A flush valve diaphragm is provided. The diaphragm includes at least two by-passes orifices. Each by-pass orifice in the diaphragm has a by-pass associated therewith. Each by-pass having a passage therethrough, allows communication with the control chamber above the diaphragm with an inlet chamber below the diaphragm. The diaphragm also integrates the function of locating and providing sealing means to the flush valve system's aux valve mechanism.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/164,421, filed Jun. 20, 2011, which is a continuation of U.S. patent application Ser. No. 12/177,813, filed Jul. 22, 2008. U.S. patent application Ser. No. 12/177,813 claims priority to U.S. Provisional Application No. 60/954,749, filed Aug. 8, 2007. The contents of all three applications are incorporated herein by reference in their entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to the field of valves. More particularly to a diaphragm type flushometer, typically for use in a urinal or water closet or the like. 
       BACKGROUND OF THE INVENTION 
       [0003]    Prior art flushometers have included a two part diaphragm-disc assembly. The diaphragm plate was typically a rubber component with a metallic core (for support). The diaphragm serves to control the main (primary) water flow through a flushometer by the use of a bypass. The relief valve seat was a separate component that engaged with the diaphragm. In prior art devices, the relief valve seat typically was an additional part also rubber molded around a metallic base. 
         [0004]    As lower flush volume fixtures have become necessary and popular, there is a need for flushometers to deliver tighter variability to each flush delivered. This requires tighter control over the components which in-turn give tighter control over the flush profile (both total volume per flush and volume per time.) 
       SUMMARY OF THE INVENTION 
       [0005]    In one embodiment, the invention provides for a reduced part count when assembled as a flush valve, thus providing the associated benefits of reduced parts such as lower cost, ease of maintenance and easy of assembly. The diaphragm of the present invention includes, in one aspect, a plurality of bypasses, in another aspect a singular diaphragm with integrated relief valve seat and in yet another aspect an improved mechanism for sealing the components of the diaphragm kit via the use of retainer. 
         [0006]    In one embodiment, the invention relates to a flush valve system comprising a flush valve body having a water inlet and a water outlet, the water inlet positioned on a side of the flush valve body and the water outlet positioned at a bottom of the flush valve body. The system further includes a barrel, having a hollow passage, disposed within the flush valve body, the barrel forming a vertical pathway for water from the water inlet to pass to the water outlet, a skirt of the barrel and the flush valve body in communication to form a seal between the water inlet and the water outlet and the flush valve body defining an inlet chamber. A diaphragm is disposed at an upper end of the barrel, sealing the inlet chamber from the hollow passage and the diaphragm defining a control chamber above the diaphragm. The diaphragm has a top surface, a bottom surface, and a side and having a central aperture, the diaphragm further including a plurality of by-pass apertures therethrough. Each of the plurality of by-pass apertures is configured to retain a by-pass, the by-pass providing a passage from the inlet chamber to the control chamber allowing equilibration of pressure. A relief valve retention ring circumscribes the central aperture and extends from the top surface of the diaphragm. The relief valve retention ring has a plurality of relief valve lugs protruding from an inner surface of the relief valve retention ring towards the central aperture. The relief valve seat is positioned on the top surface, and the relief valve seat is positioned between the relief valve retention ring and the central aperture. A relief valve is seated on the diaphragm and has a valve stem extending downward therefrom through the diaphragm into and extending beyond a guide. The guide is coupled to the diaphragm and extending downward from the diaphragm into the barrel, the guide being a generally cylindrical hollow tube in communication with the central aperture. 
         [0007]    In another embodiment in the form of a flush valve diaphragm kit, the kit comprises a diaphragm having substantially a disk-shape with a top surface, a bottom surface, and a side, with a radius of the diaphragm being substantially greater than a height of the diaphragm. The diaphragm has a central aperture positioned substantially centrally through the diaphragm and a plurality of by-pass apertures are disposed in the diaphragm, the plurality of by-pass apertures comprising passages through the diaphragm. The kit further includes a plurality of by-passes and each by-pass aperture has a by-pass associated therewith and retainably disposable therein. A relief valve retention ring circumscribes the central aperture and extends from the top surface of the diaphragm. The relief valve retention ring has a plurality of relief valve guides protruding from an inner surface of the relief valve retention ring towards the central aperture. A relief valve seat is positioned on the top surface, the relief valve seat positioned between the relief valve retention ring and the central aperture. A retainer is affixed the diaphragm to a guide, the retainer being disposable with the central aperture of the diaphragm and has a flange engagable with the top surface of the diaphragm. A relief valve has a valve stem, the relief valve seatable on the relief valve seat and retained at least partially by the relief valve retention ring, and the valve stem extending through the retainer and the guide away from the diaphragm. 
         [0008]    In yet another embodiment comprised of an diaphragm assembly for use in a flush valve, the diaphragm assembly comprises a diaphragm having a substantially cylindrical shape with a top surface, a bottom surface, and a side, with a radius of the diaphragm being substantially greater than a height of the diaphragm. The diaphragm has a central aperture positioned substantially centrally through the diaphragm. A plurality of by-pass apertures are disposed in the diaphragm, the plurality of by-pass apertures comprising passages through the diaphragm. A plurality of by-passes is included with each by-pass aperture having a by-pass associated therewith and retainably disposable therein. A relief valve retention ring circumscribes the central aperture and extends from the top surface of the diaphragm. The relief valve retention ring has a plurality of relief valve guides protruding from an inner surface of the relief valve retention ring towards the central aperture. A relief valve seat is positioned on the top surface, the relief valve seat positioned between the relief valve retention ring and the central aperture. 
         [0009]    The invention includes certain features and combinations of parts hereinafter fully described, illustrated in the accompanying figures, described below, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a cross-sectional view of a prior art flush valve; 
           [0011]      FIG. 2  is an exploded view of a flush valve diaphragm assembly; 
           [0012]      FIG. 3  is a top view of a flush valve diaphragm; and 
           [0013]      FIG. 4  is a cross-sectional view of a diaphragm assembly including a diaphragm, relief valve, and guide. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0014]    Diaphragm-type flushometers having a single bypass orifice and multiple assembled kit parts are well known, as taught in U.S. Pat. Nos. 6,616,119; 5,967,182; 5,887,848; 5,490,659; 5,213,305; and 5,332,192 and incorporated herein by reference. The invention has application for all fixtures utilizing a diaphragm flush valve, including traditional volume fixtures. However, it should be appreciated that the diaphragm assembly described herein has substantial advantages for reduced water consumption fixtures, also referred to as High Efficiency Urinals (“HEU”) and High Efficiency Toilets (“HET”). However, it should be understood that the improved diaphragm of the present invention can likewise improve performance of flushometers of various volumes per flush and is not unique to improvement of low flushing fixtures. 
         [0015]    While the diaphragm assembly described herein may be used in various flush valves,  FIG. 1  illustrates a flush valve system  100  in which the diaphragm assembly  110  described herein may be used. As shown in  FIG. 1 , the flush valve includes a flush valve  101  having an inlet  102  and an outlet  104 . A diaphragm assembly  110  is positioned to separate the inlet  102  and outlet  104  and to regulate the flow therebetween. 
         [0016]    In continued reference to  FIG. 1 , a barrel  105  forms a pathway between the inlet  102  and outlet  104 . Typically the flush valve body  101  is elongated along its vertical (longitudinal) axis  114  such that is taller than it is wide. Standard flush valve bodies generally utilize a side-entry inlet  102  (as depicted in  FIG. 1 ) such that water enters the flush valve body  101  from the side, substantially parallel with the horizontal (lateral) axis  115  of the flush valve system  100 . As also shown in  FIG. 1 , the outlet  104  is typically positioned at the “bottom” of the flush valve body  101 . The barrel  105  forming the pathway between the inlet  102  and the outlet  104  is generally positioned substantially parallel to the vertical axis  114  of the flush valve system  100 . 
         [0017]    In one embodiment, the inlet  102  feeds water into an inlet chamber  103  that surrounds the barrel  105  and whose communication with the barrel  105  (and thus the outlet  104 ) is controlled by the diaphragm assembly  110 . The diaphragm assembly  110  is positioned on the barrel  105  for controlling the flow of water from the inlet  102  through the outlet  104 . Water from the inlet chamber  103  will flow “over” the top of the barrel  105  and into the interior of the barrel  105  to the outlet  104  when the diaphragm assembly  110  is “open”, i.e. lifted off of the diaphragm seat  106 . 
         [0018]    In one embodiment of the diaphragm assembly  110 , the diaphragm assembly  110  includes a flexible diaphragm  116 . The diaphragm  116 , in one embodiment, has a substantially disc-like shape with a top surface  116   a,  a bottom surface  116   b,  and a side or outer periphery  116   c,  with the outer diameter of the diaphragm  116  being substantially greater than a height (thickness) of the diaphragm  116 . The diaphragm  116  is secured about its periphery  116   c.  In one embodiment, the diaphragm periphery  116   c  is secured to the valve body  101 . The diaphragm  116  is seated on a diaphragm seat  106 , which is an uppermost portion of the barrel  105 . The diaphragm  116 , when seated on the diaphragm seat  106 , forms a seal that prevents water from passing from the inlet  102 , via the inlet chamber  103 , into an interior of the barrel  105  (and subsequently out through the outlet  104 ). 
         [0019]    The operation of the diaphragm assembly  110  is controlled by the balance of pressures between the inlet chamber  103  and a control chamber  107 . The control chamber  107  is defined as a portion of the interior of the flush valve body  101  above the diaphragm assembly  110  and opposite the inlet chamber  103 , such that pressure of the control chamber  107  operates on the diaphragm  116  opposite the pressure from the inlet chamber  103  (typically due to the pressure of the water in the water supply line (not shown) itself). Thus, the inlet chamber  103  pressure operates to push the diaphragm  116  off the diaphragm seat  106 , and the control chamber  107  pressure operates to press the diaphragm  116  to the diaphragm seat  106 . 
         [0020]    As shown in  FIGS. 1 ,  2 , and  4 , in certain embodiments, the diaphragm assembly  110  includes a disc  109  integral to the diaphragm and forming a relief valve seat  117 . The diaphragm assembly  110  includes a central aperture  108 . In this embodiment, the relief valve assembly  119  includes a relief valve head  121  seated on the relief valve seat  117  and over the central aperture  108 . The relief valve head  121  has a relief valve stem  122  extending therefrom through the diaphragm  116  and through guide  120 . The guide  120  extends from the diaphragm  116  downwards towards the outlet  104  and is disposed within the barrel  105 . In one embodiment, the guide  120  is affixed to the diaphragm assembly  110  such as via a retainer  112 , which may be, for example, a threaded screw matching the threads on an inner portion of the guide  120  and having a flange  111  for retaining the diaphragm  116 . In this embodiment, the relief valve stem  122  extends through the retainer  112  and the relief valve head  121  is seated over the retainer  112 . The diaphragm  116  forms a seal at the diaphragm seat  106  as previously discussed, and the guide  120  extends downward therefrom through the barrel  105 . The guide  120  is aligned with the aperture  108  of the diaphragm  116 , such that a pathway from the pressure chamber  107  to the barrel  105  is defined. 
         [0021]    Referencing  FIG. 1 , as stated, the relief valve head  121  is positioned within the aperture  108  of the diaphragm  116  for controllably sealing the control chamber  107  from the barrel  105 . The relief valve head  121  seats upon the diaphragm  116  at the relief valve seat  117  to form a seal and includes a valve stem  122  that extends downward, through the guide  120 , to a point where it is engagable with a plunger  124  in communication with a handle  125 . The valve stem  122  is able to move a limited distance along the vertical axis  114  without unseating the relief valve head  121  from the relief valve seat  117 . The valve stem  122  is positioned in the guide  120  and a lower end  122   a  of the valve stem  122  is unattached such that movement of the lower end  122   a  will pivot the valve stem  122  and exert force on the relief valve head  121 . 
         [0022]    In one embodiment (best shown in  FIG. 1 ), at the upper portion of the barrel  105 , a refill head  130  is disposed about the guide  120  between the barrel  105  and the guide  120 . The refill head  130  has a central aperture  221 , allowing the refill head  130  to be disposed about the guide  120 . The guide  120  includes a refill head retention flange  129  for retaining the refill head  130  to the diaphragm  116 . Thus, the refill head  130  is bounded, before the flush valve system  100  is activated, by the barrel  105 , the guide  120  and the diaphragm  116 . When the flush valve system  100  is activated, the refill head  130  moves up along the vertical axis  114  with the guide  120  (and a central portion of the diaphragm  116 ) such that it is bounded by the guide  120  and the diaphragm  116 , but is substantially exposed to the intake chamber  103 . Thus, as the diaphragm  116  continues its upstroke opening an annular passage  127  underneath the diaphragm  116 , the refill head  130  rises as well. The refill head  130  allows the flow of the water initiated by the upstroke of the diaphragm  116  from the inlet chamber  103  through the barrel  105  and ultimately to the outlet  104 . The shape of the refill head  130  determines the flow path of the water. 
         [0023]    Actuation of the handle  125  slides the plunger  124 , which engages the lower end of the valve stem  122 , pivoting it, results in movement of the relief valve head  121  (typically tilting it) breaking the seal between the relief valve head  121  and the relief valve seat  117  on the diaphragm  116 . The tilting of the relief valve head  121  vents the pressure in the control chamber  107  above the diaphragm assembly  110 . The release of the pressure in the control chamber  107  releases the seal of the diaphragm  116  against the diaphragm seat  106 , allowing water to flow from the inlet chamber  103  (which is replenished via the inlet  102 ) past the annular passage  127  over the diaphragm seat  106  of the barrel  105  into the interior of the barrel  105 . This unseating of the diaphragm  116  is often referred to as the “upstroke” of the diaphragm  116 , and the downward motion of the diaphragm  116  reseating is referred to as the “downstroke” with the entire cycle referred to as the “stroke” of the diaphragm  116 . The stroke of the diaphragm  116  determines the time period that water can flow into the barrel  105  from the inlet chamber  103 , which is constantly being filled by water from the inlet  102  and ultimately though the barrel  105  to the outlet  104  to accomplish the “flush”. 
         [0024]    In one embodiment, illustrated in  FIG. 2  the diaphragm  116  is provided as part of a kit. The flushometer diaphragm kits are preferably made up of the diaphragm  116 , a relief valve mechanism  119 , diaphragm guide  120 , optionally a refill ring (not shown), a retainer  112 , and refill head  130 . The diaphragm kit of the present invention includes, in one aspect, a plurality of bypasses  206 , in another aspect a singular diaphragm  116  with integrated relief valve seat  117  (disk  109 ), and in yet another aspect an improved mechanism for sealing the components of the diaphragm kit via the use of retainer  112 . 
         [0025]      FIGS. 2 and 4  best illustrate one embodiment of the structure of the diaphragm assembly  110 . The diaphragm assembly  110  includes a diaphragm  116  having a central aperture  108 , as described above, for allowing passage of the relief valve stem  122  therethrough. In one embodiment, the central aperture  108  is adapted to receive a retainer  112  that engages the guide  120 . As discussed above, in one embodiment the diaphragm  116  further includes a rigid disc  109  that the diaphragm  116  is molded about (best illustrated in cross-sectional  FIGS. 1 and 4 ). The material above the disk  109  serves as the relief valve seat  122 . The diaphragm  116  also includes at least two by-pass apertures  205  each for receiving a by-pass  206 . In an alternative embodiment, at least three by-pass apertures  205  are provided. Each by-pass  206  has a passage  207  therethrough. 
         [0026]    The at least two by-pass aperture  205  in the diaphragm  116  place the control chamber  107  in communication with the inlet chamber  103 . The by-pass apertures  205  are adapted to receive a by-pass  206 . The by-pass  206  includes a housing having a passage  207  therethrough. Each by-pass  206  is shaped to fit the by-pass aperture  205  in the diaphragm  116 . It should be appreciated that various size passages  207  (passage diameter) may be utilized to provide for various flush profiles. The by-pass aperture  205  is spaced from the center aperture  108  of the diaphragm  116  sufficiently to provide sufficient water flow to the pressure chamber even during a flush cycle when the diaphragm  116  flexes upwards. It will also be appreciated that it is preferred, structurally, that the by-pass aperture  205  is spaced sufficiently from the periphery  116   c  of the diaphragm  116  and also from the central aperture  108  of the diaphragm  116 . 
         [0027]    In one embodiment, the multiple by-pass apertures  205  are equally spaced from one another. The equal spacing of the aperture  205  provides for a more even influx of water (and pressure) into the control chamber  107  (via the by-pass body  206  disposed in the aperture  205 ) than with a singular by-pass aperture or unequally spaced multiple apertures. A disadvantage of a single bypass is the angular orientation of the fixed aperture in the diaphragm  116  relative to the inlet  102 . The local pressure within the valve body  101  and flow of the water in the inlet  102  and inlet chamber  103  within the flushometer body annulus can affect performance of the flushometer. This requires careful alignment during assembly and throughout the lifespan of the diaphragm  116 . The uneven flow of water into the control chamber  107  and the pressurization of same can result in an uneven flexing of the diaphragm  116  resulting in increased wear and a shorter useful lifespan for the diaphragm  116 . 
         [0028]    The bypass aperture  205  provides communication between the control chamber  107  and the inlet chamber  103 . Thus, the bypass orifices  206 , in combination with the relief valve head  121  and relief valve stem  122 , control, the pressure of the pressure chamber  107 , which, in turn, controls the position of the diaphragm  116  and thus the flow of water past the annular passage  127  between the diaphragm  116  and diaphragm seat  106 . Thus, fluid (and, in certain embodiments, some air) pressure above the diaphragm  116  in the control chamber  107  maintains pressure for closing and holding the diaphragm assembly  110  on the diaphragm seat  106  after flush operation. The by-pass passage  207  is sized to allow a rate of fluid flow through the diaphragm  116  before the flush valve closes. For embodiments having more than one bypass  206 , the passages  207  there through are designed to, in total, allow a rate of fluid flow through the diaphragm  116 . 
         [0029]    In a particular embodiment, shown in  FIG. 2 , a diaphragm  116  with multiple by-passes  206  provides for having improvements for a better performing flushometer diaphragm kit assembly  110 . 
         [0030]    As previously mentioned, in one embodiment shown in  FIG. 4 , the diaphragm  116  of the present invention is a singular, or integrated, component including the relief valve seat  117  for the relief valve head  121 . This unitary construction provides for increased control over the total flush volume and the volume per time by eliminating substantial variability that was inherent in prior art two-piece designs. In one embodiment, the diaphragm  116  comprises a disc  109 , for example, constructed, for example, of a metal, which is over-molded with an elastomeric material to form the outer portion  225 . In one embodiment, the disc  109  surrounds the central aperture  108  but extends only to the relief valve retention ring  214  while the elastomeric material overcoats the disc  109  and relief valve retention ring  214  and also fox ills the extended peripheral portion, which contains the by-pass apertures of the diaphragm  116 . In one embodiment shown in  FIG. 4 , the relief valve retention ring  214  and disc  109  both are formed from the same rigid material and over-molded with the elastomeric material to form the outer portion  225 . 
         [0031]    The relief valve retention ring  214 , against which the relief valve head  121  abuts during use, is backed by a rigid core material, in one embodiment being the same material as the diaphragm core, thus providing for a more supportive cavity to retain the relief valve head  121 . This increased rigidity also results in improved performance as the prior art rubber-only design is prone to being pushed out of shape over time. The diaphragm  116  and relief valve seat  117  also includes an embodiment with a connecting piece extending from the diaphragm  116  opposite the disc. The outer portion of the connecting piece may be threaded to allow engagement with the flush valve. In one embodiment the connecting piece forms a single metallic component with the metallic portion of the diaphragm/disk unitary piece (diaphragm  116 ). In an alternative embodiment the diaphragm/disk unitary piece (diaphragm  116 ) is affixed to the kit with a separate connection component, such as the retainer  112 . This connection component may be of a different material from either the metal or elastomer from the diaphragm/disk unitary piece (diaphragm  116 ), such as a material of plastic. This material selection allows for greater cost control in manufacturing. In addition the use of a separate connection component allows for a simpler metallic portion to be used in the diaphragm/disk unitary piece (diaphragm  116 ), such as one that can be manufactured with, for example, a punch press and again allowing for greater cost control in the manufacturing process. 
         [0032]    Referring to  FIGS. 2 and 3 , the relief valve retention ring  214  includes, in one embodiment, a plurality of lugs  213  for centrally locating a seated relief valve head onto the relief valve seat  117 . In one embodiment, there are at least six lugs  213 . The lugs  213  provide for a snug fit between the relief valve retention ring  214  and relief valve head  121 . It is necessary to retain spacing between the relief valve retention ring  214  and relief valve head  121  in order to allow the relief valve head to be able to tilt sufficiently to allow water to flow out of the upper control chamber. Without sufficient spacing in this area, the relief valve will not function properly when a user activates the flush cycle. Conversely, too much space, i.e. from insufficient lugs or lugs of insufficient size relative to the spaces therebetween, will result in the relief valve head  121  having to much “play” within the seating area. This play will result in an imprecise functioning of the flushometer. Integrating the disc  109  with the diaphragm  116  also eliminates an otherwise large and unreliable sealing area between the top of the diaphragm  116  and the bottom of the disc  109 . 
         [0033]    With continued reference to  FIG. 4 , the lugs  213  have corners which are on the upper and inner portion of the relief valve retention ring  214 . In one embodiment, the left handed corners of the lugs have an angular shape  230 , while the right handed corners have a rounded shape  231 . The angular corners allow the use of the relief valve retention ring  214  to secure the diaphragm to the flushometer by providing an edge for either an automatic tool or a manual tool for engagement. In contrast the rounded corners have the opposite effect, making it more difficult to remove the diaphragm  116  from its original factory setting. Thus, in one embodiment, there are a plurality of equally spaced lugs  213 , each of the equally spaced lugs  213  including a first end proximate a second end of the adjacent lug  213 , one of the first end or the second end having an angular shaped  230  with the other having a rounded shape  231 . 
         [0034]    The outer portion of the relief valve retention ring  214  has in one embodiment, a slightly slanted or curved lower portion such that it slopes towards the center of the diaphragm  116 . This provides improved component life and performance over time by allowing the elastomeric diaphragm  116  sufficient space to move in response to pressure. In contrast, prior art diaphragms were secured to a disk that presented a flat bottom surface and an annular angular edge. The interaction of the diaphragm  116  against these surfaces over repeated operations and pressure conditions would result in wear and poor performance. Prior art assemblies also had the seat and diaphragm two separate pieces which introduced a potential leak surface between the two parts. The integrated seat and diaphragm  116  removes this sealing area and potential leak because of incompletely assembled parts. 
         [0035]    The foregoing description of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments, and with various modifications, as are suited to the particular use contemplated.