® of New Hudson, MI, which may include the INTELLI-Flush™ automatic flush actuator, as illustrated in. Conventional flushing systems lack efficient methods of communicating between electronic inputs and associated components, causing inefficiencies in the use of the electronic inputs that can lead to higher energy consumption and reduced battery life.

The present disclosure is provided to address this need and other needs in existing automatic flush actuators. 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.

Aspects of the disclosure relate to an automatic flush actuator configured for connection to a first pressure-assist flush tank having a first mounting structure and a second pressure assist flush tank having a second mounting structure different from the first flush tank. The automatic flush actuator includes a housing configured for connection to the first flush tank and the second flush tank, the housing having a first set of first mounting holes configured for connection to the first mounting structure of the first flush tank by receiving fasteners therethrough, and a second set of second mounting holes arranged differently from the first mounting holes and configured for connection to the second mounting structure of the second flush tank by receiving the fasteners therethrough, a motor supported by the housing, an actuator supported by the housing, and a gear assembly supported by the housing and coupled to the motor and the actuator. The actuator is selectively moveable to an actuation position where the actuator is configured to actuate a first flush valve of the first flush tank in the first mounting configuration, and to actuate a second flush valve of the second flush tank in the second mounting configuration. The gear assembly is configured to transfer power from the motor to the actuator to cause movement of the actuator to the actuation position.

According to one aspect, the housing further includes mounting projections extending downward from an underside of the housing, each of the mounting projections having one of the first mounting holes extending axially therethrough, wherein the mounting projections are configured to engage the first mounting structure of the first flush tank. In one configuration, each of the mounting projections has a plurality of fins extending outward around the respective mounting projection, wherein the plurality of fins have ends extending downward beyond a distal end of the respective mounting projection, and wherein each mounting projection is configured to engage the first mounting structure of the first flush tank by having a portion of the first mounting structure received between the ends of the plurality of fins. In one configuration, the housing further includes mounting recesses on the underside of the housing, the mounting recesses spaced from the mounting projections, each of the second mounting holes being open within one of the mounting recesses, wherein the mounting recesses are configured to receive portions of the second mounting structure of the second flush tank. In this configuration, each of the mounting recesses may be defined by a ridge extending around the respective second mounting hole on the underside of the housing.

According to another aspect, the housing further includes mounting recesses on the underside of the housing, each of the second mounting holes being open within one of the mounting recesses, wherein the mounting recesses are configured to receive portions of the second mounting structure of the second flush tank. In one configuration, each of the mounting recesses is defined by a ridge extending around the respective second mounting hole on the underside of the housing.

In a further configuration, the first mounting holes include four first mounting holes arranged in a first quadrilateral shape, and the second mounting holes include four second mounting holes arranged in a second quadrilateral shape that is different from the first quadrilateral shape.

In yet another configuration, the actuator includes a rotating cam that is selectively moveable by rotation between a retracted position and the actuation position, where the rotating cam has an engagement portion that extends out of the housing in the actuation position and is configured to engage the first flush valve, and wherein the rotating cam is biased to the retracted position.

Additional aspects of the disclosure relate to a pressure assist toilet flushing system including a flush tank defining an internal cavity with an inlet configured for intake of water into the internal cavity, an outlet configured for discharge of water from the internal cavity, and a flush valve configured to control discharge of water through the outlet, the flush valve having a plunger accessible on a top of the flush tank, the flush tank having a plurality of mounts arranged on the top of the flush tank around the plunger, and an automatic flush actuator. The automatic flush actuator includes a housing having a first set of first mounting holes and a second set of second mounting holes arranged differently from the first mounting holes, wherein the housing is mounted on the flush tank such that a plurality of fasteners are received in the first mounting holes and engage the mounts of the flush tank, and wherein the second mounting holes are configured for connection to another flush tank having a different mounting structure from the flush tank, a motor supported by the housing, and an actuator supported by the housing and operably coupled with the motor. The actuator is selectively moveable to an actuation position where the actuator is configured to engage the plunger of the flush valve.

According to one aspect, the actuator includes a rotating cam that is selectively moveable by rotation between a retracted position and the actuation position, where the rotating cam has an engagement portion that extends out of the housing in the actuation position to engage the plunger, and wherein the rotating cam is biased to the retracted position.

According to another aspect, the housing further includes mounting projections extending downward from an underside of the housing, each of the mounting projections having one of the first mounting holes extending axially therethrough, wherein the mounting projections are configured to engage the mounts of the flush tank. In one configuration, each of the mounting projections has a plurality of fins extending outward around the respective mounting projection, wherein the plurality of fins have ends extending downward beyond a distal end of the respective mounting projection, and wherein the mounting projections are configured to engage the mounts of the flush tank by having the mounts received between the ends of the plurality of fins.

According to a further aspect, the housing further includes mounting recesses on the underside of the housing, each of the first mounting holes being open within one of the mounting recesses, wherein the mounting recesses are configured to receive portions of the mounts of the flush tank. In one configuration, each of the mounting recesses is defined by a ridge extending around the respective first mounting hole on the underside of the housing.

According to yet another aspect, the first mounting holes include four first mounting holes arranged in a first quadrilateral shape, and the second mounting holes comprise four second mounting holes arranged in a second quadrilateral shape that is different from the first quadrilateral shape.

Further aspects of the disclosure relate to a method including sending, by an infrared sensor and using a first pulse mode, a first signal, determining, by the infrared sensor and based on sending the first signal, that an object is located within a threshold distance from the infrared sensor, activating, based on determining that the object is located within the threshold distance, a second pulse mode for the infrared sensor, sending, using the second pulse mode, a second signal from the infrared sensor, determining, based on sending the second signal, that an activation condition corresponding to the object is satisfied, sending, to a first device, a request to cause execution of a flushing function, and receiving, from the first device, a message confirming execution of the flushing function.

According to one aspect, determining that the object is located within the threshold distance includes detecting an amount of infrared light received, based on sending the first signal, by the infrared sensor, and determining whether the amount of infrared light satisfies a threshold amount of infrared light.

According to another aspect, the first pulse mode includes a single-pulse mode and the second pulse mode includes a multi-pulse mode.

According to a further aspect, the second signal includes at least one infrared pulse having a first width, and a plurality of infrared pulses having a second width.

According to yet another aspect, determining that the activation condition is satisfied includes determining that the object is located outside of the threshold distance.

According to an additional aspect, determining that the activation condition is satisfied includes determining that the object has moved within a predetermined range of motion relative to the infrared sensor.

According to another aspect, sending the request to cause execution of the flushing function comprises opening a communication window between the infrared sensor and the first device. In one configuration, the communication window is closed after receiving the message.

According to another aspect, the message includes an indication that the first device executed the flushing function.

According to another aspect, the message includes an indication of a battery level of the first device.

According to another aspect, activating the second pulse mode includes charging a capacitor for a predetermined period of time, determining a pulse sequence corresponding to the second pulse mode, and determining, for each pulse of a plurality of pulses in the pulse sequence, a pulse width.

According to another aspect, the predetermined amount of infrared light includes a predetermined number of watts.

According to another aspect, the method further includes deactivating, based on receiving the message, the second pulse mode, and reactivating the first pulse mode.

According to another aspect, the first signal includes a pulse wave transmitted approximately every second for a duration of approximately twenty-five microseconds.

According to another aspect, the second signal includes at least one pulse wave transmitted approximately every two hundred and fifty milliseconds for a duration of approximately one microsecond.

Other aspects of the disclosure relate to one or more non-transitory computer-readable media storing instructions that, when executed by one or more processors, cause a sensor to perform a method as described herein.

Further aspects of the disclosure relate to a sensor including a transmitter, a receiver, one or more processors, and memory storing instructions that, when executed by the one or more processors, configure the sensor to perform actions. Such actions include sending, using a first pulse mode, a first signal; determining, based on sending the first signal, that an object is located within a threshold distance from the sensor; activating, based on determining that the object is located within the threshold distance, a second pulse mode for the sensor; sending, using the second pulse mode, a second signal; determining, based on sending the second signal, that an activation condition corresponding to the object is satisfied; sending, to a first device, a request to cause execution of a flushing function; and receiving, from the first device, a message confirming execution of the flushing function.

According to one aspect, the transmitter includes an infrared transmitter, and/or the receiver includes one or more photoreceptor cells.

According to another aspect, determining that the object is located within the threshold distance includes detecting an amount of infrared light received, based on sending the first signal, by the receiver, and determining whether the amount of infrared light satisfies a threshold amount of infrared light.

According to a further aspect, the first pulse mode includes a single-pulse mode and the second pulse mode includes a multi-pulse mode.

According to yet another aspect, the second signal includes at least one infrared pulse having a first width, and a plurality of infrared pulses having a second width.

According to a still further aspect, determining that the activation condition is satisfied includes determining that the object is located outside of the threshold distance.

According to an additional aspect, determining that the activation condition is satisfied includes determining that the object has moved within a predetermined range of motion relative to the sensor.

Still further aspects of the disclosure relate to a system that contains a sensor including a transmitter, a receiver, one or more processors, and memory storing instructions that, when executed by the one or more processors, configure the sensor perform actions. Such actions include sending, using a first pulse mode, a first signal; determining, based on sending the first signal, that an object is located within a threshold distance from the sensor; activating, based on determining that the object is located within the threshold distance, a second pulse mode for the sensor; sending, using the second pulse mode, a second signal; determining, based on sending the second signal, that an activation condition corresponding to the object is satisfied; sending a request to cause execution of a flushing function; and receiving a message confirming execution of the flushing function. The system also includes a first device configured to receive, from the sensor, the request to cause execution of the flushing function, and send, to the sensor, the message confirming execution of the flushing function.

According to one aspect, the transmitter includes an infrared transmitter, and/or the receiver includes one or more photoreceptor cells.

According to another aspect, determining that the object is located within the threshold distance includes detecting an amount of infrared light received, based on sending the first signal, by the receiver, and determining whether the amount of infrared light satisfies a threshold amount of infrared light.

According to a further aspect, the first pulse mode includes a single-pulse mode and the second pulse mode includes a multi-pulse mode.

According to yet another aspect, the second signal includes at least one infrared pulse having a first width, and a plurality of infrared pulses having a second width.

According to a still further aspect, determining that the activation condition is satisfied includes determining that the object is located outside of the threshold distance.

According to an additional aspect, determining that the activation condition is satisfied includes determining that the object has moved within a predetermined range of motion relative to the sensor.

Other features and advantages of the disclosure will be apparent from the following description taken in conjunction with the attached drawings.

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, there is shown an example of a pressure assist toilet flushing systemthat includes a tankdefining an internal cavity, with an inletand an outletfor intake and discharge of water, and a flush valveconfigured for selectively opening and closing a valve leading to outletto control discharge of water. The flush valvemay be in the form of a replaceable flush cartridge mounted within a receiverin the tank, such that a portion of the flush cartridge is accessible outside the tankand the flush valveis positioned within the cavity to interact with an internal seal surface around the outlet. The flush valveinhas a plungerthat is depressed to open the flush valve, and the flush valvemay be positioned such that the plungeris accessible through the topof the tank, as shown in. In this configuration, the receiveris open at the topof the tankand the flush valveis sealed within the receiver, such as by threading and one or more gaskets, to seal the tank. The tankmay be constructed of a lower housing or baseforming a bottom portion of the tank, and an upper housing or coverforming a top portion of the tank, such that the baseand the covercombine to define the internal cavity. The coverinincludes the receiver, as well as a recesspositioned around the receiver, and the baseincludes the outlet. The baseand the covermay be made from plastic (including, e.g., fiber-reinforced plastic). The outletis typically connected to a toilet bowl (not shown), such that water discharged from the outletaccomplishes flushing of the bowl. In one embodiment, the tankmay 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 systemalso includes an air inducer assemblyconnected to the inletand to a water inlet conduit, which is configured to introduce liquid (e.g., water) and gas (e.g., air) into the tank. Air is drawn into and through the air inducer assemblyas the water passes through the air inducer assemblyfrom the water inlet conduit, e.g., by the Venturi effect, such that water and air pass through the inletinto the tank. This pressurizes the tank, such that water can be forced into the toilet for improved flushing.

The combination of the tank, the flush valve, and the air inducer assemblyinmay be configured for creating a flush volume of 1.6 gallons per flush (gpf) or 1.28 gpf.illustrate another embodiment of a systemthat includes the same or similar features and components as the system in, including a tank, a flush valve, and an air inducer assemblythat include the same or similar features to the corresponding components in the embodiment of. The same reference numbers are used to refer to corresponding similar components in describing the embodiments of. The tankinhas a peripheral shape and a size that are different from the embodiment of, and may also include internal components that are differently configured. The combination of the tank, the flush valve, and the air inducer assemblyinmay be configured for achieving a smaller flush volume than in the embodiment of, for example a flush volume of 1.0 gpf.

The flush valvemay be actuated in a variety of different ways, including through use of mechanical means, electronic means, or a combination of the two, to push the plunger. Multiple actuation mechanisms may be used in some embodiments, including a mechanical actuator (e.g., a lever) and/or an electromechanical actuator (e.g., an electronically-actuated cam).

The systemsinuse an automatic flush actuation unit or automatic flush actuatorthat actuates the flush valveto initiate the flush cycle. The systemas shown inalso includes a manual input deviceand an electronic input devicethat are electronically connected to the automatic flush actuatorto transmit a signal to the automatic flush actuatorto actuate the flush valve, as shown in. The manual input deviceis configured for mounting on the side of the toilet tank (not shown), e.g., in place of the actuation lever, and includes a buttonthat can be pushed by the user to activate the automatic flush actuator. The electronic input deviceis configured for mounting on the wall above the toilet and includes a wall plateand a sensor, which may be an infrared (IR) sensor or other user sensor. The electronic input devicemay send a signal to activate the automatic flush actuatorbased on sensing a user and/or an action of the user. For example, the electronic input devicemay sense the presence of a user, the user stepping away from the toilet, a gesture (e.g., a hand wave) by the user, or other user action. Additionally, the logic determining when a user action may activate the automatic flush actuatormay be stored and processed at the automatic flush actuatorand/or at the electronic input device, or elsewhere. It is understood that the systeminmay include the same or similar configuration, such as the use of the same or similar manual input deviceand automatic flush actuator.