Flush toilet

A toilet includes an inlet structure, a bowl structure, and an outlet structure. The inlet structure is configured to receive water. The bowl structure has a toilet bowl including a rim and a sump, a split fluidly connected to the inlet structure and including a first passage and a second passage, a shelf located below the rim of the toilet bowl and fluidly connected to the first passage, a side channel fluidly connected to the second passage, and a diverter that redirects the water from the side channel to the sump of the toilet bowl. The outlet structure is fluidly connected to the sump and is configured to discharge water from the sump into a drain.

BACKGROUND

The present application relates generally to the field of toilets. More specifically, this application relates to toilets having a flush structure that improves the overall flush efficiency of the toilet.

There is a constant desire and need within the field of toilets (and other water using devices) to become ever more efficient and use less water, such as during each flush cycle, much like the ever increasing desire to improve fuel efficiency of internal combustion engines. Also similar to slight improvements in fuel efficiency in engines, even a slight improvement in flush efficiency for toilets can have a monumental impact on water conservation (i.e., reduction of water consumption) given the number of toilets and flush cycles used daily (not just in the U.S., but on a global scale). Thus, there is constant pressure to find new ways to improve flush efficiency, even if only a slight improvement is recognized. Despite this constant pressure to increase flush efficiency and decrease water consumption, such improvements are easier said than done.

Further, providing a proper flush in which all of the contents (e.g., solid waste, liquid waste, etc.) in the toilet bowl are removed from the toilet bowl during a single flush cycle is a competing interest to increasing flush efficiency and decreasing water usage. Current toilets aimed at using one gallon of water per flush provide poor overall flush performance (e.g., leaving contents in the toilet bowl following the first flush), which results in customer dissatisfaction and often additional flushes to completely remove the contents from the toilet bowl, therefore, defeating the gains in efficiency by requiring multiple flushes to achieve proper flushing.

SUMMARY

At least one exemplary embodiment of the application relates to a toilet having an inlet structure, a bowl structure, and an outlet structure. The inlet structure is configured to receive water. The bowl structure has a toilet bowl including a rim and a sump, a split fluidly connected to the inlet structure and including a first passage and a second passage, a shelf located below the rim of the toilet bowl and fluidly connected to the first passage, a side channel fluidly connected to the second passage, and a diverter that redirects the water from the side channel to the sump of the toilet bowl. The outlet structure is fluidly connected to the sump and is configured to discharge water from the sump into a drain.

Another exemplary embodiment of the application relates to a toilet including an inlet structure, a bowl structure, and an outlet structure. The inlet structure includes an inlet for receiving water, a horizontal section, and an elbow fluidly connecting the inlet to the horizontal section. The elbow includes a breaking radius and has a circular cross sectional shape. The bowl structure includes a toilet bowl having a rim and a sump, a split located downstream of the horizontal section and having a first passage and a second passage, a shelf located below the rim and fluidly connected to the first passage, a side channel fluidly connected to the second passage, and a diverter that redirects the water from the side channel to an inlet opening into the sump. The outlet structure includes a trapway that is fluidly connected to the sump and has an outlet.

Another exemplary embodiment of the application relates to a toilet including a toilet bowl and a shelf. The toilet bowl includes a rim. The shelf is located below the rim and is spaced apart from the rim. Together, the rim and the shelf form an inset channel that extends along at least a portion of the perimeter of the toilet bowl. A height of the inset channel, between the rim and the shelf, decreases continuously in a flow direction.

DETAILED DESCRIPTION

Referring generally to the FIGURES, disclosed herein are toilets having a flush structure that improves the overall flush efficiency of the toilet. That is, the flush structure allows the toilet to properly flush the contents in the bowl using less water. For example, the toilets are configured to flush the contents in the bowl using a single flush containing one gallon or less of water per flush (1.0 gpf). In this way, the toilets of this application can completely remove the contents from the bowl using a single flush cycle of reduced volume, such as using 1.0 gpf or less of water.

FIGS.1-3illustrate an exemplary embodiment of a flush structure for a toilet1with streamlines (e.g., velocity streamlines) passing through the flush structure. The streamlines were modeled using a CFD model on a computer with the aim of evaluating the flush efficiency of the new structure, such as by comparing the streamlines to streamlines in other toilet flush structures. The CFD streamlines correlate to efficiency. For example, decreases in velocity streamlines can indicate drops/reductions in fluid pressure or energy, which is indicative of efficiency loss. Also, for example, swirling and turbulence of streamlines can indicate drops in fluid pressure or energy. By tailoring the flush structure to reduce the velocity drops and turbulence, the overall efficiency of the toilet flush system can be increased.

The illustrated flush structure includes an inlet structure2, a bowl structure4, and an outlet structure6. The inlet structure2receives water from a source, such as a tank, and delivers water to the bowl structure4. The bowl structure4is configured to direct the water received from the inlet structure2into the bowl to wash the contents in the bowl to an outlet of the toilet1as well as clean the inside (e.g., internal) surfaces of the bowl. The outlet structure6is configured to direct the water and the contents in the bowl from the toilet1, such as to a drainpipe or other sewer line.

The illustrated inlet structure2delivers flush water into the bowl structure4and includes an inlet17(shown inFIG.2) that can interface with (or include) a flush valve (not shown), which controls the flow (e.g., volume and timing) of flush water into the inlet structure2upon activation of a flush cycle of the toilet1. The illustrated inlet17extends generally downward (e.g., vertically) to an elbow12(shown inFIG.1) having a breaking radius, which advantageously helps completely evacuate air, rather than a sharp break or turn, in which air gets trapped. As a non-limiting example, the breaking radius of the elbow12is approximately 0.75 inches (¾″) at the inner radius. As shown, a horizontal section10(shown inFIG.1) extends from the elbow12to the bowl structure4. The illustrated cast inlet structure (e.g., the inlet17shown inFIG.6) is configured having a generally circular cross-sectional shape, which improves flow efficiency over an inlet, such as the inlet17″ shown inFIG.7, having a “U” or “D” cross-sectional shape, which current processes (e.g., manufacturing) necessitate. New processes, such as a “tile-on-rim” process allows the inlet structure (e.g., the inlet17, the horizontal section10, etc.) to have the generally circular shape. Further, the size (e.g., diameter) of the drain cast inlet structure can be reduced because of the efficiency gain and the circular cross-sectional shape. While the embodiment ofFIGS.1-3illustrate a drain cast vitreous inlet structure, it is to be understood that other material and manufacturing processes are included in the scope of this disclosure.

The bowl structure4includes a split20(shown inFIG.1) downstream from the horizontal section10of the inlet structure2, where the split20includes a first passage22and a second passage23. The first passage22(or upper passage) opens into a fluvial terrace or shelf16(also shown inFIGS.1and5) that is located around an inside of a top of the bowl and underneath a rim14(shown inFIG.5). The rim14does not include an enclosed rim channel, fluid channel, or other fluid delivery or water carrying feature. That is, the illustrated rim14is a solid, planar member that overhangs the shelf16(seeFIG.5). As shown inFIG.5, the shelf16is configured to direct flush water in a single direction (e.g., clockwise or counterclockwise depending on the location of the shelf inlet24) around the shelf16and the bowl resulting in a swirl flush. As shown inFIG.5, the shelf16has a compound radius leading from the shelf inlet24, where the compound radius includes an inner radius28and a radius30into the bowl. According to one example, the inner radius28is approximately 0.25 inches (¼″) and the outer radius30into the bowl is approximately 0.75 inches (¾″), where each radius remains substantially constant around the bowl. The combination of the inner radius28and outer radius30(e.g., breaking radius) into the bowl along with the shelf width combine to define variable water shed rate around the perimeter of the toilet1. Further, the shelf16is elevated in the bowl relative to the first passage22or upper passage (e.g., a central axis of the first passage22). That is, the water feed18(shown inFIG.1) from the first passage22to the shelf16slopes upwardly moving forward/downstream from the first passage22to the shelf16. This advantageously prevents refill water from entering the bowl through the shelf16, especially when the refill water continues to run such as from a leaking valve, which eliminates stains or streaking in the bowl under the shelf16from the excess refill water. Instead, any excess refill water drains into the second passage23and into the sump through an opening therein.

The bowl structure4including the shelf16is configured to maximize coverage of the internal or inside surfaces of the bowl with water during a flush cycle while using as little water as possible during each flush cycle. According to one example, the toilet1is configured to divert approximately 15-30% of the total flush water (e.g., 0.15-0.30 gallons for a 1 gal. flush) to the first passage22(e.g., the upper passage). Sending less than 15% of the total flush water through an enclosed rim channel (for other toilets) or an upper passage (e.g., for the toilets of this application) can lead to less than desirable (e.g., intermittent) coverage of the inside surfaces of the bowl, whereas sending too much (e.g., 50% or more) water through the rim or upper passage can lead to poor overall flush performance.

As shown inFIG.1, the second passage23(e.g., the lower passage) opens into a lower part (e.g., the sump) of the bowl after passing through one or more side channels and a diverter13in the sump or “pug” of the toilet bowl. As shown best inFIGS.2and3, the illustrated toilet (e.g., bowl structure) includes a two channel structure having a right side channel (RSC)32that extends from the split20downwardly around a right side of the bowl and a left side channel (LSC)34that extends from the split20downwardly around a left side of the bowl. Thus, each side channel of the RSC32and LSC34does not extend within or inside the bowl, but rather around an outside of the bowl. As shown inFIG.3, each side channel has a somewhat arcuate shape (when viewed from underneath) and the RSC32and the LSC34are symmetrically opposite about a central longitudinal axis36(e.g., through the opening into the bowl from the diverter13). A single channel toilet can include either the RSC32or LSC34. According to one example, the toilet1is configured to divert approximately 60-75% of the total flush water (e.g., 0.60-0.75 gallons for a 1 gal. flush system) to the second passage23(e.g., the lower passage) and through the one or more side channels.

The diverter13(e.g., diverter plate) shown inFIG.3is configured to re-converge the water from the RSC32and the LSC34prior to the water entering the sump of the bowl through a lower opening (e.g., sump jet, sump opening, etc.) into the bowl. That is, the diverter13takes the two circular flows through the RSC32and the LSC34and converges the two flows into a single straight flow into the bowl. As shown inFIG.3, the diverter13includes an inward (e.g., concave) projection38or indentation at the front of the diverter13, which forms a general “W” shape with the RSC32and the LSC34and the lower opening into the sump. This arrangement reduces swirling and turbulence of the converging streamlines, as compared to, for example, the design (e.g., toilet103) shown inFIG.4having a rounded front138with no indentation, which results in significant swirling and turbulence that lead to energy loss resulting in a reduced flush efficiency.

Returning toFIG.1, the outlet structure6from the bowl includes a trapway15having a variable size (e.g., diameter) along a length. The trapway15includes an upleg40that extends upwardly and rearwardly from the sump of the bowl to a weir or dam, a downleg42that extends downwardly from the dam, and an outleg44that extends forward from a downstream end of the downleg42to an outlet19of the toilet. According to one example, the upleg40of the trapway15has a generally common size (e.g., a diameter of 2.125 inches), the downleg42and outleg44of the trapway15each have a generally common size (e.g., a diameter of 2.000 inches or less), and the outlet19has a diameter of 2.00-2.50 inches. The illustrated outlet19is shown extending forward and downward at an angle of 10-20° (ten to twenty degrees). This variable size arrangement of the trapway15is configured to set up a siphon quicker, as well as provide faster priming and a quicker, longer siphon during each flush cycle. Further, the outlet19configuration increases the discharge flow rate by 15% or more. For comparison, a 90° (ninety degrees) turn (at the outlet) leads to water impacting the wall of the trapway and results in energy loss during the flush cycle.

The geometry and arrangement of inlet structure, the bowl structure, and the outlet structure are provided for illustrative purposes only. It will be appreciated that various alternatives and combinations are possible without departing from the inventive concepts disclosed herein. For example, in some exemplary embodiments, the geometry of the shelf and/or rim may be modified to further improve flushing efficiency.FIGS.8-11show a toilet200including a variable height swirl flush rim structure, shown as rim structure202, according to an exemplary embodiment. In other embodiments, the rim structure202may be incorporated as part of the toilet1ofFIGS.1-3.

As shown inFIG.8, the rim structure202includes a shelf216(e.g., fluvial terrace, lower ledge, etc.) that is located along an upper region of the toilet bowl, along an upper portion of a waste receiving surface246of the toilet bowl. Additionally, the rim structure202includes a rim214(e.g., a ceiling, etc.) disposed at a top of the toilet bowl, above the shelf216. The rim214forms an upper surface of the toilet bowl. The rim214extends inwardly from an outer perimeter of the toilet bowl, such that is overhangs the shelf216. Together, the shelf216and the rim214form an inset channel248that extends along a perimeter of the toilet bowl (e.g., the waste receiving surface246).

The shelf216is configured to direct flush water in a single direction (e.g., clockwise or counterclockwise depending on the direction in which water is received within the shelf216) around the shelf216and the perimeter of the waste receiving surface246, resulting in a swirl or vortex flow pattern (i.e. a swirl flush). In various exemplary embodiments, the shelf216has a compound radius, which may be the same or similar to that described for the toilet1ofFIGS.1-3. As shown inFIG.9, the toilet200further includes a shelf inlet224, which is configured to direct water from at least one of a flush tank of the toilet200(not shown) or a water supply line connected to an inlet of the toilet200to the inset channel248. For example, the shelf inlet224may form part of a first passage (e.g., upper passage) that extends downstream from an inlet structure of the toilet200as described with reference to the toilet1ofFIGS.1-3.

The rim structure202is configured to improve water coverage along a perimeter of the toilet bowl during a flush, without increasing the amount of water provided to the inset channel248via the shelf inlet224.FIG.9shows a top view of the toilet200in which the rim structure202has been separated into sections along the perimeter of the toilet bowl, each forming ¼ portion of the overall perimeter of the toilet bowl. Water enters the inset channel248at section A through the shelf inlet224and flows along the perimeter from A to sections B, C, and D, sequentially (e.g., clockwise, etc.).FIG.10shows a panoramic side view from inside the toilet bowl, in the area of the inset channel248. As shown inFIGS.8and10, a height of the inset channel248, between the rim214and the shelf216, varies continuously along the length of the inset channel248(e.g., along a perimeter of the waste receiving surface246). In particular, the height of the inset channel248decreases continuously along the length of the inset channel248in a flow direction249along the length of the inset channel248. As shown inFIG.10, an upper surface250of the shelf216is substantially horizontal (e.g., is equidistant from the sump of the toilet bowl along a perimeter of the waste receiving surface246). A lower surface252of the rim214is sloped downwardly (e.g., tapered), toward the shelf216, such that the lower surface252of the rim214and the upper surface250of the shelf216converge toward one another in the flow direction249. In other embodiments, the shelf216may slope upwardly toward the rim214along the length of the inset channel248in the flow direction249. In yet other embodiments, both the rim214and the shelf216may slope toward one another (e.g., the rim214and the shelf216may both be angled relative to a horizontal plane extending through the toilet bowl and/or an upper surface of the toilet bowl/rim214). In various exemplary embodiments, a height254of the inset channel248, between the rim214and the shelf216, may vary within a range between approximately 0.5 inches and 1 inch.

FIG.11shows a cross sectional view through the inset channel248during a flush operation.FIG.12shows a cross sectional view through an inset channel348of another a toilet300, in which the height of the inset channel348(between the rim and the shelf) is constant along the perimeter of the toilet bowl. The height254of the inset channel248of the toilet200ofFIG.11, at any position along the perimeter of the toilet bowl, may be less than the height of the inset channel348of the toilet300ofFIG.12. According to various exemplary embodiments, the heights may differ by a factor of two or greater. Among other benefits, reducing the height of the inset channel248reduces the vertical space that the water can flow upwardly along an inner surface256of the inset channel248, which reduces fluid losses in the direction of flow (compare, e.g.,FIG.11toFIG.12, whereFIG.12illustrates that the water flow forms a “wave” shape with the upper portion of the water cresting over and back onto itself, which illustrates lost energy in the flow during its flow around the perimeter). This limits the amount of fluid energy that is lost from water flowing vertically within the inset channel248, thereby allowing the fluid to move a longer distance through the inset channel248before flowing downwardly along the waste receiving surface246toward the sump of the toilet bowl. The reduction in fluid losses along the inset channel248is accompanied by a reduction in the amount of fluid required to sustain full 360° vortex (e.g., swirl) along the perimeter of the toilet bowl (e.g., along the inset channel248). At least some of the benefits observed for the toilet200ofFIGS.8-11may also be realized by selectively reducing the height of the inset channel within certain regions along the perimeter of the toilet bowl; for example, by selectively reducing the height of the inset channel beginning at, and following, a sharp curve along the perimeter of the toilet bowl such as in an area near the front of the toilet bowl.FIG.13shows an example of an inset channel438of another rim structure402, according to an exemplary embodiment. As shown inFIG.13, the inset channel438includes two portions, a first portion460that extends between the shelf inlet (on the left of segment A) and a forward region through a central axis through the toilet bowl (between segments B and C), and a second portion462that extends between the forward region and a downstream end of the inset channel438(between segments D and A). A height464of the first portion460is approximately constant along the length of the first portion460, while a height466of the second portion462decreases continuously along the length of the second portion462.

It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

The term “coupled,” as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. Such members may be coupled mechanically, electrically, and/or fluidly.

It is important to note that the construction and arrangement of the toilets and the components/elements, as shown in the various exemplary embodiments, are illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. For example, each inlet structure or component thereof, each bowl structure or component thereof, and/or each outlet structure or component thereof described herein may be incorporated into any other embodiment of this application. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.