Toilet engine and shroud

Abstract

A toilet includes at least an engine and a shroud. The engine includes a rim having an annular member, a water outlet, a toilet bowl, a water channel configured to dispense water into the toilet bowl from the water outlet, and an upstream trapway passage. The shroud includes a downstream trapway passage united with both the upstream trapway passage and a trapway outlet. The upstream trapway passage is spaced apart from the downstream trapway passage when the water flows through the upstream trapway passage and the downstream trapway passage to the trapway outlet.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 627,660 filed on Jan. 31, 2024, which is hereby incorporated by reference in its entirety.FIELD

[0002] The present application relates to toilets and manufacturing techniques for toilets.BACKGROUND

[0003] Toilets are essential fixtures in residential, commercial, and industrial spaces, serving as a fundamental element of hygiene and sanitation. Traditional toilets are primarily constructed from materials such as ceramic, porcelain, or stainless steel, which offer durability and aesthetic appeal. However, the assembly and transportation processes for these conventional toilets is cumbersome as the toilets are very heavy and bulky.

[0004] In recent years, there has been a growing demand for more customizable solutions in various industries, including the production of toilets. Manufacturers are constantly seeking innovative methods to optimize production efficiency and enhance performance of the toilet. Consequently, there is a need for a toilet that combines easier assembly and lighter transportation weight while being high-quality and customizable.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Exemplary embodiments are described herein with reference to the following drawings, according to an exemplary embodiment.

[0006] FIG. 1 illustrates a toilet with a tank according to an exemplary embodiment of the present disclosure.

[0007] FIG. 2 illustrates a tankless toilet according to an exemplary embodiment of the present disclosure.

[0008] FIG. 3 illustrates a toilet formed by setting the engine within the shroud according to an exemplary embodiment of the present disclosure.

[0009] FIG. 4 illustrates the engine of the toilet being lifted from the shroud according to an exemplary embodiment of the present disclosure.

[0010] FIG. 5 illustrates the shroud and engine separated and unglazed according to an exemplary embodiment of the present disclosure.

[0011] FIG. 6 illustrates the rim of the engine of the toilet according to an exemplary embodiment of the present disclosure.

[0012] FIG. 7 illustrates the toilet bowl of the engine of the toilet according to an exemplary embodiment of the present disclosure.

[0013] FIG. 8 illustrates the rim of the engine of the toilet and the toilet bowl of the engine of the toilet bonded together according to an exemplary embodiment of the present disclosure.

[0014] FIG. 9 illustrates the underside of the engine of the toilet according to an exemplary embodiment of the present disclosure.

[0015] FIG. 10 illustrates the shroud and the downstream trapway passage according to an exemplary embodiment of the present disclosure.

[0016] FIG. 11 illustrates the underside of the shroud of the toilet according to an exemplary embodiment of the present disclosure.

[0017] FIG. 12 illustrates the trapway joint according to an exemplary embodiment of the present disclosure.

[0018] FIG. 13 illustrates the trapway joint according to another exemplary embodiment of the present disclosure.

[0019] FIG. 14 is a flowchart illustrating the steps to form the toilet from an engine and shroud according to an exemplary embodiment of the present disclosure.SUMMARY

[0020] This disclosure aims to provide a sustainable solution that reduces the burden of transportation, assembly time and cost, as well an increase in the ability to customize and design the interior of a bathroom. The division of the toilet into multiple sections in combination with a trapway joint system, and a manufacturing method thereof allows for more maneuverability and lighter weight parts required for transportation and assembly. This disclosure adaptability allows for the creation of toilets in various shapes, sizes, and designs, catering to diverse consumer preferences and requirements.

[0021] In an example embodiment, a toilet includes: an engine including a rim having an annular member, a water outlet, a toilet bowl, a water channel configured to dispense water into the toilet bowl from the water outlet, and an upstream trapway passage, water passage, pipe, section, portion, or the like; and a shroud including a downstream trapway passage, water passage, pipe, section, portion, or the like, united with both the upstream trapway passage and a trapway outlet. The upstream trapway passage is spaced apart from the downstream trapway passage when the water flows through the upstream trapway passage and the downstream trapway passage to the trapway outlet.

[0022] In another example embodiment. A toilet trapway joint system is described. The system includes: an engine including a rim having an annular member, a water outlet, a toilet bowl, a water channel configured to dispense water into the toilet bowl from the water outlet, and an upstream trapway passage; a shroud including a downstream trapway passage united with both the upstream trapway passage and a trapway outlet; a trapway joint configured to unite the upstream trapway passage of the engine to the downstream trapway passage of the shroud. The upstream trapway passage is spaced apart from the downstream trapway passage when the water flows through the upstream trapway passage and the downstream trapway passage to the trapway outlet.

[0023] In yet another embodiment, a method of manufacturing a toilet is further described. The method includes forming an engine that includes at least a rim, a toilet bowl, and an upstream trapway passage; forming a shroud separately from the engine, the shroud including a downstream trapway passage which is fluidly connected with the upstream trapway passage; applying a flint powder around at least a portion of a perimeter between the engine and the shroud to prevent bonding; curing the engine and the shroud fitted together; and separating the engine from the shroud.

[0024] In another embodiment, a toilet includes an engine including a rim having an annular member, a water outlet, a toilet bowl, a water channel configured to dispense water into the toilet bowl from the water outlet, and a vitreous upstream trapway passage, a non-vitreous downstream trapway passage aligned with both the vitreous upstream trapway passage of the engine and coupled to a trapway outlet, and a shroud coupled to the non-vitreous downstream trapway passage.DETAILED DESCRIPTION

[0025] The following embodiments include a toilet, toilet trapway joint system, and a method of manufacturing the toilet applicable in a bathroom setting. Various embodiments are described and illustrated separately. However, each of these embodiments is usable together in a single implementation, device, or system. It should be understood that the present disclosure is not limited to the details and methodology set forth in the detailed description or illustrated in the figures. It should be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0026] When a component, element, device, or the like of the present disclosure is described as having a purpose or performing an operation, function, or the like, the component, device, or element should be considered herein as being “configured to” meet that purpose or to perform that operation or function.

[0027] By dividing the toilet into two halves or other portions, the assembly process becomes simpler, allowing for ease of transportation and installation in various environments. Additionally, this disclosure facilitates enhanced maintenance and repair procedures, as individual components can be accessed and replaced with greater ease. By dividing the toilet into portions, this allows for the unique customization of the toilet so that it may aesthetically fit more integrally into the design of the bathroom. A particular engine with a specific shape may be chosen from a range of options and a matching shroud may be selected from an even wider change of options including many formed from other materials.

[0028] This disclosure integrates with both tank and tankless toilets which further improves the ability of customization for aesthetic purposes.

[0029] Described herein are a toilet, a trapway joint system, and a method of manufacturing and assembling thereof. More specifically, the present disclosure describes a toilet and a method of manufacturing thereof. The toilet includes an engine with an upstream trapway passage and a shroud with a downstream trapway passage that are attached together via a trapway joint system to fluidly couple the trapway. The trapway includes two portions: an upstream trapway; and a downstream trapway. The upstream trapway may be referred to as a passage, water passage, pipe, section, portion, or the like; and the downstream trapway passage may be referred to as a passage, water passage, pipe, section, portion, or the like. The toilet may provide less of a burden for the transportation thereof as well as customizable designs of the toilet and, more specifically, the shroud of the toilet.

[0030] FIG. 1 illustrates a toilet 1 formed by setting the engine 100 within a shroud 200 according to an exemplary embodiment of the present disclosure. The toilet 1 of FIG. 1 is in final operational form after manufacturing and installation. The toilet 1 includes an engine 100 having at least a rim 105, a toilet bowl 107, and an upstream trapway passage 108. The shroud 200 includes at least an integrated support 203 and a downstream trapway passage 201. The engine 100 of the toilet 1 is set in place within the shroud 200 of the toilet 1. Both the engine 100 of the and the shroud 200 of the toilet 1 are glazed and assembled for the assembled toilet 1. Additional, different, or fewer components may be included.

[0031] A water supply is connected to the tank 102. The tank 102 is configured to store water. Water is directed from the tank 102 into the toilet bowl 107, and then down into the upstream trapway passage 108 of the engine 100 of the toilet 1. The toilet bowl 107 is provided to receive fecal matter, urine, or other objects / materials deposited into the toilet 1. Upon actuation / release of an actuator 109, the supply of water is provided from the tank 102 to the toilet bowl 107.

[0032] Movement of the actuator 109 (e.g., flush button or lever) may open a flush valve unit to discharge water from the tank 102. The flush valve unit is configured to allow / restrict the supply of water from the tank 102 to the toilet bowl 107. In particular, the flush valve unit allows / restrict the supply of water from the tank 102 to the toilet bowl 107, upon actuation / release of the actuator 109. The flushing cycle may include generation of a siphon to assist the flushing action and waste removal.

[0033] Between operational cycles (e.g., flush cycles) of the toilet 10, the water (and waste) is collected in the first portion of the trapway (in addition to the receptacle of the bowl), such that a weir prohibits the water from passing past the weir and into the second portion of the trapway. The first portion of the trapway may be upstream trapway passage 108. The second position of the trapway may be downstream trapway portion 201.

[0034] FIG. 2 illustrates a tankless toilet 1 formed by setting the engine 100 within the shroud 200 according to an exemplary embodiment of the present disclosure. The toilet 1 of FIG. 2 is in final operational form after manufacturing and installation. The toilet 1 includes an engine 100 having at least a rim 105, a toilet bowl 107, and an upstream trapway passage 108. The shroud 200 includes at least an integrated support 203 and a downstream trapway passage 201. The engine 100 of the toilet 1 is set in place within the shroud 200 of the toilet 1. Both the engine 100 of the and the shroud 200 of the toilet 1 are glazed and assembled for the assembled toilet 1. Additional, different, or fewer components may be included.

[0035] As shown in FIG. 2, the toilet 1 is a tankless toilet configured to receive water from a water supply conduit. The water supply conduit is configured to fill the toilet bowl 107 with water, upon actuation / release of at least one flush button or actuator. The actuator may be incorporated into a flushometer or another type of valve. Flushing is enabled in the toilet bowl 107, corresponding to the supply of water from the water supply conduit to the toilet bowl 107.

[0036] The toilet 1 may include a pedestal (e.g., base, stand, support, etc.). In some embodiments, the pedestal may be mounted to the wall of a lavatory and receive water through the water supply conduit. The water supply conduit may be a water supply line inside a household, a commercial property, or another type of building. The water supply conduit may be configured to supply water at a city water pressure or a well pump pressure. The water supply conduit may be a pipe, tube, or other water delivery mechanism extending from a wall of the building.

[0037] In some examples, optionally, the toilet 1 may be connected to a pressurized water diverter valve 118. The valve 118 may be physically coupled to a lever 119 or another type of actuator. The valve 117 is configured to use water pressure from the water supply to release water into the toilet 1. When the lever 119 is actuated, pressure in a chamber of the valve 118 causes water to be released. In one example, the lever 119 may cause a plate to be tilted and high pressure open the valve 118. In some example, the plate included a piston and in other examples the plate includes a diaphragm.

[0038] FIG. 3 illustrates a toilet 1 formed by setting the engine 100 within a shroud 200 according to an exemplary embodiment of the present disclosure. The toilet 1 includes an engine 100 having at least a rim 105, an annular member 106 of the rim 105, and a toilet bowl 107. The toilet 1 also includes the shroud 200. The engine 100 of the toilet 1 is set in place within the shroud 200 of the toilet 1. Both the engine 100 of the and the shroud 200 of the toilet 1 are glazed and assembled for the assembled toilet 1. Additional, different, or fewer components may be included.

[0039] FIG. 4 illustrates the engine 100 of the toilet 1 being placed into the shroud 200 of the toilet 1. The upstream trapway passage 108 of the engine 100 of the toilet 1 connects to the downstream trapway passage 201 of the shroud 200 of the toilet 1. As shown in FIG. 4, the engine 100 of the toilet 1 is separated from the shroud 200.

[0040] The engine 100 of the toilet 1 and the shroud 200 of the toilet 1 fit together and remain connected via the force of gravity from the weight of the engine 100 of the toilet 1, adhesive, or other mechanical fasteners. A wide range of adhesives can be used to connect the engine 100 of the toilet 1 and the shroud 200 of the toilet 1 including but not limited to quick-setting and strong adhesives that bond rapidly with non-porous surfaces, epoxy adhesives that must be mixed prior to use and create strong bonds on materials such as ceramics which also providing resistance to chemicals.

[0041] FIG. 5 illustrates the shroud 200 of the toilet 1 and the engine 100 of the toilet 1 separated and unglazed according to an exemplary embodiment of the present disclosure. The shroud 200 includes an integrated support 203 which partially supports the weight of the front end of the engine 100 of the toilet 1. The engine 100 of the toilet 1 includes the rim 105, the toilet bowl 107, and the upstream trapway passage 108.

[0042] FIG. 5 further illustrates the structural components of the shroud 200 of the toilet 1 and the engine 100 of the toilet 1 that are configured to interlock and attach together via a second bonding material to form the toilet 1.

[0043] FIG. 6 illustrates the rim 105 of the engine 100 of the toilet 1 according to an exemplary embodiment of the present disclosure.

[0044] FIG. 6 includes a rim 105 with an annular member 106 which refers to the curved shape of the rim 105. The rim 105 attaches to the toilet bowl 107 and upstream trapway passage 108 of the toilet 1 via a first bonding material.

[0045] FIG. 7 illustrates the toilet bowl 107 of the engine 100 of the toilet 1 according to an exemplary embodiment of the present disclosure.

[0046] FIG. 7 illustrates the travel of water from the tank 102 or the wall in a tankless embodiment of the toilet 1. Water enters through the water channel 103, exits out the water outlet 104, and enters into the toilet bowl 107 of the toilet 1.

[0047] Water may be delivered from the tank 102 or the water supply conduit to the water outlet 104 of the engine 100 of the toilet 1. The water outlet 104 is fluidly connected to the water channel 103 to receive the water from the tank 102 or the water supply conduit. After the water travels through the water channel 103 of the toilet within the engine 100 of the toilet 1 and directly under the rim 105 of the engine 100 of the toilet 1, the water will exit through the water outlet 104 of the engine 100 of the toilet 1 and enter the toilet bowl 107 of the engine 100 of the toilet 1. Water from the water outlet 104 is directed into the toilet bowl 107 at an angle that allows the water to swirl around the toilet bowl 107. The swirling of the water from the water outlet 104 into the toilet bowl 107 allows the water to clean all surfaces within the toilet bowl 107 and carry away with it any contents of the toilet bowl 107. Further, a siphoning effect will occur when the toilet bowl 107 empties. This siphoning effect will enhance the pull of the water from the toilet bowl 107 into the upstream trapway passage 108 of the engine 100 of the toilet 1.

[0048] The water outlet 104 directed towards an interior of the toilet bowl 107 may deliver the water in the interior of the toilet bowl 107 in a swirl-flow manner. The water outlet 104 is angled or directed at the acute angle relative to the water flow direction. As the water outlet 104 is angled at the acute angle, the water outlet 104 allows exit of water to the interior of the toilet bowl 107 in the swirl-flow manner.

[0049] In some embodiments, other directions or angle of the water outlet 104 may be used including clockwise, counterclockwise, or straight down into the toilet bowl 107.

[0050] FIG. 8 illustrates the rim 105 of the engine 100 of the toilet 1 and the toilet bowl 107 and the upstream trapway passage 108 of the engine 100 of the toilet 1 bonded together according to an exemplary embodiment of the present disclosure.

[0051] FIG. 8 illustrates the rim 105 of the engine 100 of the toilet 1 after it has been attached to the toilet bowl 107 and the upstream trapway passage 108 of the engine 100 of the toilet 1 via a first bonding material. Together, the rim 105 of the engine 100 of the toilet 1 and the toilet bowl 107 and upstream trapway passage 108 of the engine 100 of the toilet 1 form the engine 100 of the toilet 1.

[0052] FIG. 9 illustrates the underside of the engine 100 of the toilet 1 according to an exemplary embodiment of the present disclosure. The engine 100 of the toilet 1 includes a rim 105, a toilet bowl 107, and an upstream trapway passage 108.

[0053] FIG. 9 illustrates the shape of the upstream trapway passage 108. The upstream trapway passage 108 has a u-shaped bend to it that is characteristic of trapways and other plumbing fixtures. The u-shaped trapway prevents sewer gases from entering the bathroom from the sewer system. The trapway does this by holding water in the bottom of the u-shaped trapway that then acts as a seal and barrier creating a physical blockage. The u-shaped trapway also allows water to collect due to gravity and thus water flowing from the toilet 1 will replenish this u-shaped trapway creating the seal whenever water is used from the toilet 1. As discussed above, when the toilet 1 is flushed and the water from the tank 102, or a similar amount of water from the water supply conduit in the wall, is drained completely into the upstream trapway passage 108, a siphon effect occurs pulling out all of the water contents from the upstream trapway passage 108 except for enough to fill the u-shaped trapway of the upstream trapway passage 108.

[0054] FIG. 9 also illustrates the seal created by the first bonding material between the toilet bowl 107 of the engine 100 of the toilet 1 and the rim 105 of the engine 100 of the toilet 1. Alternatively, the rim 105 may be formed integrally with the engine 100. Also shown is the closest end to the toilet bowl 107 of the base of the upstream trapway passage 108 which will rest on the integrated support 203 of the shroud 200 of the toilet 1 shown in FIG. 3.

[0055] Plumbing fixtures, such as toilets and urinals include a sump in which liquid and / or waste are collected. The sump being fluidly connected to a bowl of the toilet through which liquid and / or other waste may enter the sump. The sump is also fluidly connected to a trapway leading to a drain or sewer. Liquid and / or other waste flow from the sump through the trapway to a drain or sewer during a flushing operation. A jet orifice may be provided in the sump. The jet orifice fluidly connects a drain channel, which supplies water to the jet orifice, to the sump. Water supplied from the drain channel, through the jet orifice, and to the sump facilitates the removal of liquid and / or other waste from the plumbing fixture during a flushing process.

[0056] The toilet 1 is configured such that a drain channel can direct a flow of water from the water supply source to the jet orifice, where the flow of water can be introduced to the sump, for example, to help prime a siphon in the trapway to induce a flush cycle and empty the contents of the toilet bowl 107.

[0057] FIG. 10 illustrates the downstream trapway passage 201 and the integrated support 203 of the shroud 200 of the toilet 1 according to an exemplary embodiment of the present disclosure. The integrated support 203 comes in contact with the toilet bowl 107.

[0058] FIG. 10 illustrates the downstream trapway passage 201 of the shroud 200 of the toilet 1 that is configured to be connected to the upstream trapway passage 108 of the engine 100 of the toilet 1.

[0059] FIG. 11 illustrates the underside of the shroud 200 of the toilet 1 according to an exemplary embodiment of the present disclosure.

[0060] FIG. 11 illustrates the wax ring area 202 connecting the downstream trapway passage 201 to the trapway outlet. The wax ring area 202 is positioned between the bottom of the toilet 1 and the flange, also known as the trapway outlet or the drainpipe, which is a pipe fitting in the floor and is used to create a watertight seal. The primary function of the wax ring is to create a water-tight seal between the toilet 1 and the drainpipe preventing leaks of wastewater and odors. The wax ring area 202 also helps ensure that water and waste from the toilet 1 flush properly move into the plumbing system without leaking onto the bathroom floor.

[0061] Modern wax rings are often circular and made from a mix of wax and rubber or other materials to enhance their durability and flexibility. During installation, the wax ring is placed on the flange before lowering the toilet 1 onto it. The weight of the toilet 1 compresses the wax ring, creating a secure seal between the toilet 1 and the drain. The wax ring allows for a degree of flexibility, compensating for any unevenness or irregularities in the floor or base of the toilet 1. This flexibility helps ensure a proper seal even in less-than-ideal conditions.

[0062] In some embodiments, the shroud 200 has a base that provides a wax ring area 202 for the downstream trapway passage 201 to connect to the trapway outlet and is referred to as a closed foot shroud 200. The shroud 200 does not have a base thus there is no wax ring area 202 for the downstream trapway passage 201 to connect to the trapway outlet foot and this design is referred to as an open foot shroud 200. With regard to an open foot shroud 200, clay batts are required as refractory support made out of sacrificial clay to prevent warp or splay around the perimeter of the foot due to shrink / warp that occurs in the firing process. Eliminating the need for this clay batt has the benefit of reducing the cost of production of the shroud 200.

[0063] FIG. 12 illustrates the trapway joint 300 according to an exemplary embodiment of the present disclosure.

[0064] FIG. 12 illustrates the trapway joint 300 of the toilet 1. The trapway joint 300 of the toilet 1 includes an upstream trapway clamp 302 which attaches to the upstream trapway passage 108 of the engine 100 of the toilet 1 and a downstream trapway clamp which attaches to the downstream trapway passage 201 of the shroud 200 of the toilet 1. The upstream trapway clamp 302 and the downstream trapway clamp 303 then both clamp to the trapway seal ring 301 to create a fluidly coupled trapway for the toilet 1. A release 304 allows both the upstream trapway clamp 302 and the downstream trapway clamp 303 to detach from the trapway seal ring 301 after the upstream trapway clamp 302 and the downstream trapway clamp 303 have already been attached to the trapway seal ring 301. Included on the trapway seal ring 301 is a plurality of trapway seal ring ridges 305 on the outer surface of the trapway seal ring 301. The plurality of trapway seal ring ridges 305 allow the upstream trapway clamp 302 and the downstream trapway clamp 303 to clamp to the trapway seal ring 301.

[0065] Within the center of the trapway seal ring is an inner trapway seal ring space 306. Fluids from the upstream trapway passage 108 enter the inner trapway seal ring space 306 and flow through it to the other end of the trapway seal ring 301 into the downstream trapway passage 201. In between the upstream trapway passage 108 and the downstream trapway passage 201 is a trapway gap 307 which allows the flexibility when attaching upstream trapway clamp 302 and the downstream trapway clamp 303 to the trapway seal ring 301.

[0066] In an embodiment, the trapway joint 300 utilizes a hinging locking mechanism that secures both the upstream trapway clamp 302 which is attached to the upstream trapway passage 108 of the engine 100 of the toilet 1 and the downstream trapway clamp 303 which is attached to the downstream trapway passage 201 of the shroud 200 of the toilet 1, to the trapway seal ring 301. The locking mechanism may be unlocked via a release 304 which may be a button, lever, switch, press, pull mechanism, or the like. Once this release 304 is enacted which in turn unlocks the locking mechanism, it will allow both the upstream trapway clamp 302 and the downstream trapway clamp 303 to hinge and outwardly rotate away from the trapway seal ring 301 thus releasing both the upstream trapway clamp 302 and the downstream trapway clamp 303 from the trapway seal ring 301.

[0067] In another embodiment, the trapway joint 300 utilizes a hinging locking mechanism similar to above except the trapway seal ring 301, after being placed between both the upstream trapway passage 108 and the downstream trapway passage 201, may then hinge its clamps to secure itself onto both the upstream trapway passage 108 and the downstream trapway passage 201. The trapway joint 300 with this type of hinging locking mechanism may also include a release 304 that unlocks the trapway seal ring 301 allowing it to rotate its clamps off the upstream trapway passage 108 and the downstream trapway passage 201 and thus detaching from both the upstream trapway passage 108 and the downstream trapway passage 201.

[0068] In another embodiment, the trapway joint 300 utilizes a rotating locking mechanism. The trapway seal ring 301 may be placed between both the upstream trapway passage 108 and the downstream trapway passage 201. The trapway seal ring 301 may then rotate to secure itself onto both the upstream trapway clamp 302 which is attached to the upstream trapway passage 108 and the downstream trapway clamp 303 which is attached to the downstream trapway passage 201. The trapway joint 300 with this type of rotating locking mechanism may also include a release 304 that unlocks the trapway seal ring 301 allowing it to be rotated in the opposite direction and thus detaching from both the upstream trapway clamp 302 which is attached to the upstream trapway passage 108 and the downstream trapway clamp 303 which is attached to the downstream trapway passage 201.

[0069] In another embodiment, the trapway joint 300 utilizes a sliding locking mechanism. The trapway seal ring 301 may be placed between both the upstream trapway passage 108 and the downstream trapway passage 201. The upstream trapway clamp 302 which is attached to the upstream trapway passage 108 and the downstream trapway clamp 303 which is attached to the downstream trapway passage 201 may then slide over the trapway seal ring 301 to lock to the trapway seal ring 301. The trapway joint 300 with this type of sliding locking mechanism may also include a release 304 that unlocks the upstream trapway clamp 302 and the downstream trapway clamp 303 allowing them to slide off the trapway seal ring 301 in the opposite direction and thus detaching from the trapway seal ring 301.

[0070] FIG. 13 illustrates a trapway joint 300 according to another exemplary embodiment of the present disclosure. The trapway joint 300 may be primarily formed of rubber or plastic (e.g., non-vitreous) and may have one or more fasteners. The trapway joint 300 may server as the downstream trapway passage and be aligned with the vitreous flush engine 100.

[0071] In this example, the trapway joint 300 may be directly connected and aligned to the floor or floor mounted gasket (referred to in the alternative as floor mount) during installation of the toilet 1. The floor mount may include a trapway outlet for the trapway joint 300 to connect to a sewer or septic line (e.g., waste passage). In one embodiment, the trapway joint 300 may be connected to the floor mount to a bracket or other external mounting system, which is secured from the exterior of the shroud 200. Thus, the trapway joint 300 may include tabs to receive a bracket for connection to the flour mount. In one embodiment, the trapway joint 300 is connected to the floor mount and internally connected to the shroud 200 via an internal mounting system. In both examples, the trapway joint 300 is connected to the engine 100. Thus, the trapway joint 300 may include tabs to receive a bracket for connection to the engine 100.

[0072] The trapway joint 300 of the toilet 1 includes an upstream trapway end 308 which attaches to the upstream trapway passage of the engine 100 of the toilet 1 and a downstream trapway end 309 which attaches to the downstream trapway passage 201 of the shroud 200 of the toilet 1 and / or the floor mount. Between the upstream trapway end 308 and the downstream trapway end 309 is a fluids medium passage 310 that transfers incoming fluids from the upstream trapway passage through the upstream trapway end 309 and out through the downstream trapway end 309 into the downstream trapway passage.

[0073] Some examples using the trapway joint 300 may include a shroud 200 that is modified from other embodiments described herein. For example, at least a portion 222 of the bottom of the shroud 200 to provide space for the trapway joint 300. Thus, the wax ring area 202 may be removed, or otherwise omitted from the shroud 200 when using the trapway joint 300.

[0074] A toilet may include an engine including a rim having an annular member, a water outlet, a toilet bowl, a water channel configured to dispense water into the toilet bowl from the water outlet, and a vitreous upstream trapway passage. The toilet may include a non-vitreous downstream trapway passage aligned with both the vitreous upstream trapway passage of the engine and coupled to a trapway outlet and a shroud coupled to the non-vitreous downstream trapway passage.

[0075] In one example, a mounting bracket (e.g., trapway joint 300) is external to the shroud and configured to couple the shroud and the non-vitreous downstream trapway passage. In another example, the mounting bracket (e.g., trapway joint 300) is internal to the shroud and configured to couple the shroud and the non-vitreous downstream trapway passage.

[0076] FIG. 14 is a flowchart 3 illustrating the steps to form the toilet 1 from an engine 100 and shroud 200 according to an exemplary embodiment of the present disclosure. Additional or fewer acts may be needed.

[0077] At act S101, an engine 100 of the toilet 1 is formed that includes a rim 105, a toilet bowl 107, and an upstream trapway passage. At act S101, a rim 105 of the engine 100 of the toilet 1 may be molded separately from the toilet bowl 107 and the upstream trapway passage of the engine 100 of the toilet 1. Once the toilet bowl 107 and the upstream trapway passage of the engine 100 of the toilet 1 are molded as well, the rim 105 of the engine 100 of the toilet 1 and the toilet bowl 107 and the upstream trapway passage of the engine 100 of the toilet 1 may be bonded together to form the engine 100 of the toilet 1.

[0078] In some embodiments, the engine 100 may be formed out of vitreous china which typically includes a combination of clay, flint, quartz and other additives. The selected materials are mixed together to ensure even distribution of these components, creating a uniform and blend. This material is than molded to the specific shape of the desired style for the engine 100.

[0079] At act S103, a shroud 200 of the toilet 1 is formed that includes a downstream trapway passage 201. At act S103, a shroud 200 of the toilet 1 may include the addition of a wax ring area 202 which connects to a trapway outlet. In some embodiments, the shroud 200 may be formed out of vitreous china which typically includes a combination of clay, flint, quartz and other additives. The selected materials are mixed together to ensure even distribution of these components, creating a uniform and blend. This material is than molded to the specific shape of the desired style of shroud 200.

[0080] The shroud 200 can also be formed out of other ceramic materials such as fireclay, or another lower cost / higher sustainability ceramic material. The shroud 200 can also be formed out of non-ceramic materials such as natural stone materials, resins, plastics, metals, or the like.

[0081] At act S105, a powder is applied around at least a portion of a perimeter between the engine 100 of the toilet 1 and the shroud 200 of the toilet 1 to prevent bonding or fusing during the curing process in the kiln. The powder may be a ceramic powder. The powder may be selected from materials having a high barrier to bonding or resistance to high temperatures during the curing process in the kiln. One example powder is flint.

[0082] At act S107, the engine 100 of the toilet 1 and the shroud 200 of the toilet 1 are cured in the kiln together as if they were assembled in their final form so that the curing process is uniform for both the engine 100 of the toilet 1 and the shroud 200 of the toilet 1. Curing begins shortly after the composition is poured into the mold 400. The curing process can involve various techniques, including chemical reactions or exposure to specific environmental conditions such as heat, pressure, or ultraviolet (UV) light. The choice of curing method depends on the composition and the material used.

[0083] As the curing progresses, the material continues to solidify. The bonds between molecules strengthen, and the material becomes more rigid and stable. This solidification process ensures that the toilet 1 will have the necessary strength and durability.

[0084] In some embodiments, the process of curing is referred to as vitrifying, or vitrification, and may be utilized. Vitrification is the process of transforming a material into a glass or glass-like substance. This process typically involves heating a material to a high temperature until it melts and then rapidly cooling it to form an amorphous, non-crystalline solid. Vitrification results in a smooth, glossy, and often transparent or translucent surface.

[0085] Curing is the process of hardening a material, often involving chemical reactions, while vitrification is the specific process of transforming a material into a glassy state through controlled heating and cooling. The two processes serve different purposes but can be interconnected in certain manufacturing applications.

[0086] Once the curing process is complete, the engine 100 of the toilet 1 and the shroud 200 of the toilet 1 may be removed from the kiln and allowed to cool down. After the engine 100 of the toilet 1 and the shroud 200 of the toilet 1 are removed from the kiln, the material will appear smooth, glassy, and non-porous surface characteristic of vitreous china.

[0087] At act S109, the engine 100 of the toilet 1 may be removed from the shroud 200 of the toilet 1. The engine 100 of the toilet 1 and the shroud 200 of the toilet 1 should separate easily because of the addition of the powder (e.g., flint) in act S105.

[0088] At act S111, a seconding bonding or sealing material may be applied to both the engine 100 of the toilet 1 and the shroud 200 of the toilet 1 so that they will bond once assembled in the desired setting. One example bonding or sealing material is caulk.

[0089] At act S113, the engine 100 of the toilet 1 and the shroud 200 of the toilet 1 are coupled together via the trapway joint 300 of the toilet 1. The trapway joint 300 of the toilet 1 includes an upstream trapway clamp 302 which attaches to the upstream trapway passage of the engine 100 of the toilet 1 and a downstream trapway clamp 303 which attaches to the downstream trapway passage 201 of the shroud 200 of the toilet 1. The upstream trapway clamp 302 and the downstream trapway clamp 303 then both clamp to the trapway seal ring 301 to create a fluidly coupled trapway for the toilet 1.

[0090] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.

[0091] While this specification contains many specifics, these should not be construed as limitations on the scope of the invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

[0092] One or more embodiments of the disclosure may be referred to herein, individually and / or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.

[0093] It is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.

Claims

1. A toilet comprising:an engine including a rim having an annular member, a water outlet, a toilet bowl, a water channel configured to dispense water into the toilet bowl from the water outlet, and an upstream trapway passage; anda shroud including a downstream trapway passage united with both the upstream trapway passage and a trapway outlet,wherein the upstream trapway passage is spaced apart from the downstream trapway passage when the water flows through the upstream trapway passage and the downstream trapway passage to the trapway outlet.

2. The toilet of claim 1, further comprising:a sump connected to the toilet bowl to carry the water and contents out of the toilet bowl to the upstream trapway passage and downstream trapway passage.

3. The toilet of claim 1, further comprising:a trapway joint including:a trapway seal;an upstream trapway clamp adhered to the upstream trapway passage of the engine and configured to attach to the trapway seal;a downstream trapway clamp adhered to the downstream trapway passage of the shroud and configured to attach to the trapway seal; anda release.

4. The toilet of claim 1, further comprising:a trapway joint configured to join the upstream trapway passage of the engine to the downstream trapway passage of the shroud.

5. The toilet of claim 1, further comprising:a first bonding material configured to unite the rim and the toilet bowl via curing in response to being subjected to an elevated temperature.

6. The toilet of claim 1, further comprising:a powder applied around at least a portion of a perimeter between the engine and the shroud to prevent bonding.

7. The toilet of claim 1, further comprising:a mechanical fastener configured to unite the engine and the shroud.

8. The toilet of claim 7, wherein the mechanical fastener further comprises clips, clamps, or bolts.

9. The toilet of claim 1, further comprising:a second bonding material applied between the engine and the shroud to bond the engine and the shroud.

10. A toilet trapway joint system comprising:an engine including a rim having an annular member, a water outlet, a toilet bowl, a water channel configured to dispense water into the toilet bowl from the water outlet, and an upstream trapway pipe;a shroud including a downstream trapway pipe united with both the upstream trapway pipe and a trapway outlet; anda trapway joint configured to unite the upstream trapway pipe of the engine to the downstream trapway pipe of the shroud,wherein the upstream trapway pipe is spaced apart from the downstream trapway pipe when the water flows through the upstream trapway pipe and the downstream trapway pipe to the trapway outlet.

11. The toilet trapway joint system of claim 10, further comprising:an outlet fluidly connected to the toilet bowl to carry the water and contents out of the toilet bowl.

12. The toilet of claim 10, further comprising:a trapway joint including:a trapway seal;an upstream trapway clamp adhered to the upstream trapway pipe of the engine and configured to attach to the trapway seal;a downstream trapway clamp adhered to the downstream trapway pipe of the shroud and configured to attach to the trapway seal; anda release.

13. The toilet of claim 10, further comprising:a trapway joint configured to join the upstream trapway pipe of the engine to the downstream trapway pipe of the shroud.

14. The toilet trapway joint system of claim 10, further comprising:a first bonding material configured to unite the rim and the toilet bowl via curing in response to being subjected to an elevated temperature.

15. The toilet trapway joint system of claim 10, further comprising:a powder applied around at least a portion of a perimeter between the engine and the shroud to prevent bonding.

16. The toilet trapway joint system of claim 10, further comprising:a mechanical fastener configured to join the engine and the shroud.

17. The toilet trapway joint system of claim 10, further comprising:a second bonding material applied between the engine and the shroud to bond the engine and the shroud together.

18. A method of forming a toilet, the method comprising:forming an engine that includes at least a rim, a toilet bowl, and an upstream trapway passage;forming a shroud separately from the engine, the shroud including a downstream trapway passage which is fluidly connected with the upstream trapway passage;applying a powder around at least a portion of a perimeter between the engine and the shroud to prevent bonding;curing the engine and the shroud fitted together; andseparating the engine from the shroud.

19. The method of claim 18, further comprising:coupling the rim and the toilet bowl via curing a first bonding material in response to being subjected to an elevated temperature.

20. The method of claim 18, further comprising:adding a second bonding material between the engine and the shroud to bond the engine and the shroud together.

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