Abstract:
A waxless modular seal prevents leaks in the connection between the base of a toilet and the drain pipe. The waxless modular seal comprises a rubber portion and a resiliently compressible toroid-shaped foam ring, both of which are, in combination, designed to replace a traditional wax seal. The waxless modular seal captures the foam ring between an upper sealing ring and a lower sealing ring. Each sealing ring and the foam ring comprises a protrusion and at least one vertically disposed aperture, the apertures being sized sufficiently so as to allow a fastener to pass through the apertures. The foam ring may comprise a plurality of foam rings.

Description:
[0001]    This Application claims the benefit of U.S. Provisional Application No. 61/905,797, filed Nov. 18, 2013. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to toilets and toilet sealing products. More specifically, the present invention relates to a modular waxless seal for preventing leaks at the connection between the base of a toilet and the drain pipe disposed below the toilet base. 
       BACKGROUND OF THE INVENTION 
       [0003]    It is well known in the art that wax seals are used for the connection between a toilet base and a drain pipe into which waste and water flow from the toilet. Generally speaking, such seals work relatively well and last for a long time. However, when wax seals leak, the resulting water can damage floors and, if allowed to continue, can eventually cause damage to other parts of a home or building. Additionally, such seals can generally only be set once and are generally difficult for non-professionals to install properly in that the wax used in the seal tends to adhere to everything, including the hands of the installer. Further, if the toilet is not tightened down properly over the seal, the seal can be damaged by rocking of the toilet, which can occur during use of the toilet over time. 
         [0004]    Therefore, in the experience of this inventor, there is need for a seal that is chemically resistant and does not absorb water. There is a further need for a seal with antimicrobial properties. Additionally, there is a further need for a more resilient type of seal so as to provide an upward sealing force against the toilet. There is an additional need for a seal that directs waste and waste water into the waste drain and prevents the waste and waste water from coming into contact with the flange. 
       SUMMARY OF THE INVENTION 
       [0005]    In accordance with the foregoing, the present invention provides a modular waxless seal that is intended to replace traditional wax seals. The modular waxless seal of the present invention is comprised of two primary structures and is manufactured from two primary materials. One material is a closed cell polyvinyl chloride (PVC) foam which is compressible, chemically resistant and does not absorb water. The closed cell PVC foam has been engineered to allow a specific compression force and to provide a rebound memory force so as to maintain the seal. The second structure is made of CHLORAZONE® rubber, a pliable and chemically resistant material (CHLORAZONE is a registered mark of Lavelle Industries, Inc.). The rubber seal is the only material that is contacted by waste and waste water passing between the toilet and the drain pipe. The CHLORAZONE® rubber contains a germicide to prevent the seal from supporting bacterial life. 
         [0006]    Importantly, the resilient nature of the closed cell PVC foam that is used allows the seal to remain in contact with the floor and the bottom of the toilet flange in the event of any rocking. Additionally, the modular seal is clean and will not adhere to an installer&#39;s hands. Likewise, the modular seal is much easier to remove and replace than a customary wax seal. Additionally, the seal can provide certain anti-microbial properties. The modular seal of the invention is particularly valuable in that it can be used in above floor installations, below floor installations and flush installations by using a different height closed cell PVC foam section. 
         [0007]    The foregoing and other features of the modular waxless seal of the present invention will be apparent from the detailed description that follows. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a top and side perspective view of the waxless modular seal described herein. 
           [0009]      FIG. 2  is a side cross-sectional and exploded view of the waxless modular seal described herein. 
           [0010]      FIG. 3  is a top and side perspective view of the waxless modular seal described herein as it would appear in an above floor installation. 
           [0011]      FIG. 4  is a side elevation view of the waxless modular seal shown in  FIG. 3 . 
           [0012]      FIG. 5  is a side cross-sectional view of the waxless modular seal shown in  FIG. 4 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0013]    Referring now to the drawings in detail, wherein like-numbered elements refer to like elements throughout,  FIG. 1  illustrates the preferred embodiment of a waxless modular seal, generally identified  1 , constructed in accordance with the present invention.  FIG. 2  shows an exploded view of the waxless modular seal  1  and its component parts and other elements that are present when the seal  1  is installed. It is to be understood that the elements shown in  FIG. 2 , however, are not shown in the positions that they would be in upon installation, which will be apparent in this detailed description. 
         [0014]    Continuing with  FIG. 2 , it will be seen that a bottom portion  31  of a toilet (not shown in its entirety) is installed over a drain pipe  3  and is secured to a floor (also not shown) by means of a closet flange  11 , which surrounds the drain pipe  3 . The closet flange  11  provides a central aperture  17  and a circumferential flange  13  that further comprises a pair of apertures  15 . Mounting bolts  21  protrude upwardly through the apertures  15  in the closet flange  11 . Further, the bottom portion  31  of the toilet comprises a waste hole  33  and a toilet flange  35  that is used to mount the toilet portion  31  to the closet flange  11 . The toilet flange  35  further comprises a pair of apertures  37  that are intended to align with the mounting bolts  21  that protrude upwardly from the closet flange  11 . The toilet portion  31  is then secured over the closet flange  11  by threading a washer  43  and a nut  41  down the mounting bolt  21  to secure the bottom portion  31  of the toilet to the closet flange  11 . 
         [0015]    In order to prevent leaks between the bottom portion  31  of the toilet and the waste hole  3 , the present invention provides a waxless modular seal  1  that is interposed between the toilet flange  31  and the closet flange  11 . The modular seal  1  is comprised of two principal components, a rubber portion  51  and at least one closed cell PVC foam portion  81 ,  91 . 
         [0016]    The rubber portion  51  employs chemical resistant CHLORAZONE® rubber and provides a single, generally cylindrical, elongated, continuous lining that is intended to prevent waste from leaking between the bottom portion  31  of the toilet and the drain hole  3 . Further, the CHLORAZONE® rubber contains a germicide to prevent the seal from supporting bacterial life. Lastly, the rubber portion  51  preferably comprises the components of an upper seal ring  53 , a central section  61 , a lower sealing ring  71  and a ring horn  181 , the rubber portion  51  comprising a unitary structure or a structure that is assembled from the foregoing components. 
         [0017]    The upper seal ring  53  extends circumferentially outwardly from a center section  61  of the generally cylindrical rubber portion  51  and is situated generally perpendicular to the center section  61  when the center section  61  is uncompressed, as is shown in  FIG. 2 . The upper seal ring  53  further comprises a pair of opposite protrusions or “ears”  55 , the ears  55  each further comprising a mounting bolt aperture  57 . See  FIG. 1 . The upper seal ring  53  further comprises a plurality of annular beads  59  extending upwardly from a top surface  58  of the ring  53 . The annular beads  59  are designed to provide a sealing interface with the lower surface  38  of the toilet bowl flange  35  and to absorb any imperfections in the lower surface  38  of the toilet bowl flange  35 . In the preferred embodiment, the innermost bead  159  is larger than the other beads  59 . See  FIG. 5 . 
         [0018]    The center section  61  of the generally cylindrical rubber portion  51  provides an aperture  63  through which waste and waste water can flow. 
         [0019]    The lower sealing ring  71  extends circumferentially outwardly from the center section  61  and is situated generally perpendicular to the center section  61  and is in a plane that is parallel to a plane within which the upper sealing ring  53  lays. The lower sealing ring  71  also comprises a pair of opposing protrusions or ears  73 , each of said ears  73  further comprising mounting bolt apertures  75 . The lower sealing ring  71  further comprises a plurality of annular beads  79  extending downwardly from a bottom surface  78  of the ring  71 . The annular beads  79  are designed to provide a sealing interface with the closet flange  11  and to absorb any imperfections in the circumferential portion  13  of the closet flange  11 . In the preferred embodiment, the innermost bead  179  is larger than the other beads  79 . See  FIG. 5 . The lower sealing ring  71  also acts as a support or a bridge. That is, closet flanges generally have many openings. The lower sealing ring  71  allows a bridge so the foam rings  81 ,  91  may have uniform distribution, thereby preventing a waste and waste water leak path. 
         [0020]    The ring horn  181  is the bottommost portion of the waxless seal  1  and is designed to direct the flow of waste and waste water such that it goes into the drain pipe  3  and never comes into contact with the closet flange  11 . The ring horn  181  may taper inwardly towards the bottom. 
         [0021]    As indicated above, the modular waxless seal  1  further comprises two square toroid-shaped closed cell PVC foam rings (or simply “foam rings”)—a first foam ring  81  having a thickness and a second foam ring  91  having a thickness, the thickness of the second foam ring  91  being less than that of the first foam ring  81 . Both foam rings  81 ,  91  comprise a pair of opposing protrusions or “ears”  83 ,  93 , respectively, that are disposed 180° from each other, and each ear  83 ,  93  further comprising a mounting bolt aperture  85 ,  95 . The foam rings  81 ,  91  are manufactured of chemically resistant material. The inner diameters and the outer diameters of the foam rings  81 ,  91  are substantially the same, as is the shape of the ears  83 ,  93  of each ring  81 ,  91 , respectively. 
         [0022]    The foam rings  81 ,  91  are designed to be installed between the upper sealing ring  53  and the lower sealing ring  71 , and further around the central section  61 . Therefore, the foam rings  81 ,  91  are designed to allow a certain degree of compression when force is applied, but, when the compressive force is removed, are designed to impart “memory” to the foam rings  81 ,  91  such that they will repeatedly return to their uncompressed state. Likewise, in their respective uncompressed states, the foam rings  81 ,  91  are designed to provide a certain degree of continuous upward pressure on the bottom surface  38  of the toilet flange  35  so as to maintain a continuous seal, albeit not one strong enough to damage the porcelain of the toilet. 
         [0023]    The waxless modular seal  1  of the claimed invention is designed to be used with all styles of flanges, that is, above floor flanges as well as flush and below floor flanges. For example, in the case of above floor flanges, there would be less clearance between the bottom of the toilet and the flange  11 . In such application, only the second foam ring  91  is used. In the case of a flush mount or below floor flanges  11 , both foam rings  81 ,  91  would be used. 
         [0024]      FIGS. 3-5  illustrate an example of the use of the second foam ring  91  such as might be used in the case of an above-floor flange. As can be seen, when the second foam ring  91  is used, the center section  61  of the generally cylindrical rubber portion  51  is flexible enough to accommodate the decreased height of the waxless seal  1 . 
         [0025]    In view of the foregoing, it will be apparent that the present invention provides an improved waxless modular seal that allows for easy and repeated installation. It will also be apparent that the modular seal provides an improved seal between the toilet and the drain pipe. It will be further apparent that this inventive configuration significantly reduces the mess created when installing and removing the wax seals of the prior art and greatly improves ease of installation and removal.