Abstract:
A fill valve assembly for a toilet tank is described. The fill valve assembly includes a two part design. The fill valve assembly includes a fill valve that connects or engages with a shank. A connection between the fill valve and the shank is located in an interior of the tank, which is easily accessed. The fill valve may be easily replaced by disconnecting the fill valve from the shank.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 61/898,930 filed Nov. 1, 2013, U.S. Provisional Patent Application No. 61/898,916 filed Nov. 1, 2013, and U.S. Provisional Patent Application No. 61/898,901 filed Nov. 1, 2013, which are all hereby incorporated by reference in their entireties. U.S. Non-Provisional application Ser. No. 14/529,264, filed Oct. 31, 2014, is also hereby incorporated by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention relates to fill valves for toilets. 
       BACKGROUND OF INVENTION 
       [0003]    Fill valves are typically installed in the bottom of toilet tanks. The installation of the fill valves usually occurs in the field, but sometimes the fill valves are installed to the toilet tank in the factory. Typical fill valves include a one piece construction that is positioned in the tank with a bottom portion extending through a hole in a bottom wall of the tank. A nut is threaded to the bottom portion to secure against the bottom surface of the toilet tank. 
         [0004]    Fill valves routinely fail due to constant use, hard water, and failed internal seals. Fill valves are typically replaced every 3 to 5 years. When they are replaced, an installer must use a bucket and towel, as the excess water that cannot be flushed (that pools beneath the edge of the flush valve) empties out the bottom of the tank. Moreover, the nut that secures the fill valve to the tank is below the tank, which may difficult to access. Finally, the entire fill valve is typically discarded during the replacement process. 
         [0005]    Also, many fill valves are cracked or split during the installation when the installers are tightening the nut that connects the fill valve to the toilet tank or when the hose connector of a water supply is connected to the fill valve. When the fill valve is cracked or split, the whole fill valve must be replaced. 
         [0006]    Finally, some fill valves have an over molded brass shank at the base. About 20% to 30% by volume of all fill valves sold in the United States have this over molded design. Unfortunately, when these fill valves fail, the brass shank is discarded with the fill valve. 
       SUMMARY 
       [0007]    A fill valve assembly for a toilet tank is described. The fill valve assembly includes a two part design. The fill valve assembly includes a fill valve that connects or engages with a shank. A connection between the fill valve and the shank is located in an interior of the tank, which is easily accessed. The fill valve may be easily replaced by disconnecting the fill valve from the shank. During replacement, the shank is not removed or unsealed from the tank. As such, replacement of the fill valve is convenient, easy, and does not require clean-up. Importantly, the brass shank, which typically does not fail, is not discarded by the replacement of the fill valve. 
         [0008]    The replacement of the fill valve does not require a bucket or towel. The old fill valve is disconnected from the shank in the inside of the tank and replaced with a new fill valve. The new fill valve may connect to the old shank. The old shank does not typically require removal from a fill valve hole in the bottom of the tank, so residual water in the tank will not drip out the fill valve hole. 
         [0009]    The shank described herein may be made with a brass construction. The toilet may only require a single installation of the brass shank during the lifetime of the toilet. The use of a brass shank will generally reduce claims caused by failed plumbing connections. This reduces costs. 
         [0010]    The fill valve assembly also helps to prevent over tightening. The connecting device maintains the seal or connection between the shank and the fill valve. The shank and the fill valve have an engineered seal and need not be over tightened. 
         [0011]    The fill valve uses a male and female fitting combination that enables a user or installer to make a sealed connection on an internal diameter of the shank by way of an o-ringed male part of the fill valve assembly. The internal diameter of the shank provides a female part. 
         [0012]    A connecting device is rotatably attached to the male part. The connecting device also engages to an outer surface of the female part such that the sealed fitting assemblies will not disconnect under normal pressure of a fluid working through the assemblies. 
         [0013]    In some aspects, the shank may be pre-installed to the tank at the factory. This may make it more likely that the installer/final owner will use and continue to use and/or replace the fill valve with the same brand of the fill valve. 
         [0014]    In one aspect, a fill valve assembly for a toilet tank is described. The fill valve assembly includes a shank. The shank includes a lower end and an upper end. The upper end includes an internal diameter. The fill valve assembly further includes a fill valve, which includes a shaft, a supply end, and a connecting device. The supply end seals against the internal diameter of the upper end of the shank. The connecting device secures the supply end to the upper end of the shank to maintain the seal between the supply end and the upper end of the shank. 
         [0015]    In another aspect, a fill valve assembly for a toilet tank is described. The fill valve assembly includes a shank, which includes a lower end and an upper end. The upper end includes a first sealing surface. The fill valve assembly includes a fill valve, which includes a shaft, a connecting device, and a second sealing surface. The first sealing surface of the shank seals with the second sealing surface of the fill valve. The connecting device engages the fill valve to the upper end of the shank. 
         [0016]    In another aspect, a fill valve for a toilet tank is described. The fill valve includes a float. The fill valve includes a shaft, which includes a lower end with an external sealing surface. A connecting device rotatably engages to the lower end of the shaft. The connecting device covers at least a portion of the external sealing surface. 
         [0017]    In another aspect, a fill valve assembly is described. The fill valve includes a male part. The male part includes one or more o-rings positioned about an exterior of the male part. A shank includes a female part, which includes an internal sealing surface and an outer engaging surface. The internal sealing surface of the female part receives the shank of the male part in a sealing engagement. A connecting device is rotatably attached to the male part. The connecting device engages the outer engaging surface of the female part to hold the male part and the female part together to maintain the sealing engagement. 
         [0018]    In another aspect, a toilet tank is described. The tank defines a reservoir to hold water. An opening is in a bottom wall of the tank. A shank passes through the opening. A nut secures the shank to the tank. The nut tightens against a lower surface of the bottom wall. A fill valve connects to an upper end of the shank. The upper end passes into an interior of the tank. 
         [0019]    In another aspect, a method of installing a fill valve for toilet tank is described. The method includes passing a shank through an opening of a toilet tank, wherein an upper end of the shank is in the toilet tank. The method includes providing a fill valve. The method includes engaging the fill valve to the upper end of the shank. 
         [0020]    In another aspect, a method of replacing a fill valve is described. The method includes disconnecting a first fill valve from a shank, wherein the shank passes through an opening of a toilet tank, wherein the upper end of the shank is in the toilet tank. The method includes connecting a second fill valve to the upper end of the shank. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0021]      FIG. 1  is a perspective view of the fill valve assembly installed to a toilet tank. 
           [0022]      FIG. 2  is a bottom perspective view of the fill valve assembly. 
           [0023]      FIG. 3  is a close-up, perspective view of the fill valve assembly installed to a toilet tank. 
           [0024]      FIG. 4  is a sectional view of the fill valve assembly installed to a toilet tank. 
           [0025]      FIG. 5  is a perspective view of the shank. 
       
    
    
     DETAILED DESCRIPTION OF INVENTION 
       [0026]    A fill valve assembly  5  is shown in  FIGS. 1-5 . The fill valve assembly  5  is used in a toilet bowl tank  210  control a refilling of the tank  210  after the tank  210  is flushed. The fill valve assembly  5  includes a fill valve  200  that engages to a shank  220 . The shank  220  passes through an opening  212  of the tank  210 . The shank  220  includes a lower end  230  and an upper end  240 . A water supply line  238  is engaged to the lower end  230  to provide fresh water to the tank  210 . 
         [0027]    The fill valve  200  may include a float  202  that rises and falls with the fluctuation of the water level in the toilet bowl tank  210 . When the float  202  rises to a determined level, the fill valve  200  shuts off the water supply into the toilet bowl tank  210 . In the aspect shown in the  FIGS. 1-5 , the float  202  travels on a vertical axis provided by a valve body  205 . In other aspects, the float  202  may connect to the fill valve  210  by an arm or other lever extending from the fill valve  210 . The valve body  205  may be adjustable in height in order to determine a level of water in the tank  210 . 
         [0028]    The valve body  205  includes a supply end  208  and a connecting device  90 , which engages or connects to the shank  220 . The supply end  208  is generally formed on a lower portion of the fill valve  200 . The supply end  208  is generally formed opposite of the float  202 . With reference to  FIG. 4 , the connecting device  90  engages the supply end  208  with the upper end  240  of the shank  220 . The connecting device  90  fluidly connects with the upper end  240  of the shank  220  to provide water to the fill valve  200 . 
         [0029]    During installation, the shank  220  is inserted through the opening  212  of the tank  210 . The upper end  240  of the shank  220  passes into the tank  210 , and the lower end  230  is positioned outside of and below the tank  210 . The lower end  230  of the shank  220  includes an external threaded surface  232 . A nut  240  threadingly engages the external threaded surface  232  to tighten the shank  220  to the toilet bowl tank  210 . The water supply line  238  supplies water to the fill valve  200  in order to fill the toilet bowl tank  210 . In other aspects, the lower end  230  of the shank  220  may include other connection surfaces and connection types to engage the water supply line  238 . 
         [0030]    The shank  220  will now be described in greater detail. With reference to  FIG. 5 , the shank  220  includes the lower end  230 , which connects to the water supply  238 . The lower end  230  includes the external threaded surface  232 . The shank  220  further defines an internal diameter  245  that provides for fluid flow through the shank  220 . The lower end  230  is integral with or transitions into the upper end  240 . In some aspects, the shank  220  expands in width or diameter to form a lip  238 . The lip  238  forms a shoulder, flange, or the like that catches a washer  260  to urge the washer  260  against a seal  265  in order to seal the shank  220  to the tank  210 . The lip  238  is generally positioned between the lower end  230  and the upper end  240  of the shank  220 . The shank  220  may include the lower end  230  generally opposite of the upper end  240 . When the nut  240  is tightened to the lower end  240  of the shank  220 , the lip  238  is pulled closer to the tank wall  210 , thus pulling the washer  260  and compressing the seal  265  against the opening  212  of the tank  210 . 
         [0031]    The upper end  240  of shank  220  includes a threaded external diameter  242 . Opposite of the threaded external diameter  242 , the upper end  240  includes the internal diameter  245  that forms an internal sealing surface  247 . The internal diameter  245  is generally smooth through the internal sealing surface  247 . 
         [0032]    The connecting device  90  is rotatably engaged to the fill valve body  205 . The supply end  208  forms a male part that inserts into the upper end  240  of shank  220 . The connecting device  90  threadingly engages to the threaded external diameter  242  of the upper end  240  of the shank  220 . Although the connecting device  90  is exemplified as a nut in  FIGS. 1-5 , the connecting device  90  may include any number of devices that maintain the seal between the supply end  208  and the shank  220 . 
         [0033]    The connecting device  90  is held in the rotational engagement to the supply end  208  via a retaining ring  213 . The retaining ring  213  circumscribes the supply end  208 . The supply end  208  includes a groove  288  that receives the retaining ring  213 . The connecting device  70  includes a shoulder  285  that catches against the retaining ring  213 . Until tightened to the shank  220 , the connecting device  90  may freely rotate relative to the supply end  208 . 
         [0034]    An annular gap  270  is formed between a threaded internal diameter  255  of the connecting device  90  and the supply end  208  of the fill valve  200 . This annular gap  270  forms a space or void that is sized to receive the upper end  240  of the shank  220 . This annular gap  270  may extend approximately from the groove  288  holding the retaining ring  213  to a tip  209  of the supply end  208 . 
         [0035]    The supply end  208  of the valve body  205  forms a sealing surface  214 . The sealing surface  214  is formed externally on the supply end  208 . The sealing surface  214  is formed on the outer diameter of the supply end  208 . The sealing surface  214  may include one or more grooves  217 . The sealing surface  214  may be generally smooth between the one or more grooves  217 . The sealing surface  214  may have intermittent smooth surfaces that form the sealing surface  214 . The grooves  217  may retain or include o-rings  249  that form a seal between the sealing surface  214  of the supply end  208  and the internal sealing surface  247  of the upper end  240  of the shank  220 . The insertion of the supply end  208  into the upper end  240  of the shank  220  forms a sealing engagement between the internal sealing surface  247  of the upper end  240  of the shank  220  and the sealing surface  214  of the supply end  208 . The connecting device  90  holds the internal sealing surface  247  of the shank  220  to the sealing surface  214  of the supply end  208  in the sealing engagement. During normal operation, the connecting device  90  prevents this sealing engagement from becoming unsealed. 
         [0036]    The connecting device  90  also shrouds the o-rings  249  on the supply end  208 . The connecting device  90 , in this way, protects the o-rings  249  during shipping and/or before final installation. A scarred or damaged o-ring  249  might fail - leading to leaks and costly repairs. The connecting device  90  also shrouds the sealing surface  214  of the supply end  208 . The connecting device  90  protects the sealing surface  214  during shipping and/or before final installation. Scarring or damage to the sealing surface  214  or debris on the sealing surface  214  might cause improper sealing—also leading to leaks and costly repairs. 
         [0037]    The connecting device  90  includes walls  93  extending from a first end  105  to a second end  108 . The walls  93  define or form the threaded internal diameter  255 , which threadingly engages the threaded external diameter  242  of the upper end  240  of the shank  220 . The walls  93  include an external surface  99  that may include any of a variety of scallops  102  or other gripping regions or surfaces. 
         [0038]    When the fill valve  200  requires replacement, the connecting device  90  of the fill valve  200  is disconnected from the upper end  240  of the shank  220 . As the connecting device  90  is in the toilet bowl tank  210 , the fill valve  200  is easily replaced since there is easy access to the old fill valve  200  through the top opening of the tank  210 . Further, as the shank  220  is not required to be removed from the opening  212  of the tank  210 , water does not leak out through the opening  212 . The integrity of the seal between the shank  220  and the tank  210  is not required to be interrupted by the replacement of the fill valve  200 . 
         [0039]    The connecting device  90  for engaging the fill valve  210  to the shank  220  may include any of variety of devices, such as nuts, threaded connectors, push-pull connectors, snap connectors, quarter or half turn nuts, etc. The connecting device  90  holds or maintains the sealing engagement between the supply end  208  of the fill valve  210  and the upper end  240  of the shank  220 . 
         [0040]    The connecting device  90  may formed from thermoplastics, such as glass filled nylon, polyethylene, polypropylene, or acrylonitrile butadiene styrene. The shank  220  may be formed from brass, metals, metal alloys, and plastics typically used in the plumbing industry. 
         [0041]    It should be understood from the foregoing that, while particular embodiments of the invention have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the present invention. Therefore, it is not intended that the invention be limited by the specification; instead, the scope of the present invention is intended to be limited only by the appended claims.