US20130269093A1

US20130269093A1 - Toilet flapper from stainless steel

Info

Publication number: US20130269093A1
Application number: US13/766,472
Authority: US
Inventors: Dennis P. VLACH
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-04-16
Filing date: 2013-02-13
Publication date: 2013-10-17

Abstract

Improvements in a toilet flapper that is formed from an assembly of stainless steel components. The flapper includes hinge pivoting arms, the main body and the float as an integrated assembly. The integrated assembly is made from stamped and formed thin stainless steel sheet metal components that provide sufficient buoyance to allow the flapper to open and close. The toilet flapper made from stainless steel for the float to be sufficiently sized to fit within the throat of the drain pipe and also provide sufficient buoyancy for operation. The toilet flapper made from stainless steel for the flapper to remain flat. The seat remains flat because the stainless steel is essentially not affected by chemicals or age. The stainless steel is preferably 300 series and more preferably 304 stainless, but other types will provide similar sealing and structural functionality.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Provisional Application Ser. No. 61/624,735 filed Apr. 16, 2012 the entire contents of which is hereby expressly incorporated by reference herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention
This invention relates to improvements in a flapper for a toilet. More particularly, the present toilet flapper is made from stainless steel that creates a flapper that will not deteriorate from contamination of water and chemicals.
2. Description of Related Art Including Information Disclosed under 37 CFR 1.97 and 1.98.
Most toilets utilize a flapper valve that is opened to flush the toilet. When the valve is opened is allows water that is held in a storage tank to enter into the bowl of the toilet and flush material within the toilet down the drain and into the septic system. Typically the flapper valve is made from a molded plastic material. The water supply into a house from the water companies often contains chlorine that deteriorates plastics and rubbers. It is also common to place disinfectants or other chemicals into the storage tank to clean and disinfect the water such as chlorine, or bleach. While these chemicals clean the water they can have a detrimental effect on a plastic flapper valve. The flapper can deform thereby allowing water to seep around the seal and cause water loss.
A number of patents have been made to address these issues. Exemplary examples of patents and or publication that try to address toilet flapper valves problem(s) are identified and discussed below.
Patents or publications that are constructed from an assembly of components are disclosed in U.S. Pat. No. 3,369,259 that issued on Feb. 20, 1968 to R. E. Harold, U.S. Pat. No. 6,173,457 that issued on Jan. 16, 2001 to Gary R. Higgins and Published application US 2006/0195977 that published on Sep. 7, 2006 to Ching-chen Shieh disclose toilet, flush, drain or flapper valves. These valves are constructed from a number of plastic and or elastomeric components that are assembled to make the flapper valve. While they disclose an assembly of components the majority of the components are plastics that can be affected by chemicals that are used to clean toilets and chlorine from major water supply companies.
U.S. Pat. No. 1,255,090 that issued on Jan. 29, 1918 to R. A. Gaily and U.S. Pat. No. 5,400,444 that issued on Mar. 28, 1995 to Jacques E. Boyer both disclose valves or flush valves with a metallic element. In these patents the metallic element is typically a spring that is not effected by the toilet chemicals. Neither of these patents discloses the entire body of the valve being constructed from metal.
Recent flapper valve designs have been made from a single homogeneous elastomeric material. Examples of these designs are found in U.S. Pat. No. 4,499,616 that issued on Feb. 19, 1985 to Dwight N. Johnson, U.S. Pat. No. 5,117,514 that issued on Jun. 2, 1992 to Robert A. Richter, U.S. Pat. No. 5,983,412 that issued on Nov. 16, 1999 to Var E. Lordahl and U.S. Pat. No. 7,891,028 that issued on Feb. 22, 2011 to Anthony Camargo et al. The use of a homogeneous elastomeric material provides a cost effective solution making a flapper valve, but while the material can shrink, and potato chip from harsh cleaning materials thereby requiring replacement.
What is needed is a flapper valve that never requires replacement. The majority of the flapper valve must be made from a material that is not affected by harsh cleaning chemicals. The proposed flapper valve in this document provides a solution to this problem.

BRIEF SUMMARY OF THE INVENTION

It is an object of the toilet flapper made from stainless steel for the flapper to be entirely made from stainless steel except for a replaceable seal. The flapper includes hinge pivoting arms, the main body and the float as an integrated assembly. The integrated assembly is made from stamped and formed thin stainless steel sheet metal components that provide sufficient buoyance to allow the flapper to open and close. An assembly of two or more components creates the hinge, flapper cover that provides support for a seal and the float.
It is an object of the toilet flapper made from stainless steel for the float to be sufficiently sized to fit within the throat of the drain pipe and also provide sufficient buoyancy for operation. The metal itself is heavier than the surrounding water and the float must be sufficiently formed to provide smooth water flow for the flushing process. The flow of the water around the float provides the flushing force to push waste out of the toilet bowel.
It is another object of the toilet flapper made from stainless steel for the seal to be replaceable. While the body of the float will not deteriorate from harsh chemicals the seal material can be affected by some chemicals. The only function of the seal is to prevent water from flowing through a closed flapper. Over time the seal may take a formed seat around the porcelain of the toilet drain. While the seal may harden, the shape of the sealing surface will remain essentially unchanged whereby minimizing a requirement to change the elastomeric seal.
It is still another object of the toilet flapper made from stainless steel for the flapper to remain flat. The seat remains flat because the stainless steel is essentially not affected by chemicals or age. The stainless steel is preferably 300 series and more preferable 304 stainless, but other types will provide similar sealing and structural functionality such as but not limited to 316L stainless or titanium.
Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 shows an exploded view of the toilet flapper made from stainless steel.

FIG. 2 shows an assembled view of the toilet flapper made from stainless steel.

FIG. 3 shows a cross-sectional view of the toilet flapper made from stainless steel.

FIG. 4 is a bottom perspective view of the toilet flapper made from stainless steel.

FIG. 5 is a top perspective view of the toilet flapper made from stainless steel.

FIG. 6 shows an elevation view, shown partially in cross-section of the toilet flapper made from stainless steel installed within a flushing mechanism in a toilet tank.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows an exploded view of the toilet flapper 10 made from stainless steel, FIG. 2 shows an assembled view of the toilet flapper 10 made from stainless steel, FIG. 3 shows a cross-sectional view of the toilet flapper made from stainless steel 10, FIG. 4 is a bottom perspective view of the toilet flapper made from stainless steel and FIG. 5 is a top perspective view of the toilet flapper made from stainless steel.
The flapper 10 is made from essentially entirely made from stainless steel except for a replaceable seal 61. The flapper includes hinge member 20 having pivoting arms 27 and 28, the main body 40 and the float 50 as an integrated assembly 10. The integrated assembly is preferably made from stamped and formed 300 series stainless steel and samples have been made using 304 stainless, but other types will provide similar sealing and structural functionality including but not limited to 316L stainless, titanium, brass, copper bronze, aluminum or other materials. Functional units of the stainless steel components have been fabricated from material having a thickness of about 0.015 inches thick. This thickness of material is thin enough to provide sufficient buoyance to allow the flapper to open and close. An assembly of two or more components creates the hinge, flapper cover that provides support for a seal and the float.
The hinge member 20 has an essentially flat bottom surface a surrounding raised lip that provides structural strength. The hinge member is initially stamped from flat material and is bent, stamped, drawn or otherwise formed to create the final shape. Two arms 27 and 28 extend from the supporting head section. Dimples or structural bends 23 create additional strength to the arms and prevent twisting of the arms 27 and 28. At the ends of the arms hinge pivot members exist that pivot on pivoting lug(s) 75 as shown in FIGS. 3 and 4. The pivoting members may be configured to have a formed bearing surface 21 that spreads the pivot surface over a larger area to reduce premature failure of the pivoting lug(s) 75. The ends of the pivot engagement members 24 may also be slightly bent outward to make connection with the pivoting log(s) 75 easier as well and create a different location where the ends might cut a notch in a softer pivoting lug. In addition to the formed bearing surface the top of the arms 27 and 28 may have an extended formed area 22 that provides a broader surface for a user to press on the top of the arms to engage the pivoting portion of the arm(s) onto the pivoting lug(s) 75.
A hole 26 in the front of the hinge member is provided as a connection member for a pull chain that opens the flapper valve 10. Hole 25 is a locating hole uses for fabrication of the hinge member 20. A hole 29 in the center of the head provides a connection for the main body 40. The hinge member 20 has a flat under surface for mounting the main body 40.
The main body 40 is formed with a number of steps. The lower portion of the main body has a lower lip 41. Within the lower lip 41 a gasket or seal 61 is located. The gasket 61 is shown in this embodiment as a flat member, but it is also contemplated that the gasket 61 can be formed with a labyrinth seal or be conically shaped to fit within a drain opening. The gasket 61 is fairly compliant and flexible to accommodate angular and surface imperfections in the drain seat. A raised lip 42 extends from the gasket seat area. The raised lip 42 provides a side bearing surface for the float 50. The top 43 of the main body has a hole 44 for a connection mechanism to secure the main body to the hinge member. A gasket seal holder 51 provides a seat for locating a float 50.
The float 50 is sufficiently sized to fit within the throat of the drain pipe and also provide sufficient buoyancy for operation. The metal itself is heavier than the surrounding water and the float must be sufficiently formed to provide smooth water flow for the flushing process. The flow of the water around the float provides the flushing force to push waste out of the toilet bowel. The internal volume of the float is preferably between one and two cubic inches, and more preferably between 1.4 and 1.8 cubic inches. The variation of the internal volume is based upon the materials and the open/close cycle of the valve.
A fastener 60 secures the hinge member 20 to the main body 40. The fastening member creates a water tight seal between these two components.
FIG. 6 shows an elevation view, shown partially in cross-section of the toilet flapper made from stainless steel installed within a flushing mechanism in a toilet tank. The bottom wall 80 of a conventional flush tank supporting a drain outlet housing 81 with an overflow stand pipe 71 that is formed in the conventional manner such as molding and includes a through passageway in the stand pipe 71 for flow to bypass the main flushing drain 81 by flowing through bypass opening 84. A gasket 82 seals the drain pipe 81 with the bottom wall 80 of the toilet tank.
The stand pipe 71 has pivoting lugs on each side of the stand pipe 71 for mounting the pivoting arms pivot 21. The upwardly extending portions of the pivot lugs 75 providing handle means against which the fingers of the hand may be pressed using the stand pipe 71 as a fulcrum to move the pivot lugs 75.
The toilet flapper 10 is pivotally mounted on the pivot lugs 75 by a pair of pivot legs 27 and 28 which extends from in hinge member 20, main body 40 and the float 50. The legs 27 and 28 are spaced in an essentially parallel relation and which are mounted on the outwardly extending portions of the pivot lugs 75. Each of the pivot legs 27 and 28 is sufficiently flexible to permit the extending ends to slightly flex as they connect onto the pivot lug(s) 75.
The toilet flapper 10 includes an annular cushion 61 joined to the flapper cover 40 that aligns concentrically with respect to the peripheral wall 83 and aligned so as to bear substantially at the inner edge of the bottom wall 83 to form an annular air space for cushioning the bottom surface of the gasket 61. The bottom surface of the annular casket 61 presents a substantially annular seating surface for abutment with the drain outlet rim 83 when the toilet flapper 10 is in its seated position. The seating surface 83 and the peripheral wall are approximately one half as thick as the top wall so as to be relatively flexible, and as the level of the stored water begins to rise above the toilet flapper 10. The gravity head of the water acts downwardly against the rigid top wall of the hinge 20 causing the relatively flexible gasket 61 to deform and create a seal. The gasket 61 acts together bottom of the flapper cover and the drain seat 83 to concentrate the gravity head of water at the inner and outer edges creating a seating surface.
To initiate a flush the arm 70 is raised thereby lifting chain, or links 74 from a slack position 72 to a raised position 73 thereby creating a flush that allows water to flow past the flapper valve 10. Once the water level within the tank is reduced the flapper valve 10 will drop into the drain 83 thereby closing the flush valve.
Thus, specific embodiments of a toilet flapper made from stainless steel have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.

Claims

1. A toilet flapper comprising:

an assembly of a hinge, flapper cover and a float;

said hinge connects from pivot points on a stand pipe;

said hinge connects to a flapper cover that is sized to accept a seal that prevents undesirable flow through a toilet flush valve fitting, and

a float that is sized to fit within said toilet flush valve fitting and provide sufficient buoyancy to operate a flushing cycle.

2. The toilet flapper according to claim 1 wherein said assembly is made from 300 series stainless steel.

3. The toilet flapper according to claim 2 that is made from 300 series stainless steel.

4. The toilet flapper according to claim 3 wherein said toilet flapper is more preferably made from 304 series stainless steel.

5. The toilet flapper according to claim 1 wherein at least one component from said assembly is constructed from stamped or drawn plate material.

6. The toilet flapper according to claim 1 wherein said seal is replaceable.

7. The toilet flapper according to claim 1 that further includes a seal holder.

8. The toilet flapper according to claim 7 wherein said seal holder is secured to said float.

9. The toilet flapper according to claim 8 wherein said seal secures onto said seal holder.

10. The toilet flapper according to claim 1 wherein said seal is a flat disk.

11. The toilet flapper according to claim 1 wherein said seal is a conical ring.

12. The toilet flapper according to claim 1 wherein said float has an internal volume of between 1 and 2 cubic inches.

13 The toilet flapper according to claim 12 wherein said internal volume is more preferably between 1.4 and 1.8 cubic inches.

14. The toilet flapper according to claim 1 wherein said flapper valve is connected to a flush arm with a coupling.

15. The toilet flapper according to claim 14 wherein said coupling is a semi-rigid coupling or a flexible coupling.

16. The toilet flapper according to claim 14 that further includes a hook that connects to a flushing arm.

17. The toilet flapper according to claim 1 wherein said assembly is secured with at least two fastener.

18. The toilet flapper according to claim 17 wherein said at least one fastener is a rivet.

19. The toilet flapper according to claim 1 wherein said hinge has formed bearing surface corners.