Abstract:
An improved control valve in combination with a pressurized water closet having a housing, a spool rotatable within the housing, a valve stem threading engaging the spool but fixed from rotating relative to the housing and a needle valve extending from the valve stem and into the housing orifice, creating a self cleaning valve adjustable by rotating the spool, which adjusts the depth of the needle valve in the orifice, and thus adjusting the effective opening of the orifice.

Description:
This Application claims priority from Provisional Application No. 60/195,094 Filed: Apr. 6, 2000; And is a Continuation in Part of U.S. patent application Ser. No. 09/827,736, filed Apr. 6, 2001, now U.S. Pat. No. 6,732,997. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to an improved control valve for a pressurized water closet, and such a valve in combination with a pressurized water closet that precisely regulates the refill volume of a toilet bowl. 
   2. Related Art 
   The basic components of a pressurized water closet are a water vessel, a flush valve and a flush valve actuator. The aforesaid components are generally installed internally of a conventional water closet. The pressurized water closet is energized by water pressure from a conventional fresh water supply system. 
   In operation, as the water level rises in the water vessel after flush, air internally of the water vessel is compressed. When water pressure in the vessel equals the supply line pressure or when it causes the pressure regulator valve to shut, in the event of supply line pressure greater than that allowed by the regulator, flow of water into the water vessel ceases and the system is conditioned for operation. When the flush valve actuator is actuated, the flush valve opens whereafter the compressed air in the water vessel pushes the water stored therein into the water closet bowl at relatively high discharge pressure and velocity, flushing waste therefrom with minimum water consumption. 
   The aforesaid features of the pressurized flush system result in stronger and more effective extraction and drain line carry, cleaner bowls, fewer drain line clogs, no hidden leakage of water between flushes, and smaller sized pipe systems. The system produces a flushing action which clears and cleans a toilet bowl while consuming less than one and six tenths gallons of water while meeting the highest municipal codes. The toilet bowl is emptied by one flush without drain line “drop-off” common to many low water volume, or gravity-flow type toilets. 
   In operation, actuation of the manual operator creates a pressure differential across a flush valve piston disposed in a flush valve cylinder. The flush valve piston and a flush valve therefore move upwardly at a controlled rate. 
   Upward or opening movement of the flush valve permits water to be ejected into the toilet bowl from the water vessel under relatively high pressure effecting extraction of the contents of the toilet bowl. Flush commences simultaneously with manual depression of the flush valve actuator and is time controlled so as to produce a prolonged high energy surge of water which carries bowl waste into the sewer. 
   Closure of the flush valve is timed by the distribution ratio of incoming water to the upper chamber of the flush valve cylinder and the water vessel. When the manual flush valve actuator is released, the fluid flow path from the upper chamber of the flush valve cylinder to ambient is closed. At this point, a predetermined portion of the water supplied under pressure from the water supply system flows directly to the upper chamber of the flush valve cylinder. The remaining portion of water supplied by the system flows to the main chamber of the water vessel. When the upper chamber of the flush valve cylinder is filled, and the flush valve is closed, all incoming water is directed into the water vessel. 
   Water rising in the water vessel under regulated water system pressure compresses the air entrapped therein until it reaches either the line or regulated pressure of approximately 30 psi, whichever occurs first. At this point, flow stops and the system is ready to be flushed again. 
   SUMMARY OF THE INVENTION 
   Current control valves for pressurized water closet flushing systems do not permit the ready and simple adjustment of the predetermined portion of the water supplied under pressure while maintaining a flush action independent of actuator depression and a self-cleaning action. 
   Specifically, the present invention provides a ready and simple manual adjustment of the amount of water to be provided in a flush (the refill volume) while maintaining a flush action independent of actuator depression. The present invention also provides a self-cleaning action. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an elevational view of a water closet flushing system. 
       FIG. 2  is a cross sectional view taken along the line  2 — 2  of  FIG. 1  of a fully charged pressurized water closet flushing system according to the prior art. 
       FIG. 3  is a cross sectional view of the instant invention wherein the metering pin is maximally advanced. 
       FIG. 4  is a view similar to  FIG. 1  wherein the metering pin is minimally advanced; 
       FIG. 5  is a sectioned axial view of a valve similar to the valve shown in  FIGS. 3 and 4 ; 
       FIG. 6  is a side view of a valve according to a preferred embodiment of the present invention wherein the needle valve pin is tapered. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   As seen in  FIGS. 1 and 2 , a pressurized water closet flushing system  110 , in accordance with a known design represented by U.S. Pat. No. 5,970,271 to Martin, et al, is shown in operative association with a conventional water closet tank  112 . Major components of the system  110  are a water vessel  114 , an internal flush valve assembly  116 , and a manifold  118  comprising an integral flush valve actuator  122 , a water pressure regulator  124 , an air induction regulator  125 , a disinfectant reservoir  126 . 
   Water is supplied to the system  110  from a pressurized source (not shown) and flows upwardly without restriction through an inlet conduit  127  and vacuum breaker  128 , thence laterally to the manifold  118 . Water is free to flow through the conduit  127  to the manifold  118  at system pressure thence, after regulation, to both the flush valve assembly  116  and water vessel  114 , as will be described. 
   In the preferred constructed embodiment disclosed, the water vessel  114  comprises a pair of vertically stacked half sections  132  and  134 . The upper section  132  of the water vessel  114  has a pair of downwardly extending partitions  135  and  136  that create isolated chambers  137  and  138 , respectively, as long as the water level is above the weld joint between the sections  132  and  134  of the water vessel  114 , a typical condition between flushes. Accordingly, because the compressed air in the chambers  137  and  138  which powers the system  110  is isolated, a leak in an upper portion of the flush valve assembly  116  will not result in the system  110  becoming waterlogged. 
   The manifold  118 , comprising the water pressure regulator  124 , air induction regulator  125  and flush valve actuator  122 , is mounted on the upper section  132  of the water vessel  114 . 
   The manifold  118  also includes the flush valve actuator  122  according to the existing art, which comprises a cylindrical housing  180  with a manually operable spool  182  disposed internally thereof that is slidably journaled in a sleeve  184 . The spool  182  carries a valve  185  that is normally seated on a valve seat  186 . A needle valve  187  is supported on one end of the spool  182  so as to extend into an orifice  188  in the housing  180  to define the area of an annular water inlet orifice that controls the flow of water to the flush valve  116 . 
   Movement of the spool  182  of the flush valve actuator  122  against the bias of a spring  192  moves the valve  185  off its seat  186  to open communication between an upper chamber “C” of the flush valve  16 , through an orifice  94  to a pressure relief tube  96  to initiate flush. The tube  96  communicates with ambient pressure in the toilet bowl (not shown). 
   In operation, the water vessel  114  is fully charged with air and water and the system  110  is ready for flush. Zones (A), (B), (C) and (E) are pressurized. Zones (D), (F), and (G) are at atmospheric pressure. Flush occurs when the actuator spool  182  of the flush valve actuator  122  is depressed, allowing pressurized water in zone “C” to discharge through the actuator  122  into zone “D” thence to zone “F” as well as to flow through the water inlet conduit. The pressure differential established between zone “E” and zone “C” forces the piston  216  of the flush valve assembly  116  to life, creating an escape path for water in zone “E” through the discharge aperture  209  into the toilet bowl at zone “F”. It is to be noted that the piston  216  of flush valve assembly  116  lifts, for example, 0.40 inches, discharging only a corresponding volume of water from zone “C”. This volume of water is determined to be the amount of water capable of being discharged through the flush valve actuator  22  in {fraction (1/4 )} second. As a result, the same amount of water is required after each flush to refill zone “C” and cause the flush valve  210  to seal regardless of whether the spindle  182  of the flush valve actuator  122  is depressed for more than ¼ second. 
   As flush progresses, pressure in zone “E” begins to lower, allowing the regulator  124  to begin opening and flow to begin through zone “A” to zones “B” and “C”, flow through zones “A” and “B” is at maximum when pressure within vessel “E” is zero. 
   It is to be noted that the size of the needle valve orifice  188  in conjunction with the needle valve  187  controls the flow rate of new water into the upper chamber “C” of the flush valve  116 . Clogging of the annulus by particles in the water supply system is minimized because, when depressed, the needle valve  187  clears any foreign matter that lodges in the orifice  188 . 
   Refill volume of the toilet bowl utilizing this existing valve actuator can be varied by varying the diameter of the orifice  188  in conjunction with the diameter of the needle valve  187 , which varies the ratio of water passed into zone “C” respectively, thus speeding or slowing movement of the piston  216  and closure of the flush valve assembly  116  after flushing and/or the amount of bowl refill water passed through the water vessel  114  to the toilet bowl (not shown). As a result, the system  110  can be precisely tuned to different bowl configurations to obtain maximum water conservation and performance. The present invention provides an external manual adjustment for the bowl refill volume. 
   Referring to  FIGS. 3 and 4  and in accordance with a preferred constructed embodiment of the instant invention, an adjustable fluid metering valve  10  comprises a generally cylindrical housing  20  with a manually operable spool valve member (hereafter “spool”)  22  disposed internally thereof that is slidably journaled on a sleeve  24 . The spool  22  has an externally threaded portion  26  at one end thereof that rotatably engages a generally right circular cylindrical valve stem  30 . In a preferred embodiment, housing  20  defines an inlet  62 , through which water from zone C can enter housing  20  during a flush event, when used in conjunction with a pressurized water closet, for instance, the water closet described herein. Housing  20  further defines an outlet  64 , for discharge of water to zone F. Between flushes, spool  22  is preferably biased against a seat  66  by action of a biasing spring  68  acting on knob  50 , and thereby blocks fluid communications between inlet  62  and outlet  64 . When a flush event is initiated, knob  50  is pushed axially inward relative to housing  50 , lifting spool  22  from seat  66 , and establishing fluid communications between inlet  62  and outlet  64 . 
   The valve stem  30  is slidably journaled in the cylindrical housing  20  and has a plurality of longitudinal grooves or slots  32  therein, that engage a plurality of splines or tabs  36  protruding from the interior of the housing  20 , restricting or preventing rotation of the valve stem  30  with respect to the housing  20 . The valve stem  30  further has an internally threaded portion  38  that is engaged by the externally threaded portion of the spool  22 . An alternative embodiment is shown in  FIG. 5 , illustrating a sectioned view of a control valve. In the  FIG. 5  embodiment, a splined valve stem  130  is shown positioned within a housing  120 . Valve stem  130  includes at least one longitudinal spline  132  that is received in a groove  131  in housing  120 . Various modifications, including number of spline-groove pairs, dimensions of the splines and grooves, etc., could be made to the  FIG. 6  embodiment without departing from the scope of the present invention, so long as the valve stem  130  is “limited in rotation in the housing.” Still further embodiments (not shown) might utilize a square, oval or otherwise non-circular valve stem, and the rotation-limiting features disclosed herein should therefore not be taken to limit the scope of the present invention. It is only necessary that the respective shapes of housing  20  and valve stem  30  be such that valve stem  30  cannot rotate therein when spool  22  is rotated by manipulation of knob  50 . An alternative embodiment (not shown) might utilize a spool that is fixed from rotation, and a valve stem rotatable with respect to the housing. A rod could be positioned in a longitudinal bore in the spool, and connected to the external knob. In such a design, the valve stem could be fixedly mounted to the rod, and axially adjusted by a threaded engagement of the rod with the longitudinal bore in the spool. In a manner similar to other disclosed embodiments, such a design would allow actuation of the internal flush valve assembly in response to inward displacement of the external knob  50 , lifting the spool from its seat and opening fluid communications past seat  66 . 
   The spool  22  is rotated by an external manual adjustment knob  50 . As the spool  22  rotates, the valve stem  30  is restricted from rotation, and thus is driven by the rotation of the spool threads to slide inwardly or outwardly, depending upon the direction of rotation. Although the illustrated embodiments include an internally threaded valve stem and an externally threaded spool, this relationship might be reversed without departing from the scope of the present invention. A needle valve pin  40  is supported on one end of the valve stem  30  so as to extend into an orifice  60  in the housing  20  to define the area of an annular water inlet orifice that controls the flow of water to, for example, a flush valve in a water closet. The maximum diameter of the needle valve pin  40  is less than the diameter of the orifice  60  such that fluid communication therethrough is not interrupted by the action of the valve. 
   The orifice  60  in conjunction with the needle valve pin  40  of the instant invention minimizes the lodging of any foreign matter in the orifice  60  as the needle valve pin  40  can be readily advanced past the orifice to clear any obstruction therein. As used herein, the term “orifice” should be understood as referring to the three-dimensional, narrowed region of housing  20  into which pin  40  can extend. 
   When an adjustable flush valve actuator according to the present invention is used in conjunction with a pressurized water closet, as for example disclosed in U.S. Pat. No. 5,970,527 to Martin, et al, the refill volume of a toilet bowl can be varied by varying the diameter of the orifice  60  by advancing the needle valve pin  40  therein, which varies the volume of water passed into a pressurized chamber of the water closet (not shown) to obtain maximum water conservation and performance. The depth of penetration of the needle valve pin  40  in orifice  60  affects a fluid flow rate therethrough. Further, the valve pin may be tapered to allow for a more dramatic variation of volume control for a given rotation of the control knob. An illustrative embodiment of a valve stem  240  having a tapered valve pin  242  is shown in FIG.  6 . Other degrees of taper and lengths of the tapered region might be utilized in other embodiments (not shown), depending on the desired performance characteristics. For instance, where a particularly dramatic difference in refill volume is desired for a given rotation of the control knob  50 , the needle valve pin  40  can be designed with a relatively short length of the tapered region, and a relatively steep degree of tapering. Further, use of tapered pins having flattened end surfaces is contemplated, similar to the pins shown in  FIGS. 3 and 4 , as well as embodiments having pins that taper to a point, as in a conventional needle valve. Still other embodiments (not shown) could utilize a straight/cylindrical valve pin in conjunction with a tapered orifice that narrows in a direction away from the valve stem, to achieve a similar effect. Again, in such an embodiment significant variation in the dimensions and degree of the tapered region could exist without departing from the scope of the present invention. 
   While the preferred embodiment of the invention has been disclosed, it should be appreciated that the invention is susceptible of modification without departing from the spirit of the invention or the scope of the subjoined claims.