The present invention generally relates to toilets. More specifically, the invention relates to a toilet sub-assembly for retro-fit applications.
When providing toilet assemblies for retro-fit applications, it is necessary for a manufacturer to keep on hand a large inventory of toilet assemblies to accommodate a wide variety of toilet rough-ins. As used herein, rough-in or rough-in dimension is the measurement or dimension defined as the distance from the wall behind the toilet out to the center of the closet/toilet flange or from the floor up to the center of the closet/toilet flange, which is mounted in the floor or wall, respectively, of the restroom area and connected a drain pipe. Sometimes rough-in dimensions also refer to minimum distances to the sides and front of the toilet assembly, but as used herein the term relates to the aforementioned dimension.
The standard rough-in dimension is 12 inches. It is not uncommon, however, to have rough-ins of 10 or 14 inches. Notwithstanding the above, rough-ins down to about 4 inches are also sometimes encountered. In such instances, long lead times are required for the custom manufacturing of a toilet for the obscure rough-in dimension. Such long lead times can be problematic in the course of a construction project, particularly when the project involves the retro-fitting of an institution having a large number of restroom areas with varying rough-ins. Such institutions may include, without limitation, correctional, mental, long-term care, physical rehabilitation and residential (short-term or long-term) institutions. This issue is problematic for both the institution and the toilet manufacturer.
In overcoming the enumerated drawbacks and other limitations of the related art, the present invention provides a toilet sub-assembly.
In one aspect, the invention provides a toilet sub-assembly. The toilet sub-assembly including a toilet base having a bowl with an upper lip and a lower wall, the latter of which defines a sump and a bowl outlet. The toilet base also includes a waste conduit connected at a first end to the sump through the bowl outlet for the discharging of water and waste from the bowl. The waste conduit has a second end that is distal to the first end. The toiled sub-assembly further includes at least two waste tube couplings. Each of the waste tube couplings includes a conduit connecting end and a waste outlet connecting end. The conduit connecting end is configured for attachment to the second end of the waste conduit. Each of the waste tube couplings has a configuration that defines a different position for the waste outlet connecting end, relative to the conduit connecting end, when attached to the waste conduit.
In another aspect of the invention, each of the waste tube couplings includes a rigid tube member.
In a further aspect of the invention, the second ends of the waste tube couplings are configured for connecting to the second end of the waste conduit through a pipe coupling.
In an additional aspect of the invention, the pipe coupling is a flexible pipe coupling.
In still another aspect of the invention, one of the waste tube couplings is connected to the second end of the waste conduit.
In another aspect, the invention provides a toilet sub-assembly including a toilet base including a bowl having an upper lip and a lower wall defining a sump and a bowl outlet. The toilet base also including a waste conduit connected at a first end to the sump through the bowl outlet for the discharging of water and waste from the bowl, the waste conduit having a second end distal to the first end; at least two waste tube couplings, each of the waste tube couplings having a conduit connecting end and a waste outlet connecting end, the conduit connecting end being configured for attachment to the second end of the waste conduit, each of the waste tube couplings having a configuration defining a different positioning of the waste outlet connecting end relative to the bowl when attached to the waste conduit.
In still another aspect of the invention, each of the waste tube couplings includes a rigid tube member.
In a further aspect of the invention, the second ends of the waste tube couplings are configured for connecting to the second end of the waste conduit through a pipe coupling.
In an additional aspect of the invention, the pipe coupling is a flexible pipe coupling.
In yet another aspect of the invention, one of the waste tube couplings is connected to the second end of the waste conduit.
In still another aspect, the invention provides a toilet sub-assembly including a toilet base with a bowl having an upper lip and a lower wall that defines a sump and a bowl outlet. The toilet sub-assembly also includes a housing supporting the bowl and a waste conduit connected at a first end to the sump, through the bowl outlet, for discharging water and waste from the bowl. The waste conduit includes a second end, distal to the first end. The toilet sub-assembly includes at least two waste tube couplings, each of the waste tube couplings has a conduit connecting end and a waste outlet connecting end. The conduit connecting ends are configured for attachment to the second end of the waste conduit. Additionally, each of the waste tube couplings has a configuration that defines a different positioning of the waste outlet connecting end, relative to the housing, when attached to the waste conduit.
In a further aspect of the invention, the housing includes a plurality of mounting features defining different mounting locations along the housing for connecting of the waste tube couplings to the housing.
In an additional aspect of the invention, the mounting features are a plurality of mounting bores defined through the housing.
In a yet another aspect of the invention, the mounting bores are defined through a bottom flange of the housing.
In a still further aspect of the invention, a mounting bracket connected to one or more of the mounting features, the mounting bracket being repositionable relative to the housing by connecting of the mounting bracket to different ones of the mounting features.
In yet an additional aspect of the invention, each of the waste tube couplings includes a rigid tube member.
In yet another aspect of the invention, the second ends of the waste tube couplings are configured for connecting to the second end of the waste conduit through a pipe coupling.
In a yet a further aspect of the invention, the pipe coupling is a flexible pipe coupling.
In yet in an additional aspect of the invention, one of the waste tube couplings is connected at its conduit connecting end to the second end of the waste conduit and at its waste outlet connecting end to the housing.
In a still further aspect of the invention, the invention provides a toilet sub-assembly having a toilet base including a bowl with an upper lip and a lower wall that defines a sump and a bowl outlet. The toilet base additionally includes a waste conduit connected to the bowl outlet for discharging water and waste from the bowl. At least two waste tube couplings are provided with each having a conduit connecting end and a waste outlet connecting end. The conduit connecting end is configured for attachment to an end of the waste conduit, and each of the waste tube couplings have a configuration defining a different rough-in dimension for an assembled toilet incorporating that waste tube coupling.
In a further aspect of the invention, one of the at least two waste tube couplings has a configuration defining a standard rough-in dimension of about 12 inches.
In an additional aspect of the invention, one of the at least two waste tube couplings has a configuration defining a non-standard rough-in dimension greater than 12 inches.
In also another aspect of the invention, at least two waste tube couplings have a configuration defining a non-standard rough-in dimension less than 12 inches.
In still another aspect of the invention, one of the at least two waste tube couplings has a configuration defining a rough-in dimension for a wall outlet.
Further objects, features and advantages of the present invention will become readily apparent to persons skilled in the art after reviewing the following description, including the claims, with reference to the drawings that are appended to and form a part of this specification.
As used in the description that follows, directional terms such as “upper” and “lower” are used with reference to the orientation of the elements as presented in the Figures. Accordingly, “upper” indicates a direction toward the top of the Figure and “lower” indicates a direction toward the bottom of the Figure. The terms “left” and “right” are similarly interpreted. The terms “inward” or “inner” and “outward” or “outer” indicate a direction that is generally toward or away from a central axis of the referred to part whether or not such an access is designated in the Figures. An axial surface is therefore one that faces in the axial direction. In other words, an axial surface faces in a direction along the central axis. A radial surface therefore faces radially, generally away from or toward the central axis. It will be understood, however, that in actual implementation, the directional references used herein may not necessarily correspond with the installation and orientation of the corresponding components or device.
Referring now to the drawings, a toilet sub-assembly embodying the principles of the present invention is generally illustrated in
Referring now to the perspective view of
As shown in
The lower end of the bowl 12 defines a sump 32, which terminates in a bowl outlet 34 through which waste and water is discharged from the bowl 12.
Connected to the bowl 12 at the bowl outlet 34 is one end, the proximal end 36, of the waste conduit 16. In the industry, the waste conduit 16 is also referred to as a P-trap and is provided in a round tubular form.
Between the proximal end 36 and an opposing distal end 38, the waste conduit 16 is provided with a curvature 40 such that it initially extends downward from the bowl outlet 34 then curves rearward and upward to the distal end 38. Provided in this manner, residual water in the waste conduit 16 prevents odorous gas traveling upward from the drain pipe from being emitted through the bowl outlet 34 and the bowl 12 and into the room where the resulting toilet assembly is installed.
The toilet base 11 is adapted for individual attachment of one of at least two waste tube couplings, generally designated at 18, that are differently configured. The provision of multiple, differently configured waste tube couplings 18 allows a common toilet base 11 to accommodate a variety of different rough-ins. A manufacturer is therefore not require stock a complete inventory of toilets with different rough-ins that are sparingly ordered or to extend long lead times in order to supply toilets of different rough-ins.
While the toilet base 11 may be adapted to couple to as many waste tube couplings 18 as desired, for illustrative purposes, however, four different waste tube couplings 18 are discussed herein. These are individually seen in
Illustrated in 3A, 4A and 5A are waste tube couplings 18 intended to accommodate a different rough-in dimensions of a floor outlet. For example, the waste tube coupling 18 of
Each waste tube coupling 18 includes a conduit 42, preferably of a round tubular form, defining a passageway from a coupling end 44 and a discharge end 46. Between the coupling end 44 and the discharge end 46, the conduit 42 is provided with a curvature 48 that redirects the passageway from an upwardly extending direction, seen at the coupling end 44, to a downwardly extending direction, seen at the discharge end 46. Additionally, the configuration of the curvature 48 is such that it cooperates in defining the location of the discharge end 46 and the rough-in dimension of the assembled toilet.
It is noted that, as used herein, the term “curvature” in naming the curvature 48 of the waste tube couplings 18 is not intended to mean or imply that the portion of the conduit 42 between the coupling end 44 and the discharge end 46 is curved over its entire length. As used described herein, the curvature 48 may include straight sections as well as curved sections over its length.
Referring now to the waste tube coupling 18 of
After the straight length portion 50, the curvature 48 includes a curved length portion 56. The curved length portion 56 is curved over an angle that may be less than, equal to, or greater than 180°. As seen in
Subsequent to the curved length portion 56, in
Depending on the length of the various straight sections and the angle of curvature of the various curved sections, the position of the discharge end 46 relative to the coupling end 44 may be varied, which in turn varies the position of the discharge end 46 relative to the bowl 12 and the rough in dimension of the assembled toilet.
Varying these dimensions can and may alter the overall height and overall axial length of the waste tube coupling 18. For example, the waste tube coupling 18 of
At the discharge end 46, the waste tube coupling 18 may include with a gasket flange 64. The gasket flange 64 cooperates with a wax seal or other feature to form a watertight seal around the closet flange at the installation site. The gasket flange 64 may be secured to the final straight length portion 62 or elbow portion 60 by welding or other known methods.
Referring now exclusively to
At its opposing lateral ends, the mounting bracket 66 is provided with a series of mounting bores 68. The bores 68 allow for the securement of the mounting bracket 66, and therefore the waste tube coupling 18, to a weldment 70 that is further secured to the bottom of the toilet's skirt 14. While also shown in
Referring now to those latter figures, the weldment 70 includes left and right side brackets 72 that are connected at their forward ends by a front support plate or bracket 74 and at their rearward ends by a rear support bracket 76. Collectively, the various components of the weldment 70 provide additional rigidity to the bottom of the skirt 14 and the toilet overall.
Each of the side brackets 72 is provided with a series of bores 78 along its length, which may be over a substantial length of the base of the toilet (as defined by the portion of the skirt adjacent floor on which the toilet is to be placed). Preferably series of bores 78 are provided over at least a quarter of the length of the base, more preferably over half of the length of the base and most preferably over three quarters of the length of the base. Providing the bores 78 in this manner, over a length of the weldment 70, allows for a wide range of accommodation for attachment of the waste tube coupling 18 via its mounting bracket 66.
In
While illustrated as being attached to one another through the use of fasteners 80 and bores 66, 78 provided in the mounting bracket 66 and the side brackets 72, it will be appreciated that other securement mechanisms could alternatively be used. For example, the respective bores 66 and 78 could be omitted and the mounting bracket 66 welded to the side brackets 72 once generally located relative to each other.
Regarding the wall outlet embodiment of
To secure the waste tube coupling 18 to toilet base 11, the waste tube coupling 18 may be provided with a track bracket 82 on the inner sider of the gasket flange 54. Preferably, the end of the elbow portion 60 extends through a central opening in the track bracket 82. The track bracket 82 is secured by fasteners 84 at its upper and lower ends to upper and lower cross supports 86, 88. In the embodiment of
In all embodiments, to secure an assembled toilet 10′ at the wall of the installation site, a mounting channel 90 is attached to the sidewalls of the skirt 14 at the very rear of the toilet base 11. The mounting channel 90 is generally U-shaped in cross section and utilizes side flanges 92 for mounting to the skirt 14. Extending between the side flanges 92 is a bottom wall 94 of the mounting channel 90. The bottom wall 94 includes a central opening 96 and thereby defines a frame about the perimeter of the rear of the toilet 10. When provided in the wall outlet embodiment, the discharge end 48 of the waste tube coupling 18 extends through the central opening 96.
The bottom wall 94 also includes four mounting openings 98, which are generally located in the four corners of the frame defined by the bottom wall 94. The mounting openings 98 receive studs or bolts to facilitate securement and flush mounting of the assembled toilet 10′ to the wall of the installation site.
As a person skilled in the art will really appreciate, the above description is meant as an illustration of at least one implementation of the principles of the present invention. This description is not intended to limit the scope or application of this invention since the invention is susceptible to modification, variation and change without departing from the spirit of this invention, as defined in the following claims.
This application is a non-provisional patent application claiming benefit under 35 U.S.C. 119(e) to U.S. provisional patent application No. 62/646,667, filed on Mar. 22, 2018, the entire contents of which are hereby incorporated by reference.
Number | Date | Country | |
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62646667 | Mar 2018 | US |