Kits, Assemblies and Methods for No-Tools Toilet Installation

• US 20110173743A1
• Filed: 01/19/2011
• Published: 07/21/2011
• Est. Priority Date: 01/19/2010
• Status: Active Grant

• Current Assignee: AS America Incorporated (LIXIL Group Corp.)
• Original Assignee: AS IP Holdco, LLC
• Inventors: Grover, David, Walsh, James P., Jensen, Robert M.
• Granted Patent: US 9,169,629 B2
• Time in Patent Office: Days
• US Class Current: 4/420
• CPC Class Codes: E03D 1/26 Bowl with flushing cistern mounted on the rearwardly extending end of the bowl shape or material of the cistern E03D1/01; constructional features of the bowl E03D11/02 - E03D11/12
• CPC Class Codes: E03D 11/16 Means for connecting the bowl to the floor, e.g. to a floor outlet
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Kits and methods for installing a toilet bowl or assembly without tools are described. The methods and assembly work with an existing flange or can include a standard closet flange configured to receive a flange bolt. The kits and assemblies include a flange bolt wherein the bolt head is configured so as to fit through an opening in a flange so that the bolt head contacts the lower surface of the flange and the end portion of the bolt stem extends upwardly; and a bolt locking knob, wherein the interior surface of the knob is configured so that when the end of the bolt stem is placed within the knob, it contacts the bolt stem in locking engagement and the knob can be hand tightened. The bolts size is coordinated with the size of the locking knobs to eliminate the use of tools on installation.

Claims

1. An assembly for installing a toilet bowl, comprising:

(a) a flange having an upper surface, a lower surface and an opening extending from the upper surface to the lower surface that is configured to receive a flange bolt;

(b) a flange bolt having a bolt head and a bolt stem extending from the bolt head and having an end portion opposite the bolt head, wherein the stem has a length measured longitudinally along the stem and an outer surface and the bolt head is configured so as to fit through the opening in the flange so that the bolt head contacts the lower surface of the flange and the end portion of the stem extends upwardly from the upper surface of the flange; and

(c) a bolt locking knob having an interior surface defining an opening extending through the knob, wherein the interior surface is configured so that upon installation of the toilet bowl, when the end of the bolt stem is placed within the opening in the bolt locking knob, the interior surface of the knob contacts the exterior surface of the bolt stem in locking engagement and the knob is able to be hand tightened on the bolt stem, wherein the length of the bolt stem is pre-sized so that the end portion of the stem of the flange bolt is substantially within the opening in the bolt locking knob.

2. The assembly according to claim 1, wherein the bolt locking knob further comprises a downwardly extending portion and the opening in the bolt locking knob extends through the knob and the downwardly extending portion thereof.

3. The assembly according to claim 1, further comprising a flange nut configured to fit over the end of the bolt stem and over the stem so that at least a portion of the flange nut contacts the upper surface of the flange and is stably locked against the bolt stem.

4. The assembly according to claim 3, wherein the flange nut is generally planar having an upper surface and a lower surface and having an opening therethrough, wherein the opening fits over the end of the bolt head, and further comprises a bent portion on either side of the opening of the flange nut that bends outwardly and upwardly from the upper surface of the flange nut so that the bent portions of the flange nut engage the outer surface of the stem.

5. The assembly according to claim 3, wherein the flange nut comprises metal, polymer material, reinforced polymer material, composite material or combinations thereof.

6. The assembly according to claim 1, further comprising a cover configured to be placed over the bolt locking knob.

7. The assembly according to claim 1, wherein the flange has two openings and the assembly comprises two flange bolts.

8. The assembly according to claim 1, wherein the opening in the flange has a first portion sized to receive the bolt head and a slot-like portion for adjusting the flange bolt position after the bolt head is passed through the first portion of the opening.

9. The assembly according to claim 1, wherein the bolt head is generally planar and has a generally rectangular peripheral shape.

10. The assembly according to claim 1, wherein the flange comprises an insert portion within an interior of the flange that extends downwardly for insertion into a drain conduit.

11. The assembly according to claim 1, wherein the bolt locking knob has an outer periphery shaped to facilitate manual tightening of the knob.

12. The assembly according to claim 1, wherein at least a portion of the stem of the flange bolt is threaded and the interior surface of the bolt locking knob is threaded so that the outer surface of the flange bolt is configured for locking engagement with the interior surface of the locking knob through mating threads.

13. The assembly according to claim 1, wherein the assembly further comprises at least one mounting block.

14. A kit for installing a toilet bowl comprising

(a) a flange bolt having a bolt head and a bolt stem extending from the bolt head and having an end portion opposite the bolt head, wherein the stem has a length measured longitudinally along the stem and an outer surface and the bolt head is configured so that upon installation it will fit through an opening in a closet flange so that the bolt head contacts a lower surface of a closet flange and the end portion of the stem extends upwardly from an upper surface of a closet flange;

(b) a bolt locking knob having an interior surface defining an opening extending through the knob, wherein the interior surface of the bolt locking knob is configured so that upon installation of a toilet bowl, when the end of the bolt stem is placed within the opening in the bolt locking knob, the interior surface of the knob contacts the exterior surface of the bolt stem in locking engagement and the knob is able to be hand tightened on the bolt stem, wherein the length of the bolt stem is pre-sized so that the end portion of the stem of the flange bolt is substantially within the opening in the bolt locking knob; and

(c) instructions for installing a bowl.

15. The kit according to claim 14, wherein the bolt locking knob further comprises a downwardly extending portion and the opening in the bolt locking knob extends through the knob and the downwardly extending portion thereof.

16. The kit according to claim 14, wherein the instructions describe a tool-free installation of the toilet bowl.

17. The kit according to claim 14, further comprising a flange having an upper surface, a lower surface and an opening extending from the upper surface to the lower surface that is configured to receive a flange bolt.

18. The kit according to claim 14, further comprising a flange nut configured to fit over the end of the bolt stem and over the stem so that upon installation at least a portion of the flange nut will contact an upper surface of a closet flange and be stably locked against the bolt stem.

19. The kit according to claim 14, further comprising a cover configured to be placed over the bolt locking knob.

20. The kit according to claim 14, further comprising at least one mounting block, wherein the mounting block is configured so as to suspend a portion of a toilet bowl above a mounting surface for ensuring placement of a flange bolt through a mounting hole on a toilet bowl to be installed.

21. The kit according to claim 20, comprising two mounting blocks, wherein one mounting block is configured so as to suspend a bottom surface of a toilet bowl in a front portion thereof above a mounting surface and another mounting block is configured so as to suspend the bottom surface of the toilet bowl in a rear portion thereof above the mounting surface.

22. The kit according to claim 20, wherein the mounting block has a length measured longitudinally along the block which is the same or greater than a width of a toilet bowl to be installed using the kit as measured transversely across a toilet bowl.

23. The kit according to claim 20, wherein the mounting block comprises a material of sufficient strength to suspend a toilet bowl during installation for ensuring placement of a flange bolt through a mounting hole on the toilet bowl to be installed.

24. The kit according to claim 20, wherein the mounting block comprises at least one material selected from the group consisting of wood, oriented strand board, medium density fiberboard, metal, foam, polymeric materials, and composite materials.

25. The kit according to claim 20, comprising a pull tab for facilitating removal of the mounting block.

26. An assembly for installing a two-piece toilet assembly wherein the toilet assembly includes a bowl portion and a separate tank portion, comprising:

(a) a flange having an upper surface, a lower surface and an opening extending from the upper surface to the lower surface that is configured to receive a flange bolt;

(b) a flange bolt having a bolt head and a bolt stem extending from the bolt head and having an end portion opposite the bolt head, wherein the stem has a length measured longitudinally along the stem and an outer surface and the bolt head is configured so that upon installation of a bowl portion of a two-piece toilet assembly, the bolt head will fit through the opening in the flange so that the bolt head contacts the lower surface of the flange and the end portion of the stem extends upwardly from the upper surface of the flange;

(c) a bolt locking knob having an interior surface defining an opening extending through the knob, wherein the interior surface is configured so that upon installation of a bowl portion of a two-piece toilet assembly, when the end of the bolt stem is placed within the opening of the bolt locking knob, the interior surface of the knob contacts the exterior surface of the bolt stem in locking engagement and the knob is able to be hand tightened on the bolt stem, wherein the length of the bolt stem is pre-sized so that the end portion of the stem of the flange bolt is substantially within the opening in the bolt locking knob; and

(d) a handle fastener having an interior surface defining an opening therein configured to receive a tank locking bolt for fastening a toilet tank to a toilet bowl in a toilet assembly in locking engagement, the handle fastener having an outer surface configured for manual tightening.

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33. A kit for installing a two-piece toilet assembly wherein the toilet assembly includes a bowl portion and a separate tank portion, comprising:

(a) a flange bolt having a bolt head and a bolt stem extending from the bolt head and having an end portion opposite the bolt head, wherein the stem has a length measured longitudinally along the stem and an outer surface and the bolt head is configured so that upon installation of a bowl portion of a two-piece toilet assembly, the bolt head will fit through the opening in a closet flange so that the bolt head contacts a lower surface of a closet flange and the end portion of the stem extends upwardly from an upper surface of a closet flange;

(b) a bolt locking knob having an interior surface defining an opening extending through the knob, wherein the interior surface is configured so that upon installation of a bowl portion of a two-piece toilet assembly, when the end of the bolt stem is placed within the opening of the bolt locking knob, the interior surface of the knob contacts the exterior surface of the bolt stem in locking engagement and the knob is able to be hand tightened on the bolt stem, wherein the length of the bolt stem is pre-sized so that the end portion of the stem of the flange bolt is substantially within the opening in the bolt locking knob;

(c) a handle fastener having an interior surface defining an opening therein configured to receive a tank locking bolt for fastening a toilet tank to a toilet bowl in a toilet assembly in locking engagement, the handle fastener having an outer surface configured for manual tightening; and

(d) instructions for installing a two-piece toilet assembly having a toilet bowl and a toilet tank.

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43. A method for installing a toilet bowl on a mounting surface without using tools, comprising:

(a) providing a flange bolt comprising a bolt head and a bolt stem extending from the bolt head and having an end portion opposite the bolt head, wherein the stem has a length measured longitudinally along the stem and an outer surface;

(b) inserting the flange bolt through an opening in a flange, wherein the flange comprises an upper surface, a lower surface and the opening, wherein the opening extends from the upper surface to the lower surface and is configured to receive a flange bolt, so that the bolt head fits through the opening in the flange, the bolt head contacts the lower surface of the flange and the end portion of the stem extends upwardly from the upper surface of the flange and positioning the flange on a mounting surface;

(c) placing a toilet bowl having a mounting hole extending through a base thereof over the stem of the flange bolt so that the end portion of the stem extends upwardly through the mounting hole;

(d) placing a bolt locking knob over the end portion of the flange bolt stem, wherein the bolt locking knob has an interior surface defining an opening extending through the locking knob and an interior portion thereof, wherein the bolt locking knob is placed so that when the end portion of the bolt stem is within the opening of the bolt locking knob, the interior surface of the bolt locking knob contacts the exterior surface of the bolt stem in locking engagement and wherein the length of the bolt stem is pre-sized so that upon placement of a toilet bowl over the flange bolt and placement of the bolt locking knob over the end portion of the flange bolt stem, the end portion of the flange bolt stem is substantially within the opening of the bolt locking knob; and

(e) manually tightening the knob on the bolt stem.

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57. An installed toilet assembly wherein the toilet assembly includes a bowl portion and a separate tank portion, comprising:

a flange having an upper surface, a lower surface and an opening extending from the upper surface to the lower surface that is configured to receive a flange bolt, the lower surface of the flange contacting an installation surface;

a toilet bowl having a mounting hole extending through a base thereof and an upper surface having a rear portion having a tank mounting hole extending therethrough;

a flange bolt having a bolt head and a bolt stem extending from the bolt head and having an end portion opposite the bolt head, wherein the stem has a length measured longitudinally along the stem and an outer surface and the bolt head fits through the opening in the flange so that the bolt head contacts the lower surface of the flange and the end portion of the stem extends upwardly from an upper surface of a closet flange; and

a bolt locking knob having an interior surface defining an opening extending through the knob, wherein the end of the bolt stem is within the opening of the bolt locking knob, the interior surface of the knob contacts the exterior surface of the bolt stem in locking engagement and the knob is hand tightened on the bolt stem, wherein the length of the bolt stem is pre-sized and the end portion of the stem of the flange bolt is substantially within the opening in the bolt locking knob.

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64. A method for installing a toilet bowl on a mounting surface, comprising:

(a) providing a flange bolt comprising a bolt head and a bolt stem extending from the bolt head and having an end portion opposite the bolt head, wherein the stem has a length measured longitudinally along the stem and an outer surface;

(b) inserting the flange bolt through an opening in a flange, wherein the flange comprises an upper surface, a lower surface and the opening, wherein the opening extends from the upper surface to the lower surface and is configured to receive a flange bolt, so that the bolt head fits through the opening in the flange, and the end portion of the stem extends upwardly from the upper surface of the flange and positioning the flange on the mounting surface;

(c) positioning a mounting block on the mounting surface;

(d) placing a toilet bowl having a mounting hole extending through a base thereof so as to be near or over the stem of the flange bolt and lowering the toilet bowl until at least a portion of a lower surface of the toilet bowl rests on the mounting block;

(e) ensuring that the stem of the flange bolt is within the mounting hole and upright; and

(f) removing the mounting block.

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