RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Patent Application 62/132,400, entitled "Improved Fill Valve" filed March 12, 2015.

FIELD

[0002] This disclosure relates generally to valves for filling toilet tanks with water.

BACKGROUND

[0003] Fill valves in toilets provide water for refilling a toilet tank and for delivering water from the tank into the corresponding bowl during a flush cycle.

[0004] Current fill valves typically use floats to sense water level, a nd thus turn the water flow on and off. A first problem with such designs is that a large amount of force is actually required to turn the fill valve on and off. As a result, the floats tend to be large and occupy a significant amount of space in the toilet tank. An example of this is the traditional piston and ballcock design which has a relatively large float positioned on the end of a relatively long lever arm. One big disadvantage of these ballcock valves are the large amount of space they require to operate in the toilet tank. A long lever arm is required to generate enough force to overcome the hydraulic force through the fill valve in order to close the fill valve. A second problem with these current fill valves is that they tend to be noisy. However, one advantage of piston valves is that they do provide good flowrate at low pressures and they work with loose tolerance parts.

[0005] Another example of a traditional fill valve design is a pilot valve. Pilot valves are designed to improve upon the ballcock valves, wherein the pilot valve uses a smaller float or activator to depressurize or pressurize a control chamber on top of a rubber diaphragm. Pilot valves, however, suffer from several noticeable shortcomings. For example, pilot valves are incapable of providing sufficient fast flow rate at substantially low pressure. Furthermore, the pilot valve typically requires tight tolerance parts to work properly. [0006] Accordingly, a need exists to provide a fill valve which offers the high flowrate at low pressures as seen in piston valves and the low activation force requirements as seen in pilot valves. Ideally, such a system would therefore provide high flow rates with only small activation forces being capable of turning the valve on and off.

SUMMARY

[0007] The following simplified summary is provided in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview, and is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

[0008] In a preferred aspect, the present system provides a fill valve system, comprising: (a) a water supply member; (b) a valve assembly at a top end of the water supply member, the valve assembly comprising: (i) a fluid chamber in fluid communication with the water supply member, the fluid chamber having a top opening and a bottom opening, (ii) a float; (iii) a stem connected to the float, the stem being moveable up and down with upward and downward movement of the float; (iv) an upper seal at the top of the stem, wherein the upper seal is positioned below the top opening in the fluid chamber and can be moved upwards to seal the top opening when the stem is moved upwardly by upward movement of the float, and (v) a lower seal at the bottom of the stem, wherein the lower seal is positioned below the bottom opening in the fluid chamber and can be moved upwards to seal the bottom opening when the stem is moved upwardly by upward movement of the float.

[0009] As will be explained, upward movement of the float moves the stem to move the upper and lower seals to seal the upper and lower openings in the valve assembly and thus stop water from passing through the valve assembly. Conversely, downward movement of the float moves the stem to move the upper and lower seals to un-seal the upper and lower openings in the valve assembly and thus permit water to pass through the valve assembly.

[0010] In preferred embodiments, the upper seal is larger than the lower seal. As a result, the total force required to open or close the valve is very small since the water pressure acting on the two seals will tend to cancell out. The use of such a small activation force will thereby enable the float that is used to be small as well. Specifically, only a small buoyant force (from the float) will be required to close the fill valve, and only a small weight (from the float) will be required to open the fill valve.

[0011] When the present fill valve is open, water can advantageously refill the toilet tank quickly since water passes out of the fill valve through both the upper and lower openings in the valve assembly.

[0012] When the present fill valve is closed, the water pressure on the larger top seal will keep both the top and bottom seals firmly against the upper and lower openings in the valve assembly. The top seal is pushed closed by the water pressure in the fill valve. Conversely, the bottom seal is pushed open by the water pressure in the fill valve. However, since the top seal is larger than the bottom seal, the water pressure on the top seal will be greater than the water pressure on the bottom seal. Since the top and bottom seals are connected together by the same moveable stem, the larger water pressure on the top seal will cause both the top seal and the bottom seal to remain closed (until the float drops and pulls both seals open).

[0013] In optional preferred embodiments, the bottom of the float is open. When the water level in the tank drops below the float, the weight of the float will open the top and bottom openings in the valve assembly (by pulling the top and bottom seals away from these two openings). Conversely, when the water level in the tank rises around the float, the buoyancy of the float will close the top and bottom openings in the valve assembly (by pushing the top and bottom seals against these two openings).

[0014] In other aspects, the present system provides a method of operating a fil l valve, comprising: (a) decreasing the water level in a toilet tank, thereby causing a float to move downwardly; (b) moving a stem downwardly, the stem being connected to the float; (c) opening top and bottom openings in a fluid chamber, wherein the stem is connected to an upper sea l and a lower seal, and wherein (i) the upper seal is positioned at the top of the stem below the top opening in the fluid chamber, and (ii) the lower seal is positioned at the bottom of the stem below the bottom opening in the fluid chamber; such that water can flow through the fill valve and out of both the top and bottom openings in the fluid chamber and into the toilet tank.

[0015] To the accomplishment of the foregoing and related ends, certain illustrative aspects are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the claimed subject matter may be employed and the claimed subject matter is intended to include all such aspects and their equivalents. Other advantages and novel features may become apparent from the following detailed description when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a first perspective view of an exemplary low activation force fill valve.

[0017] FIG. 2 is a second perspective view of the low activation force fill valve.

[0018] FIG.3 is an exploded perspective view of the exemplary low activation force fill valve.

[0019] FIG. 4A is a sectional side elevation side view of the exemplary low activation force fill valve with the fill valve in an open position.

[0020] FIG. 4B is a close-up view of the top portion of FIG. 4A.

[0021] FIG. 5 is a sectional side elevation side view of the exemplary low activation force fill valve with the fill valve in a closed position.

[0022] FIG. 5B is a close-up view of the top portion of FIG. 5A.

DETAILED DESCRIPTION

[0023] The features of the presently disclosed solution may be economically molded or assembled by using one or more distinct parts and associated components which, may be assembled together for removable or integral application with a known or to-be-designed toilet flushing systems in an economical manner, wherein the features of the present disclosure may form the herein disclosed servicing apparatus regardless of the particular form. Unless defined otherwise, all terms of art, notations and other scientific terms or terminology used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0024] In some cases, terms with commonly understood meanings are defined herein for clarity and/or for ready reference, and the inclusion of such definitions herein should not necessarily be construed to represent a substantial difference over what is generally understood in the art. All patents, applications, published applications and other publications referred to herein are incorporated by reference in their entirety. If a definition set forth in this section is contrary to or otherwise inconsistent with a definition set forth in the patents, application, published applications and other publications that are herein incorporated by reference, the definition set forth in this section prevails over the definition that is incorporated herein by reference.

[0025] The disclosed solution can now be better understood turning to the following detailed description. It is to be expressly understood that the illustrated embodiments are set forth as examples and not by way of limitations on the embodiments as ultimately defined in the claims.

[0026] The fill valve system 10 in FIGS. 1 to 5 preferably comprises: (a) a water supply member 26; (b) a valve assembly 11 at a top end of water supply member 26, the valve assembly comprising: (i) a fluid chamber 13 in fluid communication with water supply member 26, fluid chamber 13 having a top opening 21 and a bottom opening 23, (ii) a float 5; (iii) a stem 3 connected to float 5, stem 3 being moveable up and down with upward and downward movement of float 5; and (iv) an upper seal 14 at the top of stem 3, wherein upper seal 14 is positioned below top opening 21 in fluid chamber 13 and can be moved upwards to seal top opening 21 when stem 3 is moved upwardly by upward movement of float 5, and (v) a lower seal 16 at the bottom of stem 3, wherein lower seal 16 is positioned below bottom opening 23 in fluid chamber 13 and can be moved upwards to seal bottom opening 23 when stem 3 is moved upwardly by upward movement of float 5.

[0027] Upward movement of float 5 moves stem 3 to in turn move both the upper and lower seals 14 and 16 to seal the upper and lower openings 21 and 23 in the valve assembly and thus stop water from passing through the valve assembly. Conversely, downward movement of float 5 moves stem 3 to move both upper and lower seals 14 and 16 to un-seal the upper and lower openings 21 and 23 in the valve assembly and thus permit water to pass through the valve assembly.

[0028] When upper and lower openings 21 a nd 23 are simultaneously opened (i.e. : when float 5 drops and pulls stem 3 downwards) then water flows out of both the top and bottom openings 21 and 23 to quickly refill the toilet tank 4. The advantage of this design is that it can accommodate a large flow volume, rapidly refilling toilet tank 4 without causing excessive noise.

[0029] Preferably, the upper seal 14 is larger than the lower seal 16. As a result, a greater amount of force will be applied to seal 14 than seal 16. The water pressure in fluid chamber 13 will tend to push upper seal 14 closed, whereas the water pressure in fluid chamber 13 will tend to push lower seal 16 open. However, since seal 14 is larger than seal 16, the pressure to close top opening 21 (with seal 14) is larger than the pressure to open bottom opening (with seal 16). Therefore, the valve will tend to remain closed.

[0030] In preferred aspects, the bottom of float 5 is open. Thus, when the water level in tank 4 drops (during a flush), float 5 will be above water, and will fall under it's own weight, pulling stem 3 downward and thereby turning the fill valve on by opening openings 21 and 23. When the water level in tank 4 has refilled, float 5 will become buoyant (as its open bottom end is met with the rising water in the tank). As a result, float 5 will move upwards, moving stem 3 upwards, thus forcing seals 14 and 16 against openings 21 and 23, closing the fill valve and stopping the re-filling of the tank.

[0031] As can be seen, stem 3 preferably passes through the top and bottom openings 21 and 23 in fluid chamber 13. As can also be seen, float 5 and stem 3 can be formed as an integral unit.

[0032] The present system also preferably provides a cap 20 on the top of fluid chamber 13, cap 20 forming a chamber above the top opening 21 of the fluid chamber. Optionally, cap 20 may have an upper outlet 22 as shown.

[0033] The present system also provides a method of operating a fill valve, comprising: (a) decreasing the water level in toilet tank 4, thereby causing float 5 to move downwardly; (b) moving stem 3 downwardly, stem 3 being connected to float 5; (c) opening top and bottom openings 21 and 23 in fluid chamber 13, wherein stem 3 is connected to an upper seal 14 and a lower seal 16, and wherein (i) upper seal 14 is positioned at the top of stem 3 below top opening 21 in the fluid chamber, and (ii) lower seal 16 is positioned at the bottom of stem 3 below bottom opening 23 in fluid chamber 13; such that water can flow through the fill valve 10 and out of both top and bottom openings 21 and 23 in fluid chamber 13 and into the toilet tank 4.

[0034] In further aspects, the method comprises: (d) increasing the water level in toilet tank 4, thereby causing float 5 to move upwardly; and thereby (e) moving stem 3 upwardly thereby moving upper and lower seals 14 and 14 to seal the top and bottom openings 21 and 23 in fluid chamber 13, thereby stopping water flow through the fill valve 10. [0035] Fill valve 10 is designed to be opened with a small stroke and relatively or substantially low activation force while also permitting a relatively fast flow rate due to two openings 21 and 23 associated with seals 14 and 16. Moreover, fill valve 10 is also capable of sustaining overall higher flow rates at substantially low pressures while also being suitable for parts or other components in system 10 with relatively loose tolerance.

[0036] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the embodiments disclosed and described herein. Therefore, it is understood that the illustrated and described embodiments have been set forth only for the purposes of examples and that they are not to be taken as limiting the embodiments as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the embodiments include other combinations of fewer, more or different elements, which are disclosed above even when not initially claimed in such combinations.

[0037] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what incorporates the essential idea of the em bodiments.

[0038] What has been described above includes examples of one or more embodiments. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the aforementioned

embodiments, but one of ordinary skill in the art may recognize that many further combinations and permutations of various embodiments are possible. Accordingly, the described embodiments are intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term "includes" is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term "comprising" as

"comprising" is interpreted when employed as a transitional word in a claim.