Toilet Shell and Frame

This application claims priority benefit of Provisional Application No. 63/634,198 (Docket No. 010222-24018A-US) filed on Apr. 15, 2024, which is hereby incorporated by reference in its entirety.

The present disclosure relates generally to toilets.

Conventional toilets may be formed nearly entirely from porcelain or other ceramic materials. The porcelain may be treated or coated with vitreous china. As part of the manufacturing process, the toilet is fired at a high temperature until it is hardened.

Certain advantages may be realized when portions of the toilet are manufactured from other materials. A toilet, with interchangeable or removable parts that allow access to the internal components of the toilet, can improve the ease of maintenance and repair of the toilet. For example, removable panels provide access to the inside of the toilet, improving maintenance possibilities.

Various examples of a toilet with modular panels Are described. Various colors, textures, designs, artwork, images, patterns, photographs, or combinations thereof may be added to the modular panels. The modular panels may be removed and replaced with other panels with different aesthetics.

is a view of a toiletaccording to an exemplary embodiment.is an example exploded view or assembly of the toilet of. The exterior of the toilet is formed by a cowling, a front shell, at least one side panel(e.g., left side panel and right side panel), and a skirt. Optionally, a raised platformof the cowlingmay house an internal component such as a vacuum breaker. The interior of the toilet, described in more detail below, includes a flush engine having at least a bowl, a frame, and a base. As shown in, the toiletmay be assembled by attaching components of the shell in a predetermined order. For example, the front shellmay be attached to the flush engine and/or the cowlingfirst, then the side panelsare attached to the flush engine and/or the cowlingsecond, and the skirtis attached over the side panelsand/or the front shellto secure the components together. That is, the skirtis configured to overlap the side panelsand the base. Other sequences for assembly are possible. Additional, different or fewer components may be included.

The cowlingmay be formed from resin, polymer or plastic materials. The cowlingmay include one or more openingsfor securing a toilet seat assembly to the toilet. The toilet seat assembly may include a cover member (e.g., lid), a seat member (e.g., ring), and a hinge that facilitates relative movement between the cover member and the seat member.

The cowlingincludes a bowl openingform a rimaround a circumference of toilet bowl. The shroud formed from side paneland front shellmay also be configured to include a plurality of walls having varying shapes that together form the enclosure for the toilet bowlhaving an opening formed by the rim. The wall of the pedestal may extend downward and/or rearward from the bowlto form a lower portion (e.g., platform) configured to support the toilet bowl.

The side panels are designed to be easily removable for cleaning and access to the internal components (e.g. trap valve) for servicing. In one embodiment, the side panels install by pivoting on the bottom edge and then hooking and/or snapping into features on the cowl core. There is a vertical groove on the back edge of the front shell and a horizontal groove on the cowlingthat mate with the side panelfor alignment. The user removes the side panelby gripping the back edge (for example, depressing a snap fit button on the cowl core). The side panelmay be removed before the front shell.

The cowling(e.g., top member) forms a plateau for supporting the seat assembly. The cowlingmay be a surface plate covering the rim of the toilet bowl. The cowlingmay include one or more than one opening, wherein each opening is configured to receive a fastening device (e.g., bolt, screw, etc.) to couple (e.g., attach) the seat assembly to the top member. As another example, the top member may include one or more than one fastening device (e.g., bolts, recessed nuts, etc.). The seat assembly may include a hinge, hinge shoulders configured to receive a fastener, a seat coupled to the hinge and a cover coupled to the hinge.illustrates an example seat.

The cowlingmay include a raised platform. The raised platformmay cover a vacuum breaker that controls the water supply to the toilet. The vacuum breaker prevents water from being siphoned from the toiletin a direction reverse to that of the water supply. The raised platformmay also include a user input (e.g., button) for operation of the toilet. The raised platformmay include a mount and/or a charger for a remote control for the toilet. The vacuum breaker may include a bibcock valve. The vacuum breaker may include a disc (e.g., plastic) that is pressed forward by water supply pressure to close or otherwise cover one or more holes. If the supply line pressure goes down, the disc opens the holes to let in air (e.g., atmospheric air) to prevent the backflow of water.

The cowlingserves as the rigid internal structure for a plastic cover, as described below. The cowlingmay load vertically onto the top rim surface of the toilet bowlof the flush engine. The cowlingmay include an elastomer overmolding to create functional seals against the internal rim surface of the vitreous of the toilet bowl. The seals are configured to keep water and other materials contained within the toilet bowl. The seals are also configured to dampen loads on the top cowling. This may prevent noise and shifting between the components. The cowlingmay also serve as the top positioning and mounting interface for the front shelland side panels. The cowlingmay also support a top flush button assembly, which may be coupled to the cowling. The cowlingmay also support a bidet wand assembly, which may be coupled to the cowling.

illustrates a first example frame and basefor the toilet of. The frame includes at least one horizontal frame or support memberand at least one vertical frame or support member. The horizontal support membersand vertical support membersmay be joined or fastened together at joints. The rear vertical support membersprovide support for the rear of the cowl.

The basemay be formed from resin, or plastic material. The frame may be formed from metal acrylonitrile butadiene styrene (ABS), polycarbonate, or another hard material having high tensile strength.

The baseincludes at least one openingconfigured to pass a trapway or other drain pipe coupled to the flush engine. Flushing the toiletcauses water and other material deposited into the toiletto travel through the drain pipe and the at least one opening. The baseis a connection interface between a floor flange and the drain pipe or trapway outlet. The baseprovide support for the flush engine. The baseis a mount for the frame (directly for support memberand indirectly for support member). The baseprovides anchor points for mounting the external components including the side paneland the front shell.

The basemay include one or more openingsconfigured to support the flush engine. The openingsmay be configured to position the flush at a particular position so that the toilet bowlalights with the bowl opening. The flush engine may include protrusions that extend into the openings. The protrusions may include locking members configured to lock the flush engine to the base.

illustrates a flush engine in the toilet of the.provides another view of the toiletand flush engine. The flush include includes the bowl, a trapway, at least one jet port, and a drain pipe.

The flush engine may also include a supply line supportconfigured to support a water linethat feeds the at least one jet port. The jet portmay include an electronically controlled valve that opens the water passage to provide water to the sump of the toilet. The jet portmay include a water pump (e.g., using pressurize air) to propel water to the sump. The water pushes water in the water seal of the trapwayto break the siphon or otherwise force water to the drain of the toilet. A floor gasketconnects the toiletto a sewer pipe, septic pipe, or other sanitary path.

A spacermay couple the supply line supportto the base. The spacer sets the height of the surface of the rim of the bowl openingto a predetermined height. The spacermay compensate for the variation in the height of the bowl and flatness of the pedestal bottom.

illustrates an example latching mechanism for the toilet of the.

The latching mechanism (on the baseside) may include a flexible boardattached to the base. The flexible board may include a plastic sheet in a U-shaped such that one arm of the sheet may flex toward the other sheet. The latching mechanism (on the front shellside) may include a spring loaded ball or bearing(spring member). As the front shellis placed on the base, the latching mechanism couples the front shellto the base. In one example, the spring balland the flexible boardboth flex until the front shellsnaps into place (as shown in other examples, the front shellmay include a detente or projection that mates with the baseor cowling). When the front shellis released from the base, for example by reaching through windowand pulling tab, the spring balland the flexible boardpush against each other to provide an upward force to the front shell.

illustrates an example side panelsfor the toilet of the. The side panelsin this example include tabs. In some examples, tabsmay be fastened to the vertical armsof the frame. In other examples, the tabsmay press against the vertical armsand be held in place by the elastic force of the tabs or friction.

illustrates a second example frame for the toilet of. In this example, the frame includes vertical arms, horizontal arms, and at least one slanted arm. The horizontal armand slanted armmay be braced against the vertical arm. The horizontal armand slanted armmay form a lateral brace coupled to the frame that at least partially supports the frame. The lateral brace may include gripsconfigured to grip the flush engine (e.g., toilet bowl).

illustrates a release of a side panelfor the toilet of.illustrate pivoting attach points for the side panelin a first example.

As shown in, the side panel, may include a pivoting slot(first pivoting member) that receives a post(second pivoting member) of the cowlingor the frame. The rear of the side panelis first angled into come in contact with the toiletso that the slotreceiving the post. One set of postand slotmay be on the top of the side panel() and another set of postand slotmay be on the bottom of the side panel(). The rotation of the postin the slotpermits the angled partial removal or installation of the side panelas shown in.

In the alternative or in addition, the baseof the toiletmay include an angle limit hookconfigured to hold the at least one side panelto the baseat a predetermined angle range. For example, the side panelmay include another slotthat receives the angle limit hook. The angle limit hookengages the slotto hold the side panelto the base. As the side panelpivots away from the base, at some predetermined angle, the angle limit hookdisengages the slot, which release the side panelto be removed from the toilet. Example predetermined angles for the angle limit hookinclude 15 degrees, 20 degrees, and 30 degrees. Other angles are possible.

illustrate an example removal of the side panel in a second example. In this example, the side panelsare translated back towards the wall to disengage a series of tabsinterfacing with the cowling, and then the side panelpivots and slides out from the bottom skirt. The tabsand receiving openings in the cowlingform a snap lock. In, the side panelsslide backward until the snap locks is disengaged. In, the side panelis rotated to create clearance from the cowling. In, the side panel is raised and removed from the skirt.

illustrates an example latching mechanism for the front shell. The shellmay include a projection. The cowlingmay be coupled with or integrally include an extension mountincluding an aperture. The apertureand projectionmay lock together. The extension mountand the apertureform a latching mechanism. In one example, the front shellor the cowlingflexes under a force that causes the projection to push into the apertureand position the front shelland extensionmount in a predetermined position. Also shown in, the cowlingmay be semi-permanently connected to the bowl using a screwor other fastener. The mountmay include threadsto receive the screw.

illustrates a second example frame for the toilet ofincluding cowling. The cowling may include a pattern of openings.

illustrates an example cowling. The cowlingmay include flexible supportthat supports the skin or top cover. The flexible supportmay follow a predetermined pattern around the perimeter of the cowling. The flexible supportmay be a first seal between the cowlingand the flush engine. A wipermay be coupled to the seal or flexible supportand provide a second seal between the cowlingand the flush engine. As shown in, the wiperis position between the cowlingand the toilet bowl. The wiperprevents contamination or entry of water or other materials in the toilet bowlfrom escaping into the space around the cowlingsuch as between the cowlingand the top cover.illustrates another view for the seal for the cowling.

illustrates a screw for coupling the cowlingto the toilet bowl. The cowlingfits over the outer rim of the toilet bowl. A fastener such as a screwmay screw in below a lip of the outer rim of the toilet bowl. The screwis configured to prevent the cowlingfrom being removed from the toilet bowlwithout first at least partially removing the screw.

illustrates a screw for coupling the cowlingto the front shell. The cowlingfits over the outer rim of the toilet bowl. A fastener such as a screwmay couple the cowlingto the front shellto the cowling. The screwis configured to prevent the cowlingfrom being removed from the toilet bowlwithout first at least partially removing the screw.

illustrates a screw for cowlingthe cowling to a separate mount. The mountmay be affixed (e.g., glued) to the toilet bowl. A fastener such as a screwmay couple the cowlingto the mountin order to secure the cowlingto the toilet bowl. The screwis configured to prevent the cowlingfrom being removed from the toilet bowlwithout first at least partially removing the screw.

illustrates a snap fit for coupling the cowlingto the bowl shelf of the toilet bowlusing a snap fit. For example, snap fastenermay receive a protrusion from the toilet bowl.

illustrates another view of cowlingand cowling cover. The cowling coveror skin may be a single layer outer shell for the top surface. The cowling covermay be antibacterial. The cowling covermay be considered an aesthetic layer and find structure support in the cowling. The cowling covermay be held in with the seat bolts fastened to openingsfor the seat assembly and a snap fit to an elastomer outer lip on the cowling.

illustrates a skirtand a stationary skirt track. The skirtmay be a single, standalone part that is fastened to the base(and/or frame legs). The skirtmay include three parts as with the panels to facilitate molding, in which case it could also be made integral with the side and front shells to reduce overall part costs. One or more fastenersmay fasten the skirtto the vertical armsof the frame.

illustrate an example attachment for the front shell. The cowlingand/or the basemay include a bracketto receive a fastenerthat is coupled to the front shelland openings(e.g., threaded holes). In this embodiment the front shellmay include a series of tabsat the top that slot into grooves in the cowlingto position it. The front shellis then fastened to both the cowlingand basewith screwsthat may or may not require a tool. It is intended to be removable by the user for cleaning. Alternatively, the screwscould be eliminated and the panel could be retained with snap or ball and detent features.

illustrate another example with a track, as described above. The front shellslides in on the trackon the baseand then lifts vertically up into snap fits in the cowling. Gripson the bottom of the front shellallow the user to pull the panel down and out.

illustrate pivoting side panels. In an alternate version the side panel pivots about the back edge like a cabinet door and is held at the front by a push-to-open latch that is mounted on either the frame, base or cowl core. The panel pivots on features protruding from the base and cowl core. After a prescribed amount of rotation (e.g. 15 degrees) the panel can slide out of the pivot to be completely removed.

illustrates a set of example latch hookson the side panelthat are configured to snap fit with openingson the cowlingand/or the base.

illustrates a storage spacewithin the toilet. The sided panelmay be removed or partially open to reveal the storage space. The interior of the toiletmay include a liner or frame to partition off the storage space. The storage spacemay include multiple sections or dividers. The storage spacemay include shelves, pockets, or other structure that is secured to the frame of the toilet.

In another example, as shown by, the side panelmay include an integrated storage compartment. The storage compartmentmay be coupled to the sided paneland rotate along with the side panel.

The storage spaces may be configured for toilet paper, feminine products, magazines, cleaning tablets, tools, or other objects.

illustrates one example flow chart for assembly of the toilet.

At act S, attached the front shellto the baseor the cowling.

At act S, pivotally attach a first end of the side panelto the baseor the cowling.

At act S, snap a second end of the side panelto the baseor the cowling.

At act S, slide a skirtover the sided panel.

At act S, secure the skirtto the baseor the cowling.

illustrates an example controllerfor operation of the toilet. The controllermay include a processor, a memory, and a communication interfacefor interfacing with devices or to the internet and/or other networks. In addition to the communication interface, a sensor interface may be configured to receive data from sensors (e.g., proximity sensors to trigger the operation of the toilet).