The present invention relates generally to closet flanges used with household toilets.
A “closet flange” (sometimes called a “toilet flange”) is used to connect and secure a toilet to a building's plumbing system. Generally, closet flanges have a radial flange portion located at the proximal end of a tubular portion. Typically, closet flanges are produced from metals such as cast iron or brass, or plastics such as polyvinyl chloride (PVC) or acrylonitrile butadiene styrene (ABS).
Plastic closet flanges are bolted to the floor/subfloor of the building in alignment with the end of a waste pipe. The tubular portion of the closet flange is commonly attached to the waste pipe using solvent cement to chemically weld the closet flange and the waste pipe together. Closet flanges are usually installed during rough-in installation, and the plumbing system must be tested, typically hydrostatically tested, prior to installation of the plumbing fixtures. A typical building code might require that the plumbing system be free of leaks under 10 feet of head at 4.3 psi for 15 minutes.
In order to test the system, the closet flanges (and all system openings) must be plugged or capped. This is typically accomplished by installing a test ball or using a “knock out” closet flange that has a thin, molded piece of plastic that seals off the closet flange opening. When a knock-out closet flange is used, the knock-out piece is removed such as by hitting it with a hammer.
The use of a knock-out closet flange presents several issues. For example, the knock-out piece is often difficult to remove and requires tools to hit and/or pry it out. Sometimes, the knock-out piece does not breakaway flush but will instead break into multiple random pieces. These pieces can fall down into the plumbing drainage system which can cause blockages. In addition, removal of the knock-out piece can create sharp edges in the closet flange opening, which might eventually cause a flow obstruction to the toilet or may cause the installer's hands to be cut. Damage to the remaining body of the closet flange may also occur when the knock-out piece is removed. Finally, if the knock-out piece is molded too thin, it may not have sufficient strength to hold a test (i.e., it may leak).
The present invention recognizes and addresses the foregoing considerations, and others, of prior art constructions and methods.
According to one aspect, the present invention provides a closet flange for use in installation of a toilet in relation to a waste pipe. The closet flange comprises a body formed of polymeric material, the body including a tubular portion having a proximal end and a distal end and a flange portion located at the proximal end of the tubular portion. The flange portion extends radially outward with respect to the tubular portion of the body, the flange portion defining an inner periphery forming a drain opening aligned with an interior of the tubular portion and further defining an outer periphery. The flange portion also defines a plurality of fastener openings therethrough for use in securing the closet flange to a mounting surface. A seal membrane is removably attached to the flange portion so as to cover the drain opening in a water-tight manner.
In an exemplary embodiment, the body is formed of PVC material and the seal membrane is formed of a fabric material weldable to PVC. For example, the seal membrane may be formed of PVC fabric and welded to the flange portion about the drain opening.
In an exemplary embodiment, the flange portion may define an annular recess circumscribing the drain opening in which an annular ridge is situated, the seal membrane being welded to the flange portion at the annular ridge. The seal membrane may be welded to the flange portion radially inside of the plurality of fastener openings. In addition, the seal membrane may be sized to cover at least some of the fastener openings. Preferably, the seal membrane may further define a pull tab to facilitate its removal from the body in a peeling action.
According to another aspect, the present invention provides a closet flange for use in installation of a toilet in relation to a waste pipe. The closet flange comprises a body formed of polymeric material, the body including a tubular portion having a proximal end and a distal end and a flange portion located at the proximal end of the tubular portion. The flange portion extends radially outward with respect to the tubular portion of the unitary body and defines an inner periphery forming a drain opening aligned with an interior of the tubular portion and further defines an outer periphery. The flange portion further defines a plurality of fastener openings therethrough for use in securing the closet flange to a mounting surface. A seal membrane formed of a flexible fabric material is also provided. The seal membrane is welded to the flange portion at an annular weld seam about the drain opening so as to cover the drain opening in a water-tight manner.
A still further aspect of the present invention provides a method of installing a toilet to a mounting surface defining an opening at which an end of a waste pipe is located. The method involves providing a closet flange including a tubular portion having a proximal end and a distal end. A flange portion is located at the proximal end of the tubular portion and defines a drain opening. A seal membrane formed of a flexible fabric material is welded to the flange portion at an annular weld seam about the drain opening so as to cover the drain opening in a water-tight manner. A tubular portion of the closet flange is slidably positioned on an outer surface of the waste pipe. The seal membrane is removed from the flange portion to open the drain opening. The flange portion of the closet flange is secured to the mounting surface. A ring gasket is positioned at a drain opening defined in the flange portion of the closet flange. The toilet is positioned with respect to the mounting surface such that a drain of the toilet will be circumscribed by the ring gasket.
These and other novel aspects, features and advantages of the present invention will be apparent from the following disclosure of a preferred embodiment of the invention as depicted in the accompanying drawings.
A full and enabling disclosure of the present invention, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which:
Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
As used herein, any usage of the terms “pipe” and the “end” of a pipe are intended to be understood and interpreted, in their broadest generic sense not inconsistent with but not limited to any common industry usage. A “pipe” is used herein to encompass any tubular structure capable of fluid conveyance therethrough and an “end” of a pipe is any termination of the tubular structure defining an opening through which fluid enters or exits the pipe. A “pipe” may be linear (straight) or non-linear (e.g., curvilinear) in the direction of fluid conveyance, and may be of differing transverse cross-sectional shapes, often round but not necessarily cylindrical or uniform in transverse cross-section. Pipes include for example tubular structures with uniform inner and outer diameters defining a cylindrical tubular structure, as are often commonly referred to as pipes, but also include other tubular components.
Referring now also to
The inner diameter of tubular portion 32 is sized to receive the end of waste pipe 22. Thus, when closet flange 26 is installed, tubular portion 32 is inserted into the gap of hole 20 surrounding the outer surface of waste pipe 22. Flange portion 34 preferably defines openings, such as holes 36 and/or slots 38, for receipt of fasteners (e.g., bolts) for securing closet flange 26 to the mounting surface (i.e., floor 18 in this case).
Flange portion 34 further defines two diametrically-opposed arcuate slots 40, each having a widened insertion portion 42 and a narrower retention portion 44. As can be explained most easily with reference to
As shown in
In a preferred embodiment, seal 54 comprises a disc of a suitable flexible fabric material which is appropriately impermeable to fluid. For example, seal 54 may be formed of a polymeric material or other fabric material that is compatible with the material of the body of closet flange 26, preferably a polymeric material or other fabric material without a plasticizer. Non-limiting examples of such polymeric or other fabric materials include, but are not limited to, a PVC containing fabric. In this case, seal 54 is adhered to flange portion 34 at an annular attachment location 58 (
As one skilled in the art will appreciate, PVC fabric generally utilizes a suitable woven core which has been coated with PVC to add strength and fluid impermeability. A PVC fabric is advantageous where the flange body is formed of PVC because of the similarity of the materials of the components. For example, a suitable adhesive that adheres to PVC might be used to form the attachment location 58. In this embodiment, however, attachment location 58 is formed as a welded seam, e.g., by sonic welding, whereby material of flange portion 34 and material of seal 54 are fused together.
Referring now particularly to
Those skilled in the art will readily understand that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications, and equivalent arrangements, the present invention being limited only by the claims appended hereto and equivalents thereof.
This application claims priority from U.S. provisional patent application No. 62/860,296, filed Jun. 12, 2019, the entire contents of which are incorporated herein by reference.
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