Patent Publication Number: US-8534313-B1

Title: Toilet fill valve auxiliary shutoff mechanism

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application 61/682,121, filed on Aug. 10, 2012, and incorporated herein by reference. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
     Not Applicable. 
     FIELD OF THE INVENTION 
     This invention relates to valve actuators, and more particularly to a toilet fill valve shutoff mechanism. 
     DISCUSSION OF RELATED ART 
     Conventional toilet fill valves include a fill valve float mechanism that lifts an arm in response to a rising water level in a toilet tank. The arm closes the toilet fill valve when lifted by the fill valve float mechanism. Such prior art valves, and other toilet components, are prone to frequent failure. For example, when a toilet becomes “plugged” due to an obstruction in the toilet drain, flushing of the toilet may result in overflow of the toilet bowl and subsequent property damage to the surrounding area. Prior art toilet valves do not provide for shutting the water supply off when a high-level condition in a toilet bowl is detected, which would be beneficial for reducing property damage. 
     Further, prior art toilet fill valves may leak, that is, not completely shut off when the water level in the toilet tank reaches the “full” water level position within the tank. As such, the water level in the tank can reach a high-level where water either continuously drains down an auxiliary drain if the toilet includes such a provision, or water could overflow the toilet tank and again result in property damage. 
     The prior art flush valve in a toilet is also prone to frequent failures. In one instance, the flush valve may become “stuck open” whereby the fill valve runs continuously because the water level in the tank is never able to rise. As a result, a significant amount of water may be wasted while such a valve is stuck open. Moreover, such prior art flush valves may leak, which results in the water level in the tank slowly lowering until the float reaches a point that it opens the fill valve. As the fill valve typically introduces water into the tank at a faster rate than such a leaky flush valve leaks water, the water level in the tank rises to the point where the float shuts off the fill valve. But the flush valve continues to leak, and a repeating cycle of filling the tank ensues, again resulting in a significant waste of water and greater expense to the property owner. None of the prior art toilet fill valves provides for detecting either of these flush valve fault conditions to shut-off the water and prevent waste thereof. 
     Therefore, there is a need for a device that can detect a toilet bowl high water level fault, a toilet tank high water level fault, a “stuck open” flush valve, and a leaky flush valve and shut-off the toilet fill valve accordingly. Such a needed device would be relatively easy to affix to prior art fill valves, and would be relatively easy to install on a conventional toilet. Such a needed device would further provide means for alerting a user as to the fault condition. The present invention accomplishes these objectives. 
     SUMMARY OF THE INVENTION 
     The present invention is an auxiliary actuator for a toilet fill valve of the type having a fill valve float mechanism that lifts an arm in response to a rising water level in a toilet tank. The arm closes the toilet fill valve when lifted by the fill valve float mechanism, as is known in the art. 
     The auxiliary actuator comprises a plunger slidably and vertically oriented under the arm of the toilet fill valve to lift the arm sufficient to close the toilet fill valve when the plunger is in a raised position. A biasing means urges the plunger into the raised position. 
     A solenoid mechanism is normally de-energized and adapted to engage a latching mechanism of the plunger when the plunger is in a lowered position. The solenoid mechanism when energized disengages from the latching mechanism to allow the plunger to be urged into the raised position by the biasing means. 
     An electronic sensing circuit is included that has at least one sensor and a power source. The electronic sensing circuit is electrically connected with the solenoid mechanism to energize the solenoid mechanism upon detection of a fault condition based on the input of the at least one sensor. The electronic sensing circuit may further include a control module that has a circuit board, a reset switch, a mode selector switch, an audible warning device, and at last one LED indicator. As such, the audible warning device and/or the at least one LED indicator may be energized by the electronic sensing circuit to alert a user to the fault condition. The control module may further include an external port, such that the electronic sensing circuit may set an indication of a type of fault condition thereon. As such, an external alarm system connected to the external port may be utilized to alert a user to the fault condition. 
     The at least one sensor may be a water level sensor for sensing the water level in the toilet tank. The electronic sensing circuit may be programmed to detect a slow leak in the flush valve of the toilet tank by observing over a predetermined period of time a repeating pattern of the water level decreasing relatively slowly compared with a regular flush of the toilet, and then increasing as the fill valve refills the toilet tank. As such a fault condition is established and the electronic sensing circuit energizes the solenoid mechanism to essentially “turn off” the toilet until the slow leak in the flush valve is fixed. Further, the at least one LED indicator may be energized to indicate a slow flush valve leak, or an indication of such a fault condition may be transmitted by the wireless transmitter or otherwise conveyed to the external alarm system. The electronic sensing circuit may be further programmed to detect a stuck-open flush valve by observing a continuous low water level in the toilet tank. The electronic sensing circuit may be further programmed to detect a leaking fill valve by observing a continuous high water level in the toilet tank. 
     The at least one sensor may be a water level sensor for sensing the water level in a toilet bowl, and the electronic sensing circuit may be programmed to detect a “plugged toilet” fault condition by observing a high water level in the toilet bowl. 
     In an alternate embodiment the biasing means is a hydraulic mechanism powered by water pressure from the toilet fill valve. In such an embodiment, a solenoid operated valve normally is de-energized and is adapted to block water pressure from the toilet fill valve from raising the plunger. The solenoid operated valve, when energized because of the detection of a fault, allows water pressure from the toilet fill valve to raise the plunger to close the toilet fill valve. 
     The present invention is a device that detects a toilet bowl high water level fault, a toilet tank high water level fault, a “stuck open” flush valve, and a leaky flush valve and shuts-off the toilet fill valve accordingly. The present invention is relatively easy to affix to prior art toilet fill valves, and is relatively easy to install on a conventional toilet. The present device further provides means for alerting a user as to the fault condition. Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The objects and features of the present invention which are believed to be novel, are set forth with particularity in the appended claims. This present invention, both as to its organization and manner of operation, together with further description, taken in conjunction with accompanying drawings in which: 
         FIG. 1  is a front perspective view showing a prior art toilet fill valve with the actuation mechanism of the present invention attached and integrated therewith; 
         FIG. 2  is a rear perspective of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view of  FIG. 1  showing the fill valve open; 
         FIG. 4  is a cross-sectional view of  FIG. 1  showing the fill valve closed; 
         FIG. 5  is an exploded perspective view of the actuator mechanism of  FIG. 1 ; 
         FIG. 6  is an installation drawing showing the invention installed in a typical toilet; 
         FIG. 7  is a perspective diagram of a control module of the present invention and an external alarm system; 
         FIG. 8  is a cross-sectional view of an alternate embodiment of the invention that includes a hydraulic mechanism powered by water pressure from the toilet fill valve and a solenoid operated valve, the toilet valve in an open position; and 
         FIG. 9  is a cross-sectional view of  FIG. 8 , but showing the toilet valve in a closed position. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Illustrative embodiments of the invention are described below. The following explanation provides specific details for a thorough understanding of and enabling description for those embodiments. One skilled in the art will understand that the invention may be practiced without such details. In other instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments. 
     Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” Words using the singular or plural number also include the plural or singular number respectively. Additionally, the word “herein,” “above,” “below” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. When the claims use the word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list and any combination of the items in the list. 
       FIGS. 1-5  illustrate an auxiliary actuator  11  for a toilet fill valve  10  of the type having a fill valve float mechanism  26  that lifts an arm  16  in response to a rising water level  8  in a toilet tank  9 . The arm  16  closes the toilet fill valve  10  when lifted by the fill valve float mechanism  26 . 
     The auxiliary actuator  11  comprises a plunger  13  slidably and vertically oriented under the arm  16  of the toilet fill valve  10  to lift the arm  16  sufficient to close the toilet fill valve  10  when the plunger  13  is in a raised position  50 . A biasing means  15  urges the plunger into the raised position  50  ( FIG. 4 ). 
     A solenoid mechanism  18  is normally de-energized and adapted to engage a latching mechanism  17  of the plunger  13  when the plunger  13  is in a lowered position  40  ( FIG. 3 ). The solenoid mechanism  18  when energized disengages from the latching mechanism  17  to allow the plunger  13  to be urged into the raised position  50  by the biasing means  15 . 
     The plunger  13  is preferably contained in a plunger housing  14 . The biasing means  15 , such as a spring, is positioned below the plunger  13  and oriented to push the plunger  13  upwards against the underside of the float arm  16 . The latching mechanism  17  may include a circumferential groove. A solenoid mechanism  18  is positioned within a solenoid housing  27  such that a solenoid armature  19  engages the circumferential groove  270  of the plunger  13 . The solenoid armature  19  is biased against the circumferential groove  270  of the plunger  13  by a solenoid armature spring  20 . In one embodiment, the plunger housing  14  and the solenoid housing  27  are positioned in a mounting bracket  28  and attached to the commercially available fill valve  10 . 
     The plunger  13  preferably has a beveled end  21  so that when it is manually pushed downward, the beveled end  21  pushes against the solenoid armature  19 , causing it to retract. When the plunger  13  is manually pushed down to a position where the circumferential groove  270  aligns with the solenoid armature  19 , the solenoid armature  19  is then pushed forward by the solenoid armature spring  20  to engage the circumferential groove  270  of the plunger  13 , thus preventing the plunger  13  moving to its raised position  50  under the influence of the biasing means  15 . When the solenoid  18  receives a signal from the electronic sensing circuit  60  it retracts, withdrawing the solenoid armature  19  from the circumferential groove  270  of the plunger  13 . This allows the biasing means  15  to push the plunger  13  upwards against the float arm  16 , causing the fill valve  10  to close as though the fill valve float mechanism  26  had raised in response to the rising water level  8  in the toilet tank  9 . Once the plunger  13  has been released and the fill valve  10  is closed, it must be reset manually by pushing downward on the float arm  16  until the solenoid armature  19  re-engages the circumferential groove  270  of the plunger  13 . 
     An electronic sensing circuit  60  is included that has at least one sensor  12  and a power source  70 , such as a battery, AC adapter  72 , or the like. The electronic sensing circuit  60  is electrically connected with the solenoid mechanism  18  to energize the solenoid mechanism  18  upon detection of a fault condition based on the input of the at least one sensor  12 . 
     The electronic sensing circuit  60  may further including a control module  22  that has a circuit board  80  ( FIG. 7 ), a reset switch  90 , a mode selector switch  100 , an audible warning device  110 , and at last one LED indicator  120 . As such, the audible warning device  110  and the at least one LED indicator  120  may be energized by the electronic sensing circuit  60  to alert a user to the fault condition. 
     The control module  22  may further include an external port  160 , such that the electronic sensing circuit  60  may set an indication of a type of fault condition thereon. As such, an external alarm system  170  connected to the external port  160  may be utilized to alert a user to the fault condition. The control module  22  may include a wireless transmitter  180  for wirelessly transmitting an indication of the fault condition to the external alarm system  170 . Such an external alarm system may be a dedicated alarm system located remotely from the toilet and having access to a power source, or it may be alternately incorporated into a computer software application through a wireless networking protocol such as Wi-Fi, Bluetooth, or the like. 
     The at least one sensor  12  may be a water level sensor  130  for sensing the water level  8  in the toilet tank  9 . Such a water level sensor  130  may include, for example, a body  23  and a float  24 . The sensor  130  may further include any type of electronic sensing device such as a series of reed switches, a linear potentiometer, a linear variable differential transformer (LVDT), a magnetostrictive transducer, or other mechanism for sensing the position of the float  24  on the body  23 . 
     The electronic sensing circuit  60  may be programmed to detect a slow leak in the flush valve (not shown) of the toilet tank  9  by observing over a predetermined period of time a repeating pattern of the water level  8  decreasing relatively slowly compared with a regular flush of the toilet, and then increasing as the fill valve  10  refills the toilet tank  9 . As such a fault condition is established and the electronic sensing circuit  60  energizes the solenoid mechanism  18  to essentially “turn off” the toilet until the slow leak in the flush valve is fixed. Further, the at least one LED indicator  120  may be energized to indicate a slow flush valve leak, or an indication of such a fault condition may be transmitted by the wireless transmitter  180  or otherwise conveyed to the external alarm system  170 . 
     The at least one sensor  12  may be the water level sensor  130  for sensing the water level in the toilet tank  9  as above, and the electronic sensing circuit  60  may be further programmed to detect a stuck-open flush valve by observing a continuous low water level  140  in the toilet tank  9 . As such a fault condition may be established and the electronic sensing circuit  60  may energize the solenoid mechanism  18  to essentially “turn off” the toilet until the stuck-open flush valve condition is fixed. Further, the at least one LED indicator  120  may be energized to indicate a stuck-open flush valve condition, or an indication of such a fault condition may be transmitted by the wireless transmitter  180  or otherwise conveyed to the external alarm system  170 . 
     The at least one sensor  12  may be a water level sensor  25  ( FIG. 6 ) for sensing the water level in a toilet bowl  7 . The toilet bowl water level sensor  25  may be one or more float switches (not shown), a capacitive type sensor (not shown), or any other suitable type of water level sensor. The electronic sensing circuit  60  may be programmed to detect a toilet bowl high water level fault by observing a high water level  152  in the toilet bowl  7 . As such a fault condition may be established and the electronic sensing circuit  60  may energize the solenoid mechanism  18  to essentially “turn off” the toilet until the “plugged toilet” condition is fixed. Further, the at least one LED indicator  120  may be energized to indicate a plugged toilet condition, or an indication of such a fault condition may be transmitted by the wireless transmitter  180  or otherwise conveyed to the external alarm system  170 . 
     The at least one sensor  12  may be the water level sensor  130  for sensing the water level  8  in the toilet tank  9  as above, and the electronic sensing circuit  60  may be further programmed to detect a leaking fill valve  10  by observing a continuous high water level  150  in the toilet tank  9 . As such a fault condition may be established and the electronic sensing circuit  60  may energize the solenoid mechanism  18  to essentially “turn off” the toilet until the leaking fill valve condition is fixed. Further, the at least one LED indicator  120  may be energized to indicate a leaking fill valve condition, or an indication of such a fault condition may be transmitted by the wireless transmitter  180  or otherwise conveyed to the external alarm system  170 . 
       FIG. 8  shows an alternate embodiment where the biasing means  15  is a hydraulic mechanism  200  powered by water pressure from the toilet fill valve  10 . In such an embodiment a solenoid operated valve  210  normally is de-energized and is adapted to block water pressure from the toilet fill valve  10  from raising the plunger  13  to close the toilet fill valve  10 . The solenoid mechanism  211  shown in this embodiment is a “push type” as opposed to a “pull type” shown previously as item # 18 , although either type may be utilized.  FIG. 8  shows the solenoid  211  de-energized and the valve spool  214  in its normal position blocking the water pressure from the pressure tap  213  in the toilet fill valve  10 . Water pressure is obtained from the toilet fill valve  10  by means of a hose  215 , or other water passage connected from the inlet side of the toilet fill valve  10 . 
       FIG. 9  shows the alternative embodiment when a fault condition has been established by the electronic sensing circuit  60  and a signal has been sent to the solenoid  211 , causing it to be energized. The solenoid armature  212  extends, pushing the valve spool  214  to the right, directing water pressure from the pressure tap  213  in the toilet fill valve  10  into the area below the plunger  13 , causing it raise, lifting the float lever arm  16  and shutting off the toilet fill valve  10 . 
     The alternate embodiment hydraulic mechanism may be reset manually by pushing the valve spool  214  back to its normal position and then pushing the plunger  13  downward, expelling the water from beneath it. 
     While a particular form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims. 
     Particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the invention. 
     The above detailed description of the embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above or to the particular field of usage mentioned in this disclosure. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. Also, the teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments. 
     All of the above patents and applications and other references, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions, and concepts of the various references described above to provide yet further embodiments of the invention. 
     Changes can be made to the invention in light of the above “Detailed Description.” While the above description details certain embodiments of the invention and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Therefore, implementation details may vary considerably while still being encompassed by the invention disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. 
     While certain aspects of the invention are presented below in certain claim forms, the inventor contemplates the various aspects of the invention in any number of claim forms. Accordingly, the inventor reserves the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention.