Abstract:
Disclosed are valve assemblies for controlling flow from a toilet bowl to a trap way. In one form there is a cartridge unit in which a pivotable gate is mounted. The gate can swing from a blocking/closing position to a position in which it is essentially hidden away in a recess out of the main flow path. The surface of the gate facing the bowl is inwardly dished to further facilitate flow optimization.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   Not applicable. 
   STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable. 
   BACKGROUND OF THE INVENTION 
   The present invention relates to toilets, and more particularly to toilet valves controlling the outflow of waste from a toilet bowl to a toilet trap. 
   Although flushing toilets greatly aid in the sanitary disposal of human excrement, water usage is impacted by such devices. As the need and desire to conserve water increases, there is a corresponding desire to reduce the volume of water used per average flush of a toilet. 
   A typical toilet includes a valve upstream of the toilet bowl, such as at the bottom of a water storage tank. When the toilet is flushed, the valve in the water tank opens, and the tank water is able to flush into the toilet bowl. 
   With these conventional toilets there is typically a delay between the beginning of the flushing cycle and the time that most of the crude waste has been removed from the bowl. An undesirably large amount of flushing water is required just to move the main waste out of the bowl, and a further amount is needed to provide the final rinse. 
   One way of reducing this problem is to provide a trap configured with an inlet valve and shaped such that when the inlet valve is opened most of the waste water will drop out of the bowl regardless of any new flush water entering. Examples of this approach include U.S. Pat. Nos. 168,613, 234,570, 279,048, 299,333, and 4,016,609. 
   However, such valves are necessarily placed in a blocking position relative to the outflow of waste from the bowl. Even when fully open they typically impede the flow of fluid and waste out of the bowl to some extent. Moreover, they sometimes result in clogging, maintenance or wear problems. Also, they may be expensive to produce or install, or be unreliable over prolonged usage. 
   For example, U.S. Pat. No. 4,016,609 disclosed a toilet having a bendable member for controlling waste outflow from a toilet basin. The resiliency of the bendable member was critical for proper operation, which resiliency could degrade over time. Additionally, the valve was not easily installed into the toilet. 
   Hence, a need still exists for improved toilet trap valve assemblies, particularly those which facilitate flushing with reduced amounts of water. 
   SUMMARY OF THE INVENTION 
   In one aspect the present invention provides a toilet having a bowl with a discharge outlet, a trap in fluid communication with the discharge outlet, and a valve positioned to control outflow from the discharge outlet to the trap. This valve is in the form of a cartridge unit having a first housing part, a second housing part linked to the first housing part so as to define a cavity there between, and a pivotable gate positioned in the cavity so as to be able to swing between a first position essentially closing off flow through the discharge outlet to a second position permitting flow from the discharge outlet to the trap. 
   Particularly in accordance with the present invention the cavity has a recess along one of its walls. When the pivotable gate is in the second position a portion of the pivotable gate is housed in the recess. This helps move the gate out of the way and thereby increases the efficiency of the water force flowing out of the bowl. This then further reduces the need for as much water to complete an effective flushing cycle. 
   In preferred forms of the invention pivoting of the pivotable gate can be driven by movement of a mechanical or hydraulic linkage that extends outside of the housing parts. This can be connected to a controller which also controls initiation and ending of the water flush. 
   In other preferred forms the pivotable gate carries a deformable seal suitable to seal against a housing part when the pivotable gate is in the first position, and the pivotable gate has an inwardly dished side facing the toilet bowl when the pivotable gate is in the first position. This helps the flow when the gate is in the open position to occur much more smoothly. There can also be an outwardly dished side of the gate which is configured to face a housing part when the pivotable gate is in the second position. 
   In another preferred aspect of the invention the trap has a normal trap water level to restrict back flow of sewer gases to the bowl, and the pivotable gate is positioned above that water level. Further, the valve cartridge can provide a flow path that bends from an essentially vertical path adjacent the bowl discharge outlet to a path at least somewhat horizontal. 
   In another aspect of the invention the invention can provide such a cartridge valve suitable to connect to such a toilet. 
   In a further aspect of the invention there can be provided a toilet trap way for carrying waste from a toilet bowl to a toilet trap. The trap way has a gate valve at its inlet end in the form of a pivotable gate movable between a first position essentially closing off flow through the trap way and a second position permitting flow through the trap way. The trap way has a recess along one of its walls and when the pivotable gate is in the second position a portion of the pivotable gate can be housed in the recess. 
   The present invention advantageously reduces the amount of water needed to complete a flush cycle with a given degree of cleaning. Further, the incidence of maintenance problems is reduced by keeping the gate above the normal trap water level in an air pocket. Further, if maintenance issues arise, the valve cartridge can be replaced without having to dispose of the trap or bowl when the cartridge unit forms of the valve are used. 
   These and still other advantages of the present invention will be apparent from the detailed description which follows and the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a vertical cross-sectional view through a toilet in which is installed an embodiment of the present invention; 
       FIG. 2  is a perspective view of an outlet valve of  FIG. 1 ; 
       FIG. 3  is a perspective view of one of the housing halves, and the gate, of the valve of  FIG. 2 ; 
       FIG. 4  is an enlarged cross-sectional view taken along line  4 - 4  of  FIG. 2 ; 
       FIG. 5  is an exploded perspective view of the valve of  FIG. 2 ; 
       FIG. 6  is a perspective view of a second embodiment of a valve according to the present invention; 
       FIG. 7  is a cross-sectional view taken along line  7 - 7  of  FIG. 6 ; 
       FIG. 8  is an exploded perspective view of the valve of  FIG. 6 ; 
       FIG. 9  is a perspective view of a third embodiment of a valve according to the present invention; 
       FIG. 10  is a cross-sectional view taken along line  10 - 10  of  FIG. 9 ; and 
       FIG. 11  is an exploded perspective view of the valve of  FIG. 9 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring first to  FIG. 1 , there is shown the lower portion of a toilet  20  which includes a bowl  22  having a discharge outlet  24 , a trap  26  in fluid communication with discharge outlet  24 , and a discharge valve cartridge  28  in accordance with the present invention located between bowl  22  and trap  26 . 
   Toilet  20  will typically include other elements such as a water tank or other water supply source (not shown), a seat, a lid and/or other covering elements on the bowl (again all not shown). A control mechanism (again not shown) can be mechanically or otherwise linked to a flush mechanism which both starts the flush cycle and pivots the gate  40  from a closed position to an open one, and then back again. Alternatively, one could manually move the gate by rotating stem  52  manually. 
   Toilet  20  can include a flange  30  near the bottom of bowl  22 , and/or other connecting elements such as fasteners (not shown), and a gasket  32 , for connecting valve cartridge  28  at flange  33 . In any event, trap  26  has a trap water level  34  for preventing return of sewer gas, and can be connected to valve cartridge  28  at collar  35  with a flexible piece of rubber and/or other elements such as clamps (all not shown). Valve cartridge  28  permits the passage of waste and fluid from bowl  22  to trap  26 . 
   Referring more particularly to  FIGS. 2-5 , valve cartridge  28  includes a first housing part  36 , a second generally mirror image housing part  38  connected to first housing part  36 , and a pivotable gate  40  mounted inside a cavity defined between the first and second housing parts  36 / 38 . 
   Gate  40  includes an inwardly dished side  42  and an outwardly dish side  44  which includes a contour  46 . The contour  46  mimics a contour  48  formed on the inside wall of the cavity formed by the housing parts. 
   As shown in  FIG. 4 , when gate  40  is pivoted by rotatable stem  52 , it pivots down and against contour  48 . This moves the gate out of the blocking/sealing position. 
   It should be appreciated that between flushes waste material will not normally stay in the trap above trap water level  34 . Thus, waste won&#39;t typically collect against contour  48 . Note also that valve cartridge  28  has a gasket  50  to help maintain a proper seal between the outer edge of the gate and the trap wall. Note further that the presence of an air pocket  54  also facilitates maintenance of the stem  52 . 
   During a flushing cycle, one trips a flush initiator which ultimately pivots the gate  40  out of the closed position permitting waste to rapidly evacuate through inlet  56  of the valve cartridge. It is preferred that the start of the flush water will be delayed slightly to permit most of the evacuation to occur before clean flush water starts to rinse the bowl. 
   After a defined period the flap valve will return to the  FIG. 1  closed position, and preferably be latched in that position so that some water can be positioned in the bowl above the flap between flushes. The inlet water will then be shut off, ending the flush cycle. 
   Stem  52  is inserted into socket  58 , and through socket  60  for connection to a torque element (not shown) as was previously discussed. The first housing part  36  and second housing part  38  are preferably joinable along a plane approximately parallel to a direction of flow  62 . Pins  64  in second housing part  38 , and corresponding holes  66  in first housing part  36 , allow for proper alignment of the two housings  36 ,  38 . 
   Referring now to  FIGS. 6-8 , a second discharge valve  70  can be used with a toilet (not shown). It has a 90° elbow bend between the discharge outlet of the bowl and the beginning of a trap or other waste conduit. 
   Discharge valve  70  does not have two mirror image housing halves. Rather, there is a main housing part  72 , a covering housing part  74 . There is, however, still a pivotable gate  76  installed between the parts  72 / 74 . 
   Gate  76  includes an inwardly dished side  78  facing the bowl (when the valve is closed) and an outwardly dished side  80  facing the trap, where side  80  includes a contour  82 . First housing part  72  includes a recess  84  complementary in shape to contour  82 . 
   When gate  76  opens it pivots into recess  84 , and contour  82  positions in recess  84 . This reduces resistance to flow, and prevents waste material from collecting behind gate  76 . 
   Discharge valve  70  has a valve gasket  86  to help maintain a proper seal, and a shaft  88  connected to gate  76 . Note also air pocket  90  and bushings  92 . Pin  94  can connect into shaft  88  for connection to a torque element (not shown) as previously discussed. 
   Discharge valve  70  includes a main flow channel indicated at  96 , and air pocket  90  is located offset from main flow channel  96  and above the trap water level. Shaft  88  is inserted into bushings  92 , and placed in shaft channel  98 , where second housing part  74  constrains the flat surfaces  100  of bushings  92 , and shaft  88 , and correspondingly gate  76 , rotate within bushings  92 . 
   First housing part  72  and second housing part  74  are joinable along a plane transverse to direction of flow  102 , and can be connected to the toilet bowl at second housing part  74 , and to the trap at flange  104  using a variety of fasteners (not shown). 
   Referring now to the embodiment of  FIGS. 9-11 , valve  110  can be positioned in replacement for valve cartridge  28  in fluid communication with a toilet bowl and trap. It primarily differs with respect to its seal configuration on its flap. 
   There is a first housing part  112 , a second housing part  114  connected to first housing part  112 , and a pivotable gate  116  mounted there between. Gate  116  includes a side  118  and a side  120 , where side  120  includes a contour  122 . Housing parts  112 ,  114  include a recess  124  for tightly receiving contour  122 . 
   Valve  110  has a valve gasket  126  to help maintain a proper seal. There is also a shaft  128  connected to gate  116 . First housing part  112  includes an air pocket  130 . Shaft  128  is connected to housing parts  112 ,  114  in air pocket  130  at sockets  132 ,  134 , respectively. 
   Shaft  128  can be connected to a torque element (not shown) as previously discussed. Valve  110  includes a main flow channel indicated at  136 , and air pocket  130  is located offset from main flow channel  136  and above the trap water level. First housing part  112  and second housing part  114  are joinable along a plane approximately parallel to direction of flow  138 . 
   Valve  110  connects to the toilet bowl at flange  140 , and connects to the trap at flange  142 , and in both instances can use a variety of fasteners (not shown). Pins  144  in second housing part  114 , and corresponding holes  146  in first housing part  112 , allow for proper alignment of the two housings  112 ,  114 . 
   Regardless of the embodiment, the flap valve can be housed in a separate cartridge unit which facilitates assembly and replacement if needed. Further, the likelihood of maintenance being needed is reduced by minimizing the exposure of the flap valve rear side to waste. 
   While preferred embodiments of the present invention have been disclosed, it should be appreciated that still other modifications and variations to the preferred embodiments will be apparent to those skilled in the art, and are intended to be within the spirit and scope of the invention. For example, while the trap valve could be used with a metallic bowl and/or trap, it could also be used with toilet components made of other materials (e.g. vitreous; plastics). Further, the concave/convex nature of the trap and rear side of the flap can be reversed. 
   Therefore, the present invention is not to be limited to just the described most preferred embodiments. To ascertain the full scope of the invention, the claims which follow are referenced. 
   INDUSTRIAL APPLICABILITY 
   The invention provides toilets which have a discharge valve controlling flow from the bowl to the trap, where the discharge valve is designed to reduce impingement on water flow during the flush cycle.