Battery-Free Flushometer and Power System Therefor

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a nonprovisional of, and claims priority to, U.S. Provisional Application No. 63/666,504, filed Jul. 1, 2024, and U.S. Provisional Application No. 63/756,498, filed Feb. 10, 2025, both of which prior applications are incorporated by reference herein in their entireties.

TECHNICAL FIELD

This disclosure relates to flushing devices, and more specifically to flushometers that use one or more power generation and storage systems to avoid necessitating usage of a battery for power.

BACKGROUND

Flushometers and other flushing devices are a ubiquitous presence in most commercial restrooms, as well as in some homes or other locations. Flushometers typically utilize a valve body having an inlet, an outlet, a handle opening, and a removable cap for accessing the valve. Most such flushometers utilize a control stop associated with the valve body and positioned immediately upstream of the water supply, allowing the valve to be isolated from the water supply line by closing the control stop.

Many modern flushometers include one or more manual and/or automatic activation mechanisms that require electrical power for operation. For example, manual or automatic activation mechanisms may use a solenoid to activate the flush valve, such as by opening a relief chamber for a diaphragm or piston. As another example, automatic activation mechanisms may use a variety of sensors to detect user presence, location, occupancy, gestures, and other parameters, as well as computer devices to process and take action based on input from such sensors. Flushometers and/or associated devices may require electrical power for additional purposes as well.

A large portion of electronically activated commercial flushometers and faucets are operated by energy efficient electronics that do not require hardwired power but operate on batteries. Battery operated devices provide a lot of installation convenience, as it is not required to route power from transformers to individual fixtures in the bathroom. Alternatively, it is possible to provide power to the sensors through wireless power. However, wireless power sources also require installation and power routing to be feasible in a bathroom which can be inconvenient and expensive.

Battery-operated devices are an inconvenience in that batteries must be replaced regularly. In addition to the replacement cost of batteries, there is also an inherent reduced reliability of battery-operated devices. Batteries also require expenditure of energy and materials for manufacturing, and may require disposal as well, both of which present environmental concerns. Some devices supplement battery power with the aid of power harvesting such as photovoltaic power or hydroelectric power. However, harvesting power has limitations. Photovoltaic power alone does not provide enough energy for situations where the power cells are small, and lights are turned off for extended periods etc. Thus, photovoltaic cells are normally used to extend battery life. Hydraulic power is only available while a flushometer or a faucet is dispensing water, and a battery backup is needed to avoid energy depletion when sensing for users, but the device is not activated for extended periods of time. Thus, a need exists for a flushometer that can perform in a satisfactory manner without the use of a battery, as well as a power system that can provide a flushometer with this capability.

The present disclosure is provided to address this need and other needs in existing flushometers. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.

BRIEF SUMMARY

General aspects of the present disclosure relate to a battery-free flushometer that includes a combination of a power generation system, a power storage system, and/or a power management system to enable the flushometer to operate without the need for connection to an external power source, changing spent batteries, or recharging spent batteries using an external power source, as well as structures supporting this functionality.

Aspects of the disclosure relate to a flushometer including a valve assembly including a valve body having an inlet and an outlet, and a valve mechanism configured to selectively permit passage of water from the inlet through the outlet of the valve body, a power generation system, and a power storage system. The power generation system includes a hydraulic turbine assembly positioned downstream of the outlet and configured to receive the water discharged through the outlet, and a photovoltaic cell configured to generate electrical power by converting light energy to the electrical power. The hydraulic turbine assembly includes an impeller configured to rotate during passage of the water through the hydraulic turbine assembly to generate electrical power, and the hydraulic turbine assembly is further configured to be positioned upstream of a plumbing fixture receiving the water passing through the hydraulic turbine assembly. The power storage system is electrically connected to the hydraulic turbine assembly and the photovoltaic cell and includes a power storage device configured to receive and store at least a portion of the electrical power generated by the hydraulic turbine assembly and at least a portion of the electrical power generated by the photovoltaic cell. The power storage system is further configured to discharge stored electrical power to actuate the valve assembly.

According to one aspect, the flushometer is configured to operate without receiving power from an external power source and without requiring interchanging of batteries.

According to another aspect, the power storage device is a long term storage device configured for storing power for normal usage of the flushometer. The power storage system further includes a cold start storage device configured for storing sufficient power to activate at least one flush cycle of the flushometer, where both the long term storage device and the cold start storage device are configured for receiving the electrical power generated by the hydraulic turbine assembly and the electrical power generated by the photovoltaic cell.

According to a further aspect, the flushometer also has a power management system including a processor and a memory, where the power management system is configured for controlling a flow of the electrical power into and out of the power storage system and for monitoring a level of power in the power storage system. In one configuration, the power management system is configured for determining when a power level of the power storage system is critically low and initiating, in response to determining that the power level of the power storage device is critically low, a sentinel flush by actuating the valve assembly in a manner configured to permit the water to flow through the outlet to the hydraulic turbine assembly. The sentinel flush causes the hydraulic turbine assembly to generate additional electrical power.

According to yet another aspect, the hydraulic turbine assembly further includes a stator assembly configured to support the impeller and to deliver the water to the impeller. In one configuration, the stator assembly delivers the water to the impeller primarily in an axial direction relative to an axis of rotation of the impeller. In another configuration, the stator assembly delivers the water to the impeller primarily in a radial direction relative to an axis of rotation of the impeller.

According to a still further aspect, the hydraulic turbine assembly further includes a stator assembly configured to engage a shaft on which the impeller is mounted to support the impeller for rotation, a magnet connected to the shaft and configured to rotate with the impeller, and a conductive coil positioned around the magnet. Rotation of the magnet is configured to cause an electrical current in the conductive coil to generate the electrical power.

According to an additional aspect, the flushometer also has an actuation system configured for actuating a flush cycle of the valve assembly. The actuation system includes a solenoid electrically connected to the power storage system and configured for operation by receiving electrical power from the power storage system. In one configuration, the flushometer also includes a sensor configured for detecting presence of a user, and the actuation system is in communication with the sensor and configured for actuating the flush cycle in response to the sensor detecting the presence of the user. The sensor is electrically connected to the power storage system and configured for operation by receiving electrical power from the power storage system.

Additional aspects of the disclosure relate to a flushometer including a valve assembly comprising a valve body having an inlet and an outlet, and a valve mechanism configured to selectively permit passage of water from the inlet through the outlet of the valve body, a hydraulic turbine assembly positioned downstream of the outlet and configured to receive the water discharged through the outlet, a head connected to the valve assembly at a location spaced from the hydraulic turbine assembly, wherein the head contains components including an electrical device, and a conductor extending from the hydraulic turbine assembly to the electrical device within the head. The hydraulic turbine assembly includes an impeller configured to rotate during passage of the water through the hydraulic turbine assembly to generate electrical power, and the hydraulic turbine assembly is further configured to be positioned upstream of a plumbing fixture receiving the water passing through the hydraulic turbine assembly. The conductor has an exposed portion extending along an outer surface of the valve body, and the flushometer also includes a cover member engaged with the valve assembly and having a shroud engaged with the outer surface of the valve body and covering the exposed portion of the conductor.

According to one aspect, the cover member further includes a collar extending at least partially around a portion of the valve body to engage the cover member with the valve body, and the shroud extends from the collar along the outer surface of the valve body. In one configuration, the collar extends completely around the portion of the valve body, and the collar has a split configuration to permit attachment and removal of the cover member without disconnecting the valve mechanism from attached plumbing.

According to another aspect, the shroud has a central channel receiving the conductor and a protective material on opposite sides of the central channel, the protective material configured to resist ingress of liquid.

According to a further aspect, the hydraulic turbine assembly further includes a stator assembly configured to engage a shaft on which the impeller is mounted to support the impeller for rotation, a magnet connected to the shaft and configured to rotate with the impeller, and a conductive coil positioned around the magnet. Rotation of the magnet is configured to cause an electrical current in the conductive coil to generate the electrical power.

According to yet another aspect, the electrical device includes a power storage device configured to store at least a portion of the electrical power generated by the hydraulic turbine assembly.

According to a still further aspect, the valve body has threading configured for connection to an additional component, and the valve body has a groove extending transversely through the threading to permit passage of the conductor through the groove.

According to an additional aspect, the valve assembly further includes a valve cover connected to the valve body, and the head further includes a mounting plate connected to the valve cover and supporting the head and the components contained by the head. The mounting plate is adjustably connected to the valve cover to permit the mounting plate and the head to be rotatable with respect to the valve cover to adjust a rotational orientation of the head. In one configuration, the mounting plate has a first arcuate slot and a second arcuate slot, and the mounting plate is adjustably connected to the valve cover by fasteners received through the first arcuate slot and the second arcuate slot, such that the first and second arcuate slots permit the mounting plate to be rotatable with respect to the valve cover.

Further aspects of the disclosure relate to a method including receiving and storing, in a power storage device, electrical power generated by a hydraulic turbine assembly in fluid communication with a flushometer includes a valve assembly configured to selectively permit passage of water from an inlet through an outlet thereof, monitoring a power level of the power storage device and determining when the power level is critically low, and initiating, in response to determining that the power level of the power storage device is critically low, a sentinel flush. The hydraulic turbine assembly is positioned downstream of the outlet and receives the water discharged through the outlet, and the hydraulic turbine assembly includes an impeller configured to rotate during passage of the water through the hydraulic turbine assembly to generate the electrical power. The sentinel flush actuates the valve assembly to cause the water to flow through the outlet to the hydraulic turbine assembly, causing the hydraulic turbine assembly to generate additional electrical power. The method further includes storing at least a portion of the additional electrical power generated by the hydraulic turbine assembly in the power storage device.

Other features and advantages of the disclosure will be apparent from the following description taken in conjunction with the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To allow for a more full understanding of the present disclosure, it will now be described by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a schematic diagram illustrating one embodiment of a power system for use with a flushometer, according to aspects of the present disclosure;

FIG. 2 is a front view of one embodiment of a flushometer according to aspects of the present disclosure;

FIG. 3 is a cross-section view of the flushometer of FIG. 2;

FIG. 4 is a perspective view of the flushometer of FIG. 2;

FIG. 5 is an exploded perspective view of a turbine assembly of the flushometer of FIG. 2;

FIG. 6 is a flow diagram illustrating one embodiment of a method for low-power operation according to aspects of the present disclosure, which is usable in connection with the system of FIG. 1;

FIG. 7 is a perspective view of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 8 is a side view of the flushometer of FIG. 8;

FIG. 9 is a perspective view of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 10 is a side view of a portion of the flushometer of FIG. 9;

FIG. 11 is a side view of a portion of the flushometer of FIG. 9;

FIG. 12 is a front view of a portion of the flushometer of FIG. 9;

FIG. 13 is a perspective view of a cover member of the flushometer of FIG. 9;

FIG. 14 is a top view of the cover member of FIG. 13;

FIG. 15 is a front view of a portion of the flushometer of FIG. 9;

FIG. 16 is a perspective view showing a step in assembly of the flushometer of FIG. 9;

FIG. 17 is a perspective view showing another step in assembly of the flushometer of FIG. 9;

FIG. 18 is a perspective view showing another embodiment of the cover member of FIG. 13;

FIG. 19 is a top view of another embodiment of a cover member according to aspects of the present disclosure, shown in an open position;

FIG. 20 is a top view of the cover member of FIG. 19, shown in a closed position;

FIG. 21 is a perspective view of another embodiment of a flushometer according to aspects of the present disclosure, including the cover member of FIG. 19;

FIG. 22 is a perspective view showing a step in assembly of the flushometer of FIG. 21;

FIG. 23 is a perspective view showing another step in assembly of the flushometer of FIG. 21;

FIG. 24 is a perspective view showing another step in assembly of the flushometer of FIG. 21;

FIG. 25 is a magnified cross-section view of a portion of the flushometer of FIG. 21;

FIG. 26 is a perspective view illustrating one embodiment of a conductor routing configuration usable with the flushometer of FIG. 21, according to aspects of the present disclosure;

FIG. 27 is a perspective view illustrating another embodiment of a conductor routing configuration usable with the flushometer of FIG. 21, according to aspects of the present disclosure;

FIG. 28 is a side view of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 29 is a front view of the flushometer of FIG. 28;

FIG. 30 is a perspective view of a portion of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 31 is a perspective view of a cover member of the flushometer of FIG. 30;

FIG. 32 is a perspective view of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 33 is a perspective view of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 34 is a front view of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 35 is a front view of a portion of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 36 is a side view of a portion of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 37 is a perspective view of the portion of the flushometer of FIG. 36;

FIG. 38 is a front view of another embodiment of a flushometer according to aspects of the present disclosure, schematically illustrating an example view range of a sensor and rotatability of a portion of the flushometer;

FIG. 39 is a perspective view of a portion of the flushometer of FIG. 38, with components removed to show internal structure;

FIG. 40 is a side view of a portion of the flushometer of FIG. 38, with components removed to show internal structure;

FIG. 41 is a perspective view of a portion of the flushometer of FIG. 38, with components removed to show internal structure;

FIG. 42 is a perspective view of the portion of the flushometer of FIG. 41, with additional components removed to show internal structure;

FIG. 43 is a perspective view of the portion of the flushometer of FIG. 42, with additional components removed to show internal structure;

FIG. 44 is a top view of the portion of the flushometer of FIG. 43;

FIG. 45 is a top view of a turbine assembly of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 46 is a cross-section view taken along lines 46-46 of FIG. 45;

FIG. 47 is a cross-section view illustrating the turbine assembly of FIG. 46, with water flow through the turbine assembly schematically illustrated;

FIG. 48 is a top view of the turbine assembly of FIG. 45, with water flow schematically illustrated;

FIG. 49 is a cross-section view taken along lines 49-49 of FIG. 45, with water flow through the turbine assembly schematically illustrated;

FIG. 50 is a top view of a turbine assembly of another embodiment of a flushometer according to aspects of the present disclosure;

FIG. 51 is a top view of the turbine assembly of FIG. 50, with water flow schematically illustrated;

FIG. 52 is a cross-section view taken along lines 52-52 of FIG. 50;

FIG. 53 is a cross-section view taken along lines 53-53 of FIG. 50;

FIG. 54 is a cross-section view illustrating the turbine assembly of FIG. 53, with water flow through the turbine assembly schematically illustrated;

FIG. 55 is a cross-section view taken along lines 55-55 of FIG. 52;

FIG. 56 is a cross-section view illustrating the turbine assembly of FIG. 55, with water flow through the turbine assembly schematically illustrated;

FIG. 57 is a cross-section view illustrating the turbine assembly of FIG. 55, with an impeller removed to show additional detail; and

FIG. 58 is a cross-section view taken along lines 58-58 of FIG. 57.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will herein be described in detail example embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the following description of various example structures according to the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example devices, systems, and environments in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, example devices, systems, and environments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.

FIG. 1 illustrates one embodiment of a power system 100 for use with a flushometer or other flushing device, which includes a power generation system 110, a power storage system 120, a power management system 130, a flushometer actuation system 140, a sensor 150, a user interface 160, a programmable pulse generator 170, and a main control unit 180. The system 100 may be used in connection with various different flushometers, which may have various different valve configurations, including diaphragm-based valves, piston-based valves, or other types of flush valves and actuation mechanisms therefor. FIGS. 2-5 illustrate one embodiment of a flushometer 10 that may be used in connection with a power system 100 as disclosed herein, or which may be used independently of the power system 100. Other examples of flushometers that may be used in connection with the system 100 disclosed herein are shown and described in detail in U.S. Patent Application Publication No. 2022/0025627 A1, the entire disclosure of which is incorporated by reference herein. In other embodiments, the system 100 may be used in connection with a different type of flushing device, such as a pressure-assist flush system. In further embodiments, the system 100 may be incorporated into a different type of plumbing fixture to permit battery-free operation, such as a faucet.

The power generation system 110 is configured for harvesting or otherwise generating electrical power and generally includes at least one power generating device. In one embodiment, the power generation system 110 includes a plurality of power generating devices that operate to generate power in different manners. In the embodiment illustrated in FIG. 1, the power generation system 110 includes a photovoltaic (PV) cell 112, sometimes referred to as a “solar cell,” to generate power by converting light energy to electrical power, and a hydraulic turbine assembly 114, configured to generate power by hydraulic generation using water flowing through the flushometer and/or the conduits connected to the flushometer. The photovoltaic cell 112 may be designed or “tuned” to generate power from indoor lighting. The hydraulic turbine assembly 114 in one embodiment is positioned at or downstream of the outlet of the flushometer 10, to make it easier to seal and access for any maintenance, and the structure and positioning of the hydraulic turbine assembly 114 are described in greater detail herein. In other embodiments, the hydraulic turbine assembly 114 may be positioned at other locations, such as upstream of the flushometer 10, within the valve body 20, etc. The use of multiple power generating devices permits harvesting of power in a wider variety of different operation conditions. For example, a photovoltaic cell 112 can only generate power when the lights are turned on, and a hydraulic turbine assembly 114 can only generate power while the flushometer is dispensing water. Neither of these devices may provide sufficient power generation alone, but the combination of the two devices may provide sufficient power generation to obviate the need for a battery, particularly if the power is stored and managed properly. In particular, the operation of these devices is complementary, as the photovoltaic cell 112 provides continuous power when the lights are on, while the hydraulic turbine assembly provides larger, shorter-duration power when the flushometer is in use (water is flowing). In other embodiments, the power generation system 110 may use other power generating devices instead of or in addition to the photovoltaic cell 112 and/or the hydraulic turbine assembly 114. For example, the power generation system 110 may include energy harvesting technology (e.g., using a piezoelectric material), to harvest a portion of the energy expended by the user in operating the user interface 160. It is understood that if the system 100 is incorporated into a different type of plumbing fixture, the power generation system 110 may be modified for the specific application. For example, if the system 100 is used in a faucet, a photovoltaic cell 112 and a hydraulic turbine assembly 114 may be used, with the hydraulic turbine assembly 114 positioned in the path of the water flowing to the faucet outlet.

The power storage system 120 stores power generated by the power generation system 110 for use in operating the flushing device. The power storage system 120 in FIG. 1 includes a cold-start storage device 122 and a long term storage device 124. The cold-start storage device 122 is configured for storing sufficient power to activate at least one flush cycle of the flushometer, which permits the hydraulic turbine assembly 114 to generate more power to charge the power storage system 120. The long term storage device 124 is configured for storing power for normal usage of the flushometer over the long term. In one embodiment, both the cold-start storage device 122 and the long term storage device 124 are configured as ultra-low leakage energy storage elements, such as low-leakage capacitors (e.g., hybrid capacitors) or thin film storage elements. In one embodiment, the power storage system 120 does not use any electrochemical battery, including any rechargeable or non-rechargeable battery or any removable or non-removable battery.

The power management system 130 is configured to manage the delivery of power to the power storage system 120 and/or the usage of power from the power storage system 120 to power other components of the system 100, in order to optimize power usage and minimize power loss. The power management system 130 in FIG. 1 is a high-efficiency energy management system and includes a computing device in the form of a power management integrated circuit (PMIC) 132 that directs the harvested power to the power storage system 120 and manages how the power flows from the power storage system 120 to the other components of the system 100. The power management system 130 may be configured to prevent over-charging of the power storage system 120, and may monitor energy generated by the hydraulic turbine assembly 114 in real time for this purpose. The power management system 130 may also be configured to change from a normal operating mode to a low-power operating mode when the power level of the power storage system 120, particularly the long term storage device 124, is low. Such a low-power mode may include initiating one or more “sentinel” flushes, which are not based on user activation, but instead are configured to permit rapid power charging via the hydraulic turbine assembly 114. FIG. 6 illustrates one embodiment of a method for use in operating a low-power mode, which may be executed by the power management system 130, and which is described in greater detail herein. The power management integrated circuit 132 may include components such as one or more processors 134, one or more memories 136, and one or more communication devices 138 (e.g., a transceiver), as known in the art for processing, storing, and transmitting/receiving data, respectively.

The flushometer actuation system 140, the sensor 150, the user interface 160, the programmable pulse generator 170, and the main control unit 180 are configured to operate flushing of the flushing device according to desired operations. The flushometer actuation system 140 generally includes an electronically-operated flush actuator that is configured to actuate a flush cycle, such as by voiding a relief chamber as described herein. The flushometer actuation system 140 in FIG. 1 includes a solenoid 142 as the flush actuator, the operation of which is described in greater detail with respect to FIGS. 2-5, a solenoid power unit 144, a solenoid driver 146, and a solenoid feedback 148. The solenoid power unit 144 is in electrical communication with the power storage system 120 via the power management system 130, and receives electrical power to operate the solenoid 142. The solenoid driver 146 controls the operation of the solenoid 142 based on communication with the main control unit 180, such as receiving an activation signal from the main control unit 180. The solenoid power unit 144 may also include at least one or more processors, memories, and/or communication devices as described herein, and may make decisions regarding energy management for the solenoid 142. The solenoid feedback 148 also communicates with the main control unit 180, and is configured to send information regarding the operation of the solenoid 142 (e.g., solenoid on/off, solenoid plunger status) to the main control unit 180.

The sensor 150 is configured for detecting the presence of a user for automatic activation of the actuation system 140 and is in communication with the main control unit 180 to deliver information. The sensor 150 in FIG. 1 is an infrared (IR) sensor, but other types of sensors or combinations of sensors may be used in other embodiments. In one embodiment, the main control unit 180 may activate the actuation system 140 based on the sensor 150 sensing the presence of a user and then sensing that the user is no longer present in proximity to the toilet. In other embodiments, the sensor 150 may be configured for detecting additional information other than the proximate presence of the user, such as user presence at a distance, occupancy information, user gestures (e.g., a wave), and other information that may be used by the main control unit 180 for operation of the system 100. For example, the main control unit 180 may change a mode of operation of the system 100 or a portion thereof in response to detection of a user at a distance and/or in close proximity.

The user interface 160 is configured to receive user input to manually activate the actuation system 140 (i.e., an override) and/or to communicate information to the user. In the embodiment of FIG. 1, the user interface 160 includes a button 161 (see FIG. 2), which may be a mechanical button, a touch screen, a piezo button, or other device for sensing user touch, and a sensor status indicator for communicating sensor status to the user (e.g., by alphanumeric indicia, on/off or different colored lighting, etc.). In one embodiment, the button 161 may be equipped with energy harvesting technology (e.g., using a piezoelectric material), such that some of the energy expended by the user in pressing the button 161 is converted to electricity to charge the power storage system 120. The user interface 160 is in communication with the main control unit 180 to communicate activation of the button and/or information to the indicator. In other embodiments, the flushometer may include either the sensor 150 or the user interface 160, but not both, and a different type of user interface may be used in other embodiments.

The programmable pulse generator 170 is in communication with the main control unit 180 and the sensor 150 and is configured to control generation of pulses from the sensor 150, e.g., the time between pulses in normal operation and/or in different operation modes. The pulse generator 170 in FIG. 1 includes a pin diode driver, and the pulse generator 170 is programmable to adjust the pulse frequency/intervals. The programmable pulse generator 170 may be configured to generate different pulse intervals during different operation modes, such as a higher frequency during normal operation or a lower frequency during shutdown operation in a low-power operation mode as shown in FIG. 6.

The main control unit 180 controls operation of the flushometer or other flush device and is in communication with the flushometer actuation system 140, the sensor 150, the user interface 160, and the programmable pulse generator 170 for this purpose. The main control unit 180 transmits instructions and receives input from these devices as described herein, and may include at least one or more processors 184, one or more memories 186, and one or more communication ports 188 (e.g., a transceiver), as known in the art for processing, storing, and transmitting/receiving data, respectively. A controller power unit 182 provides power to the main control unit 180 and is in communication with the power storage system 120 via the power management system 130 for this purpose. In the embodiment of FIG. 1, the power management system 130 controls the power input to the main control unit 180, and the power input may be deactivated or minimized during a low-power mode or sleep mode. However, in other embodiments, the main control unit 180 may be capable of overriding and/or controlling some aspects of the operation of the power management system 130. It is understood that the main control unit 180 may communicate directly with the power management system 130 and may transmit information to the power management system 130 regarding the status of various components of the system 100 and/or the flushometer.

FIG. 6 illustrates one embodiment of a method 200 for operation of the system 100, which includes a low-power operation mode. The method 200 may be executed by one or more computer devices within the system, including the power management integrated circuit 132 and/or the main control unit 180. In a normal power state, the method 200 proceeds in normal operation 210. If a determination is made, such as by the power management system 130, that the power level of the power storage system 120, e.g., the long term storage device 124, is critically low, the method 200 can proceed along a first path 220 or a second path 230. In one embodiment, the system 100 is configured such that the method 200 proceeds only along one of the two paths 220, 230 by default. In another embodiment, the system 100 is configured such that a decision is made, such as by the power management system 130, whether to proceed along the first path 220 or the second path 230. The decision may be made based on various factors, such as the overall power level in the power storage system 120, or the power level in a component of the power storage system 120. For example, the method 200 may proceed along the second path 230 if the cold start storage device 122 has sufficient power for a cold start, and may proceed along the first path 220 if the cold start storage device 122 does not have sufficient power for a cold start. In the first path 220, the system 100 initiates a sentinel flush at 240 by activating the solenoid 142, which causes the hydraulic turbine assembly 114 to generate power to charge the components of the power storage system 120. In the second path 230, the system 100 goes into a shutdown state at 250 until an event is detected to activate the system. For example, the sensor 150 may detect the presence of a user, the system 100 may sense the restroom lights being turned on (e.g., via a sensor or the photovoltaic cell 112 generating power above a threshold level), the button 161 of the user interface 160 may be activated, or the power level of the cold start storage device 122 may be detected to be critically low such that charging is necessary. In one embodiment, the system 100 takes different actions based on different events or combinations of events. When the event is detected, the system 100 initiates a cold start at 260 using the energy stored in the cold start storage device 122, resulting in a system boot up at 270 and potentially initiating a sentinel flush at 240. Depending on the energy level of the cold start storage device 122, the cold start 260 may be delayed until sufficient photovoltaic power is generated to reach a power threshold. For example, the system 100 may be programmed such that when the lights in the restroom are detected to be off, no pulses are generated from the sensor 150, and startup can only occur by activation of the button 161 of the user interface 160. On the other hand, if the lights in the restroom are detected to be on, the sensor 150 may begin emitting pulses, and the system 100 may take action based on data from the sensor 150. In either path 220, 230, the system 100 returns to normal operation 210 after initiating a sentinel flush 240.

Additionally or alternatively, the method 200 may perform a different action to cause power generation by the power generation system 110, which action may depend on the type of power generation device(s) used. For example, the system 100 (e.g., the main control unit 180 or the power management system 130) may communicate with external components, such as turning the restroom lights on to permit the photovoltaic cell 112 to generate power.

FIGS. 2-5 illustrate an example embodiment of a flushometer 10 that may be used with a power system 100 as disclosed herein. The flushometer 10 includes a valve body 20 with a valve cover 21, together defining an internal cavity 22 through which water can flow from a control stop 12 to the toilet. The valve body 20 includes an inlet 23 that is connected to a tail piece 14 that is connected to the control stop 12 to deliver water to the inlet 23 and into the internal cavity 22, and an outlet 24 configured to deliver water to a toilet (not shown, but located downstream from the outlet 24). The flushometer 10 also includes a head 50 having a head cover 51 defining a head cavity 52 that is sealed from the liquid in the valve body 20. The head cover 51 is connected to the valve body 20 by a coupling ring 53, which is threaded to the valve body 20 to permit easy removal of the head cover 51 for service and maintenance. The head 50 also includes the override button 161 mounted on the head cover 51, a window 54 in the head cover 51 for the sensor 150, and a recess or opening 55 in the top of the head cover 51 for mounting of the photovoltaic cell 112. The electronics of the system 100 are contained within the head cavity 52, and FIG. 3 schematically illustrates the location of electronic components at 56. These components may include some or all components of the power storage system 120, the power management system 130, the programmable pulse generator 170, and/or the main control unit 180, as well as potentially some components of the actuation system 140, e.g., the solenoid power unit 144, the solenoid driver 146, and/or the solenoid feedback 148. The solenoid 142 is positioned at least partially in the head cavity 52 and is in communication with the valve body 20 as shown in FIG. 3.

The valve body 20 contains a valve mechanism 30 configured to selectively allow passage of water from the inlet 23 through the internal cavity 22 and out through the outlet 24 to accomplish flushing of the toilet, forming a valve assembly. The valve mechanism 30 includes a moveable valve member 31 that can move vertically within the cavity 22, and a diaphragm 32 connected to the valve member 31. The diaphragm 32 is fixed to the valve body 20 by clamping between the valve body 20 and the valve cover 21 around the edges thereof, and the center portion of the diaphragm 32 moves upward and downward with the valve member 31. The valve body 20 includes a valve seat 25 located below the diaphragm 32, and a relief chamber 26 located above the diaphragm 32. When the valve member 31 is in a sealed position (see FIG. 3), the diaphragm 32 is pressed against the valve seat 25 to seal the valve and prevent water from flowing to the outlet 24. The valve seat 25 is formed by a cylindrical internal wall 27 within the valve body 20 that defines a valve passage 28 therethrough. In the sealed position, the relief chamber 26 is filled with water, equalizing the pressure on both sides of the diaphragm 32, and the valve member 31 remains in a static position. The valve member 31 has a disc portion 39 at the top, located above the diaphragm 32, a stem 40 extending downward through the diaphragm 32 and defining a passage 36, and a flow control member 41 threaded onto the outside of the stem 40. The flow control member 41 has contours that cooperate with surfaces of the valve seat 25 and the internal wall 27 to gradually decrease flow through the valve passage 28 as the valve is closed.

The valve mechanism 30 also includes a snorkel 33 for venting the relief chamber 26, which extends downward through the passage 36 in the valve member 31, a nozzle 34 connected to the snorkel 33 to feed water from the relief chamber 26 into and through the snorkel 33, and a sleeve 35 that provides a sealed passage for the snorkel 33 through the relief chamber 26. The snorkel 33 also has a coiled reinforcing member 37 to provide reinforcement and stiffness. The nozzle 34 is sealed within a venting passage 38 in the valve cover 21 in fluid communication with the solenoid 142, which is in fluid communication with the relief chamber 26 by a solenoid passage (not shown). When the solenoid 142 is activated, water from the relief chamber 26 is permitted to pass through the venting passage 38 and the nozzle 34, through the snorkel 33 and through the passage 36 in the valve member 31 to the outlet 24. This action evacuates the relief chamber 26, which causes the valve member 31 and the center portion of the diaphragm 32 to move upward to an open position. When the valve member 31 is in the open position, the diaphragm 32 no longer engages the valve seat 25, and the valve is open to permit water to flow from the inlet 23 through the valve passage 28 to the outlet 24. The diaphragm 32 is provided with one or more bypasses (not shown) formed by small openings through the diaphragm 32, that permit water to pass gradually through the diaphragm 32 to refill the relief chamber 26 after it is voided. As the relief chamber 26 refills, the valve member 31 gradually moves back downward and eventually returns to the sealed position to seal the diaphragm 32 against the valve seat 25. It is understood that the valve mechanism 30 may include additional components in other embodiments, and may have a configuration where a component other than the diaphragm 32 (even a component not proximate to the diaphragm 32) seals the valve. Further, in one embodiment, the turbine input frequency may be monitored by the system 100 to calculate flush volume and estimate fluid pressure, allowing an adjustable controller to regulate water flow (via solenoid driver timing) via variable valve open and close times.

A vacuum breaker 42 is located in a vacuum breaker tube 45 between the outlet 24 and the toilet, and a vacuum breaker coupling 43 operably connects the vacuum breaker 42 to the valve body 20. In the embodiment of FIGS. 2-5, the hydraulic turbine assembly 114 is positioned between the outlet 24 and the vacuum breaker 42, such that the hydraulic turbine assembly 114 is connected to the outlet 24 of the valve body 20 and the vacuum breaker coupling 43 is connected to the hydraulic turbine assembly 114. One embodiment of the hydraulic turbine assembly 114 is illustrated in FIGS. 3 and 5. The hydraulic turbine assembly 114 in this embodiment includes a housing 111 that connects to the valve body 20 and the vacuum breaker coupling 43. The housing 111 is tubular to form a passage for the water flowing from the outlet 24, and contains and/or supports the other components of the hydraulic turbine assembly 114. The hydraulic turbine assembly 114 also includes a stator assembly including an upper stator 113 and a lower stator 115, an impeller 116 located between the upper and lower stators 113, 115, a permanent magnet 118 connected to the impeller 116, and a conductive coil 119 supported by the upper stator 113 and positioned around the permanent magnet 118. The impeller 116 has a shaft 117 engaged with the upper and lower stators 113, 115, such that water flowing through the hydraulic turbine assembly 114 causes the impeller 116 to spin. The permanent magnet 118 spins with the impeller 116, which causes an electrical current to form in the coil 119. A conductor 44 (see FIG. 4) in the form of a wire is connected to the coil 119 and extends along the valve body 20 to the head 50 to transmit power generated by the hydraulic turbine assembly 114 to the power storage system 120 and/or the power management system 130. In other embodiments, other types of conductors 44 may be used to connect the hydraulic turbine assembly 114 to the power storage system 120 and/or the power management system 130. For example, a flexible circuit board (also referred to as a “flex circuit”) may be used as a conductor 44, and such a flex circuit may use one or more conductive materials (e.g., metal or carbon) deposited or otherwise bonded on a flexible substrate (e.g., a flexible polymer).

FIGS. 7-37 illustrate additional embodiments of conductors 44 and routing configurations for the same, as well as cover members 60 and other structures for protecting the conductors 44. The conductor 44 may advantageously be routed to pass outside the valve body 20, so as to avoid interfering with operations of the valve mechanism 30 and to avoid corrosion or shorting due to contact with water in the valve body 20. Such cover members 60 offer protection for the conductor 44 in these configurations, to resist damage or severing of the conductor 44, which may disable transmission, storage, and use of the power generated by the hydraulic turbine assembly 114. In various embodiments, the hydraulic turbine assembly 114 and the conductor 44 may be provided as a singular, inseparable unit/device along with one or more other components, including at least the power management system 130 (e.g., PMIC 132). In such embodiments, the entire unit must be assembled at the same time, and the components can only be moved as far away from each other as determined by the design of the system, e.g., the length of the conductors 44 used. In various other embodiments, multiple sub-systems can be provided separately and subsequently connected, including by removable or non-removable connections. Such electronic connections may be made with matching sets of connectors (e.g., male and female), such as the connector 83 shown in FIGS. 10-11 and 26-27. This scenario allows for a more flexible and versatile assembly. For example, the conductor 44 may be separate from and connectable to the hydraulic turbine assembly 114 and/or the power management system 130 (e.g., PMIC 132). Still further embodiments may be used, including combinations of these configurations, i.e., using both fixed and removable connections. It is understood that the embodiments in FIGS. 7-37 may each be configured according to any of these connection configurations. It is also understood that different embodiments among FIGS. 7-37 may include some features that are similar, identical, and/or shared among multiple embodiments. Such features may not be re-described multiple times in detail herein for the sake of brevity, and similar reference numbers may be used in the drawing figures to refer to such similar, identical, and or shared features.

FIGS. 7-8 illustrate an embodiment of a flushometer 10 that includes a power system 100 as disclosed herein, with a conductor 44 (e.g., a wire or flex circuit) that extends outside and away from the valve body 20 through the space between the hydraulic turbine assembly 114 and the head 50 to connect to the power storage system 120 and/or the power management system 130. The conductor 44 is protected by a cover member 60 in this embodiment in the form of a conduit 61 that extends from the housing 111 of the hydraulic turbine assembly 114 to the head cover 51 of the head 50. The conduit 61 is a rigid tube in this embodiment, such as a metal or hard plastic tubing. In another embodiment, a cover 60 in the form of a flexible conduit 61 may be used, such as a flexible armored shielding or cable cover. Fittings 62, such as grommets or similar structures, may be used to connect the ends of the conduit 61 to the head cover 51 and the housing 111.

FIGS. 9-17 illustrate another embodiment of a flushometer 10 that includes a power system 100 as disclosed herein, with a conductor 44 that extends outside the valve body 20 and along the outer surface of the valve body 20 between the hydraulic turbine assembly 114 and the head 50 to connect to the power storage system 120 and/or the power management system 130. In this embodiment, the conductor 44 is illustrated in the form of a flex circuit, but the disclosed configuration accommodates other conductors 44, including wires. The conductor 44 is protected by a cover member 60 in this embodiment in the form of a shroud 63 that extends along the outer surface of the valve body 20 to cover the conductor 44. The shroud 63 has an S-curved configuration to follow the contour of the valve body 20 closely, for secure protection. The shroud 63 also is generally U-shaped in cross-section, with a central channel 65 to provide room for the conductor 44. The shroud 63 may include a protective material 66 extending along the edges of the channel 65 to resist ingress of liquid, e.g., a soft, compliant material such as rubber or foam. The protective material 66 may be adhered to the shroud 63, such as with a peel-off backing. The cover member 60 also has a collar 64 for connection to the valve body 20. The collar 64 in this embodiment is circular in shape and extends around a portion of the valve body 20, and the shroud 63 extends upward and away from the collar 64 along the valve body 20. The channel 65 extends from the shroud 63 into the collar 64, to permit passage of the conductor 44 beneath the collar 64. In this embodiment, the collar 64 has a split configuration with a snap-latch including interlocking tabs 68 that releasably engage each other to connect the ends of the collar 64 together. The collar 64 may have sufficient flexibility to separate the ends of the collar sufficiently for “opening” the collar to allow it to pass around the corresponding portions of the valve body 20, for installation and removal. The collar 64 may alternately be provided with a hinge 67 as shown in FIGS. 19-27 in another embodiment.

In the embodiment of FIGS. 9-17, the valve body 20 has surface features to assist with passage of the conductor 44 along the outer surface of the valve body 20. For example, grooves 69 extend through the threads 57 at the top of the valve body 20 for connection to the head cover 51 and the coupling ring 53 thereof, and through the threads 58 at the bottom of the valve body 20 for connection to the cover 111 of the hydraulic turbine assembly 114 or for connection to the vacuum breaker 42. Installation of the cover member 60 is shown in FIGS. 16-17, and the valve body 20 has a circumferential recess 59 just above the threads 58 to engage and receive a portion of the collar 64. The conductors 44 (e.g., wires or flex circuit) may also be adhered to the valve body 20 or the cover member 60 for case of assembly and installation, as described herein with respect to FIGS. 26 and 27, and FIG. 10 shows the conductor 44 adhered to the valve body 20 by tape 75. After the cover 111 of the hydraulic turbine assembly 114 is threaded onto the threads 58, the bottom of the collar 64 is positioned immediately adjacent to the cover 111, and the top of the shroud 63 extends to the bottom of the head cover 51, such that the entire exposed length of the conductor 44 is covered. The shroud 63 further includes a lip 70 at the distal end, which extends upward into the groove 69 in the threads 57 to further protect the conductor 44 and is received between the valve body 20 and the head cover 51 to secure the shroud 63 in connection with the valve body 20. The collar 64 in FIGS. 9-17 also has a depending flange 73 around at least a portion of the bottom side of the collar 64, and the depending flange 73 is recessed radially inward with respect to the adjacent portions of the collar 64. This permits the depending flange 73 to be received behind a complementary flange 74 at the top of the cover 111 when the cover 111 is connected to the threads 58 at the bottom of the valve body 20, as described below and shown in FIG. 25.

FIGS. 38-44 illustrate another embodiment that includes the flushometer 10 of FIGS. 9-17 with additional features for connecting the head 50 to the valve body 20 and the conductor 44. The flushometer 10 includes a valve body 20 and a valve cover 21 connected together and defining an internal cavity 22 through which water can flow from a control stop 12 to the toilet as described herein, and the head 50 is connected to the valve body 20 and the valve cover 21. The head 50 includes a head cover 51 defining a head cavity 52 that is sealed from the liquid in the valve body 20. The head cover 51 is connected to the valve body 20 and the valve cover 21 by a mounting plate 90 that connects to the valve cover 21 and supports the other components of the head 50. As described herein, the valve body 20 has a groove 69 for the conductor 44 to pass through the threads 57 at the top of the valve body 20 without damage, and the valve cover 21 includes an adjacent groove 69 allowing the conductor 44 to pass into the head cavity 52 for connection to various electronics. The connection of the conductor 44 to such electronics is not shown in FIGS. 38-44, but it is understood that the connection may be accomplished as disclosed herein and/or using conventional means. A ring 91 is threadably connected to the top of the valve body 20 and shields the conductor 44 between the valve body 20 and the head cavity 51, and the ring 91 may additionally function as a coupling ring for the head 50 and/or the valve cover 21 in some embodiments. The valve cover 21 also includes a solenoid connection 149 for connection of a solenoid 142 (see FIG. 44) to place the solenoid 142 in communication with the internal cavity 22 for operation of the flush valve as described herein.

The valve cover 21 is connected to the top of the valve body 20 in a configuration that includes structure to resist rotation of the valve cover 21 with respect to the valve body 20, as such relative rotation could result in the conductor 44 being severed and/or disconnected from necessary components. As shown in FIG. 40, the valve body 20 and the valve cover 21 have one or more complementary tabs 19 and slots 29, such that each tab 19 is received in a slot 29 (see FIG. 40) to resist relative rotation of the components. In this embodiment, the valve cover 21 has two tabs 19 on opposite sides of the valve cover 21, and the valve body 20 has two corresponding slots 29. However, in other embodiments, a different number of tabs 19 and slots 29 may be used, and/or the locations of the tabs 19 and the slots 29 may be transposed between the valve cover 21 and the valve body 20.

The mounting plate 90 is releasably mounted to the valve cover 21 in this embodiment, and includes supporting structures for connection to and/or supporting the other components of the head 50 and at least some components contained within the head cavity 52. The mounting plate 90 in FIGS. 38-44 is a ring-shaped structure with a central aperture 92 to allow components to pass through the mounting plate 90, such as the solenoid connection 149. The mounting plate 90 also has a plurality of legs 93 extending upward around the periphery, which are used for mounting and/or supporting other components of the head 50. As shown in FIGS. 39 and 41, the head 50 includes a housing 94 that contains the sensor 150 and additional electronic components (not shown), which may include some or all components of the power storage system 120, the power management system 130, the programmable pulse generator 170, and/or the main control unit 180, as well as potentially some components of the actuation system 140, e.g., the solenoid power unit 144, the solenoid driver 146, and/or the solenoid feedback 148. The housing 94 includes slots 95 that receive two of the legs 93 of the mounting plate 90. The housing 94 can be slid downward over the mounting plate 90 from above, and the legs 93 are inserted into the slots 95 to hold the housing 94 in place (and thereby hold the sensor 150 in place as well). The legs 93 are also rounded around the edges, and the head cover 51 can be slid downward around the legs 93, such that the legs 93 engage the head cover 51 to hold the head cover 51 in place. The head cover 51 may further be secured to the mounting plate 90 in one embodiment using set screws (not shown) connecting the head cover 51 to one or more of the legs 93, or other connecting structure, such as other fasteners, interlocking tabs/slots, quarter-turn interlocking, complementary threading, etc. The head cover 51 is an annular structure in the embodiment of FIGS. 38-44, and additional components are connected to the mounting plate 90 above the head cover 51 after connection of the head cover 51. One or more top plates 96 are connected to the tops of at least some of the legs 93, e.g., via set screws, and the top plates 96 are configured for supporting the photovoltaic cell 112 and the override button 161. A top cover 97 is secured above the top plates 96 and the photovoltaic cell 112, and the override button 161 is accessible through the top cover 97. In the embodiment of FIGS. 38-44, the top cover 97 is a separate piece from the head cover 51, and may be secured by set screws connecting the top cover 97 to the legs 93 of the mounting plate 90 and/or engagement around the periphery by the head cover 51. The top cover 97 also is configured to permit sufficient light to pass through to facilitate collection of energy by the photovoltaic cell 112.

The mounting plate 90 in the embodiment of FIGS. 38-44 is additionally configured to be adjustable rotationally with respect to the valve cover 21 and the valve body 20. This configuration permits proper rotational alignment of the head 50 without rotating the valve cover 21 and potentially damaging and/or disconnecting the conductor 44 as described herein. As shown in FIGS. 42-44, the mounting plate 90 has one or more arcuate slots 98 configured to receive fasteners 99 therethrough for connection to the valve cover 21, e.g., using set screws received in one or more apertures 89 in the valve cover 21. The fasteners 99 can be inserted through the arcuate slots 98 and into the apertures 89 in this embodiment, and before the fasteners 99 are completely tightened, the mounting plate 90 can be rotated with respect to the valve cover 21. During this rotation, the fasteners 99 travel along the lengths of the arcuate slots 98, and thus, the arcuate slots 98 define the range of rotational adjustment of the mounting plate 90 with respect to the valve cover 21. In this configuration, the mounting plate 90 can be adjusted with respect to the valve cover 21 and the valve body 20, thereby enabling adjustment of the entire head 50 and all components therein, to compensate for any necessary rotational adjustment. For example, the head 50 may need to be rotated to ensure that the sensor 150 is facing in the proper orientation. FIG. 38 schematically illustrates this rotational adjustment, and also schematically illustrates an example of the field of view of the sensor 150, which can be adjusted by rotating the head 50. To assemble the head 50 in this embodiment, the ring 91 is threaded onto the valve body 20, and the mounting plate 90 is then connected to the valve cover 21 via fasteners 99. The housing 94 can be connected to the mounting plate 90 prior to or after connection of the mounting plate 90 to the valve cover 21. Any necessary electrical connections can be completed during or after mounting of the housing 94. Rotational adjustment of the mounting plate 90 may be made at this time. The head cover 51, the top plates 96, the photovoltaic cell 112, the button 161, and the top cover 97 are then connected to close the head 50 and complete installation.

FIG. 18 illustrates another embodiment of a collar 64 that is usable in connection with the cover member 60 of FIGS. 9-17. In this embodiment, the collar 64 has a split configuration with a latch including apertures 71 to receive a fastener (e.g., a screw or bolt) to connect the ends of the collar 64 together. The cover member 60 may otherwise be configured similar or identical to the configuration shown in FIGS. 9-17 and disclosed herein.

FIGS. 19-27 illustrate another embodiment of a flushometer 10 that includes a power system 100 as disclosed herein, with a conductor 44 that extends outside the valve body 20 and along the outer surface of the valve body 20 between the hydraulic turbine assembly 114 and the head 50 to connect to the power storage system 120 and/or the power management system 130, similar to the embodiment of FIGS. 9-17. In this embodiment, the conductor 44 is illustrated in the form of a flex circuit, but the disclosed configuration accommodates other conductors 44, including wires. The conductor 44 is protected by a cover member 60 in this embodiment, and the cover member 60 includes many features in common with the cover member 60 of FIGS. 9-17. The cover member 60 in FIGS. 19-27 includes a shroud 63 that is similar or identical to the shroud 63 of FIGS. 9-17, and will therefore not be described again in detail. The cover member 60 of FIGS. 19-27 also includes a collar 64 that is circular in shape and extends around a portion of the valve body 20, and the shroud 63 extends upward and away from the collar 64 along the valve body 20. The channel 65 extends from the shroud 63 into the collar 64, to permit passage of the conductor 44 beneath the collar 64. In this embodiment, the collar 64 has a split configuration with a hinge 67 permitting the collar 64 to open by pivoting, and lips 72 at the ends of the collar 64 that overlap each other. The collar 64 in FIGS. 19-27 also has a depending flange 73 around at least a portion of the bottom side of the collar 64, and the depending flange 73 is recessed radially inward with respect to the adjacent portions of the collar 64. This permits the depending flange 73 to be received behind a complementary flange 74 at the top of the cover 111 when the cover 111 is connected to the threads 58 at the bottom of the valve body 20, as shown in FIG. 25. This locks the collar 64 in position on the valve body 20, and also locks the collar 64 in the closed position, without the need for additional locking structures such as in FIGS. 9-18. The valve body 20, and the features thereof that interact with the cover member 60, are similar or identical those of the embodiment of FIGS. 9-17, and will therefore not be described again in detail.

As discussed herein, the conductor 44 may be adhered to a substrate (e.g., the valve body 20, the cover member 60, or another component) by an adhesive component during installation to assist with assembly and installation. For example, the conductor 44 may be adhered by a liquid adhesive or an appropriate tape (e.g., a two-sided tape such as 3M™ Brand VHB™ Tape). FIGS. 26 and 27 illustrate two potential such configurations, in which the conductor 44 is in the form of a flex circuit. In FIG. 26, the conductor 44 is adhered to the valve body 20 by tape 75 in the correct position for installation, such that the cover member 60 can be simply connected in place without needing to adjust the positioning of the conductor 44. In FIG. 27, the conductor 44 is adhered by tape 75 to the inner surface of the cover member 60 within the channel 65, such that when the cover member 60 is connected to the valve body 20 in the proper position, the conductor 44 will follow the proper path along the valve body 20. Still other configurations are possible. It is understood that such configurations may be used to case installation and assembly in any or all embodiments disclosed herein.

FIGS. 28-29 illustrate another embodiment of a flushometer 10 that includes a power system 100 as disclosed herein, with a conductor 44 that extends outside the valve body 20 and along the outer surface of the valve body 20 between the hydraulic turbine assembly 114 and the head 50 to connect to the power storage system 120 and/or the power management system 130, similar to the embodiment of FIGS. 9-17. In this embodiment, the conductor 44 is not depicted, but may be in any form disclosed herein. The conductor 44 is protected by a cover member 60 in this embodiment, which is in the form of a shroud 63 that extends along the outer profile of the valve body 20, similar to the shrouds 63 of FIGS. 9-17 and 19-27. In this embodiment, the cover member 60 has no collar 64, although a collar 64 as disclosed herein may be used in other embodiments. The shroud 63 may be connected to the valve body 20 using an adhesive or other bonding material and/or by using interlocking lips/flanges such as the lip 70 and the depending flange 73 in FIGS. 9-17 and 19-27. The shroud 63 in FIGS. 28-29 has a higher profile than the shrouds 63 of FIGS. 9-17 and 19-27, and it is understood that the shroud 63 of FIGS. 28-29 may otherwise include any other features of such shrouds 63.

FIGS. 30-31 illustrate another embodiment of a flushometer 10 that includes a power system 100 as disclosed herein, with a conductor 44 that extends outside the valve body 20 and along the outer surface of the valve body 20 between the hydraulic turbine assembly 114 and the head 50 to connect to the power storage system 120 and/or the power management system 130, similar to the embodiment of FIGS. 9-17. In this embodiment, the conductor 44 is not depicted, but may be in any form disclosed herein. The conductor 44 is protected by a cover member 60 in this embodiment, and the cover member 60 includes many features in common with the cover member 60 of FIGS. 9-18. The cover member 60 in FIGS. 30-31 includes a shroud 63 that has an S-curved profile shape that is similar to that of the shroud 63 of FIGS. 9-17, as well as a similar U-shaped cross-section with a central channel 65 to provide room for the conductor 44. The cover member 60 of FIGS. 30-31 also includes a collar 64 that is circular in shape and extends around a portion of the valve body 20, and the shroud 63 extends upward and away from the collar 64 along the valve body 20. The collar 64 in FIGS. 30-31 is similar or identical to the collar 64 of the embodiment of FIG. 18, including a split configuration with a latch including apertures 71 to receive a fastener (e.g., a screw or bolt) to connect the ends of the collar 64 together. A wall 76 extends upward from the collar 64 at the juncture with the shroud 63, which may provide reinforcement for the connection between the shroud 63 and the collar 64. The valve body 20 in FIG. 30 has a circumferential recess 59 just above the threads 58 to engage and receive a portion of the collar 64, similar to FIGS. 9-17 and 19-27, as well as a wider recess 77 extending upward from the circumferential recess 59 to receive and accommodate the wall 76.

FIGS. 32 and 33 illustrate additional embodiments of a flushometer 10 that include a power system 100 as disclosed herein, with a conductor 44 that extends outside the valve body 20 between the hydraulic turbine assembly 114 and the head 50 to connect to the power storage system 120 and/or the power management system 130. In these embodiments, the conductor 44 is not depicted, but may be in any form disclosed herein. The conductor 44 is protected by a cover member 60 in these embodiments in the form of a shell 79 that encloses the entirety of the valve body 20 other than the inlet 23, as well as the hydraulic turbine assembly 114. It is understood that the cover member 60 has an opening 78 located around the inlet 23. These shells 79 may be a single-piece or multi-piece cover, such as having a clamshell configuration or multiple separate pieces that connect together. It is understood that the multiple pieces may be connected by numerous different techniques, such as locking or interlocking/mating components, threaded connections, holes or other structures for connection of external fasteners, structures configured for application of bonding materials, etc. As some or all of the valve body 20 is covered in these embodiments, the routing configuration for the conductor 44 is provided more freedom, and the conductor 44 may be configured to run along the outer surface of the valve body 20 or separately from the valve body 20, among several configurations. The shell 79 in FIG. 32 is configured to match the contours of the valve body 20 more closely, and the shell 79 in FIG. 33 has a different outer profile than the valve body 20. In other embodiments, the shell 79 extends around different portions of the valve body 20 and/or other components of the flushometer, including portions of the head 50, the hydraulic turbine assembly 114, the vacuum breaker 42, etc.

FIGS. 34 and 35 illustrate additional embodiments of a flushometer 10 that include a power system 100 as disclosed herein, with a conductor 44 that extends outside the valve body 20 between the hydraulic turbine assembly 114 and the head 50 to connect to the power storage system 120 and/or the power management system 130. In these embodiments, the conductor 44 is not depicted, but may be in any form disclosed herein. The conductor 44 is protected by a cover member 60 in these embodiments in the form of a shell 79 that encloses the entirety of the valve body 20 other than the inlet 23, but does not enclose the hydraulic turbine assembly 114, unlike the cover members 60 of FIGS. 32 and 33. It is understood that the cover member 60 has an opening 78 located around the inlet 23. The shell 79 in FIG. 34 is a two-piece cover, including a top piece 80 and a bottom piece 81 that are joined together from the top and bottom to form the shell 79. Each piece 80, 81 defines a portion of the opening 78 in this configuration. The top and bottom pieces 80, 81 may be connected by numerous different techniques, such as locking or interlocking/mating components, threaded connections, holes or other structures for connection of external fasteners, structures configured for application of bonding materials, etc. The shell 79 in FIG. 35 is a single-piece cover member, and the opening 78 is formed as a slot in the side of the shell 79, such that the shell 79 can be slid upward around the valve body 20 and the inlet 23 from below. The cover member 60 in FIG. 35 may also include a latch 84 or other connection mechanism to fasten the shell 79 around the valve body 20, which may have any configuration described herein. As nearly all of the valve body 20 is covered in these embodiments, the routing configuration for the conductor 44 is provided more freedom, and the conductor 44 may be configured to run along the outer surface of the valve body 20 or separately from the valve body 20, among several configurations.

In further embodiments, the cover member 60 may be formed by a material applied to the valve body 20. FIGS. 36 and 37 illustrate another embodiment of a flushometer 10 that includes a power system 100 as disclosed herein, with a conductor 44 that extends outside the valve body 20 and along the outer surface of the valve body 20 between the hydraulic turbine assembly 114 and the head 50 to connect to the power storage system 120 and/or the power management system 130, similar to the embodiment of FIGS. 9-17. The valve body 20 is illustrated with only a vacuum breaker assembly 42 in FIG. 36, and the valve body 20 is shown alone with the conductor 44 in FIG. 37. Nevertheless, it is understood that other components such as the head 50 and the hydraulic turbine assembly 114 may be connected in the same manner as in FIGS. 9-17. In this embodiment, the conductor 44 is illustrated in the form of a flex circuit, but the disclosed configuration accommodates other conductors 44, including wires. The valve body 20, and the features thereof that interact with the cover member 60, are similar or identical those of the embodiment of FIGS. 9-17, and will therefore not be described again in detail. In the embodiment of FIGS. 36 and 37, the cover member 60 is formed by a strip 82 of tape or other adhered material. The strip 82 in FIGS. 36-37 is silver-colored to match the chrome color of the valve body 20. In other embodiments, other colors of strips 82 may be used, such as to provide complementary colors or accented colors, or to provide information (e.g., a logo or identification). Strips 82 of various widths may also be used, for functional and/or aesthetic reasons. In another embodiment (not shown), a cover member 60 formed of an applied material may be applied to a larger portion of the valve body 20, such as a shrink wrapping material or other wrapping material around most or all of the valve body 20. Such an applied wrapping material provides a wide variety of potential aesthetic configurations, including portions having various degrees of transparency and opacity, such that visibility of selected portions of the valve body 20 may be provided. Still further different applied materials may be used in other embodiments.

The various embodiments of cover members 60 disclosed herein may be provided with coatings, surface treatments, surface contours, and/or other features to deliver a desired external appearance and/or to provide specific properties. In one embodiment, a cover member 60 may be provided with a surface finish that is similar or identical to the surface finish of the valve body 20, in order to appear as part of the valve body 20. For example, the cover member 60 may be chrome plated or provided with a surface finish by physical vapor deposition (PVD) to match the surface of the valve body 20, or may be painted a similar color to the valve body 20. As another example, the cover member 60 may be painted or finished with a color that is complementary to the valve body 20, or that is distinct from the valve body 20 to provide a visual accent. As a further example, surface enhancements such as applying labels, laser etching, pad printing, etc., could be used for aesthetic purposes and/or to convey information about the product, among other reasons. As yet another example, the cover member 60 may be provided with a coating, treatment, feature, etc. to provide a functional benefit, such as water resistance, corrosion resistance, increased strength, or other benefits.

In other embodiments, the configuration and/or positioning of the hydraulic turbine assembly 114 may be different. For example, a different configuration of a hydraulic turbine assembly 114 may be used, or multiple turbine assemblies may be used, in various embodiments. Such multiple turbine assemblies may be positioned in the same or similar locations, or at different locations. As another example, the hydraulic turbine assembly 114 may be positioned upstream of the flushometer 10, such as within the tail 14, within the control stop 12, or as a separate component installed between the valve body 20 and the control stop 12, in various embodiments. As a further example, the hydraulic turbine assembly 114 may be positioned within the valve body 20, such as within the inlet 23 or the outlet 24, in various embodiments. It is understood that the routing of the conductor(s) 44 and the configuration of the cover member 60 (if present) may be altered based on changes in the configuration of the hydraulic turbine assembly 114.

FIGS. 45-49 illustrate another embodiment of a hydraulic turbine assembly 114 that includes many components and features similar to those of the hydraulic turbine assembly 114 of FIGS. 2-5, and which may be used in connection with any flushometer 10 disclosed herein. Such previously-disclosed components and features of this embodiment may not be described again in detail for the sake of brevity, and it is understood that the hydraulic turbine assembly 114 of FIGS. 45-49 may include any components and features disclosed herein (including alternate embodiments thereof) unless otherwise stated. Similar to the embodiment of FIGS. 2-5, the hydraulic turbine assembly 114 in FIGS. 45-49 is positioned between the outlet 24 of the valve body 20 and the vacuum breaker 42, such that the hydraulic turbine assembly 114 is connected to the outlet 24 of the valve body 20 and the vacuum breaker coupling 43 is connected to the hydraulic turbine assembly 114. The hydraulic turbine assembly 114 in this embodiment includes a housing 111 that connects to the valve body 20 and the vacuum breaker coupling (not shown in this embodiment) in the same manner as the hydraulic turbine assembly 114 of FIGS. 2-5. The housing 111 is tubular to form a passage for the water flowing from the outlet 24, and contains and/or supports the other components of the hydraulic turbine assembly 114. The hydraulic turbine assembly 114 also includes a stator assembly including an upper stator 113 and a lower stator 115, an impeller 116 located between the upper and lower stators 113, 115, a permanent magnet 118 connected to the impeller 116, and a conductive coil 119 supported by the upper stator 113 and positioned around the permanent magnet 118. The impeller 116 has a shaft 117 operably engaged with the upper and lower stators 113, 115, such that water flowing through the hydraulic turbine assembly 114 causes the impeller 116 to spin. The permanent magnet 118 spins with the impeller 116, which causes an electrical current to form in the coil 119, which is connected to other electronic components by a conductor 44 as disclosed herein (not shown in FIGS. 45-49).

The hydraulic turbine assembly 114 of FIGS. 45-49 includes an upper stator 113 and a lower stator 115 configured to deliver water to the impeller 116 in a direction that is at least partially or primarily axial with respect to the axis of rotation of the impeller 116 (i.e., downward), and the impeller 116 is configured to achieve rotation with such axial water flow. The upper stator 113 in this embodiment includes a central dome 101 that is recessed on the underside to contain the permanent magnet 118 and the conductive coil 119 and engages with the top end of the shaft 117. A potting compound 102 or other filler material may fill a portion of the central dome 101 to contain and encase the conductive coil 119, which may also encase an electrical connection (not shown) between the conductor 44 and the conductive coil 119.

The upper stator 113 also has an annular trough 103 on the top side, surrounding a periphery of the central dome 101, with one or more passages 104 extending through the upper stator 113 within the annular trough 103. The curvature and raised height of the central dome 101 relative to the annular trough 103 causes the water to flow to the annular trough 103 and into the passages 104 as the water flows through the upper stator 113, as shown in FIGS. 47 and 48. The upper stator 113 in FIGS. 45-49 has nine passages 104, and it is understood that the number and dimensions of the passages 104 may increase or decrease the flow rate of water through the upper stator 113 and through the hydraulic turbine assembly 114 overall. Each of the passages 104 in this embodiment has a blade 105 extending downward from the annular trough 103 and defining a portion of the passage 104. The blades 105 each extend downward at the top ends and transition to horizontally extending at the bottom ends, and in the embodiment of FIGS. 45-49, each of the blades 105 is smoothly curved to form approximately a 90° turn from the top to the bottom thereof. The blades 105 are also curved in a horizontal direction, such that the blades 105 are curved radially around the central dome 101, following the curvature of the annular trough 103. In this configuration, the passages 104 and the blades 105 cause the water to flow both downward and circumferentially through the upper stator 113, as shown in FIG. 49, thereby forming a counterclockwise vortex-like flow as the water travels to the impeller 116. The upper stator 113 also includes a plurality of support ribs 190 extending radially outward from the central dome 101 above the passages 104, to provide increased structural support for the upper stator 113.

The impeller 116 has a plurality of impeller blades 106 extending radially outward around the periphery thereof, which are arranged to be engaged by the flowing water and thereby spin the impeller 116. The impeller blades 106 may be curved and/or angled in a manner to advantageously interact with the vortex-like flow of the water delivered by the upper stator 113, and in the embodiment of FIGS. 45-49, the impeller 116 may be configured similarly to the impeller 116 depicted in FIG. 5.

The lower stator 115 of the hydraulic turbine assembly 114 in FIGS. 45-49 is connected to the upper stator 113 around the peripheries of the upper and lower stators 113, 115, and the lower stator 115 engages the lower end of the shaft 117 and supports the impeller 116 from below. The upper stator 113 and the lower stator 115 thereby define an impeller chamber 107 through which the water flows. The lower stator 115 also includes one or more passages 108 for water to exit the impeller chamber 107 after the water passes the impeller 116. These passages 108 are angled radially inwardly with respect to the axis of the impeller 116, to cause the water to flow radially inwardly, as shown in FIGS. 46-47. The shaft 117 may be engaged at the upper and lower ends by rotation-assisting mounting structures 109, such as bushings, bearings, etc. FIG. 46 depicts rotation-assisting mounting structures 109 in the form of a bushing at the top end of the shaft 117 and a plurality of bearings at the bottom end of the shaft 117. The hydraulic turbine assembly 114 operates to generate power in a manner as disclosed herein. The water exiting the lower stator 115 then continues downstream as disclosed herein, such as to a vacuum breaker and/or a plumbing fixture.

FIGS. 50-58 illustrate another embodiment of a hydraulic turbine assembly 114 that includes many components and features similar to those of the hydraulic turbine assemblies 114 of FIGS. 2-5 and 45-49, and which may be used in connection with any flushometer 10 disclosed herein. Such previously-disclosed components and features of this embodiment may not be described again in detail for the sake of brevity, and it is understood that the hydraulic turbine assembly 114 of FIGS. 50-58 may include any components and features disclosed herein (including alternate embodiments thereof) unless otherwise stated. Similar to the embodiments of FIGS. 2-5 and 45-49, the hydraulic turbine assembly 114 in FIGS. 50-58 is positioned between the outlet 24 of the valve body 20 and the vacuum breaker 42, such that the hydraulic turbine assembly 114 is connected to the outlet 24 of the valve body 20 and the vacuum breaker coupling 43 is connected to the hydraulic turbine assembly 114. The hydraulic turbine assembly 114 in this embodiment includes a housing 111 that connects to the valve body 20 and the vacuum breaker coupling (not shown in this embodiment) in the same manner as the hydraulic turbine assembly 114 of FIGS. 2-5. The housing 111 is tubular to form a passage for the water flowing from the outlet 24, and contains and/or supports the other components of the hydraulic turbine assembly 114. The hydraulic turbine assembly 114 also includes a stator assembly including an upper stator 113 and a lower stator 115, an impeller 116 located between the upper and lower stators 113, 115, a permanent magnet 118 connected to the impeller 116, and a conductive coil 119 supported by the upper stator 113 and positioned around the permanent magnet 118. The impeller 116 has a shaft 117 operably engaged with the upper and lower stators 113, 115, such that water flowing through the hydraulic turbine assembly 114 causes the impeller 116 to spin. The permanent magnet 118 spins with the impeller 116, which causes an electrical current to form in the coil 119, which is connected to other electronic components by a conductor 44 as disclosed herein (not shown in FIGS. 50-58).

The hydraulic turbine assembly 114 of FIGS. 50-58 includes an upper stator 113 and a lower stator 115 configured to deliver water to the impeller 116 in a direction that is primarily radial with respect to the axis of rotation of the impeller 116, and the impeller 116 is configured to achieve rotation with such radial water flow. The upper stator 113 in this embodiment includes a central dome 101 that is recessed on the underside to contain the permanent magnet 118 and the conductive coil 119 and engages with the top end of the shaft 117. A potting compound 102 or other filler material may fill a portion of the central dome 101 to contain and encase the conductive coil 119, which may also encase an electrical connection (not shown) between the conductor 44 and the conductive coil 119.

The upper stator 113 also has an annular passage 191 surrounding a periphery of the central dome 101 and extending through the upper stator 113, permitting water to pass through the upper stator 113. The upper stator 113 also has a plurality of ribs 190 extending from the central dome 101 across the annular passage 191 to reinforce the structure of the upper stator 113. The curvature and raised height of the central dome 101 causes the water to flow into and through the annular passage 191 as the water flows through the upper stator 113, as shown in FIGS. 51 and 54. In other embodiments, the upper stator 113 may include smaller passages that may be greater in number, and it is understood that the number and dimensions of the passage(s) through the upper stator 113 may increase or decrease the flow rate of water through the upper stator 113 and through the hydraulic turbine assembly 114 overall.

The lower stator 115 of the hydraulic turbine assembly 114 in FIGS. 50-58 is connected to the upper stator 113 around the peripheries of the upper and lower stators 113, 115, and the lower stator 115 engages the lower end of the shaft 117 and supports the impeller 116 from below. The upper stator 113 and the lower stator 115 thereby define an impeller chamber 107 through which the water flows. Additionally, the upper stator 113 and the top of the lower stator 115 define an annular trough 103 around the central dome 101 to collect water flowing through the hydraulic turbine assembly 114, as shown in FIGS. 51 and 54. The lower stator 115 includes a channel 192 in communication with the annular trough 103 that forms a passage to direct the flow of water through the lower stator 115. The channel 192 is wider at the outer end (at the annular trough 103) and narrower at the inner end (at the impeller chamber 107, and is oriented and angled downwardly (axially) and substantially tangentially to the impeller chamber 107. In this configuration, the channel 192 delivers water to the impeller chamber 107 in a substantially tangential and radial (clockwise) direction with respect to the axis of rotation of the impeller 116, i.e., substantially horizontally as shown in FIG. 56. The channel 192 and the overall structure of the upper and lower stators 113, 115 in the embodiment of FIGS. 50-58 are designed to accommodate a relatively low flow rate through the hydraulic turbine assembly 114, e.g., for a urinal or other low-flow usage. In other embodiments, based on the flow rate magnitude needed for proper function of the hydraulic turbine assembly 114 and the flushometer 10, multiple channels 192 may be used and/or the cross sectional flow area of the channel(s) 192 can be altered. For example, the height or width (in the orientation shown) of the channel(s) 192 can be changed to increase/decrease flow area and rate. If multiple channels 192 are used, the cross sectional flow area of each is independent of the others (i.e. all can be different sizes, as required by device function).

The impeller 116 has a plurality of impeller blades 106 extending outwardly around the periphery thereof, which are arranged to be engaged by the flowing water and thereby spin the impeller 116. The impeller blades 106 may be curved and/or angled in a manner to advantageously interact with the radial flow of the water delivered by the lower stator 115. In the embodiment of FIGS. 50-58, the impeller blades 106 do not extend directly radially outward from the impeller 116, but instead extend in a direction that is substantially tangential to the periphery of the shaft 117. In this configuration, the flowing water causes clockwise rotation of the impeller 116, as shown in FIG. 56.

The lower stator 115 also includes one or more passages 108 for water to exit the impeller chamber 107 after the water passes the impeller 116. These passages 108 permit the water to flow downward and substantially freely out of the impeller chamber 107. The shaft 117 may be engaged at the upper and lower ends by rotation-assisting mounting structures 109, such as bushings, bearings, etc. FIG. 52 depicts rotation-assisting mounting structures 109 in the form of a bushing at the top end of the shaft 117 and a plurality of bearings at the bottom end of the shaft 117. The hydraulic turbine assembly 114 operates to generate power in a manner as disclosed herein. The water exiting the lower stator 115 then continues downstream as disclosed herein, such as to a vacuum breaker and/or a plumbing fixture.

Various embodiments of flushometers and power systems and methods therefor have been described herein, which include various components and features. In other embodiments, the flushometer, power system, or method may be provided with any combination of such components and features. It is also understood that in other embodiments, the various devices, components, and features of the flushometers or power systems described herein may be constructed with similar structural and functional elements having different configurations, including different ornamental appearances.

The embodiments of flushometers, power systems, and methods disclosed herein provide multiple benefits and advantages over existing technologies. For example, the power system may be used to provide a flushometer or other flushing device that does not include any electrochemical battery, including removable or non-removable and rechargeable or non-rechargeable batteries. The use of one or more low-leakage storage device(s), multiple power generation devices, photovoltaic cells tuned for improved power generation with indoor lighting, a power management system, and a various energy conservation methods described herein all contribute to the ability of the power system to successfully power a flushometer without a battery. The combination of some or all of these features drastically improves the ability of the power system to operate without a battery. Avoiding the use of a battery improves power usage and reduces the need for maintenance and service. Additionally, the flushometer configurations disclosed herein are especially suitable for use with a battery-free power system, but also provide reliable flush performance with a different type of power system. Still other benefits and advantages are recognizable to those skilled in the art.

Several alternative embodiments and examples have been described and illustrated herein. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. The terms “top,” “bottom,” “front,” “back,” “side,” “rear,” “proximal,” “distal,” and the like, as used herein, are intended for illustrative purposes only and do not limit the embodiments in any way. Nothing in this specification should be construed as requiring a specific three dimensional orientation of structures in order to fall within the scope of this invention, unless explicitly specified by the claims. When used in description of a method or process, the term “providing” (or variations thereof) as used herein means generally making an article available for further actions, and does not imply that the entity “providing” the article manufactured, assembled, or otherwise produced the article. The term “approximately” as used herein implies a variation of up to 10% of the nominal value or property modified by such term, or up to 10% of a midpoint value of a range modified by such term. “Integral joining technique,” as used herein, means a technique for joining two pieces so that the two pieces effectively become a single, integral piece, including, but not limited to, irreversible joining techniques such as welding, brazing, soldering, or the like, where separation of the joined pieces cannot be accomplished without structural damage thereto. Additionally, the term “plurality,” as used herein, indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying claims.