Toilet bowl flange fastening system

Abstract

The present disclosure relates to a system and methods for enhancing the stability and ease of toilet bowl installation. In some embodiments, the system comprises alignment fasteners, alignment couplings, and flanges configured to enable fixed alignment of mounting fasteners with toilet bowl apertures. The alignment coupling aligns the fastener substantially perpendicular to the flange face, addressing the instability issues posed by conventional mounting bolts. In some embodiments, the system includes features such as cutting grooves for adjustable fastener length and / or tool engagement portions for ease of installation. In some embodiments, extendable aligning fasteners allow for customizable length, ensuring adaptability to various installation scenarios. In some embodiments, a kit may include combinations of portions of the system described herein. This innovative approach overcomes challenges associated with uneven flooring and improper fastening techniques, providing a reliable and efficient solution for toilet bowl installation.

Description

TOILET BOWL FLANGE FASTENING SYSTEMCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 551,838, filed February 9, 2024, which is hereby incorporated herein by reference in its entirety for all purposes.BACKGROUND

[0002] The installation of a toilet bowl involves several steps. First, the area is prepared by ensuring a level and stable floor surface. Next, the toilet bowl flange is placed over a sewer pipe and affixed securely to the floor using appropriate fastening means, such as bolts or screws. Once a wax ring or similar sealant is applied, the toilet bowl is lowered into position and secured in place by mounting bolts. FIG. 1 illustrates a toilet installation process according to some embodiments.

[0003] Conventional mounting bolts can exhibit a tendency to lean in various directions. FIG. 2 shows a mounting bolt of the prior art leaning in an undesirable manner. This instability can result from factors such as uneven flooring, irregularities in the flange ring, or improper fastening techniques. The unpredictable leaning of mounting bolts poses a challenge to installers as it complicates the alignment of the toilet bowl during the installation process. This instability not only hinders the installation process but also compromises the overall stability and longevity of the toilet fixture.

[0004] Recognizing the limitations of the existing mounting bolt systems, the disclosure is directed to a system and methods to overcome these challenges, enhancing the stability and ease of installation, thereby providing an improved solution for the installation of toilet bowls.SUMMARY

[0005] In some embodiments, the disclosure is directed to a system and / or kit that is configured to enable fixed alignment of mounting fasteners with toilet bowl fastener apertures. In accordance with some embodiments, the system can be described as comprising one or more alignment fasteners (e.g., mounting fasteners), one or more alignment couplings, one or more fastener extensions, one or more bolts, one or more washers, one or more nuts, and / or one or more flanges.

[0006] In some embodiments, an alignment coupling is configured to align an alignment fastener substantially perpendicular to at least a portion of a flange face of the flange. In some embodiments, the alignment fastener includes a stem. In some embodiments, the alignment coupling includes a coupling aperture. In some embodiments, the stem is configured to pass through the coupling aperture. In some embodiments, the flange includes a flange slot. In some embodiments, engagement of the alignment coupling with the flange slot is configured to align the alignment fastener substantially perpendicular to the flange face of the flange.

[0007] In some embodiments, the flange slot includes an alignment coupling opening. In some embodiments, the alignment coupling opening is configured to not engage a flange slot engagement portion of the alignment coupling. In some embodiments, all portions of the alignment coupling are configured to pass through the alignment coupling opening. In some embodiments, flange slot includes a slot engagement region. In some embodiments, the slot engagement region is configured to engage the flange slot engagement portion of the alignment coupling.

[0008] In some embodiments, the stem includes one or more cutting grooves. In some embodiments, the one or more cutting grooves include a reduced cross-section on the stem. In some embodiments, the stem comprises threading. In some embodiments, a width of the threading is greater than a width of the reduced cross-section. In some embodiments, the stem includes a tool engagement portion. In some embodiments, the tool engagement portion includes one or more of a slot, an aperture, and a flat face.

[0009] In some embodiments, the system further comprises a fastener extension. In some embodiments, relative rotation between the fastener extension and the stem is configured to cause the stem to extend or retract into the fastener extension. In some embodiments, the alignment fastener comprises a bolt.A non-limiting example implementation of the system is described below in relation to the accompanied drawings.DRAWING DESCRIPTION

[0010] FIG. 1 illustrates a toilet installation process according to some embodiments.

[0011] FIG. 2 shows mounting bolts of the prior art leaning in an undesirable manner.

[0012] FIG. 3 depicts a toilet bowl installation using aligning fasteners according to some embodiments.

[0013] FIG. 4 shows the aligning fasteners of FIG. 3 in an engaged configuration according to some embodiments.

[0014] FIG. 5 illustrates cuttable aligning fasteners according to some embodiments.

[0015] FIG. 6 shows a sectional view of the aligning fasteners illustrated in FIG. 5 according to some embodiments.

[0016] FIG. 7 shows extendable aligning fasteners according to some embodiments.

[0017] FIG. 8 depicts a section view of FIG. 7 according to some embodiments.

[0018] FIG. 9 illustrates fixed head extendable aligning fasteners according to some embodiments.

[0019] FIG. 10 depicts an alignment fastener kit according to some embodiments.

[0020] FIG. 11 shows non-limiting tool engagement portions according to some embodiments.DETAILED DESCRIPTION

[0021] Some embodiments of the disclosure are directed to systems and methods of use for aligning fasteners configured to self-align substantially perpendicular to a flange slot of a flange. FIG. 3 depicts a toilet bowl installation using a system including an aligning fastener kit. In some embodiments, the aligning fastener kit includes one or more of any of the flanges and / or aligning fasteners described in any of the figures, including any combination thereof, in accordance with some embodiments. In some embodiments, each flange includes one or more flange slot configured to engage a flange slot engagement portion of an alignment coupling. In some embodiments, each flange slot includes an alignment coupling opening configured to enable a flange wall engagement portion to pass therethrough, where the alignment coupling opening is configured to not engage a flange slot engagement portion of an alignment coupling. In some embodiments, the flange slot includes a slot engagement region configured to engage a flange slot engagement portion of an alignment coupling.

[0022] As shown in FIG. 4, in some embodiments, each of the aligning fasteners include a fastener stem and / or one or more alignment couplings. In some embodiments, one or more fasteners include threaded fasteners (e.g., threaded stems, bolts, and the like). In some embodiments, the fasteners include a floor engagement portion. In some embodiments, the floor engagement portion comprises a substantially flat face. In some embodiments, the flat face is less than or equal to the width of the threads of a fastener, which allows the flat face to pass through a coupling aperture of the alignment coupling during installation.

[0023] FIG. 4 further shows the aligning fasteners in an engaged position in accordance with some embodiments. In some embodiments, according to a method of use, the alignment coupling is configured to be inserted into an alignment coupling opening within a flange slot of the flange. In some embodiments, the flat face portion of the fastener is configured to be inserted into the alignment coupling, which, according to some embodiments, may be done before or after the alignment coupling is inserted into the flange slot. In some embodiments, downward motion of the fastener is configured to cause the alignment coupling to rise and press against the underside (i.e., side facing the floor) of the flange collar. In some embodiments, the alignment coupling is configured to raise in response to a rotation of the fastener. In some embodiments, the alignment coupling is configured to raise in response to a rotation of the fastener while the flat face is in contact with a floor. In some embodiments, the engagement of the fastener flat face with the floor and the engagement of the alignment coupling against the flange collar is configured to align the fastener stem substantially perpendicular to the flange collar and / or flange face.

[0024] FIG. 5 illustrates cuttable aligning fasteners, as well as details of the alignment coupling according to some embodiments. In some embodiments, the alignment coupling includes one or more flange slot engagement portions configured to interfere and / or engage with the slot wall of the flange slot when the alignment fastener is rotated. In some embodiments, the one or more flange slot engagement portions comprise one or more flat faces, where the flat faces are configured to prevent rotation of the alignment coupling when engaged with at least a portion of the slot wall.

[0025] In some embodiments, the alignment coupling comprises a flange wall engagement portion. In some embodiments, the one or more flange wall engagement portions are configured to interfere with the flange wall of the flange. In some embodiments, the one or more flange wall engagement portions comprise one or more flat faces, where the flat faces are configured to prevent rotation of the alignment coupling when engaged with at least a portion of the flange wall, where the flange wall is located beneath the flange collar and / or flange upper face.

[0026] Still referring to FIG. 5, in some embodiments, one or more fasteners described herein comprise a tool engagement portion. In some embodiments, the tool engagement portion comprises at least one flat portion of a fastener stem, which includes a threaded stem in this nonlimiting example. In some embodiments, one or more fasteners comprise one or more of a round stem portion and a tool engagement portion. In some embodiments, one or more fasteners mayinclude an open head portion. In some embodiments, the open head portion is configured to pass through one or more removable couplings, which include a washer and a nut in this non-limiting example.

[0027] FIG. 6 shows a section view of FIG. 5 according to some embodiments. In some embodiments, the one or more fasteners comprise one or more cutting grooves configured to provide a location void of threading to allow cutting the aligning fastener to a different length with less force and in less time. The non-limiting fastener in FIG. 6 includes a first cutting groove, a second, cutting groove, and a third cutting groove, although more or less cutting grooves can be integrated according to some embodiments. In some embodiments, each cutting groove comprises a stem reduced cross-section portion. In some embodiments, the stem reduced cross-section is approximately the width of a non-threaded portion of the stem, however, various cross-section diameters may be used so long as the reduced cross-section is able to withstand the torque requirements of the installation.

[0028] FIG. 7 shows extendable aligning fasteners, and FIG. 8 depicts a section view of FIG. 7 in accordance with some embodiments. In some embodiments, the system is configured to enable one or more fastener extensions to be coupled to a fastener. The first fastener in FIG. 8 is shown without a fastener extension and is similar to the left aligning fastener in FIG. 6. However, in some embodiments, the aligning fasteners in FIGs. 7 and 8 include one or more cutting grooves as depicted in the right aligning fastener of FIG. 6.

[0029] Adjacent the first fastener A, the next fastener B includes a single fastener extension in a retracted position, where the fastener is inserted fully into the extension internal portion, best shown in FIG. 8 in accordance with some embodiments. In some embodiments, the extension internal portion includes threads configured to engage same pitched threads of the fastener stem.

[0030] The next extendable aligning fastener C to the right is shown in an extended position in FIGs. 7 and 8, where less of a portion of the fastener stem is in engagement with the extension internal portion than in the retracted position, and / or where the overall length of the extendable aligning fastener is greater than the retracted position, in accordance with some embodiments.

[0031] In some embodiments, the next extendable aligning fastener D to the right depicts a dual fastener extension arrangement. In some embodiments, an extension external portion of a first fastener extension is configured to engage the extension internal portion of a second fastener extension to extend the extendable aligning fasteners even further. In some embodiments, relativerotation between the fastener extension and the stem is configured to cause the stem to extend or retract into the fastener extension.

[0032] A user may combine as many fastener extensions as desired in accordance with some embodiments. In some embodiments, the fastener extension comprises an extension shoulder. In some embodiments, the extension shoulder is configured to engage a portion of the extension internal portion wall, and / or is configured to engage the face of a removable fastener. The extendable aligning fasteners include a washer and / or nut in this non-limiting example according to some embodiments. In some embodiments, a kit includes one or more stems, one or more aligning fasteners, one or more alignment couplings, one or more fastener extensions, one or more washers, one or more nuts, and / or one or more bolts.

[0033] FIG. 9 illustrates expanded head extendable aligning fasteners according to some embodiments. In some embodiments, one or more fastener stems include an integrated expanded head, which may include an expanded top portion that extends past the edges of the fastener stem. In some embodiments, a non-limiting example expanded head fastener includes a bolt. In some embodiments, one or more fastener extensions include a floor engagement portion. In some embodiments, the floor engagement portion comprises a flat face. In some embodiments, the flat face is less than or equal to the width of the threads of the external portion of the fastener extension, which allows the flat face to pass through the alignment coupling during installation. Engagement of the alignment coupling with the flange using the fastener extension is the same as described above with reference to FIGs. 3 and 4 for all arrangements disclosed herein according to some embodiments. The structure of the fastener extensions in FIG. 9 are the same as those shown in FIGs. 7 and 8, but in this non-limiting example the fastener extensions are inverted in accordance with some embodiments.

[0034] FIG. 10 depicts an alignment fastener kit according to some embodiments. In some embodiments, a toilet bolt kit for replacement or repair work may comprise two or more pairs of threaded stems having different lengths. The kit may include any combination of stems described herein, but in this non-limiting example the kit includes a pair of first length stems, a pair of second length stems, and / or a pair of third length stems, to facilitate toilet bowl installation without the need to cut the stems according to some embodiments. As previously described, in some embodiments, one or more stems comprise a first tool engagement portion configured to enable atool to rotate the stem about the stem axis. The first tool engagement portion includes a flat portion of the stem in this non-limiting example according to some embodiments.

[0035] FIG. 11 shows additional non-limiting tool engagement portions according to some embodiments. In addition to, or as an alternative to, a first tool engagement portion, a fastener stem and / or extendable fastener extension external portion may include a second tool engagement portion and / or a third tool engagement portion. In some embodiments, the second tool engagement portion includes a screwdriver slot (flathead and / or Philips compatible) located on a top portion of the stem. In some embodiments, a third tool engagement portion includes a polygon recess, which is configured to engage multi-point tools such as Allen wrenches or hex heads.

[0036] It is understood that the system is not limited in its application to the details of construction and the arrangement of components set forth in the previous description or illustrated in the drawings. The system and methods disclosed herein fall within the scope of numerous embodiments. The previous discussion is presented to enable a person skilled in the art to make and use embodiments of the system. Any portion of the structures and / or principles included in some embodiments can be applied to any and / or all embodiments: it is understood that features from some embodiments presented herein, including those in different figures, are combinable with other features according to some other embodiments. Thus, some embodiments of the system are not intended to be limited to what is illustrated but are to be accorded the widest scope consistent with all principles and features disclosed herein.

[0037] Some embodiments of the system are presented with specific values and / or setpoints. These values and setpoints are not intended to be limiting and are merely examples of a higher configuration versus a lower configuration and are intended as an aid for those of ordinary skill to make and use the system.

[0038] Any text in the drawings is part of the system’s disclosure and is understood to be readily incorporable into any description of the metes and bounds of the system. Any functional language in the drawings is a reference to the system being configured to perform the recited function, and structures shown or described in the drawings are to be considered as the system comprising the structures recited therein. It is understood that defining the metes and bounds of the system using a description of images in the drawing does not need a corresponding text description in the written specification to fall with the scope of the disclosure.

[0039] Furthermore, acting as Applicant’s own lexicographer, Applicant imparts the explicit meaning and / or disavowal of claim scope to the following terms:

[0040] Applicant defines any use of “and / or” such as, for example, “A and / or B,” or “at least one of A and / or B” to mean element A alone, element B alone, or elements A and B together. In addition, a recitation of “at least one of A, B, and C,” a recitation of “at least one of A, B, or C,” or a recitation of “at least one of A, B, or C or any combination thereof’ are each defined to mean element A alone, element B alone, element C alone, or any combination of elements A, B and C, such as AB, AC, BC, or ABC, for example.

[0041] “Substantially” and “approximately” when used in conjunction with a value encompass a difference of 5% or less of the same unit and / or scale of that being measured.

[0042] As used herein, “can” or “may” or derivations thereof are used for descriptive purposes only and are understood to be synonymous and / or interchangeable with “configured to” when defining the metes and bounds of the system.

[0043] In addition, the term “configured to” means that the limitations recited in the specification and / or the claims must be arranged in such a way to perform the recited function: “configured to” excludes structures in the art that are “capable of’ being modified to perform the recited function but the disclosures associated with the art have no explicit teachings to do so. For example, a recitation of a “container configured to receive a fluid from structure X at an upper portion and deliver fluid from a lower portion to structure Y” is limited to systems where structure X, structure Y, and the container are all disclosed as arranged to perform the recited function. The recitation “configured to” excludes elements that may be “capable of’ performing the recited function simply by virtue of their construction but associated disclosures (or lack thereof) provide no teachings to make such a modification to meet the functional limitations between all structures recited. The recitation “configured to” can also be interpreted as synonymous with operatively connected when used in conjunction with physical structures.

[0044] It is understood that the phraseology and terminology used herein is for description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompassboth direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

[0045] The previous detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict some embodiments and are not intended to limit the scope of embodiments of the system.

[0046] Although method operations are presented in a specific order according to some embodiments, the execution of those steps do not necessarily occur in the order listed unless explicitly specified. Also, other housekeeping operations can be performed in between operations, operations can be adjusted so that they occur at slightly different times, and / or operations can be distributed in a system which allows the occurrence of the processing operations at various intervals associated with the processing, as long as the processing of the overlay operations are performed in the desired way and result in the desired system output.

[0047] It will be appreciated by those skilled in the art that while the system has been described above in connection with particular embodiments and examples, the system is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. Various features and advantages of the system are set forth in the following claims.

Claims

We Claim:

1. A system comprising: an alignment fastener, an alignment coupling, and a flange; wherein the alignment coupling is configured to align the alignment fastener substantially perpendicular to a flange face of the flange.

2. The system of claim 1, wherein the alignment fastener includes a stem.

3. The system of claim 2, wherein the alignment coupling includes a coupling aperture.

4. The system of claim 3, wherein the stem is configured to pass through the coupling aperture.

5. The system of claim 4, wherein the flange includes a flange slot.

6. The system of claim 5, wherein engagement of the alignment coupling with the flange slot is configured to align the alignment fastener substantially perpendicular to the flange face of the flange.

7. The system of claim 5, wherein the flange slot includes an alignment coupling opening.

8. The system of claim 7, wherein the alignment coupling opening is configured to not engage a flange slot engagement portion of the alignment coupling.

9. The system of claim 8, wherein all portions of the alignment coupling are configured to pass through the alignment coupling opening.

10. The system of claim 9, the flange slot includes a slot engagement region.

11. The system of claim 10, wherein the slot engagement region is configured to engage the flange slot engagement portion of the alignment coupling.

12. The system of claim 2, wherein the stem includes one or more cutting grooves.

13. The system of claim 12, wherein the one or more cutting grooves include a reduced cross-section on the stem.

14. The system of claim 13, wherein the stem comprises threading.

15. The system of claim 14, wherein a width of the threading is greater than a width of the reduced cross-section.

16. The system of claim 2, wherein the stem includes a tool engagement portion.

17. The system of claim 16, wherein the tool engagement portion includes one or more of a slot, an aperture, and a flat face.

18. The system of claim 6, further comprising a fastener extension.

19. The system of claim 18, wherein relative rotation between the fastener extension and the stem is configured to cause the stem to extend or retract into the fastener extension.

20. The system of claim 19, wherein the alignment fastener comprises a bolt.

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