Reconfigurable Flapper Assembly for Toilet Flush Valve

This patent application claims the benefit of U.S. Provisional Patent Application No. 63/649,766, filed May 20, 2024, 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 seal member 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 relative to the valve body of the flush valve to allow the flapper to be pivotally moved upwardly and away from the drain hole by means of a pull 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 body.

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. Three typical flush valve sizes are 2″, 3″, and 3.5″ flush valves. The principal differences between these three 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″ and 3.5″ flush valve. Additionally, the spacing of the center of the drain hole relative to the pivotal connection between the flapper and the valve body may vary.

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″ and 3.5″ flush valves than the 2″ flush valve, the diameter of the seal for the 3″ and 3.5″ flush valves is typically larger than the seal for the 2″ flush valve, and the flapper typically requires a larger amount of buoyancy for the 3″ and 3.5″ flush valves to prevent the larger flow of water from overwhelming the flapper and prematurely closing the flush valve. Further, the spacing between the connection of the legs to the valve body and the center of the seal member is often greater for the larger flush valve.

One problem is thus that a single flapper is typically not conducive to being used with different sized flush valves. Further improvements in providing a reconfigurable flapper assembly are desirable.

Further, in some situations, after the toilet has been flushed and the handle has been released, the flapper will remain in an open orientation as the tank has not sufficiently drained to allow for the flapper to seal on the valve body. However, the chain will drop rapidly and can get tangled around various components of the flapper.

A further problem is that the valve seats of the valve bodies may vary in size, shape, and orientation such that for one universal flapper assembly (or kit) to be used with different valve seats, the seal member may need to be pivotal relative to frame of the flapper to properly adjust the seal members orientation to mate with the valve seat in a generally flat orientation. Given the large number of flush valve configurations, the seal member may need to have 15 degrees range of motion.

However, the further the point that serves as the axis of rotation for the flapper is from the sealing face, the harder it is for the flapper to swing in either direction so as to lay flat on the valve seat. If a large moment arm is provided between the seal face of the seal member and the pivotal connection that allows for the pivoting motion of the seal member, abrasion of the seal member and seal face can occur. Further, this can result in binding or the flapper getting stuck on the valve body causing a fast leak failure.

The present disclosure includes new and improved flapper assemblies that rectify one or more deficiencies in the current state of the art.

In one example, a flapper assembly for a flush valve for a toilet is provided. The flapper assembly may be actuatable by a pull chain that has a first chain link. The first chain link has a length, a width and a thickness. The flapper assembly includes a frame and a chain link connector. The frame defines a pivot axis about which the frame rotates in operation during flushing operations. The frame has an upward opening chain link receiving slot spaced from the pivot axis. The upward opening chain link receiving slot is configured to receive the first chain link therein with at least a portion of the chain link extending out of the chain link receiving slot. The chain link connector is configured to secure the first chain link within the chain link receiving slot.

In one example, the chain link connector is a ring member that extends around a portion of the frame adjacent the chain link receiving slot and through the first chain link.

In one example, a chain tube extends around the pull chain and the first chain link. The chain tube has an axial length that's at least twice that of an axial length of the first chain link.

In one example, the chain tube is sized to maintain the portion of the pull chain within the chain tube in a substantially straight orientation with the first chain link. A portion of the portion of the first chain link extending from the chain link receiving slot being received within the chain tube.

In one example, a width and a thickness of the chain link receiving slot are substantially equal to the width and thickness of the first chain link. This may provide a friction fit between the chain link and the portion of the frame defining the chain link receiving slot.

In one example, the chain link receiving slot is sized and configured to prevent more than plus or minus 15 degrees of pivotal movement of the first chain about an axis that is parallel to the thickness of the first chain link when the chain link is inserted into the chain link receiving slot.

In one example, the chain link receiving slot is sized to have a friction fit with the first chain link.

In one example, a chain tube clip is attachable to the pull chain. The chain tube clip limits axial movement of the chain tube along the pull chain away from the first chain link and frame when assembled thereto.

In another example, flapper assembly for a flush valve for a toilet is provided. The flush valve has a valve seat. The flapper assembly includes a seal member having a first side providing a sealing face configured to seal with the valve seat and a second side providing a back support face opposite the first side. The flapper assembly includes a frame assembly including a main frame, a seal support body and a pivotal connection arrangement. The main frame is operably configured to pivotally attach to the valve body of a toilet. This may be done by snap connecting to pivot points of the valve body. The seal support body has a seal support flange defining a seal support surface. The seal support surface defining a support plane. The seal member is attachable to the frame assembly with the back support face facing the seal support surface of the seal support flange. The sealing face faces away from the seal support surface.

The pivotal connection arrangement pivotally connects the seal support body to the main frame. The pivotal connection arrangement has a first portion provided by a first arm member of the main frame and a second portion provided by the seal support body. One of the first and second portions is a first pivot pin and the other one of the first and second portions is a first pin receiver. The first pin receiver pivotally receives the first pivot pin to pivotally connect the seal support body for pivotal movement about a pivot axis to the first arm of the main frame. The pivot axis is substantially parallel to the support plane. The first pivot pin has an outermost pivot surface positioned closest to the seal member. The outermost pivot surface having an outermost extent that is substantially co-planar with the support plane.

In one example, the outermost extent of the outermost surface is no further than 2 millimeters from the support plane.

In one example, the outermost extent of the outermost surface is positioned coplanar with or on a side of the support plane opposite the sealing face.

In one example, the first arm provides the first pin receiver therein.

In one example, the first arm has a distal end providing an outermost extent of the first arm. The outermost extent of the first arm is positioned on a first side of the support plane. The sealing surface is on the first side of the support plane.

In one example, the seal support body defines an aperture therethrough. The first arm extends through the aperture in the seal support body.

In an example, a flapper assembly for a flush valve for a toilet is provided. The flush valve has a valve seat provided by a valve body. The flapper assembly has a seal member and a frame assembly. The seal member has a first side providing a sealing face configured to seal with the valve seat and a second side providing a back support face opposite the first side. The frame assembly includes a main frame, a seal support body, and a pivot connection arrangement. The main frame is operably configured to pivotally attach to the valve body of a toilet. The seal support body has a seal support flange defining a seal support surface. The seal support surface defines a support plane. The seal member is attachable to the frame assembly with the back support face facing the seal support surface of the seal support flange and the sealing face facing away from the seal support surface. The pivotal connection arrangement pivotally connects the seal support body to the main frame. The pivotal connection arrangement has a first portion provided by a first arm member of the main frame and a second portion provided by the seal support body. One of the first and second portions is a first pivot pin and the other one of the first and second portions is a first pin receiver. The first pin receiver pivotally receives the first pivot pin to pivotally connect the seal support body for pivotal movement about a pivot axis to the first arm of the main frame. The pivot axis is substantially parallel to the support plane. The first arm has a distal end that provides an outermost extent of the first arm. Both the outermost extent of the first arm and the sealing surface are positioned on a same first side of the support plane.

In one example, the seal support body defines an aperture therethrough. The first arm extends through the aperture in the seal support body.

In one example, the outermost extent of the first arm is positioned between the support plane and the sealing surface.

In one example, a gap is formed between the back support face of the seal member and the seal support surface of the seal support flange.

In one example, the pivotal connection arrangement includes a third portion provided by a second arm member of the main frame and a fourth portion provided by the seal support body. One of the third and fourth portions is a second pivot pin and the other one of the third and fourth portions is a second pin receiver. The second pin receiver pivotally receives the second pivot pin to pivotally connect the seal support body for pivotal movement about the pivot axis to the second arm of the main frame. The second arm has a distal end that provides an outermost extent of the second arm. The outermost extent of the second arm is positioned on a same first side of the support plane.

In one example, the first and second pivot pins extend axially away from one another.

In an example, a flapper assembly for a flush valve for a toilet is provided. The flush valve a valve seat provided by a valve body. The flapper assembly includes a seal member and a frame assembly. The seal member has a first side providing a sealing face configured to seal with the valve seat. The frame assembly includes a main frame which includes a main body and first and second legs. The main frame is operably configured to pivotally attach to the valve body of a toilet for pivotal movement about a pivot axis between a seated position and an unseated position. The main body has first, second, third and fourth attachment locations. Each attachment location has an attachment abutment facing away from the pivot axis. The first and second attachment locations are spaced apart a first distance from one another parallel to the pivot axis. The third and fourth attachment locations spaced apart a second distance from one another different than the first distance.

The first leg has a first body portion selectively attachable to the first and third attachment locations and a first pivot lever attached to the first body portion at a first fulcrum. The first pivot lever includes a first lever arm and a first lever abutment. The first pivot lever is configured such that when the first body portion is attached to the first or third attachment location and the first lever arm is moved in a first direction relative to the first fulcrum the first lever abutment disconnects from the attachment abutment of the corresponding one of the first or third attachment locations. The second leg has a second body portion selectively attachable to the second and fourth attachment locations. The second leg has a second pivot lever attached to the second body portion at a second fulcrum. The second pivot lever includes a lever arm and a second lever abutment. The second pivot lever is configured such that when the second body portion is attached to the second or fourth attachment location and the second lever arm is moved in a first direction relative to the second fulcrum the second lever abutment disconnects from the attachment abutment of the corresponding one of the second or fourth attachment locations.

In one example, the first lever arm is located on a first side of the first fulcrum and the first lever abutment is located on a second side of the first fulcrum. As such, when the first lever arm is moved towards the first body portion, the first lever abutment moves away from the first body portion. The second lever arm is located on a first side of the second fulcrum and the second lever abutment is located on a second side of the second fulcrum. As such, when the second lever arm is moved towards the second body portion, the second lever abutment moves away from the second body portion.

In one example, the first lever arm and first lever abutment pivot about the first fulcrum. The second lever arm and the second lever abutment pivot about the second fulcrum.

In one example, the first, second, third and fourth attachment locations each have a leg post defining a polarizing slot extending between first and second ends. The polarizing slot has a polarizing mouth in a side thereof extending between the first and second ends defining a leg post mounting axis. The first leg has a polarizing tab that extends through a corresponding polarizing mouth while the first leg is axially slid along the leg post mounting axis of the leg post of the first or third attachment location while mounting or dismounting the first leg to or from the leg post of the first or third attachment location. The second leg has a polarizing tab that extends through a corresponding polarizing mouth while the second leg is axially slid along the leg post mounting axis of the leg post of the second or fourth attachment location while mounting or dismounting the second leg to or from the leg post of the second or fourth attachment location.

In one example, while mounting the first or second leg to a corresponding leg post of a corresponding attachment location, the polarizing tab of the corresponding first or second leg extends through the polarizing mouth of the corresponding leg post generally perpendicular to the leg post mounting axis of the corresponding leg post.

In one example, the first leg has a first post receiver configured to receive a distal end of the leg post of the first and third attachment locations. The polarizing tab of the first leg is located, at least in part, within the first post receiver. The second leg has a second post receiver configured to receive a distal end of the leg post of the second and fourth attachment locations, the polarizing tab of the second leg being located, at least in part, within the second post receiver.

In one example, the first leg has a first indicator proximate a distal end thereof and the second leg has a second indicator proximate a distal end thereof. The first and second attachment locations have a same first identifier proximate thereto. The third and fourth attachment locations have a same second identifier proximate thereto. The first indicator aligns with the first identifier proximate the first attachment location when the first leg is mounted to the first attachment location. The first indicator aligns with the second identifier proximate the third attachment location when the first leg is mounted to the third attachment location. The second indicator aligns with the first identifier proximate the second attachment location when the second leg is mounted to the second attachment location. The second indicator aligns with the second identifier proximate the fourth attachment location when the second leg is mounted to the fourth attachment location.

In one example, the first indicator includes a cutout region in the first leg that surrounds, at least in part, the corresponding first or second indicator when attached to the corresponding one of the first attachment location or the third attachment location.

In one example, the first indicator includes an arrow that points at the corresponding first or second indicator when the first leg is attached to the corresponding one of the first attachment location or the third attachment location.

In one example, the first body portion, first lever arm, first lever abutment, and first fulcrum are formed from a single, continuous piece of material. In one example, the second body portion, second lever arm, second lever abutment, and second fulcrum are formed from a single, continuous piece of material.

A single, continuous piece of material shall be something such as being molded as a single continuous pour or a component machined from a single piece of material. It should not include separate components independently formed and then secured together.

In one example, the first lever abutment is provided by a hook member. The second lever abutment is provided by a hook member.

In one example, the first and third attachment locations are axially offset from one another a third distance parallel to an offset axis that is perpendicular to the pivot axis. The second and fourth attachment locations are axially offset from one another the third distance parallel to the offset axis.

In one example, the first and second attachment locations are axially offset a same distance from the pivot axis. The third and fourth attachment locations are axially offset a same distance from the pivot axis.

In an example, a flapper assembly for a flush valve for a toilet is provided. The flush valve has a valve seat. The flapper assembly includes a seal member and a frame assembly. The seal member has a first side providing a sealing face configured to seal with the valve seat. The frame assembly includes a main frame that includes a main body as well as first and second legs. The main frame is operably configured to pivotally attach to the valve body of a toilet for pivotal movement about a pivot axis between a seated position and an unseated position. The main body has first, second, third, fourth, fifth and sixth attachment locations. The first and second attachment locations are spaced apart a first distance from one another parallel to the pivot axis. The third and fourth attachment locations are spaced apart a second distance from one another different than the first distance. The fifth and sixth attachment locations are spaced apart a third distance from one another different than the first and second distances. The first leg has a first body portion selectively attachable to the attachment locations. The second leg has a second body portion selectively attachable to the attachment locations.