Patent ID: 8297296

Claim:
A method for manufacturing a diaphragm, comprising: providing a segmented insert comprising a plurality of members connected to each other, wherein the segmented insert comprises a plurality of trapezoidal members with protrusions extending outward from a major surface of the trapezoidal members, wherein the plurality of trapezoidal members are connected to each other on their outermost edge by a runner; placing the insert in a mold, and molding a diaphragm body of elastomeric material around the insert so that the insert is embedded within the elastomeric material to provide the flush valve diaphragm with: a flexible body portion; a central passageway; a peripheral sealing portion comprising a sealing ring extending along the periphery of the body, the sealing portion with a thickness greater than the thickness of a portion of the body within the sealing ring, wherein the flexible body portion is within the peripheral sealing portion; a first integral ring on a first side of the body radially spaced from the sealing ring; and a second integral ring on an opposite second side of the body radially spaced from the sealing ring, and during the practice of molding a diaphragm body of elastomeric material, integrally forming a filter in a body of the diaphragm between the sealing ring and the first integral ring and between the sealing ring and the second integral ring; a bypass chamber positioned between the first integral ring and the sealing ring; an exit chamber positioned between the second integral ring and the sealing ring; and a bypass orifice extending from and allowing fluid communication between the bypass chamber and the exit chamber.