Wall-hung toilet with improved load-bearing capacity

Abstract

A wall hung toilet is described which has a toilet body having a toilet body inlet, a back plate having at least a first and a second lower fastener opening therethrough, a toilet body outlet, a bowl and a base. The bowl has an interior surface defining a interior area for receiving fluid, an inlet for introducing fluid to the interior area of the bowl and a bowl outlet. A trapway for passing fluid from the bowl outlet to the toilet body outlet is also included. The base of the toilet body extends from a front bowl portion of the base to a rear portion of the base that contacts the back plate, and the base is configured so as to distribute load bearing forces when applied to the bowl in use towards each of a first area around the first fastener opening and a second area around the second fastener area.

Claims

1. A wall hung toilet, comprising a toilet body having a toilet body inlet, a back plate having at least a first and a second fastener opening therethrough which are situated on a lower portion of the back plate, a toilet body outlet, a bowl and a base; wherein the bowl has an interior surface defining a interior area for receiving fluid, an inlet for introducing fluid to the interior area of the bowl and a bowl outlet; and a trapway for passing fluid from the bowl outlet to the toilet body outlet, wherein the base of the toilet body has a lower surface with a generally V-shaped configuration in lower plan view, said base having a first angled wall and a second angled wall which each extend from a front bowl portion of the base to a rear portion of the base that contacts the back plate, wherein the first and second angled walls meet the back plate at a distance measured transversely from an exterior surface of the first or second angled wall along the back plate to a longitudinal axis through a center of the first or second fastener opening closest to the first or second angled wall of less than about 5 cm such that the base distributes load bearing forces when applied to the bowl in use towards each of a first area around the first fastener opening and a second area around the second fastener opening.

2. The wall hung toilet according to claim 1, wherein the toilet body inlet is configured to receive a flushing fixture.

3. The wall hung toilet according to claim 1, wherein the toilet body further comprises a jet and a rim inlet, each for receiving fluid passing through the toilet body inlet.

4. The wall hung toilet according to claim 3, wherein the bowl is a rimless bowl and the rim inlet feeds water directly into the bowl along the interior surface of the bowl.

5. The wall hung toilet according to claim 1, wherein the toilet body further comprises a rim that extends substantially around the upper periphery of the bowl and defines a rim channel, and wherein the rim has an inlet in fluid communication with a manifold beneath the toilet bowl inlet and the rim has at least one rim outlet for allowing fluid to pass from within the rim channel to the interior area of the bowl.

6. The wall hung toilet according to claim 5, wherein the jet defines a jet path therethrough and the jet has an inlet in fluid communication with the manifold and a jet outlet in fluid communication with the interior area of the bowl in a sump area.

7. The wall hung toilet according to claim 1, wherein the fastener openings are bolt holes and are each configured for receiving a mounting bolt.

8. The wall hung toilet according to claim 1, having at least four fastener openings, wherein each of the fastener openings is a bolt hole configured for receiving a mounting bolt.

9. The wall hung toilet according to claim 8, wherein two of the at least four fastener openings are in an upper portion of the back plate.

10. The wall hung toilet according to claim 1, wherein the distance from the exterior surface of the first angled wall to the longitudinal axis through the center of the closest fastener opening is less than about 3 cm.

11. The wall hung toilet according to claim 1, wherein the toilet is capable of bearing a load of at least 1500 pounds in use when fully installed on a wall.

12. The wall hung toilet according to claim 11, wherein the toilet is capable of bearing a load of at least 2,000 pounds in use when fully installed on a wall.

13. A wall hung toilet, comprising a toilet body having a toilet body inlet, a back plate having at least a first and a second fastener opening therethrough in a lower portion of the back plate, a toilet body outlet, a bowl, a jet, a rim inlet, a manifold and a base, wherein the manifold is beneath the toilet body inlet for dividing flow between the jet and the rim inlet; wherein the bowl has an interior surface defining a interior area for receiving fluid, an inlet for introducing fluid to the interior area of the bowl and a bowl outlet; and a trapway for passing fluid from the bowl outlet to the toilet body outlet, wherein the base of the toilet body has a lower surface with a generally V-shaped configuration in lower plan view, said base having a first angled wall and a second angled wall which each extend from a front bowl portion of the base to a rear portion of the base that contacts the back plate, wherein the first and second angled walls meets the back plate at a distance measured transversely from an exterior surface of the first or second angled wall along the back plate to a longitudinal axis through a center of the first or second fastener opening closest to the first or second angled wall of less than about 5 cm such that the base distributes load bearing forces when applied to the bowl in use towards each of a first area around the first fastener opening and a second area around the second fastener opening.

14. The wall hung toilet according to claim 13, wherein the toilet body inlet is configured to receive a flushing fixture.

15. The wall hung toilet according to claim 13, wherein the rim extends substantially around the upper periphery of the bowl and defines a rim channel, and wherein the rim has an inlet in fluid communication with the manifold and at least one rim outlet for allowing fluid to pass from within the rim channel to the interior area of the bowl.

16. The wall hung toilet according to claim 13, wherein the jet defines a jet path within the jet and the jet has an inlet in fluid communication with the manifold and a jet in fluid communication with the interior area of the bowl in a sump area.

17. The wall hung toilet according to claim 13, wherein the fastener opening is configured for receiving a mounting bolt.

18. A wall hung toilet, comprising a toilet body having a toilet body inlet, a back plate having at least a first and a second fastener opening therethrough in a lower portion of the back plate, a toilet body outlet, a bowl and a base; wherein the bowl has an interior surface defining a interior area for receiving fluid, an inlet for introducing fluid to the interior area of the bowl and a bowl outlet; and a trapway for passing fluid from the bowl outlet to the toilet body outlet, wherein the base of the toilet body has a lower surface with a generally angled V-shaped or curved V-shaped configuration in lower plan view, said base having a first angled wall and a second angled wall which each extend from a front bowl portion of the base to a rear portion of the base that contacts the back plate, wherein the first and second angled walls meet the back plate at an area near the first or second fastener opening that is closest thereto such that the base distributes load bearing forces when applied to the bowl in use towards each of a first area around the first fastener opening and a second area around the second fastener opening.

19. The wall hung toilet according to claim 18, wherein the toilet is capable of bearing a load of at least 1500 pounds in use when fully installed on a wall.

20. The wall hung toilet according to claim 19, wherein the toilet is capable of bearing a load of at least 2,000 pounds in use when fully installed on a wall.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:

(2) FIG. 1 is a front elevational view of a Prior Art carrier for a wall hung toilet;

(3) FIG. 2 is a photographic representation of a bottom perspective view of a Prior Art wall hung toilet;

(4) FIG. 2A is a representation of an “upside down T” stress vector configuration of an exemplary prior art wall hung toilet such as that of FIG. 2;

(5) FIG. 2B is a representation of a stress vector configuration of a wall hung toilet according to the present invention;

(6) FIG. 3 is a back plan view of a wall hung toilet described herein and shown in FIG. 8;

(7) FIG. 4 is a rear and bottom perspective view of the wall hung toilet of FIG. 8;

(8) FIG. 5 is a bottom perspective view of the wall hung toilet of FIG. 8;

(9) FIG. 6 is a partial cross-sectional view of the wall hung toilet of FIG. 8 showing a portion of the jet path and the trapway path within the interior of the wall hung toilet;

(10) FIG. 7 is a bottom plan view of the wall hung toilet of FIG. 8;

(11) FIG. 8 is an angled right side perspective view of a wall hung toilet as described herein;

(12) FIG. 9 is an angled left side perspective view of the wall hung toilet of FIG. 8; and

(13) FIG. 10 is a representation of performance data for evaluation of the process capacity of load.

DETAILED DESCRIPTION OF THE INVENTION

(14) The present invention is directed to a wall hung toilet suitable for mounting on a four-hole carrier or similar device such as prior art carrier C of FIG. 1. The toilet is designed to remove the “upside down T” stress vector configuration and instead convey load directly to the carrier at areas close to the lower bolt holes. Such a structural configuration avoids having to form an overly thick back plate while providing a toilet capable of bearing significantly increased load when in use.

(15) As used herein, the wall hung toilet, is a toilet wherein the toilet body is mounted to a wall using a mounting system and not supported by the floor. Such toilets are generally known in the art and come with a variety of features, including direct flush valves, hidden tanks or cisterns if desired, single-, dual- or multi-flush options, various bowl designs and rim, jet and/or trapway configurations. It is within the scope of the invention to adopt any or all of such bowl features in the present invention and benefit from the concept of the present invention to improve such prior art wall hung toilets.

(16) As the concept behind the wall hung toilet herein relies on a structural adjustment, it is further possible to apply the features of the wall hung toilet herein to any wall mounted bath or kitchen fixture not supported by the floor, including sinks, bidets, urinals, fountains, basins and the like. The present invention however, for convenience is being described herein with respect to a wall hung toilet as such fixtures tend to bear the most weight in a wall hung installation. The toilet body will be described with respect to a preferred embodiment shown in FIGS. 3-9 herein. It should be understood, however, that other variations in bowl design, flush mechanisms, inlets, outlets, rim and/or jet design, trapway geometry, fixture surface or body material, and the like can be varied within the scope of the invention and without departing from the spirit thereof.

(17) With reference to FIGS. 8 and 9, a toilet, generally referred to herein as toilet 10, is shown which has a toilet body 12 and a back plate 14. The toilet body 12 is that portion of the toilet having the basic features of the toilet aside form the back plate. The toilet body and back plate may be formed as a molded part as a single unitary unit using known toilet molding techniques or as two or more separate pieces combined according to standard manufacturing techniques known in the art or to be developed.

(18) The back plate 14 is configured so as to have a preferably flush and smooth front facing surface 16 when viewing the installed toilet from a user's perspective as shown in FIGS. 8 and 9. From the rear view of the back plate, however, the back plate may be, but need not be, a solid surface. As shown, back plate 14 is formed so as to have a solid, flat edge surface 18 which is configured to work with and receive fasteners from a carrier system chosen. The back plate 14 will contact the carrier via the fastener opening to avoid transfer of load to a wall (not shown) when installed. A small gap typically lies between the back plate and the wall on installation and is generally caulked for a neat appearance.

(19) The back plate 14 is further configured to have at least a first and a second fastener opening 20, 22 in a lower portion 19 of the back plate and extending therethrough from the front facing surface 16 toward the back of the back plate 14 for contacting a wall. Mounting bolts (not shown) or threaded rods as are known in the art for wall hung toilet mounting on carriers such as carrier C of FIG. 1 or other fasteners may be passed through openings 20, 22, which may be, for example bolt holes as shown, or holes configured to received a threaded rod, for mounting the wall hung toilet on a wall. The first and second fastener opening 20, 22 are preferably configured (size and cross-sectional shape) to accommodate the selected fastener for use in an installation and/or with a particular carrier assembly. Preferably four such fastener openings, in this case additional openings 24, 26 are also provided for mounting the top of the back plate against a wall. In such an arrangement two additional fastener openings 24, 26 are in an upper portion 21 of the back plate 14, while the first and second fastener openings 20, 22 are preferably in a lower portion 19 of the back plate.

(20) The back surface of the back plate, in addition to an edge surface 18, may include other molded features or reinforcements, for example, in the area of the back of the mounting holes, around the bowl outlet, etc.

(21) The toilet body 12 is molded so as to have a toilet body inlet 28 and a toilet body outlet 30. The inlet 28 may be configured in the manner of any prior art wall hung toilet or standard toilet and is preferably configured to accommodate a fixture for introducing fluid into the toilet body and ultimately into the toilet bowl as described further below. Fluid, such as flush water, may be introduced in a wall hung toilet directly through the back of the toilet body in an inlet conduit into the rear portion of the toilet from behind the back plate, or, as shown herein, be introduced through an inlet 28 positioned on an upper surface 32 of the toilet bowl 34. The flush water may be introduced by a flushometer, a flush valve installed in a casing, exterior unit or within the wall depending on design preference and the flush system and trim chosen. Similarly, activation may be provided for flushing the bowl using a flush handle mounted on the bowl, on a flushometer handle, a wall mounted actuation button or pad, an automatic sensor, or remote controlled flush system as are known in the art. The flush mechanism or activation system is not critical to the invention herein.

(22) The toilet body outlet 30 may be in direct communication with a drain opening to a sewer or to a conduit connecting the outlet to such drain. Further, the toilet body outlet 30 may actually be only the end of one portion of a trapway having an additional portion thereof behind the wall. However, the portion of the toilet body through which flush water exits and passes out of the back plate 14 is the toilet body outlet 30 as that term is used herein.

(23) The toilet body further includes a bowl 34 which may be of a round, elongated, oval, oblong, square, trapezoidal or other design configuration. The bowl 34 is configured to have an interior surface 36 of the bowl 34 that defines an interior area 38 for receiving fluid, and preferably also for retaining sufficient fluid between flush cycles. The interior area 38 includes a lower, sump area 40 having a bowl outlet 42. The bowl 34 preferably also has a bowl inlet 44. The bowl inlet may coincide with the toilet body inlet, but is preferably also some form of rim inlet. The bowl inlet is preferably shaped and/or sized so as to allow for introduction of fluid into the interior area 38 of the bowl 34.

(24) In one embodiment, as exemplified herein, the bowl inlet 44 is in the form of at least one, and preferably as shown, a plurality of openings. In such a configuration, the bowl 34 has a rim 46 that extends substantially around the upper periphery of the bowl and defines a rim channel 48 as is known in the art. The rim channel has an inlet, which may be from a divided flow path (using isolated flow paths from independent valves) or may be from a more natural separation created by the configuration of the rim channel and a toilet manifold 54. The rim channel also has an outlet(s) 52 which may also serve as toilet bowl inlets 44. The rim and flow from the outlets 52 may be pressurized by design of the bowl for enhancement to flushing and cleaning, while conserving water use. The manifold 54 is an area beneath (or in front of) the toilet inlet (depending on the type of toilet design). Flush water entering the toilet inlet would pass through the manifold before going through the rim inlet or, if a jet is provided, the manifold may have two outlets to provide flow to a rim channel inlet as well as to the jet.

(25) A jet 58 for use in the invention may be single or multiple path jetways such as pathway 60 that curve around the toilet bowls herein as are known in the art and may have a variety of configurations within the scope of the invention. The jet introduces a stream of flush water at the bottom of the toilet bowl through a jet outlet 62. Flush water may be introduced to through a jet inlet 64 which also is a manifold outlet. The jet water is preferably of high flow either from a high flow valve or a pump. The water from the jet enters the bottom sump 50 area of the bowl 36.

(26) Rimless toilets and pump pressure designed toilets and bidets are also known and can be used within the scope of the invention herein and benefit therefrom. In such a design, flush water is introduced to a single (or multiple) rim inlet(s) by conduit (in the case of a pump device) or through a single inlet under pressure from another source such as a high flow flush valve. Such rim inlets need not be in a rim channel. For example an upper rim (or periphery in this instance) of a bowl may not define a channel, but extend around the upper portion of the bowl. Interior surface features (such as ledges or concave areas) may be provided to guide water substantially around the rim before dropping to the interior of the bowl for a more vortex flow.

(27) The toilet 10 also includes at least a partial, and preferably a complete, trapway 56 for passing fluid from the bowl outlet to the toilet body outlet.

(28) The toilet body includes a base 66. The base 66 of the toilet body 12 extends from a front bowl portion 68 of the base 66 to a rear portion 70 of the base 66 that contacts the back plate 14. The base 66 is configured so as to distribute load bearing forces when applied to the bowl in use towards each of a first area 72 around the first fastener opening 20 and a second area 74 around the second fastener area 22.

(29) An example of this may be seen not only by the curved V-shaped configuration of the bottom of the base 66 when viewed in a bottom plan view so as to view the lower surface 23 of the base, but also with respect to FIG. 2B. The curved V-shape is preferred for aesthetic reasons, however, a more angled V-shape is also within the scope of the invention. The base 66 includes at least one angled wall 76, the lower surface of which is the same as the lower surface 23 of the base. The at least one angled wall 76 meets the back plate of the toilet at a distance d measured transversely along the back plate from the exterior surface 25 of the angled wall 76 to a longitudinal axis Z-Z′ extending longitudinally on the back plate through the center of the closest fastener opening to the exterior surface 25 of the angled wall. If the upper and lower fastener openings are aligned, the axis Z-Z′ would extend through two of such fastener openings. The distance d is preferably no more than about 5 cm, or no more than about 3 cm.

(30) Preferably, as shown there are two angled walls, 76, 78 which merge at the front of the base in either a point (angled V) or curve (curved V) to define a V-shaped configuration. The lower surface 23 of each, which is also the lower surface of the base, in such a design is continuous. The angled walls 76, 78 preferably form an acute angle α between the walls formed when the walls are directed toward the areas 72, 74 around the fastener openings 20, 22 in the lower portion 19 of the back plate 14. The angle formed distributes the load so as to form an angled vector as shown in FIG. 2B. Each wall is preferably a distance d of no greater than about 5, or no greater than about 3 as measured along the base plate transversely from the exterior surface 25 of each wall (which in this design would also be continuous over both walls on the base) to the closest fastener opening.

(31) When failure generally occurs using such a design, it is located generally at one of the two fasteners inserted through the fastener openings at the top of the back plate. In nearly all cases, the toilet remains mounted to the carrier by the remaining fasteners, preferably three additional fasteners, which helps to prevent injury in the event of a field failure. In most prior art designs, failure occurs in a catastrophic manner emanating from one of the bottom two fastener openings and often results in the bowl falling from the carrier to the floor with the result of occurrences of injury.

(32) The wall hung toilet herein is capable of bearing a load of at least about 1,500 pounds when fully installed using a carrier system or other mounting system on a wall and bearing weight by a user. In some embodiments herein, the toilet is capable of bearing a load of at least about 1,500 pounds, more preferably at least about 1,700 pounds, and most preferably at least about 2,000 pounds, in use when fully installed on a wall.

(33) The invention will now be described in connection with the following non-limiting example:

EXAMPLE

(34) Chinaware wall hung toilet samples were formed according to the present invention as shown in FIGS. 3-8. They were subjected to load testing by applying a steadily increasing load and the load at which the ceramic failed was recorded. The average load at failure for 40 samples tested was 2,190 pounds, which was over three times the minimum code requirement. The flush performance of the samples was also outstanding scoring over 1,000 g on the MaP test. FIG. 10 shows the performance data for evaluation of the process capacity of load.

(35) The inventive product is also advantageous from a manufacturing standpoint in that it can be cast in a relatively standard, seven piece mold system. Geometric features of the trapway, critical for flush performance, are formed by the foot core, side wall and back core molds.

(36) It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.