Reconfigurable Flapper for Different Sized Flush Valves

This patent application is a Continuation of U.S. patent application Ser. No. 17/411,272, filed Aug. 25, 2021, which is now pending, the entire teachings and disclosure of which are incorporated herein by reference thereto. This patent application claims the benefit of U.S. Provisional Patent Application No. 63/070,637, filed Aug. 26, 2020, the entire teachings and disclosure of which are incorporated herein by reference thereto.

This invention generally relates to flush valves for toilets and more particularly to the flapper of a flush valve.

Conventional gravity-operated flush toilets have several basic components. The porcelain or china components include a bowl and a water tank mounted on top of a rear portion of the bowl. The bowl and tank can be separate pieces bolted together to form a two-piece toilet. Other gravity-operated flush toilets are made as a one-piece toilet in which the bowl and tank are made as one continuous integral piece of china.

More importantly, the plumbing components of a gravity-operated flush toilet include a fill valve in the tank which is connected to a water supply line, a drain hole in the bottom of the tank that communicates with the bowl, and a flush valve (also referred to as a flapper valve) that normally closes and seals the drain hole.

Flappers for flush valves are typically formed as a structure having a rim for sealing the drain hole with the flapper valve rim following flushing. The flapper is often formed of a soft elastomeric material and is hinged to allow the flapper to be pivotally moved upwardly and away from the drain hole by means of a chain that is connected to the flush handle on the outside of the tank. Once the tank sufficiently empties, the flapper then returns to a position where it seals the drain hole of the flush valve.

Such flush valve flappers are also typically formed to include a ballast structure which is a dome-like or cone-shaped structure that controls the buoyancy of the flapper. The buoyancy of a flapper is an important function because it determines how much or how little water is emptied from the tank upon flushing, thus creating water conservancy issues. The buoyancy of the flapper is determined by how quickly air is allowed to escape from the ballast.

Unfortunately, toilet flush valves come in different sizes. Two typical flush valve sizes are a 2″ flush valve and a 3″ flush valve. The principle differences between these two sizes is that the diameter of the drain hole and associated valve seat provided thereby, the size of the piping associated therewith, and the flow rate of water out of the drain hole. These features are typically smaller for the 2″ flush valve as compared to the 3″ flush valve.

Due to the differences in sizes, the legs for attaching the flapper to the rest of the flush valve are typically spaced further apart for the 3″ flush valve than the 2″ flush valve, the diameter of the seal for the 3″ flush valve is typically larger than the seal for the 2″ flush valve, and the flapper typically requires a larger amount of buoyancy for the 3″ flush valve to prevent the larger flow of water from overwhelming the flapper and prematurely closing the flush valve.

One problem is thus that a single flapper is typically not conducive to being used with different sized flush valves.

The present application provides improvements over the current state of the art as it relates to toilet flush valves and particularly flapper assembly kits for flush valves of different configurations.

In an example, a toilet flapper assembly kit includes a frame, first and second buoyancy assemblies and first and second seal members. The frame includes a main frame, a pair of adjustable legs and a buoyancy assembly attachment. The pair of adjustable legs adjustably attach to the main frame. The pair of legs are adjustable in at least one of a spacing between the legs or a length of the legs. The buoyancy assembly attachment attaches to the main frame. The buoyancy assembly attachment has a buoyancy assembly attachment interface. The first buoyancy assembly attaches to the buoyancy assembly attachment interface. The first buoyancy assembly provides a first amount of buoyancy when attached to the buoyancy assembly attachment. The second buoyancy assembly attaches to the buoyancy assembly attachment interface. The second buoyancy assembly provides a second amount of buoyancy when attached to the buoyancy assembly attachment. The second amount is different than the first amount. The first seal member has a first characteristic for sealing with a valve seat (e.g. for a drain hole) of a first size flapper valve assembly. The second seal member has a second characteristic for sealing with a valve seat of a second size flapper valve assembly. The second size is different than the first size.

In an example, a toilet flapper assembly kit includes a frame and first and second buoyancy assemblies attachable to the frame.

In a particular embodiment, the frame includes a main frame, a pair of adjustable legs and a buoyancy assembly attachment. The pair of adjustable legs adjustably attach to the main frame. The pair of legs are adjustable in at least one of a spacing between the legs or a length of the legs. The buoyancy assembly attachment attaches to the main frame. The buoyancy assembly attachment has a buoyancy assembly attachment interface. The first buoyancy assembly attaches to the buoyancy assembly attachment interface. The first buoyancy assembly provides a first amount of buoyancy when attached to the buoyancy assembly attachment. The second buoyancy assembly attaches to the buoyancy assembly attachment interface. The second buoyancy assembly provides a second amount of buoyancy when attached to the buoyancy assembly attachment. The second amount is different than the first amount.

In one example, the kit further includes first and second seal members. The first seal member has a first characteristic (e.g. size/shape/material) for sealing with a valve seat of a first size flapper valve assembly. The second seal member has a second characteristic for sealing with a valve seat of a second size flapper valve assembly. The second size being different than the first size.

In one example, a toilet flapper assembly kit includes a frame and first and second buoyancy assemblies is provided. The frame includes a buoyancy assembly attachment having a buoyancy assembly attachment interface. The first buoyancy assembly is attachable to the buoyancy assembly attachment interface. The first buoyancy assembly provides a first amount of buoyancy when attached to the buoyancy assembly attachment. The second buoyancy assembly attaches to the buoyancy assembly attachment interface. The second buoyancy assembly provides a second amount of buoyancy when attached to the buoyancy assembly attachment. The second amount is different than the first amount. In some embodiments, the buoyancy assembly attachment interface may have one feature for attaching the first buoyancy assembly and a second feature for attaching the second buoyancy assembly.

In one example, the toilet flapper assembly kit further includes first and second seal members having different sizes for use in different size flapper valve assemblies.

In one example, a toilet flapper assembly kit includes a frame, first and second buoyancy assemblies and first and second seal members. The frame includes a main frame, a pair of legs including a first leg and a second leg and a buoyancy assembly attachment. The pair of legs are adjustably attachable to the main frame in at least one of a spacing between the legs or a length of the legs. The buoyancy assembly attachment has a first buoyancy assembly attachment interface and a second buoyancy assembly attachment interface that is configured differently than the first buoyancy assembly attachment interface (e.g. size, shape or location). The first buoyancy assembly attaches to the first buoyancy assembly attachment interface. The first buoyancy assembly provides a first amount of buoyancy when attached to the buoyancy assembly attachment. The second buoyancy assembly attaches to the second buoyancy assembly attachment interface. The second buoyancy assembly provides a second amount of buoyancy when attached to the buoyancy assembly attachment. The second amount of buoyancy is different than the first amount. The first seal member attaches to the frame and has a first characteristic for sealing with a valve seat of a first size flapper valve assembly. A second seal member attaches to the frame and has a second characteristic for sealing with a valve seat of a second size flapper valve assembly. The second size being different than the first size.

In one example, the first buoyancy assembly attachment interface is a first annular undercut region and the first buoyancy assembly has a first radially extending annular project that snap engages with the first annular undercut region to secure the first buoyancy assembly to the buoyancy assembly attachment. The second buoyancy assembly attachment interface is a second annular undercut region and the second buoyancy assembly has a second radially extending annular project that snap engages with the second annular undercut region to secure the second buoyancy assembly to the buoyancy assembly attachment.

In one example, the first buoyancy assembly attachment interface has a first diameter and the second buoyancy assembly attachment interface has a second diameter that is different than the first diameter.

In one example, each leg of the pair of legs has a first end attached to the main frame and a second end configured to mount the leg to a support in a pivotable manner about a flapper pivot axis (typically provided by attachment posts of the flush valve). The buoyancy assembly attachment is attachable to the main frame between first and second orientations. The first buoyancy assembly attachment interface and the second buoyancy assembly attachment interface are spaced farther from the flapper pivot axis in the first orientation than in the second orientation.

In one example, the first and second buoyancy assembly attachment interfaces define a central axis and are axially offset from one another along the central axis.

In one example, the main frame and buoyancy assembly attachment have a pin and receiver connection interface including an attachment pin extending from one of the main frame and the buoyancy assembly attachment and an attachment pin receiver provided by the other one of the main frame and the buoyancy assembly attachment. The attachment pin or attachment pin receiver provided by the buoyancy assembly attachment is positioned in a non-rotation symmetric manner relative to a central axis of the buoyancy assembly attachment such that insertion of the attachment pin into the attachment pin receiver along an insertion axis with a first relative angular orientation about the insertion axis positions the first and second buoyancy attachment interfaces in a first position relative to the pair of legs and insertion of the attachment pin into the attachment pin receiver along the insertion axis with a second relative angular orientation about the insertion axis positions the first and second buoyancy attachment interfaces in a second position relative to the pair of legs.

In one example, the attachment pin is insertable into the attachment pin receiver in a discrete number of relative angular orientations about the insertion axis with at least two of the discrete number of relative angular orientations being angularly spaced apart about the insertion axis 180 degrees.

In one example, the attachment pin receiver has a non-circular inner periphery and the attachment pin has an alignment portion that has a non-circular outer periphery. The inner periphery of the attachment pin receiver and outer periphery of the alignment portion engage to inhibit angular motion between the main frame and buoyancy assembly attachment when engaged.

In one example, the buoyancy assembly attachment includes a first key and a second key. The first buoyancy assembly has a third key that engages the first key when the first buoyancy assembly is attached to the buoyancy assembly attachment. The second buoyancy assembly has a fourth key that engages the second key when the second buoyancy assembly is attached to the buoyancy assembly attachment. The engagement of the first and third keys orients the first buoyancy assembly at a different angular orientation about a central axis of the buoyancy assembly attachment than the angular orientation of the second buoyancy assembly about the central axis when the second and fourth keys engage.

In one example, one of the first key and the third key is a first notch and the other one of the first key and the third key is a first projection. One of the second key and the fourth key is a second notch and the other one of the second key and fourth key is a second projection.

In one example, the first characteristic is an outer diameter of the first seal member. The second characteristic is an outer diameter of the second seal member. The second diameter being different than the first diameter.

In one example, the main frame and the buoyancy assembly attachment are formed as a one-piece, unitary body formed from a continuous piece of material.

In one example the first buoyancy assembly has a first volume and the second buoyancy assembly has a second volume that is less than the first volume.

In one example, the frame includes a seal mounting groove that opens in a radially outward direction. The bottom (e.g. radially innermost surface) of the mounting groove has a groove diameter. The first and second seal members each has an inner diameter that is substantially equal to the groove diameter such that the first seal member may be mounted to the frame within the mounting groove or the second seal member may be mounted to the frame within the mounting groove.

In one example, the mounting groove is provided by the buoyancy assembly attachment.

In one example, the frame includes first and second pairs of leg mounting features. Each pair including an inner leg mounting feature and an outer leg mounting feature. The first and second pairs of leg mounting features are laterally spaced apart. The first and second inner leg mounting features being positioned laterally between the first and second outer leg mounting features. The first leg has a first cooperating feature configured to engage, selectively, the first inner and outer leg mounting features to vary a position of the first leg relative to the frame. The second leg has a second cooperating feature configured to engage, selectively, the second inner and outer leg mounting features to vary a position of the second leg relative to the frame. The first inner and outer leg mounting features are first male connectors and the first cooperating feature is a first female connector. Each first male connector has an anti-rotation boss, an offset boss, and an oblong head portion. The offset boss is interposed between the anti-rotation boss and the oblong head portion. Each first male connector defines a first leg mounting axis. The first female connector includes an opening having an anti-rotation region having an inner periphery sized and shaped to engage the anti-rotation bosses to inhibit rotation of the first leg relative to the frame about the first leg mounting axis absent elastic deformation of one or both of the anti-rotation boss or the anti-rotation region. The first female connector includes a throat region offset from or provided by the anti-rotation region having an oblong cross-section sized and/or shaped to receive the oblong head therethrough when the first leg is in a first angular orientation about the first leg mounting axis relative to the frame and sized and/or shaped to prevent the oblong head from passing therethrough when the first leg is in a second angular orientation about the first leg mounting axis relative to the frame. The second inner and outer leg mounting features are second male connectors and the second cooperating feature is a second female connector. Each second male connector has an anti-rotation boss, an offset boss, and an oblong head portion. The offset boss is interposed between the anti-rotation boss and the oblong head portion. Each second male connector defines a second leg mounting axis. The second female connector includes an opening having an anti-rotation region having an inner periphery sized and shaped to engage the anti-rotation bosses to inhibit rotation of the second leg relative to the frame about the second leg mounting axis absent elastic deformation of one or both of the anti-rotation boss or the anti-rotation region. The second female connector includes a throat region offset from or provided by the anti-rotation region having an oblong cross-section sized and/or shaped to receive the oblong head therethrough when the second leg is in a first angular orientation about the second leg mounting axis relative to the frame and sized and/or shaped to prevent the oblong head from passing therethrough when the second leg is in a second angular orientation about the second leg mounting axis relative to the frame.

In an example, a method of assembling a flapper assembly is provided. The method includes providing a flapper assembly kit as outlined above. The method includes attaching the first and second legs to the frame with a selected spacing therebetween. The method includes selecting one of the first or second buoyancy assemblies. The method includes attaching the selected one of the first or second buoyancy assemblies to the frame.

In one example, the method includes selecting one of the first or second seal members. The method includes attaching the selected one of the first or second seal members to the frame.

Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.

illustrates a flapper assembly kitfor use in toilet flush valves. The flapper assembly kitallows for a single kit to be provided for different sized toilet flush valves. For example, the flapper assembly kitcan be configured to provide a flapper assemblyfor a 2″ flush valve() or configured to provide a flapper assemblyfor a 3″ flush valve(). While 2″ and 3″ flush valves,are referenced herein, other size flush valves could be incorporated into the flapper assembly kit.

With reference to, the flapper assembly kitincludes a frame, a first buoyancy assembly(also referred to as a ballast), a second buoyancy assembly(also referred to as a ballast), a first seal memberand a second seal member.

In this embodiment, the frameincludes a main frame member(also referred to simply as a main frame), first and second legs(only one of which is illustrated in) and a buoyancy assembly attachment(also referred to as a top cone). While these components are illustrated as separate components in this kit, various ones or all of these components, in other embodiments, could be combined into single component formed from a single continuous piece of material. For example, some embodiments may have the main frame memberand the top coneformed as a single component. Alternative embodiments, could have the main frame memberand the legsformed as a single component.

With additional reference to), the legspivotally connect the flapper assembly,to attachment posts,for motion about flapper pivot axes,, respectively. This allows the user to open the flush valve,by pivoting the flapper assembly,away from the corresponding valve seats,of corresponding valve bodies,, illustrated by arrows,.

illustrate a single leg. While two legs are provided in a flapper assembly,, the legsare identical so a single leg only need be described. Legextends between a first endconfigured for selective attachment to the main frameand a second endfor attachment to the attachment posts,. In this embodiment, the second endcan be resiliently snap attached to attachment posts,as well as to allow for the pivotal motion of the flapper assembly,, once attached to the attachment posts,.

illustrate the main frame member. The main frame memberincludes a plurality of leg mounting features(also referred to herein as male connectors) forming first and second pairs of leg mounting features,(one pair for one leg and the other pair for the other leg). Each leghas a cooperating mounting feature(also referred to herein as female connectors) proximate the first endthat can be selectively engaged with the leg mounting features.

In this embodiment, the main frameis symmetrical along a center line() and the first and second pairs of leg mounting features,are laterally spaced apart along axisthat is perpendicular to center line. Further, within a particular pair,, the leg mounting featuresare laterally spaced apart from one another along axisdefining inner and outer mounting features (e.g. inner mounting features are closer to center lineand the inner mounting featuresare located latterly between the outer mounting features). The lateral spacing provided by the leg mounting featuresprovides different spacing S between the second endsof the legsto accommodate different sized pipes/valve bodies,from which posts,extend (see e.g.).

In this embodiment, the leg mounting featuresare male connectorsin the form of axially extending pins.

Each male connectordefines a leg mounting axisalong which a legreceives the male connectorduring assembly. Each male connector, in this example, includes an anti-rotation boss, an offset bossand an oblong head portion. The offset bossoffsets the anti-rotation bossfrom the oblong head portion.

With reference to, the anti-rotation bosshas a non-circular outer periphery that cooperates with a corresponding anti-rotation regionof the female connectorsof the legs. The anti-rotation regionof the female connectors, in this example, have a square inner periphery that is sized and shaped to engage with the outer periphery of the anti-rotation boss. This non-circular engagement inhibits undesirable rotation of the legsrelative to the main frameabout leg mounting axis. In some embodiments, the anti-rotation bossand anti-rotation regionare configured to allow for plastic deformation so that the legscan be rotated relative to the main frameupon the application of sufficient torque, but not under normal use once assembled in the flush valve,.

The oblong head portionprevents axial disengagement of the female connectorsof legsfrom the male connectorsof the main frame member. More particularly, the female connectorincludes a throat regionthat is sized and shaped to receive the oblong head portiontherethrough in a first angular orientation about axisof the legsrelative to the main frame member, but that prevents axial removal of the oblong head portiontherethrough in a second angular orientation about axisof the legsrelative to the main frame. As illustrated in, the height H1 of the throat regionis greater than the width W1 such that the throat regionis oblong as well. Similarly, the length L1 of the oblong head portionis greater than width W2 of the oblong head portion. Notably, the length L1 is greater than the width W1 of the throat region. Thus, when the width W1 is aligned with the length L1, the oblong head portioncannot pass through the throat region.

Notably, the female connectorshave an enlarged regionthat is sized to allow for rotation of the oblong head portiontherein about axis.

Therefore, to attach a legto the main frame member, the user aligns the oblong head portionwith the throat region, inserts the male connectorinto the female connectorwith the head portionpast the throat regionand then rotates the leg about axis. When properly axially inserted, the anti-rotation bosswill be received in the anti-rotation regionand sufficient force will need to be applied to cause elastic deform of one or both of the main frame memberor the legto allow for the rotation. Once properly rotated, the legwill be locked to the main frame member.

As will be appreciated, the user will select which male connectorsto attach the legs(e.g. both legs will typically be mounted to the outer male connectorsfor larger flush valves while both legs will typically be mounted to the inner male connectorsfor smaller flush valves).