Patent Publication Number: US-11391391-B2

Title: Discharge valve system and method

Description:
RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 16/151,306, filed on Oct. 3, 2018, which claims priority to U.S. provisional application Ser. No. 62/567,653, filed on Oct. 3, 2017, the entire contents of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     Conventional discharge valves generally require undesirably high activation forces, and often do not provide options to maintain an opening, to close adequately during small fluid level drops, to be useable with various flow rates, provide a short return stroke, and/or provide a positive closing action. 
     SUMMARY 
     Some fluid valve assembly comprising an outlet base dimensioned to be positioned at least partially through a drain in a fluid tank, and a float assembly including a moveable float. In some embodiments, the moveable float is configured to form an at least partially fluid-tight seal at a first end when the moveable float is coupled to the outlet base, and to form a flow opening when the moveable float is at least partially decoupled from the outlet base. Some embodiments include a housing positioned with the moveable float, where the housing encloses a suction device coupled to a moveable piston. Some embodiments include an actuable diaphragm positioned in the outlet base, and a compressed air tube or passageway coupled to one side the actuable diaphragm. In some embodiments, the actuable diaphragm is configured and arranged to be actuated by compressed air to move the moveable piston. 
     In some embodiments, as a result of movement of the moveable piston, the suction device comprises a suction cup configured to be deformed against an inner surface of the housing forming a vacuum chamber. In some embodiments, the seal comprises a coupling of a lower lip of the moveable float and an upper lip of the outlet base. 
     Some embodiments comprise a fluid sensor. Some further embodiments comprise an air tube or passageway coupled to the housing and fluidly coupling the fluid sensor to the housing. Some further embodiments comprise a lower ballast region at the first end of the moveable float positioned between an inner wall and an outer wall of the first end. 
     Some embodiments comprise an upper ballast region at a second end of the moveable float, where the upper ballast is positioned between inner and outer walls of the second end. In some embodiments, the lower ballast region is configured to gain fluid to form a weight ballast when the moveable float is decoupled from the outlet base and the flow opening is present with fluid flowing from the fluid tank through the drain. 
     Some embodiments further comprise an inverted cup element built couple or integrated with the float. In some embodiments, the inverted cup element is configured and arranged to generate buoyancy to lift from fluid flowing from the fluid tank when the flow opening is present. In some embodiments, the inverted cup element is configured and arranged to be exposed to atmospheric pressure when the float is not yet exposed to buoyant force. In some other embodiments, the inverted cup element includes an air vent. 
     Some embodiments include an fluid valve assembly comprising an outlet base dimensioned to be positioned at least partially through a drain in a fluid tank. Some embodiments include a float assembly including a moveable float, where the moveable float is configured to form an at least partially fluid-tight seal at a first end when the moveable float is coupled to the outlet base, and to form a flow opening when the moveable float is at least partially decoupled from the outlet base. Some embodiments include a housing positioned with the moveable float that encloses a suction device coupled to a moveable piston. Some embodiments further comprise an actuable diaphragm positioned in the outlet base. 
     Some embodiments include a compressed air tube or passageway coupled to one side the actuable diaphragm that is configured and arranged to be actuated by compressed air to move the moveable piston. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a discharge valve assembly in a closed position according to at least one embodiment of the invention. 
         FIG. 2  is a perspective view of a discharge valve assembly in an open position according to at least one embodiment of the invention. 
         FIG. 3  is a cross-sectional view of a discharge valve assembly in a fully open position according to at least one embodiment of the invention. 
         FIG. 4  is a cross-sectional view of a discharge valve assembly in a closed position according to at least one embodiment of the invention. 
         FIG. 5  is cross-sectional view of a discharge valve assembly in an initial cracking open position according to at least one embodiment of the invention. 
         FIG. 6  is a rear view of the discharge valve assembly according to at least one embodiment of the invention. 
         FIG. 7A  is a partial cross-sectional view of the discharge valve assembly with float closed in accordance with some embodiments of the invention. 
         FIG. 7B  is a partial cross-sectional view of the discharge valve assembly with float open in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
     The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives which fall within the scope of embodiments of the invention. 
     Some embodiments include a discharge valve assembly for a fluid reservoir which requires a particular flowrate or different flowrates for fluid evacuation. In some embodiments, the discharge valve assembly  100  can shut off precisely and accurately at different fluid levels, substantially or completely independent of back pressure from the outlet. Further, some embodiments enable a small activation force to crack the seal open, and the seal pops up under the effect of a built in buoyancy or other force created by water or other fluid that travels upward inside the discharge valve assembly float. 
     Referring to  FIGS. 1-5 , some embodiments of the invention provide a discharge valve assembly  100  with low activation force and shutoff controlled by fluid levels, where the activation force is typically much lower than (and often a small fraction of) the activation forces required by conventional designs. Some embodiments include a discharge valve assembly  100  that features an initial small activation force to crack open a drain seal. For example, in reference to  FIG. 1  showing a discharge valve assembly  100  in a closed position, and  FIGS. 3-5 , showing the discharge valve assembly in various stages or states of operation, some embodiments comprise a float assembly  101  that can be positioned in a toilet tank T over a drain D. In some embodiments, the toilet bowl (not shown) can be positioned below drain D. 
     In some embodiments of the invention, the float assembly  101  can comprise a buoyant float  105  with lower lip  113  at the first end  105   a . In some embodiments, the float  105  can be moveable up and down based on a user-actuated flush and/or a fluid level in the tank T. In some embodiments, the discharge valve assembly  100  can comprise an outlet base  125  including an outlet  127  and upper lip  129 . The non-limiting embodiment shown in  FIG. 1  shows the discharge valve assembly  100  in a closed position or state where the lower lip  113  of the float  105  of the float assembly  10  is coupled to the upper lip  129  of the outlet base  105  forming a seal  130 . In some embodiments, fluid entering the tank T can at least partially surround the float assembly  101  (e.g., such as prior to a flush and/or at some point after a prior flush). In some embodiments, the two lips  127 ,  129  forming seal  130  can seal a drain D (thereby retaining water in tank T). 
     Some embodiments include a discharge valve assembly  100  that can fully extend to its full open stroke by itself to create adequate flowrate to evacuate fluid from a reservoir as intended. In other embodiments, the discharge valve assembly  100  can extend a portion of its stroke but still create adequate flowrates. For example,  FIG. 2  is a perspective view of a discharge valve assembly  100  in an open position according to at least one embodiment of the invention. In some embodiments, the float  105  can move substantially upward based on a fluid level change in the tank T. In some embodiments, the fluid level change can be based on a user-actuated flush and/or a fluid level changing for other reasons in the tank T. In this instance, the float  105  can at least partially decouple from the outlet base  125  where the upper lip  129  of the outlet base  105  separates from the lower lip  113  of the float  105 . 
     In some embodiments, the discharge valve assembly  100  can comprise an adjustable fluid level sensor  157 . In some embodiments, the adjustable level sensor  157  can allow a wide range of adjustment to control the residual fluid level in the reservoir using adjustment mount  159 . In some embodiments, the adjustment mount  159  can be coupled to an extension  161  that extends from the outlet base  125  adjacent the upper lip  129 . 
     In some embodiments of the invention, the discharge valve assembly  100  can maintain an open position (e.g., such as the open position of the non-limiting embodiment of  FIG. 2 ) until a preset fluid level is reached. In some embodiments, this can be accomplished and/or enabled using the above-mentioned adjustable level sensor  157 . In some embodiments, the discharge valve assembly  100  can be quickly released to its closed position (e.g., as shown in the non-limiting embodiment of  FIG. 1 ). Some embodiments include a system and apparatus to assist discharge valve assembly  100  closure during a small drop in fluid level. 
     In some embodiments, the discharge valve assembly  100  can be used for multiple applications that require different flowrates. For example, some embodiments of the discharge valve assembly  100  include a system and apparatus to adjust the open strokes of the discharge valve assembly  100  to control the flow rate at the outlet  127  of the outlet base  125  without changing the structure of the discharge valve assembly  100 . In some embodiments, the discharge valve assembly  100  includes a very short turn-on stroke. Some embodiments provide a positive closing action. 
     Some embodiments of the invention can include a suction or vacuum generating device such as a suction cup  163  coupled to a piston  152  within inner housing  150  within the float  105  of the discharge valve assembly  100 . In some embodiments, an evacuation of air from the suction cup  163  can create at least a partial vacuum which may result in the suction cup  163  contracting against at least one surface. For example, in some embodiments, the suction cup  163  can deform or move against an inner surface  151  of the inner housing  150 , thereby sealing to form a vacuum chamber  165 . In some embodiments, this vacuum chamber  165  can be connected to a level sensor  157  via an air tube  155  as shown in  FIGS. 3, 4 and 5 . In some embodiments, the level sensor  157  can be coupled to the discharge valve assembly  100  as shown, or can be located remotely and coupled to the discharge valve assembly  100 . 
     As described earlier, in some embodiments of the invention, the float  105  can be moveable up and down based on a user-actuated flush and/or an otherwise changing fluid level in the tank T (where fluid flow  200  is marked by arrows). In reference to at least  FIGS. 1, 3, and 5 , in some embodiments, an activation force can be created by a pneumatic force on the piston  152  that is of sufficient magnitude to at least partially push the float  105  upward (i.e., away from the outlet base  125 ). In some embodiments of the invention, a pneumatic button (not shown) can be pushed or actuated by a user to cause or enable compressed air to flow in tube  114  to one side of a diaphragm  195 . 
     In some embodiments, the pneumatic force on the piston  152  is of sufficient magnitude to overcome a downward force on the float  105  of the discharge valve assembly  100 , and the float  105  can at least partially decouple from the outlet base  125  where the upper lip  129  of the outlet base  105  separates from the lower lip  113  of the float  105 . In some embodiments, this action can occur quickly or instantly as demonstrated in  FIG. 5 , where a flow opening  32  can form between the float  105  and the outlet base  125 . In some embodiments, as soon as the discharged fluid flows inside the float  105  (shown as arrows in  FIG. 5 ), a vented inverted cup  154  built inside or coupled to the float  105  can generate enough buoyancy to lift the float  105  against the downward forces urging the float down during the closing stage to completely open the discharge valve assembly  100  (shown in  FIG. 3 ). In some embodiments, this vacuum force can take over control of the motion of the float  105 . In some embodiments, force created by the vacuum can hold the float at an open position until the fluid level in the tank T drops below the level sensor  157 . At that point, air can enter the vacuum chamber  165  of the suction cup  163  through the level sensor  157  and the air tube  155  to relieve at least a portion of the negative pressure pulling on the float  105 . 
     Some further embodiments include fluid ballast weights that can control buoyancy and/or movement of the float  105 . For example, some embodiments include a ballast weight region  109   a  positioned at the upper section  107  of the float  105  (second end  105   b ), and generally positioned between an inner wall  183   a  and an outer wall  183   b . Some further embodiments include a ballast weight region  109   b  at the first end  105   a , positioned inside of the float  105  (marked as  109   b ) and generally positioned between inner wall  181   a  and outer wall  181   b . In some embodiments, any fluid within either or both of the ballast weight regions  109   a ,  109   b  can comprise a ballast weight that can control buoyancy and/or movement of the float  105 , and/or can force the float  105  downward. In some embodiments, as the float  105  reaches the outlet base  125 , the discharge valve assembly  100  move back to a closed position or state where the lower lip  113  of the float  105  of the float assembly  10  is coupled to the upper lip  129  of the outlet base  105  forming a seal  130 . Further, any replacement fluid entering the tank T can at least partially surround the float assembly  101  and the seal  130  can substantially seal a drain D. 
     In reference to  FIG. 7A , showing a partial cross-sectional view of the discharge valve assembly with float closed in accordance with some embodiments of the invention, and  FIG. 7B , showing a partial cross-sectional view of the discharge valve assembly with float open, in accordance with some embodiments of the invention, a built-in buoyancy cup or other fluid containing structure inside the float of the discharge valve assembly  100  can include an air venting capability or functionality (e.g., such as the sliding air gate  300  shown in  FIG. 7B ), so that when the valve is in a closed position (shown in  FIG. 7A ), the cup  154  can be exposed to atmosphere pressure while the float  105  is not yet exposed to buoyant force. Further, when the float  105  is cracked open (shown in  FIG. 7B ), the fluid can enter the inside chamber (shown as fluid  200 ) of the float  105  and the built-in buoyancy cup  154 , producing a buoyant force. In some embodiments, the buoyant force that can lift the float  105  up, away from the sucking force, due to the flow downward into the opening of the base structure  125 , to bring the float  105  to its fully open position. In some embodiments, at this time, the air venting system and apparatus (e.g., sliding air gate  300  will automatically open to vent the air ( 310 ) trapped inside the built-in buoyancy cup ( 310   a ) and allow fluid to enter this space. In some embodiments, the fluid then overspills through this air venting system and apparatus (sliding air gate  300 ) to at least partially fill the bottom fluid ballast weight ( 109   b ) of the float  105 . This fluid ballast weight can be used to later close the valve. In some embodiments, the fluid ballast weight cup includes venting hole(s) ( 175 ) to drain the fluid after the valve is closed to remove the weight from the float  105  and be ready for the next cycle. 
     In some embodiments, the upper weight ballast of the float (marked as  109   a ) (e.g., as shown in  FIGS. 3-5 ) can be submerged in the fluid reservoir when the discharge valve assembly  100  is at its closed position (shown in  FIGS. 4 and 5 ). Further, it can include venting hole  109   c  along its wall (e.g., see  FIG. 6 ). In some embodiments, when submerged, any fluid inside the upper weight ballast  109   a  does not exert force on the float  105 . Further, when the float  105  is lifted to its open position, gravity force from the upper weight ballast  109   a  can apply a downward force on the float  105  to assist closing the discharge valve assembly  100  when the vacuum force is released from the system. 
     This upper weight ballast  109   a  is one example embodiment of a system and apparatus that can be used to push the float  105  down against residual fluid (shown as  15  in  FIG. 3 ) in the tank T to achieve a small closing stroke for the discharge valve assembly  100  when fluid in the tank T is too high above the bottom weight ballast  109   b . In another example embodiment generally equivalent to the upper weight ballast  109   a , a conventional spring or other biasing member (not shown) that will be compressed when the float  105  is at its open position can be used to create a downward force on the float  105 . In some embodiments, the combination of the upper weight ballast  109   a , bottom weight ballast  109   b  and the adjustable level sensor  157  can allow a wide range of adjustment to control the residual fluid level in the tank T. 
     Some embodiments of the invention can utilize the buoyant force to open the discharge valve assembly  100  at the desired time, and then to make it disappear quickly or immediately afterward to remove its effects on the closing action of the float  105 . Further, some embodiments of the invention can utilize a vacuum force generated by the upward motion of the float  105  to hold the float  105  at its open position. 
     Some further embodiments of the invention can create potential energy on the weight ballasts  109   a ,  109   b  to be ready for closing the discharge valve assembly  100  when the adjustable level sensor  157  releases the vacuum energy exerted on the float  105 . Additionally, some embodiments of the invention can induce the potential energy from the weight ballasts  109   a ,  109   b  to be removed from the float  105  of the discharge valve assembly  100  after it is closed so that this potential energy will not need to be maintained during the closing time of the discharge valve assembly  100 , and thereby not contributing to negative effects such as requiring extra activation force to overcome it during the opening stage. In some embodiments, any of the systems and methods disclosed herein can minimize the overall activation force to open the discharge valve assembly  100 . 
     Some further embodiments include a method to control the open strokes of the float  105  of the discharge valve assembly  100  to control flowrates for different applications. In some embodiments, by adjusting a stop on the float  105  for its upward motion, the opening distance between the float  105  and the sealing surface ( 129 ) can be altered to change the discharge flowrate. In some embodiments, this method of adjusting the open stroke of the float  105  can be enabled by the vacuum force that is stronger than any sucking or dragging force on the float  105  if it is exposed to the stream of fluid flowing down into the outlet base  125 . 
     It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the description and figures, and the following claims.